• Author / Uploaded
• Ahmed Kamal

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721F - 821F - 921F 4 - ELECTRICAL

CONTENT



Page AIC PRESENTATION

2

FAULT RETRIEVING

3

AIC NAVIGATION

6

VEHICLE FAULT LIST

14

ENGINE FAULT LIST

15

TRANSMISSION FAULT LIST



19

CAN BUS COMMUNICATION FAULT LIST

21

SCR FAULT LIST

22

AUTOMATIC ENGINE SHUT DOWN

24

PARKING BRAKE CONTROL & TEST

27



FAN CONTROL & FAN REVERSING

28

AUTO IDLE

30

AIC ELECTRICAL CIRCUIT

31

ELECTRICAL CIRCUIT

4A-1

Racine / Monthyon Training centers

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4 - ELECTRICAL

721F - 821F - 921F

ADVANCED INFORMATION CENTER

1

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15

3

4

6

5

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10

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1. Low brake pressure 9. Lack of steering pressure 2. High beam 10. Parking brake (ON engaged) 3. Transmision oil temperature 11. Right turn 4. Caution master 12. Fuel level gauge 5. Multi fonction LCD display 13. Fuel level at minimum 6. Stop master indicator 14. Engine coolant temperature gauge 7. Hydraulic oil temperature gauge 15.Left turn indicator 8. Wait to start / engine preheating LCD DISPLAY (5) The display (5) shows in different zones various information depending on operating conditions or AIC setting. The display shown below is in normal operating conditions. Shows F,R,N required by operator Blinks if F or R, while transmission clutches disconnected

Shows Hourmeter Engine Speed Travel Speed depending of operating conditions, and options selected

Shows transmission clutch disengaged, if Park brake OFF Shows differential lock Shows Engine Power Mode MAX AUTO STD ECO

Shows Max Gear allowed when in automatic mode. Blank in Manual Shows current transmission gear

Shows Time in 12 or 24 mode with a blinking semi colon

New Diesel Exhaust Fluid (DEF) Gauge & Icon

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Indicates current transmission mode: Operation OK A Automatic M Manual Operation not OK C Substitute Clutch L Limp Home S Transmission ShutDown U TCU shutdown

Racine / Monthyon Training centers

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721F - 821F - 921F 4 - ELECTRICAL CAN BUS ARCHITECTURE

Racine / Monthyon Training centers

4 - ELECTRICAL

721F - 821F - 921F ESC

FAULT CODES RETRIVING

UP

General Fault Code Identification 1. Press and hold the escape key (ESC) and (UP) for more than 2 seconds to access the fault codes.

DN

ENT

2. Select YELLOW, or RED for active fault code or select MEMORY for non active faults.

No red active error No yellow active error

3. Depress the ENT swich to read the fault code display.

10 non active faults in memory

FAULT CODE DISPLAY Show number in the list and total of errors in the list

Show fault code status: WHITE YELLOW RED MEMORY

Error description Error code

Date and hour when the last same error start

Total active time

Total occurence

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Racine / Monthyon Training centers

721F - 821F - 921F 4 - ELECTRICAL Direct reading of an active fault 1. This can be done when the yellow alarm or the red alarm is ON as shown on the picture depressing the ESC key: Alarm

ESC KEY

2. White Faults: A. Operator can acknowledge it by pressing the enter key (ENT). B. The message will disappear. ESC C. The fault will remain in White list as long as active. D. It will be recorded in Memory when closed. 3. Yellow Faults, buzzer will beep once every 2 seconds: A. Operator can acknowledge it by pressing the enter key (ENT). B. The message will disappear. C. Buzzer will not beep anymore D. Yellow lamp will stay ON. E. Fault will remain in yellow list until it is closed. ENT

UP

DN

4. Red Faults, buzzer will be continuous, alternating sounds: A. Operator can acknowledge it by pressing the enter key (ENT). B. Buzzer will change to a less stressing sound, but will remain. C. Message will remain on display with indication of URGENT STOP. KEYPAD :

ESC: to return to previous menu ENT: to select the menu shown in reverse video area UP & DN: to go deeper in the menu.

FAULT CODE GROUPING 1. 1000 to 1999 Vehicle errors. 2. 2000 to 2999 Not used. 3. 3000 to 3999 Engine errors. 4. 4000 to 4999 Transmission errors. 5. 5000 to 5999 Eltro-hydraulic system errors. 6. 6000 to 6999 Reserved. 7. 7000 to 7999 Reserved. 8. 8000 to 8999 Optional equipment IE: GPS. 9. 9000 to 9999 Internal AIC errors. 10. 19000 to 199999 SCR

Racine / Monthyon Training centers

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4 - ELECTRICAL

721F - 821F - 921F

AIC NAVIGATION The software inside the AIC is designed to provide many menus of information available to the operators and service technician. Somes menus are for readable information, other are programmable or use to service the machine. Reading menus They can be displayed in Metric or English units (according the programmation of the preferences): Engine Speed, Travel Speed, Fuel Level, Volts, Engine Cool Temperature, Engine Air Temperature, Engine OilTemperature, Engine Oil Press, Trans Oil Temperature, Hyd Oil Temperature, Trans Sump Temperature, Radiator Temperature, Hardware, Software, TRIP 1 & TRIP 2 with Last Reset Date/Time - Time - Fuel used - Fuel consumption per hour. Programmable menus: Power Mode (MAXIMUM, STANDARD, AUTOMATIC, ECONOMIC) Preferences (languages, units, clock) Options (Fan auto, Idle auto, Show RPM, Show Km/h Display (Day and Night) Clock (AM/PM or 24H a day) Configuration (Change model, Tire selection, Gear limits) Service menus Parking brake test Clutch calibration process Fan test (due to variable speed of drive motor) Special (for factory reset and reset errors) Menu acces To access the menus use the switches of the keypad located close the parking brake switch on the steering column. ESC Several types of screen can be displayed:

ENT

UP DN

When screen has no highlighted menu, arrow keys (UP or DN) change from screen to screen. ENT will select THAT screen, and go deeper, in that direction. ESC will go back to previous level

When screen have a highlighted menu use the arrow keys (UP or DN) to navigate between menu choices ENT will select THAT area, and go deeper ESC will go back to previous level

When screen have a flashing video area arrow keys (UP or DN) change the value. ENT will select THAT value, and record it. ESC will forget the changes and go back to previous level.

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Racine / Monthyon Training centers

G ear G ear G ear G ear G ear G ear

01 « S p la sh » scre e n w ith lo g o , h o u rm e te r a n d m odel Racine / Monthyon Training centers

K e e p p re ss E N T d u rin g P o w e r U p

w ith w ith w ith w ith w ith w ith

M : n o rm a l o p e ra tio n, M a n u a l A : n o rm a l o p e ra tio n, A u to m a tic C : S u b stitu te C lu tch L : L im p h o m e S : T ra n s S h u td o w n U : T C U S h u td o w n

E N G IN E M o d e s MAX STD AUTO ECO

T im e Fuel A ve ra g e

2 4 C u rre n t L a n g.

ESC

E n g lish D e u tsch F ra n ca is

T R IP 2

I

DN UP

ENT

T im e Fuel A ve ra g e

E N T = re se t E S C = ca n ce l

C o n firm P le a se

UP ESC ENT

ESC ENT

Eng Speed T ra ve l S p e e d F u e l L e ve l D e f L e ve l

C o n firm P le a se

T R IP 2

L a st R e se t D a te/T im e

ENT

IN F O 1

E N T = re se t E S C = ca n ce l

DN UP

DN

ESC

I

ENT

L a st R e se t D a te/T im e

UP

If n o a ctio n

DN

T R IP 1

T R IP 1

Eng Eng Eng Eng

ESC ENT

I

IN F O 2 C ool Tem p A ir T e m p O ilT e m p O il P re ss

DN UP

A d B lu e L e ve l & D e f Ico n

I

IN F O 3

T ra n s O il T e m p H yd O il T e m p T ra n s S u m p T e m p R a d ia to r T e m p

DN

ESC ENT

DN UP

V o lta g e D ef Tem p Fan PW M

U P ESC

IN F O 4

ENT

UP DN

4-

721F - 821F - 921F 4 - ELECTRICAL

T ra n sm issio n M o d e s

AIC NAVIGATION

POW ER UP

4 - ELECTRICAL

721F - 821F - 921F

AIC MENUS Main Menu access

ESC

UP DN

ENT

Depress ENTER for 2 secondes

M ain M enu Settings Display Diagnostics Service

Settings Engine

Diagnostics

Display O PT

O ptions

Transm .

Language

Joyst. Steer

Units Clock

!

Show Errors Cluster Transm .

Backlight Factory Set

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Racine / Monthyon Training centers

Service Calibration Slct_Tires

721F - 821F - 921F 4 - ELECTRICAL AIC MENUS Setting Menu acces

Settings Engine Transm . Joyst. Steer

Transm . Engine Auto Idle

Transm .

M ax G ear

4

M ax G ear

M in G ear

1

M in G ear PO W ERINCH

Power M ode

Joyst Steer 5

JSS _ Spd

2

1 ON

EngO ptions Factory Set

(5 Speed )

(4 Speed )

(O ption ) (O ption )

Auto Idle

Power M ode

EngO ptions

O ff

M AX

Fan Auto

ON

Low

STANDARD AUTO ECO

W orkIdle

Deflt

Accelerated

Factory Set Reset Engine Settings Confirm Please

Racine / Monthyon Training centers

Auto Shtdwn Econom y

O FF

Interval

30 m in O FF

Protection

4-

O ptions

4 - ELECTRICAL

O PT

AIC MENUS

Display menu access

4 - 10 Display

Language Units Clock

Racine / Monthyon Training centers

Backlight Factory Set

O PT O ptions

Language

Engine Spd

ON

G round Spd

ON

Clock

Units

English

M etric

Deutsch Francais Italiano Espagnol Portugue

English Im perial

Form at Hour M inute Day M onth Year

12 Hr 12 30 1 1 2011

Backlight Day Disp . Day LED Night Disp . Night LED

Factory Set 20 20 5 5

Reset Display Settings Confirm Please

721F - 821F - 921F

721F - 821F - 921F 4 - ELECTRICAL AIC MENUS Diagnostics menu access

Diagnostics

!

Show Errors Cluster Transm .

!

Show Errors

Transm .

Cluster

RED YELLO W

0 0

HW P/N SW P/N

W HITE

0

Ldr

M EM O RY

2

Ver

87372814 84340740 1.8 .0.0 3.0 .2.8

SW HW

6057 018 121 6009 365 007

VER 932 ___ tdz _ Luc SER 4506 JCW Fw

M EM O RY 1/2 19605 W arning SCR Control CAN M sg Engine Tim eout 17 NO V 10,Hr 1

1067 0.00

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4 - ELECTRICAL

721F - 821F - 921F

AIC MENUS Service

Service menu access

Calibration



Slct_ Tires

Select Tires

Calibration

TireSize

ClutchCalib

20 .5 Rad

PedalCalib ParkBrake Fan Test

ClutchCalib

PedalCalib

ParkBrake

Fan Test

Test Park Brake

Switch to Fixed Fan Speed M ode

Confirm Please

Confirm Please

Confirm Please

PedalCalib

ParkBrake

Push Pedal Full

Test Park Brake

Test at fixed

Engage 3rdM anual Press Esc

Fan Speed Press Esc

To Exit

To Exit

PedalCalib Change O K Now , Turn Key O FF ..

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Racine / Monthyon Training centers

Confirm Please

Fixed 70 %

AdjustSpeed 70% Speed

735

Reset

*****

Actual PW M

420

721F - 821F - 921F 4 - ELECTRICAL AIC MENUS System menu access This menu System can only be reached at key on. The technician must press and hold the escape key (upper left key) during key on, the menu will then appear. This should be in the service manual, but not in the operators manual.

ESC

System ChangeM odel ResetErrors Factory Set

ChangeM odel 621 F 721 F 821 F 921 F 1021 F 1021 F HD 1121 F

ResetErrors Reset Confirm Please

Racine / Monthyon Training centers

Factory Set Reset Confirm Please

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4 - ELECTRICAL

721F - 821F - 921F

VEHICLE ERRORS FAULT CODE LIST

1310 Hydraulic Filter Is Blocked 1311 Engine Air Filter Is Blocked 1312 Hydraulic Oil Temperature Is Above Normal 1313 Hydraulic Oil Temperature Is Too High 1314 Transmission Oil Temperature Is Above Normal 1315 Transmission Oil Temperature Is Critically High 1316 Brake pressure too low or sensor defect 1317 Steering Pressure Low 1318 Engine Coolant Temperature Is Above Normal 1319 Engine Coolant Temperature Is Critically High 1320 Engine Oil Pressure Is Too Low 1321 Engine Oil Pressure Is Below Normal 1322 Engine Oil Pressure Is Above Normal 1323 Battery voltage Is too low 1324 Battery voltage Is too high 1325 Oil Temperature Is Too High 1326 Engine Coolant Level Is low. Add coolant fluid. 1327 Vehicle Movement Occurred During Accelerated Idle 1328 Vehicle Movement Occurred When Shifting to Low Idle 1329 Water in fuel sensor not detected 1331 Electrical Charging System Voltage Is Critically Low 1332 Water Detected In Fuel 1333 Engine Overspeed Detected 1334 Intake Manifold Temperature Is Critically High 1335 Brake pressure too low or sensor defect 1336 Warning - Transmission Oil Filter Restriction Is Too High 1341 Secondary Steering Pressure Too Low 1342 Steering Pressure Sensor Open Circuit 1343 Secondary Steering Pressure Sensor Open Circuit 1812 JSS Armrest Switch Short To Ground Or Battery Or Open Circuit 1816 JSS Activation Button Has Mechanical Defect Or Open Circuit 1820 JSS Relay, JSS Valve, or JSS Joystick power supply connection error. 1821 JSS Relay 85/AIC1.21 Short To Ground, Relay 86/87a Short To Power Or Activation Switch Failure 1823 JSS Relay 87 Open Circuit Or Short To Power Or Permanent Ground 1824 JSS Activation Button Short To Battery 1830 JSS Activation Switch Pin3 and C5.E Pin 1 Open Circuit 1831 JSC Wrong Operation - Internal Fault 1832 JSC Input Signal From JSS Joystick Out Of Range 1833 JSC Output Signal To Valves Out Of Range 1834 JSC Output Signal Short Circuit To Battery Or JSC Internal Relay Is Defective 1835 JSS Valve Pin 4 Or JSC Pin 5 Open Circuit Or Short To Ground Or Power 1836 JSC Board Temperature Out Of Range Or Short Circuit At Power Outputs 1837 JSC Pin 3 Switched Power Supply Out Of Range 1838 JSS Calibration Result: JSS Joystick Neutral Sw out of range. Exchange Joystick. 1839 Joystick Signal Out of Range due to failed calibration. Check JSS (ground) connections. 1841 JSS Valve Internal Error, Spool Position Not Accurate, Or Signal Voltage Out Of Range 1842 JSS Valve Pin 2 (Alarm Signal) Open Circuit 1843 JSS Pilot Pressure Too High 1844 JSS Pilot Pressure Switch Short Circuit To Ground 1845 JSS Pilot Pressure Too Low 1846 JSS Standard Steering Orbitrol LS Pressure Switch Short To Power Or Ground 1847 Model type information not available in JSC. Verify Model Type setting in AIC. 1850 JSS Joystick Internal Failure Or Pins 2, 4, Or 6 Open Circuit Or Short To Power Or Ground 1852 JSS Joystick Internal Failure Or Pin 5 Open Circuit 1860 Timeout of C5.E CAN Message Detected By JSC 1861 Timeout of AIC CAN Message Detected By JSC 1863 JSS F-N-R Did Not Start - Transmission Controller Internal Failure

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Racine / Monthyon Training centers

721F - 821F - 921F 4 - ELECTRICAL ENGINE FAULT CODES LIST 3000 Unknown ECM SPN Error Code 3001 Foot Throttle Sensor Signal Is Not Plausible 3002 Foot Throttle Sensor Signal Is Above Maximum Range 3003 Foot Throttle Sensor Signal Is Below Minimum Range 3004 Foot Throttle Sensor Has No Signal 3006 Coolant Temperature Sensor Error - Signal Not Plausible 3007 Coolant Temperature Sensor Signal Is Above Maximum Range 3008 Coolant Temperature Sensor Signal Is Below Minimum Range 3009 Coolant Temperature Sensor Signal (via CAN) Is Null 3010 Air Intake Temperature Sensor Signal Is Above Maximum Range 3011 Air Intake Temperature Sensor Signal Is Below Minimum Range 3012 Air Intake Temperature Sensor Signal (via CAN) Is Null 3015 Fuel Temperature Signal Is Above Maximum Range 3016 Fuel Temperature Signal Is Below Minimum Range 3019 Boost Pressure Sensor Signal Is Above Maximum Range 3021 Boost Pressure Sensor Signal (via CAN) Is Null 3022 Boost Pressure Sensor Signal Is Not Plausible 3023 Atmospheric Pressure Sensor Signal Is Not Plausible 3024 Atmospheric Pressure Sensor Signal Is Above Maximum Range 3025 Atmospheric Pressure Sensor Signal Is Below Minimum Range 3028 Oil Pressure Too Low 3029 Oil Pressure Sensor Is Short Circuited To The Battery 3030 Oil Pressure Sensor Is Short Circuited To Ground 3031 Oil Pressure Sensor Has Hardware Error 3032 Oil pressure too high 3033 Oil Temperature Sensor Signal Is Not Plausible 3034 Oil Temperature Sensor Signal Is Above Maximum Range 3035 Oil Temperature Sensor Signal Is Below Minimum Range 3036 Oil Temperature Sensor CAN Transmission Disturbed 3037 Boost Pressure Sensor Signal Low 3039 Cruise Control Actuating Device - Evaluation Error 3047 High Pressure Pump Relay Short Circuited To Battery 3048 High Pressure Pump Relay Short Circuited To Ground 3051 Battery Voltage To The Electronic Control Module Is Too High 3052 Battery Voltage To The Electronic Control Module Is Too Low 3059 ECM Afterrun was Interrupted 3060 Cylinder 1 - unclassifiable error in injector 3061 Cylinder 1 - Injector Cable Short Circuit (Low Side to Battery) 3062 Cylinder 1 - Signal Low 3063 Cylinder 1 - Injector Cable Short Circuit (High Side to Low Side) 3064 Cylinder 5 - unclassifiable error in injector 3065 Cylinder 5 - Injector Cable Short Circuit (Low Side to Battery) 3066 Cylinder 5 - Signal Low 3067 Cylinder 5 - Injector Cable Short Circuit (High Side to Low Side) 3068 Cylinder 3 - unclassifiable error in injector 3069 Cylinder 3 - Injector Cable Short Circuit (Low Side to Battery) 3070 Cylinder 3 - Signal Low 3071 Cylinder 3 - Injector Cable Short Circuit (High Side to Low Side) 3072 Cylinder 6 - unclassifiable error in injector 3073 Cylinder 6 - Injector Cable Short Circuit (Low Side to Battery) 3074 Cylinder 6 - Signal Low 3075 Cylinder 6 - Injector Cable Short Circuit (High Side to Low Side) 3076 Cylinder 2 - unclassifiable error in injector 3077 Cylinder 2 - Injector Cable Short Circuit (Low Side to Battery) 3078 Cylinder 2 - Signal Low 3079 Cylinder 2 - Injector Cable Short Circuit (High Side to Low Side) 3080 Cylinder 4 - unclassifiable error in injector 3081 Cylinder 4 - Injector Cable Short Circuit (Low Side to Battery) 3082 Cylinder 4 - Signal Low 3083 Cylinder 4 - Injector Cable Short Circuit (High Side to Low Side)

Racine / Monthyon Training centers

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4 - ELECTRICAL

721F - 821F - 921F

ENGINE FAULT CODES LIST 3088 Crankshaft Sensor Has Lost Synchronization 3089 Crankshaft Sensor Is Defective 3090 Camshaft Sensor Has Lost Phase 3091 Camshaft Sensor Phase Synchronization Has Failed 3092 Offset Between Camshaft and Crankshaft Is Not Plausible 3093 Offset Between Camshaft and Crankshaft Is Outside Boundaries 3095 Backup Mode - Operating With Camshaft Sensor Only 3096 ECM BusOff on Vehicle CAN bus 3097 ECM BusOff on Engine private CAN bus 3098 Timeout of CAN Message TSC1-TE (When Active) 3099 Timeout of CAN Message TSC1-TE (When Inactive) 3100 Timeout of CAN Message TSC1-AE (When Active) 3101 Timeout of CAN Message TSC1-AE (When Inactive) 3102 Rail Pressure Sensor CP3 Signal Is Below Minimum Range 3104 Rail Pressure Relief Valve Is Open 3105 Rail Pressure Relief Valve Requests Pressure Shock 3106 Rail Pressure Relief Valve Did Not Open After Pressure Shock 3107 Metering Unit Is Short Circuited To The Battery 3108 Metering Unit Is Short Circuited To Ground 3110 Rail Pressure Sensor Offset Monitoring Signal Is Above Maximum Range 3111 Rail Pressure Sensor Offset Monitoring Signal Is Below Minimum Range 3112 Rail Pressure Sensor CP3 Signal Is Above Maximum Range 3113 Main Relay 1 (High Pressure Pump) Shorted to Battery 3114 Main Relay 1 (High Pressure Pump) Shorted To Ground 3118 Engine Controller 12V Sensor Supply Voltage Is Above the Upper Limit 3119 Engine Controller 12V Sensor Supply Voltage Is Below The Lower Limit 3131 Grid Heater Always Switched On 3133 Cold Start Lamp - No Load 3134 Cold Start Lamp - Shortcircuit to Battery 3135 Cold Start Lamp - Shortcircuit to Ground 3136 Cold Start Lamp - Excessive Temperature 3137 Metering Unit Has An Open Load 3138 Metering Unit Signal Is Not Plausible 3141 Set point Of The Fuel Volume Flow Through Metering Unit Is Lower Than The Calculated Limit 3142 High pressure test - test active 3145 Terminal 15 - No Signal 3147 Oil Temperature Sensor Signal Is Above Normal Range 3148 Coolant Temperature Sensor Dynamic Test - Failure (Minimum Temperature Raise Not Reached) 3154 Grid Heater Relay Is Short Circuited To Battery 3155 Grid Heater Relay Is Short Circuited To Ground 3156 Grid Heater Relay Has No Load 3157 Engine Dataset Information Was Not Available From EDC In Required Time 3158 Engine Dataset Does Not Match Dataset Registered For This Machine 3160 Fan Actuator Short Circuit to Battery 3161 Fan Actuator Short Circuit to Ground 3162 Fan Actuator - No Load 3163 Fan Actuator Temperature Too High 3166 Fuel filter heater relay short to VCC 3167 Fuel filter heater relay short to ground 3168 Fuel filter heater relay disconnected or open circuit 3169 Fuel Filter Heater Relay Signal Not Plausible 3176 Fuel Delivery Exceeded Threshold For Pressure In Overrun Mode 3177 Engine Overspeed Detected 3178 Timeout of CAN Message BC2EDC1 3179 Timeout of CAN Message BC2EDC2 3180 Timeout of CAN Message VCM2EDC 3181 Rail Pressure Positive Deviation Too High Concerning Setpoint 3182 Timeout of CAN Message RxCCVS 3183 Timeout of CAN Message TSC1-VR (When Active) 3184 Timeout of CAN Message TSC1-VR (When Inactive) 3185 Timeout of CAN message TF

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Racine / Monthyon Training centers

721F - 821F - 921F 4 - ELECTRICAL ENGINE FAULT CODES LIST 3188 Cylinder1 Has An Open Load 3192 Cylinder2 Has An Open Load 3196 Cylinder3 Has An Open Load 3200 Cylinder4 Has An Open Load 3204 Cylinder5 Has An Open Load 3208 Cylinder6 Has An Open Load 3210 Bank1 - General Short Circuit On Injection Cable 3211 Bank1 - Injection Cable Is Short Circuited On Low Side To Ground 3212 Bank1 - No Signal 3213 Bank1 - Unclassifiable Error 3218 Bank2 - General Short Circuit On Injection Cable 3219 Bank2 - Injection Cable Is Short Circuited On Low Side To Ground 3220 Bank2 - No Signal 3221 Bank2 - Unclassifiable Error 3227 Injection Processor (CY33X) Error - Internal Reset / Clock Loss / Voltage Too Low 3228 Injection Processor (CY33X) Error - Unlocked / Initialization Failure 3229 Injection Processor (CY33X) Error - Injections Limited By Software 3230 Injection Processor (CY33X) Error - SPI Communication Failure 3231 Injection Processor Error - Internal Reset / Clock Loss / Voltage Too Low 3232 Injection Processor Error - Unlocked / Initialization Failure 3233 Injection Processor Error - Test Mode 3234 Injection Processor Error - SPI Communication Failure 3238 ECM Internal SPI Communication Error - CJ940 3239 ECM EEPROM - Read Operation Failure 3240 ECM EEPROM - Write Operation Failure 3241 ECM EEPROM - Default Value Used 3242 ECM (Locked) Recovery Occurred 3243 ECM Recovery (Suppressed) - Recovery Occurred 3244 ECU Recovery (Visible) - Recovery Occurred 3245 ECM Processor - Watchdog Not Plausible 3246 Shutoff Paths During Initialization - Watchdog 3247 Shutoff Paths During Initialization - Supply Voltage Too High 3248 Shutoff Paths During Initialization - Supply Voltage Too Low 3249 TPU Monitoring - Time Deviation between TPU and System Not Plausible 3250 Dataset - Variant Defect 3251 Dataset - Requested Variant Could Not Be Set 3252 Controller Watchdog - SPI Communication Failure 3253 ADC Monitoring - Reference Voltage Too High 3254 ADC Monitoring - Reference Voltage Too Low 3255 ADC Monitoring - Test Impulse Error 3256 ADC Monitoring - Queue Error 3258 High Side Power - Shortcircuit to Battery 3259 High Side Power - Shortcircuit to Ground 3260 Low Side Power - Open Load 3261 Low Side Power - Shortcircuit to Battery or Excess Temperature 3262 Low Side Power - Shortcircuit to Ground 3265 Overrun Monitoring - Injection Time Too Long 3266 Redundant Engine Speed in Overrun Monitoring - Speed Signal Not Plausible 3267 Main Relay 3 Failure - Shorted To High Source 3268 Main Relay 3 Failure - Shorted To Low Source 3278 The ECU Supply Voltage CJ940 Is Above Its Upper Limit 3279 The ECU Supply Voltage CJ940 Is Below Its Lower Limit 3280 Sensor Supply Voltage 1 - High 3281 Sensor Supply Voltage 1 - Low 3283 Sensor Supply Voltage 2 - High 3284 Sensor Supply Voltage 2 - Low 3285 Sensor Supply Voltage 3 - High 3286 Sensor Supply Voltage 3 - Low 3290 Turbo Compound Monitoring Error - Signal Not Plausible 3297 Rail Pressure Positive Deviation High And Fuel Flow Setpoint Value High 3301 Rail Pressure Negative Deviation Too High On Minimum Metering 3305 Rail pressure below minimum limit in controller mode Racine / Monthyon Training centers

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4 - ELECTRICAL

721F - 821F - 921F

ENGINE FAULT CODES LIST 3309 Rail pressure above maximum limit in controlled mode 3313 Rail Pressure Drop Rate Is Higher Than Expected 3315 Minimum Number of Injections Not Reached - Stop Engine 3316 Minimum Number of Injections Not Reached - Stop Engine 3317 Minimum Number of Injections Not Reached - Stop Engine 3318 Minimum Number of Injections Not Reached - Stop Engine 3319 DM1DCU SPN2 Message - Error In DCU Active 3320 DM1DCU SPN3 Message - Error In DCU Active 3321 DM1DCU SPN4 Message - Error In DCU Active 3322 DM1DCU SPN5 Message - Error In DCU Active 3334 Timeout of CAN message TSC1-PE Torque (When Active) 3335 Timeout of CAN message TSC1-PE Torque (When Inactive) 3338 Timeout of CAN message TSC1-VE Speed (When Inactive) 3339 Timeout of CAN message TSC1-VE Speed (When Active) 3350 Terminal 50 - Always On 3354 Main Relay 4 (Engine Brake Exhaust Valve) - Shortcircuit to Ground 3355 Main Relay 4 (Engine Brake Exhaust Valve) - Shortcircuit to Battery 3358 CAN Transmit Timeout 3363 Atmospheric Pressure Sensor Signal Is Not Plausible 3367 Coolant temperature test failure 3368 INFO: Torque limitation due to OBD Performance Limiter by legislation 3369 INFO: Torque reduction due to smoke reduction 3370 INFO: Torque limitation due to Engine Protection ( torque, engine overspeed, and overheating) 3371 INFO: Torque limitation due to Fuel Quantity Limitation because of injector system errors 3512 DCU State Monitoring - DCU Not Ready In Time 3513 SCR Catalyst Not Present - Relation Of Temp Behaviour Between Both Catalyst Temp Not Plausible 3517 Ambient Air Temperature Sensor Failure (Of Humidity Sensor) - Signal Too High 3518 Ambient Air Temperature Sensor Failure (Of Humidity Sensor) - Signal Too Low 3521 NOx Estimation Failure - Estimated NOx Signal Not Reliable 3528 NOx Sensor Plausibility Failure - Signal Not Plausible 3529 NOx Sensor Failure - Open Load 3530 NOx Sensor Failure - Short Circuit 3532 NOx Sensor Failure - Sensor Not Ready In Time 3533 CAN Message Timeout - NOx (From NOx Sensor) 3537 CAN Message Timeout - DM1DCU (From DCU) 3541 CAN Message Timeout - SCR1 (From DCU) 3545 INFO: SCR Dosing Valve Overheat Protection - Torque Limit Level2 For SCR Protection Active 3546 INFO: SCR Dosing Valve Overheat Protection - Torque Limit Level1 For SCR Protection Active 3549 Humidity Sensor Signal Ratio Failure - Signal Ratio Above Limit 3550 Humidity Sensor Signal Ratio Failure - Signal Ratio Below Limit 3555 CAN Message Timeout - SCR2 (From DCU) 3557 INFO: Humidity Sensor Possibly Saturated With Water Droplets - Signal Ratio Above Limit 3558 INFO: Humidity Sensor Possibly Saturated With Water Droplets - Signal Ratio Below Limit 3561 NOx Value Not Plausible (Aftertreatment Plausibility) 3577 DM1DCU SPN1 Message - Error In DCU Active 3581 Performance Limitation Active Due To Either Stage 3585 Engine Shut Off Urea Level (After Idling Phase) 3586 Temperature After Catalyst Not Plausible 3587 Temperature Before Catalyst Not Plausible 3588 Ambient Temperature Of Humidity Or Both Catalyst Temperatures Not Plausible 3589 Deviation Between Up And Down Stream Catalyst Temperature Too High During Operation 3591 SCR Catalyst Thermal Aging Limit Exceeded - P0422 Main Catalyst Efficiency Below Threshold 3593 Poor Reagent Quality 3594 Torque Limitation Due To SCR 3599 Error Path Of Catalyst Not Present - P0421 Warm Up Catalyst Efficiency Below Threshold 3602 Defect Ratio Between Threshold Limits - P0425 Catalyst Temperature Sensor Circuit 3611 Catalyst Efficiency Lower Than First NOx Prediction Threshold Level 3612 Catalyst Efficiency Lower Than Second NOx Prediction Threshold Level 3613 Efficiency Of Catalyst System Too High 3614 SRA2EDC - High Effort Fault 3615 SRA2EDC - Initialization Fault 3616 Torque Limitation Due To Turbo Charger Protection 4 - 18

Racine / Monthyon Training centers

721F - 821F - 921F 4 - ELECTRICAL TRANSMISSION FAULT CODES LIST 4113 Logical error at FNR switch of gear shift unit. 4114 Logical Error At Direction Select Signal 4116 Logical Error At Parkbrake Status 4117 Logical Error At Direction Select Signal 2 4119 Short Circuit To Ground At Ride Control 4120 Short Circuit To Battery Voltage At Ride Control 4121 Open Circuit At Ride Control 4122 Short Circuit To Ground At Brake Light 1 4123 Short Circuit To Battery Voltage At Brake Light 1 4124 Open Circuit At Brake Light 1 4125 Short Circuit To Ground At Brake Light 2 4126 Short Circuit To Battery Voltage At Brake Light 2 4127 Open Circuit At Brake Light 2 4133 Short Circuit To Battery Voltage Or Open Circuit At Transmission Sump Temperature Sensor Input 4134 Short Circuit To Ground At Transmission Sump Temperature Sensor Input 4135 Short Circuit To Battery Or Open Circuit At Retarder / Torque Converter Output Temp Sensor 4136 Short Circuit To Ground At Retarder / Torque Converter Output Temperature Sensor 4138 Inch Sensor - Signal Mismatch 4145 Short Circuit To Battery Voltage Or Open Circuit At Engine Speed Input 4146 Short Circuit To Ground At Engine Speed Input 4147 Logical Error At Engine Speed Input 4148 Short Circuit To Battery Voltage Or Open Circuit At Turbine Speed Input 4149 Short Circuit To Ground At Turbine Speed Input 4150 Logical Error At Turbine Speed Input 4151 Short Circuit To Battery Voltage Or Open Circuit At Internal Speed Input 4152 Short Circuit To Ground At Internal Speed Input 4153 Logical Error At Internal Speed Input 4154 Short Circuit To Battery Voltage Or Open Circuit At Output Speed Input 4155 Short Circuit To Ground At Output Speed Input 4156 Logical Error At Output Speed Input 4158 Output Speed Zero Does Not Fit To Other Speed Signals 4180 Message From Vehicle Controller Has Timed Out 4181 Joystick Steering - JSS Joystick CAN Message Time Out 4182 Timeout of CAN Message of Engine Configuration 4183 Timeout of CAN Message EEC1 4184 Timeout of CAN Message EEC3 4185 CAN Bus - Test Mode message is defective or was not received 4193 CAN Bus - AEB Request CAN message was not received 4197 CAN Bus - Engine Torque message is defective or was not received 4201 CAN Bus - Engine Reference Torque message is defective or was not received 4202 CAN Bus - Engine Actual Torque message is defective or was not received 4203 CAN Bus - Engine Nominal Friction Torque message is defective or was not received 4206 CAN Bus - Engine EEC2 message was not received 4209 Short Circuit To Battery Voltage At Clutch K1 4210 Short Circuit To Ground At Clutch K1 4211 Open Circuit At Clutch K1 4212 Short Circuit To Battery Voltage At Clutch K2 4213 Short Circuit To Ground At Clutch K2 4214 Open Circuit At Clutch K2 4215 Short Circuit To Battery Voltage At Clutch K3 4216 Short Circuit To Ground At Clutch K3 4217 Open Circuit At Clutch K3 4218 Converter Clutch Short Circuit To Battery Voltage 4219 Converter Clutch Short Circuit To Ground 4220 Converter Clutch Open Circuit 4225 Short Circuit To Battery Voltage At Clutch K4 4226 Short Circuit To Ground At Clutch K4 4227 Open Circuit At Clutch K4 4228 Short Circuit To Battery Voltage At Clutch KV 4229 Short Circuit To Ground At Clutch KV 4230 Open Circuit At Clutch KV

Racine / Monthyon Training centers

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4 - ELECTRICAL

721F - 821F - 921F

TRANSMISSION FAULT CODES LIST 4231 Short Circuit To Battery Voltage At Clutch KR 4232 Short Circuit To Ground At Clutch KR 4233 Open Circuit At Clutch KR 4234 Short Circuit To Ground of DLM Transversal Output 4235 Short Circuit To Battery At DLM Transversal Output 4236 Open Circuit At DLM Transversal Output 4241 Short Circuit To Ground At Relay Reverse Warning Alarm 4242 Short Circuit To Battery Voltage At Relay Reverse Warning Alarm 4243 Open Circuit At Relay Reverse Warning Alarm 4273 Slippage At Clutch K1 4274 Slippage At Clutch K2 4275 Slippage At Clutch K3 4276 Slippage At Clutch K4 4277 Slippage At Clutch KV 4278 Slippage At Clutch KR 4279 Transmission sump temperature is too high 4281 Engine speed overspeed condition detected 4282 Voltage At Oil Filter Maintenance Switch Out Of The Allowed Range (Dirty Filter) 4283 Converter lock up clutch slippage was detected when not expected 4284 Transmission Output Speed Is Too High 4288 Engine Torque Or Engine Power Overload 4289 Transmission Output Torque Overload 4290 Transmission Input Torque Overload 4291 Oil Temperature At Converter Output Is Above Limit 4292 Short Circuit To Ground At Joystick Status Indicator 4293 Short Circuit To Battery Voltage At Joystick Status Indicator 4294 Open Circuit At Joystick Status Indicator 4298 CAN Bus - Engine Retarder Configuration message was not received 4299 CAN Bus - Engine ERC1 message was not received 4305 Short Circuit To Battery Voltage At Power Supply For Sensors 4306 Short Circuit To Ground At Power Supply For Sensors 4307 Battery voltage is too low 4308 Battery voltage is too high 4309 Error At Solenoid Power Supply VPS1 4310 Error At Solenoid Power Supply VPS2 4323 Display Output Short Circuit to Battery Voltage 4324 Display Output Short Circuit to Ground 4325 Vehicle Id#1 Timeout 4326 CAN Bus - Illegal CAN request for VIN / ID 4337 General EEPROM Fault 4338 Configuration Error 4339 General Application Error (ZF Internal) 4341 Clutch Calibration Fault 4342 Clutch Adjustment Data Lost Or Inch Pedal Calibration Data Lost

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Racine / Monthyon Training centers

721F - 821F - 921F 4 - ELECTRICAL INTERNAL AIC & CAN BUS FAULT CODES LIST 9100 CreateMbx 20ms DM1 BAM 9101 AddMsg DM1 BAM 9102 AddMsg DM1 PCK 9103 Timeout Packet 9104 Missed Packed 9105 CreateMbx 20ms DM1 PACKETS 9106 InitCAN, check diagmsg 9107 InitCAN, check diagmsg 9108 InitCAN, check diagmsg 9110 Error Index Out Of Range In Set Error 9111 Null Error !, Not Permitted 9121 Logical Error When Retrieving Flash Data 9122 Logical Error When Retrieving Flash Data 9123 Logical Error When Retrieving Flash Data 9124 Logical Error When Retrieving Flash Data 9125 Never Started Receiving Message 9126 Never Started Receiving Message 9127 Never Started Receiving Message 9128 CAN Timed Out During Operation 9129 CAN Timed Out During Operation 9130 CAN Timed Out During Operation 9132 CAN Timed Out During Operation 9133 Never Started Receiving Message 9134 Timeout of C5.E CAN Message Detected By AIC 9135 Timeout of JSC CAN Message Detected By AIC 9136 CAN Message Stopped From The Speed Limit Module C5F 9138 Hardware Part Number Unknown In Software 9140 Logical Error in List 0 9141 Logical Error in List 1 9142 Logical Error in List 2 9143 Logical Error in List 3 9144 Logical Error in List 4 9145 Logical Error in List 5 9146 Logical Error in List 6 9147 Logical Error in List 7 9152 Logical Error When Retrieving Flash Data 9153 Logical Error When Retrieving Flash Data 9154 Logical Error When Retrieving Flash Data 9155 Logical Error When Retrieving Flash Data 9156 Logical Error When Retrieving Flash Data 9157 Logical Error When Retrieving Flash Data 9160 Hour Meter Failure - Both Copies Wrong 9161 Hour Meter Failure - One Of Two Copies Wrong 9162 Hour Meter Failure - Pre-Crank And After-Crank Check Wrong 9173 SCR controller CAN timeout 9174 SCR controller CAN did not start 9175 CreateMbx 20ms DM1 BAM (SCR Controller) 9176 AddMsg DM1 BAM (SCR Controller) 9177 AddMsg DM1 PCK (SCR Controller) 9178 Timeout Packet (SCR Controller) 9179 CreateMbx 20ms DM1 PACKETS (SCR Controller) 9180 VCM Controller CAN Timeout 9181 VCM Controller CAN Did Not Start 9182 Wheel Loader Configuration Plausibility Failure - Wrong Engine Type

Racine / Monthyon Training centers

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4 - ELECTRICAL

721F - 821F - 921F

SCR FAULT CODES LIST 19001 Battery Voltage Sensing (Electrical) - Signal High (P0563) 19002 Battery Voltage Sensing (Electrical) - Signal Low - (P0562) 19003 Battery Voltage Sensing (Electrical) - Signal Above High Error Threshold (P0563) 19004 Battery Voltage Sensing (Electrical) - Signal Below Low Error Threshold (P0562) 19010 Temperature Sensor After Catalyst (Electrical) - Signal High (P042D) 19011 Temperature Sensor After Catalyst (Electrical) - Signal Low (P042C) 19019 Temperature Sensor Before Catalyst (Electrical) - Signal High (P0428) 19020 Temperature Sensor Before Catalyst (Electrical) - Signal Low (P0427) 19021 Temperature Sensor Before Catalyst (Electrical) - Signal Above High Error Threshold 19022 Temperature Sensor Before Catalyst (Electrical) - Signal Below Low Error Threshold 19037 Sensor Supply 2 (5V Internal; For Urea Pressure Sensors) - Supply Voltage Too High (P204D) 19038 Sensor Supply 2 (5V Internal; For Urea Pressure Sensors) - Supply Voltage Too Low (P204C) 19046 UREA Pressure Sensor In Box (Electrical) - Supply Voltage Error (P204A) 19047 UREA Pressure Sensor In Box (Electrical) - Signal High (P204D) 19048 UREA Pressure Sensor In Box (Electrical) - Signal Low (P204C) 19055 UREA Temperature Sensor In Box (Electrical) - Signal High (P2045) 19056 UREA Temperature Sensor In Box (Electrical) - Signal Low (P2044) 19057 UREA Temperature Sensor In Box (Electrical) - Out Of Range High (P2043) 19058 UREA Temperature Sensor In Box (Electrical) - Out Of Range Low (P2043) 19064 Volt. Supply Internal Heaters 1 (UB1) Electrical - Open Circuit To UB1 (P20C5) 19065 Volt. Supply Internal Heaters 1 (UB1) Electrical - Short To Battery At UB1 (P20C8) 19073 Volt. Supply 2 - Tube Heaters (UB2) Electrical - Short To Battery At UB2 (P20C4) 19074 Volt. Supply 2 - Tube Heaters (UB2) Electrical - Short Circuit To Ground UB2 (P20C3) 19075 Volt. Supply 2 - Tube Heaters (UB2) Electrical - Open Circuit To UB2 (P20C1) 19082 Volt. Supply 3 - Coolant Control & Reverting Valve (UB3) Electrical - Short To Battery (P20A3) 19083 Volt. Supply 3 - Coolant Control & Reverting Valve (UB3) Electrical - Short To Ground (P20A2) 19084 Volt. Supply 3 - Coolant Control & Reverting Valve (UB3) Electrical - Open Circuit (P20A0) 19091 Monitoring VDD11 Voltage - Dosing Valve - Supply Voltage High (P0659) 19092 Monitoring VDD11 Voltage - Dosing Valve - Supply Voltage Low (P0658) 19093 Monitoring VDD25 Voltage - Dosing Valve - Supply Voltage High (P0659) 19094 Monitoring VDD25 Voltage - Dosing Valve - Supply Voltage Low (P0658) 19100 UREA Level Sensor (Electrical) - Supply Voltage Error (P203E) 19101 UREA Level Sensor (Electrical) - Signal High (P203D) 19102 UREA Level Sensor (Electrical) - Signal Low (P203C) 19109 UREA Temperature Sensor In Tank (Electrical) - Signal High (P205D) 19110 UREA Temperature Sensor In Tank (Electrical) - Signal Low (P205C) 19145 Dosing Valve (Electrical) - Short Circuit To Battery (P2049) 19146 Dosing Valve (Electrical) - Short Circuit To Ground (P2048) 19147 Dosing Valve (Electrical) - Open Load (P2047) 19148 Dosing Valve (Electrical) - Dosing Valve Permanent «On» (Detection Via Fast Decay) (P209B) 19149 Dosing Valve (Electrical) - Short Circuit To Ground (P2048) 19150 Dosing Valve (Electrical) - Dosing Valve Permanent «On» (Detection Via Fast Decay) (P209B) 19154 UREA Pump Speed - Pump Motor Unplugged (P208B) 19155 UREA Pump Speed - Pump Motor Blocked (P208A) 19156 UREA Pump Speed - Pump Overspeed (P208D) 19157 UREA Pump Speed - Hall Sensors Defect (P208B) 19163 Cooling Control Valve - Short Circuit To Battery (P20A3) 19164 Cooling Control Valve - Open Load (P20A0) 19172 Cooling Control Valve - Short Circuit To Ground (P20A2) 19181 Reverting Valve Electrically - Short Circuit To Battery (P20A3) 19182 Reverting Valve Electrically - Short Circuit To Ground (P20A2) 19183 Reverting Valve Electrically - Open Load (P20A0) 19184 Reverting Valve Electrically - Short Circuit To Ground (P20A2) 19262 Tank Heating Valve - Short Circuit To Battery (P20B4) 19263 Tank Heating Valve - Short Circuit To Ground (P20B3) 19264 Tank Heating Valve - Open Load (P20B1) 19265 Tank Heating Valve - Short Circuit To Ground (P20B3) 19289 Temperature After Catalyst Too Low - Catalyst Heating Time Failed - (P042B) 19290 Temperature After Catalyst Too Low - Catalyst Heating Time Failed - (P042B) 19325 UREA Temperature In Tank Out Of Range (P205B)

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Racine / Monthyon Training centers

721F - 821F - 921F 4 - ELECTRICAL SCR FAULT CODES LIST 19334 System Frozen And Not Free In Time - Inlet Line Defreezing Failed (P20C2) 19335 System Frozen And Not Free In Time - Pressure Line Defreezing Failed (P20BE) 19336 System Frozen And Not Free In Time - Pressure Build-Up In Detection Mode Failed (P20C5) 19337 System Frozen And Not Free In Time - Back-Flow Line Defreezing Failed (P20B9) 19343 Coolant Control Valve Mechanically - Mechanical Defective Blocked Open (P20A3) 19344 Coolant Control Valve Mechanically - Mechanical Defective Blocked Closed (P20A0) 19352 Reverting Valve Mechanically - Valve Does Not Open (P20A0) 19361 Battery Voltage (Actual Value) - High Battery Voltage (P0562) 19362 Battery Voltage (Actual Value) - Low Battery Voltage (P0563) 19370 UREA Pressure Too Low - Pump Motor Error During Commissioning (Pump Not Delivering) (P208B) 19379 UREA Temperature Too Low During Commissioning - Temp. Not Plausible During Commissioning 19415 Empty UREA Tank Empty (P203F) 19496 UREA Pressure Plausibility Error At System Startup - Pressure Above Threshold (P204B) 19505 UREA Box Temperature Plausibility Error (Dynamic/Static) - Out of Range (P2043) 19514 UREA Tank Temperature Plausibility Error (Dynamic/Static) - Out Of Range (P205B) 19532 Back Flow Line Clogged (P2063) 19541 Coolant Control Valve Mechanically - Blocked Closed (P20A1) 19550 Pressure Line Blocked (P209B) 19559 Low Urea Level 1 (Warning) - Urea Level Below Limit 1 (P203F) 19568 Low Urea Level 2 (Warning) - Urea Level Below Limit 2 (P203F) 19577 CAN Receive Frame Error - E2SCR - Urea Quantity Not In Range (P0600) 19578 CAN Receive Frame Error - E2SCR - Dosing Status Not In Range (P0600) 19579 CAN Receive Frame Error - E2SCR - Message Not Received (P0600) 19580 CAN Receive Frame Error - E2SCR - Too Many CAN Messages (P0600) 19581 CAN Receive Frame Error - E2SCR - SAE J1939 Check For CAN Receive Signal (P0600) 19595 CAN Receive Frame Error - EEC1 - Engine Torque Not In Range (P0600) 19596 CAN Receive Frame Error - EEC1 - Engine Speed Not In Range (P0600) 19597 CAN Receive Frame Error - EEC1 - Message Not Received (P0600) 19598 CAN Receive Frame Error - EEC1 (Driver Demand, Speed, Torque) - Too Many CAN Messages (P0600) 19599 CAN Receive Frame Error - EEC1 - Torque Driver Demand Not In Range (P0600) 19604 CAN Receive Frame Error - ET1 - Oil Temperature Not In Range (P0600) 19605 CAN Receive Frame Error - ET1 - Not Received (P0600) 19606 CAN Receive Frame Error - ET1 (Oil And Water Temp Engine) - Too Many Can Messages (P0600) 19607 CAN Receive Frame Error - ET1 - Water Temperature Not In Range (P0600) 19649 UREA Tank Level Error - No CAN Signal For Level Sensor - Sensor Supply Error (P203A Reagent) 19650 UREA Tank Level Error - CAN Signal Not In Range For Level Sensor - SRC High (P203D) 19651 UREA Tank Level Error - Erroneous CAN Signal For Level Sensor - SRC Low (P203C) 19652 UREA Tank Level Error - Sensor Signal/Message Timeout 19653 UREA Tank Level Error - Tank Level Sensor Too Many CAN Messages (P203C) 19654 UREA Tank Level Error - Tank Level Sensor Open Circuit (P203C) 19676 CAN Receive Frame Error - Ambient Air Temperature Signal Not In Range (P0600) 19677 CAN Receive Frame Error - Ambient Air Temperature Message Not Received (P0071) 19678 CAN Receive Frame Error - Ambient Air Temperature Sending Too Many CAN Messages (P0071) 19679 CAN Receive Frame Error - Ambient Air Temperature - Barometric Pressure Not In Range (P0071) 19721 EEPROM / Checksum Failures - EEPROM Write Error (P062F) 19722 EEPROM / Checksum Failures - No Corresponding Variant Number Error (P062F) 19723 EEPROM / Checksum Failures - EEPROM Communication Error (P062F) 19724 EEPROM / Checksum Failures - EEPROM Detection Error Or Codierwort Error (P062F) 19725 EEPROM / Checksum Failures - Wrong EEPROM Size (P062F) 19730 Ignition «On» Signal K15 - Digital Input Ignition On Not Sensed During Initialization (P2530) 19739 Main Relay - Main Relay Shut Off Too Late (P0687) 19740 Main Relay - Main Relay Short Circuit (P0685) 19741 Main Relay - Main Relay Open Circuit (P0687) 19742 Main Relay - Main Relay Shut Off Too Early (Before EEPROM Update) (P0685) 19748 UREA Temperature Too High In Pump Module (Emergency Shut Off) (P2043) 19749 UREA Leakage Test Failed (Emergency Shut Off) (Static Or Dynamic) (P202D) 19757 Group Error Path - Error Belonging To Group Urea Injection Control (P208B) 19766 Group Error Path - Error Belonging To Group Air Control (P20A7) 19775 Group Error Path - Error Belonging To Group Catalyst Temperature - Out Of Range (P0426) 19784 Group Error Path - Error Belonging To Group NOx Exceeded - Active (P2000) 19793 Group Error Path - Error Belonging To Group UREA Tank Empty - Active (P203F)

Racine / Monthyon Training centers

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4 - ELECTRICAL

721F - 821F - 921F

SCR FAULT CODES LIST 19802 19803 19804 19805 19806 19807 19808 19813 19817 19818 19822 19999

UREA Tank Temp Not Plausible With Pump Module Temp - Sensor Signal/Message Timeout (P0600) UREA Tank Temp Not Plausible With Pump Module Temp - Too Many CAN Messages (P0600) UREA Tank Temp Not Plausible With Pump Module Temp - Tank Temp Sensor Open Circuit (P205A) UREA Tank Temp Not Plausible With Pump Module Temp - Tank Temp Sensor Short To Battery (P205D) UREA Tank Temp Not Plausible With Pump Module Temp - Tank Temp Sensor Short To Ground (P205C) UREA Tank Temp Not Plausible With Pump Module Temp - Tank Temperature Too High (P205B) UREA Tank Temp Not Plausible With Pump Module Temp - Tank Temperature Too Low (P205B) Startup Cycle Counter For Pressure Drop During Dosing (P208B) Plausibility Of Urea Dosing Valve Stuck - Dosing Valve Blocked (P202F) Plausibility Of Urea Dosing Valve Stuck - Dynamic Urea Leakage Test Leakage Detected (P202D) Urea Dosing Valve Stuck Position Unknown - Dynamic Urea Leakage Test Leakage Detected (P202D) Unknown DENOX Fault Code

AUTOMATIC ENGINE SHUT DOWN The AIC will have the ability shut down the engine in one of two modes: ECONOMY MODE Economy Mode is intended to provide a means for the operator to set the machine up so the engine and electrical system automatically shutdown after a set period of time while in an idle condition. ENGINE PROTECTION MODE Protection mode is intended to provide a higher level of system protection in addition to the engine specific protection system. This functionality must be set with EST in the menu CONFIGURATION / vehicle Options

Through the AIC menus the operator is able to turn the feature ON and OFF along with setting the timeout interval (5-60 min. in 5 min. increments)

Conditions for Shutdown: 1- Transmission in Neutral 2- Vehicle not moving 3- Engine at Idle Shutdown Parameters: Engine Oil Pressure < 10 psi 0.7bar Engine Coolant Temp > 230°F 110 C° Trans Oil Temp > 257°F 125 C° Hydraulic Oil Temp > 230°F 110 C°

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Racine / Monthyon Training centers

721F - 821F - 921F 4 - ELECTRICAL AUTOMATIC ENGINE SHUT DOWN Engine running:

Key switch is turned ON ECB K1 is de-energized PRM-C is energized PRM-B is energized Pin 40 of the engine controller receives 24 volts through the fuse ECA - F9 and through the contact DC3-DC4 of the master switch: the engine is running (if yet started).

PIN 40 KEY SWITCH FUSED 24 Volts for engine running

Engine shuts down: Key switch is turned ON

The relay ECD F3/F4 finds ground through the AIC connector 1 pin 22 The relay ECB-K1finds a ground through the relay ECD F3/F4. ECB-K1 is energized. The 2 relays PRM-C and PRM-B get a disconnected ground and are switched OFF (de-energized) The Ignition line is no longer supplied with 24 Volts The pin 40 on the engine controller doesn’t receive 24Volt. The engine shuts down.

PIN 40 KEY SWITCH FUSED 0 Volt = AIC ENGINE SHUT DOWN SIGNAL

Racine / Monthyon Training centers

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4 - ELECTRICAL

721F - 821F - 921F

TRANSMISSION CLUTCH CALIBRATION & CHANGE MODEL Conditions for a successfull calibration: Transmission in neutral Engine revolution between 800 rpm and 1200 rpm Parking brake engaged Transmission sump temperature arround 75°C- 80°C (use the menu INFO 3 Iine 3) No related fault code with the transmission Machine stopped (0,0 km/H) NOTES: On machines equipped with powerinch (ICCO) on the transmission, turn off the POWERINCH in the AIC before warming up the transmission oil. Unsuccessfull calibration: In case of unsuccessfull calibation turn off the key switch to exit the calibration menu (In calibration menu the transmission cannot engage)

C LU T C H C A LIB R A T IO N P R O C E S S

C A LIB G /B C A LIB G /B

M ode init 2 m ax 2

A djust K 1

C A LIB G /B

A djust K 2

If conditions OK, start calibration

C onfirm P lease

C A LIB G /B C A LIB G /B A djust K 3

C A LIB G /B A djust K 4

If conditions not m et

C A LIB G /B A djust KV A djust K R

C A LIB G /B

C A LIB G /B

C A LIB G /B

C A LIB G /B

N ot P erm itted

N ot P erm itted

N ot P erm itted

N ot P erm itted

W hile M oving

O ilT em p too low P ress E S C

N ot in N eutral P ress E S C

P arkB rake O F F P ress E S C

C A LIB G /B

C A LIB G /B

N ot P erm itted

N ot P erm itted

E ngineR P M low P ress E S C

E ngineR P M H igh P ress E S C

C A LIB G /B N ot P erm itted O.ilT em p T oo H igh P ress E S C

P ress E S C

C A LIB G /B

If P rocessus

If P rocessus unsuccessfull

com pleted O K C A LIB G /B

C A LIB G /B C hange not done

C hange O K N ow sw itch off T he engine

CHANGE MODEL C hange M odel

521 F 621 F 721 F 821 F 921 F

E nt

C hange M odel E nt

C hange M odel

C hange M odel N o answ er from T ransm ission P ress E sc

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UP DN

ENT

If P rocessus failed on T rans , then all changes aborted

C hange O K N ow S w itch O ff T he key sw itch

P ress E sc

In P rocess !

If P rocessus com pleted O K for T rans , then A IC changed also

E sc aborts process . A rrow keys inactive .

O peration F ailed

ESC

S elect

C onfirm P lease

A djust W K F or m achine w ith torque converter Lockup (5 gears )

C hange M odel

C hange M odel

C hange not D one

C hange not D one

O peration F ailed

S hifter N ot in N eutral

P ress E sc

Racine / Monthyon Training centers

P ress E sc

C hange M odel C hange not D one T rans N ot in N eutral P ress E sc

721F - 821F - 921F 4 - ELECTRICAL PARKING BRAKE Normal operation At POWER UP park brake is engaged (i.e. no current to the solenoid). If operator puts in Forward / Reverse, the conditions to disengage the park brake (all needed, in order of checking) are: 1- Vehicle in operating mode (i.e. ignition key ON, and all AIC initialization finished) 2- Not in park brake test 3- Gear lever in Forward or Reverse 4- Brake accumulator pressure high enough If the Park Brake switch was in ON position, the operator switches to the OFF position. If it was already in the OFF position, the operator must cycle it ON and OFF. Then the park brake is disengaged If one condition 3 - 4 is not met, a corresponding message is shown on display. Depending of the case, a message will also explain what to do with the park brake switch, disengage or cycle. Example : It indicates the operator to change the parking brake switch position. Conditions to re-engage the park brake; any one criteria alone does it: 1- Loose accumulator brake pressure 2- Vehicle going in power off mode 3- Engine goes in AutoIdle 4- Operator switch to Park Brake ON Additionnally, the park brake can be automatically engaged when : System goes in accelerated idle mode System return to normal idle from low idle, by itself (i.e. not operator induced).

Park brake test This menu allows the operator to place the transmission into gear when the parking brake is applied. This will not happen otherwise Operator can select the park brake test in the menus.This engages immediately the park brake. If, for any reason, using pad keys, the operator leaves the specific park brake test, then the test mode is disengaged. When in test mode, AIC send via CAN the information to the ZF controller, which then allow engaging a gear simultaneously to having the park brake engaged. Before going in that mode, AIC checks the park brake switch is in ON position. If not, it shows a message screen requiring to engage park brake. The message screen “Ready” appear during the test if gearbox clutches are engaged (as indicated by ZF controller) and the 3rd gear manual is engaged. If those conditions are not met, then a message screen indicates to engage 3rd gear manual. With the transmission in 3rd gear and the park brake applied, the operator is to press the accelerator fully and view whether the machine moves. The test will not display whether the test was ssuccessfull or not. The operator must determine whether the machine has moved or not. The operator should have his foot over the brake pedal as well in case it does move.

Racine / Monthyon Training centers

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4 - ELECTRICAL

721F - 821F - 921F

FAN CONTROL Speed operation modes 1 Normal Operation mode 2 Fan Test at 100% (allow to set individually the max fan speed ) 3 Fan Test at 70% ( allow to set the fan speed needed to carry out the noise test) To adjust the fan speed the AIC sends a variable current to a proportionnal solenoid valve located into the fan reversing valve. The proportionnal solenoid valve adjusts the hydraulic motor pressure, which correspond then to a torque on the fan, hence a given speed. Then the fan PWM setpoint is the maximum required value from the 4 channels. The current default values are: Min Max Coolant (oulet or radiator) 1 70°C 85°C Air inlet Hydraulic Oil (return manifold) Transmission Oil (TCO)

2 3 4

70°C

85°C

70°C

85°C

70°C

85°C

When the clutch calibration process is engaged, the TCO temperature control channel is disabled, by setting is requirement to the minimum. Normal mode: - If the option AutoFan control is set : Fan speed is controlled Reversing is active Reversing can then be Manual or Automatic depending of the operator selection on the switch. - If the option AutoFan control is not set : Fan speed is maximum.

3 2

1

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4

Racine / Monthyon Training centers

721F - 821F - 921F 4 - ELECTRICAL Fan reversing modes 1 Disable mode 2 Manual mode 3 Auto mode Fan will reverse automaticlly when AIC option is selected in the Fan menu . It will also vary fIt will vary speeds according to various temperature sensors It will switch between manual and auto mode according to the position of the auto switch. Auto control ( ie manual + auto, by opposition to fixed speed) will be disabled only at the next power up, while it can be enabled any time by changing the option selection. I n Manual mode Reversing will last as long as the operator push on the button. After the time reversed identical to the automatic mode ( ie 20 sec at more than 1600 rpm, or 60 seconds in any case), the fan will go back to normal. If operator release and press again immediately , an other period will start. He can keep doing that as long as he would want, except that, if the temperature of coolant or of hydraulic drifted more than 3°C, the cycle will stop. When back to normal forward speed, nothing stops him to do it again. In Auto mode Auto mode simply start a cycle exactly like if the operator pushes on the manual button. It does it after 30 minutes since the last reversing cycle (whether that last one was initiated automatically, or manually).

In auto mode, a reversal will be initiated only when engine speed is > 1600 rpm. Once initiated, the cycle will go through in any case, according to the logic above, and another 30 mn delay will be initiated. A manual cycle can always be initiated, even if engine speed below 1600 rpm. In every case (manual or automatic), the fan reversal is disabled if hydraulic oil temperature is below 10°C. If it is a manual request, an error message is displayed on the screen, so that operator knows why it does not operate.

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4 - ELECTRICAL

721F - 821F - 921F

AUTO IDLE For 721F, 821F & 921F, 3 Idle speeds are defined: Low Idle 600 rpm Normal Idle 900 rpm Accelerated Idle 1200 rpm 1) Auto Idle Option not selected: Idle is constant at Normal Idle 2) Auto idle Option selected: Operation uses: Normal Idle Mode But 2 other states can occur: Accelerated Idle Mode Low Idle Mode Accelerated Idle mode is used when weather is cold and machine not warm enough, to accelerate warming up of hydraulics and engine. Low idle mode depends on the folowing conditions: Be in Normal Idle mode Coolant temp over limit (70°C) Engine speed below 1000 rpm Gear lever in Neutral If those conditions are met for 60 seconds consecutively, the system tries to set low idle. Note : When setting Low Idle, the system expect the actual engine speed to become below Low Idle + 100 rpm (= 700 rpm) within 6 seconds. If this does not happen, it will stay in Normal idle. C oolant T em p > 70C E ngine S peed < 1000 rpm T ransm ission in N E U T R A L

N O R M A L ID LE E ngine S peed = 900 rpm

A /C C lutch N O T O N

L O W ID L E C O N D IT IO N S 60 seconds

C oolant T em p < 60 C

D eactivates A ux F N R

E ngine S peed < 450 rpm P ark B rake

A /C C lutch O N

ENGAGED*

L ow Id le

S ystem V oltage < 24 V * O nly if N O T m oving

E ngine S peed = 7 00 rpm

T hrottle P osition > 32 % T ransm ission N O T N E U T R A L

G round S peed < 0 .1 K m /h C oolant T em p < 85 C T E ngine S peed < 1000 rpm

A C C E L E R A T E D ID L E C O N D IT IO N S

T ransm ission in N E U T R A L

60 seconds

S tart E ngine C oolant T em p > 95 C

N O R M A L ID LE E ngine S peed = 900 rpm

T hrottle P osition > 32 % E ngine S peed > 1300 rpm T ransm ission N O T N E U T R A L G round S peed > 0.1 kph

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Racine / Monthyon Training centers

A cce lerated Idle E ngine S peed = 1200 rpm P ark B rake = E ngaged

721F - 821F - 921F 4 - ELECTRICAL CIRCUIT OF THE AIC +BAT

Ignition K ey 15

+BAT

A IC , v e rs io n W h e e l L o a d e r

2:21

W ake U p 1 D oor S w itch

2:02

W ake U p 2

D IG 1 4K 7

4K7

R e s e rv e

+BAT D IG 2

2:03 4K7

B rake A ccu P ressure

D IG 3 4K7

B rakeP ressure S W

+BAT D IG 3

2:05

red

LD7 red

T ransm ission O il T em p.

L D 12 & D IG 11 g reen

P ark B rake S w itch

2:06

F an R eversal S W , M anual

LD 11

F an R eversal S W , A uto

LD8 & D IG 12 g reen

LD 18 D IG 2 5

D IG 2 6

D IG 5

E ngine C oolant T em p .

F uel Level LD17

2:07

D IG 6

L D 10 am b er

4K 7 +BAT

H ydraulic O il T em p.

LD 16

4K 7 +BAT

L D 15 am b er

LCD 128 H x 112 V p ixels

LD 5

LD9

+BAT

L D 14 yello w

L D 13 red

+BAT

2:04

LD1 & 2

LD3 & 4 yello w

LD6 b lu e

2:08

D IG 7 4K 7

Left T urn S w itch

2 :09

D IG 11 V re f

4K7 R ight T urn S w itch

2:10

5V S ensor O utput

5 V - O u t se n se A N 1 2 / a na lo g ue 12

D IG 12 4K 7 4K7

in te rn a l P C B T e m p e ra tu r

υ

2:12

a n a lo g u e 1 3 L ig h t s e n s e

C oupler S w itch

1:14

a n a lo g u e 9

D IG 17

LS D 5

4K 7

1:20

C N H ref.n o .

2:16

K eyS W S tartP osition

2 :17

5 0a

2 :18

D IG 24

2 :19

D IG 25

C u rr en t s e n s e A N 7/ an al o gu e7

R eserve

2:23

C u rr en t s en s e A N 6/ an al o gu e6

D IG 26

PW M

HSD1

B uzzer

1:13 HSD2 1:25 HSD4 1:07 HSD4 1:26 HSD5 1:19

K eypad P ow er S upply D om e Light F an S peed C ontrol V alve E ther S tart

V oltm eter Input

1:15

D IG 27

a n a lo g u e 2

D IG 28

D IG 29

1:18

D IG 30

F r o nt A xle T e m p 1:08

+5V0

R ad i at o r T e m p 1:11

P o we r G ND 2 : 15

3 5 2 0R @ 2 0 °C

+BAT 664 R

Br ak e Pre ss u re 1 :10

Se n so r GND

Po w e r GND

3 5 2 0R @ 2 0 °C

664 R

a n a lo g u e 5

1 :1 2

1 :0 3

1 :0 4

F req Input 30 -600 H z

3 5 2 0R @ 2 0 °C

664 R

AN6

C AN L o

C AN H i

Ba tte ry P e r m a ne n t 2 :2 0

120R

Ba tte ry P e r m a ne n t

2:24

S pecial Input

2 :1 4

R e se rv e

2:26

+5V0

+ 5V 0 D IG 31

1:24 C oolant Level S ense

H y d r a u li c O i l T e m p 1:09

AN7

+BAT

3 5 2 0R @ 2 0 °C

664 R

a n a lo g u e 1 1

4K 7 4K7

R e a r A xle T e m p 1:05

+5V0

AN5

a n a lo g u e3

33 R ...240 R

664 R

AN4

a n a lo g u e 4

1:17

R e s e rv e

1:02

+ 5V 0

AN3

1:16

4K 7 A lternate Idle

F u e l L e ve l

a n a lo g u e1

4K 7 C om fort S teer «C om fort »

664 R

AN2

C ha s s is GND

C om fort S teer «S tandard»

1:01

+ 5V 0

Racine / Monthyon Training centers

4 -2 0 m A

a n a lo g u e 0

P .S e ns o r

D IG 34

2 :2 2

S ervice B rake S W

664 R

AN1

4K 7

+BAT

P ilot C ontrols R elayd

24 0 R

2 :25 4K 7

+BAT

PW M

+ 5V 0

R e s e rv e

+BAT

V alve P arking B rake R elayd

4K 7

5 V S ensor O ut

+BAT

P W M5

R eserve

4K7 +BAT

PW M

PWM3

4K7 +BAT

PW M

D IG 23 4K7

P ilot C ontrol S w itch

E ngine S hutdow n R elay

a na lo g u e8

+BAT

PW M

an al og u e1 0

+BAT

C om fort S teering V alve

C A S E B rand : 87372814

D IG 22 4K 7

G ro u n d se n se A N A _ G N D _ C/

+BAT

LS D 4

AN9/

2:13

5 V S ensor S upply

F an reversal

1:23

PW M8

W ait to S tart sw itch

LS D 3

A N 1 3/

D IG 16 4K 7

+BAT

1:22

PWM 2

R eserve

LS D 2

D IG 15

2:11 +BAT

1:21

PWM4

S t e er in g P r e s s u r e S W

2 :0 1

LS D 1 +BAT

1 :0 6

+BAT

Gr o un d s en se A N A _ G N D _S /

+BAT

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4 - ELECTRICAL

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721F - 821F - 921F

Racine / Monthyon Training centers