Katolight D415FGJ4 troubleshooting: 80 fault codes and 161 symptom-cause-remedy entries from the manufacturer's own service documentation.
Katolight D415FGJ4 — full specs, parts & maintenance.
| Code | Meaning | Cause | Remedy |
|---|---|---|---|
| 1 | PRE HI ENGINE TEMP. Engine continues to operate. | Engine has begun to overheat and engine temperature has risen to approximately 215°F (102°C). | Reduce load if possible by turning off non-critical loads; Check air inlets and outlets and remove any obstructions to airflow; Open doors or windows in generator area to increase ventilation; If engine can be stopped, follow procedure in Step 2. |
| 2 | HI ENGINE TEMP LED. Engine shuts down. | Engine has overheated (engine temperature has risen above 225°F/107°C) or coolant level is low (sets with coolant level sensor). | Allow engine to cool down completely before proceeding; Check coolant level and replenish if low. Look for possible coolant leakage points and repair if necessary; Check for obstructions to cooling airflow and correct as necessary; Check for a slipping fan belt and tighten if loose; Reset control and restart after locating and correcting problem. Contact your Dealer or Distributor if none of the above. |
| 3 | PRE LOW OIL PRESSURE. Engine continues to operate. | Engine oil pressure has dropped to 20 psi (138kPa). | If generator is powering critical loads and cannot be shut down, wait until next shutdown period and then follow Step 4 procedure. If engine can be stopped, follow procedures in Step 4. |
| 4 | LOW OIL PRESSURE. Engine shuts down. | Engine oil pressure has dropped to 15 psi (103kPa). | Check oil level, lines and filters. If oil system is okay, but oil level is low, replenish. Reset control and restart. Contact your Dealer or Distributor if oil pressure is not in the range of 35 to 55 psi (241 to 379 kPa). |
| 5 | OVERCRANK. Engine stops cranking. Or Engine runs, shuts down, and LOW OIL PRESSURE. | 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 (See Maintenance section of Engine Manual); Check for dirty or plugged air filter and replace if necessary (See Maintenance section of Engine Manual); Refer to Step 4; Reset the control and restart after correcting the problem. Contact your Dealer or Distributor for service if none of the above. |
| 6 | OVERSPEED. Engine runs and then shuts down. | Engine has exceeded normal operating speed. | Refer to governor adjust procedure. Contact your Dealer or Distributor for service. |
| 7 | UNIT NOT IN AUTO. | AUTO/OFF/RUN switch is in the OFF position which will prevent automatic starting if an automatic transfer switch is used. | Move the AUTO/OFF/RUN switch to the AUTO position for automatic starting. |
| 8 | LOW FUEL. Engine continues to run. | Diesel fuel supply is running low. | Check fuel supply and replenish as required. |
| 9 | LOW FUEL and LOW OIL. | Engine has run out of fuel. | Check fuel level and replenish as required. See Engine Manual for fuel system priming procedure. |
| 10 | LOW ENGINE TEMPERATURE. Set is in standby mode but not operating. | Engine coolant heater is not operating or is not circulating coolant. | Check for the following conditions: Coolant heater not connected to power supply. Check for blown fuse, open circuit. |
| SPN 100 FMI 03 | Throttle # 3 Input High | ||
| SPN 100 FMI 04 | Throttle # 3 Input Low | ||
| SPN 102 FMI 03 | Throttle # 2 Input High | ||
| SPN 102 FMI 04 | Throttle # 2 Input Low | ||
| SPN 105 FMI 03 | Throttle # 1 Input High | ||
| SPN 105 FMI 04 | Throttle # 1 Input Low | ||
| SPN 105 FMI 08 | Throttle # 1 Abnormal Pulse Width | ||
| SPN 105 FMI 09 | Throttle # 1 CAN Invalid | ||
| SPN 107 FMI 01 | Fuel Supply Pressure Extremely Low | ||
| SPN 107 FMI 03 | Fuel Supply Pressure Input Voltage High | ||
| SPN 107 FMI 04 | Fuel Supply Pressure Input Voltage Low | ||
| SPN 107 FMI 16 | Fuel Supply Pressure Moderately High | ||
| SPN 107 FMI 18 | Fuel Supply Pressure Moderately Low | ||
| SPN 410 FMI 03 | Water in Fuel Continuously Detected | ||
| SPN 410 FMI 04 | Water in Fuel Signal Voltage High | ||
| SPN 110 FMI 03 | Water in Fuel Signal Voltage Low | ||
| SPN 110 FMI 04 | Water in Fuel Detected | ||
| SPN 110 FMI 16 | Water in Fuel Detected | ||
| SPN 111 FMI 31 | Engine Oil Pressure Extremely Low | ||
| SPN 158 FMI 01 | Engine Oil Pressure Input Voltage High | ||
| SPN 174 FMI 03 | Engine Oil Pressure Input Voltage Low | ||
| SPN 174 FMI 04 | Engine Oil Pressure Moderately Low | ||
| SPN 611 FMI 18 | Manifold Air Pressure Input Voltage High | ||
| SPN 611 FMI 03 | Manifold Air Pressure Input Voltage Low | ||
| SPN 620 FMI 03 | Manifold Air Temperature Input Voltage High | ||
| SPN 620 FMI 04 | Manifold Air Temperature Input Voltage Low | ||
| SPN 620 FMI 16 | Manifold Air Temperature Moderately High | ||
| SPN 620 FMI 00 | Air Filter Restriction High | ||
| SPN 620 FMI 31 | Air Filter Restriction High | ||
| SPN 620 FMI 00 | Engine Coolant Temperature Extremely High | ||
| SPN 620 FMI 03 | Engine Coolant Temperature Input Voltage High | ||
| SPN 620 FMI 04 | Engine Coolant Temperature Input Voltage Low | ||
| SPN 620 FMI 15 | Engine Coolant Temperature High (Least Severe) | ||
| SPN 620 FMI 16 | Engine Coolant Temperature Moderately High | ||
| SPN 620 FMI 01 | Engine Coolant Level Low | ||
| SPN 620 FMI 17 | ECU Power Down Error | ||
| SPN 620 FMI 03 | Fuel Temperature Input Voltage High | ||
| SPN 620 FMI 04 | Fuel Temperature Input Voltage Low | ||
| SPN 620 FMI 03 | Injector Wiring Shorted to Power Source | ||
| SPN 620 FMI 04 | Injector Wiring Shorted to Ground | ||
| SPN 627 FMI 01 | Injector Supply Voltage Problem | ||
| SPN 629 FMI 12 | ECU Error | ||
| SPN 629 FMI 13 | ECU Error | ||
| SPN 636 FMI 02 | Cam Position Input Noise | ||
| SPN 636 FMI 08 | Cam Position Input Missing | ||
| SPN 636 FMI 10 | Cam Position Input Pattern Error | ||
| SPN 637 FMI 02 | Crank Position Input Noise | ||
| SPN 637 FMI 07 | Crank Position/Cam Position Out of Sync | ||
| SPN 637 FMI 08 | Crank Position Input Missing | ||
| SPN 637 FMI 10 | Crank Position Input Pattern Error | ||
| SPN 639 FMI 13 | CAN (Network) Error | ||
| SPN 651 FMI 05 | Cylinder # 1 EUI Circuit Open | ||
| SPN 651 FMI 06 | Cylinder # 1 EUI Circuit Shorted | ||
| SPN 652 FMI 05 | Cylinder # 2 EUI Circuit Open | ||
| SPN 652 FMI 06 | Cylinder # 2 EUI Circuit Shorted | ||
| SPN 653 FMI 05 | Cylinder # 3 EUI Circuit Open | ||
| SPN 653 FMI 06 | Cylinder # 3 EUI Circuit Shorted | ||
| SPN 654 FMI 05 | Cylinder # 4 EUI Circuit Open | ||
| SPN 654 FMI 06 | Cylinder # 4 EUI Circuit Shorted | ||
| SPN 655 FMI 05 | Cylinder # 5 EUI Circuit Open | ||
| SPN 655 FMI 06 | Cylinder # 5 EUI Circuit Shorted | ||
| SPN 656 FMI 05 | Cylinder # 6 EUI Circuit Open | ||
| SPN 656 FMI 06 | Cylinder # 6 EUI Circuit Shorted | ||
| SPN 970 FMI 02 | Auxiliary Engine Shutdown Switch Signal Invalid | ||
| SPN 970 FMI 31 | Auxiliary Engine Shutdown Switch Active | ||
| SPN 971 FMI 31 | External Fuel Derate Switch Active | ||
| SPN 1109 FMI 31 | Engine Shutdown Warning | ||
| SPN 1110 FMI 31 | Engine Shutdown | ||
| SPN 1569 FMI 31 | Fuel Derate | ||
| SPN 2000 FMI 13 | Security Violation |
| Symptom | Cause | Remedy |
|---|---|---|
| Engine Will Not Crank | Weak battery | Replace battery. |
| Engine Will Not Crank | Corroded or loose battery connections | Clean battery terminals and connections. |
| Engine Will Not Crank | Defective main switch or start safety switch | Repair switch as required. |
| Engine Will Not Crank | Starter solenoid defective | Replace solenoid. |
| Engine Will Not Crank | Starter defective | Replace starter. |
| Hard to Start or Will Not Start | Poor fuel quality | Drain fuel and replace with quality fuel of the proper grade. |
| Hard to Start or Will Not Start | Slow cranking speed | Check for problem in the charging/starting system. |
| Hard to Start or Will Not Start | Too high viscosity crankcase oil | Drain crankcase oil and replace with correct viscosity oil. |
| Hard to Start or Will Not Start | Electronic control system problem or basic engine problem | See your John Deere engine distributor or servicing dealer. |
| Engine Misfiring or Runs irregularly | Electronic control system problem or basic engine problem | See your John Deere engine distributor or servicing dealer. |
| Lack of Engine Power | Poor fuel quality | Drain fuel and replace with quality fuel of the proper grade. |
| Lack of Engine Power | Engine overloaded | Reduce engine load. |
| Lack of Engine Power | Improper crankcase oil | Drain crankcase oil and replace with correct viscosity oil. |
| Lack of Engine Power | Electronic control system problem or basic engine problem | See your John Deere engine distributor or servicing dealer. |
| Black or Gray Exhaust Smoke | Engine overloaded | Reduce engine load. |
| Black or Gray Exhaust Smoke | Engine burning oil | See LUBRICATION SYSTEM TROUBLESHOOTING, later in this section. |
| Black or Gray Exhaust Smoke | Air cleaner restricted or dirty | Replace air cleaner element as required. |
| Black or Gray Exhaust Smoke | Defective muffler/exhaust piping (causing back-pressure) | Replace muffler or defective piping. |
| Black or Gray Exhaust Smoke | Electronic control system problem or basic engine problem | See your John Deere engine distributor or servicing dealer. |
| White Exhaust Smoke | Engine compression too low | Determine cause of low compression and repair as required. See your John Deere engine distributor or servicing dealer. |
| White Exhaust Smoke | Defective thermostat(s) (does not close) | Test thermostats; replace thermostats as required. (See Service as Required section.) |
| White Exhaust Smoke | Coolant entering combustion chamber (failed cylinder head gasket or cracked cylinder head) | Repair or replace as required. See your John Deere engine distributor or servicing dealer. |
| White Exhaust Smoke | Failed water-to-air aftercooler (6105AF & 6125AF engines only) | Remove and inspect water-to-air aftercooler. See your John Deere engine distributor or servicing dealer. |
| Engine Idles Poorly | Poor fuel quality | Drain fuel and replace with quality fuel of the proper grade. |
| Engine Idles Poorly | Air leak on suction side of air intake system | Check hose and pipe connections for tightness; repair as required. |
| Engine Idles Poorly | Electronic control system problem or basic engine problem | See your John Deere engine distributor or servicing dealer. |
| Excessive Fuel Consumption | Poor fuel quality | Drain fuel and replace with quality fuel of the proper grade. |
| Excessive Fuel Consumption | Engine overloaded | Reduce engine load. |
| Excessive Fuel Consumption | Air cleaner restricted or dirty | Replace air cleaner element as required. |
| Excessive Fuel Consumption | Compression too low | Determine cause of low compression and repair as required. |
| Excessive Fuel Consumption | Leaks in fuel supply system | Locate source of leak and repair as required. |
| Abnormal Engine Noise | Worn main or connecting rod bearings | Determine bearing clearance. See your John Deere engine distributor or servicing dealer. |
| Abnormal Engine Noise | Excessive crankshaft end play | Check crankshaft end play. See your John Deere engine distributor or servicing dealer. |
| Abnormal Engine Noise | Loose main bearing caps | Check bearing clearance; replace bearings and bearing cap screws as required. See your John Deere engine distributor or servicing dealer. |
| Abnormal Engine Noise | Worn connecting rod bushings and piston pins | Inspect piston pins and bushings. See your John Deere engine distributor or servicing dealer. |
| Abnormal Engine Noise | Scored pistons | Inspect pistons. See your John Deere engine distributor or servicing dealer. |
| Abnormal Engine Noise | Worn timing gears or excess backlash | Check timing gear backlash. See your John Deere engine distributor or servicing dealer. |
| Abnormal Engine Noise | Excessive valve clearance | Check and adjust valve clearance. See your John Deere engine distributor or servicing dealer. |
| Abnormal Engine Noise | Worn camshaft lobes | Inspect camshaft. See your John Deere engine distributor or servicing dealer. |
| Abnormal Engine Noise | Worn rocker arm shaft(s) | Inspect rocker arm shafts. See your John Deere engine distributor or servicing dealer. |
| Abnormal Engine Noise | Insufficient engine lubrication | See LUBRICATION SYSTEM TROUBLESHOOTING, later in this section. |
| Abnormal Engine Noise | Turbocharger noise | See AIR INTAKE SYSTEM TROUBLESHOOTING, later in this section. |
| Low Oil Pressure | Low crankcase oil level | Fill crankcase to proper oil level. |
| Low Oil Pressure | Clogged oil cooler or filter | Remove and inspect oil cooler. See your John Deere engine distributor or servicing dealer. |
| Low Oil Pressure | Excessive oil temperature | Remove and inspect oil cooler. See your John Deere engine distributor or servicing dealer. |
| Low Oil Pressure | Defective oil pump | Remove and inspect oil pump. See your John Deere engine distributor or servicing dealer. |
| Low Oil Pressure | Incorrect oil | Drain crankcase and refill with correct oil. |
| Low Oil Pressure | Oil pressure regulating valve failure | Remove and inspect oil pressure regulating valve. See your John Deere engine distributor or servicing dealer. |
| Low Oil Pressure | Broken piston spray jet | Replace piston spray jet. See your John Deere engine distributor or servicing dealer. |
| Low Oil Pressure | Clogged oil pump screen or cracked pick-up tube | Remove oil pan and clean screen/replace pick-up tube. |
| Low Oil Pressure | Excessive main or connecting rod bearing clearance | Determine bearing clearance. See your John Deere engine distributor or servicing dealer. |
| High Oil Pressure | Improper oil classification | Drain crankcase and refill with correct oil. |
| High Oil Pressure | Oil pressure regulating valve bushing loose (wanders) | Remove and inspect oil pressure regulating valve. See your John Deere engine distributor or servicing dealer. |
| High Oil Pressure | Improperly operating regulating valve | Remove and inspect oil pressure regulating valve. See your John Deere engine distributor or servicing dealer. |
| High Oil Pressure | Plugged piston spray jet | Replace piston spray jet. See your John Deere engine distributor or servicing dealer. |
| High Oil Pressure | Stuck or damaged filter bypass valve | Remove and inspect filter bypass valve. See your John Deere engine distributor or servicing dealer. |
| High Oil Pressure | Stuck or damaged oil cooler bypass valve | Remove and inspect oil cooler bypass valve. See your John Deere engine distributor or servicing dealer. |
| Excessive Oil Consumption | Too low viscosity crankcase oil | Drain crankcase and refill with correct viscosity oil. |
| Excessive Oil Consumption | Crankcase oil level too high | Drain oil until oil level is correct. |
| Excessive Oil Consumption | External oil leak(s) | Determine source of oil leak(s) and repair as required. |
| Excessive Oil Consumption | Oil control rings worn or broken | Replace piston rings. See your John Deere engine distributor or servicing dealer. |
| Excessive Oil Consumption | Scored cylinder liners or pistons | Remove and inspect cylinders and liners; replace as required. See your John Deere engine distributor or servicing dealer. |
| Excessive Oil Consumption | Worn valve guides or stems | Inspect and measure valve stems and valve guides; repair as required. See your John Deere engine distributor or servicing dealer. |
| Excessive Oil Consumption | Excessive oil pressure | See High Oil Pressure above. |
| Excessive Oil Consumption | Piston ring grooves excessively worn | Remove and inspect pistons. See your John Deere engine distributor or servicing dealer. |
| Excessive Oil Consumption | Piston rings sticking in ring grooves | Remove and inspect pistons. See your John Deere engine distributor or servicing dealer. |
| Excessive Oil Consumption | Insufficient piston ring tension | Remove and inspect pistons. See your John Deere engine distributor or servicing dealer. |
| Excessive Oil Consumption | Piston ring gaps not staggered | Remove and inspect pistons. See your John Deere engine distributor or servicing dealer. |
| Excessive Oil Consumption | Front and/or rear crankshaft oil seal faulty | Replace oil seals. See your John Deere engine distributor or servicing dealer. |
| Fuel in Oil | See LOW PRESSURE FUEL SYSTEM TROUBLESHOOTING later in this section. | |
| Coolant in Oil | See COOLING SYSTEM TROUBLESHOOTING later in this section. | |
| Engine Overheats | Lack of coolant in cooling system | Fill cooling system to proper level. |
| Engine Overheats | Radiator core and/or side screens dirty | Clean radiator as required. |
| Engine Overheats | Engine overloaded | Reduce engine load. |
| Engine Overheats | Too low crankcase oil level | Fill crankcase to proper oil level. |
| Engine Overheats | Loose or defective fan belt | Replace fan belt as required. Check belt tensioner. (See Lubrication and Maintenance 500 Hour/12 Month section.) |
| Engine Overheats | Defective thermostat(s) | Test thermostat opening temperature; replace thermostats as required. (See Service as Required section.) |
| Engine Overheats | Damaged cylinder head gasket | Replace cylinder head gasket. See your John Deere engine distributor or servicing dealer. |
| Engine Overheats | Defective coolant pump | Replace coolant pump. See your John Deere engine distributor or servicing dealer. |
| Engine Overheats | Defective radiator cap | Replace radiator cap as required. |
| Coolant in Crankcase | Cylinder head gasket defective | Replace cylinder head gasket. See your John Deere engine distributor or servicing dealer. |
| Coolant in Crankcase | Cylinder head or block cracked | Locate crack, repair/replace components as required. |
| Coolant in Crankcase | Cylinder liner seals leaking | Remove and inspect cylinder liners. See your John Deere engine distributor or servicing dealer. |
| Coolant in Crankcase | Leaking oil cooler | Pressure test oil cooler; repair/replace as required. See your John Deere engine distributor or servicing dealer. |
| Coolant in Crankcase | Defective oil cooler O-rings | Remove and inspect oil cooler O-rings; replace as required. See your John Deere engine distributor or servicing dealer. |
| Coolant in Crankcase | Faulty coolant pump seal; weep hole plugged; coolant leaking through bearing | Replace coolant pump seals. See your John Deere engine distributor or servicing dealer. |
| Coolant in Crankcase | Inadequate swage on injector sleeve | Replace injector sleeve. See your John Deere engine distributor or servicing dealer. |
| Coolant in Crankcase | Faulty injector sleeve O-ring and EUI O-rings faulty | Remove suspected EUI, replace O-rings as required. See your John Deere engine distributor or servicing dealer. |
| Coolant Temperature Below Normal | Defective thermostat(s) | Test thermostats; replace thermostats as required. (See Service as Required section.) |
| Hard to Start or Will Not Start | Air leak in intake manifold. | See ENGINE TROUBLESHOOTING earlier in this section. |
| Engine Misfiring or Runs Irregularly | Bearings not lubricated (insufficient oil pressure) | See ENGINE TROUBLESHOOTING earlier in this section. |
| Black or Grey Exhaust Smoke | Air leak in engine intake or exhaust manifold | See ENGINE TROUBLESHOOTING earlier in this section. |
| Lack of Engine Power | Improper clearance between turbine wheel and turbine housing | See ENGINE TROUBLESHOOTING earlier in this section. |
| Turbocharger “Screams” | Broken blades (or other wheel failures) | Check intake manifold gasket and manifold; repair as required. See your John Deere engine distributor or servicing dealer. |
| Turbocharger Noise or Vibration | Bearings not lubricated (insufficient oil pressure) | Determine cause of lack of lubrication; repair as required. See your John Deere engine distributor or servicing dealer. |
| Turbocharger Noise or Vibration | Air leak in engine intake or exhaust manifold | Check intake and exhaust manifold gaskets and manifolds; repair as required. See your John Deere engine distributor or servicing dealer. |
| Turbocharger Noise or Vibration | Improper clearance between turbine wheel and turbine housing | Inspect turbocharger; repair/replace as required. See your John Deere engine distributor or servicing dealer. |
| Turbocharger Noise or Vibration | Broken blades (or other wheel failures) | Inspect turbocharger; repair/replace as required. See your John Deere engine distributor or servicing dealer. |
| Oil on Turbocharger Compressor Wheel or in Compressor Housing (Oil Being Pushed or Pulled through Center Housing) | Excessive crankcase pressure. | Determine cause of excessive crankcase pressure; repair as required. See your John Deere engine distributor or servicing dealer. |
| Oil on Turbocharger Compressor Wheel or in Compressor Housing (Oil Being Pushed or Pulled through Center Housing) | Air intake restriction | Determine cause of intake restriction; repair as required. See your John Deere engine distributor or servicing dealer. |
| Oil on Turbocharger Compressor Wheel or in Compressor Housing (Oil Being Pushed or Pulled through Center Housing) | Drain tube restriction | Determine cause of drain tube restriction; repair as required. See your John Deere engine distributor or servicing dealer. |
| Oil in Intake Manifold or Dripping from Turbocharger Housing | Excessive crankcase pressure | Determine cause of excessive crankcase pressure; repair as required. See your John Deere engine distributor or servicing dealer. |
| Oil in Intake Manifold or Dripping from Turbocharger Housing | Air intake restriction | Determine cause of intake restriction; repair as required. See your John Deere engine distributor or servicing dealer. |
| Oil in Intake Manifold or Dripping from Turbocharger Housing | Drain tube restriction | Determine cause of drain tube restriction; repair as required. See your John Deere engine distributor or servicing dealer. |
| Oil in Intake Manifold or Dripping from Turbocharger Housing | Damaged or worn housing bearings | Inspect turbocharger; repair/replace as required. See your John Deere engine distributor or servicing dealer. |
| Oil in Intake Manifold or Dripping from Turbocharger Housing | Unbalance of rotating assembly | Inspect turbocharger; repair/replace as required. See your John Deere engine distributor or servicing dealer. |
| Oil in Intake Manifold or Dripping from Turbocharger Housing | Damage to turbine or compressor wheel or blade | Inspect turbocharger; repair/replace as required. See your John Deere engine distributor or servicing dealer. |
| Oil in Intake Manifold or Dripping from Turbocharger Housing | Dirt or carbon build-up on wheel or blade | Inspect turbocharger; repair/replace as required. See your John Deere engine distributor or servicing dealer. |
| Bearing wear | Inspect turbocharger; repair/replace as required. See your John Deere engine distributor or servicing dealer. | |
| Oil starvation or insufficient lubrication | Determine cause of lack of lubrication; repair as required. See your John Deere engine distributor or servicing dealer. | |
| Shaft seals worn | Inspect turbocharger; repair/replace as required. See your John Deere engine distributor or servicing dealer. | |
| Turbocharger Turbine Wheel Drag | Carbon build-up behind turbine wheel caused by coked oil or combustion deposits | Inspect turbocharger; repair/replace as required. See your John Deere engine distributor or servicing dealer. |
| Turbocharger Turbine Wheel Drag | Dirt build-up behind compressor wheel caused by air intake leaks | Inspect turbocharger; repair/replace as required. See your John Deere engine distributor or servicing dealer. |
| Turbocharger Turbine Wheel Drag | Bearing seizure or dirty, worn bearings | Inspect turbocharger; repair/replace as required. See your John Deere engine distributor or servicing dealer. |
| Fuel in Oil | Cracked or worn electronic unit injector (EUI) O-ring | Remove suspected EUI; replace EUI O-ring as required. See your John Deere engine distributor or servicing dealer. |
| Fuel in Oil | Cracked cylinder head | Locate crack; repair/replace components as required. See your John Deere engine distributor or servicing dealer. |
| Fuel Aeration | EUI hold-down clamp loose | Tighten hold-down clamp cap screw to proper torque. See your John Deere engine distributor or servicing dealer. |
| Fuel Aeration | Cracked or worn electronic unit injector (EUI) O-ring | Remove suspected EUI; replace EUI O-ring as required. See your John Deere engine distributor or servicing dealer. |
| Fuel Pressure Low | Plugged fuel filter | Replace fuel filter. |
| Fuel Pressure Low | Restricted fuel line | Locate restriction; repair as required. |
| Fuel Pressure Low | Faulty fuel transfer pump | Remove fuel transfer pump; repair/replace pump as required. See your John Deere engine distributor or servicing dealer. |
| Diagnostic gauge communication error with the ECU | Contact your servicing dealer for help in correcting these codes. | |
| Diagnostic gauge communication error with the ECU | Contact your servicing dealer for help in correcting these codes. | |
| Diagnostic gauge communication error with the ECU | Contact your servicing dealer for help in correcting these codes. | |
| Generator produces no voltage or residual voltage | Regulator Fuse Blown | Check fuse with an ohmmeter. Replace bad fuse, refer to regulator manual. |
| Generator produces no voltage or residual voltage | Voltmeter Off | Check to be sure meter phase selector switch is not in the off position. |
| Generator produces no voltage or residual voltage | Incorrect Connections | Verify generator connections. Refer to drawings supplied with generator set and section 3. |
| Generator produces no voltage or residual voltage | Defective Connections/Wiring | Inspect all wiring for grounds, open circuits, short circuits. Refer to section 8. |
| Generator produces no voltage or residual voltage | Defective Voltmeter | Verify proper operation of panel meter with another meter that is known to be accurate. Refer to section 8. |
| Generator produces no voltage or residual voltage | No Regulator Input | Measure voltage at regulator input (PMG output) refer to section 8. |
| Generator produces no voltage or residual voltage | Defective Diodes, Surge Suppressor, or Generator Windings | Test generator with constant excitation (12 volt battery test) refer to section 8 and 12. |
| Generator produces no voltage or residual voltage | Voltage Regulator Protective Shutdown Circuits are Operating | Correct problem and adjust regulator. Refer to regulator manual. |
| Generator produces no voltage or residual voltage | Voltage Regulator Inoperative | Adjust or replace regulator. Refer to regulator manual. |
| Generator produces low voltage - no load | Underspeed Operation | Check speed using tachometers and/or frequency meters. |
| Generator produces low voltage - no load | Defective Voltmeter | Verify operation of panel meter with another meter that is known to be accurate. Refer to section 8. |
| Generator produces low voltage - no load | Residual Voltage | Disconnect F1 and F2 leads at the voltage regulator. If voltage goes down continue on to next step, if voltage does not change refer to troubleshooting for symptoms of “No Voltage - Residual Voltage”. |
| Generator produces low voltage - no load | Incorrect Generator Connections | Verify generator connections refer to drawings supplied with generator set and section 3. |
| Generator produces low voltage - no load | Defective Connections/Wiring | Inspect all wiring for grounds, open circuits, short circuits, loose connections, dirty connections. |
| Generator produces low voltage - no load | Regulator Adjustments | Adjust regulator. Refer to regulator manual. Check exciter field volts. Refer to section 8 and 12. |
| Generator produces low voltage - no load | Defective Diodes, Surge Suppressor, or Generator Windings | Test generator with constant excitation (12 volt battery test). Refer to section 8 and 12. |
| Generator produces low voltage - no load | Voltage Regulator not Operating Properly | Adjust or replace regulator. Refer to regulator manual. |
| Generator produces low voltage when load is applied | Overload | Measure amps and verify that the load does not exceed the nameplate rating of the generator. Refer to section 8. |
| Generator produces low voltage when load is applied | Overload - Defective Ammeter | Verify operation of ammeter by using a separate meter that is known to be accurate. |
| Generator produces low voltage when load is applied | Droop Circuit | If the generator set is equipped for paralleling, some voltage droop is normal as load increases. Refer to the regulator instruction manual. |
| Generator produces high voltage | Defective Voltmeter | Verify operation of panel meter with another meter that is known to be accurate. Refer to section 8. |
| Generator produces high voltage | Incorrect Operating Speed | Verify speed with tachometer or frequency meter. |
| Generator produces high voltage | Incorrect Connections | Verify generator connections. Refer to drawings supplied with generator set and section 3. |
| Generator produces high voltage | Defective Connections/Wiring | Inspect all wiring for grounds, open circuits, short circuits. |
| Generator produces high voltage | Regulator Adjustments | Adjust regulator. Refer to regulator manual. |
| Generator produces high voltage | Diode Polarity Incorrect | Check diodes, verify proper diodes are installed and polarity is correct. Refer to section 6. |
| Generator produces high voltage | Voltage Regulator not Operating Properly | Adjust or replace regulator. Refer to regulator instruction manual. |
| Generator voltage is fluctuating | Incorrect Speed | Verify speed with tachometer or frequency meter. |
| Generator voltage is fluctuating | Unstable Speed | Verify governor stability. |
| Generator voltage is fluctuating | Voltage Regulator Stability | Adjust regulator stability. Refer to regulator manual. |
| Generator voltage is fluctuating | Defective/Loose Connections | Inspect all wiring for loose or dirty connections. |
| Generator voltage is fluctuating | Defective Diodes, Surge Suppressor, or Generator Windings | Test generator with constant excitation (12 volt battery test). Refer to section 8 and 12. |
| Generator voltage is fluctuating | Remote Voltage Adjust (If used) | Check operation. Refer to regulator manual. |
| Generator voltage is fluctuating | Defective Regulator | Replace regulator. Refer to regulator manual. |
| Generator operates satisfactorily when cold, but shuts down when warm | Regulator Shutdown on Over Temperature | Correct cooling problems. Refer to regulator manual. |
| Generator builds voltage from startup, then goes to low (residual) voltage | Regulator Protective Circuit is Operating | Check indicators on regulator. Correct problems and adjust regulator as required. Refer to regulator manual. |
| Equipment runs normally on utility power, but will not run on generator set | Voltage Waveform is Distorted | Analyze load. Excessive SCR (Thyristor) loading will cause distortion. Some equipment may be sensitive to distorted waveforms. Refer to Marathon Electric. |
Fault codes and symptom→remedy steps extracted from this model’s service/owner documentation; verify against the official manual before servicing.
Documented causes: Too low viscosity crankcase oil; Crankcase oil level too high; External oil leak(s); Oil control rings worn or broken. See the table for the matching fixes.
Documented causes: Worn main or connecting rod bearings; Excessive crankshaft end play; Loose main bearing caps; Worn connecting rod bushings and piston pins. See the table for the matching fixes.
Documented causes: Low crankcase oil level; Clogged oil cooler or filter; Excessive oil temperature; Defective oil pump. See the table for the matching fixes.