Cummins/Onan PCC 3100 troubleshooting: 39 fault codes and symptom-cause-remedy entries from the manufacturer's own service documentation.
Cummins/Onan PCC 3100 — full specs, parts & maintenance.
All Cummins/Onan fault codes →
| Code | Meaning | Cause | Remedy |
|---|---|---|---|
| 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. b. Contact an authorized service center. |
| 221 | Shutdown lamp lights. MESSAGE: FAIL TO CRANK 221 − SHUTDOWN | 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 | Shutdown lamp lights. Engine will not crank. MESSAGE: OVERCRANK 222 − SHUTDOWN | 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 | Shutdown lamp lights. Engine runs and then shuts down. MESSAGE: OVERSPEED 223 − SHUTDOWN | Contact an authorized service center. | |
| 230 | Warning lamp lights. MESSAGE: LOW DC VOLTAGE 230 − WARNING | 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 | Warning lamp lights. MESSAGE: HIGH DC VOLTAGE 231 − WARNING | Contact an authorized service center. | |
| 232 | Warning lamp lights. MESSAGE: WEAK BATTERY 232 − WARNING | Discharged or defective battery. See Warning message 230, LOW DC VOLTAGE. | |
| 240 | Warning lamp lights. MESSAGE: LOW FUEL DAY 240 − WARNING | Check fuel supply and replenish as required. | |
| 241 | Warning lamp lights. MESSAGE: LOW FUEL 241 − WARNING | Check fuel supply and replenish as required. | |
| 250 | Shutdown lamp lights. MESSAGE: EEPROM ERROR 250 − SHUTDOWN | Indicates PCC memory error. Data corruption of critical operating parameters. Contact an authorized service center. | |
| FAIL TO CRANK 221 - SHUTDOWN | Shutdown lamp lights. Engine will not crank. MESSAGE: FAIL TO CRANK 221 − SHUTDOWN | 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 222 | Shutdown lamp lights. Engine stops cranking. MESSAGE: OVERCRANK 222 − SHUTDOWN | 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. | |
| 101 | Engine continues to operate at reduced RPM. | ||
| 102 | Engine shuts down and will not crank. | Indicates local or remote Emergency Stop. To reset the local Emergency Stop button : Pull the button out or turn the switch clockwise (button with arrow) and allow it to pop out. Move the Run/Off/Auto switch to Off. Press the Reset switch. Select Run or Auto, as required. | |
| LOW COOLANT LVL | 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. b. If radiator level is low and coolant bottle level is correct, defective coolant bottle hose or radiator cap. c. Reset control and restart after locating and correcting problem. |
| OVERSPEED | Engine runs and then shuts down. Shutdown lamp lights. MESSAGE: OVERSPEED 223 − SHUTDOWN | Indicates engine has exceeded normal operating speed. (115% 1% of nominal). a. Check for possible fault with control or starting system. | |
| LOW FUEL-DAY | 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 | Warning lamp lights. MESSAGE: EEPROM ERROR 251 − WARNING or 252 − WARNING | Indicates PCC memory error. Data corruption of noncritical operating parameters. | |
| CUSTOMER FAULT 1 | Shutdown lamp lights. MESSAGE: CUSTOMER FAULT 1 260 − SHUTDOWN or GROUND FAULT 261 − SHUTDOWN or DAY TANK 262 − SHUTDOWN or HIGH GEN TEMP 263 − 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. | |
| CUSTOMER FAULT 1 | Warning lamp lights. MESSAGE: CUSTOMER FAULT 1 260 − WARNING or GROUND FAULT 261 − WARNING or RUPTURE BASIN 262 − WARNING or HIGH GEN TEMP 263 − 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. | |
| HIGH AC VOLTAGE | Shutdown lamp lights. MESSAGE: HIGH AC VOLTAGE 301 − SHUTDOWN | Indicates that one or more of the phase voltages has exceeded 130% of nominal, or has exceeded 110% of nominal for 10 seconds. | |
| LOW AC VOLTAGE | Shutdown lamp lights. MESSAGE: LOW AC VOLTAGE 303 − SHUTDOWN | Indicates that one or more of the phase voltages has | |
| 301 | HIGH AC VOLTAGE | ||
| 303 | LOW AC VOLTAGE | ||
| 313 | UNDER FREQUENCY | ||
| 320 | OVERCURRENT | Warning | |
| 322 | SHORT CIRCUIT | Shutdown | |
| 330 | OVERLOAD | Warning | |
| 335 | REVERSE POWER | Shutdown | |
| 101 | IDLE MODE | When the genset is operating in 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 genset returns to normal speed and voltage.When the engine idle function is enabled, the control automatically gensets lower oil pressure warning and shutdown trip points to reflect the lower operating speed. When the engine idle function is removed and the genset reverts to normal operating speed, the control automatically resets oil pressure warning and shutdown trip points to the normal settings. | |
| 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. | |
| 200 | LOW OIL PRESSURE | If generator is powering critical loads and cannot be shut down, wait until next shutdown period and then follow 201-SHUTDOWN procedure. To check oil pressure, access the Oil Pressure menu prior to clearing the fault. | |
| 204 | OIL PRES SENDER | Indicates that the control has sensed that the engine oil pressure sender is out of its working range. Check that the engine oil pressure sender is properly connected. | |
| 210 | LOW COOLANT TEMP | Set 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 Coolant 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. Open heater element. Check current draw of heater. | |
| 211 | HIGH COOLANT TEMP | 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. | |
| 213 | COOLANT SENDER | 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. |
| Symptom | Cause | Remedy |
|---|---|---|
| Shutdown lamp lights. | Check coolant level and replenish if low. Look for possible coolant leakage points and repair if necessary. | |
| 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. | |
| 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. | A. Check for battery disconnected, discharged, or improperly connected. b. 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: Indicates mag pickup speed indication is not being sensed or does not match generator set output frequency.. See the table for the matching fixes.
Documented causes: There is no DC power to the control.. See the table for the matching fixes.
Documented causes: Indicates engine coolant level has fallen below the trip point. Allow engine to cool down completely before proceeding.. See the table for the matching fixes.