65 Volvo Penta generator fault/alarm codes with symptom, cause and remedy — compiled from Volvo Penta service and controller documentation.
| Code | Meaning / symptom | Cause | Remedy |
|---|---|---|---|
| 1, 2 | Starter motor rotates slowly. | ||
| 103°C | Coolant temp and oil pressure switches | ||
| 105 Code 6.5 | Engine not running -> The engine cannot be started. Engine running -> Engine goes to idle and can only be stopped with the emergency stop. | Datalink error (CAN) | Check that the 8-pin connector is not damaged. • Check that the wiring between the CIU and the engine control unit (ECU) is not damaged. • Check that sleeves 11 and 12 in the CIU connector are not damaged. • Check the contact pressure in sleeves 1 and 2 in the red cable glove of the engine control module (EMS). |
| 109 Code 4.8 | The engine can only be stopped using the emergency stop on the engine. | Stop input engine control unit (ECU). Short to negative (-). | Check that the wiring to the ignition key/start button is not damaged. Check the contact pressure in sleeve ”H” in the 23-pin connector. |
| 12 | Natural phenomena, such as lightning strike, flood | ||
| 12, 13 | Black exhaust smoke. | ||
| 12, 13, 15, 25 | High fuel consumption. | ||
| 13 | War, uprising, terrorist actions or other force majeure events | ||
| 14 | KS signal is not present. | ||
| 14, 15, 22 | Blue or white exhaust smoke. | ||
| 15, 22 | Blue or white exhaust smoke | ||
| 16 | Too low lubrication oil pressure. | ||
| 17, 18, 19, 20 | Excessive coolant temperature. | ||
| 17, 18, 19, 20, 28 | Excessive coolant temperature | ||
| 2, 23 | No, or poor charge. | Flat batteries; Poor contact/open circuit in cables; Main switch turned off; Faulty ignition lock; Faulty main relay; Faulty starter motor relay; Faulty starter motor/solenoid; Lack of fuel: – fuel taps closed – fuel tank empty/wrong tank connected; Blocked fuel filter/pre-filter (because of contamination, or paraffin fraction separation in fuel at low temperature).; Air in the fuel system; Water/contamination in fuel; Faulty injection pumps; Insufficient air supply to engine: – blocked air filter – air leakage between turbo-charger and engine inlet pipe. – fouled compressor section in turbocharger – faulty turbocharger – poor engine bay ventilation | |
| 2, 4 | Engine can not be stopped. | ||
| 2.1, PID/SPN 97 | Water in Fuel (Code 2.1, PID/SPN 97) | * Empty the primary fuel filter indicator for Water in Fuel (Code 2.9, PID/SPN 97) | |
| 20 | Too low coolant temperature. | ||
| 202 Code 4.1 | Alarm lamp does not work. | Oil pressure alarm. Short to positive (+). | Check that the wiring and connection to the alarm lamp are not damaged. |
| 208 Code 5.2 | The engine cannot be started. | Start input on CIU. Short to negative (-). | Check that the connections to the ignition key are not damaged. • Check that the wiring to the ignition key is not damaged. |
| 210 Code 5.2 | The engine starts immediately when the ignition is turned on. | Start input on CIU. Short to positive (+) or activated too long. | Check that the connections to the ignition key are not damaged. • Check that the wiring to the ignition key is not damaged. |
| 211 Code 5.3 | The engine stops. After 40 seconds an error code is shown. During this time, the engine cannot be started. When the error code is blinked out on the diagnostic lamp, the engine can be started but not stopped. | Stop input on CIU. Short to positive (+) or activated too long. | Check that the connections to the ignition key are not damaged. • Check that the wiring to the ignition key is not damaged. |
| 213 Code 6.4 | Instruments and alarm lamps stop working. | Datalink (CAN) error, CIU | Check that the 8-pin connector is not damaged. • Check that the wiring between the CIU and the engine control unit (ECU) is not damaged. • Check that sleeves 11 and 12 in the CIU connector are not damaged. • Check the contact pressure in sleeves 1 and 2 in the red cable glove of the engine control unit (ECU). |
| 220 Code 4.3 | Indicator lamp does not work. | Lamp to indicate operation. Interruption Response: Indicator lamp does not work. | Check the alarm lamp. Check that the wiring to the alarm lamp is not damaged. Check sleeve ”N” in the 23-pin connector. Check the contact pressure in sleeve 33 in the black connector of the engine control unit (ECU). |
| 221 Code 4.3 | The indicator lamp shines constantly. | Lamp to indicate operation. Short to negative (-). | Check that the wiring and connection to the alarm lamp are not damaged. |
| 3.1, PID/SPN 100 | Oil Pressure Sensor (Code 3.1, PID/SPN 100) | * Check that the oil pressure sensor cable is not damaged * Check that the oil pressure sensor is correctly connected * Check oil pressure sensor function | |
| 3.2, PID/SPN 105 | Boost Temperature Sensor (Code 3.2, PID/SPN 105) | * Check that the boost temperature sensor connector is correctly installed * Check that the boost temperature sensor cable is not damaged * Check that the boost temperature sensor is correctly installed * Check boost temperature sensor function | |
| 3.4, PID/SPN 102/106 | Boost Pressure Sensor (Code 3.4, PID/SPN 102/106) | * Check that the boost pressure sensor connector is correctly installed * Check that the boost pressure sensor cable is not damaged * Check that the boost pressure sensor is correctly installed * Check boost pressure sensor function | |
| 3.5, PID/SPN 106 | Boost Pressure Sensor (Code 3.5, PID/SPN 106) | * Check that the charge air pressure sensor connector is correctly installed * Check that the charge air pressure sensor cable is not damaged * Check that the charge air pressure sensor is correctly installed * Check charge air temperature sensor function | |
| 3.6, PID/SPN 94 | Fuel Pressure Sensor (Code 3.6, PID/SPN 94) | * Check that the fuel pressure sensor connector is correctly installed. * Check that the fuel pressure sensor cable is not damaged. * Check that the fuel pressure sensor is correctly installed. * Check fuel pressure sensor-function. | |
| 3.8, PID/SPN 94 | Fuel Pressure (Code 3.8, PID/SPN 94) | * Low supply pressure | * Check if it is possible to build up pressure with the hand pump * Check the fuel filter * Check the fuel pre-filter |
| 35 Code 4.2 | Alarm lamp lights constantly. | Alarm for high coolant temp. Linked to Stand Alone interface. Short to negative (-). | Check that the wiring to the alarm lamp is not damaged. Check that the alarm lamp is fitted correctly. |
| 36 Code 6.1 | Limited engine output (if this protective feature has not been disabled by the parameter setting tool). Alarm lamp lights. | Oil temperature is too high | Check the oil level. • Check the oil temperature. • Check the oil system thermostat. • Check the function of the oil temperature sensor. |
| 38 Code 6.5 | Engine not running: the engine cannot be started. Engine running: engine goes to idle and can only be stopped using the emergency stop. | Datalink (CAN) error, engine control module (EMS) | Check that the 8-pin connector is not damaged. • Check that the wiring between the CIU and the engine control unit (ECU) is not damaged. • Check that sleeves 11 and 12 in the CIU connector are not damaged. • Check the contact pressure in sleeves 1 and 2 in the red cable glove of the engine control module (EMS). |
| 41 Code 4.6 | Engine will not start. | Start relay on starter motor. Short to positive (+). | Check that the wiring to the relay is not damaged. Check the function of the relay. |
| 42 Code 4.6 | Engine will be started -> The starter motor engages, but no start request is made when the ignition is switched on. Engine running -> The starter motor engages, but no start request is made. Engine being started -> The starter motor does not disengage once the engine is started. | Start relay on starter motor. Short to negative (-). | Check that the wiring to the relay is not damaged. Check the function of the relay. |
| 43 Code 5.1 | The instrument panel loses power when the key is twisted to start position. The engine will not start. | Main relay. Short to positive (+). | Check that the wiring to the relay is not damaged. • Check the function of the relay. |
| 5.4, PID 45/SPN 626 | Preheating Relay (Code 5.4, PID 45/SPN 626) | Short circuit to positive (+) or +. Preheating can not be activated. earth (ground) (-). Open circuit. - Preheating is constantly connected. | * Check that the relay input cable is not damaged. * Check relay function. |
| 5.5, PID/SPN 107 | Air Filter Pressure (Code 5.5, PID/SPN 107) | * Tao large pressure drop | |
| 5.6, PID/SPN 107 | Air Filter Sensor (Code 5.6, PID/SPN 107) | * Check that the air filter sensor contact is correctly installed * Check that the cable harness to air filter sensor has not been damaged Check the air filter sensor functionality | |
| 5.7, PID/SPN 98 | Oil Level (Code 5.7, PID/SPN 98) | * Oil level to low | * Check the oil level |
| 5.9; PID/SPN 98 | Oil Level Sensor (Code 5.9; PID/SPN 98) | * Check that the cable harness to the oil level sensor has not been damaged * Check the oil level sensor function | |
| 6.2, PID/SPN 105 | Boost Temperature (Code 6.2, PID/SPN 105) | * Boost temperature is too high | * Check the coolant level * Check the charge air cooler (cleanliness) * Check boost temperature sensor function * Check the function of the thermostat |
| 6.6, PID/SPN 100 | Oil Pressure (Code 6.6, PID/SPN 100) | * Oil pressure is too low | * Check oil level * Check that the air filter is not blocked * Check system pressure valves and safety valves in the oil system * Check oil pressure sensor function |
| 60 Code 6.2 | Engine output is limited to 50% (if this protective feature has not been disabled by the parameter setting tool). | Intake air temperature is too high | Check the coolant level. • Check the intercooler (cleanness). • Check the function of the charge air temperature sensor. • Check the function of the thermostat. |
| 738 | Air filter restriction indicator | ||
| 74 Code 5.4 | Preheating cannot be activated. | Preheating relay. Connection interruption | Check that the wiring to the input on the relay is not damaged. • Check the function of the relay. • Check the contact pressure in sleeve 36 in the red cable glove of the engine control unit (ECU). |
| 75 Code 5.4 | Preheating is constantly activated. | Preheating relay. Short to negative (-) | Check that the wiring to the input on the relay is not damaged. • Check the function of the relay. |
| 8, 9, 10, 11 | Starter motor rotates normally but engine does not start. | ||
| 8, 9, 10, 11, 13 | Engine starts but stops again. | ||
| 97°C | Coolant temp and oil pressure switches | ||
| DTC 12 | Diagnostic Trouble Code 12 | ||
| DTC 14 | Engine Coolant Temperature (ECT) Sensor Circuit - Low Temperature Indicated | ||
| DTC 15 | Engine Coolant Temperature (ECT) Sensor Circuit - High Temp Indicated | ||
| DTC 21 | Throttle Position (TP) Sensor Circuit - Signal Voltage High (Non-Scan) | ||
| DTC 22 | Throttle Position (TP) Sensor Circuit - Signal Voltage Low (Non-Scan) | ||
| DTC 23 | Intake Air Temperature (IAT) Sensor Circuit - Low Temp Indicated (Non-Scan) | ||
| DTC 25 | Intake Air Temperature (IAT) Sensor Circuit - High Temp Indicated (Non-Scan) | ||
| DTC 33 | Manifold Absolute Pressure (MAP) Sensor Circuit - Signal Voltage High (Non-Scan) | ||
| DTC 34 | Manifold Absolute Pressure (MAP) Sensor Circuit - Signal Voltage Low (Non-Scan) | ||
| DTC 41 | Ignition Coil 1 Control Circuit (Scan) | ||
| DTC 44 | Knock Sensor (KS) 1 Circuit (Scan) | ||
| DTC 51 | Calibration Checksum Failure | ||
| DTC 81 | Cuts Out, Misses Symptom | ||
| DTC-81 | Non-Scan DiagnosticS |
Compiled from Volvo Penta service manuals and controller documentation. Cause/remedy shown where extracted; always verify against the manual for your exact model.
Engine not running -> The engine cannot be started. Engine running -> Engine goes to idle and can only be stopped with the emergency stop.. Cause: Datalink error (CAN). Remedy: Check that the 8-pin connector is not damaged. • Check that the wiring between the CIU and the engine control unit (ECU) is not damaged. • Check that sleeves 11 and 12 in the CIU connector are not damaged. • Check the contact pressure in sleeves 1 and 2 in the red cable glove of the engine control module (EMS)..
The engine can only be stopped using the emergency stop on the engine.. Cause: Stop input engine control unit (ECU). Short to negative (-).. Remedy: Check that the wiring to the ignition key/start button is not damaged. Check the contact pressure in sleeve ”H” in the 23-pin connector..
No, or poor charge.. Cause: Flat batteries; Poor contact/open circuit in cables; Main switch turned off; Faulty ignition lock; Faulty main relay; Faulty starter motor relay; Faulty starter motor/solenoid; Lack of fuel: – fuel taps closed – fuel tank empty/wrong tank connected; Blocked fuel filter/pre-filter (because of contamination, or paraffin fraction separation in fuel at low temperature).; Air in the fuel system; Water/contamination in fuel; Faulty injection pumps; Insufficient air supply to engine: – blocked air filter – air leakage between turbo-charger and engine inlet pipe. – fouled compressor section in turbocharger – faulty turbocharger – poor engine bay ventilation.
Water in Fuel (Code 2.1, PID/SPN 97). Remedy: * Empty the primary fuel filter indicator for Water in Fuel (Code 2.9, PID/SPN 97).
Alarm lamp does not work.. Cause: Oil pressure alarm. Short to positive (+).. Remedy: Check that the wiring and connection to the alarm lamp are not damaged..
The engine cannot be started.. Cause: Start input on CIU. Short to negative (-).. Remedy: Check that the connections to the ignition key are not damaged. • Check that the wiring to the ignition key is not damaged..