Cummins/Onan DQAD troubleshooting: 159 fault codes and 36 symptom-cause-remedy entries from the manufacturer's own service documentation.
Cummins/Onan DQAD — full specs, parts & maintenance.
All Cummins/Onan fault codes →
| Code | Meaning | Cause | Remedy |
|---|---|---|---|
| 204 | OIL PRES SENDER — WARNING | The control has sensed that the engine oil pressure sender is out of its working range; The sender connections could be bad; The sender, the harness, engine interface board (A31), digital board (A32), or analog board (A33) could be faulty | Check that the engine oil pressure sender is properly connected; Check the sender connections; Isolate to the sender, harness, engine interface board (A31), analog board (A33), or digital board (A32). Disconnect the oil pressure sender leads, and connect an oil pressure sender simulator to the harness. If the control responds to the simulator, replace the sender. If the control does not respond to the simulator, the PCC or the harness is bad. Install harness tool between A31 J2/P2. Check for +5 VDC at the sender (lead marked E1-B). If there is no 5 VDC at the sender: Check for 5 VDC at A31 J5-18. If yes, harness is bad. If no, check for 5 VDC at A31 J2-24. If yes, A31 is bad. If no, A33 is bad. If there is 5 VDC at the sender, use the sender simulator to generate a signal to A31 J2-23. If the pressure signal (.5 to 4.5 VDC) does not get to A31 J2-23, isolate to the harness or A31. If the pressure signal does get to A31 J2-23, refer to the analog/digital troubleshooting procedure (Table 4-30a/b) |
| 210 | LOW COOLANT TEMP — WARNING | Engine coolant heater is not operating or is not circulating coolant; Coolant heater not connected to power supply; Low coolant level; Open heater element; The sender, the harness or A31 could be bad; A31, the engine interface board, or A32, the digital board, could be bad | Check for the following conditions: a. Coolant heater not connected to power supply. Check for blown fuse or disconnected heater cord and correct as required. b. Check for low coolant level and replenish if required. Look for possible coolant leakage points and repair as required. c. Open heater element. Check current draw of heater; Isolate the source of the signal. Unplug the coolant temperature switch (S1) and reset the control. 1. If the 210 warning message drops out and does not reappear, replace the sender. 2. If the 210 warning message reappears and remains after control reset, disconnect A31 J4 and check continuity from P4−13 to GND. If there is continuity, replace the harness. If there is no continuity, replace circuit board A31; Isolate the source of the signal. Check J4−6/P4−6 on A32. 1. Install harness tool between A32 J4/P4. 2. Open J4−6 and reset the control. If fault drops out and does not return, replace A31. If fault returns after resetting the control, replace A32 |
| 211 | HIGH COOLANT TEMP — WARNING | Indicates the engine coolant temperature is getting close to the recommended maximum temperature limit: 215° F (102° C) − standby or 207° F (97° C) − prime | If generator is powering non-critical and critical loads and cannot be shut down, use the following: a. Reduce load if possible by turning off non-critical loads. b. Check air inlets and outlets and remove any obstructions to airflow. If engine can be stopped, follow HIGH COOLANT TEMP 212 − SHUTDOWN procedure. To check coolant temperature, access the coolant temperature menu prior to clearing the fault |
| 212 | HIGH COOLANT TEMP — SHUTDOWN | Indicates engine has overheated (coolant temperature has risen above the shutdown trip point: 223° F (106° C) − standby or 215° F (102° C) − prime | Allow engine to cool down completely before proceeding with the following checks: a. Check for obstructions to cooling airflow and correct as necessary. b. Check fan belt and repair or tighten if necessary. c. Check coolant mixture. d. Check blower fan and circulation pumps on remote radiator installations. e. Reset control and restart after locating and correcting problem |
| 213 | COOLANT SENDER — WARNING | Indicates that the resistance of the coolant temperature sender is out of range; The sender connections could be bad; The sender, the harness, engine interface board (A31), digital board (A32), or analog board (A33) could be faulty | Check the resistance of the sender. Resistance should be 500 to 2k ohms; Check the sender connections; Isolate to the sender, harness, engine interface board (A31), analog board (A33), or digital board (A32). Disconnect the sender, and plug in a resistive sender simulator to isolate the fault. a. If the control responds to the simulator, replace the sender. b. If the control does not respond to the simulator, refer to the high coolant temp troubleshooting procedure |
| 214 | LOW COOLANT LVL — WARNING | Indicates engine coolant level has fallen below the trip point | Allow engine to cool down completely before proceeding. a. Check coolant level in both radiator and coolant recovery bottle and replenish if low. Look for possible coolant leakage points and repair if necessary. b. Reset control and restart after locating and correcting problem. LOW COOLANT LVL Shutdown will not occur if genset is in Idle mode (low coolant warning only) |
| 215 | LOW COOLANT LVL — SHUTDOWN | Indicates engine coolant level has fallen below the trip point | Allow engine to cool down completely before proceeding. a. Check coolant level in both radiator and coolant recovery bottle and replenish if low. Look for possible coolant leakage points and repair if necessary. b. Reset control and restart after locating and correcting problem. LOW COOLANT LVL Shutdown will not occur if genset is in Idle mode (low coolant warning only) |
| 220 | MAG PICKUP — SHUTDOWN | Indicates mag pickup speed indication is not being sensed or does not match generator set output frequency | A. Restart and check RPM on the digital display |
| 221 | FAIL TO CRANK — SHUTDOWN | Indicates possible fault with control or starting system; The mag pickup signal is not being sensed | Check for the following conditions: a. Check fuse F3 on the Engine Interface board. b. Poor battery cable connections. Clean the battery cable terminals and tighten all connections. c. Discharged or defective battery. Recharge or replace the battery; Refer to the mag pickup shutdown message (220) |
| 222 | OVERCRANK — SHUTDOWN | Indicates possible fuel system problem; Restricted fuel supply due to: a. Fuel level below pickup tube in tank. b. Closed shutoff valve in supply line. c. Air in fuel system; Fuel tank solenoid not energized due to: a. Open in fuel solenoid circuit. b. Defective fuel solenoid; Engine fuel system or other engine problem; The run signal is not getting out of the engine interface board (A31). A31 may be bad; There is an open between the engine interface board (A31) and relay K8; Relay K8 is defective; CM570 module is defective; The keyswitch signal is not getting from customer interface board (A32) to the CM570 module; The keyswitch signal is not getting out of the customer interface board (A32). A32 may be bad; There is an open between the customer interface board (A32) and relay K7; Relay K7 is defective; The run signal is not getting out of the digital board (A32). A32 may be bad; The run signal is not being processed by the engine interface board (A31). A31 may be bad | A. Check for empty fuel tank, fuel leaks, or plugged fuel lines and correct as required. b. Check for dirty fuel filter and replace if necessary. c. Check for dirty or plugged air filter and replace if necessary. d. Reset the control and restart after correcting the problem; 1a. Add fuel if low. Prime the fuel system. 1b. Open any closed shutoff valve in the fuel line supplying the engine. 1c. Bleed air from fuel system. Refer to engine service manual; 2a. Check wiring continuity of fuel tank solenoid circuit. 2b. Test fuel tank solenoid. Repair or replace as necessary; 3. Refer to engine service manual; Install harness tool between A31 J4/P4. Reset the control. Attempt to start and check for B+ at A31 J4-1. If there is no B+ at A31 J4-1, replace A31; If there is B+ at A31 J4-1, check for B+ at K8-86, while attempting to crank. If there is no B+ at K8-86, isolate to connectors and wiring. Repair or replace as necessary; If there is B+ at K8-86, check for ground signal at K8-30. If open, replace K8; 4a. Check fuses FB3 and FB4 which supply B+ to the CM570 module. 4b. Check CM570 module using InSite service tool; Reset the control. Check for ground at A32 P3-10. (Control panel switch set to Off position.); Install harness tool between A32 J3/P3. Check for ground at A32 J3-10. If no ground output at A32 J3-10, replace A32; If there is ground at A32 J3-10, isolate to connectors and wires between A32 J3-10 to TB1-19 to K7-85; B+ must be present at relay K7-30 for the CM570 module to be operational. If B+ is not present, isolate to defective K7 relay/wiring. (K7-30 B+ is present during stop or run mode. Disabled only for emergency stop.); Install harness tool between A32 J4/P4. Attempt to start and check for ground signal at A32 J4−8. 1. If there is no ground signal at A32 J4−8, replace A32; If there is a ground signal at A32 J4−8, replace A31 |
| 223 | OVERSPEED — SHUTDOWN | Indicates engine has exceeded normal operating speed. (115% ±1% of nominal) | |
| 230 | LOW DC VOLTAGE — WARNING | Indicates battery voltage is below 10 VDC; Discharged or defective battery; Poor battery cable connections; Engine DC alternator; Battery charge voltage float level | A. Discharged or defective battery. Check the battery charger fuse. Recharge or replace the battery. b. Poor battery cable connections. Clean the battery cable terminals and tighten all connections. c. Check engine DC alternator. Replace engine DC alternator if normal battery charging voltage is not obtained. d. Check battery charge voltage float level if applicable (raise float level) |
| 231 | HIGH DC VOLTAGE — WARNING | Indicates battery voltage exceeds 32 VDC | Check voltage float level on battery charger if applicable (lower float level). Check engine DC alternator. Replace engine DC alternator if normal battery charging voltage is not obtained |
| 232 | WEAK BATTERY — WARNING | Indicates battery voltage drops below 60% of nominal for two seconds, during starting; Discharged or defective battery | See Warning message 230, LOW DC VOLTAGE |
| 240 | LOW FUEL−DAY — WARNING | Indicates day tank fuel supply is running low | Check fuel supply and replenish as required |
| 241 | LOW FUEL — WARNING | Indicates day tank fuel supply is running low | Check fuel supply and replenish as required |
| 250 | EEPROM ERROR — SHUTDOWN | Indicates PCC memory error. Data corruption of critical operating parameters | |
| 251 | EEPROM ERROR — WARNING | Indicates PCC memory error. Data corruption of noncritical operating parameters | |
| 252 | EEPROM ERROR — WARNING | Indicates PCC memory error. Data corruption of noncritical operating parameters | |
| 260 | CUSTOMER FAULT 1 — SHUTDOWN | When any one of these customer defined inputs is closed to ground, the corresponding fault message is displayed. The nature of the fault is an optional customer selection. These fault functions can be programmed to initiate a shutdown or a warning. As indicated by the Shutdown lamp, a shutdown response has been preselected | |
| 261 | GROUND FAULT — SHUTDOWN | When any one of these customer defined inputs is closed to ground, the corresponding fault message is displayed. The nature of the fault is an optional customer selection. These fault functions can be programmed to initiate a shutdown or a warning. As indicated by the Shutdown lamp, a shutdown response has been preselected | |
| 260 | CUSTOMER FAULT 1 — WARNING | When any one of these customer defined inputs is closed to ground, the corresponding fault message is displayed. The nature of the fault is an optional customer selection. These fault functions can be programmed to initiate a shutdown or a warning. As indicated by the Warning lamp, a warning response has been preselected | |
| 261 | GROUND FAULT — WARNING | When any one of these customer defined inputs is closed to ground, the corresponding fault message is displayed. The nature of the fault is an optional customer selection. These fault functions can be programmed to initiate a shutdown or a warning. As indicated by the Warning lamp, a warning response has been preselected | |
| 262 | CM570/ENGINE — WARNING | Indicates CM570 engine control module error condition | Check CM570 module using InSite service tool |
| 263 | CM570/ENGINE — SHUTDOWN | Indicates CM570 engine control module error condition | Check CM570 module using InSite service tool |
| 301 | HIGH AC VOLTAGE — SHUTDOWN | Indicates that one or more of the phase voltages has exceeded 130% of nominal, or has exceeded 110% of nominal for 10 seconds | |
| 303 | LOW AC VOLTAGE — SHUTDOWN | Indicates that one or more of the phase voltages has dropped below 85% of nominal for 10 seconds | |
| 313 | UNDER FREQUENCY — SHUTDOWN | Indicates that engine speed has dropped below 90% of nominal for 10 seconds. Note: Five seconds before shutdown, a Load Dump signal is initiated | Check fuel supply, intake air supply and load |
| 320 | OVERCURRENT — WARNING | Indicates that generator output current has exceeded 110% of rated for 60 seconds | Check load and load lead connections |
| 321 | OVERCURRENT — SHUTDOWN | Indicates that generator output current has exceeded 110% of rated, and that a PCC time/current calculation has initiated an overcurrent shutdown | Check load and load lead connections |
| 322 | SHORT CIRCUIT — SHUTDOWN | Indicates that generator output current has exceeded 175% of rated | Check load and load lead connections |
| 330 | OVERLOAD — WARNING | Indicates that three-phase power output exceeds 105% of standby (or 115% of prime) rating. After five seconds, the Load Dump output is activated. After 60 seconds, the OVERLOAD warning is activated | Check load and load lead connections |
| 335 | REVERSE POWER — SHUTDOWN | Indicates improper CT or PT phasing. (Non-parallel units only.) | Check CT / PT wiring. Refer to CT Installation in Section 5 |
| 200 | LOW OIL PRESSURE — WARNING | Low oil level. Clogged lines or filters; Sender or oil pump could be bad. Or the generator set may be shutting down on another fault; Harness or PCC circuit board could be bad. Isolate to the harness, engine interface board (A31), analog board (A33), or digital board (A32) | Check oil level, lines and filters. If oil system is OK but oil level is low, replenish. Oil pressure limits are listed in Table 4-3; Disconnect the oil pressure sender leads, and connect an oil pressure sender simulator to the harness. a. If the control responds to the simulator, reconnect the sender, disconnect the run 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 generator set may be shutting down on another fault (out of fuel, intermittent connector). Restart the generator set and monitor the PCC display panel for other faults. If the display does not show an acceptable oil pressure, replace the sender. If the PCC still doesn’t display an oil pressure while cranking, the oil pump may be faulty. Refer to the engine service manual. b. If the control does not respond to the simulator, the PCC or the harness is bad. Install harness tool between A31 J2/P2. Check for +5 VDC at the sender (lead marked E1-B). If there is no 5 VDC at the sender: Check for 5 VDC at A31 J5-18. If yes, harness is bad. If no, check for 5 VDC at A31 J2-24. If yes, A31 is bad. If no, A33 is bad. If there is 5 VDC at the sender, use the sender simulator to generate a signal to A31 J2-23. If the pressure signal (.5 to 4.5 VDC) does not get to A31 J2-23, isolate to the harness or A31. If the pressure signal does get to A31 J2-23, refer to the analog/digital troubleshooting procedure (Table 4-30a/b) |
| 201 | LOW OIL PRESSURE — SHUTDOWN | Low oil level. Clogged lines or filters; Sender or oil pump could be bad. Or the generator set may be shutting down on another fault; Harness or PCC circuit board could be bad. Isolate to the harness, engine interface board (A31), analog board (A33), or digital board (A32) | Check oil level, lines and filters. If oil system is OK but oil level is low, replenish. Oil pressure limits are listed in Table 4-3; Disconnect the oil pressure sender leads, and connect an oil pressure sender simulator to the harness. a. If the control responds to the simulator, reconnect the sender, disconnect the run 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 generator set may be shutting down on another fault (out of fuel, intermittent connector). Restart the generator set and monitor the PCC display panel for other faults. If the display does not show an acceptable oil pressure, replace the sender. If the PCC still doesn’t display an oil pressure while cranking, the oil pump may be faulty. Refer to the engine service manual. b. If the control does not respond to the simulator, the PCC or the harness is bad. Install harness tool between A31 J2/P2. Check for +5 VDC at the sender (lead marked E1-B). If there is no 5 VDC at the sender: Check for 5 VDC at A31 J5-18. If yes, harness is bad. If no, check for 5 VDC at A31 J2-24. If yes, A31 is bad. If no, A33 is bad. If there is 5 VDC at the sender, use the sender simulator to generate a signal to A31 J2-23. If the pressure signal (.5 to 4.5 VDC) does not get to A31 J2-23, isolate to the harness or A31. If the pressure signal does get to A31 J2-23, refer to the analog/digital troubleshooting procedure (Table 4-30a/b) |
| 211 | HIGH COOLANT TEMP warning (211) | 4−4/P4−4 on A32; Install harness tool between A32 J4/P4; Open the J4-4 circuit and reset the control; If the fault drops out and does not return, replace A31; If the fault returns after resetting the control, replace A32 | |
| 220 | MAG PICKUP shutdown message (220) — PCC is not sensing the mag pickup signal, or the mag pickup frequency does not correspond (in proportion) to the genset output frequency | The PCC may not be set for the correct generator set; Loose or damaged mag pickup wire; Damaged mag pickup (MPU); The harness, the engine interface board (A31), the analog board (A33) or the digital board (A32) could be bad | Check and correct setting if necessary; Inspect the wires, and repair or replace as necessary; To isolate the problem, reset the control and attempt to start the genset in idle mode; If the engine displays a FAIL TO CRANK shutdown message, or if the engine starts and idles, but then shuts down on a MAG PICKUP fault, 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 5.) If there is still no output, replace the MPU sender; If the MPU output is OK, install harness tool between A32 J4/P4. Check for MPU voltage at A32 J4-10 to 11, while cranking. If OK, replace A32. If not OK, use continuity checks to isolate to A31 or 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 PCC display; If they do match, multiply the frequency by 30 and compare this number to the RPM on the PCC display. If these are not the same, the MPU sender may be bad. Replace the MPU sender; If the multimeter and PCC frequencies do not match, there is a frequency sensing problem. Verify the accuracy of the PCC L1N voltage, and then refer to the analog/digital troubleshooting procedure (Table 4-30a/b) |
| 223 | OVERSPEED shutdown message (223) | Fuel system or CM570 module is bad; The engine interface board (A31) or the digital board (A32) could be bad | Refer to the engine service manual to troubleshoot fuel system; Use InSite service tool to troubleshoot CM570 module; Replace A31. If fault reappears, replace A32 |
| 230 | LOW DC VOLTAGE (230) warning message | Weak or discharged battery; Low electrolyte level in battery; Battery connections loose or dirty; Insufficient battery charging voltage; If the battery voltage is OK, the problem may be the engine interface board (A31), the digital board (A32), or the analog board (A33); If the batteries are OK, the problem may be the harness, the engine interface board (A31), the digital board (A32), or the analog board (A33) | Recharge or replace the battery. Specific gravity for a fully charged battery is approximately 1.260 at 80° F (27° C); Replenish electrolyte and recharge battery; Clean and tighten or replace the battery cable connectors and cables at the battery and the genset; Adjust charge rate of battery charging circuit, according to manufacturers instructions; Check the battery voltage at A31 J5-17. If the voltage is not OK (same as battery voltage), disconnect J5 and isolate to the harness or A31. If the voltage is OK, check battery voltage at A33 J1-31. If the voltage is not OK, replace A31. If the voltage at A33 J1-31 is OK, isolate to A33 or A32 using the analog input troubleshooting procedure (Table 4-30a/b); If the battery voltage, electrolyte, and connections are OK, check the battery voltage at A31 J5-17. If the voltage is not OK (same as battery voltage), disconnect J5 and isolate to the harness or A31. If the voltage is OK, check battery voltage at A33 J1-31. If the voltage is not OK, replace A31. If the voltage at A33 J1-31 is OK, isolate to A33 or A32 using the analog input troubleshooting procedure (Table 4-30a/b) |
| 231 | HIGH DC VOLTAGE (231) warning message — but battery voltage is OK | Excessive battery charging voltage; Engine DC alternator could be bad | Adjust charge rate of battery charging circuit according to manufacturers instructions; Replace engine DC alternator if normal battery charging voltage is not obtained |
| 232 | WEAK BATTERY (232) warning message | Weak or discharged battery; Low electrolyte level in battery; Battery connections loose or dirty; Insufficient battery charging voltage; If the battery voltage is OK, the problem may be the engine interface board (A31), the digital board (A32), or the analog board (A33); If the batteries are OK, the problem may be the harness, the engine interface board (A31), the digital board (A32), or the analog board (A33) | Recharge or replace the battery. Specific gravity for a fully charged battery is approximately 1.260 at 80° F (27° C); Replenish electrolyte and recharge battery; Clean and tighten or replace the battery cable connectors and cables at the battery and the genset; Adjust charge rate of battery charging circuit, according to manufacturers instructions; Check the battery voltage at A31 J5-17. If the voltage is not OK (same as battery voltage), disconnect J5 and isolate to the harness or A31. If the voltage is OK, check battery voltage at A33 J1-31. If the voltage is not OK, replace A31. If the voltage at A33 J1-31 is OK, isolate to A33 or A32 using the analog input troubleshooting procedure (Table 4-30a/b); If the battery voltage, electrolyte, and connections are OK, check the battery voltage at A31 J5-17. If the voltage is not OK (same as battery voltage), disconnect J5 and isolate to the harness or A31. If the voltage is OK, check battery voltage at A33 J1-31. If the voltage is not OK, replace A31. If the voltage at A33 J1-31 is OK, isolate to A33 or A32 using the analog input troubleshooting procedure (Table 4-30a/b) |
| 240 | LOW FUEL−DAY warning message (240) — fuel level is normal, DS1 on the engine interface board, A31, is on | DS1 on A31 is on, indicating that A31 is receiving a low fuel signal from the sender. The sender, the harness or the A31 circuit board could be bad | If the fuel level is normal, isolate the source of the low fuel signal. Disconnect the signal lead at the sender and reset the control; If the 240 message drops out and does not reappear, replace the sender; If the 240 message reappears and remains after control reset, disconnect J4/A31 and check continuity from P4−14 to GND; If there is continuity, replace the harness; If there is no continuity, replace circuit board A31 |
| 240 | LOW FUEL−DAY warning message (240) — fuel level is normal, DS1 on A31 is off | DS1 on A31 is off, indicating that the PCC is not receiving a low fuel signal from the sender—but the 240 message indicates that A32, the digital board, is responding to a false low fuel signal. A31, the engine interface board, or A32, the digital board, could be bad | If the fuel level is normal, isolate the source of the low fuel signal; Install a breakout connector at A32 J4; Open the J4-15 circuit and reset the control; If the fault drops out and does not return, replace A31; If the fault returns after resetting the control, go to step 3; Install harness tool between A32 J2/P2; Open the J2-19 circuit and reset the control; If the fault drops out and does not return, replace A31; If the fault returns after resetting the control, replace A32 |
| 241 | LOW FUEL warning message (241) — fuel level is normal, DS13 on the customer interface board, A34, is on | DS13 on A34 is on, indicating that A34 is receiving a low fuel signal from the customer circuit. If there is no actual fault, the problem may be a short to ground in the external wiring or a bad customer interface board (A34) | If the fuel level is normal, isolate the source of the low fuel signal. Disconnect the signal lead near the control and reset the control; If the 241 message drops out and does not reappear, there is a short to ground in the external wiring or a faulty sender; If the 241 message reappears and remains after control reset, disconnect J1/A34 and check continuity from P1−5 to GND; If there is continuity, find and repair a short to ground in the external wiring; If there is no continuity, replace circuit board A34 |
| 241 | LOW FUEL warning message (241) — fuel level is normal, DS13 (A34) is off | DS13 on A34 is off, indicating that the PCC is not receiving a low fuel signal from the sender—but the 241 message indicates that A32, the digital board, is responding to a false low fuel signal. A34, the customer interface board, or A32, the digital board, could be bad | If the fuel level is normal, isolate the source of the low fuel signal; Install harness tool between A32 J2/P2; Open the J2-19 circuit and reset the control; If the fault drops out and does not return, replace A34; If the fault returns after resetting the control, replace A32 |
| 250 | EEPROM ERROR shutdown (250) message | The EE memory on the digital board (A32) may be bad | Perform the initial start setup procedure. Turn the Run/Off/Auto switch to Off and reset the control. Simultaneously press the RESET, MENU, and PHASE SELECT keys to start the setup. Select the correct values, save your choices, and attempt to start the genset; If the genset shuts down on the same EEPROM ERROR message, replace the digital board (A32) |
| 251 | EEPROM ERROR warning (251) message | The EE memory on the digital board (A32) may be bad | Perform the adjustment procedures (described in Section 5). Save the adjustments. Reset the control. Shut off and restart the genset; If the control generates the same EEPROM ERROR message, perform the calibration procedures in Section 5. Reset the control. Shut off and restart the genset; If the control generates the same EEPROM ERROR message, replace the digital board (A32) |
| 252 | EEPROM ERROR warning (252) message | The EE memory on the digital board (A32) may be bad | If this message occurred during an adjustment, option selection, or calibration of the PCC, verify the values or choices selected and repeat the save operation. Reset the control. Shut off and restart the genset; If the control generates the same EEPROM ERROR message, replace the digital board (A32) |
| 260 | CUSTOMER FAULT (260 or 261) message — corresponding LED on customer interface board A34 is on | If the corresponding LED on the customer interface board (A34) is on, then A34 is receiving a signal from the customer circuit. If there is no actual fault, the problem may be a short to ground in the external wiring or a bad customer interface board (A34) | Isolate the source of the false signal. Disconnect the signal lead near the control and reset the control; If the message drops out, there is a short to ground in the external wiring; If the message remains, replace A34 |
| 260 | CUSTOMER FAULT (260 or 261) message — corresponding LED on customer interface board A34 is off | If the corresponding LED on the customer interface board (A34) is off, then A34 is not receiving a signal from the customer circuit. The message indicates that A32, the digital board, is responding to a false signal. A34, the customer interface board, or A32, the digital board, could be bad | Isolate the source of the false signal. Check J2/P2 on A32; Install harness tool between A32 J2/P2; Open the appropriate circuit J2-3 or J2-24 and reset the control; If the fault does not return, replace A34; If the fault reappears, replace A32 |
| 261 | CUSTOMER FAULT (260 or 261) message — corresponding LED on customer interface board A34 is on | If the corresponding LED on the customer interface board (A34) is on, then A34 is receiving a signal from the customer circuit. If there is no actual fault, the problem may be a short to ground in the external wiring or a bad customer interface board (A34) | Isolate the source of the false signal. Disconnect the signal lead near the control and reset the control; If the message drops out, there is a short to ground in the external wiring; If the message remains, replace A34 |
| 261 | CUSTOMER FAULT (260 or 261) message — corresponding LED on customer interface board A34 is off | If the corresponding LED on the customer interface board (A34) is off, then A34 is not receiving a signal from the customer circuit. The message indicates that A32, the digital board, is responding to a false signal. A34, the customer interface board, or A32, the digital board, could be bad | Isolate the source of the false signal. Check J2/P2 on A32; Install harness tool between A32 J2/P2; Open the appropriate circuit J2-3 or J2-24 and reset the control; If the fault does not return, replace A34; If the fault reappears, replace A32 |
| 262 | CM570/ENGINE warning (262) message — corresponding LED on customer interface board A34 is on | Low B+ to CM570 module during cranking. Check the following conditions: Batteries not charged; Battery connections loose or dirty; Insufficient battery charging voltage; Engine DC alternator could be bad; Defective CM570 module or engine problem; If there is no actual fault from the CM570 module, the problem may be a short to ground in the K10 relay circuit, defective K10 relay, or a bad customer interface board (A34) | Recharge or replace the battery. Specific gravity for a fully charged battery is approximately 1.260 at 80° F (27° C); Clean and tighten or replace the battery cable connectors and cables at the battery and the genset; Adjust charge rate of battery charging circuit; Replace engine DC alternator if normal battery charging voltage is not obtained; Check CM570 module using InSite service tool; Isolate the source of the false signal. Disconnect the signal lead at TB1-P4B-21 and reset the control; If the message drops out, there is a short to ground in the K10 relay circuit or relay K10 is defective; If the message remains, replace A34 |
| 263 | CM570/ENGINE shutdown (263) message — corresponding LED on customer interface board A34 is on | Defective CM570 module or engine problem; If there is no actual fault from the CM570 module, the problem may be a short to ground in the K9 relay circuit, defective K9 relay, or a bad customer interface board (A34) | Check CM570 module using InSite service tool; Isolate the source of the false signal. Disconnect the signal lead at TB1-P4B-22 and reset the control; If the message drops out, there is a short to ground in the K9 relay circuit or relay K9 is defective; If the message remains, replace A34 |
| 262 | CM570/ENGINE (262 or 263) message — corresponding LED on customer interface board A34 is off | If the corresponding LED on the customer interface board (A34) is off, then A34 is not receiving a signal from the CM570 module | Isolate the source of the false signal. Check J2/P2 on A32; Install harness tool between A32 J2/P2; Open the appropriate circuit J2-9, or J2-15 and reset the control; If the fault does not return, replace A34; If the fault reappears, replace A32 |
| 263 | CM570/ENGINE (262 or 263) message — corresponding LED on customer interface board A34 is off | If the corresponding LED on the customer interface board (A34) is off, then A34 is not receiving a signal from the CM570 module | Isolate the source of the false signal. Check J2/P2 on A32; Install harness tool between A32 J2/P2; Open the appropriate circuit J2-9, or J2-15 and reset the control; If the fault does not return, replace A34; If the fault reappears, replace A32 |
| 301 | HIGH AC VOLTAGE shutdown (301) message | The problem may be in the PCC, the alternator, or the interconnection between them; The problem may be the analog board (A33); The problem may be in the generator set itself | Set the display on the PCC to GEN, VOLTS, L-N. Start the genset and observe the voltage displayed on the digital display. If all phases of voltage are balanced and not zero, but lower than normal, the alternator and the input to the PCC are OK. The problem is in the excitation circuit for the alternator. Go to step 2; Using the harness tool, check the 3-phase ave signal at A33 J2-18. If the voltage is within the expected range, replace A32. If the voltage is not within the expected range, replace A33; Refer to the generator servicing procedures in Section 6 |
| 303 | LOW AC VOLTAGE shutdown (303) message | PMG or field wiring could be faulty; The rotating rectifier assembly (diodes CR1 through CR6) is faulty; Overload; There may be a loose connector in the control loop; The problem may be the analog board (A33) or the digital board (A32); The problem may be the regulator module (A37), the engine interface board (A31), or the digital board (A32); The problem may be the PT/CT module (A36), the analog board (A33), the customer interface board (A34), or the digital board (A32) | If output voltage is low and both A37/DS2 and A31/DS10 are on, check and repair the PMG or field wiring; Check each diode according to Servicing the Generator in Section 6. Service as necessary; Check the load and correct any overload; Check connectors J8 and J9 on A36, J3 and J5 on A34, and J7 on A37; Isolate the genset output from the load. Reset the control, restart the genset, and measure AC output voltage with a multimeter. If output voltage is high, refer to the troubleshooting section for High AC Voltage Shutdown (301). If output voltage is normal, the problem must be in the voltage sensing circuitry (A32 or A33). Isolate, using the analog input troubleshooting procedure (Table 4-30a/b). Check the phase that shows a low voltage on the PCC display; If output voltage is low, the control cannot drive the output voltage high enough. The problem could be A37, A31, or A32. Restart the genset and monitor isolated B+ supply LED A37/DS1, output duty cycle LED A37/DS2, and AVR duty cycle LED A31/DS10. If A37/DS1 is not on, disconnect A3 J7/P7 and check for B+ at P7-1. (Control must be in Run mode for B+ reading.) If B+ is OK to A37, replace A37. If A37/DS1 is on, check A31/DS10 (with the genset running). If A31/DS10 is not on with genset running, check for continuity: A31 J1-2 to J4-10 and A31 J1-1 to J4-11 (270 ohms). If no continuity, replace A31. If A31 is OK, replace A32. If A31/DS10 is on with genset running and A37/DS2 is not on, check the harness. If the harness is OK, replace A37; If the measured AC voltage is high, the control must have lost AC sensing. Check PTs (primary 1K−2.5K ohms; secondary 140−225 ohms), sensing harness wires, generator output connections, and the customer interface board for continuity. If these are OK, then check the analog and digital boards, using the analog input troubleshooting procedure (Table 4-30a/b) |
| 313 | UNDER FREQUENCY shutdown (313) message | Improper setup; Overload; Fuel or air delivery problem; Fuse FB3 or FB4 in the accessory box may be open, or B+ may not be getting to the fuses; The CM570 module, the digital board (A32), or the engine interface board (A31) could be bad | Check Initial Setup (set size) and correct, if necessary; Check the load and correct any overload, if necessary. Disconnect the load. Reset the control and attempt to restart the generator set; If the engine starts and runs, refer to the engine fuel/air delivery service procedures in the engine service manual; Check fuses FB3 and FB4 which supply B+ to the CM570 module. If open, replace the fuse with one of the same type and amp rating (10 Amps). If fuses are OK, check B+ supply back to TB2-7 and 8; Crank the genset, and check the governor duty cycle on the PCC display. If the duty cycle is OK (70%), indicates that the CM570 module may be bad (use InSite service tool). If the duty cycle is not OK, the digital board (A32) or the engine interface board (A31) may be bad. A31 - Check for continuity: A31 J1-13 to A31 J4-19 and A31 J1-14 to A31 J4-12. If no continuity, replace A31. A32 - If A31 is OK, replace A32 |
| 320 | OVERCURRENT warning (320) message | Short or Overload; Incorrect CTs or CT connections; The problem may be a bad PT/CT module (A36); The problem may be the customer interface board (A34) or connections; The problem may be the analog board (A33) or the digital board (A32) | Check the load and load cables. Repair if necessary; Check CTs and CT connections. Correct if necessary |
| 321 | OVERCURRENT shutdown (321) message | Short or Overload; Incorrect CTs or CT connections; The problem may be a bad PT/CT module (A36); The problem may be the customer interface board (A34) or connections; The problem may be the analog board (A33) or the digital board (A32) | Check the load and load cables. Repair if necessary; Check CTs and CT connections. Correct if necessary |
| 322 | SHORT CIRCUIT shutdown (322) message | Short or Overload; Incorrect CTs or CT connections; The problem may be a bad PT/CT module (A36); The problem may be the customer interface board (A34) or connections; The problem may be the analog board (A33) or the digital board (A32) | Check the load and load cables. Repair if necessary; Check CTs and CT connections. Correct if necessary |
| 330 | OVERLOAD warning (330) message | Short or Overload; Incorrect CTs or CT connections; The problem may be a bad PT/CT module (A36); The problem may be the customer interface board (A34) or connections; The problem may be the analog board (A33) or the digital board (A32) | Check the load and load cables. Repair if necessary; Check CTs and CT connections. Correct if necessary |
| HIGH COOLANT TEMP 212 | Shutdown lamp lights. MESSAGE: HIGH COOLANT TEMP 212 − SHUTDOWN | Indicates engine has overheated (coolant temperature has risen above the shutdown trip point: 223° F (106° C) − standby or 215° F (102° C) − prime.) | Allow engine to cool down completely before proceeding with the following checks: a. Check for obstructions to cooling airflow and correct as necessary. b. Check fan belt and repair or tighten if necessary. c. Check coolant mixture. d. Check blower fan and circulation pumps on remote radiator installations. e. Reset control and restart after locating and correcting problem. |
| COOLANT SENDER 213 | Warning lamp lights. MESSAGE: COOLANT SENDER 213 − WARNING | Indicates that the resistance of the coolant temperature sender is out of range. Check the resistance of the sender. Resistance should be 500 to 2k ohms. | |
| LOW COOLANT LVL 214 | Shutdown lamp lights. MESSAGE: LOW COOLANT LVL 214 − WARNING or LOW COOLANT LVL 215 − SHUTDOWN | Indicates engine coolant level has fallen below the trip point. Allow engine to cool down completely before proceeding. a. Check coolant level in both radiator and coolant recovery bottle and replenish if low. Look for possible coolant leakage points and repair if necessary. b. Reset control and restart after locating and correcting problem. LOW COOLANT LVL Shutdown will not occur if genset is in Idle mode (low coolant warning only). | |
| MAG PICKUP 220 | Shutdown lamp lights. MESSAGE: MAG PICKUP 220 − SHUTDOWN | Indicates mag pickup speed indication is not being sensed or does not match generator set output frequency. a. Restart and check RPM on the digital display. | |
| FAIL TO CRANK 221 | Shutdown lamp lights. Engine stops cranking. MESSAGE: FAIL TO CRANK 221 − SHUTDOWN | Indicates possible fault with control or starting system. Check for the following conditions: a. Check fuse F3 on the Engine Interface board. b. Poor battery cable connections. Clean the battery cable terminals and tighten all connections. c. Discharged or defective battery. Recharge or replace the battery. | |
| OVERCRANK 222 | Shutdown lamp lights. Engine runs and then shuts down. MESSAGE: OVERCRANK 222 − SHUTDOWN | Indicates possible fuel system problem. a. Check for empty fuel tank, fuel leaks, or plugged fuel lines and correct as required. b. Check for dirty fuel filter and replace if necessary. c. Check for dirty or plugged air filter and replace if necessary. d. Reset the control and restart after correcting the problem. | |
| OVERSPEED 223 | Shutdown lamp lights. Engine runs and then shuts down. MESSAGE: OVERSPEED 223 − SHUTDOWN | Indicates engine has exceeded normal operating speed. (115% ±1% of nominal). | |
| LOW DC VOLTAGE 230 | Warning lamp lights. MESSAGE: LOW DC VOLTAGE 230 − WARNING | Indicates battery voltage is below 10 VDC. a. Discharged or defective battery. Check the battery charger fuse. Recharge or replace the battery. b. Poor battery cable connections. Clean the battery cable terminals and tighten all connections. c. Check engine DC alternator. Replace engine DC alternator if normal battery charging voltage is not obtained. d. Check battery charge voltage float level if applicable (raise float level). | |
| HIGH DC VOLTAGE 231 | Warning lamp lights. MESSAGE: HIGH DC VOLTAGE 231 − WARNING | Indicates battery voltage exceeds 32 VDC. Check voltage float level on battery charger if applicable (lower float level). Check engine DC alternator. Replace engine DC alternator if normal battery charging voltage is not obtained. | |
| WEAK BATTERY 232 | Warning lamp lights. MESSAGE: WEAK BATTERY 232 − WARNING | Indicates battery voltage drops below 60% of nominal for two seconds, during starting. Discharged or defective battery. See Warning message 230, LOW DC VOLTAGE. | |
| LOW FUEL-DAY 240 | Shutdown lamp lights. MESSAGE: LOW FUEL−DAY 240 − WARNING or LOW FUEL 241 − WARNING | Indicates day tank fuel supply is running low. Check fuel supply and replenish as required. | |
| EEPROM ERROR 250 | Shutdown lamp lights. MESSAGE: EEPROM ERROR 250 − SHUTDOWN | Indicates PCC memory error. Data corruption of critical operating parameters. | |
| EEPROM ERROR 251 | Warning lamp lights. MESSAGE: EEPROM ERROR 251 − WARNING or 252 − WARNING | Indicates PCC memory error. Data corruption of noncritical operating parameters. | |
| CUSTOMER FAULT 1 260 | Shutdown lamp lights. MESSAGE: CUSTOMER FAULT 1 260 − SHUTDOWN or GROUND FAULT 261 − SHUTDOWN | When any one of these customer defined inputs is closed to ground, the corresponding fault message is displayed. The nature of the fault is an optional customer selection. These fault functions can be programmed to initiate a shutdown or a warning. As indicated by the Shutdown lamp, a shutdown response has been preselected. | |
| 101 | IDLE MODE | ||
| 102 | EMERGENCY STOP | To reset the local/remote Emergency Stop button: Pull the button out. Move the Run/Off/Auto switch to Off. Press the Reset switch. Select Run or Auto, as required. | |
| red Shutdown lamp | Shutdown fault | Make adjustments or corrections before restarting the genset | |
| 101 | IDLE MODE — Engine continues to operate at reduced RPM | Indicates that the engine is operating in idle mode. When the set is operating in the RUN mode, grounding the engine idle input causes generator build-up to be inhibited and the engine to be governed at 800 RPM. | When ground is removed from this input, the set returns to normal speed and voltage. When the engine idle function is enabled, the control automatically sets lower oil pressure warning and shutdown trip points to reflect the lower operating speed. When the engine idle function is removed and the set reverts to normal operating speed, the control automatically resets oil pressure warning and shutdown trip points to the normal settings. |
| 102 | EMERGENCY STOP — Engine shuts down and will not crank | Indicates local or remote Emergency Stop. | To reset the local Emergency Stop button: Pull the button out; Move the Run/Off/Auto switch to Off; Press the Reset switch; Select Run or Auto, as required. |
| 200 | LOW OIL PRESSURE — Warning lamp lights | Indicates engine oil pressure has dropped to an unacceptable level. | If generator is powering critical loads and cannot be shut down, wait until next shutdown period then follow 201 Low Oil Pressure procedure. If engine can be stopped, follow 201 procedure. To check oil pressure, access Oil Pressure menu prior to clearing the fault. |
| 201 | LOW OIL PRESSURE — Shutdown lamp lights | 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. Oil pressure limits are listed in Specifications. Contact an authorized service center. |
| 204 | OIL PRES SENDER — Warning lamp lights | Indicates that the engine oil pressure sender is not functioning correctly. | Check that the engine oil pressure sender is properly connected. Contact an authorized service center. |
| 210 | LOW COOLANT TEMP — Warning lamp lights; Set is in standby mode but is not operating. Warning occurs when engine coolant temperature is 70 F (21 C) or lower. NOTE: In applications where the ambient temperature falls below 40F (4C), Low Engine Temp may be indicated even though the coolant heaters are operating. | Indicates engine coolant heater is not operating or is not circulating coolant. | Check for the following conditions: a. Coolant heater not connected to power supply. Check for blown fuse or disconnected heater cord and correct as required. b. Check for low coolant level and replenish if required. Look for possible coolant leakage points and repair as required. c. Contact an authorized service center if none of the above. |
| 211 | HIGH COOLANT TEMP — Warning lamp lights | Indicates engine has begun to overheat and coolant temperature has risen to an unacceptable level: (215 F − standby / 207 F − primary). | If generator is powering non-critical and critical loads and cannot be shut down, use the following: a. Reduce load if possible by turning off non-critical loads. b. Check air inlets and outlets and remove any obstructions to airflow. If engine can be stopped, follow the next procedure. To check coolant temperature, access Coolant Temp menu prior to clearing the fault. |
| 212 | HIGH COOLANT TEMP — Shutdown lamp lights | Indicates engine has overheated (coolant temperature has risen above the shutdown trip point: 223 F − standby / 215 F − primary) or the coolant level is low. | Allow engine to cool down completely before proceeding with the following checks: a. Check coolant level and replenish if low. Look for coolant leakage and repair if necessary. b. Check for obstructions to cooling airflow and correct as necessary. c. Check fan belt and repair or tighten if necessary. d. Reset control and restart after locating and correcting problem. Contact an authorized service center if none of the above. |
| 213 | ENG COOLANT SENDER — Warning lamp lights | Indicates that the resistance of the coolant temperature sender is out of range. | Contact an authorized service center. |
| 214 | LOW COOLANT LVL — Warning lamp lights | Indicates engine coolant level has fallen below the trip point. | Allow engine to cool down completely before proceeding. a. Check coolant level and replenish if low. Look for possible coolant leakage points and repair if necessary. b. Reset control and restart after locating and correcting problem. Contact an authorized service center. |
| 215 | LOW COOLANT LVL — Shutdown lamp lights | Indicates engine coolant level has fallen below the trip point. | Allow engine to cool down completely before proceeding. a. Check coolant level and replenish if low. Look for possible coolant leakage points and repair if necessary. b. Reset control and restart after locating and correcting problem. Contact an authorized service center. LOW COOLANT LVL Shutdown will not occur if generator set is in Idle mode (low coolant warning only). |
| 220 | MAG PICKUP — Shutdown lamp lights | Indicates mag pickup speed indication is not being sensed or does not match generator set output frequency. | A. Restart and check RPM on the digital display. b. Contact an authorized service center. |
| 221 | FAIL TO CRANK — Shutdown lamp lights; Engine will not crank | Indicates possible fault with control or starting system. | Check for the following conditions: a. Poor battery cable connections. Clean the battery cable terminals and tighten all connections. b. Discharged or defective battery. Recharge or replace the battery. c. Contact an authorized service center for service of starter and starting system. |
| 222 | OVERCRANK — Shutdown lamp lights; Engine stops cranking | Indicates possible fuel system problem. | A. Check for empty fuel tank, fuel leaks, or plugged fuel lines and correct as required. b. Check for dirty fuel filter and replace if necessary. c. Check for dirty or plugged air filter and replace if necessary. d. Reset the control and restart after correcting the problem. Contact an authorized service center if none of the above. |
| 223 | OVERSPEED — Engine runs and then shuts down, Shutdown lamp lights | Indicates engine has exceeded normal operating speed. (2070 rpm @ 60 Hz; 1800 rpm @ 50 Hz) | Contact an authorized service center. |
| 230 | LOW DC VOLTAGE — Warning lamp lights | Indicates battery voltage is below 24 VDC. | A. Discharged or defective battery. Check the battery charger fuse. Recharge or replace the battery. b. Poor battery cable connections. Clean the battery cable terminals and tighten all connections. c. Contact an authorized service center if none of the above. |
| 231 | HIGH DC VOLTAGE — Warning lamp lights | Indicates battery voltage exceeds 32 VDC. | Contact an authorized service center. |
| 232 | WEAK BATTERY — Warning lamp lights | Indicates battery voltage drops below 60% of nominal for two seconds, during starting. Discharged or defective battery. | See Warning message 230, LOW DC VOLTAGE. |
| 240 | LOW FUEL DAY — Warning lamp lights | Indicates day tank fuel supply is running low. | Check fuel supply and replenish as required. |
| 241 | LOW FUEL — Warning lamp lights | Indicates fuel supply is running low. | Check fuel supply and replenish as required. |
| 250 | EEPROM ERROR — Shutdown lamp lights | Indicates PCC memory error. Data corruption of critical operating parameters. | Contact an authorized service center. |
| 251 | EEPROM ERROR — Warning lamp lights | Indicates PCC memory error. Data corruption of noncritical operating parameters. | Contact an authorized service center. |
| 252 | EEPROM ERROR — Warning lamp lights | Indicates PCC memory error. Data corruption of noncritical operating parameters. | Contact an authorized service center. |
| 260 | CUSTOMER FAULT 1 — Shutdown lamp lights | When any one of these customer defined inputs is closed to ground, the corresponding fault message is displayed. The nature of the fault is an optional customer selection. These fault functions can be programmed to initiate a shutdown or a warning. As indicated by the Shutdown lamp, a shutdown response has been preselected. | Contact an authorized service center. Note: Customer fault messages are editable. The message displayed for the code shown (260 or 261) may have been edited and may not appear as shown in this table. |
| 261 | GROUND FAULT — Shutdown lamp lights | When any one of these customer defined inputs is closed to ground, the corresponding fault message is displayed. The nature of the fault is an optional customer selection. These fault functions can be programmed to initiate a shutdown or a warning. As indicated by the Shutdown lamp, a shutdown response has been preselected. | Contact an authorized service center. Note: Customer fault messages are editable. The message displayed for the code shown (260 or 261) may have been edited and may not appear as shown in this table. |
| 260 | CUSTOMER FAULT 1 — Warning lamp lights | When any one of these customer defined inputs is closed to ground, the corresponding fault message is displayed. The nature of the fault is an optional customer selection. These fault functions can be programmed to initiate a shutdown or a warning. As indicated by the Warning lamp, a warning response has been preselected. | Note: Customer fault messages are editable. The message displayed for the code shown (260 and 261) may have been edited and may not appear as shown in this table. |
| 261 | GROUND FAULT — Warning lamp lights | When any one of these customer defined inputs is closed to ground, the corresponding fault message is displayed. The nature of the fault is an optional customer selection. These fault functions can be programmed to initiate a shutdown or a warning. As indicated by the Warning lamp, a warning response has been preselected. | Note: Customer fault messages are editable. The message displayed for the code shown (260 and 261) may have been edited and may not appear as shown in this table. |
| 262 | CM570/ENGINE — Warning lamp lights | Indicates that the engine control module (CM570) is not properly operating. | Contact an authorized service center. |
| 263 | CM570/ENGINE — Shutdown lamp lights | Indicates that the engine control module (CM570) is not properly operating. | Contact an authorized service center. |
| 301 | HIGH AC VOLTAGE — Shutdown lamp lights | Indicates that one or more of the phase voltages has exceeded 130% of nominal, or has exceeded 110% of nominal for 10 seconds. | Contact an authorized service center. |
| 303 | LOW AC VOLTAGE — Shutdown lamp lights | Indicates that one or more of the phase voltages has dropped below 85% of nominal for 10 seconds. | Contact an authorized service center. |
| 313 | UNDER FREQUENCY — Shutdown lamp lights | Indicates that engine speed has dropped below 90% of nominal for 10 seconds. NOTE: Five seconds before shutdown, a Load Dump signal is initiated. | Contact an authorized service center. |
| 320 | OVERCURRENT — Warning lamp lights | Indicates that generator output current has exceeded 110% of rated for 60 seconds. | Contact an authorized service center. |
| 321 | OVERCURRENT — Shutdown lamp lights | Indicates that generator output current has exceeded 110% of rated, and that a PCC time/current calculation has initiated an overcurrent shutdown. | Contact an authorized service center. |
| 322 | SHORT CIRCUIT — Shutdown lamp lights | Indicates that generator output current has exceeded 175% of rated. | Contact an authorized service center. |
| 330 | OVERLOAD — Warning lamp lights | Indicates that three-phase power output exceeds 105% of standby (or 115% of prime) rating. After five seconds, the Load Dump output is activated. After 60 seconds, the OVERLOAD warning is activated. | Contact an authorized service center. |
| 335 | REVERSE POWER — Shutdown lamp lights | Indicates improper CT or PT phasing. (Non-parallel units only.) | Contact an authorized service center. |
| 101 | IDLE MODE — Engine continues to operate at reduced RPM | Engine is operating in idle mode; grounding the engine idle input causes generator build-up to be inhibited and the engine to be governed at 800 RPM | When ground is removed from this input, the set returns to normal speed and voltage; control automatically sets lower oil pressure warning and shutdown trip points to reflect the lower operating speed and resets them to normal settings when idle function is removed |
| 102 | EMERGENCY STOP — Engine shuts down and will not crank | Local or remote Emergency Stop | To reset the local Emergency Stop button: Pull the button out; Move the Run/Off/Auto switch to Off; Press the Reset switch; Select Run or Auto, as required |
| 200 | LOW OIL PRESSURE — Warning lamp lights | Engine oil pressure has dropped to an unacceptable level | If generator is powering critical loads and cannot be shut down, wait until next shutdown period then follow 201 Low Oil Pressure procedure; if engine can be stopped, follow 201 procedure; to check oil pressure, access Oil Pressure menu prior to clearing the fault |
| 201 | LOW OIL PRESSURE — Shutdown lamp lights | 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; oil pressure limits are listed in Specifications; contact an authorized service center |
| 204 | OIL PRES SENDER — Warning lamp lights | Engine oil pressure sender is not functioning correctly | Check that the engine oil pressure sender is properly connected; contact an authorized service center |
| 210 | LOW COOLANT TEMP — Set is in standby mode but is not operating; warning occurs when engine coolant temperature is 70° F (21° C) or lower | Engine coolant heater is not operating or is not circulating coolant | A. Coolant heater not connected to power supply: check for blown fuse or disconnected heater cord and correct as required; b. Check for low coolant level and replenish if required, look for possible coolant leakage points and repair as required; c. Contact an authorized service center if none of the above |
| 211 | HIGH COOLANT TEMP — Warning lamp lights | Engine has begun to overheat and coolant temperature has risen to an unacceptable level (215° F standby / 207° F primary) | If generator is powering non-critical and critical loads and cannot be shut down: a. Reduce load if possible by turning off non-critical loads; b. Check air inlets and outlets and remove any obstructions to airflow; if engine can be stopped, follow the next procedure; to check coolant temperature, access Coolant Temp menu prior to clearing the fault |
| 212 | HIGH COOLANT TEMP — Shutdown lamp lights | Engine has overheated (coolant temperature has risen above the shutdown trip point: 223° F standby / 215° F primary) or the coolant level is low | Allow engine to cool down completely before proceeding: a. Check coolant level and replenish if low, look for coolant leakage and repair if necessary; b. Check for obstructions to cooling airflow and correct as necessary; c. Check fan belt and repair or tighten if necessary; d. Reset control and restart after locating and correcting problem; contact an authorized service center if none of the above |
| 213 | ENG COOLANT SENDER — Warning lamp lights | Resistance of the coolant temperature sender is out of range | Contact an authorized service center |
| 214 | LOW COOLANT LVL — Warning lamp lights | Engine coolant level has fallen below the trip point | Allow engine to cool down completely before proceeding: a. Check coolant level and replenish if low, look for possible coolant leakage points and repair if necessary; b. Reset control and restart after locating and correcting problem; contact an authorized service center |
| 215 | LOW COOLANT LVL — Shutdown lamp lights | Engine coolant level has fallen below the trip point | Allow engine to cool down completely before proceeding: a. Check coolant level and replenish if low, look for possible coolant leakage points and repair if necessary; b. Reset control and restart after locating and correcting problem; contact an authorized service center; LOW COOLANT LVL Shutdown will not occur if generator set is in Idle mode (low coolant warning only) |
| 220 | MAG PICKUP — Shutdown lamp lights | Mag pickup speed indication is not being sensed or does not match generator set output frequency | A. Restart and check RPM on the digital display; b. Contact an authorized service center |
| 221 | FAIL TO CRANK — Shutdown lamp lights; engine will not crank | Possible fault with control or starting system | Check for the following conditions: a. Poor battery cable connections: clean the battery cable terminals and tighten all connections; b. Discharged or defective battery: recharge or replace the battery; c. Contact an authorized service center for service of starter and starting system |
| 222 | OVERCRANK — Shutdown lamp lights; engine stops cranking | Possible fuel system problem | A. Check for empty fuel tank, fuel leaks, or plugged fuel lines and correct as required; b. Check for dirty fuel filter and replace if necessary; c. Check for dirty or plugged air filter and replace if necessary; d. Reset the control and restart after correcting the problem; contact an authorized service center if none of the above |
| 223 | OVERSPEED — Engine runs and then shuts down, shutdown lamp lights | Engine has exceeded normal operating speed (2070 rpm @ 60 Hz; 1800 rpm @ 50 Hz) | Contact an authorized service center |
| 230 | LOW DC VOLTAGE — Warning lamp lights | Battery voltage is below 24 VDC | A. Discharged or defective battery: check the battery charger fuse, recharge or replace the battery; b. Poor battery cable connections: clean the battery cable terminals and tighten all connections; c. Contact an authorized service center if none of the above |
| 231 | HIGH DC VOLTAGE — Warning lamp lights | Battery voltage exceeds 32 VDC | Contact an authorized service center |
| 232 | WEAK BATTERY — Warning lamp lights | Battery voltage drops below 60% of nominal for two seconds during starting; discharged or defective battery | See Warning message 230, LOW DC VOLTAGE |
| 240 | LOW FUEL DAY — Warning lamp lights | Day tank fuel supply is running low | Check fuel supply and replenish as required |
| 241 | LOW FUEL — Warning lamp lights | Fuel supply is running low | Check fuel supply and replenish as required |
| 250 | EEPROM ERROR — Shutdown lamp lights | PCC memory error; data corruption of critical operating parameters | Contact an authorized service center |
| 251 | EEPROM ERROR — Warning lamp lights | PCC memory error; data corruption of noncritical operating parameters | Contact an authorized service center |
| 252 | EEPROM ERROR — Warning lamp lights | PCC memory error; data corruption of noncritical operating parameters | Contact an authorized service center |
| 260 | CUSTOMER FAULT 1 — Shutdown lamp lights | Customer defined input is closed to ground; the nature of the fault is an optional customer selection; these fault functions can be programmed to initiate a shutdown or a warning; a shutdown response has been preselected | Contact an authorized service center; customer fault messages are editable and the message displayed for the code shown may have been edited |
| 261 | GROUND FAULT — Shutdown lamp lights | Customer defined input is closed to ground; the nature of the fault is an optional customer selection; these fault functions can be programmed to initiate a shutdown or a warning; a shutdown response has been preselected | Contact an authorized service center; customer fault messages are editable and the message displayed for the code shown may have been edited |
| 260 | CUSTOMER FAULT 1 — Warning lamp lights | Customer defined input is closed to ground; the nature of the fault is an optional customer selection; these fault functions can be programmed to initiate a shutdown or a warning; a warning response has been preselected | Customer fault messages are editable and the message displayed for the code shown may have been edited |
| 261 | GROUND FAULT — Warning lamp lights | Customer defined input is closed to ground; the nature of the fault is an optional customer selection; these fault functions can be programmed to initiate a shutdown or a warning; a warning response has been preselected | Customer fault messages are editable and the message displayed for the code shown may have been edited |
| 262 | CM570/ENGINE — Warning lamp lights | Engine control module (CM570) is not properly operating | Contact an authorized service center |
| 263 | CM570/ENGINE — Shutdown lamp lights | Engine control module (CM570) is not properly operating | Contact an authorized service center |
| 301 | HIGH AC VOLTAGE — Shutdown lamp lights | One or more of the phase voltages has exceeded 130% of nominal, or has exceeded 110% of nominal for 10 seconds | Contact an authorized service center |
| 303 | LOW AC VOLTAGE — Shutdown lamp lights | One or more of the phase voltages has dropped below 85% of nominal for 10 seconds | Contact an authorized service center |
| 313 | UNDER FREQUENCY — Shutdown lamp lights | Engine speed has dropped below 90% of nominal for 10 seconds; five seconds before shutdown, a Load Dump signal is initiated | Contact an authorized service center |
| 320 | OVERCURRENT — Warning lamp lights | Generator output current has exceeded 110% of rated for 60 seconds | Contact an authorized service center |
| 321 | OVERCURRENT — Shutdown lamp lights | Generator output current has exceeded 110% of rated, and a PCC time/current calculation has initiated an overcurrent shutdown | Contact an authorized service center |
| 322 | SHORT CIRCUIT — Shutdown lamp lights | Generator output current has exceeded 175% of rated | Contact an authorized service center |
| 330 | OVERLOAD — Warning lamp lights | Three-phase power output exceeds 105% of standby (or 115% of prime) rating; after five seconds, the Load Dump output is activated; after 60 seconds, the OVERLOAD warning is activated | Contact an authorized service center |
| 335 | REVERSE POWER — Shutdown lamp lights | Improper CT or PT phasing (non-parallel units only) | Contact an authorized service center |
| HIGH COOLANT TEMP | Shutdown lamp lights. | Allow engine to cool down completely before proceeding with the following checks: a. Check coolant level and replenish if low. Look for coolant leakage and repair if necessary. b. Check for obstructions to cooling airflow and correct as necessary. c. Check fan belt and repair or tighten if necessary. d. Reset control and restart after locating and correcting problem. Contact an authorized service center if none of the above. | |
| ENG COOLANT SENDER | Shutdown or Warning lamp lights. | Contact an authorized service center. | |
| FAIL TO CRANK | Engine will not crank. | A. Poor battery cable connections. Clean the battery cable terminals and tighten all connections. b. Discharged or defective battery. Recharge or replace the battery. c. Contact an authorized service center for service of starter and starting system. | |
| OVERCRANK | Engine stops cranking. | A. Check for empty fuel tank, fuel leaks, or plugged fuel lines and correct as required. b. Check for dirty fuel filter and replace if necessary. c. Check for dirty or plugged air filter and replace if necessary. d. Reset the control and restart after correcting the problem. Contact an authorized service center if none of the above. | |
| LOW DC VOLTAGE | Warning lamp lights. | A. Discharged or defective battery. Check the battery charger fuse. Recharge or replace the battery. b. Poor battery cable connections. Clean the battery cable terminals and tighten all connections. c. Contact an authorized service center if none of the above. |
| Symptom | Cause | Remedy |
|---|---|---|
| Engine does not crank — remote run (FAIL TO CRANK (221) message does not appear on digital display; Auto LED DS5 on the engine interface board (A31) is off; RMT Start LED DS14 on the customer interface board (A34) is on) | The Auto mode signal is not getting from engine interface board A31 to digital board A32, indicating that A31 is bad | Install harness tool between A32 J4/P4. Check for ground output at A32 J4-18. If there is no ground output (but A31 DS5 is on) engine interface board A31 is bad. Replace A31. If there is a ground output at A31 J1-18, proceed to the next step |
| Engine does not crank — remote run (FAIL TO CRANK (221) message does not appear on digital display; Auto LED DS5 on the engine interface board (A31) is off; RMT Start LED DS14 on the customer interface board (A34) is on) | The Remote run signal is not getting from customer interface board A34 to A32, indicating that A34 is bad | Install harness tool between A32 J4/P4. Reset the control. Attempt to remote start, and check for ground output at A32 J2-26. If no ground output (but A34 DS14 is on) customer interface board A34 is bad. Replace A31. If there is a ground output at A32 J2-26, proceed to the next step |
| Engine does not crank — remote run (FAIL TO CRANK (221) message does not appear on digital display; Auto LED DS5 on the engine interface board (A31) is off; RMT Start LED DS14 on the customer interface board (A34) is on) | Digital board (A32) may be bad | If, when attempting remote start, there is a ground input at A32 J2-26, and a ground input at A32 J4-18—and there is no “FAIL TO CRANK” message—and the genset does not crank; A32 is bad. Replace, A32 |
| Engine does not crank — remote run (FAIL TO CRANK (221) message does not appear on digital display; Auto LED DS5 on the engine interface board (A31) is off; RMT Start LED DS14 on the customer interface board (A34) is on) | S12 or the wiring harness may be bad; The Auto mode input is not getting from the Auto select switch (S12) to engine interface board (A31) indicating that S12, A31, or the harness is bad | Disconnect A31 J3/P3. Check continuity to ground at A31 J3-11. (J3-11 is ground out to S12.) If ground is not present, replace A31. If ground is present, place S12 in Auto and check continuity from P3-11 to P3-13. If no continuity, isolate to switch or wiring harness. Repair as necessary. If there is continuity, A31 may be bad. Reconnect J3/P3 |
| Engine does not crank — remote run (FAIL TO CRANK (221) message does not appear on digital display; Auto LED DS5 on the engine interface board (A31) is off; RMT Start LED DS14 on the customer interface board (A34) is on) | Engine interface board A31 may be bad | Install harness tool between A32 J4/P4. Check the 16 volt (nominal) supply at A32 J4-16. If the voltage is present at A32 J4-16, and ground is present at A31 P3-13—and yet A31 DS5 is off; then A31 is bad. Replace A31 |
| Engine does not crank — remote run (FAIL TO CRANK (221) message does not appear on digital display; Auto LED DS5 on the engine interface board (A31) is on; RMT Start LED DS14 on the customer interface board (A34) is off) | The remote start switch or the wiring harness may be bad; The remote start input is not getting from the remote start switch to the output of the customer interface board (A34) indicating that the switch, A34, or the harness is bad | Install harness tool between A34 J1/P1. Reset the control. Attempt remote start and check for ground at A34 J1-13. If ground level is not present, isolate to the switch or the wiring harness by checking for a start signal at TB1-5. Repair as necessary |
| Engine does not crank — remote run (FAIL TO CRANK (221) message does not appear on digital display; Auto LED DS5 on the engine interface board (A31) is on; RMT Start LED DS14 on the customer interface board (A34) is off) | Customer interface board A34 may be bad | If ground is present at A34 J1-13—and yet A34 DS14 is off, replace A34 |
| Engine does not crank — local run (FAIL TO CRANK (221) message does not appear on digital display; Run LED DS4 on the engine interface board (A31) is off) | Run/Off/ Auto select switch S12 or the wiring harness may be bad; The start input is not getting from the Run/Off/ Auto select switch (S12) to A31 indicating that S12, A31, or the harness is bad | Check continuity to ground at A31 J3-11. If ground is not present, replace A31. If ground is present, place S12 in Run and check continuity from P3-11 to P3-12. If no continuity, isolate to switch or wiring harness. Repair as necessary. If there is continuity, A31 may be bad |
| Engine does not crank — local run (FAIL TO CRANK (221) message does not appear on digital display; Run LED DS4 on the engine interface board (A31) is off) | Engine interface board A31 may be bad | Install harness tool between A32 J4/P4. Check the 16 volt (nominal) supply at A32 J4-16. If the voltage is present at A32 J4-16, and ground is present at A31 J3-12—and yet A31 DS5 is off, replace A31 |
| Engine does not crank — local run (FAIL TO CRANK (221) message does not appear on digital display; Run LED DS4 on the engine interface board (A31) is off) | Digital board A32 may be bad | If there is no +16 volt supply voltage at A32 J4-16, replace A32 |
| Engine cranks but does not start (OVERCRANK (222) message; while cranking, Run LED DS12 on the engine interface board (A31) is on) | Restricted fuel supply due to: a. Fuel level below pickup tube in tank | Add fuel if low. Prime the fuel system |
| Engine cranks but does not start (OVERCRANK (222) message; while cranking, Run LED DS12 on the engine interface board (A31) is on) | Restricted fuel supply due to: b. Closed shutoff valve in supply line | Open any closed shutoff valve in the fuel line supplying the engine |
| Engine cranks but does not start (OVERCRANK (222) message; while cranking, Run LED DS12 on the engine interface board (A31) is on) | Restricted fuel supply due to: c. Air in fuel system | Bleed air from fuel system. Refer to engine service manual |
| Engine cranks but does not start (OVERCRANK (222) message; while cranking, Run LED DS12 on the engine interface board (A31) is on) | Fuel tank solenoid not energized due to: a. Open in fuel solenoid circuit | Check wiring continuity of fuel tank solenoid circuit |
| Engine cranks but does not start (OVERCRANK (222) message; while cranking, Run LED DS12 on the engine interface board (A31) is on) | Fuel tank solenoid not energized due to: b. Defective fuel solenoid | Test fuel tank solenoid. Repair or replace as necessary |
| Engine cranks but does not start (OVERCRANK (222) message; while cranking, Run LED DS12 on the engine interface board (A31) is on) | Engine fuel system or other engine problem | Refer to engine service manual |
| Engine cranks but does not start (OVERCRANK (222) message; while cranking, Run LED DS12 on the engine interface board (A31) is on) | The run signal is not getting out of the engine interface board (A31). A31 may be bad | Install harness tool between A31 J4/P4. Reset the control. Attempt to start and check for B+ at A31 J4-1. If there is no B+ at A31 J4-1, replace A31 |
| Engine cranks but does not start (OVERCRANK (222) message; while cranking, Run LED DS12 on the engine interface board (A31) is on) | There is an open between the engine interface board (A31) and relay K8 | If there is B+ at A31 J4-1, check for B+ at K8-86, while attempting to crank. If there is no B+ at K8-86, isolate to connectors and wiring. Repair or replace as necessary |
| Engine cranks but does not start (OVERCRANK (222) message; while cranking, Run LED DS12 on the engine interface board (A31) is on) | Relay K8 is defective | If there is B+ at K8-86, check for ground signal at K8-30. If open, replace K8 |
| Engine cranks but does not start (OVERCRANK (222) message; while cranking, Run LED DS12 on the engine interface board (A31) is on) | CM570 module is defective | Check fuses FB3 and FB4 which supply B+ to the CM570 module; Check CM570 module using InSite service tool |
| Engine cranks but does not start (OVERCRANK (222) message; while cranking, Run LED DS12 on the engine interface board (A31) is on) | The keyswitch signal is not getting out of the customer interface board (A32). A32 may be bad | Install harness tool between A32 J3/P3. Check for ground at A32 J3-10. If no ground output at A32 J3-10, replace A32 |
| Engine cranks but does not start (OVERCRANK (222) message; while cranking, Run LED DS12 on the engine interface board (A31) is on) | There is an open between the customer interface board (A32) and relay K7 | If there is ground at A32 J3-10, isolate to connectors and wires between A32 J3-10 to TB1-19 to K7-85 |
| Engine cranks but does not start (OVERCRANK (222) message; while cranking, Run LED DS12 on the engine interface board (A31) is on) | Relay K7 is defective | B+ must be present at relay K7-30 for the CM570 module to be operational. If B+ is not present, isolate to defective K7 relay/wiring. (K7-30 B+ is present during stop or run mode. Disabled only for emergency stop.) |
| Engine cranks but does not start (OVERCRANK (222) message; Run LED DS12 on the engine interface board (A31) is off) | The run signal is not getting out of the digital board (A32). A32 may be bad | Install harness tool between A32 J4/P4. Attempt to start and check for ground signal at A32 J4−8. If there is no ground signal at A32 J4−8, replace A32 |
| Engine cranks but does not start (OVERCRANK (222) message; Run LED DS12 on the engine interface board (A31) is off) | The run signal is not being processed by the engine interface board (A31). A31 may be bad | If there is a ground signal at A32 J4−8, replace A31 |
| Engine cranks but does not start (FAIL TO CRANK (221) message; the engine is cranking but shutting down on a 221 fault) | The mag pickup signal is not being sensed | Refer to the mag pickup shutdown message (220) |
| Control does not power up when the Run/Off/Auto switch is set to Run or the Self Test switch is pressed. | There is no DC power to the control. | Check for battery disconnected, discharged, or improperly connected. Contact an authorized service center. |
| Warning, Shutdown, and Non-Automatic lamps are not lit. Digital display shows main menu or selected menu. | Indicates all engine systems are normal. | No corrective action required. |
| Non-Automatic lamp flashes. | Indicates Run/Off/Auto switch is not in the Auto position. This will prevent automatic starting if an automatic transfer switch is used. | Move the Run/Off/Auto switch to the Auto position for automatic operation. |
| Engine starts from generator control panel but will not start automatically or from a remote panel. (Note: The Run/Off/Auto switch must be in the Auto position for automatic or remote starting). | Check the control wiring between the remote switch and the PCC. Contact an authorized service center. | |
| No AC output voltage. | Contact an authorized service center. | |
| Control does not power up when the Run/Off/Auto switch is set to Run or the Self Test switch is pressed | There is no DC power to the control; battery disconnected, discharged, or improperly connected | Check for battery disconnected, discharged, or improperly connected; contact an authorized service center |
| Warning, Shutdown, and Non-Automatic lamps are not lit; digital display shows main menu or selected menu | Indicates all engine systems are normal | No corrective action required |
| Non-Automatic lamp flashes | Run/Off/Auto switch is not in the Auto position; this will prevent automatic starting if an automatic transfer switch is used | Move the Run/Off/Auto switch to the Auto position for automatic operation |
| Engine starts from generator control panel but will not start automatically or from a remote panel (Note: The Run/Off/Auto switch must be in the Auto position for automatic or remote starting) | Control wiring between the remote switch and the PCC | Check the control wiring between the remote switch and the PCC; contact an authorized service center |
| No AC output voltage | Contact an authorized 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: Restricted fuel supply due to: a. Fuel level below pickup tube in tank; Restricted fuel supply due to: b. Closed shutoff valve in supply line; Restricted fuel supply due to: c. Air in fuel system; Fuel tank solenoid not energized due to: a. Open in fuel solenoid circuit. See the table for the matching fixes.
Documented causes: The Auto mode signal is not getting from engine interface board A31 to digital board A32, indicating that A31 is bad; The Remote run signal is not getting from customer interface board A34 to A32, indicating that A34 is bad; Digital board (A32) may be bad; S12 or the wiring harness may be bad; The Auto mode input is not getting from the Auto select switch (S12) to engine interface board (A31) indicating that S12, A31, or the harness is bad. See the table for the matching fixes.
Documented causes: Indicates PCC memory error. Data corruption of noncritical operating parameters.; PCC memory error; data corruption of noncritical operating parameters. See the table for the matching fixes.