Fault Code 419
Cummins
Generator Overvoltage Protection Trip
Generator shuts down; controller displays Fault Code 419 – Overvoltage
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Safety Warning
This repair may involve working with high voltage components or water connections. Always unplug the appliance before removing any panels.
If you are not confident in your ability to perform this repair safely, we strongly recommend contacting a professional technician.
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Possible Causes
Faulty automatic voltage regulator (AVR), Incorrect AVR sensing wiring, Loose or corroded voltage sensing connections, Controller configuration error for voltage
How to Fix / Troubleshooting
Safety first: Isolate the generator from the load by opening the output breaker or transfer switch. Disable automatic start.
- Measure output voltage: With a multimeter, verify actual line-to-line and line-to-neutral voltage at the generator terminals. Compare to nameplate rating.
- Inspect AVR connections: Locate the Cummins AVR in the generator end. Check all sensing and power wires for tightness and corrosion.
- Check sensing leads: Ensure the AVR is connected to the correct voltage sensing points (per wiring diagram). Miswiring can cause overvoltage.
- Replace AVR if needed: If voltage remains high with correct wiring, the AVR may be defective. Replace with the correct Cummins AVR model.
- Reset and test: Clear the fault and run the generator with no load, verifying stable voltage before reconnecting loads.
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Repair Difficulty
Hard
4/5
Required Part
Automatic Voltage Regulator (AVR)
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