Cummins/Onan GGPA troubleshooting: 144 fault codes and 12 symptom-cause-remedy entries from the manufacturer's own service documentation.
Cummins/Onan GGPA — full specs, parts & maintenance.
All Cummins/Onan fault codes →
| Code | Meaning | Cause | Remedy |
|---|---|---|---|
| 121 | Speed Signal Lost — Shut down | Loose or damaged magnetic pickup (MPU) wires/connector pins. | Inspect the wires/connector pins, and repair or replace as necessary. |
| 121 | Speed Signal Lost — Shut down | Engine died | Check ignition system; Check fuel supply. |
| 121 | Speed Signal Lost — Shut down | The magnetic pickup or harness could be bad. | To isolate the problem, reset the control and attempt to start the set in Idle mode (select Idle Mode −Enable menu). If 1438 (Fail To Crank) is displayed, or if the engine starts, but then shuts down on 121 (Speed Signal Lost), the MPU sender could be bad. Remove the MPU connectors and check for 1.5 VAC (minimum) at the MPU while cranking. If no output or less than 1.5 VAC, check for damage or debris. Also check for improper adjustment of the MPU. (Refer to Section 6.) If there is still no output, replace the MPU sender. If the MPU output is OK, check for MPU voltage at P7−25 (MAG PICK+) to P7-29 (MAG PICK−) while cranking. 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 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 may be a frequency sensing problem within the Base board. |
| 135 | Oil Pressure Sensor High — No engine protection for oil pressure during genset operation. | Fault simulation was enabled with In-Power. | With InPower, verify that the fault simulation is not enabled for the oil pressure sensor. If you do not have InPower, remove battery power from the control to disable fault simulation overrides. |
| 135 | Oil Pressure Sensor High — No engine protection for oil pressure during genset operation. | The sensor connections could be bad. | Inspect the sensor and engine harness connector pins. Repair or replace as necessary. |
| 135 | Oil Pressure Sensor High — No engine protection for oil pressure during genset operation. | The sensor could be bad. | Disconnect the oil pressure sensor leads, and connect an oil pressure sensor simulator to the harness. "OIL PRESSURE SENSOR H" 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. |
| 135 | Oil Pressure Sensor High — No engine protection for oil pressure during genset operation. | The harness could be bad. | Remove connector P7 from Base board and connector from sensor. Check P7-13, 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. |
| 135 | Oil Pressure Sensor High — No engine protection for oil pressure during genset operation. | The pressure signal could be out of range. | With all connectors attached, check pressure signal (.5 to 4.5 VDC) at P7-13 (OP OUT) and P7-17 (OP COM). |
| 143 | Pre-Low Oil Pressure Sensor — Calibration-dependent. No action is taken by the PCC for code 143. Engine will shut down for code 415. | Fault simulation was enabled with InPower. | With InPower, verify that the fault simulation is not enabled for the oil pressure sensor. If you do not have InPower, remove battery power from the control to disable fault simulation overrides. |
| 143 | Pre-Low Oil Pressure Sensor — Calibration-dependent. No action is taken by the PCC for code 143. Engine will shut down for code 415. | Low oil level. Clogged lines or filters. | Check oil level, lines, and filters. If the oil system is OK but the oil level is low, replenish. |
| 143 | Pre-Low Oil Pressure Sensor — Calibration-dependent. No action is taken by the PCC for code 143. Engine will shut down for code 415. | 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 ACT−signal wire at the fuel pump actuator, 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 sensor. If the PCC 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 the next step. |
| 143 | Pre-Low Oil Pressure Sensor — Calibration-dependent. No action is taken by the PCC for code 143. Engine will shut down for code 415. | Harness could be bad. | If the control does not respond to the simulator, the harness is defective. Check for +5 VDC at the sensor (lead marked E1-A). If there is no 5 VDC at the sensor: Check for 5 VDC at P7-21. If yes, the harness is defective and must be replaced. If there is 5 VDC at the sensor, use the sensor simulator to generate a signal to P7-13 (OP OUT) and P7-17 (OP COMM). If the pressure signal (.5 to 4.5 VDC) does not get to P7, isolate to the harness. |
| 141 | Oil Pressure Sensor Low — No engine protection for oil pressure during generator set operation. | Fault simulation was enabled with InPower. | With InPower, verify that the fault simulation is not enabled for the oil pressure sensor. If you do not have InPower, remove battery power from the control to disable fault simulation overrides. |
| 141 | Oil Pressure Sensor Low — No engine protection for oil pressure during generator set operation. | The sensor connections could be bad. | Inspect the sensor and engine harness connector pins. Repair or replace as necessary. |
| 141 | Oil Pressure Sensor Low — No engine protection for oil pressure during generator set operation. | The sensor could be bad. | Disconnect the oil pressure sensor leads and connect an oil pressure sensor simulator to the harness. "OIL PRESSURE SENSOR L" 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 the next step. |
| 141 | Oil Pressure Sensor Low — No engine protection for oil pressure during generator set operation. | The harness could be defective. | Remove connector P7 from base board and the connector from the sensor. Check P7-13, 17, and 21 as follows: Check for an open circuit (10 ohms or less is OK). Check for a short circuit to the engine block ground (more than 200k ohms is OK). Check for a short circuit from pin to pin (more than 200k ohms is OK). Repair or replace as necessary. |
| 141 | Oil Pressure Sensor Low — No engine protection for oil pressure during generator set operation. | The pressure signal could be out of range. | With all connectors attached, check pressure signal (.5 to 4.5 VDC) at P7-13 (OP OUT) and P7-17 (OP COM). |
| 144 | Coolant Temperature Sensor High — No engine protection for coolant temperature during generator set operation. Possible white smoke. | Fault simulation was enabled with InPower. | With InPower, verify that the fault simulation is not enabled for the coolant sensor. If you do not have InPower, remove battery power from the control to disable fault simulation overrides |
| 144 | Coolant Temperature Sensor High — No engine protection for coolant temperature during generator set operation. Possible white smoke. | The sensor connections could be defective. | Inspect the sensor and engine harness connector pins. Repair or replace as necessary. |
| 144 | Coolant Temperature Sensor High — No engine protection for coolant temperature during generator set operation. Possible white smoke. | The sensor could be defective. | 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 the control does not respond, go to the next step. |
| 144 | Coolant Temperature Sensor High — No engine protection for coolant temperature during generator set operation. Possible white smoke. | The harness could be defective. | Measure the resistance of the coolant sensor and reconnect the harness to the sensor. Remove connector P7 from the base board and check resistance between pins P7-30 (IH20) and P7-34 (IH20 COM). If resistance is not the same, the harness is defective and must be replaced. |
| 145 | Coolant Temperature Sensor Low — No engine protection for coolant temperature during generator set operation. Possible white smoke. | Fault simulation was enabled with InPower. | With InPower, verify that the fault simulation is not enabled for the coolant sensor. If you do not have InPower, remove battery power from the control to disable fault simulation overrides. |
| 145 | Coolant Temperature Sensor Low — No engine protection for coolant temperature during generator set operation. Possible white smoke. | The sensor connections could be defective. | Inspect the sensor and engine harness connector pins. Repair or replace as necessary. |
| 145 | Coolant Temperature Sensor Low — No engine protection for coolant temperature during generator set operation. Possible white smoke. | The sensor could be defective. | 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 the control does not respond, go to the next step. |
| 145 | Coolant Temperature Sensor Low — No engine protection for coolant temperature during generator set operation. Possible white smoke. | The harness could be defective. | Remove connector P7 from the base board and disconnect the sensor. Check pins P7-30 (IH20) and P7-34 (IH20 COM) for short circuit as follows: Check for a short circuit to the engine block ground (more than 200k ohms is OK). Check for a short circuit from pin to pin (more than 200k ohms is OK). Repair or replace as necessary. Measure the resistance of the coolant sensor and reconnect the harness to the sensor. Remove connector P7 from the base board and check resistance between pins P7-30 (IH20) and P7-34 (IH20 COM). If resistance is not the same, the harness is defective and must be replaced. |
| 146 | Pre-High Cool Temp — Calibration-dependent. No action is taken by the PCC for fault code 146. Engine will shut down for fault code 151. | Fault simulation was enabled with InPower. | With InPower, verify that the fault simulation is not enabled for the coolant sensor. If you do not have InPower, remove battery power from the control to disable fault simulation overrides. |
| 146 | Pre-High Cool Temp — Calibration-dependent. No action is taken by the PCC for fault code 146. Engine will shut down for fault code 151. | Engine or sensor circuitry problem. | Isolate to the engine or sensor circuitry. Check the sensor accuracy with a thermocouple or similar temperature probe. If the PCC ambient coolant temperature reading is accurate, the engine may be overheating. Refer to the engine service manual. If the PCC ambient coolant temperature reading is not accurate, go to the next step. |
| 146 | Pre-High Cool Temp — Calibration-dependent. No action is taken by the PCC for fault code 146. Engine will shut down for fault code 151. | The sensor could be defective. | 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 the step. |
| 146 | Pre-High Cool Temp — Calibration-dependent. No action is taken by the PCC for fault code 146. Engine will shut down for fault code 151. | The harness could be defective. | Measure the resistance of the coolant sensor and reconnect the harness to the sensor. Remove connector P7 from the base board and check resistance between pins P7-30 (IH20) and P7-34 (IH20 COM). If resistance is not the same, the harness is defective and must be replaced. |
| 151 | High Coolant Temp — Calibration-dependent. No action is taken by the PCC for fault code 146. Engine will shut down for fault code 151. | Fault simulation was enabled with InPower. | With InPower, verify that the fault simulation is not enabled for the coolant sensor. If you do not have InPower, remove battery power from the control to disable fault simulation overrides. |
| 151 | High Coolant Temp — Calibration-dependent. No action is taken by the PCC for fault code 146. Engine will shut down for fault code 151. | Engine or sensor circuitry problem. | Isolate to the engine or sensor circuitry. Check the sensor accuracy with a thermocouple or similar temperature probe. If the PCC ambient coolant temperature reading is accurate, the engine may be overheating. Refer to the engine service manual. If the PCC ambient coolant temperature reading is not accurate, go to the next step. |
| 151 | High Coolant Temp — Calibration-dependent. No action is taken by the PCC for fault code 146. Engine will shut down for fault code 151. | The sensor could be defective. | 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 the next step. |
| 151 | High Coolant Temp — Calibration-dependent. No action is taken by the PCC for fault code 146. Engine will shut down for fault code 151. | The harness could be defective. | Measure the resistance of the coolant sensor and reconnect the harness to the sensor. Remove connector P7 from the base board and check resistance between pins P7-30 (IH20) and P7-34 (IH20 COM). If resistance is not the same, the harness is defective and must be replaced. |
| 197 | Low Coolant Level — No action is taken by the PCC for code 197. Engine will shut down for code 235. | The sensor or harness could be defective. | If the coolant level is normal, isolate the source of the low coolant signal. (This is a ground signal.) Disconnect the signal lead at the sender and reset the control. If the 197/235 message drops out and does not reappear, replace the sender. If the 197/235 message reappears and remains after the control is reset, remove connector P7 from the base board and check continuity from P7-32 to ground. If there is continuity, replace the harness. |
| 234 | Overspeed — Engine will shut down. | Cold engine (no coolant heaters). | Overspeed can occur when starting a very cold engine. Clear the fault and restart the generator set. |
| 234 | Overspeed — Engine will shut down. | Single step large block load removal. | Clear the fault and restart the generator set. |
| 234 | Overspeed — Engine will shut down. | Fault simulation was enabled with InPower. | With InPower, verify that the fault simulation is not enabled for the coolant sensor. If you do not have InPower, remove battery power from the control to disable fault simulation overrides. |
| 235 | Low Coolant Level — No action is taken by the PCC for code 197. Engine will shut down for code 235. | Engine coolant level has fallen below the shutdown trip point; the sensor or harness could be bad | Check coolant level and replenish if low; look for possible coolant leakage points and repair if necessary; reset control and restart after locating and correcting problem; if the coolant level is normal, isolate the source of the low coolant signal (this is a ground signal): disconnect the signal lead at the sender and reset the control; if the 197/235 message drops out and does not reappear, replace the sender; if the 197/235 message reappears and remains after control reset, remove connector P7 from Base board and check continuity from P7-32 to ground; if there is continuity, replace the harness |
| 359 | Fail to Start — Engine will not start. | The air cleaner is blocked | Service as necessary |
| 359 | Fail to Start — Engine will not start. | Restricted fuel supply | Open any closed fuel shutoff valve (valves closed for maintenance or new installations may require several crank cycles to get fuel to the generator set); fill the propane supply tank, for natural gas fueled sets check with the gas utility; check fuel pressure at the regulator (refer to Fuel Pressure), high fuel pressure will prevent the solenoid from opening; check the fuel solenoid (VDC present at K1+ lead during cranking), if not present go to step 3; dual fuel sets only: check relay K99 (refer to the wiring diagrams, VDC present at K99-30 during cranking with natural gas supply to the engine); check pressure switch wiring (propane − normally closed connected to common, natural gas − normally open connected to common); check pressure switch function (@ 3.5 inch H2O or less, should switch from natural gas to LPG); check the S14 vacuum switch (optional) for proper operation |
| 359 | Fail to Start — Engine will not start. | Problems with fuel trim valve (air fuel control) | Troubleshoot using the electronic service tool and Woodward L-Series Process Controller manual (available on the Woodward website); connect the interface harness (Cummins PN 0338−4987); verify that the software version for the electronic service tool is 2.3 or greater; launch Woodward software and allow the engine to begin cranking; at the overview screen make sure that the fuel trim valve is in open-loop mode and verify that the actual position of the valve is the same as or very close to the commanded position (66.3% for natural gas, 49.4% for liquid propane); if one or both of these is not right, verify the wiring to the HEGO sensor (see steps 5 and 6 for FC 1318); if that is not the problem, remove the fuel trim valve and check for obstructions; if there are none, replace the fuel trim valve |
| 359 | Fail to Start — Engine will not start. | Switched B+ is not present at T26 terminal block due to: fuse F10 of the engine harness assembly may be open; switched B+ relay K1 is defective | Isolate to harness, F10, or K1; remove F10 (engine harness) and check continuity, if open replace the fuse with one of the same type and amp rating (20 Amps), if fuse reopens check wiring continuity of the circuit; install a harness tool between the base board and the P7 connector, attempt to start and check for B+ at P7-9 (GEN SW B+) and P7-10 (FUEL SOL−) (these are leads to K1 SW B+ relay), if B+ is present relay K1 or the harness is defective, go to next step; attempt to start and check for B+ IN (K1-1) and B+ OUT (K1-4), if there is no B+ IN check for an open circuit, if there is B+ IN and not OUT K1 is defective or the circuit to the K1 coil is open |
| 359 | Fail to Start — Engine will not start. | The engine ignition system is malfunctioning | Refer to the wiring diagrams; check fuses F1 (15A), F2 (5A) and F3 (20A) located on Ford engine harness power block (mounted on skid near ICM); check the Ford engine harness ground lead connection (a black/white stripe wire connects to the starter ground stud); check B+ power connection of the Ford engine harness power lead (starter motor stud B1); check for spark (remove a lead and connect to a spare spark plug); check the crank shaft position sensor (315 to 385 ohms); check the cam position sensor (315 to 385 ohms) |
| 359 | Fail to Start — Engine will not start. | Incorrect demand regulator adjustment | Refer to Initial Demand Regulator Adjustment |
| 359 | Fail to Start — Engine will not start. | Actuator is inoperable because the harness or actuator is defective | Isolate to the harness or actuator; display “Governor Duty Cycle” menu, attempt to start and check for duty cycle (approximately 20% to 40% from zero to full load), if the percentage of duty cycle is displayed before the shutdown the harness or actuator is defective, go to step b (duty cycle displayed indicates the processor is functioning); remove connector P7 from the base board and check wiring continuity of the actuator circuit: P7-24 (ACT +), P7-14 (ACT SIG) and P7-36 (GND) to the appropriate terminals of the governor actuator, repair as necessary, if continuity is OK go to step c; attempt to start and check for CNTL B+ at the terminal lead ACT + of the actuator (use ACT− for meter ground), if CNTL B+ is present attempt to start and check for a pulse width modulated signal at pin 11 (ACT SIG) and pin 1 (ACT +) of the actuator, if ACT SIG is present the actuator may be defective, check actuator operation |
| 415 | Low Oil Pressure — Calibration-dependent. No action is taken by the PCC for code 143. Engine will shut down for code 415. | Fault simulation was enabled with InPower | With InPower, verify that the fault simulation is not enabled for the oil pressure sensor; if you do not have InPower, remove battery power from the control to disable fault simulation overrides |
| 415 | Low Oil Pressure — Calibration-dependent. No action is taken by the PCC for code 143. Engine will shut down for code 415. | Low oil level; clogged lines or filters | Check the oil level, lines, and filters; if the oil system is OK but oil level is low, replenish |
| 415 | Low Oil Pressure — Calibration-dependent. No action is taken by the PCC for code 143. Engine will shut down for code 415. | Sensor or oil pump could be defective; 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 ACT− signal wire at the fuel pump actuator, 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 the 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 sensor; if the PCC still doesn’t display an oil pressure while cranking, the oil pump may be defective (refer to the engine service manual); if the control does not respond to the simulator, go to the next step |
| 415 | Low Oil Pressure — Calibration-dependent. No action is taken by the PCC for code 143. Engine will shut down for code 415. | The harness could be defective | If the control does not respond to the simulator, the harness is defective; check for +5 VDC at the sensor (lead marked E1-A); if there is no 5 VDC at the sensor, check for 5 VDC at P7-21; if yes, the harness is defective; if there is 5 VDC at the sensor, use the sensor simulator to generate a signal to P7-13 (OP OUT) and P7-17 (OP COMM); if the pressure signal (.5 to 4.5 VDC) does not get to P7, isolate to the harness |
| 441 | Low Battery Voltage — PCC voltage supply approaching level at which unpredictable operation may occur. | Weak or discharged battery | Recharge or replace the battery; the specific gravity for a fully charged battery is approximately 1.260 at 80° F (27° C) |
| 441 | Low Battery Voltage — PCC voltage supply approaching level at which unpredictable operation may occur. | Low electrolyte level in the battery | Replenish electrolyte and recharge the battery |
| 441 | Low Battery Voltage — PCC voltage supply approaching level at which unpredictable operation may occur. | Battery connections loose or dirty | Clean and tighten or replace the battery cable connectors and cables at the battery and at the generator set |
| 441 | Low Battery Voltage — PCC voltage supply approaching level at which unpredictable operation may occur. | Wrong battery voltage | Verify that battery voltage 12 or 24 matches calibration |
| 441 | Low Battery Voltage — PCC voltage supply approaching level at which unpredictable operation may occur. | Insufficient battery charging voltage | Adjust the charge rate of the battery charging circuit, according to manufacture's instructions |
| 441 | Low Battery Voltage — PCC voltage supply approaching level at which unpredictable operation may occur. | Engine DC alternator could be defective | Replace the engine DC alternator if normal battery charging voltage (12 to 14 or 24 to 26 VDC) is not obtained |
| 441 | Low Battery Voltage — PCC voltage supply approaching level at which unpredictable operation may occur. | If the batteries are OK, the problem may be the harness | Remove connector P7 from the base board and check battery voltage at P7−3 (B+) to P7-7 (GND) and P7-4 (B+) to P7-8 (GND); if the voltage at P7 is not the same as the battery voltage, the harness is defective and must be replaced |
| 442 | High Battery Voltage — PCC damage will occur. | Excessive battery charging voltage | Adjust the charge rate of the battery charging circuit according to manufacturer's instructions |
| 442 | High Battery Voltage — PCC damage will occur. | Engine DC alternator could be defective | Replace the engine DC alternator if normal battery charging voltage (12 to 14 VDC) is not obtained |
| 442 | High Battery Voltage — PCC damage will occur. | Wrong battery voltage | Verify that the battery voltage (12 VDC) matches the calibration |
| 1123 | Shutdown After Battle Short | A shutdown fault occurred while Battle Short was enabled and Battle Short transitioned from enabled to disabled | Review the Fault History and perform corrective action |
| 1124 | Delayed Shutdown | A shutdown fault | |
| 1131 | Battle Short Active | Battle short function enabled | |
| 1311 | Customer Input #1 - #3 — Status, warning or shutdown | If there is no actual fault, the problem may be an external wiring problem, active input (closed or open) selection is incorrect | Disconnect the signal lead from TB1 and reset the control (CUST_IN1 − TB1-4, CUST_IN2 − TB1-5, CUST_IN3 − TB1-6); if the message drops out, the external wiring has a short or open circuit, or the active input selection (closed/open) is not correct for customer input (use the service tool to check the selection) |
| 1312 | Customer Input #1 - #3 — Status, warning or shutdown | If there is no actual fault, the problem may be an external wiring problem, active input (closed or open) selection is incorrect | Disconnect the signal lead from TB1 and reset the control (CUST_IN1 − TB1-4, CUST_IN2 − TB1-5, CUST_IN3 − TB1-6); if the message drops out, the external wiring has a short or open circuit, or the active input selection (closed/open) is not correct for customer input (use the service tool to check the selection) |
| 1317 | Customer Input #1 - #3 — Status, warning or shutdown | If there is no actual fault, the problem may be an external wiring problem, active input (closed or open) selection is incorrect | Disconnect the signal lead from TB1 and reset the control (CUST_IN1 − TB1-4, CUST_IN2 − TB1-5, CUST_IN3 − TB1-6); if the message drops out, the external wiring has a short or open circuit, or the active input selection (closed/open) is not correct for customer input (use the service tool to check the selection) |
| 1318 | Service Engine Fault — No action is taken by the PCC. A Service Engine message appears on the control display. | Intermittent fault | Reset the control (this fault must be cleared manually); check for loose connections at the heated exhaust gas oxygen sensor and at the fuel trim valve (air fuel control) |
| 1318 | Service Engine Fault — No action is taken by the PCC. A Service Engine message appears on the control display. | Improper inlet supply pressure to the generator set at the demand regulator | Verify supply pressure to the generator set at the demand regulator is 7−13.6 inches WC |
| 1318 | Service Engine Fault — No action is taken by the PCC. A Service Engine message appears on the control display. | Gas solenoid is not opening properly | Verify proper operation of the gas solenoids |
| 1318 | Service Engine Fault — No action is taken by the PCC. A Service Engine message appears on the control display. | Problem with the fuel trim valve (air fuel control) | Troubleshoot using the electronic service tool and Woodward L-Series Process Controller manual (available on the Woodward website); connect the interface harness (Cummins PN 0338−4987); verify that the software version for the electronic service tool is 2.3 or greater; launch the Woodward software and start the engine; at the overview screen check whether the fuel trim valve is in open-loop or closed-loop mode; if in open-loop mode, verify that the HEGO sensor warm light is not on, check the actual position of the valve and compare it to the commanded position, if these are not the same or very close there may be a problem with the valve or an obstruction in the valve, check the process setpoint and compare it to the open-loop set point specified for the model and fuel type (66.3% for natural gas, 49.4% for propane); if in closed-loop mode, verify that the HEGO sensor warm light is on, if not check the HEGO sensor and the wiring between the HEGO and the fuel trim valve, otherwise check the Alarms screens for the “At Max Position” or “At Minimum Position” alarms, if these alarms are active it means that either there is too much or too little fuel going to the fuel trim valve, verify the gas supply pressure and adjust the demand regulator |
| 1318 | Service Engine Fault — No action is taken by the PCC. A Service Engine message appears on the control display. | No SW B+ to the HEGO sensor and the fuel control | On the HEGO sensor, check for SW B+ at P20-D and GND at P20-C; on the fuel trim valve (air/fuel control), check for SW B+ at A20-1 and GND at A20-5; check relay K1, fuse F1, and control fuse F3 |
| 1318 | Service Engine Fault — No action is taken by the PCC. A Service Engine message appears on the control display. | No communication between the HEGO sensor and the fuel trim valve (air/fuel control) | Check for continuity between the HEGO sensor and the fuel trim valve as follows: P20-B to A20-8, P20-A to A20-3 |
| 1318 | Service Engine Fault — No action is taken by the PCC. A Service Engine message appears on the control display. | Failed HEGO sensor | Check the resistance between P20-C and P20-D (should be 2.1 + 0.4 Ohms at room temperature); check the voltage between P20-A and P20-B after the sensor has warmed up while the engine is running (should be 0−1 V) |
| 1318 | Service Engine Fault — No action is taken by the PCC. A Service Engine message appears on the control display. | Wrong fuel selection | Verify the fuel selection; if SW B+ is present at A20-11, it indicates propane fuel only |
| 1318 | Service Engine Fault — No action is taken by the PCC. A Service Engine message appears on the control display. | No communication between the generator set control and the fuel trim valve (air fuel control) | Check for continuity between the fuel trim valve (A20-9) and the generator set control (TB1-7) |
| 1318 | Service Engine Fault — No action is taken by the PCC. A Service Engine message appears on the control display. | Excessively high exhaust back pressure | See the Installation Manual |
| 1334 | Crit Scaler OR | An incorrect feature or calibration was entered into the control | |
| 1335 | Non-Crit Scaler OR | An incorrect feature or calibration was entered into the control | |
| 1416 | Fail to Shutdown | A shutdown fault was bypassed while the Battle Short feature was enabled on the power command controller | |
| 1417 | Power Down Failure | Possibility of the base board fault | |
| 1433 | Emergency Stop | A local Emergency Stop | To reset the local/remote Emergency Stop button: pull the Emergency stop button out; move the O/Manual/Auto switch to O; press the front panel Fault Acknowledge/Reset button; select Manual or Auto, as required |
| 1434 | Remote Emergency Stop | The Remote Emergency stop button has been activated; faulty connection or faulty emergency stop switch | |
| 1435 | Low Coolant Temperature — No action is taken by the PCC. The engine may not start due to slow cranking speed. | Fault simulation was enabled with InPower | With InPower, verify that the fault simulation is not enabled for the coolant sensor; if you do not have InPower, remove battery power from the control to disable fault simulation overrides |
| 1435 | Low Coolant Temperature — No action is taken by the PCC. The engine may not start due to slow cranking speed. | Fault threshold is not set correctly with InPower | Reset the threshold to the lowest allowable setting; determine the required operating range before adjusting the threshold |
| 1435 | Low Coolant Temperature — No action is taken by the PCC. The engine may not start due to slow cranking speed. | The engine coolant heater could be defective (radiant heat should be felt with your hand held close to the outlet hose); coolant heater not operating due to: coolant heater not connected to power; low coolant level; defective heater element/thermostat | Check for a blown fuse or a disconnected heater cord and correct as required; look for possible coolant leakage points and repair as required; with the coolant heater removed from the engine and power disconnected, flush with cold tap water for two minutes to close the internal heater thermostat (opens at 100 °F and closes at 80 °F), check resistance across the input power leads: open − replace the coolant heater; closed − coolant heater is OK (coil resistance of 10 to 60 ohms) |
| 1435 | Low Coolant Temperature — No action is taken by the PCC. The engine may not start due to slow cranking speed. | The sensor connections could be defective | Inspect the sensor and engine harness connector pins; repair or replace as necessary |
| 1435 | Low Coolant Temperature — No action is taken by the PCC. The engine may not start due to slow cranking speed. | The sensor could be defective | 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 the control does not respond, the harness or base board is defective and must be replaced |
| 1435 | Low Coolant Temperature — No action is taken by the PCC. The engine may not start due to slow cranking speed. | The harness could be defective | Measure the resistance of the coolant temperature sensor and reconnect the harness to the sensor; remove connector P7 from the base board and check resistance between pins P7-30 (IH20) and P7-34 (IH20 COM); if resistance is not the same, the harness is defective and must be replaced |
| 1438 | Fail to Crank — Engine will not start. | Starter is defective | Reset the control; attempt to start and test for B+ at the starter; if there is B+ at the starter, the starter could be defective, test the starter (see the engine service manual), replace the starter; if B+ is not present at the starter, go to the next step |
| 1438 | Fail to Crank — Engine will not start. | Fuse F3 on the base board may be open | Remove F3 and check continuity; if open, replace the fuse with one of the same type and amp rating (2 Amps); if F3 is OK, install a harness tool between the base board and the P7 connector, attempt to start and check for B+ at P7-23 (GEN SW B+) and P7-27 (START SOL−) (these are leads to the K4 coil); if there is a B+ signal, the Start Pilot Relay K4 or starter circuitry is defective, go to the next step |
| 1438 | Fail to Crank — Engine will not start. | Start Pilot Relay K4 or starter circuitry could be defective | Check for B+ IN at K4-1 (directly connected to battery B+); if not present, check for an open circuit; if there is B+ IN, attempt to start and test for B+ OUT at K4-4; if there is no B+ OUT at K4-4, K4 is defective and must be replaced; if there is B+ OUT at K4-4, check for an open circuit between K4-4 and the starter |
| 1438 | Fail to Crank — Engine will not start. | The Emergency Stop switch or wiring is defective | With the Emergency Stop push button not activated, remove connector P1 and check for continuity between P1-1 (ESTOP-NC1) and P1-2 (ESTOP-NC2) (if the circuit is open, the control will detect a local E-Stop condition but will not display the E-Stop condition); if circuit is open, isolate to the Emergency Stop switch and wiring; if there is continuity, go to the next step |
| 1438 | Fail to Crank — Engine will not start. | MPU/circuit is bad | Refer to Fault Code 121 instructions |
| 1442 | Weak Battery — No action is taken by the PCC. | Weak or discharged battery | Recharge or replace the battery; specific gravity for a fully charged battery is approximately 1.260 at 80° F (27° C) |
| 1442 | Weak Battery — No action is taken by the PCC. | Low electrolyte level in battery | Replenish electrolyte and recharge battery |
| 1442 | Weak Battery — No action is taken by the PCC. | Battery connections loose or dirty | Clean and tighten or replace the battery cable connectors and cables at the battery and at the set |
| 1442 | Weak Battery — No action is taken by the PCC. | Insufficient battery charging voltage | Adjust charge rate of battery charging circuit, according to manufacturers instructions |
| 1442 | Weak Battery — No action is taken by the PCC. | If the batteries are OK, the problem may be the harness | Remove connector P7 from Base board; check battery voltage at P7-3 (CNTL) to P7-7 (GND) and P7-4 (CNTL) to P7-8 (GND); if voltage is not OK, repair defective harness |
| 1443 | Battery Failed — Engine will not start. | Refer to code 1438 | Refer to code 1438 instructions |
| 1444 | KW Overload — No action taken by the PCC. | Fault threshold is not set correctly with InPower | Reset the threshold to the highest allowable setting; determine the required operating range before adjusting the threshold |
| 1444 | KW Overload — No action taken by the PCC. | Short or overload | Check the load and load cables; repair if necessary; check operation by disconnecting load and restarting generator set |
| 1444 | KW Overload — No action taken by the PCC. | Incorrect CTs or CT connections | Check CTs and CT connections; correct if necessary; refer to Current Transformer Installation |
| 1444 | KW Overload — No action taken by the PCC. | The problem may be the harness connections | Remove connector P7 from Base board; check continuity from P7 to CTs: P7-11 (CT1) to P7-12 (CT1-COM), P7-15 (CT2) to P7-16 (CT2-COM), P7-19 (CT3) to P7-20 (CT3-COM); repair connections |
| 1445 | Short Circuit — Engine will shut down. | Refer to code 1444 | Refer to code 1444 |
| 1446 | High AC Voltage — Engine will shut down. | Fault simulation was enabled with In-Power | With InPower, verify that the related fault simulation is not enabled; if you do not have InPower, remove battery power from the control to disable fault simulation overrides |
| 1446 | High AC Voltage — Engine will shut down. | Single step large block load removal | Clear fault and restart genset |
| 1446 | High AC Voltage — Engine will shut down. | Fault threshold is not set correctly with InPower | Reset the threshold to the highest allowable setting; determine the required operating range before adjusting the threshold |
| 1446 | High AC Voltage — Engine will shut down. | Generator is bad | Refer to Generator/Base Board Isolation Procedure to determine if the generator is causing the high AC voltage shutdown fault |
| 1447 | Low AC Voltage — Engine will shut down. | Fault simulation was enabled with In-Power | With InPower, verify that the related fault simulation is not enabled; if you do not have InPower, remove battery power from the control to disable fault simulation overrides |
| 1447 | Low AC Voltage — Engine will shut down. | Fault threshold is not set correctly with InPower | Reset the threshold to the lowest allowable setting; determine the required operating range before adjusting the threshold |
| 1447 | Low AC Voltage — Engine will shut down. | Overload | Check the load and correct any overload; check operation by disconnecting load and restarting generator set |
| 1447 | Low AC Voltage — Engine will shut down. | Improper connections have been made at the generator output terminals | Reconnect according to the appropriate reconnection diagram |
| 1447 | Low AC Voltage — Engine will shut down. | PMG or field wiring could be bad | Check and repair the PMG or field wiring |
| 1447 | Low AC Voltage — Engine will shut down. | Shunt wiring connection could be incorrect | Check that excitation inputs P8-21 and P8-22 are connected to the correct voltage; if misconnected to a high voltage, the AVR fault will shut down excitation and cause Low AC Voltage condition |
| 1447 | Low AC Voltage — Engine will shut down. | The rotating rectifier assembly (diodes CR1 through CR6) is faulty | Check each diode |
| 1447 | Low AC Voltage — Engine will shut down. | Loose connector | Repair connections (P8) |
| 1448 | Under Frequency — Generator set will shut down. | Fault simulation was enabled with In-Power | With InPower, verify that the related fault simulation is not enabled; if you do not have InPower, remove battery power from the control to disable fault simulation overrides |
| 1448 | Under Frequency — Generator set will shut down. | Fault threshold is not set correctly with InPower | Reset the threshold to the lowest allowable setting; determine the required operating range before adjusting the threshold |
| 1448 | Under Frequency — Generator set will shut down. | Overload | Check the load and correct any overload; check operation by disconnecting load and restarting generator set |
| 1448 | Under Frequency — Generator set will shut down. | Fuel or air delivery problem | Refer to Fuel Systems |
| 1448 | Under Frequency — Generator set will shut down. | Loose connector | Repair connections (P8) |
| 1449 | Over Frequency — No action taken by the PCC. | Fault simulation was enabled with In-Power | With InPower, verify that the related fault simulation is not enabled; if you do not have InPower, remove battery power from the control to disable fault simulation overrides |
| 1449 | Over Frequency — No action taken by the PCC. | Fault threshold is not set correctly with InPower | Reset the threshold to the highest allowable setting; determine the required operating range before adjusting the threshold |
| 1449 | Over Frequency — No action taken by the PCC. | Fuel or air delivery problem | Refer to Fuel Systems |
| 1449 | Over Frequency — No action taken by the PCC. | Loose connector | Repair connections (P7/P8) |
| 1461 | Loss of Field | Loss of field (electric) due to reverse kVAR | |
| 1466 | Modem Failure | The control can not communicate with the modem | Check for an open short circuit to ground and loose connections to the modem |
| 1468 | Network Error | A momentary loss of communication from the LonWorks network | Refer to the LonWorks network publications for more specific troubleshooting methods |
| 1469 | Speed/Hz Match | Measured speed and measured AC output frequency do not agree | Check the calibration file |
| 1471 | Over Current — No action is taken by the PCC for code 1471. Engine will shut down for code 1472. | Refer to code 1444 | Refer to code 1444 |
| 1472 | Over Current | Generator output current has exceeded 110% of rated, and a control time/current calculation has initiated an overcurrent shutdown | Check the load and load lead connections (the fault may not reset for several minutes) |
| 2323 | Network Faults 5 through 8 | Network inputs (#5−#8) are in an active state | See Fault Codes 1313−1316 for corrective action |
| 2326 | Network Faults 5 through 8 | Network inputs (#5−#8) are in an active state | See Fault Codes 1313−1316 for corrective action |
| 2335 | Excitation Fault | Parameters incorrectly configured; wiring issue(s) | |
| 2336 | Memory Error | A control memory error, resulting in data corruption of critical operating parameters | Try reloading the calibration file |
| 2341 | High Control Temperature — Warning | The control temperature is above normal (158° F [70° C]) for a time greater than the control temperature set time | Check the generator set room air flow |
| 2342 | Too Long in Idle — Warning | Maximum Idle Time parameters configured incorrectly | |
| 2342 | Too Long in Idle — Warning | Faulty coolant heater(s) | |
| 2967 | Governor Fault — Warning | Governor hardware drive circuitry contains a fault condition | |
| 2968 | AVR Fault — Warning | Indicates AVR hardware contains a fault condition | |
| 2969 | LON Failure — Warning | Indicates no communications with the LonWorks board | |
| 2972 | Field Overload — Shutdown | Max Field Time Delay parameter configured incorrectly | |
| 2972 | Field Overload — Shutdown | Voltage sensing into the base board is too low or an open or short circuit | |
| 2972 | Field Overload — Shutdown | Alternator or application issue | |
| 1244 | Engine Normal Shutdown |
| Symptom | Cause | Remedy |
|---|---|---|
| Engine Lacks Power or Is Unstable (No Fault Message) — The engine is approaching a level at which unpredictable operation may occur. | Current ambient conditions cause a derate, limiting power to less than the rated power. | Determine proper derates for ambient conditions. Refer to specification sheet for site derating factors. |
| Engine Lacks Power or Is Unstable (No Fault Message) — The engine is approaching a level at which unpredictable operation may occur. | The engine air filter element is dirty. | Replace the air filter element. |
| Engine Lacks Power or Is Unstable (No Fault Message) — The engine is approaching a level at which unpredictable operation may occur. | Check for exhaust restrictions. | See the Installation Manual. |
| Engine Lacks Power or Is Unstable (No Fault Message) — The engine is approaching a level at which unpredictable operation may occur. | The gaseous fuel is of insufficient energy content or fuel pressure. | Check with the propane supplier or the gas utility to confirm the energy content of the gaseous fuel being used. Propane must have approximately 2500 BTU's per cubic foot and natural gas 1000 BTU's per cubic foot. Check the gas supply pressure (7.0 to 13.6 inches WC) and readjust it if necessary. |
| Engine Lacks Power or Is Unstable (No Fault Message) — The engine is approaching a level at which unpredictable operation may occur. | LPG liquid converter frosts. | Check for low coolant and fill if necessary. Check for air in the cooling system and, if necessary, bleed the cooling system. |
| Engine Lacks Power or Is Unstable (No Fault Message) — The engine is approaching a level at which unpredictable operation may occur. | Incorrect demand regulator adjustment. | Refer to Initial Demand Regulator Adjustment. |
| Engine Lacks Power or Is Unstable (No Fault Message) — The engine is approaching a level at which unpredictable operation may occur. | Engine hunting at 90% to 100% of full load. | Governor Gain misadjusted. Refer to Governor/Regulator Setup Menu. No Air/Fuel adjustment available (dual fuel gensets) - check K99 wiring. K99 relay, miswired, can cause genset hunting. Refer to Initial Demand Regulator Adjustment. |
| Engine Lacks Power or Is Unstable (No Fault Message) — The engine is approaching a level at which unpredictable operation may occur. | Engine has preignition on LPG at high loads. | Check ignition timing wiring (single fuel gensets, Spec D & E only). Natural Gas: P11 to P10 LPG: P11 to K1- |
| Engine Lacks Power or Is Unstable (No Fault Message) — The engine is approaching a level at which unpredictable operation may occur. | Excessive crank time (seven seconds or more) before starting (NG or LPG vapor). | See the Installation Manual. Regulator may require adjustment. Refer to Initial Demand Regulator Adjustment. |
| Engine Lacks Power or Is Unstable (No Fault Message) — The engine is approaching a level at which unpredictable operation may occur. | Problems with fuel trim valve (air fuel control). | See instructions for FC 1318. |
| Engine Lacks Power or Is Unstable (No Fault Message) — The engine is approaching a level at which unpredictable operation may occur. | Failed HEGO sensor. | See instructions for failed HEGO sensor in FC 1318. Check to see if the hunting only occurs in closed-loop mode. Run the genset for at least three minutes. If the genset is still hunting, unplug the O2 sensor. If the hunting stops, the HEGO sensor is faulty, or the connection between the HEGO sensor and the fuel trim valve (air fuel control) is faulty. |
| Engine Lacks Power or Is Unstable (No Fault Message) — The engine is approaching a level at which unpredictable operation may occur. | The engine is worn. | Service the engine according to the engine service manual. |
Fault codes and symptom→remedy steps extracted from this model’s service/owner documentation; verify against the official manual before servicing.
Documented causes: Current ambient conditions cause a derate, limiting power to less than the rated power.; The engine air filter element is dirty.; Check for exhaust restrictions.; The gaseous fuel is of insufficient energy content or fuel pressure.. See the table for the matching fixes.
Documented causes: Intermittent fault; Improper inlet supply pressure to the generator set at the demand regulator; Gas solenoid is not opening properly; Problem with the fuel trim valve (air fuel control). See the table for the matching fixes.
Documented causes: Fault simulation was enabled with In-Power; Fault threshold is not set correctly with InPower; Overload; Improper connections have been made at the generator output terminals. See the table for the matching fixes.