TÀI LIỆU XE NÂNG DCD 200 (KALMAR DCD 200

• Faulty sensor / Faulty sensor cir-cuit connector is correctly installed.Check that the fuel pressure sensor cable is not damaged.. • Faulty sensor / Faulty sensor cir-cuit connector is

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D Error codes 1

D Error codes

mm mm mm mm mm mm

Table of Contents D Error codes

Error codes 3

Error codes, explanation 3

Error code menu, description 4

Reading out error code 7

1 Engine 9

Error codes engine, general 9

Error codes engine alternative Volvo TAD750VE 10

Error codes engine alternative Cummins QSB6.7 22

2 Transmission 39

Error codes transmission 39

8 Control system 52

Error codes machine 52

9 Frame, body, cab and accessories 62

9.4 Heating, ventilation and air conditioning 62

ECC: Reading out error code 62

ECC: Error code table 63

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2 D Error codes

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D Error codes – Error codes 3

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Error codes

Error codes, explanation

The error codes are explained in table form for Engine, Transmission

as well as Control system They are sorted according to error code number

The error code table has the following information:

B Error code level (symbol)

C Error code number

D Cause of error (symbol)

E Function (symbol)

• Code, error code's number, shown in field C on display

• Description, explanation of the error code and when it's ed

generat-• Limitation, in case of certain error codes certain functions are paired or limited to protect the machine and operator

im-• Action, information of what should be checked to find the cause of

the error code Warning page 4

D C

B

E

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4 D Error codes – Error codes

Error code menu, description

The control and monitoring system's display is divided into four fields where information is shown (see figure to the left)

• Field B: Error code level shown with a symbol

• Field C: Indicates error code

• Field D: Indicates type of error

• Field E: Indicates which function is affected by error code

• The book symbol means that there's information in the operator's manual

Field B: Error code level

The control and monitoring system gives error code information in three levels which are indicated with a symbol in the lower left corner (B) on the display unit

• StopIndicates a serious malfunction that may affect operator safety or cause machine breakdown The error code must be dealt with im-mediately Stop working with the machine and contact service im-mediately

The error code is shown automatically on the display

• WarningIndicates machine malfunction that should be taken care of as soon as possible After finished work shift with the machine, con-tact service as soon as possible

The error code is shown automatically on the display

• InformationInformation for the operator that something should be taken care

of, for example, low fuel level Rectify the cause of the error code

as soon as possible

Field C: Error code number

The control system gives error codes from three sub-systems:

• Machine:

Shown with error code number XXX on display

D C

B

E

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• EngineShown with code 1200 and error code number SPN: XXX and FMI: XXX (position D) in display SPN means Suspect Parameter Number and is an indication of the failed component and FMI means Failure Mode Identifier and are an indication of what type

of fault the component have

NOTE

If several error codes come from the engine, these are shown rolling, that is, all active error codes are displayed in the same field at approx 1s intervals

• Transmission:

Shown with code 900 and error code number SPN: XXX and FMI: XXX (position D) in the display SPN means Suspect Parameter Number and is an indication of the failed component and FMI means Failure Mode Identifier and are an indication of what type

of fault the component have

NOTE

If several error codes come from the engine, these are shown rolling, that is, all active error codes are displayed in the same field at approx 1s intervals

Field D: Type of error

1 Too high/too low temperature

2 Incorrect signal to solenoid

3 Incorrect hydraulic pressure

4 Incorrect sensor signal

5 Incorrect signal from lever

6 Too high/too low level

D B

C

D B

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6 D Error codes – Error codes

Field E: Indicates which function is affected by the error code

25 Reversible driver's seat

26 Air or particle filter

28

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Reading out error code

1 Stop the machine and identify the error code level and special

er-ror code number, see section Erer-ror code menu, description page

4 Stop the engine in the event of a Stop alarm or let the engine

run in the event of Warning or Information alarms

NOTE

If several error codes come from the engine, these are shown rolling, that is, all active error codes are displayed in the same field at approx 1s intervals.

WARNING

Stop alarms indicate a malfunction in the machine which may affect safety of the operator and others in the vicinity or may cause a breakdown – Read off the error code, Switch off the engine and carry out actions according to the error code table.

Warning and information alarms indicate tions of such character that work does not have to be stopped The machine’s capacity may be limited and certain functions may not work – Carry out actions according to the error code table as soon as possible.

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malfunc-8 D Error codes – Error codes

2 The error code is shown automatically on the display

Note all error codes

Scroll the error codes by pressing the Reset (R) function key The error codes if they are still active will occur after a defined time that can be different depending on type of alarm Error code in-formation disappears once its cause has been remedied.Deactivate display of error codes by pressing the Reset (R) func-tion key:

• In the event of Stop: If the cause of the error code remains, the error code will reappear within one minute

• In the event of Warning or Information: If the cause of the ror code remains, the error code will reappear within three minutes

er-• If the cause of the error code is gone, error code display will automatically deactivate within 30 seconds

3 Park the machine in a suitable location

For error code level "STOP" – Stop the engine

For error code level "WARNING" or "INFORMATION" – Leave the engine running or switch the machine off

4 Read the information for the error code/error codes in the error code table and perform the recommended actions

5 Restart the engine and check in the display that error codes are gone according to step 2

D C

B

E

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D Error codes – 1 Engine 9

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1 Engine

Error codes engine, general

• Display indicates error code acc to SAE J1939SPN / FMI

• J1587 indicates error code acc to SAE J1587 (for Volvo: Vodia).PID, PPID, SID, PSID / FMI

Table 1 Specification FMI

FMI Description SAE-text

0 Too high value Data valid but above normal operational range - Most severe level

1 Too low value Data valid but below normal operational range - Most severe level

2 Incorrect data Data erratic, intermittent or incorrect

3 Electrical problem Voltage above normal or shorted to high source

4 Electrical problem Voltage below normal or shorted to low source

5 Electrical problem Current below normal or open circuit

6 Electrical problem Current above normal or grounded circuit

7 Mechanical problem Mechanical system not responding or out of adjustment

8 Mechanical problem or electrical

prob-lem

Abnormal frequency, pulse width or period

10 Abnormally wide variations Abnormal rate of change

12 Component error Bad intelligent device or component

13 Incorrect calibration Out of calibration

15 Too high value Data valid but above normal operating range - Least severe level

16 Too high value Data valid but above normal operating range - Moderately severe level

17 Too low value Data valid but below normal operating range - Least severe level

18 Too low value Data valid but below normal operating range - Moderately severe level

19 Communication error Received network data in error

31 FMI is not available or the condition that

is identified by the SPN exists

Not available or condition exists

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10 D Error codes – 1 Engine

- / 0 PPID435 Torque common rail

• Fault in rail sure circuit

pres-Engine derated: pres-Engine speed limitation (1100rpm)

Fuel pressure limitation (800 bar) Engine torque reduc-tion (Stronger engine.)

/ 1 PPID435 Torque common rail

• Fault in rail sure circuit

pres-Engine derated: pres-Engine speed limitation (1100rpm)

Fuel pressure limitation (800 bar) Engine torque reduc-tion (Lack of power.)

-94 / 1 PID94 Fuel pressure

• Fuel pressure is too low

- Check if it is possible to build up

pres-sure with the hand pump

Check the fuel filter

Check the fuel pre-filter

94 / 3 PID94 Fuel pressure

• Faulty sensor / Faulty sensor cir-cuit

connector is correctly installed.Check that the fuel pressure sensor cable is not damaged

Check that the fuel pressure sensor is correctly installed

Check fuel pressure sensor function

connector is correctly installed.Check that the fuel pressure sensor cable is not damaged

Check that the fuel pressure sensor is correctly installed

Check fuel pressure sensor function

• Fuel pressure is critically low

- Check if it is possible to build up

pres-sure with the hand pump

Check the fuel filter

Check the fuel pre-filter

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97 / 4 PID97 Water in fuel

and short circuits

Check indicator function Change dicator as necessary

in-100 / 1 PID100 Oil pressure

• Oil pressure is too low

Power is reduced due to error torque map

Check oil level

Check that the oil filters are not blocked

Check system pressure valves and safety valves in the oil system.Check oil pressure sensor function

100 / 3 PID100 Oil pressure sensor

cable is not damaged

Check that the oil pressure sensor is correctly connected

100 / 5 PID100 Oil pressure

cable is not damaged

Check that the oil pressure sensor is correctly connected

105 / 0 PID105 Boost Temperature

• Boost temperature

is too high

Engine is derated Check the coolant level

Check the intercooler (cleanliness).Check charge air temperature sensor function

Check the function of the thermostat

Temperature set to 40° C Check that the charge air

tempera-ture sensor connector is correctly stalled

in-Check that the charge air ture sensor cable is not damaged.Check that the charge air tempera-ture sensor is correctly installed.Check charge air temperature sensor function

tempera-Description Limitation Action

Display J1587

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Temperature set to 40° C Check that the charge air

tempera-ture sensor connector is correctly stalled

in-Check that the charge air ture sensor cable is not damaged.Check that the charge air tempera-ture sensor is correctly installed.Check charge air temperature sensor function

tempera-106 / 0 PID106 Boost pressure

• Boost pressure is too high

Power is reduced due to error torque map

Check turbocharger compressor function

Check charge pressure sensor tion

func-Check fuel volume/injector

106 / 3 PID106 Boost pressure

The voltage exceeds the mal value or is short circuited

nor-to higher voltage

Check that the charge pressure sor connector is correctly installed.Check that the charge pressure sen-sor cable is not damaged

Check that the charge pressure sor is correctly installed

sen-Check charge pressure sensor tion

func-106 / 5 PID106 Boost pressure

Pressure set to atmospheric pressure + 30 kPa Engine performance is derated

Check that the charge pressure sor connector is correctly installed.Check that the charge pressure sen-sor cable is not damaged

Check that the charge pressure sor is correctly installed

sen-Check charge pressure sensor tion

func-108 / 2 PID108 Ambient air pressure

• Plausibility

-108 / 3 PID108 Ambient air pressure

Ambient pressure is set to 1.0 bar

-Description Limitation Action

Display J1587

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108 / 4 PID108 Ambient air pressure

Ambient pressure is set to 1.0 bar

-110 / 0 PID110 Coolant temperature

• Coolant ture too high

tempera-Engine is derated Check the coolant level

Check the intercooler (cleanliness).Check if there is air in the cooling sys-tem

Check the pressure cap on the pansion tank

ex-Check coolant temperature sensor function

Check thermostat function

110 / 4 PID110 Coolant temperature

sensor

Engine is difficult to start Check that the coolant temperature

sensor connector is correctly stalled

in-Check that the coolant temperature sensor cable is not damaged

Check that the coolant temperature sensor is correctly installed

Check coolant temperature sensor function

110 / 5 PID110 Coolant temperature

sensor

Engine is difficult to start Check that the coolant temperature

sensor connector is correctly stalled

in-Check that the coolant temperature sensor cable is not damaged

Check that the coolant temperature sensor is correctly installed

Check coolant temperature sensor function

111 / 1 PID111 Coolant level

• Coolant level is to low

Engine is derated Check the coolant level

Check coolant level monitor function

Description Limitation Action

Display J1587

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158 / 1 PID158 Battery voltage

• Below range

Problems in engine starting Check the supply voltage from the

control unit

Check the battey

Check the alternator

Check the 8-pin contact

164 / 0 PID164 Rail pressure

• Sensor out of range

Check the sensor

Check the filter

Check the fuelpumps

• Plausibility

Engine speed limitation (1100rpm) Full fuel flow de-livery, limp home with pres-sure release valve opened

An estimated rail pressure with depending to fuel quanti-

ty will be used

Check the cable harness

Check the sensor

Check the filter

Check the fuelpumps

ty will be used

Check the sensor

Check the filter

Check the fuelpumps

ty will be used

Check the sensor

Check the filter

Check the fuelpumps

190 / 0 PID190 Engine speed, engine

is / was overspeeding

Engine speed limited After the engine has stopped, look for

the reason for the high speed

626 / 3 PID45 Inlet air heater status

Preheat relay never

activat-ed White smoke for cold start Start problems in cold climate

Check that the relay input cable is not damaged

Check relay function

Induction air is hot Preheat relay is impossible to turn off

Preheat fuse will break

Display J1587

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Preheat relay never

activat-ed White smoke for cold start Start problems in cold climate

629 / 3 SID254 Controller error

• Faulty component

The Engine can not be ed

start-Change the engine control unit

636 / 2 SID21 Speed sensor,

cam-shaft

The engine start time will crease, uses only crankshaft sensor

in-Check that theengine speed sensor connector is correctly installed.Check that the engine speed sensor cable is not damaged

Check that the engine speed sensor

is correctly installed in the upper ing gear cover

tim-Check engine speed sensor function

cam-shaft

Display J1587

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crank-shaft

Engine is difficult to start, uses only cam sensor

Check that the sensor connector is correctly installed

Check that the engine speed sensor cable is not damaged

is correctly installed in the housing

flywheel-Check engine speed sensor function

crank-shaft

Engine is running with cise timing causing risk of high fuel consumption and smoke Cylinder balancing not working with risk of une-ven running

impre-Check that the sensor connector is correctly installed

crank-shaft

Engine is difficult to start, uses only cam sensor

Check that the sensor connector is correctly installed

damaged

Check that the cables between the CIU and the engine management unit are not damaged

Check that sleeves 11 and 12 in the connector on the CIU are not dam-aged

639 / 2 SID231 Communication fault J

Check that the 8-pin connector is not damaged

Check that the cables between the CIU and the engine management unit are not damaged

Display J1587

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639 / 2 SID240 Program memory

• Communication fault

The engine can not be started Re-program the unit

Change the engine control unit (EMS)

651 - 656

/ 3

SID1 - 6 Injector, cylinder #1 - 6

• Fault in the tion system

injec-Faulty injector is shut off

Limp home on rest of tors

injec-Check that the injector cables are not damaged

Check that the injector connections are not damaged

Check fuel supply pressure

Check the valve clearance

Do a compression test and check inder #1 - 6

cyl-651 - 656

/ 4

cyl-651 - 656

/ 5

Do a compression test and check

cyl-Description Limitation Action

Display J1587

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651 - 656

/ 7

damaged

cyl-651 - 656

/ 12

damaged

cyl-677 /

1675 / 3

SID39 Engine starter relay

• Fault in starter lay circuit

re-Start motor does not engage Check that connections to the ignition

key have not been damaged.Check that the cable harness to the ignition key have not been damaged

677 /

1675 / 4

677 /

1675 / 5

679 / 0 PSID97 Rail pressure release

valve

• Leakage detected

in pressure release valve

Engine derated: engine speed limitation (1100 rpm)

Fuel pressure limitation (800 bar) Engine torque reduc-tion

Contact an autorized Volvo penta workshop

679 / 3 SID42 Injection control,

pres-sure regulator

• Faulty regulator / Faulty regulator cir-cuit

Full fuel flow delivery Limp home with pressure release valve opened

Display J1587

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pres-sure regulator

Possible stall of engine

pres-sure regulator

valve

• Pressure release valve stuck close

Engine shut off after delay or engine derated Engine der-ated: engine speed limitation (1100 rpm) Fuel pressure limitation (800 bar) Engine torque reduction

valve

• Pressure release valve open

pres-sure regulator

Possible stall of engine

679 / 14 PSID97 Injection control,

pres-sure regulator

• Pressure release valve open

Engine torque reduction Full fuel flow delivery Limp home with pressure release valve opened

729 / 3 SID70 Preheat sensor Fuse for shorting wire breaks Check the cable harness

Display J1587

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729 / 4 SID70 Preheat sensor

• Faulty relay / Faulty relay circuit

Start problems in cold mate

cli-Check the cable harness

Check the preheating relay

729 / 5 SID70 Preheat sensor

• Faulty relay / Faulty relay circuit

Might get start problems in cold climate

Check the preheating relay

1079 / 3 SID232 5V sensor supply 1

-1079 / 4 SID232 5V sensor supply 1

-1080 / 3 Sid211 5V sensor supply 2

-1080 / 4 Sid211 5V sensor supply 2

-1239 / 0 PSID96 Rail pressure system

• Fault in rail sure system

pres-Engine derated: engine speed limitation (1100 rpm)

Full fuel flow delivery Limp home with pressure relief valve

1239 / 1 PSID96 Rail pressure system

Fuel pressure limitation (800 bar) Engine torque reduc-tion Engine shut off or diffi-cult to start

Display J1587

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2791 / 3 PPID19 Internal EGR status

IEGR can not be turned on Check cable harness (boost pressure

sensor)

Check the IEGR

sensor)

Check the IEGR

sensor)

Check the IEGR

• Mechanical fault

May damage turbine, creased power and emis-sions

in-Check cable harness (boost pressure sensor)

Check the IEGR

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84 / 2 P084 / 2 Machine Speed Sensor Circuit - Data

Erratic, Intermittent or Incorrect The ECU 794 lost the machine speed sig-nal

Engine speed limited to Maximum gine Speed without VSS parameter val-

En-ue Cruise control, Gear-Down Protection, and Road Speed Governor will not work

84 / 10 P084 / 10 Machine Speed Sensor Circuit

Tam-pering Has Been Detected - Abnormal Rate of Change Invalid or inappropri-ate machine speed signal Signal indi-cates an intermittent connection or VSS tampering

Engine speed limited to maximum gine speed without VSS parameter val-

en-ue Cruise control, gear-down protection, and road speed governor will not work

91 / 0 P91 / 0 Accelerator Pedal or Lever Position

Sensor 1 - Data Valid but Above mal Operational Range - Most Severe Level A frequency of more than 1500

Nor-Hz has been detected at the frequency throttle input to the ECU 794

Severe derate in power output of the engine Limp home power only

91 / 1 P91 / 1 Accelerator Pedal or Lever Position 1

Sensor Circuit Frequency - Data Valid but Below Normal Operational Range - Most Severe Level A frequency of less than 100 HZ has been detected at the frequency throttle input to the ECU 794

Severe detate in power output of the engine Limp home power only

91 / 19 P91 SAE J1939 Multiplexing Accelerator

Pedal or Lever Sensor System Error - Received Network Data Error The OEM machine electronic control unit (VECU) detected a fault with its accel-erator pedal

Engine may only idle or engine will not accelerate to full speed

91 / 2 P31 / 2 Position sensor accelerator pedal

Sensor Circuit - Shorted High High voltage detected at accelerator pedal or lever position circuit

Severe derate in power output of the engine Limp home capability only

Sensor Circuit - Voltage Below Normal

or Shorted to Low Source Low voltage detected at accelerator pedal or lever position signal circuit

Severe derate in power output of the engine Limp home capability only

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94 / 1 P94 / 1 Fuel pump delivery pressure - data

val-id but below normal operational range - moderately severe level The ECU 794 has detected the fuel pressure in the fuel rail is lower than the commanded performance

Possibly hard to start; low power; sible engine smoke Engine can possi-bly not start

pos-94 / 2 P094 / 2 Injector Metering Rail 1 Pressure - Data

Erratic, Intermittent, or Incorrect The ECU 794 has detected that the fuel pressure signal is not changing

The ECU 794 will estimate fuel sure, and power is reduced

pres-94 / 18 P94 / 0 Fuel pump delivery pressure - data

val-id but above normal operational range - moderately severe level The ECU 794 has detected fuel pressure in the fuel rail that is higher than the commanded pressure

None or possible engine noise ated with higher injection pressures (especially at idle or light load) Engine power is reduced

associ-97 / 3 P097 / 3 Water-in-Fuel Indicator Sensor Circuit -

Voltage Above Normal or Shorted to High Source High voltage detected at the water-in-fuel circuit

None on performance No water-in-fuel warning available

97 / 4 P097 / 4 Water-in-Fuel Indicator Sensor Circuit -

Voltage Below Normal or Shorted to Low Source Low voltage detected at the water-in-fuel circuit

None on performance No water-in-fuel warning available

97 / 15 P097 / 0 Water-In-Fuel Indicator - Data Valid but

Above Normal Operational Range - Least Severe Level Water has been detected in the fuel filter

Possible white smoke, loss of power, or hard starting

100 / 1 P100 / 1 Engine Oil Rifle Pressure - Data Valid

but Below Normal Operational Range - Most Severe Level Oil pressure signal indicates oil pressure is below the en-gine protection critical limit

Progressive power derate increasing in severity from time after alert If the En-gine Protection Shutdown feature is en-abled, engine will shut down 30 seconds after the red STOP lamp starts flashing

100 / 2 P100 / 2 Oil Pressure Switch Sensor Circuit -

Data Erratic, Intermittent or Incorrect

An error in the engine oil pressure switch signal was detected by the ECU 794

None on performance No engine tection for oil pressure

Display J1587

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100 / 3 P100 / 3 Oil Pressure Sensor Circuit - Voltage

Above Normal, or Shorted to High Source High signal voltage detected at the engine oil pressure circuit

pro-100 / 4 P100 / 4 Oil Pressure Sensor Circuit - Voltage

Below Normal, or Shorted to Low Source Low signal voltage detected at the engine oil pressure circuit

pro-100 / 18 P100 / 1 Engine Oil Rifle Pressure - Data Valid

but Below Normal Operational Range - Moderately Severe Level Engine oil pressure signal indicates engine oil pressure is below the engine protection warning limit

None on performance

102 / 2 P102 /2 Intake Manifold Pressure Sensor

Cir-cuit - Data Erratic, Intermittent or rect The ECU 794 has detected an intake manifold pressure signal that is too high or low for current engine oper-ating conditions

Incor-Engine power derate

102 / 2 P102 /2 Intake manifold pressure sensor circuit

- data incorrect An error in the intake manifold pressure sensor signal was detected by the ECU 794

Derate in power output of the engine

102 / 3 P102 / 3 Intake Manifold Pressure Sensor

Cir-cuit - Voltage Above Normal or Shorted

to High Source High signal voltage tected at the intake manifold pressure circuit

de-Derate in power output of the engine

102 / 4 P102 / 4 Intake Manifold Pressure Sensor

Cir-cuit - Voltage Below Normal or Shorted

to Low Source Low signal voltage tected at the intake manifold pressure circuit

de-Derate in power output of the engine

103 / 10 P103 / 10 Turbocharger speed - invalid rate of

change detected The turbocharger speed sensor has detected an errone-ous speed value

Possible-low-power estimated charger speed will be used

turbo-103 / 16 P103 / 0 Turbocharger Number 1 speed high -

warning level High turbocharger speed has been detected

Engine power derate The ECU 794 uses an estimated turbocharger speed

Display J1587

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103 / 18 P103 / 1 Turbocharger number 1 speed low -

warning level Low turbocharger speed detected by the ECU 794

Engine power derate The ECU 794 uses estimated turbocharger speed

105 / 0 P105 / 0 Intake Manifold 1 Temperature - Data

Valid but Above Normal Operational Range - Most Severe Level Intake manifold air temperature signal indi-cates intake manifold air temperature above engine protection critical limit

Progressive power and derate ing in severity from time of alert If the Engine Protection Shutdown feature is enabled, engine will shut down 30 sec-onds after the Red Stop Lamp starts flashing

increas-105 / 3 P105 / 3 Intake Manifold Air Temperature

Sen-sor Circuit - Voltage Above Normal or Shorted to High Source High signal voltage detected at intake manifold air temperature circuit

Possible white smoke Fan will stay ON

if controlled by the ECU 794 No engine protection for intake manifold air tem-perature

105 / 4 P105 / 4 Intake Manifold Air Temperature

Sen-sor Circuit - Voltage Below Normal or Shorted to Low Source Low signal volt-age detected at intake manifold air tem-perature circuit

Posible white smoke Fan will stay ON

if controlled by ECU 794 No engine protection for intake manifold air tem-perature

105 / 15 P105 / 0 Intake Manifold Temperature High -

Data Valid but Above Normal tional Range - Least Severe Level In-take manifold air temperature signal indicates intake manifold air tempera-ture above engine protection warning limit

Opera-Progressive power derate increasing in severity from time of alert

108 / 2 P108 / 2 Barometric Pressure —Data Erratic,

In-termittent, or Incorrect The ambient air pressure sensor is reading an erratic value at initial key-on

Engine power derate

108 / 3 P108 / 3 Barometric Pressure Sensor Circuit -

Voltage Above Normal, or Shorted to High Source High signal voltage de-tected at barometric pressure circuit

Engine power derate

108 / 4 P108 / 4 Barometric Pressure Sensor Circuit -

Voltage Below Normal, or Shorted to Low Source Low signal voltage detect-

ed at barometric pressure circuit

Engine power derate

Display J1587

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110 / 0 P110 / 0 Engine Coolant Temperature - Data

Valid but Above Normal Operational Range - Most Severe Level Engine coolant temperature signal indicates engine coolant temperature above en-gine protection critical limit

Progressive power derate increasing in severity from time of alert If Engine Protection Shutdown feature is ena-bled, engine will shut down 30 seconds after red Stop lamp starts flashing

Er-ratic, Intermittent, or Incorrect The gine coolant temperature reading is not changed with engine operating condi-tions

en-The ECU 794 will estimate engine ant temperature

cool-110 / 3 P110 / 3 Engine Coolant Temperature 1 Sensor

Circuit - Voltage Above Normal or Shorted to High Source High signal voltage or open circuit detected at en-gine coolant temperature circuit

if controlled by ECU 794 No engine protection for engine coolant tempera-ture

110 / 4 P110 / 4 Engine Coolant Temperature 1 Sensor

Circuit - Voltage Below Normal or Shorted to Low Source Low signal volt-age detected at engine coolant temper-ature circuit

if controlled by ECU 794 No engine protection for engine coolant tempera-ture

110 / 15 P110 / 0 Engine Coolant Temperature High -

Data Valid but Above Normal tional Range - Least Severe Level En-gine coolant temperature signal indicates coolant temperature is above the engine coolant temperature engine protection warning limit

Opera-Progressive power derate increasing in severity from time of alert

Valid but Above Normal Operational Range - Moderately Severe Level En-gine coolant temperature signal indi-cates engine coolant temperature is above engine protection warning limit

Progressive power derate increasing in severity from time of alert

111 / 1 P111 / 1 Coolant Level - Data Valid but Below

Normal Operational Range - Most vere Level Low engine coolant level detected

Se-Progressive power derate increasing in severity from time of alert If the Engine Protection Shutdown feature is ena-bled, the engine will shut down 30 sec-onds after Red Stop lamp starts flashing

Display J1587

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111 / 3 P111 / 3 Coolant Level Sensor Circuit - Voltage

Above Normal or Shorted to High Source High signal voltage detected at engine coolant level circuit

None on performance

111 / 4 P111 / 4 Coolant Level Sensor Circuit - Voltage

Below Normal or Shorted to Low Source Low signal voltage detected at the engine coolant level circuit

None on performance

157 / 0 P94 / 0 Injector Metering Rail Number 1

Pres-sure - Data Valid But Above Normal Operating Range - Most Severe Level

The ECU 794 has detected that fuel pressure in the rail fuel is higher than the commanded pressure

associ-157 / 2 P157 / 2 Injector Metering Rail 1 Pressure - Data

Erratic, Intermittent, or Incorrect the ECU 794 has detected that the fuel pressure signal is not changing

The ECU 794 will estimate fuel sure and power is reduced

pres-157 / 3 P157 / 3 Injector Metering Rail Number 1

Pres-sure Sensor Circuit - Voltage Above Normal or Shorted to High Source

High signal voltage detected at rail fuel pressure sensor circuit

Power and or speed derate

157 / 4 P157 / 4 Injector Metering Rail Number 1

Pres-sure Sensor Circuit - Voltage Below Normal or Shorted to Low Source Low signal voltage detected at the rail fuel pressure sensor circuit

Power and or speed derate

157 / 16 P157 / 0 Injector Metering Rail 1 Pressure - Data

Valid but Above Normal Operational Range - Moderately Severe Level The ECU 794 has detected that fuel pres-sure is higher than commanded pres-sure

associ-157 / 18 P157 / 1 Fuel Pump Delivery Pressure Low -

Data Valid but Below Normal tional Range - Moderately Severe Lev-

Opera-el The ECU 794 has detected that fuel pressure is lower than commanded pressure

Possibly hard to start, low power, or gine smoke Engine can possibly not start

Display J1587

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167 / 1 P167 / 1 Electrical Charging System Voltage

Low - Data Valid but Below Normal erational Range - Most Severe Level

Op-Very low battery voltage detected by the battery voltage monitor feature

Warning lamp illuminated until very low battery voltage condition is corrected

High - Data Valid but Above Normal Operational Range - Moderately Se-vere Level High battery voltage detect-

ed by the battery voltage monitor feature

Amber warning lamp illuminated until high battery voltage condition is cor-rected

Low - Data Valid but Below Normal erational Range - Moderately Severe Level Low battery voltage detected by the battery voltage monitor feature

Op-Amber lamp will light until low battery voltage condition is corrected

168 / 16 P168 / 0 Battery 1 Voltage - Data Valid but

Above Normal Operational Range - Moderately Severe Level ECU 794 supply voltage is above the maximum system voltage level

Possible electrical damage to all cal components

electri-168 / 18 S168 / 1 Battery 1 Voltage - Data Valid but

Be-low Normal Operational Range - erately Severe Level ECU 794 supply voltage is below the minimum system voltage level

Mod-Engine may stop running or be difficult

to start

171 / 3 P171 / 3 Ambient temperature sensor, circuit

fault- Abnormally high voltage or circuit to higher voltage

short-171 / 4 P171 / 4 Ambient temperature sensor, circuit

fault - Abnormally low voltage or circuit to lower voltage

short-190 / 0 P190 / 0 Engine Crankshaft Speed/Position -

Data Valid but Above Normal tional Range - Most Severe Level En-gine speed signal indicates engine speed above engine protection limit

Opera-Fuel injection disabled until engine speed fails below the overspeed limit

190 / 2 P190 / 2 Engine Crankshaft Speed/Position -

Data Erratic, Intermittent, or Incorrect

Crankshaft engine speed sensor mittent synchronization

inter-Engine can exhibit misfire as control switches from the primary to the back-

up speed sensor Engine power is duced while the engine operates on the backup speed sensor

Display J1587

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190 / 2 P190 / 2 Engine Crankshaft Speed/Position -

Loss of signal from crankshaft sensor

Engine can run rough Possibly poor starting capability Engine runs using backup speed sensor Engine power is reduced

251 / 2 P251 / 2 Real-Time Clock Power Interrupt - Data

Erratic, Intermittent or Incorrect time clock lost power

Real-None on performance Data in the ECU

794 will not have accurate time and date information

441 / 3 P441 / 3 Auxiliary Temperature Sensor Input 1 -

Voltage Above Normal, or Shorted to High Source High signal voltage or open circuit detected at the OEM auxil-iary temperature circuit

None on performance

441 / 4 P441 / 4 Auxiliary Temperature Sensor Input 1

Circuit - Voltage Below Normal, or Shorted to Low Source Low signal volt-age detected at OEM auxiliary temper-ature circuit

None on performance

558 / 2 S230 / 2 Accelerator Pedal or Lever Idle

Valida-tion Circuit - Data Erratic, Intermittent or Incorrect Voltage detected simultane-ously on both idle validation and off-idle validation switches

Engine will only idle

Valida-tion Circuit - Voltage Below Normal or Shorted to Low Source No voltage de-tected simultaneously on both the idle validation off-idle and on-idle circuits

Valida-tion Circuit - Out of CalibraValida-tion Voltage

at idle validation on-idle and off-idle cuit does not match accelerator pedal position

cir-Engine will only idle

611 / 2 P089 / 2 Auxiliary Intermediate (PTO) Speed

Switch Validation - Data Erratic, mittent, or Incorrect The position of the intermediate speed control switch 1 does not match the position of the inter-mediate speed control validation switch

Inter-Intermediate speed control switch may not operate correctly

Display J1587

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611 / 3 S232 / 3 Sensor Supply Voltage 4 Circuit -

Volt-age Above Normal or Shorted to High Source High voltage detected at +5 volt sensor supply circuit to the acceler-ator pedal position sensor

611 / 4 S232 / 4 Sensor Supply 3 Circuit - Voltage

Be-low Normal, or Shorted to Low Source

Low voltage detected on the +5 volt sensor supply circuit to the engine speed sensor

Possible hard starting and rough ning

run-611 / 4 S232 / 4 Sensor Supply Voltage 4 Circuit -

Volt-age Below Normal or Shorted to Low Source Low voltage detected at +5 VDC sensor supply circuit to the accel-erator pedal position sensor

Engine will only die

611 / 15 S151 / 0 Turbocharger compressor outlet

tem-perature - data above normal High bocharger compressor outlet

tur-temperature has been calculated by the ECU 794

Fuel is limited in an attempt to decrease the calculated turbocharger compres-sor outlet temperature

612 / 2 P190 / 2 Engine Magnetic Crankshaft Speed/

Position lost both of two signals - Data Erratic, Intermittent, or Incorrect The ECU 794 has detected that the primary engine speed sensor and the backup engine speed sensor signals are re-versed

Fueling to the injectors is disabled, and the engine can not be started

627 / 2 S251 / 2 Power Lost without Ignition Off - Data

Erratic, Intermittent or Incorrect Supply voltage to the ECU 794 fell below 6.2 volts momentarily, or the ECU 794 was not allowed to power down correctly (retain battery voltage for 30 seconds after key OFF)

Possible no noticeable performance fects or engine dying or hard starting

ef-Fault information, trip information, and maintenance monitor data can be inac-curate

627 / 2 S251 / 2 Power Supply Lost With Ignition On -

Supply voltage to the ECU 794 fell low 6.2 VDC momentarily, or the ECU

be-794 was not allowed to power down correctly (retain battery voltage for 30 seconds after key OFF)

Possible no noticeable performance fects or engine dying or hard starting

Display J1587

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627 / 2 S254 / 12 Injector Power Supply - Bad Intelligent

Device or Component The ECU 794 measured injector boost voltage is low

Possible smoke, low power, engine misfire, and/or engine will not start

629 / 12 S254 / 12 Engine Control Module - critical internal

failure Error internal to the ECU 794 lated to memory hardware failures or internal ECU 794 voltage supply cir-cuits

re-Engine may not start

629 / 12 S254 / 12 Engine Control Module Warning

Inter-nal Hardware Failure - Bad Intelligent Device or Component

No performance effects or possible vere power derate

se-630 / 2 S253 / 2 Engine Control Module Data Lost -

Severe loss of data from the ECU 794

Possible no noticeable performance fects, engine dying or hard starting

630 / 31 S240 / 11 Engine Control Module Calibration

Pro-gram Memory (RAM) Corruption - dition Exists Severe loss of data from the ECU 794

Con-Possible no noticeable performance fects, engine dying or hard starting

633 / 31 S018 / 11 Fueling Actuator Number 1 Circuit Error

Conditions Exists Fuel pump actuator circuit resistance too high or too low

Possible low power

639 / 9 S231 / 9 SAE J1939 Multiplexing PGN Timeout

Error - Abnormal Update Rate The Cummins ECU 794 did not receive a multiplexed message from an OEM VECU within the time limit or did not re-ceive it at all

One or more multiplexed devices will not operate properly One or more symptoms will occur

639 / 13 S231 / 13 SAE J1939 Multiplexing Configuration

Error - Out of Calibration The ECU 794 expected information from a multi-plexed device but only received a por-tion of the necessary information

At least one multiplexed devices will not operate properly

641 / 3 S027 / 3 VGT actuator driver circuit - voltage

above normal or shorted to high source

Possible low power Power removed from the turbocharger actuator motor

641 / 4 S027 / 4 VGT actuator driver circuit - voltage be- Possible low power Power removed

Display J1587

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644 / 2 S030 / 2 External Speed Command Input

(Multi-ple Unit Synchronization) - Data Erratic, Intermittent, or Incorrect The throttle input signal to the primary or secondary engine for multiple unit synchronization

is less than 3 percent or more than 97 percent

Primary or secondary engines may be shut down

647 / 3 S033 / 3 Fan Control Circuit - Voltage Above

Normal or Shorted to High Source

Open circuit or high voltage detected at the fan control circuit

The fan may stay on continuously or not run at all

647 / 4 S033 / 4 Fan Control Circuit - Voltage Below

Normal or Shorted to Low Source Low signal voltage detected at the fan con-trol circuit when commanded on

The fan can possibly stay on ously or not run at all

continu-651 / 5 S001 / 5 Injector Solenoid Driver Cylinder 1

Cir-cuit - Current Below Normal, or Open Circuit High resistance or no current detected at Number 1 injector DRIVER

or RETURN pin

Engine can misfire or possibly run rough

651 / 7 S001 / 7 Injector Solenoid Driver Cylinder 1 -

Mechanical System Not Responding Properly or Out of Adjustment Unin-tended fueling detected in cylinder number 1

Engine will shut down

652 / 5 S002 / 5 Injector Solenoid Driver Cylinder 2

Cir-cuit - Current Below Normal, or Open Circuit High resistance or no current detected at Number 2 injector driver or return pin

Cir-cuit - Current Below Normal, or Open Circuit High resistance or no current detected at Number 3 injector or return pin

Display J1587

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Cir-cuit - Current Below Normal or Open Circuit High resistance or no current detected at Number 1 injector driver or return pin

Cir-cuit - Current Below Normal, or Open Circuit High resistance or no current detected at Number 5 injector DRIVER

or RETURN pin

Mechanical System Not Responding Properly or Out of Adjustment Unin-tended fueling detected in cylinder Number 5

Cir-cuit - Current Below Normal, or Open Circuit High resistance or no current detected at Number 6 injector driver or return pin

Mechanical System Not Responding Properly or Out of Adjustment Unin-tended fueling detected in cylinder Number 6

677 / 3 S39 / 3 Starter Relay Circuit - Voltage Above

Normal or Shorted to High Source

Open circuit or high voltage detected at starter lockout circuit

Either the engine will not start or the gine will not have starter lockout protec-tion

Display J1587

Trang 34

677 / 4 S39 / 4 Starter Relay Circuit - Voltage Below

Normal or Shorted to Low Source Low voltage detected at starter lockout cir-cuit

The engine will not have starter lockout protection

697 / 3 S057 / 3 Auxiliary PWM Driver #1 - Voltage

Above Normal or Shorted to High Source High signal voltage detected at the analog torque circuit

Can not control transmission

697 / 4 S057 / 4 Auxiliary PWM Driver #1 - Voltage

Be-low Normal or Shorted to Low Source

Low signal voltage detected at the log torque circuit

ana-Can not control transmission

703 / 11 S051 /11 Auxiliary Equipment Sensor Input #3

(OEM Switch) - Root Cause Not Known

Possible engine power derate

723 / 2 S064 / 2 Backup Engine Speed/Position Sensor

Number 2 - Data Erratic, Intermittent, or Incorrect Camshaft engine speed sen-sor intermittent synchronization

Possible low power

723 / 2 S064 / 2 Engine Speed Sensor (Camshaft) Error

- Data Erratic, Intermittent, or Incorrect

The ECU 794 has detected an error in the camshaft position sensor signal

Possible poor starting Engine power derate

723 / 7 S064 / 7 Engine Speed Sensor/Position

Cam-shaft and CrankCam-shaft Misalignment - Mechanical System Not Responding Properly or Out of Adjustment Me-chanical misalignment between the crankshaft and camshaft engine speed sensors

Engine will run derated Excessive smoke, hard start, and rough idle possi-ble

729 / 3 S070 / 3 Intake Air Heater #1 Circuit - Voltage

Above Normal or Shorted to High Source High voltage detected at the in-take air heater signal circuit

The intake air heaters may be ON or OFF all the time

729 / 4 S070 / 4 Intake Air Heater #1 Circuit - Voltage

Below Normal or Shorted to Low Source Low voltage detected at the in-take air heater signal circuit

The intake air heaters may be ON or OFF all the time

Display J1587

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974 / 3 P974 / 3 Remote Accelerator Pedal or Lever

Po-sition Sensor 1 Circuit - Voltage Above Normal, or shorted to High Source

High voltage detected at remote erator pedal position circuit

accel-Remote accelerator will not operate

Remote accelerator position will be set

to zero percent

974 / 4 P974 / 4 Remote Accelerator Pedal or Lever

Po-sition Sensor 1 Circuit - Voltage Below Normal, or Shorted to Low Source Low voltage detected at remote accelerator pedal position signal

Remote accelerator will not operate

Remote accelerator position will be set

to zero percent

974 / 19 P29 SAE J1939 Multiplexing Remote

Accel-erator Pedal or Lever Data Error - ceived Network Data Error The OEM machine electronic control unit (VECU) detected a fault with the remote accel-erator

Re-The engine will not respond to the mote throttle Engine may only idle The primary or cab accelerator may be able

re-to be used

1043 / 3 S221 / 3 Accelerator Pedal or Lever Position

Sensor Supply Voltage Circuit - Voltage Above Normal or Shorted to High Source High voltage detected at sen-sor supply circuit for the accelerator pedal or lever position sensor

1043 / 4 S221 / 4 Accelerator Pedal or Lever Position

Sensor Supply Voltage Circuit - Voltage Below Normal or Shorted to Low Source Low voltage detected at sensor supply circuit to the accelerator pedal

or lever position sensor

Engine will only die

1043 / 4 S221 / 4 Engine Speed/Position Sensor

(Crank-shaft) Supply Voltage Circuit - Voltage Below Normal or Shorted to Low Source Low voltage detected on the ECU 794 voltage supply line to engine speed sensor

Possible hard starting and rough ning

run-1072 / 3 S028 / 3 Engine Brake Actuator Circuit #1 -

Volt-age Above Normal or Shorted to High Source Open circuit or high voltage de-tected at the engine brake solenoid number 1 signal circuit

Engine brake on cylinders 1, 2, and 3 can not be activated or exhaust brake will not operate

Display J1587

Trang 36

1072 / 4 S028 / 4 Engine Brake Actuator Circuit #1 -

Volt-age Below Normal or Shorted to Low Source Low voltage detected at the engine brake solenoid number 1 signal circuit

Engine brake on cylinders 1,2, and 3 can not be activated or exhaust brake will not operate

Volt-age Above Normal or Shorted to High Source Open circuit or high voltage de-tected at the engine brake solenoid number 2 signal circuit

Engine brake on cylinders 4, 5, and 6 can not be activated

Volt-age Below Normal or Shorted to Low Source Low voltage detected at the engine brake solenoid number 2 signal circuit

Engine brake on cylinders 4, 5, and 6 can not be activated

1075 / 3 S126 / 3 Electric Lift Pump for Engine Fuel

Sup-ply Circuit - Voltage Above Normal, or Shorted to High Source High voltage

or open detected at the fuel lift pump signal circuit

Engine can be difficult to start

1075 / 4 S126 / 4 Electric Lift Pump for Engine Fuel

Sup-ply Circuit - Voltage Below Normal, or Shorted to Low Source Low signal volt-age detected at the fuel lift pump circuit

Engine can be difficult to start

1079 / 3 S212 / 3 Sensor Supply Voltage number 1

to High Source High voltage detected

at sensor supply number 1 circuit

Engine power derate

1079 / 4 S212 / 4 Sensor Supply Voltage Number 1

to Low Source Low voltage detected at sensor supply number 1 circuit

Engine power derate

1080 / 3 S232 / 3 Sensor Supply 2 Circuit - Voltage

Above Normal or Shorted to High Source High voltage detected at sen-sor supply number 2 circuit

Engine power derate

1080 / 4 S232 / 4 Sensor Supply Voltage Number 2

Cir-cuit - Voltage Below Normal, or Shorted

to Low Source Low voltage detected at the sensor supply number 2 circuit

Engine power derate

Display J1587

Trang 37

1137 / 2 S114 / 2 Multiple Unit Synchronization Switch -

Multi-Unit synchronous ON/OFF switch and Multi-Unit synchronous compli-mentary ON/OFF switch have different values in the ECU 794

Multi-Unit synchronization feature is disabled

1172 / 3 / 3 Turbocharger Number 1 Compressor

Inlet Temperature Sensor Circuit - age Above Normal or Shorted to High Source High signal voltage detected at the turbocharger compressor inlet air temperature circuit

Volt-Engine power derate

1172 / 4 / 4 Turbocharger Number 1 Compressor

Inlet Temperature Sensor Circuit - age Below Normal or Shorted to Low Source Low signal voltage detected at the turbocharger compressor inlet air temperature sensor circuit

Volt-Engine power derate

1347 / 3 S126 / 3 High Fuel Pressure Solenoid Valve

to High Source Electronic fuel control actuator shorted high

Engine will run poorly but will be verely derated Rail pressure will be higher than commanded

se-1347 / 4 S126 / 4 High Fuel Pressure Solenoid Valve

to Low Source Electronic fuel control actuator shorted low

Engine will run poorly at idle Engine will have low power Fuel pressure will

be higher than commanded

1347 / 7 S126 / 7 Fuel Pump Pressurizing Assembly 1 -

Mechanical System Not Responding Properly or Out of Adjustment A pump-ing imbalance between the front and rear pumping plungers has been de-tected

Engine will not run or possible low er

pow-1347 / 7 S126 / 7 Fuel Pumping Element Number 1

(Front) - Mechanical System Not sponding Properly or Out of Adjust-ment

Re-Engine will not run or possible low er

pow-1378 / 31 S153 / 11 Change Lubricating Oil and Filter -

Condition Exists Change engine oil and filter

None on performance; maintenance minder only

Display J1587

Trang 38

1388 / 3 P223 / 3 Auxiliary Pressure Sensor Input 1

Cir-cuit - Voltage Above Normal, or

Short-ed to High Source High signal voltage detected at the OEM pressure circuit

None on performance

1388 / 4 P223 / 4 Auxiliary Pressure Sensor Input 1

Cir-cuit - Voltage Below Normal, or Shorted

to Low Source Low signal voltage or open circuit detected at the OEM pres-sure circuit

None on performance

2789 / 15 / 0 Exhaust gas temperature - data above

normal High exhaust temperature has been calculated by the electronic con-trol system

Derate in power output of the engine in attempt to decrease the calculated ex-haust gas temperature value

Display J1587

Trang 39

D Error codes – 2 Transmission 39

mm mm mm mm mm mm

2 Transmission

Error codes transmission

In case of serious transmission malfunctions the control unit uses two modes with reduced functionality to protect the transmission against damage, Limp-home mode and Shut-down mode

For more detailed description see section 2 Transmission, group 2.8 Control system transmission.

Code

00.50 There is a problem related to

the internal RAM (in CPU)

Controller reverts to a "shut down" mode and will force neutral 0

Hardware related fault - related to in the ternal RAM

in-Contact Kalmar Industries AB for more mation

infor-00.51 There is a problem related to

the system RAM (in CPU)

Hardware related fault - related to in the tem RAM

sys-Contact Kalmar Industries AB for more mation

the external RAM

Hardware related fault - related to in the ternal RAM

ex-Contact Kalmar Industries AB for more mation

the Flash program memory

Hardware related fault - related to in the flash program memory

Contact Kalmar Industries AB for more mation

infor-20.60 Pressure feed-back line is

in-dicating there is no system

pressure present, allthough

pressure should be there

The analog input ANI0 is in the 1500 - 4000 ohm range, while it should be in the 500 -

20.61 Pressure feed-back line is

in-dicating there is system

pressure present, allthough

pressure should NOT be

there

The analog input ANI0 is in the 500 - 1500 ohm range, while it should be in the 1500 -

4000 ohm range

Check the wiring between the controller and the pressure feedback sensor

Trang 40

40 D Error codes – 2 Transmission

30.04 Power supply out of range

-> below minimum

Controller will save all logged information to flash, will pow-erdown, and force all outputs off

Power supply to the controller too low:APC200 12V supply version: < 9 V.APC200 24V supply version: < 16V.Check power supply cables to the controller Check alternator, check the connection ca-bles between the battery and the alternator, check the battery

30.05 Power supply out of range

-> above maximum

The controller will have duced proportional control accuracy due to reduced PWM duty cycle

re-Power supply to the controller too high:APC200 12V supply version: > 18 V.APC200 24V supply version: > 32 V.Check power supply, check if a jump start setup is still connected

31.00 Voltage supply for the

sen-sors : Vsense (8V) is out of

range -> below minimum

The controller will have duced sensor signals

re-Voltage supply for the sensors : Vsense (8V)

is below 7,2 V

Check power supply Check the controller.31.01 Voltage supply for the sen-

sors : Vsense (8V) is out of

range -> above maximum

The controller will have duced sensor signals

re-Voltage supply for the sensors : Vsense (8V)

is above 8,8 VCheck power supply Check the controller.40.06 Invalid shift lever direction

Check the wiring between the controller and the shiftlever concerning the forward and the reverse signal

40.08 Seat orientation input was

changed while the parking

brake was not active, or/and

the shiftlever was not in

neu-tral, or/and the machine was

41.06 Invalid shift lever position

de-tected

The controller will not allow range shifting, however driv-ing is still possible

The controller receives from the shiftlever an unknown range shift pattern

Check the wiring between the controller and the shiftlever concerning the range signals

Code

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