Cummins/Onan PCC 3100 troubleshooting: 163 fault codes and 4 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 |
|---|---|---|---|
| 102 | EMERGENCY STOP — Shutdown lamp lights | 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 — 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 and then follow 201-SHUTDOWN procedure; To check oil pressure, access the 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 Table 4-3. |
| 204 | OIL PRESS SENDER — Warning lamp lights | 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 — Warning lamp lights | Engine coolant heater is not operating or is not circulating coolant; Coolant heater not connected to power supply; Low coolant level; Open heater element | Check for blown fuse or disconnected heater cord and correct as required; Check for low coolant level and replenish if required. Look for possible coolant leakage points and repair as required; Check current draw of heater. |
| 211 | HIGH COOLANT TEMP — Warning lamp lights | Engine coolant temperature is getting close to the recommended maximum temperature limit: 215 F (102 C) — standby or 207 F (97 C) — prime | Reduce load if possible by turning off non-critical loads; 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 lamp lights | 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: Check for obstructions to cooling airflow and correct as necessary; Check fan belt and repair or tighten if necessary; Check coolant mixture; Check blower fan and circulation pumps on remote radiator installations; Reset control and restart after locating and correcting problem. |
| 213 | COOLANT SENDER — Warning lamp lights | The resistance of the coolant temperature sender is out of range | Check the resistance of the sender. Resistance should be 500 to 2k ohms. |
| 214 | LOW COOLANT LVL — Shutdown lamp lights | Engine coolant level has fallen below the trip point | Allow engine to cool down completely before proceeding: Check coolant level in both radiator and coolant recovery bottle and replenish if low. Look for possible coolant leakage points and repair if necessary; If radiator level is low and coolant bottle level is correct, defective coolant bottle hose or radiator cap; 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 lamp lights | Engine coolant level has fallen below the trip point | Allow engine to cool down completely before proceeding: Check coolant level in both radiator and coolant recovery bottle and replenish if low. Look for possible coolant leakage points and repair if necessary; If radiator level is low and coolant bottle level is correct, defective coolant bottle hose or radiator cap; 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 lamp lights | Mag pickup speed indication is not being sensed or does not match generator set output frequency | Restart and check RPM on the digital display. |
| 221 | FAIL TO CRANK — Engine will not crank; Shutdown lamp lights | Possible fault with control or starting system | Check fuse F3 on the Engine Interface board; Poor battery cable connections. Clean the battery cable terminals and tighten all connections; Discharged or defective battery. Recharge or replace the battery. |
| 222 | OVERCRANK — Engine stops cranking; Shutdown lamp lights | Possible fuel system problem | Check for empty fuel tank, fuel leaks, or plugged fuel lines and correct as required; Check for dirty fuel filter and replace if necessary; Check for dirty or plugged air filter and replace if necessary; Reset the control and restart after correcting the problem. |
| 223 | OVERSPEED — Engine runs and then shuts down; Shutdown lamp lights | Engine has exceeded normal operating speed (115% 1% of nominal) | |
| 230 | LOW DC VOLTAGE — Warning lamp lights | Battery voltage is below 10 VDC; Discharged or defective battery; Poor battery cable connections; Engine DC alternator; Battery charge voltage float level | Check the battery charger fuse. Recharge or replace the battery; Clean the battery cable terminals and tighten all connections; Check engine DC alternator. Replace engine DC alternator if normal battery charging voltage is not obtained; Check battery charge voltage float level if applicable (raise float level). |
| 231 | HIGH DC VOLTAGE — Warning lamp lights | 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 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 | Day tank 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 | |
| 251 | EEPROM ERROR — Warning lamp lights | PCC memory error. Data corruption of noncritical operating parameters | |
| 252 | EEPROM ERROR — Warning lamp lights | PCC memory error. Data corruption of noncritical operating parameters | |
| 260 | CUSTOMER FAULT 1 — Shutdown lamp lights | Customer defined input is closed to ground; shutdown response has been preselected | |
| 261 | GROUND FAULT — Shutdown lamp lights | Customer defined input is closed to ground; shutdown response has been preselected | |
| 262 | DAY TANK — Shutdown lamp lights | Customer defined input is closed to ground; shutdown response has been preselected | |
| 263 | HIGH GEN TEMP — Shutdown lamp lights | Customer defined input is closed to ground; shutdown response has been preselected | |
| 260 | CUSTOMER FAULT 1 — Warning lamp lights | Customer defined input is closed to ground; warning response has been preselected | |
| 261 | GROUND FAULT — Warning lamp lights | Customer defined input is closed to ground; warning response has been preselected | |
| 262 | RUPTURE BASIN — Warning lamp lights | Customer defined input is closed to ground; warning response has been preselected | |
| 263 | HIGH GEN TEMP — Warning lamp lights | Customer defined input is closed to ground; warning response has been preselected | |
| 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 | |
| 303 | LOW AC VOLTAGE — Shutdown lamp lights | One or more of the phase voltages has dropped below 85% of nominal for 10 seconds | |
| 313 | UNDER FREQUENCY — Shutdown lamp lights | Engine speed has dropped below 90% of nominal for 10 seconds | Check fuel supply, intake air supply and load. Note: Five seconds before shutdown, a Load Dump signal is initiated. |
| 320 | OVERCURRENT — Warning lamp lights | Generator output current has exceeded 110% of rated for 60 seconds | Check load and load lead connections. |
| 321 | OVERCURRENT — Shutdown lamp lights | Generator output current has exceeded 110% of rated, and a PCC time/current calculation has initiated an overcurrent shutdown | Check load and load lead connections. |
| 322 | SHORT CIRCUIT — Shutdown lamp lights | Generator output current has exceeded 175% of rated | Check load and load lead connections. |
| 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 | Check load and load lead connections. |
| 335 | REVERSE POWER — Shutdown lamp lights | Improper CT or PT phasing (Non-parallel units only) | Check CT / PT wiring. Refer to CT Installation in Section 5. |
| 221 | ENGINE DOES NOT CRANK—LOCAL OR REMOTE RUN — "FAIL TO CRANK" (221) message; Reset and attempt to start: Start LED DS11 on the engine interface board turns on | Starter could be bad | Reset the control. Attempt to start, and test for B+ at the starter. If there is B+ at the starter, the starter could be bad. Test starter (see engine service manual). Replace the starter. |
| 221 | ENGINE DOES NOT CRANK—LOCAL OR REMOTE RUN — "FAIL TO CRANK" (221) message; Reset and attempt to start: Start LED DS11 on the engine interface board turns on | If there is no B+ at the starter, start solenoid K4 could be bad | Reset the control. Attempt to start, and test for B+ into and out of start solenoid contacts. If there is B+ in, but not out, check for B+ at the start solenoid coil. If there is B+ at the coil, check ground connection. If ground connection is good, the start solenoid is bad. Replace the start solenoid. If there is B+ into and out of the start solenoid contacts, check for an open between the start solenoid contacts and the starter. If there is no B+, go to the next step. |
| 221 | ENGINE DOES NOT CRANK—LOCAL OR REMOTE RUN — "FAIL TO CRANK" (221) message; Reset and attempt to start: Start LED DS11 on the engine interface board turns on | If there is no B+ at the start solenoid coil (K4), the backup start disconnect contacts in the regulator output module (A37) could be open (indicating that A37 is bad) | Disconnect J7/P7 at the regulator output module. Test for continuity at A37 J7-5/J7-6. If there is no continuity, the regulator output module is bad. Replace A37. |
| 221 | ENGINE DOES NOT CRANK—LOCAL OR REMOTE RUN — "FAIL TO CRANK" (221) message; Reset and attempt to start: Start LED DS11 on the engine interface board turns on | If there is continuity at A37 J7-5/J7-6, there may be an open between A37 and A31, an open between A37 and K4, or A31 may be bad | If there is continuity at A37 J7-5/J7-6, reset the control, attempt to start, and check for B+ at A37 P7-5. |
| 221 | 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. |
| 221 | 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. |
| 221 | 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 there is no +16 volt supply voltage at A32 J4-16, A32 is bad. Replace A32. |
| 221 | 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. |
| 221 | 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. |
| 221 | 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. |
| 221 | 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. |
| 221 | 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. |
| 222 | ENGINE CRANKS BUT DOES NOT START — "OVERCRANK" (222) message; While cranking, Run LED DS12 on the engine interface board (A31) is on; While cranking, Run LED DS2 on the governor output module (A38) is on | Restricted fuel supply due to: Fuel level below pickup tube in tank; Closed shutoff valve in supply line; Fuel injectors clogged; Air in fuel system | Add fuel if low. Prime the fuel system; Open any closed shutoff valve in the fuel line supplying the engine; Refer to engine service manual; Bleed air from fuel system. Refer to engine service manual. |
| 222 | ENGINE CRANKS BUT DOES NOT START — "OVERCRANK" (222) message; While cranking, Run LED DS12 on the engine interface board (A31) is on; While cranking, Run LED DS2 on the governor output module (A38) is on | The mechanical fuel linkage could be binding, loose, or damaged | Inspect the mechanical fuel linkage, and repair or replace as necessary. Follow the procedure in the engine repair manual to check the EFC for binding or damage. Disconnect the actuator connector, and connect +12 VDC from the battery to the actuator. The actuator should click upon application and removal of the voltage. If the actuator does not click, refer to the engine manual. If the actuator clicks, reconnect the wires to the actuator. |
| 222 | ENGINE CRANKS BUT DOES NOT START — "OVERCRANK" (222) message; While cranking, Run LED DS12 on the engine interface board (A31) is on; While cranking, Run LED DS2 on the governor output module (A38) is on | Fuel solenoid (K1) on the injection pump not energized due to: Open in fuel solenoid circuit or defective governor module; Defective fuel solenoid | Reset the control. Attempt to start and check for B+ at the K1 fuel solenoid coil on the injection pump and at output of governor module. Check continuity from J6-20 and 21 to J6-19; Check wiring continuity of fuel solenoid circuit. Test fuel solenoid. Repair or replace as necessary. |
| 222 | ENGINE CRANKS BUT DOES NOT START — "OVERCRANK" (222) message; While cranking, Run LED DS12 on the engine interface board (A31) is on; While cranking, Run LED DS2 on the governor output module (A38) is on | Fuel tank solenoid not energized due to: Open in fuel tank solenoid circuit; Defective fuel tank solenoid | Check wiring continuity of fuel tank solenoid circuit; Test fuel tank solenoid. Repair or replace as necessary. |
| 222 | ENGINE CRANKS BUT DOES NOT START — "OVERCRANK" (222) message; While cranking, Run LED DS12 on the engine interface board (A31) is on; While cranking, Run LED DS2 on the governor output module (A38) is on | Engine fuel injection or other engine problem | Refer to the engine service manual. |
| 222 | ENGINE CRANKS BUT DOES NOT START — "OVERCRANK" (222) message; While cranking, Run LED DS12 on the engine interface board (A31) is on; While cranking, Run LED DS2 on the governor output module (A38) is off | 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. |
| 222 | ENGINE CRANKS BUT DOES NOT START — "OVERCRANK" (222) message; While cranking, Run LED DS12 on the engine interface board (A31) is on; While cranking, Run LED DS2 on the governor output module (A38) is off | There is an open between the engine interface board (A31) and the governor output module (A38) | If there is B+ at A31 J4-1, install harness tool between A38 J6/P6. Check for B+ at A38 J6-19, while attempting to crank. If there is no B+ at A38 J6-19, isolate to connectors and wiring. Repair or replace as necessary. |
| 222 | ENGINE CRANKS BUT DOES NOT START — "OVERCRANK" (222) message; While cranking, Run LED DS12 on the engine interface board (A31) is on; While cranking, Run LED DS2 on the governor output module (A38) is off | The run signal is not getting through the governor output module (A38). A38 may be bad | If there is B+ at A31 J4-1, and there is B+ at A38 J6-19, check continuity from A38 J6-15 to battery ground, if not continuity replace harness, if continuity, replace A38. |
| 222 | 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. |
| 222 | 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. |
| 221 | 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). |
| 200 | LOW OIL PRESSURE WARNING (200) OR SHUTDOWN (201) — "LOW OIL PRESSURE" warning (200) or shutdown (201) message | Low oil level. Clogged lines or filters | 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. |
| 200 | LOW OIL PRESSURE WARNING (200) OR SHUTDOWN (201) — "LOW OIL PRESSURE" warning (200) or shutdown (201) message | Sender or oil pump could be bad. Or the generator set may be shutting down on another fault | Disconnect the oil pressure sender leads, and connect an oil pressure sender simulator to the harness. 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, blown governor fuse, 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. |
| 200 | LOW OIL PRESSURE WARNING (200) OR SHUTDOWN (201) — "LOW OIL PRESSURE" warning (200) or shutdown (201) message | Harness or PCC circuit board could be bad. Isolate to the harness, engine interface board (A31), analog board (A33), or digital board (A32) | 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 4-29a/b). |
| 204 | "OIL PRESSURE SENDER" warning (204) message | 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 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. "OIL PRES SENDER" warning is displayed after the fault condition is sensed for 10 seconds. 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 4-29a/b) |
| 213 | "COOLANT SENDER" warning (213) message | 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 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. If the control responds to the simulator, replace the sender. If the control does not respond to the simulator, refer to the high coolant temp troubleshooting procedure |
| 210 | "LOW COOLANT TEMP" warning (210) message — Coolant level is normal, Heater is OK, Coolant temp on front panel display is OK, DS3 on the engine interface board A31 is on | DS3 / A31 is on, indicating that engine interface board A31 is receiving a low coolant temp from the sender; The sender, the harness or A31 could be bad | Isolate the source of the signal. Unplug the coolant temperature switch (S1) and reset the control. If the 210 warning message drops out and does not reappear, replace the sender. 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 |
| 210 | "LOW COOLANT TEMP" warning (210) message — Coolant level is normal, Heater is OK, Coolant temp on front panel display is OK, DS3 on the engine interface board A31 is off | DS3 / A31 is off, indicating that engine interface board A31 is not receiving a low engine temp signal from the sender—but the 210 message indicates that A32, the digital board, is responding to a false low engine temp signal; A31, the engine interface board, or A32, the digital board, could be bad | Isolate the source of the signal. Check J4-6/P4-6 on A32. Install harness tool between A32 J4/P4. 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 (211) or shutdown (212) message — Coolant mixture and level is normal, No airflow obstructions, Fan belt is OK | Engine problem: Coolant pump could be faulty; Thermostat could be faulty; There could be an obstruction in the coolant flow; External coolant pump (with remote radiator) could be faulty; External radiator fan motor (with remote radiator) could be faulty; The generator set may have been overloaded; Sender, harness or PCC circuit board could be bad | Refer to the engine service manual if there are any physical indications of overheating; Correct any overload condition; If there are no physical indications of overheating, check to see if the PCC accurately displays ambient engine temperature. 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, isolate to the sender, harness, engine interface board (A31), analog board, or digital board. Disconnect the coolant temperature sender leads, and connect a coolant temperature sender simulator to the harness. If the control responds to the simulator, replace the sender. If the control does not respond to the simulator, install harness tool between A31 J5/P5. Connect the coolant temperature sender simulator (and B+) to A31 J5. If the control displays the correct simulated temperature, replace the harness. If the control does not display the correct simulated temperature, install harness tool at A31 J2/P2, and open lines 18/19 (and 14/15, if applicable). Check for continuity between A31 J2-18 to 19 (for coolant temp L), and A31 J2-14 to 15 (for coolant temp R). If no continuity, then A31 is bad. If continuity is OK, then send a simulated temperature signal and measure the voltage out of A31 (A31 J2-18 to 19, and A31 J2-14 to 15). If voltage is not OK (refer to the analog board inputs and outputs, Table 4-30), replace A33. If voltage is OK, refer to the analog/digital troubleshooting procedure (Table 4-29a/b) |
| 212 | "HIGH COOLANT TEMP" warning (211) or shutdown (212) message — Coolant mixture and level is normal, No airflow obstructions, Fan belt is OK | Engine problem: Coolant pump could be faulty; Thermostat could be faulty; There could be an obstruction in the coolant flow; External coolant pump (with remote radiator) could be faulty; External radiator fan motor (with remote radiator) could be faulty; The generator set may have been overloaded; Sender, harness or PCC circuit board could be bad | Refer to the engine service manual if there are any physical indications of overheating; Correct any overload condition; If there are no physical indications of overheating, check to see if the PCC accurately displays ambient engine temperature. 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, isolate to the sender, harness, engine interface board (A31), analog board, or digital board. Disconnect the coolant temperature sender leads, and connect a coolant temperature sender simulator to the harness. If the control responds to the simulator, replace the sender. If the control does not respond to the simulator, install harness tool between A31 J5/P5. Connect the coolant temperature sender simulator (and B+) to A31 J5. If the control displays the correct simulated temperature, replace the harness. If the control does not display the correct simulated temperature, install harness tool at A31 J2/P2, and open lines 18/19 (and 14/15, if applicable). Check for continuity between A31 J2-18 to 19 (for coolant temp L), and A31 J2-14 to 15 (for coolant temp R). If no continuity, then A31 is bad. If continuity is OK, then send a simulated temperature signal and measure the voltage out of A31 (A31 J2-18 to 19, and A31 J2-14 to 15). If voltage is not OK (refer to the analog board inputs and outputs, Table 4-30), replace A33. If voltage is OK, refer to the analog/digital troubleshooting procedure (Table 4-29a/b) |
| 214 | "LOW COOLANT LVL" warning (214) or shutdown (215) message — Coolant level is normal, DS2 on the engine interface board A31 is on | DS2 on A31 is on, indicating that A31 is receiving a low coolant signal from the sender; The sender, the harness or the A31 circuit board could be bad | 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 215 shutdown message drops out and does not reappear, replace the sender. If the 215 shutdown message reappears and remains after control reset, disconnect J4/A31 and check continuity from P4-7 to GND. If there is continuity, replace the harness. If there is no continuity, replace circuit board A31 |
| 215 | "LOW COOLANT LVL" warning (214) or shutdown (215) message — Coolant level is normal, DS2 on the engine interface board A31 is on | DS2 on A31 is on, indicating that A31 is receiving a low coolant signal from the sender; The sender, the harness or the A31 circuit board could be bad | 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 215 shutdown message drops out and does not reappear, replace the sender. If the 215 shutdown message reappears and remains after control reset, disconnect J4/A31 and check continuity from P4-7 to GND. If there is continuity, replace the harness. If there is no continuity, replace circuit board A31 |
| 214 | "LOW COOLANT LVL" warning (214) or shutdown (215) message — Coolant level is normal, DS2 on the engine interface board A31 is off | DS2 on A31 is off, indicating that A31 is not receiving a low coolant signal from the sender—but the 215 message indicates that A32, the digital board, is responding to a false low coolant signal; A31, the engine interface board, or A32, the digital board, could be bad | If the coolant level is normal, isolate the source of the low coolant signal. Check J4-4/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 |
| 215 | "LOW COOLANT LVL" warning (214) or shutdown (215) message — Coolant level is normal, DS2 on the engine interface board A31 is off | DS2 on A31 is off, indicating that A31 is not receiving a low coolant signal from the sender—but the 215 message indicates that A32, the digital board, is responding to a false low coolant signal; A31, the engine interface board, or A32, the digital board, could be bad | If the coolant level is normal, isolate the source of the low coolant signal. Check J4-4/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) — This indicates that the 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 set 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 4-29a/b) |
| 223 | "OVERSPEED" shutdown message (223) | The mechanical fuel linkage could be binding, loose, or damaged; The governor output module (A38) or the digital board (A32) could be bad | Inspect the mechanical fuel linkage, and repair or replace as necessary. Follow the procedure in the engine repair manual to check the EFC for binding or damage. Disconnect the actuator connector, and connect +12 VDC from the battery to the actuator. The actuator should click upon application and removal of the voltage. If the actuator does not click, refer to the engine manual. If the actuator clicks, reconnect the wires to the actuator. Reset the control, and start the set while monitoring the PCC duty cycle display. If the duty cycle goes high (above 40%) and the set shuts down on overspeed, replace A32. If the duty cycle goes to zero and the set shuts down on overspeed, replace A38 |
| 230 | "LOW DC VOLTAGE" (230) or "WEAK BATTERY" (232) warning message; "HIGH DC VOLTAGE" (231) warning message — But battery voltage is OK | Weak or discharged battery; Low electrolyte level in battery; Battery connections loose or dirty; Insufficient battery charging voltage; Excessive battery charging voltage; Engine DC alternator could be bad; 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); If the battery voltage is OK, the problem may be 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 set; Adjust charge rate of battery charging circuit, according to manufacturers instructions; Replace engine DC alternator if normal battery charging voltage is not obtained; 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 4-29a/b); 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 4-29a/b) |
| 231 | "LOW DC VOLTAGE" (230) or "WEAK BATTERY" (232) warning message; "HIGH DC VOLTAGE" (231) warning message — But battery voltage is OK | Weak or discharged battery; Low electrolyte level in battery; Battery connections loose or dirty; Insufficient battery charging voltage; Excessive battery charging voltage; Engine DC alternator could be bad; 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); If the battery voltage is OK, the problem may be 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 set; Adjust charge rate of battery charging circuit, according to manufacturers instructions; Replace engine DC alternator if normal battery charging voltage is not obtained; 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 4-29a/b); 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 4-29a/b) |
| 232 | "LOW DC VOLTAGE" (230) or "WEAK BATTERY" (232) warning message; "HIGH DC VOLTAGE" (231) warning message — But battery voltage is OK | Weak or discharged battery; Low electrolyte level in battery; Battery connections loose or dirty; Insufficient battery charging voltage; Excessive battery charging voltage; Engine DC alternator could be bad; 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); If the battery voltage is OK, the problem may be 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 set; Adjust charge rate of battery charging circuit, according to manufacturers instructions; Replace engine DC alternator if normal battery charging voltage is not obtained; 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 4-29a/b); 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 4-29a/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 (A31) and DS13 (A34) are 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 set. If the set 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 set. If the control generates the same EEPROM ERROR message, perform the calibration procedures in Section 5. Reset the control. Shut off and restart the set. 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 set. If the control generates the same EEPROM ERROR message, replace the digital board (A32) |
| 260 | "CUSTOMER FAULT" (260, 261, 262 or 263) message — And 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, 261, 262 or 263) message — And 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 |
| 262 | "CUSTOMER FAULT" (260, 261, 262 or 263) message — And 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 |
| 263 | "CUSTOMER FAULT" (260, 261, 262 or 263) message — And 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, 261, 262 or 263) message — And 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, J2-24, J2-9, or J2-15 and reset the control. If the fault does not return, replace A34. If the fault reappears, replace A32 |
| 261 | "CUSTOMER FAULT" (260, 261, 262 or 263) message — And 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, J2-24, J2-9, or J2-15 and reset the control. If the fault does not return, replace A34. If the fault reappears, replace A32 |
| 262 | "CUSTOMER FAULT" (260, 261, 262 or 263) message — And 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, J2-24, J2-9, or J2-15 and reset the control. If the fault does not return, replace A34. If the fault reappears, replace A32 |
| 263 | "CUSTOMER FAULT" (260, 261, 262 or 263) message — And 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, J2-24, 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 regulator module (A37), the engine interface board (A31), or the digital board (A32); 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. If one or more phases of voltage are high or the voltages are unbalanced, the PCC is not measuring all phases of voltage and is responding to the low "average" of the three phases of voltage. Go to step 3; 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 set, 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 4-29a/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 set 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 set running). If A31/DS10 is not on with set 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 set 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 4-29a/b) |
| 313 | "UNDER FREQUENCY" shutdown (313) message | Improper setup; Overload; Fuel or air delivery problem; The governor output module (A38), 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; Disconnect the wire to the fuel solenoid, reset the control, and crank the set. DS2 on the governor output module A38 should light. If the duty cycle LED (DS1) on the governor output module (A38) slowly becomes bright, the governor output module (A38), the digital board (A32), and the engine interface board (A31) are functioning properly. If DS1 does not light or instantly becomes bright, A31, A32 or A38 may be bad. A38 - Crank the set, and check the governor duty cycle on the PCC display. If the duty cycle is OK (60% max), replace governor output module (A38). 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) or shutdown (321), or "SHORT CIRCUIT" shutdown (322), or 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. Refer to Current Transformer Installation in Section 5; Disconnect the PT/CT module and check the 3-ohm resistors (J8-15 to 14, J8-22 to 23, J8-7 to 8). Replace the module if necessary; Check continuity from A36—through A34—to A33. Repair the connection or replace A34 if necessary. Refer to Section 8 for pin reference; Isolate, using the analog input troubleshooting procedure (Table 4-29a/b). Check the bad phase or phases |
| 321 | "OVERCURRENT" warning (320) or shutdown (321), or "SHORT CIRCUIT" shutdown (322), or 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. Refer to Current Transformer Installation in Section 5; Disconnect the PT/CT module and check the 3-ohm resistors (J8-15 to 14, J8-22 to 23, J8-7 to 8). Replace the module if necessary; Check continuity from A36—through A34—to A33. Repair the connection or replace A34 if necessary. Refer to Section 8 for pin reference; Isolate, using the analog input troubleshooting procedure (Table 4-29a/b). Check the bad phase or phases |
| 322 | "OVERCURRENT" warning (320) or shutdown (321), or "SHORT CIRCUIT" shutdown (322), or 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. Refer to Current Transformer Installation in Section 5; Disconnect the PT/CT module and check the 3-ohm resistors (J8-15 to 14, J8-22 to 23, J8-7 to 8). Replace the module if necessary; Check continuity from A36—through A34—to A33. Repair the connection or replace A34 if necessary. Refer to Section 8 for pin reference; Isolate, using the analog input troubleshooting procedure (Table 4-29a/b). Check the bad phase or phases |
| 330 | "OVERCURRENT" warning (320) or shutdown (321), or "SHORT CIRCUIT" shutdown (322), or 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. Refer to Current Transformer Installation in Section 5; Disconnect the PT/CT module and check the 3-ohm resistors (J8-15 to 14, J8-22 to 23, J8-7 to 8). Replace the module if necessary; Check continuity from A36—through A34—to A33. Repair the connection or replace A34 if necessary. Refer to Section 8 for pin reference; Isolate, using the analog input troubleshooting procedure (Table 4-29a/b). Check the bad phase or phases |
| 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. |
| MAG PICKUP | 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. | |
| FAIL TO CRANK | Shutdown lamp lights. 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 | Shutdown lamp lights. Engine stops cranking. 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 | 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 DC VOLTAGE | 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. 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 | Warning lamp lights. MESSAGE: HIGH DC VOLTAGE 231 − WARNING | A. Check voltage float level on battery charger if applicable (lower float level). b. Check engine DC alternator. Replace engine DC alternator if normal battery charging voltage is not obtained. | |
| WEAK BATTERY | Warning lamp lights. MESSAGE: WEAK BATTERY 232 − WARNING | A. Discharged or defective battery. See Warning message 230, LOW DC VOLTAGE. | |
| 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 | Shutdown lamp lights. MESSAGE: EEPROM ERROR 250 − SHUTDOWN | Indicates PCC memory error. Data corruption of critical operating parameters. | |
| 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 | |
| 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. | |
| 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 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. |
| 200 | LOW OIL PRESSURE | 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 | 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 | 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 — 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 | 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 | 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 | Indicates that the resistance of the coolant temperature sender is out of range. | Contact an authorized service center. |
| 214 | LOW COOLANT LVL | 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 — LOW COOLANT LVL Shutdown will not occur if generator set is in Idle mode (low coolant warning only). | 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. |
| 220 | MAG PICKUP | 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 — 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 — 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. | Indicates engine has exceeded normal operating speed. (2070 rpm @ 60 hz; 1800 rpm @ 50 hz) | Contact an authorized service center. |
| 230 | LOW DC VOLTAGE | 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 | Indicates battery voltage exceeds 32 VDC. | Contact an authorized service center. |
| 232 | WEAK BATTERY | 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 | Indicates day tank fuel supply is running low. | Check fuel supply and replenish as required. |
| 241 | LOW FUEL | Indicates fuel supply is running low. | Check fuel supply and replenish as required. |
| 250 | EEPROM ERROR | Indicates PCC memory error. Data corruption of critical operating parameters. | Contact an authorized service center. |
| 251 | EEPROM ERROR | Indicates PCC memory error. Data corruption of noncritical operating parameters. | Contact an authorized service center. |
| 252 | EEPROM ERROR | Indicates PCC memory error. Data corruption of noncritical operating parameters. | Contact an authorized service center. |
| 260 | CUSTOMER FAULT 1 | 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. |
| 261 | GROUND FAULT | 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. |
| 262 | DAY TANK | 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. |
| 263 | HIGH GEN TEMP | 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. |
| 262 | RUPTURE BASIN | 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. | |
| 301 | HIGH AC VOLTAGE | 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 | 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 | 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 | Indicates that generator output current has exceeded 110% of rated for 60 seconds. | Contact an authorized service center. |
| 321 | OVERCURRENT | 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 | Indicates that generator output current has exceeded 175% of rated. | Contact an authorized service center. |
| 330 | OVERLOAD | 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 | Indicates improper CT or PT phasing. (Non-parallel units only.) | Contact an authorized service center. |
| 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. b. 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. | |
| OVERSPEED 223 | Shutdown lamp lights. Engine runs and then shuts down. MESSAGE: OVERSPEED 223 − SHUTDOWN | Contact an authorized service center. | |
| LOW DC VOLTAGE 230 - WARNING | 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. | |
| HIGH DC VOLTAGE 231 - WARNING | Warning lamp lights. MESSAGE: HIGH DC VOLTAGE 231 − WARNING | Contact an authorized service center. | |
| WEAK BATTERY 232 | Warning lamp lights. MESSAGE: WEAK BATTERY 232 − WARNING | Discharged or defective battery. See Warning message 230, LOW DC VOLTAGE. | |
| LOW FUEL DAY 240 | Warning lamp lights. MESSAGE: LOW FUEL DAY 240 − WARNING | Check fuel supply and replenish as required. | |
| LOW FUEL 241 | Warning lamp lights. MESSAGE: LOW FUEL 241 − WARNING | 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. Contact an authorized service center. |
| Symptom | Cause | Remedy |
|---|---|---|
| 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. |
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: Fuel level below pickup tube in tank; Closed shutoff valve in supply line; Fuel injectors clogged; Air in fuel system; The mechanical fuel linkage could be binding, loose, or damaged; Fuel solenoid (K1) on the injection pump not energized due to: Open in fuel solenoid circuit or defective governor module; Defective fuel solenoid; Fuel tank solenoid not energized due to: Open in fuel tank solenoid circuit; Defective fuel tank solenoid. See the table for the matching fixes.
Documented causes: Starter could be bad; If there is no B+ at the starter, start solenoid K4 could be bad; If there is no B+ at the start solenoid coil (K4), the backup start disconnect contacts in the regulator output module (A37) could be open (indicating that A37 is bad); If there is continuity at A37 J7-5/J7-6, there may be an open between A37 and A31, an open between A37 and K4, or A31 may be bad. See the table for the matching fixes.
Documented causes: 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). See the table for the matching fixes.