Cummins/Onan BGE troubleshooting: 29 fault codes and symptom-cause-remedy entries from the manufacturer's own service documentation.
Cummins/Onan BGE — full specs, parts & maintenance.
All Cummins/Onan fault codes →
| Symptom | Cause | Remedy |
|---|---|---|
| Disconnecting Set from RV Systems | 1. First disconnect the negative (-) battery cable from the baitery and then disconnect the battery cables from the genset. 2. Disconnect the remote control wiring harness connector at the genset. 3. Disconnect the generator output wiring and conduit from the power distribution panel or box on the vehicle. Tag all wires to make reconnections easier. 4. Disconnect the exhaust tailpipe from the outlet of the muffler and then remove the muffler. See EXHAUST SYSTEM under Engine Subsystems. 5. Disconnect the fuel line from the genset. Follow the applicable instructions depending on the fuel. | |
| Dizziness | IF YOU OR ANYONE ELSE EXPERIENCE ANY OF THESE SYMPTOMS, GET OUT INTO THE FRESH AIR IMMEDIATELY. If symptoms persist, seek medical attention. Shut down the unit and do not operate until it has been inspected and repaired. | |
| Muscular Twitching | IF YOU OR ANYONE ELSE EXPERIENCE ANY OF THESE SYMPTOMS, GET OUT INTO THE FRESH AIR IMMEDIATELY. If symptoms persist, seek medical attention. Shut down the unit and do not operate until it has been inspected and repaired. | |
| Vomiting | IF YOU OR ANYONE ELSE EXPERIENCE ANY OF THESE SYMPTOMS, GET OUT INTO THE FRESH AIR IMMEDIATELY. If symptoms persist, seek medical attention. Shut down the unit and do not operate until it has been inspected and repaired. | |
| Weakness and Sleepiness | IF YOU OR ANYONE ELSE EXPERIENCE ANY OF THESE SYMPTOMS, GET OUT INTO THE FRESH AIR IMMEDIATELY. If symptoms persist, seek medical attention. Shut down the unit and do not operate until it has been inspected and repaired. | |
| Inability to Think Coherently | IF YOU OR ANYONE ELSE EXPERIENCE ANY OF THESE SYMPTOMS, GET OUT INTO THE FRESH AIR IMMEDIATELY. If symptoms persist, seek medical attention. Shut down the unit and do not operate until it has been inspected and repaired. | |
| The engine fails to crank. | A. Try starting at the genset rather than at the remote control. b. Replace fuse F1 on the control panel if it has blown. c. Clean and tighten the positive (+) and negative (-) battery cable connections at the battery and the genset. d. Recharge the battery. Refer to the battery manufacturer's recommendations. | |
| The engine cranks slowly. | A. Disconnect the air conditioner and other large loads. b. Clean and tighten the positive (+) and negative (-) battery cable connections at the battery and the genset. c. Recharge the battery. Refer to the battery manufacturer's recommendations. d. Change the engine oil to oil having the proper viscosity for the ambient temperature. See Table 1. | |
| The engine cranks but fails to start. | A. Check the fuel tank and fill if necessary. b. Open any closed fuel shut off valve. c. Check engine oil level and add oil as necessary. d. Replace fuse F2 (side of control panel) if it has blown. e. Service the air cleaner. f. Secure the spark plug leads on the spark plugs. g. Replace the spark plugs. | |
| The engine runs and then stops or surges. | A. Check the fuel tank and fill if necessary. b. Check the engine oil level and add oil as necessary. Drain excess oil if the level is above the dipstick Full mark. c. Check and reset the carburetor preheater lever and altitude adjust knob. See Varying Weather and Altitude. d. Secure the spark plug leads on the spark plugs. e. Replace the spark plugs. | |
| There is no electrical power even though the genset runs. | A. Reset tripped circuit breakers. See Powering Equipment. b. Unless there is an automatic power transfer switch, plug the boat power cord into the genset power output receptacle (if so equipped) or turn the pontoon boat power selector switch to its genset position (if so equipped). | |
| The remote battery condition meter indicates low voltage. | A. Clean and tighten the positive (+) and negative (-) battery cable connections at the battery and the genset. b. Recharge the battery. Refer to the battery manufacturer's recommendations. | |
| The genset keeps stalling or the circuit breaker keeps tripping. | Try running with fewer appliances connected. See Powering Equipment. | |
| Black smoke exits the tailpipe. | Service the air cleaner. | |
| FAILS TO CRANK | 1. Low battery. 2. Bad battery connection. 3. Blown fuse. | 1. Check battery electrolyte level. 2. Clean and tighten all battery and cable connections. 3. Replace fuse on control box. See specifications for proper fuse rating. |
| CRANKS SLOWLY | 1. Low battery. 2. Bad battery connection. 3. Oil is too heavy. 4. Load connected. | 1. Check battery electrolyte level. 2. Clean and tighten all battery and cable connections. 3. Replace with lighter oil. 4. Remove load. |
| CRANKS BUT WON’T START | 1. Fuel below genset pick-up level 2. Fuel supply shutoff valve closed. 3. Carbon deposits on spark plugs. 4. Blown fuel pump/in tank. | 1. Add fuel. 2. Fully open fuel supply valve. 3. Remove spark plugs and clean. 4. Replace fuse with same type and rating. If problem persists, see Onan service center. |
| EXHAUSTING BLACK SMOKE | 1. Rich fuel mixture. 2. Dirty air filter. 3. Choke stuck. | 1. Turn main fuel adjustment in 1/8 turn (location of adjustment is shown in Figure 3-1). 2. Replace air filter. 3. Contact an Onan service center. |
| UNIT RUNS THEN STOPS | 1. Out of fuel. 2. Low oil level. 3. Excess oil. | 1. Refill fuel tank. 2. Add oil if necessary. 3. Reduce engine oil level. |
| UNIT RUNS BUT SURGES | 1. Loose or worn spark plug leads at spark plugs and ignition coil. 2. Ignition coil, wiring, or control components defective. 3. Faulty spark plugs. 4. Governor out of adjustment. | 1. Check security of spark plug leads at spark plugs and ignition coil. Replace leads if worn. 2. Contact an Onan representative. 3. Remove and clean or replace faulty spark plugs. 4. Contact an Onan service center. |
| Eng Cranks But Will Not Start (Genset) | -01 Check: - Spark plugs - Ignition coil - Ignition module -02 Perform checks in step 01 | |
| Engine Overfueling (Genset) | -01 Check: - Spark plugs - Fuel pressure at carburetor - Vacuum pull−off - Electric choke heater -02 Perform checks in step 01 - Check: - Governor adjustments - Carburetor adjustments -03 Perform checks in step 02 - Check: - Ignition coil - Ignition module | |
| Engine Unstable (Hunts) (Genset) | -01 Check: - Fuel supply - Fuel Lines for leakage - Loose wire connection -02 Perform checks in step 01 - Check: - Governor linkage for binding - Governor adjustments - Carburetor adjustments | |
| Engine Will Not Crank (Genset) | -01 Check: - Low battery voltage - Terminal connection−loose or dirty - Battery cable size - Starter drive engagement -02 Perform checks in step 01 - Check: - Remote control - Connections on PCB control board - Start solenoid - Starter | |
| High/Low AC Output (Genset) | -01 Check: - Broken or loose wires - Voltage regulator - Transformer regulator - Engine speed - Voltage ad | |
| Smoke and rough operation | Oil in the cylinders has not been burned off yet. | Continue running the generator set until the oil in the cylinders is burned. |
| Generator set runs louder than usual, compartment has holes to the interior, or exhaust system has leaks | Do not operate the generator set and have the exhaust system repaired as soon as possible. See your Onan service center. | |
| CRANKS BUT WON'T START | 1. Fuel below genset pickup level in tank. 2. Fuel supply shutoff valve closed. | 1. Add fuel. 2. Fully open fuel supply valve. 3. Remove spark plugs and clean. 4. Add oil if necessary. |
| UNIT RUNS THEN SURGES | 1. Loose or worn spark plug leads. 2. Ignition coil, wiring, or control components defective. 3. Faulty spark plugs. 4. Governor defective. 5. Incorrect fuel mixture. | 1. Check security of spark plug leads at spark plug and ignition coil. 2. Contact an Onan service center. 3. Remove and clean or replace faulty spark plugs. 4. Contact an Onan service center. 5. Contact an Onan service center. |
Fault codes and symptom→remedy steps extracted from this model’s service/owner documentation; verify against the official manual before servicing.
Documented causes: 1. Low battery. 2. Bad battery connection. 3. Blown fuse.. See the table for the matching fixes.
Documented causes: 1. Low battery. 2. Bad battery connection. 3. Oil is too heavy. 4. Load connected.. See the table for the matching fixes.
Documented causes: 1. Fuel below genset pick-up level 2. Fuel supply shutoff valve closed. 3. Carbon deposits on spark plugs. 4. Blown fuel pump/in tank.. See the table for the matching fixes.