Cummins/Onan C38 D5 troubleshooting: 95 fault codes and 14 symptom-cause-remedy entries from the manufacturer's own service documentation.
Cummins/Onan C38 D5 — full specs, parts & maintenance.
All Cummins/Onan fault codes →
| Code | Meaning | Cause | Remedy |
|---|---|---|---|
| 1 | HIGH COOLANT TEMP — Lamp: Shutdown; Indicates engine has overheated (coolant temperature has risen above the shutdown trip point) | Allow engine to cool down completely before proceeding with the following checks: Check coolant level and replenish if low. Look for possible coolant leakage points and repair if necessary; Check for obstructions to cooling airflow and correct as necessary; Check fan belt and repair or tighten if necessary; Check blower fan and circulation pumps on remote radiator installations; Reset control and restart after locating and correcting problem. | |
| 2 | LOW OIL PRESSURE — Lamp: Shutdown; Indicates engine oil pressure has dropped below the shutdown trip point | Check oil level, lines and filters. If oil system is OK but oil level is low, replenish. Reset control and restart. If oil switch is used, check switch performance. | |
| 12 | HIGH AC VOLTAGE — Lamp: Shutdown; Indicates that one or more of the phase voltages has exceeded 130% of nominal for 0 second, or has exceeded high ac voltage threshold of nominal for time delay seconds | ||
| 13 | LOW AC VOLTAGE — Lamp: Shutdown; Indicates that one or more of the phase voltages has dropped below low ac voltage threshold for time delay seconds | ||
| 14 | OVER FREQUENCY — Lamp: Shutdown; Indicates frequency is 10% above base frequency for approximately 10 seconds | ||
| 15 | UNDER FREQUENCY — Lamp: Shutdown; Indicates that engine speed has dropped below 90% of nominal for approximately 10 seconds | Check fuel supply, intake air supply and load. | |
| 27 | EXCITATION FAULT — Lamp: Shutdown; Indicates a loss of all three voltage sense leads or failure in excitation circuit | Check field wiring (X1 and X2) for shorts or opens. (Refer to Section 7.) | |
| 38 | FIELD OVERLOAD — Lamp: Shutdown; Indicates that the Field AVR Duty Cycle has been at the maximum for at least 15 seconds | ||
| 45 | SPEED SIGNAL LOST — Lamp: Shutdown; Indicates that no magnetic pickup pulses are sensed for a Loss of Speed delay. If a magnetic pickup is not installed, then speed sensing is performed by monitoring AC line frequency, this fault cannot occur | ||
| 46 | HIGH AC CURRENT — Lamp: Shutdown; Indicates that an individual phase of alternator output current has exceeded high current threshold of the rated output current continuously for more than time delay seconds | Check load and load lead connections. | |
| 61 | EMERGENCY STOP — Lamp: Shutdown; Indicates remote Emergency Stop | To reset the remote Emergency Stop button: Open (disable) remote emergency stop button; Move the rocker switch to the OFF position or press the OFF button; Select the desired operating mode (manual or remote). | |
| 71 | SPEED HZ MATCH — Lamp: Shutdown; Indicates that measured speed and measured AC output frequency do not agree | Check genset setup for number of flywheel teeth. | |
| 72 | FAIL TO CRANK — Lamp: Shutdown; The genset has failed to sense rotation for two start attempts. Indicates possible fault with control, speed sensing or starting system. Can only occur in gensets with magnetic pickup installed and enabled | ||
| 73 | FAIL TO START — Lamp: Shutdown; Indicates possible fuel system or air induction problem. (Engine cranks but fails to start) | Check for empty fuel tank, fuel leaks, or plugged fuel lines and correct as required; Check for dirty fuel filter and replace if necessary; Check for dirty or plugged air filter and replace if necessary; Reset the control and restart after correcting the problem. | |
| 74 | FAIL TO STOP — Lamp: Shutdown; Genset continues to run after receiving shutdown command from the controller | ||
| 77 | SHUTDOWN AFTER BS — Lamp: Shutdown; A shutdown fault occurred while the Battle Short mode was enabled | Check fault history for faults that may have been bypassed. | |
| 92 - 95 | AUX I/O MODULE INPUT 9 – 12 — Lamp: Shutdown; The nature of the Aux I/O Module fault is an optional customer selection. Example inputs: Low Fuel Day Tank, Water In Fuel, Ground Fault, etc | Each of the fault functions can be programmed (using InPower service tool or access to Setup menu), as follows: Warning, Shutdown or Event (Default = Warning) (See fault code 234–237 for Warning and code 171–174 for Event); Change display name using up to 32 characters. | |
| 96 | OIL TEMP HIGH — Lamp: Shutdown; Indicates that the engine oil temperature is above normal and has reached the shutdown trip point. (I/O Module option.) | ||
| 98 | AMBIENT TEMP HIGH — Lamp: Shutdown; Indicates ambient temperature is above normal and has reached the shutdown trip point. (I/O Module option.) | ||
| 99 | FUEL LEVEL LOW — Lamp: Shutdown; Indicates that fuel level has reached the shutdown trip point. (I/O Module option.) | ||
| 102 | VOLTAGE BIAS OOR — Lamp: Shutdown; Indicates the voltage bias circuit output is out of range (OOR), high or low. (I/O Module option.) | ||
| 103 | SPEED BIAS OOR — Lamp: Shutdown; Indicates the speed bias circuit output is out of range (OOR), high or low. (I/O Module option.) | ||
| 106 | I/O MODULE LOST — Lamp: Shutdown; Indicates the data link between the I/O module and the Base board is lost | ||
| 163 - 170 | BASE I/O MODULE INPUT 1 – 8 — Lamp: None; The nature of the Base I/O Module event is an optional customer selection | Each event function can be programmed (using InPower service tool or access to Setup menu), as follows: Change display name using up to 32 characters; Select active low or high input. | |
| 171 - 174 | AUX I/O MODULE INPUT 9 – 12 — Lamp: None; The nature of the Aux I/O Module event is an optional customer selection | Each event function can be programmed (using InPower service tool or access to Setup menu), as follows: Change display name using up to 32 characters; Select active low or high input. | |
| 202 | PRE-HIGH COOL TMP — Lamp: Warning; Indicates engine is operating near cooling system capacity. Increase in load or higher ambient temperature may cause High Coolant Temp (1) shutdown | Review code 1 correction list for other possible causes. | |
| 203 | LOW COOLANT TEMP — Lamp: Warning; Set is not operating. Warning occurs when engine coolant temperature is 70F (21C) or lower. NOTE: In applications where the ambient temperature falls below 40F (4C), Low Coolant Temp may be indicated even though the coolant heaters are operating | Indicates engine coolant heater is not operating or is not circulating coolant; Coolant heater not connected to power supply; Low coolant level; Open heater element | Check for the following conditions: Coolant heater not connected to power supply. Check for blown fuse or disconnected heater cord and correct as required; Check for low coolant level and replenish if required. Look for possible coolant leakage points and repair as required; Open heater element. Check current draw of heater. Coolant temperature must be below 70F (default setting) for one minute to activate warning and be above 70F for five minutes before the warning can be cleared. |
| 212 | COOL SENSOR OOR — Lamp: Warning; Indicates that the control has sensed that the engine coolant temperature sensor output is out of range (high or low). This fault will only occur if water temperature sensor is equipped on the genset | Check sender/connectors/wires. | |
| 213 | LOW BATTERY — Lamp: Warning; Indicates battery voltage supply to the control is approaching a low level at which unpredictable operation will occur | Discharged or defective battery; Poor battery cable connections; Battery wiring/calibration; Engine DC alternator; Battery charge voltage float level | Check the battery charger fuse. Recharge or replace the battery; Clean the battery cable terminals and tighten all connections; Check battery wiring/calibration; Check engine DC alternator. Replace engine DC alternator if normal battery charging voltage is not obtained; Check battery charge voltage float level if applicable (raise float level). |
| 214 | HIGH BATTERY — Lamp: Warning; Indicates battery voltage supply to the control is approaching a high level at which damage to the control can occur | Check float level on battery charger if applicable (lower float level); Check battery wiring/calibration. | |
| 215 | PRE-LOW OIL PRESSURE — Lamp: Warning; Indicates engine oil pressure has dropped below the warning trip point. This warning will only occur if genset is equipped with an oil pressure sender | If generator is powering critical loads and cannot be shut down, wait until next shutdown period and then follow code 2 procedure. | |
| 216 | HIGH AC CURRENT — Lamp: Warning; Indicates that one or more of the phase currents has exceeded high ac warning threshold for time delay seconds | Check load and load lead connections. | |
| 217 | OIL PRESS SENSOR OOR — Lamp: Warning; Indicates that the control has sensed that the engine oil pressure sensor output is out of range (high or low). This warning will only occur if genset is equipped with an oil pressure sender | Check sender/connectors/wires. | |
| 218 | BATTLE SHORT ACTIVE — Lamp: Warning; Indicates that the control is in Battle Short mode - used to bypass several fault shutdowns for genset operation during emergencies | ||
| 219 | CHARGER FAILURE — Lamp: Warning; Indicates the battery charging alternator has not reached an acceptable voltage range within the selected period (default = 120 seconds) | Refer to engine service manual if this fault occurs. If not failed, check wiring. | |
| 220 | FAIL TO SHUTDOWN — Lamp: Warning; Genset continues to run after receiving shutdown command from the controller. Battle Short feature enabled - used to bypass several critical fault shutdowns for genset operation during emergencies | ||
| 221 | WEAK BATTERY — Lamp: Warning; Indicates that during cranking, the battery voltage is at or below the weak battery warning trip point for a time greater than or equal to the weak battery set time | See code 213 for corrective action. | |
| 225 | ANNUNCIATOR OUTPUT CONFIGURATION ERROR — Lamp: Warning; Indicates a mismatch in the configuration of one of the annunciator relay outputs | ||
| 226 - 233 | Base I/O Module Input 1 — 8 — Lamp: Warning; The nature of the Base I/O Module fault is an optional customer selection. Example inputs: Low Fuel Day Tank, Water in Fuel, Ground Fault, etc | Each of the fault functions can be programmed (using InPower service tool or access to Setup menu), as follows: Warning, Shutdown or Event (Default = Warning) (See fault code 84–91 for shutdown and code 163–170 for Event); Change display name using up to 32 characters. | |
| 234-237 | AUX I/O MODULE INPUT 9–12 — Lamp: Warning; The nature of the Aux I/O Module fault is an optional customer selection. Example inputs: Low Fuel Day Tank, Water in Fuel, Ground Fault, etc | Each of the fault functions can be programmed (using InPower service tool or access to Setup menu), as follows: Warning, Shutdown or Event (Default = Warning) (See fault code 92–95 for shutdown and code 171–174 for Event); Change display name using up to 32 characters. | |
| 238 | OIL TEMP HIGH — Lamp: Warning; Indicates engine has begun to overheat (oil temperature has risen to an unacceptable level). Increase in load or higher ambient temperature may cause High Oil Temp (code 96) shutdown. (I/O Module Option.) | ||
| 239 | OIL TEMP OOR — Lamp: Warning; Indicates the oil temperature sensor output is out of range (OOR), high or low. (I/O Module option.) | ||
| 242 | AMBIENT TEMP HIGH — Lamp: Warning; Indicates the ambient temperature has exceeded the warning threshold for genset room temperature. Increase in load may cause Ambient Temp High (code 98) shutdown. (I/O Module Option.) | ||
| 243 | AMBIENT TEMP OOR — Lamp: Warning; Indicates the ambient temperature sensor output is out of range (OOR), high or low. (I/O Module Option) | ||
| 244 | FUEL LEVEL LOW — Lamp: Warning; Indicates that the fuel has dropped below the low fuel level trip point. Allows time to refill before fuel level low (code 99) shutdown occurs. (I/O Module Option) | ||
| 245 | FUEL LEVEL OOR — Lamp: Warning; Indicates the fuel level sensor output is out of range (OOR), high or low. (I/O Module Option) | ||
| 252 | I/O MODULE LOST — Lamp: Warning; Indicates an intermittent data link between the I/O module and the Base board | ||
| 1/202 | HIGH OR PRE-HIGH COOLANT TEMPERATURE (SHUTDOWN/SHUTDOWN) — Calibration-dependent. No action is taken by the Control for code 202. Engine will shut down for code 1 | Fault simulation was enabled with a PC based service tool | With a PC based service tool, verify that the fault simulation is not enabled for the coolant sensor. If you do not have a PC based service tool, remove battery power from the control to disable fault simulation overrides. |
| 1/202 | HIGH OR PRE-HIGH COOLANT TEMPERATURE (SHUTDOWN/SHUTDOWN) — Calibration-dependent. No action is taken by the Control for code 202. Engine will shut down for code 1 | Engine or sensor circuitry problem | Check the sensor accuracy with a thermocouple or similar temperature probe. If the coolant temperature reading is accurate, the engine may be overheating. Refer to the engine service manual. If the coolant temperature reading is not accurate, go to next step. |
| 1/202 | HIGH OR PRE-HIGH COOLANT TEMPERATURE (SHUTDOWN/SHUTDOWN) — Calibration-dependent. No action is taken by the Control for code 202. Engine will shut down for code 1 | The sensor could be bad | Disconnect the sensor and connect a coolant temperature sensor simulator to the harness. If the control responds to the simulator, replace the sensor. If control does not respond, go to next step. |
| 1/202 | HIGH OR PRE-HIGH COOLANT TEMPERATURE (SHUTDOWN/SHUTDOWN) — Calibration-dependent. No action is taken by the Control for code 202. Engine will shut down for code 1 | The harness or Base board could be bad | Measure the resistance of the coolant sensor and reconnect harness to sensor. Remove connector P11 from Base board and check resistance between pins P11-18 (H20) and P11-6 (H20 COM). If resistance is not the same, harness is bad. If resistance is the same, Base board is bad. |
| 2/215 | LOW OIL OR PRE-LOW PRESSURE (WARNING/SHUTDOWN) OIL PRESSURE SENSOR TYPE : SENDER — Calibration-dependent. No action is taken by the Control for code 215. Engine will shut down for code 2 | Fault simulation was enabled with a PC based service tool | With a PC based service tool, verify that the fault simulation is not enabled for the oil pressure sensor. If you do not have a PC based service tool, remove battery power from the control to disable fault simulation overrides. |
| 2/215 | LOW OIL OR PRE-LOW PRESSURE (WARNING/SHUTDOWN) OIL PRESSURE SENSOR TYPE : SENDER — Calibration-dependent. No action is taken by the Control for code 215. Engine will shut down for code 2 | Low oil level. Clogged lines or filters | Check oil level, lines and filters. If oil system is OK but oil level is low, replenish. |
| 2/215 | LOW OIL OR PRE-LOW PRESSURE (WARNING/SHUTDOWN) OIL PRESSURE SENSOR TYPE : SENDER — Calibration-dependent. No action is taken by the Control for code 215. Engine will shut down for code 2 | Sensor or oil pump could be bad. Or the generator set may be shutting down on another fault | Disconnect the oil pressure sensor leads, and connect an oil pressure sensor simulator to the harness. If the control responds to the simulator, reconnect the sensor, disconnect the + signal wire at the fuel solenoid, and crank the engine. Check the oil pressure reading on the digital display. If the display shows an acceptable oil pressure, the problem may not be in the oil or oil sensing system. The genset may be shutting down on another fault (out of fuel, intermittent connector). Restart the genset and monitor the display panel for other faults. If the display does not show an acceptable oil pressure, replace the sensor. If the Control still doesn't display an oil pressure while cranking, the oil pump may be bad. Refer to the engine service manual. If the control does not respond to the simulator, go to next step. |
| 2/215 | LOW OIL OR PRE-LOW PRESSURE (WARNING/SHUTDOWN) OIL PRESSURE SENSOR TYPE : SENDER — Calibration-dependent. No action is taken by the Control for code 215. Engine will shut down for code 2 | Harness or Base board could be bad | If the control does not respond to the simulator, the Base board or the harness is bad. Check for +5 VDC at the sensor (lead marked S1). If there is no 5 VDC at the sensor: Check for 5 VDC at P11-17. If yes, harness is bad. If no, Base board is bad. If there is 5 VDC at the sensor, use the sensor simulator to generate a signal to P11-17 (OP OUT) and P11-5 (OP COMM). If the pressure signal (.5 to 4.5 VDC) does not get to P11, isolate to the harness. If the pressure signal does go to P11, the Base board is bad. |
| 2/215 | LOW OIL OR PRE-LOW PRESSURE (WARNING/SHUTDOWN) OIL PRESSURE SENSOR TYPE : SENDER — Calibration-dependent. No action is taken by the Control for code 215. Engine will shut down for code 2 | Low Oil Pressure fault set points could be incorrect | Verify set points against the normal operating pressures of the engine. Refer to engine manual. |
| 12 | HIGH AC VOLTAGE (SHUTDOWN) — Engine will shut down | Fault simulation was enabled with a PC based service tool | With a PC based service tool, verify that the related fault simulation is not enabled. If you do not have a PC based service tool, remove battery power from the control to disable fault simulation overrides. |
| 12 | HIGH AC VOLTAGE (SHUTDOWN) — Engine will shut down | Single step large block load removal | Clear fault and restart genset. |
| 12 | HIGH AC VOLTAGE (SHUTDOWN) — Engine will shut down | Fault threshold is not set correctly with PC based service tool | Reset the threshold to the highest allowable setting. Determine the required operating range before adjusting the threshold. |
| 12 | HIGH AC VOLTAGE (SHUTDOWN) — Engine will shut down | Base board or generator is bad | Refer to Generator/Base Board Isolation Procedure in Section 7 to determine if the Base board is causing the high AC voltage shutdown fault. |
| 12 | HIGH AC VOLTAGE (SHUTDOWN) — Engine will shut down | Voltage sense connections/set up could be incorrect | See Section 17 for proper corrective actions. |
| 13 | LOW ACE VOLTAGE (SHUTDOWN) — Engine will shut down | Fault simulation was enabled with a PC based service tool | With a PC based service tool, verify that the related fault simulation is not enabled. If you do not have a PC based service tool, remove battery power from the control to disable fault simulation overrides. |
| 13 | LOW ACE VOLTAGE (SHUTDOWN) — Engine will shut down | Fault threshold is not set correctly with a PC based service tool | Reset the threshold to the lowest allowable setting. Determine the required operating range before adjusting the threshold. |
| 13 | LOW ACE VOLTAGE (SHUTDOWN) — Engine will shut down | Overload | Check the load and correct any overload. Check operation by disconnecting load and restarting generator set. |
| 13 | LOW ACE VOLTAGE (SHUTDOWN) — Engine will shut down | Improper connections have been made at the generator output terminals | Reconnect according to the appropriate reconnection diagram. See Section 9. |
| 13 | LOW ACE VOLTAGE (SHUTDOWN) — Engine will shut down | Voltage sense or setup wiring connection could be incorrect | Check that excitation inputs P13-5 and P13-6 are connected to the correct voltage. |
| 13 | LOW ACE VOLTAGE (SHUTDOWN) — Engine will shut down | The rotating rectifier assembly (diodes CR1 through CR6) is faulty | Check each diode. See genset service manual |
| 13 | LOW ACE VOLTAGE (SHUTDOWN) — Engine will shut down | Loose connector or Base board is bad | Repair connections (P13) or replace the Base board if necessary. |
| 13 | LOW ACE VOLTAGE (SHUTDOWN) — Engine will shut down | Voltage sense connections/setup could be incorrect | See section 17 for proper connections |
| 14 | Over Frequency (Shutdown) — Generator set will shut down. | Fault threshold is not set correctly with PC based service tool; Fuel or air delivery problem; Governor fault; Loose connector or Base board is bad | Reset the threshold to the highest allowable setting. Determine the required operating range before adjusting the threshold; Refer to the engine service manual; Check governor frequency adjustment (Refer to Section 7); Repair connections (P12/P13) or replace the Base board if necessary |
| 15 | Under Frequency (Shutdown) — Generator set will shut down. | Fault threshold is not set correctly with PC based service tool; Overload; Fuel or air delivery problem; Governor fault; Loose connector or Base board is bad | Reset the threshold to the lowest allowable setting. Determine the required operating range before adjusting the threshold; Check the load and correct any overload. Check operation by disconnecting load and restarting generator set; Refer to the engine service manual; Check fuel shutoff solenoid adjustment; Repair connections (P13) or replace the Base board if necessary |
| 31 | Overspeed (Shutdown) — Engine will shut down. | Cold engine (no coolant heaters); Single step large block load removal; Fault simulation was enabled with a PC based service tool; Fault threshold is not set correctly with PC based service tool; Monitor the engine rpm using PC based service tool; Governor fault; Flywheel tooth count incorrect; Mechanical Fuel system setup could be incorrect | Overspeed can occur when starting a very cold engine. Clear fault and restart genset; Clear fault and restart genset; With PC based service tool, verify that the fault simulation is not enabled for the coolant sensor. If you do not have PC based service tool, remove battery power from the control to disable fault simulation overrides; Reset the threshold to the highest allowable setting. Determine the required operating range before adjusting the threshold; If the RPM is not correct, refer to fault code 45 for corrective action; Check fuel shutoff solenoid adjustment; Replace defective injection pump unit; For gensets with magnetic pickup installed, verify flywheel tooth count is correct for the engine type. Refer to section 7.11.1 for a table; Verify fuel stop settings for the application |
| 45 | Speed Signal Lost (Shutdown) (Genset with MPU) — Engine will shut down. | Loose or damaged magnetic pickup (MPU) wires/connector pins; The magnetic pickup, harness or Base board could be bad | Inspect the wires/connector pins, and repair or replace as necessary; To isolate the problem, reset the control and attempt to start the set. If 72 (Fail To Crank) is displayed, or if the engine starts, but then shuts down on 45 (Speed Signal Lost), the MPU sender could be bad. Remove the MPU connectors and check for 3.5 to 15 VAC at the MPU while cranking. If no output, check for damage or debris. Also check for improper adjustment of the MPU. (Refer to Section 7.11.) If there is still no output, replace the MPU sender. If the MPU output is OK, check for MPU voltage at P11-12 (MAG PICK+) to P11-24 (MAG PICK-) while cranking. If OK, replace the Base board. If not OK, use continuity checks to isolate connectors/harness. If the engine starts and idles, and does not display a fault, then there could be a frequency mismatch problem. Measure generator output frequency with a digital Multimeter and compare to the frequency on the operator panel or PC based service tool. Verify number of flywheel teeth has been correctly configured (see Section 7.11.1). If they do match, multiply the frequency by 30 and compare this number to the RPM on the operator panel or PC based service tool. If these are not the same, the MPU sender may be bad. Replace the MPU sender. If the Multimeter and control frequencies do not match, there is a frequency sensing problem within the Base board. Replace Base board |
| 46/216 | High AC Current (Shutdown/Warning) — No action is taken by the control for code 216. Engine will shut down for code 46. | Fault threshold are not set correctly with PC based service tool; Short or Overload; Incorrect CTs, CT Connections, or CT setup; The problem may be the Base board or harness connections; Incorrect rating setup | Reset the threshold to the desired or correct setting. Determine the required operating range before adjusting the threshold; Check the load and load cables. Repair if necessary. Check operation by disconnection load and restarting generator set; Check CTs, CT connections, correct if necessary. Refer to Current Transformer Setup in Section 6.6; Remove connector P12 from Base board. Check continuity from P12 to CTs. P12-1 (CT1) to P12-4 (CT1-COM) P12-2 (CT2) to P12-5 (CT2-COM) P12-3 (CT3) to P12-6 (CT3-COM) Repair connections; Check rating setup in control. Correct if necessary |
| 72 | Fail To Crank (Shutdown) (Local or Remote) — Engine will not start. | Starter is bad; Base board/K7 Starter Relay is bad; The Emergency Stop switch or wiring is defective; MPU/circuit or Base board is bad | Reset the control. Attempt to start, and test for B+ at the starter. If there is B+ at the starter, the starter could be bad. Test starter (see engine service manual). Replace the starter. If B+ is not present at the starter, go to next step; Check wiring continuity/test K7 relay. Remove lead from K7-COM and check for B+ at lead COM (directly connected to battery B+). If there is no B+, check for open circuit between K7-COM and battery B+. If B+ is present, reconnect lead COM to K7. Remove lead from K7-N/O. Attempt to start and check for B+ at terminal K7-N/O. If B+ is present, check for open circuit between K7-N/O and SW terminal of starter. If B+ is not present, the Base board/K7 relay is bad; With Emergency Stop push button not activated, remove configurable leads from TB1-15 and TB1-16 and check for continuity between these two leads. If circuit is open, isolate to Emergency Stop switch and wiring. If there is continuity, go to next step; Refer to Code 45 instructions |
| 73 | Fail To Start (Shutdown) Mechanical Governed Engine — Engine will not start. | Restricted fuel supply due to: a) Fuel level below pickup tube in tank. b) Closed shutoff valve in supply line. c) Fuel injectors clogged. d) Air in fuel system; Glow plugs are not heating due to: a) Glow plug(s) is bad. b) Base board is bad. c) Glow Plug Relay is bad; The engine fuel system is worn or malfunctioning or has lost prime (fuel lift pump, injection pump, injectors, timing); The engine is worn or malfunctioning mechanically | 1a. Add fuel if low. Prime the fuel system. 1b. Open any closed shutoff valve in the fuel line supplying the engine. 1c. Refer to engine service manual. 1d. Bleed air from fuel system. Refer to engine service manual; The Base board determines at what temperature and duration of time that the glow plugs will be energized. Using sensed coolant temperature, the glow plugs are energized at 77F (25C) and colder. The glow plugs are energized for up to 15 seconds when the coolant temperature is -5F (-20.5C) or colder. Time duration (15-0 seconds) is linear between -5F and 77F. With coolant temperature colder than 77F (25C): 2a. Each glow plug should be warm to the touch if the engine has just been cranking. First clean and tighten the terminal of any cold glow plug and then replace it if necessary. 2b. Install harness tool between Base board P11 connector. Attempt to start and check for B+ at P11-2 (RELAY COIL B+) and P11-19 (GLOW PLUG SOL). (These are leads to K2 coil.) If B+ is not present, the Base board is bad. If B+ is present, go to step c. 2c. Check for B+ at glow plug relay. If not present, check for open circuit. If there is B+ at glow plug relay, attempt to start and test for B+ at other end of glow plug relay. If B+ is not present, glow plug relay is bad. If B+ is present, check for open circuit between glow plug relay contact and glow plugs; Service according to the engine service manual; Service according to the engine service manual |
| 73 | Fail To Start (Shutdown) Electronic Governed Engine — Engine will not start. | Restricted fuel supply due to: i. Fuel level below pickup tube in tank. ii. Closed shutoff valve in supply line. iii. Fuel injectors clogged. iv. Air in fuel system; The governor linkage needs adjustment; Injection pump actuator not energized due to the harness, governor actuator governor module or the base board is bad; The engine fuel system is worn or malfunctioning or has lost prime (fuel lift pump, injection pump, injectors, timing); The engine is worn or malfunctioning mechanically | 1a. Add fuel if low. Prime the fuel system. 1b. Open any closed shutoff valve in the fuel line supplying the engine. 1c. Refer to engine service manual. 1d. Bleed air from fuel system. Refer to engine service manual; Repair and adjust the linkage as necessary (refer to Section 7); Isolate to harness, governor actuator or Base board. 3a. Display “Governor Duty Cycle” menu. Attempt to start and check for duty cycle (44% is about average). If percentage of duty cycle is displayed before shutdown, the harness, actuator governor or output circuit of control is bad, go to step 4b. (Duty cycle displayed indicates processor is functioning, but output circuitry of Base board could still be defective.) If the duty cycle is not displayed the control is bad, or is configured incorrectly. Check configuration. 3b. Remove connector P11 from control and check wiring continuity of actuator circuit. P11-14 (GOV-DR+) and P11-7 (GOV-DR-) to appropriate +/- terminals of governor module and between J1-4 on governor module and actuator. If continuity is OK, go to step 4c. 3c. Disconnect the two leads attached to the injection pump actuator. Measure the resistance across the two actuator terminals. A reading of 2.3 ohms indicates that the actuator circuit is OK. (This test only shows that the actuator circuit is not opened or shorted, but not if there is binding.) Replace actuator assembly if open or short is measured. If actuator is OK, go to step 4d. 3d. Remove power from control for one minute. Put power back on the control and check for B+ at J11-14. If not present, control is bad. If present, go to step 4e. 3e. Attempt to start and check for CNTL B+ at terminal lead ACT + of governor actuator (use engine block for metering ground). If not present, check wiring or SW B+ control function and J1-3 of governor module. If CNTL B+ is present, attempt to start and check for GOV PWM (pulse wide modulated) signal (measure across terminals of actuator and across J1-2 to J1-1 of governor module). If not present on J1, control is bad. If not present on actuator, governor module is bad; Service according to the engine service manual; Service according to the engine service manual |
| 75/76 | Configurable Input (Shutdown) — Shutdown. | If there is no actual fault, the problem may be an external wiring problem | Disconnect the signal lead from TB1 and reset the control. Check the following two points. CUST_IN1 – TB1-14 CUST_IN2 – TB1-12 If the message drops out, the external wiring has a short circuit. Grounding of either input activates fault |
| 202 | Pre-High Coolant Temp (Warning) | Refer to code 1 | Refer to code 1 |
| 203 | Low Coolant Temperature (Warning) — No action is taken by the control. Engine may not start due to slow cranking speed. | Fault simulation was enabled with PC based service; Fault threshold is not set correctly with a PC based service tool; The engine coolant heater could be bad. (Radiant heat should be felt with hand held close to outlet hose.); The sensor connections could be bad; The sensor could be bad; The harness or Base board could be bad | With PC based service tool, verify that the fault simulation is not enabled for the coolant sensor. If you do not have a based service tool, remove battery power from the control to disable fault simulation overrides; Reset the threshold to the lowest allowable setting. Determine the required operating range before adjusting the threshold; Coolant heater not operating due to: Coolant heater not connected to power. Check for blown fuse, or disconnected heater cord and correct as required. Low coolant level. Look for possible coolant leakage points and repair as required. Defective heater element/thermostat. With coolant heater removed from engine and power disconnected, flush with cold tap water for two minutes to close internal heater thermostat (opens at 100F and closes at 80F). Check resistance across input power leads: a) Open - replace coolant heater. b) Closed - coolant heater OK (coil resistance of 10 to 60 ohms); Inspect the sensor and engine harness connector pins. Repair or replace as necessary; Disconnect the sensor, and plug in a resistive sensor simulator to isolate the fault. If the control responds to the simulator, replace the sensor. If control does not respond, harness or Base board are bad; Measure the resistance of the coolant temperature sensor and reconnect harness to sensor. Remove connector P11 from Base board and check resistance between pins P11-18 (H20) and P11-6 (H20 COM). If resistance is not the same, harness is bad. If resistance is the same, Base board is bad |
| 204/205 | Configurable Input (Warning) — Warning. | If there is no actual fault, the problem may be an external wiring problem | Disconnect the signal lead from TB1 and reset the control. Check the following pins. CUST_IN1 - TB1-14 CUST_IN2 - TB1-12 If the message drops out, the external wiring has a short circuit. Grounding of either input activates fault |
| 212 | Coolant Sensor OOR (High/Low) (Warning) — No engine protection for coolant temperature during genset operation. Possible white smoke. | The sensor connections could be bad; The sensor could be bad; The harness or Base board could be bad | Inspect the sensor and engine harness connector pins. Repair or replace as necessary; Disconnect the sensor, and plug in a resistive sensor simulator to isolate the fault. If the control responds to the simulator, replace the sensor. If control does not respond, go to next step; 3a. Remove connector P11 from Base board and disconnect sensor. Check pins P11-18 (H20) and P11-6 (H20 COM) for short circuit as follows: Check for a short circuit to the engine block ground (more than 200k ohms OK). Check for a short circuit from pin to pin (more than 200k ohms OK). Repair or replace as necessary. 3b. Measure the resistance of the coolant sensor and reconnect harness to sensor. Remove connector P11 from Base board and check resistance between pins P11-18 (H20) and P11-6 (H20 COM). If resistance is not the same, harness is bad. If resistance is the same, Base board is bad |
| 213 | Low Battery (Warning) — The control’s voltage supply approaching level at which unpredictable operation may occur. | Weak or discharged battery; Low electrolyte level in battery; Battery connections loose or dirty; Insufficient battery charging voltage; Engine DC alternator could be bad; If the batteries are OK, the problem may be the harness or the Base board; Fault threshold could be bad | Recharge or replace the battery. Specific gravity for a fully charged battery is approximately 1.260 at 80F (27C); Replenish electrolyte and recharge battery; Clean and tighten or replace the battery cable connectors and cables at the battery and the set; Adjust charge rate of AC powered battery charging circuit, according to manufactures instructions; Replace engine DC alternator if normal battery charging voltage (12 to 14 VDC) is not obtained; Remove connector P11 from Base board and check battery voltage at P11-3 & 15 (B+) to P11-9 & 10 (GND). If the voltage at P11 is not the same as the battery voltage, the harness is bad. If the voltage at P11 is OK, the Base board is bad; Check fault threshold against requirement of the application |
| 214 | High Battery Voltage (Warning) — Control damage will occur. | Excessive battery charging voltage; Engine DC alternator could be bad; Fault threshold could be bad | Adjust charge rate of AC powered battery charging circuit according to manufacturers instructions; Replace engine DC alternator if normal battery charging voltage (12 to 14 VDC) is not obtained; Check fault threshold against requirement of the application |
| 215 | Pre-Low Oil Pressure (Warning) | Refer to code 2 for oil pressure sender | Refer to code 2 for oil pressure sender |
| 216 | High AC Current (Warning) | Refer to code 46 | Refer to code 46 |
| 217 | Oil Pressure Sensor OOR (High/Low) (Warning) — No engine protection for oil pressure during genset operation. | The sensor connections could be bad; The sensor could be bad; The harness could be bad; The Base board could be bad | Inspect the sensor and engine harness connector pins. Repair or replace as necessary; Disconnect the oil pressure sensor leads, and connect an oil pressure sensor simulator to the harness. “OIL PRESSURE SENSOR OOR” warning is displayed after the fault condition is sensed for 10 seconds. If the control responds to the simulator, replace the sensor. If control does not respond, go to next step; Remove connector P7 from Base board and connector from sensor. Check P11-6, 17 & 21 as follows: Check for a short circuit from pin to pin (more than 200k ohms OK). Check for an open circuit (10 ohms or less OK). Repair or replace as necessary; With all connectors attached, check pressure signal (.5 to 4.5 VDC) at P11-17 (OP OUT) and P11-6 (OP COM). If in range, replace Base board |
| 221 | Weak Battery (Warning) | Refer to code 213 | Refer to code 213 |
| 222-224 | Configurable Input (Warning) — Warning. | If there is no actual fault, the problem may be an external wiring problem | Disconnect the signal lead from TB1 and reset the control. Check the following pins. These connections are on the Universal Annuciator. CONF_ANNUC_IN1 - TB1-14 CONF_ANNUC_IN2 - TB1-12 If the message drops out, the external wiring has a short circuit. Grounding of either input activates fault |
| 225 | Annunciator Configuration Error (Warning) — Warning | Network configuration is bad; Bad device on network | Check setup of devices on the network against duplicate use of the same Annunciator relay output; Troubleshoot network for malfunctioning devices |
| 216 | High AC Current warning message | High AC current warning fault condition active for the duration of the H. Curr Warning Time Delay (threshold set from 110 to 130% of rated AC current; time delay of 10 to 60 seconds) | |
| 46 | High AC Current shutdown message | High AC current shutdown fault condition active for the duration of the H. Curr Shutdown Time Delay (threshold set from 130 to 190% of rated AC current; time delay of 2 to 60 seconds) | Engine shuts down |
| 81 u | Generator set output frequency cannot be maintained. | ||
| 59 | High AC voltage shutdown (Output voltage on any phase exceeds pre-set values). | ||
| 27 | Low AC voltage shutdown (Voltage on any phase has dropped below a preset value). |
| Symptom | Cause | Remedy |
|---|---|---|
| Engine does not crank in manual mode (no fault message) — Engine will not start | No power supplied to control; Poor battery cable connections | Clean the battery cable terminals and tighten all connections; Remove connector P11 and check for B+ at P11-3 & 15 and GND at P11-9 & 10. If B+ or ground missing, isolate to harness and TB BAT terminal mounted on engine block. If B+ and ground check OK, cycle power to base board by reconnecting P11 and retry operation. |
| Engine does not crank in manual mode (no fault message) — Engine will not start | No power supplied to front membrane panel | Check for B+ at TB1-1 and GND at TB1-4. If B+ or ground missing, the base board is bad. If B+ and ground check OK, remove P1 from back of front membrane panel. Check for B+ at P1-3 and ground at P1-5. If B+ or ground missing, repair harness. |
| Engine does not crank in manual mode (no fault message) — Engine will not start | Base board not properly calibrated or corrupt calibration | Confirm that the installed calibration part number matches the serial plate information. Re-enter calibration file if necessary. |
| Engine does not crank in manual mode (no fault message) — Engine will not start | The Emergency Stop switch or wiring is defective | With Emergency Stop push button not activated (switch closed), remove configurable leads from TB1-15 and TB1-16 and check for continuity between these two leads. If circuit is open, isolate to Emergency Stop switch and wiring. If there is continuity, go to next step. |
| Engine does not crank in manual mode (no fault message) — Engine will not start | The menu display manual Run button, harness or the Base board is bad | Check for continuity between P11-4 (RUN) to P11-8 (GND). If no continuity when pressing the manual Run button, isolate to front membrane panel and wiring. If there is continuity, the Base board is bad. |
| Engine does not crank in manual mode (no fault message) — Engine will not start | Oil Pressure switch or wiring is defective | Remove P11 connection and check wiring between P11-6 and P11-7 to the switch; Verify control is configured for the type of switch installed; Verify proper operation of the switch |
| Engine does not crank in manual mode (no fault message) — Engine will not start | Oil Pressure sender, setup on wiring is defective | Remove P11 connection and check wiring between P11-6, P11-17 and P11-5 (for 3-wire sender) to the sender; Verify control is configured for the type of sender; Verify operation of the sender |
| Engine does not crank in remote mode (no fault message) — Engine will not start in remote mode, but starts in manual mode | The remote start switch or configurable wiring is faulty | Reset the control. Attempt to start, and check for ground at TB1-11. If ground level is not present, isolate to the remote switch or configurable wiring. Repair as necessary. If ground is present, go to next step. |
| Engine does not crank in remote mode (no fault message) — Engine will not start in remote mode, but starts in manual mode | The menu display Auto button, harness or the Base board is bad | Check for continuity between P11-16 (AUTO) to P11-8 (GND). If no continuity when pressing the menu display Auto button, isolate to front membrane panel or wiring harness. If there is continuity, the Base board is bad. |
| CONFIGURABLE INPUT #1 & #2 — Lamp: Shutdown; The nature of the fault is an optional configurable selection. Example inputs: Low Fuel Day Tank, Water In Fuel, Ground Fault, etc | Each of the fault functions can be programmed (using service tool or operator panel), as follows: Warning or Shutdown (Default: Warning) (See fault code 204/205 for Warning); Change display name using up to 32 characters. | |
| CONFIGURABLE INPUT #1, #2 — Lamp: Warning; The nature of the fault is an optional configurable selection. Example inputs: Low Fuel Day Tank, Water In Fuel, Ground Fault, etc | Each of the fault functions can be programmed (using service tool), as follows: Warning or Shutdown (Default: Warning) (See fault code 75/76 for Shutdown); Change display name using up to 32 characters. | |
| Output voltage on any phase exceeds pre-set values. | Values adjustable from 105-125% of nominal voltage, with time delay adjustable from 1-10 seconds. Default value is 110% for 5 seconds. | |
| Voltage on any phase has dropped below a preset value. | Adjustable over a range of 50-95% of voltage, time delay 2-20 seconds. Default value is 90% for 5 seconds. | |
| Generator set output frequency cannot be maintained. | Settings are adjustable from 2-10 Hz below nominal governor set point, for a 500-2000 half cycles delay. Default: 5 Hz, 1000 half |
Fault codes and symptom→remedy steps extracted from this model’s service/owner documentation; verify against the official manual before servicing.
Documented causes: Fault simulation was enabled with a PC based service tool; Fault threshold is not set correctly with a PC based service tool; Overload; Improper connections have been made at the generator output terminals. See the table for the matching fixes.
Documented causes: No power supplied to control; Poor battery cable connections; No power supplied to front membrane panel; Base board not properly calibrated or corrupt calibration; The Emergency Stop switch or wiring is defective. See the table for the matching fixes.
Documented causes: Fault simulation was enabled with a PC based service tool; Low oil level. Clogged lines or filters; Sensor or oil pump could be bad. Or the generator set may be shutting down on another fault; Harness or Base board could be bad. See the table for the matching fixes.