CUMMINS DIESEL

ENGINE FAULT CODE

GUIDE

H40.00-52.00XM-16CH

(H1050, 1150HD-CH) [E117]; RS45-27CH,

RS45-30CH, RS45-27IH, RS46-33CH, RS46-30IH,

RS46-36CH, RS46-33IH First Used on 1563,

1566, 1567, 1568, 1570, and Up [A222]

PART NO. 1573930

600 SRM 1172

SAFETY PRECAUTIONS

MAINTENANCE AND REPAIR

• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly

fastened, and that the load being lifted is balanced. Make sure the crane, cables, and
chains have the capacity to support the weight of the load.

• Do not lift heavy parts by hand, use a lifting mechanism.

• Wear safety glasses.

• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair

on electric lift trucks. Disconnect the battery ground cable on internal combustion lift
trucks.

• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT

THE LIFT TRUCK ON BLOCKS in the Operating Manual or the Periodic Mainte-
nance section.

• Keep the unit clean and the working area clean and orderly.

• Use the correct tools for the job.

• Keep the tools clean and in good condition.

• Always use HYSTER APPROVED parts when making repairs. Replacement parts

must meet or exceed the specifications of the original equipment manufacturer.

• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before

using force to remove parts.

• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs,

or if the unit needs repairs.

• Be sure to follow the WARNING and CAUTION notes in the instructions.

• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel

are flammable. Be sure to follow the necessary safety precautions when handling these
fuels and when working on these fuel systems.

• Batteries generate flammable gas when they are being charged. Keep fire and sparks

away from the area. Make sure the area is well ventilated.

NOTE: The following symbols and words indicate safety information in this
manual:

WARNING

Indicates a condition that can cause immediate death or injury!

CAUTION

Indicates a condition that can cause property damage!

Cummins Diesel Engine Fault Code Guide

Table of Contents

TABLE OF CONTENTS

General ...............................................................................................................................................................

1

Description .........................................................................................................................................................

1

Base Control System .....................................................................................................................................

1

Fault Code Snapshot Data ............................................................................................................................

1

Maintenance Monitor (A222 Only) ...................................................................................................................

2

General ...........................................................................................................................................................

2

Electronic Throttle Calibration .........................................................................................................................

2

Electronic Throttle Calibration Procedure...................................................................................................

2

Fault Codes ........................................................................................................................................................

2

General ...........................................................................................................................................................

2

E117................................................................................................................................................................

3

Access .........................................................................................................................................................

3

Exit.............................................................................................................................................................

4

A222................................................................................................................................................................

4

Access .........................................................................................................................................................

4

Exit.............................................................................................................................................................

4

This section is for the following models:

H40.00-52.00XM-16CH (H1050, 1150HD-CH) [E117];

RS45-27CH, RS45-30CH, RS45-27IH, RS46-33CH, RS46-30IH, RS46-36CH,

RS46-33IH First Used on 1563, 1566, 1567, 1568, 1570, and Up [A222]

©2005 HYSTER COMPANY

i

"THE

QUALITY

KEEPERS"

HYSTER

APPROVED

PARTS

600 SRM 1172

Description

General

This section covers the base control system, electronic throttle calibration, and the dash display fault codes for
the Cummins diesel engine.

Description

BASE CONTROL SYSTEM

The engine control system is an electronically-oper-
ated fuel control system that also provides many op-
erator, vehicle, or equipment features.

The base functions of the control system include fu-
eling and timing control, limiting the engine speed
operating range between the low and high idle set
points, and reducing exhaust emissions while opti-
mizing engine performance. The system can also con-
trol the engine brakes, up to two cooling fans, an air
compressor, and a powershift transmission.

The control system uses inputs from the operator and
its sensors to determine the fueling and timing re-
quired to operate at the desired engine speed.

The electronic control module (ECM) is the control
center of the system. It processes all of the inputs
and sends commands to the fuel system, vehicle, and
engine control devices.

The ECM performs diagnostic tests on most of its cir-
cuits and will activate a fault code if a problem is de-
tected in one of these circuits. Along with the fault
code identifying the problem, a snapshot of engine
operating parameters at the time of fault activation
is also stored in memory.

Active fault codes will cause a diagnostic light to
come ON and alert the operator.

The control system utilizes a number of sensors to
provide information on engine operating parameters.
These sensors include the following:
• Coolant Temperature Sensor
• Intake Air Temperature Sensor
• Intake Manifold Pressure Sensor
• Oil Pressure/Temperature Sensor
• Engine Position Sensor
• Ambient Air Pressure Sensor
• Fuel Inlet Restriction Sensor

The following inputs are provided by original equip-
ment manufacturer (OEM) selected devices:
• Accelerator Pedal Position Sensor
• Idle Validation Switch
• Diagnostic Switch (E117 only)
• Increment/Decrement Switch (E117 only)

FAULT CODE SNAPSHOT DATA

This is additional fault code information, which can
be obtained by using INSITE™. The snapshot data
records the value or state of the control system sen-
sors and switches at the time a fault occurred. This
data is stored for the first occurrence of the fault,
since it was last cleared, and the most recent occur-
rence. This data can be very valuable when trying to
recreate or determine engine operating conditions at
the time of a fault.

The operator or technician can create a snapshot of
the engine’s operating conditions and the state of the
control system’s sensors and switches. This is per-
formed using the diagnostic switch while the engine
is running.

1

Fault Codes

600 SRM 1172

Maintenance Monitor (A222 Only)

GENERAL

The maintenance monitor (oil change monitor) fea-
ture provides a method of monitoring the oil change
interval in the engine and signaling the operator
when an oil change is needed.

The maintenance

monitor counts the hours of engine operation and
subtracts this from the oil change interval time.
The maintenance monitor feature also allows for

extended oil change intervals when the customer is
using such products as Premium Blue 2000. Pro-
gramming tools can be used to display the percent of
the current interval that has been consumed.

When a certain calibrated percentage of the oil
change interval time has been used, the mainte-
nance light will flash when the key is turned to ON
and a warning flag is set.

Electronic Throttle Calibration

The electronic throttle calibration is advised after
any throttle adjustment or throttle sensor replace-
ment. It is also advised when the main power has
been disconnected, such as changing the batteries or
disconnecting the batteries for maintenance.

ELECTRONIC THROTTLE CALIBRATION
PROCEDURE

1.

Turn the ignition ON.

2.

Press the throttle slowly to maximum throttle,
and then fully release the throttle.

3.

Repeat this procedure three times.

NOTE: Not performing the calibration will generate
the fault code E0431, but eventually the performance
of the lift truck (E117) or ReachStacker

®

(A222) will

return to normal operation.

Fault Codes

GENERAL

The control system can show and record operation
anomalies, which present themselves as fault codes.
These codes will make troubleshooting easier. The
fault codes are recorded in the engine control module
(ECM). They can be read using the fault lights in the
cab panel or with INSITE™.

The two types of fault codes are as follows:
• Engine electronic control fault codes: A fault has

been detected with the engine or control system.

• Information codes: An event that could provide im-

portant information has occurred with the engine
or control system.

All fault codes recorded will either be active (fault
code is currently active on the engine) or inactive

(fault code was active at some time, but is not cur-
rently active).

The warning light is yellow and indicates the need
to repair the fault at the first available opportunity.
See Figure 1 or Figure 2.

The stop light is red and indicates the need to stop
the engine as soon as it can be safely done. The en-
gine should remain shut down until the fault can be
repaired. See Figure 1 or Figure 2.

The maintenance light will be ON when some type
of maintenance is required. This light could indicate
water in the fuel filter, low crankcase oil level, low
coolant level, high coolant temperature, high intake
air temperature, or high oil temperature. See Fig-
ure 1 or Figure 2.

2

600 SRM 1172

Fault Codes

1.

YELLOW WARNING LIGHT

2.

RED STOP LIGHT

3.

YELLOW MAINTENANCE LIGHT

4.

DIAGNOSTIC SWITCH

5.

INCREMENT/DECREMENT SWITCH

Figure 1. Error Code Display (E117)

E117

Access

To check for active engine electronic fuel system and
engine protection system fault codes, proceed as fol-
lows:

1.

Place the lift truck on a solid, level surface.

2.

Apply the park brake.

3.

Turn the key switch OFF and move the diagnos-
tic switch to the ON position. See Figure 1.

4.

Turn the lift truck key switch to the ON position.

NOTE: If no active fault codes are recorded, both
lights will be ON and stay ON.

If active fault codes are recorded, both lights will be
ON momentarily, then begin to flash the code of the
recorded faults. For descriptions of error codes, see
Table 1.

The fault code will flash in the following sequence:
1.

First, the yellow warning light will flash. Then,
there will be a short one- or two-second pause.
After that, the number of the recorded fault code
will flash in red. There will be a one- or two-sec-
ond pause between each number. When the num-
ber has finished flashing in red, a yellow light
will appear again. The three-digit code will re-
peat in the same sequence.

2.

The lights flash each fault code out three times
before advancing to the next code. To skip to
the next fault code, move the increment/decre-
ment switch momentarily to the increment (+)
position. See Figure 1. To go back to the pre-
vious fault code, momentarily move the incre-
ment/decrement switch to the decrement ( ) po-
sition. If only one active fault is recorded, the
same fault code will continuously be displayed
when either (+) or ( ) switch is pressed.

3

Fault Codes

600 SRM 1172

1.

RED STOP LIGHT

2.

YELLOW WARNING LIGHT

3.

YELLOW MAINTENANCE LIGHT

Figure 2. Error Code Display (A222)

Exit

To exit the fault log mode, turn OFF the diagnos-
tic switch. If the diagnostic switch is left ON, some
faults may not be logged by the ECM.

A222

Access

In case of an active fault, indicated by the stop/warn-
ing/maintenance lights, select the diagnostic mode
and proceed as follows:
1.

Place the ReachStacker

®

on a solid, level surface.

2.

Apply the park brake.

3.

Shut down the engine.

4.

Turn the key switch to the ON position.

5.

Operate the throttle pedal three times, this de-
fines the throttle pedal as diagnostic switch.

The warning light will flash once to indicate the start
of the fault code sequence. The stop light will then
flash out a three digit code. Example: flash, flash,
pause indicates the number 2. This process repeats
until the diagnostic mode is switched OFF, or the
throttle pedal is operated. Each time the throttle
pedal is operated the next fault code is flashed by the
stop light. See Figure 2.

Exit

Turn the key switch to the OFF position to leave di-
agnostic mode.

4

600 SRM 1172

Fault Codes

Table 1. Error Code Descriptions

Fault Condition Present/Maintenance Required

Fault Code Readout

Limited Operating

Conditions

Warning Light

Engine Stop

Warning Light

Maintenance

Warning Light

Fault

Code

Description

ON

111

Engine control
module, critical
internal failure.

ON

115

Engine speed/position
sensor circuit, loss of
both signals from
magnetic pickup
sensor.

ON

121

Engine speed/position
sensor circuit, loss of
one signal from the
magnetic pickup
sensor.

ON

122

Intake manifold
pressure sensor #1
circuit, shorted high.

ON

123

Intake manifold
pressure sensor #1
circuit, shorted low.

ON

131

Accelerator pedal
position sensor
circuit, shorted high.

ON

132

Accelerator pedal
position sensor
circuit, shorted low.

ON

133

Remote accelerator
pedal position sensor
circuit, shorted high.

ON

134

Remote accelerator
pedal position sensor
circuit, shorted low.

ON

135

Engine oil pressure
sensor circuit,
shorted high.

ON

141

Engine oil pressure
sensor circuit,
shorted low.

ON

143

Engine oil pressure
low warning.

5

Fault Codes

600 SRM 1172

Table 1. Error Code Descriptions (Continued)

Fault Condition Present/Maintenance Required

Fault Code Readout

Limited Operating

Conditions

Warning Light

Engine Stop

Warning Light

Maintenance

Warning Light

Fault

Code

Description

ON

144

Engine coolant
temperature sensor
circuit, shorted high.

ON

145

Engine coolant
temperature sensor
circuit, shorted low.

ON

147

Accelerator pedal
position sensor
circuit, low frequency.

ON

148

Accelerator pedal
position sensor
circuit, high
frequency.

ON

151

Engine coolant
temperature high,
critical.

ON

153

Intake manifold
temperature sensor
#1 circuit, shorted
high.

ON

154

Intake manifold
temperature sensor
#1 circuit, shorted
low.

ON

155

Intake manifold
temperature #1 high,
critical.

187

Sensor supply voltage
#2 circuit, shorted
low.

ON

198

Lamp circuit, high
voltage detected,
when low voltage was
expected.

ON

199

Lamp circuit, low
voltage detected,
when high voltage
was expected.

6

600 SRM 1172

Fault Codes

Table 1. Error Code Descriptions (Continued)

Fault Condition Present/Maintenance Required

Fault Code Readout

Limited Operating

Conditions

Warning Light

Engine Stop

Warning Light

Maintenance

Warning Light

Fault

Code

Description

211

Additional
OEM/Vehicle
diagnostic codes
have been logged.
Check other ECMs
for DTCs.

ON

212

Engine oil
temperature sensor
circuit, shorted high.

ON

213

Engine oil
temperature sensor
circuit, shorted low.

ON

214

Engine oil
temperature high,
critical.

ON

216

Air compressor wet
tank pressure signal
circuit, high voltage.

ON

217

Air compressor wet
tank pressure signal
circuit, low voltage.

ON

218

Air compressor wet
tank pressure signal
circuit, too high or too
low voltage.

219

Low oil level in the
centinel makeup oil
tank.

ON

221

Ambient air pressure
sensor circuit,
shorted high.

ON

222

Ambient air pressure
sensor circuit,
shorted low.

ON

223

Engine oil burn
valve solenoid circuit,
shorted low.

ON

227

Sensor supply voltage
#2 circuit, shorted
high.

7

Fault Codes

600 SRM 1172

Table 1. Error Code Descriptions (Continued)

Fault Condition Present/Maintenance Required

Fault Code Readout

Limited Operating

Conditions

Warning Light

Engine Stop

Warning Light

Maintenance

Warning Light

Fault

Code

Description

ON

234

Engine high speed,
critical.

ON

235

Engine coolant level
low, critical.

ON

237

External speed
input (multiple unit
sychronization), data
incorrect.

ON

241

Vehicle speed
sensor circuit, data
incorrect.

ON

242

Vehicle speed sensor
circuit, tampering
has been detected.

ON

245

Fan clutch circuit,
shorted low.

ON

249

Ambient air
temperature sensor
circuit, high voltage.

ON

254

Fuel shutoff valve
circuit, shorted low.

ON

255

Fuel shutoff valve
circuit, shorted high.

ON

256

Ambient air
temperature sensor
circuit, high voltage.

ON

285

SAE J1939
multiplexing PGN
time-out error.

ON

286

SAE J1939
multiplexing
configuration error.

ON

287

SAE J1939
multiplexing
accelerator pedal
sensor, system error.

ON

288

SAE J1939
multiplexing remote
throttle, data error.

8

600 SRM 1172

Fault Codes

Table 1. Error Code Descriptions (Continued)

Fault Condition Present/Maintenance Required

Fault Code Readout

Limited Operating

Conditions

Warning Light

Engine Stop

Warning Light

Maintenance

Warning Light

Fault

Code

Description

ON

293

Auxiliary
temperature sensor
input #1 circuit,
shorted high.

ON

294

Auxiliary
temperature sensor
input #1 circuit,
shorted low.

ON

295

Ambient air pressure
sensor circuit, data
incorrect.

ON

297

Auxiliary pressure
sensor input #2
circuit, shorted high.

ON

298

Auxiliary pressure
sensor input #2
circuit, shorted low.

ON

299

Engine shutdown
commanded by
J1939.

ON

311

Injector solenoid
valve cylinder #1
circuit, grounded
circuit.

ON

312

Injector solenoid
valve cylinder #5
circuit, grounded
circuit.

ON

313

Injector solenoid
valve cylinder #3
circuit, grounded
circuit.

ON

314

Injector solenoid
valve cylinder #6
circuit, grounded
circuit.

ON

315

Injector solenoid
valve cylinder #2
circuit, grounded
circuit.

9

Fault Codes

600 SRM 1172

Table 1. Error Code Descriptions (Continued)

Fault Condition Present/Maintenance Required

Fault Code Readout

Limited Operating

Conditions

Warning Light

Engine Stop

Warning Light

Maintenance

Warning Light

Fault

Code

Description

ON

319

Real time clock,
power interrupt.

ON

321

Injector solenoid
valve cylinder #4
circuit, open circuit.

ON

322

Injector solenoid
valve cylinder #1
circuit, open circuit.

ON

323

Injector solenoid
valve cylinder #5
circuit, open circuit.

ON

324

Injector solenoid
valve cylinder #3
circuit, open circuit.

ON

325

Injector solenoid
valve cylinder #6
circuit, open circuit.

ON

331

Injector solenoid
valve cylinder #2
circuit, open circuit.

ON

332

Injector solenoid
valve cylinder #4
circuit, open circuit.

ON

338

Idle shutdown vehicle
accessory/ignition
bus relay circuit,
voltage or open circuit
detected.

ON

339

Idle shutdown vehicle
accessory/ignition
bus relay circuit, low
voltage or faulty ECM
output circuit.

ON

341

Engine control
module, data lost.

ON

343

Engine control
module, internal
hardware failure.

10

600 SRM 1172

Fault Codes

Table 1. Error Code Descriptions (Continued)

Fault Condition Present/Maintenance Required

Fault Code Readout

Limited Operating

Conditions

Warning Light

Engine Stop

Warning Light

Maintenance

Warning Light

Fault

Code

Description

ON

349

Transmission output
shaft, speed high
warning.

ON

352

Sensor supply voltage
#1 circuit, shorted
low.

ON

386

Sensor supply voltage
#1 circuit, shorted
high.

ON

387

Accelerator pedal
position sensor
supply voltage circuit,
shorted high.

ON

415

Engine oil pressure
low, critical.

ON

418

Water in fuel
indicator high,
maintenance.

ON

419

Intake manifold
pressure sensor
signal error.

ON

422

Engine coolant level
sensor circuit, data
incorrect.

426

SAE J1939 datalink,
cannot transmit.

ON

428

Water in fuel sensor
circuit, shorted high.

ON

429

Water in fuel sensor
circuit, shorted low.

ON

431

Accelerator pedal idle
validation circuit,
data incorrect.

ON

432

Accelerator pedal idle
validation circuit, out
of calibration.

ON

433

Intake manifold
pressure sensor
circuit, data
incorrect.

11

Fault Codes

600 SRM 1172

Table 1. Error Code Descriptions (Continued)

Fault Condition Present/Maintenance Required

Fault Code Readout

Limited Operating

Conditions

Warning Light

Engine Stop

Warning Light

Maintenance

Warning Light

Fault

Code

Description

ON

434

Power lost without
ignition OFF.

ON

435

Engine oil pressure
sensor circuit, data
incorrect.

ON

441

Battery #1 voltage
low, warning.

ON

442

Battery #1 voltage
high, warning.

ON

443

Accelerator pedal
position sensor
supply voltage circuit,
shorted low.

ON

465

Wastegate actuator
#1 circuit, high
voltage.

ON

466

Wastegate actuator
#1 circuit, low voltage
or faulty ECM output
circuit.

ON

469

Cab thermostat
circuit, E3 will cycle
the engine between
20 minutes RUN and
15 minutes OFF, or
will not autostart
the engine for cab
comfort mode. Will
not be disabled.

ON

471

Low crankcase oil
level.

ON

472

Crankcase oil level
sensor circuit, high or
low voltage.

ON

474

Starter solenoid
lockout relay circuit,
low voltage.

ON

475

Electronic air
compressor governor
circuit, low voltage.

12

600 SRM 1172

Fault Codes

Table 1. Error Code Descriptions (Continued)

Fault Condition Present/Maintenance Required

Fault Code Readout

Limited Operating

Conditions

Warning Light

Engine Stop

Warning Light

Maintenance

Warning Light

Fault

Code

Description

ON

476

Electronic air
compressor governor
circuit, high voltage.

ON

489

Transmission output
shaft (tailshaft),
speed low warning.

ON

491

Wastegate actuator
#2 circuit, high
voltage.

ON

492

Wastegate actuator
#2 circuit, low voltage
or faulty ECM output
circuit.

ON

527

Auxiliary input/
output #2 circuit,
shorted high.

ON

528

OEM alternate
torque validation
switch, data
incorrect.

ON

529

Auxiliary input/
output #3 circuit,
shorted high.

ON

536

Autoshift low gear
actuator circuit, low
voltage detected
when high voltage
commanded or
voltage detected
when no voltage is
commanded.

ON

537

Autoshift high gear
actuator circuit, low
voltage detected
when high voltage
commanded or
voltage detected
when no voltage is
commanded.

13

Fault Codes

600 SRM 1172

Table 1. Error Code Descriptions (Continued)

Fault Condition Present/Maintenance Required

Fault Code Readout

Limited Operating

Conditions

Warning Light

Engine Stop

Warning Light

Maintenance

Warning Light

Fault

Code

Description

ON

538

Autoshift neutral
gear actuator circuit,
low voltage detected
when high voltage
commanded or
voltage detected
when no voltage is
commanded.

ON

541

Starter relay/
interlock circuit
at ECM, incorrect
voltage.

ON

544

Autoshift failure,
at least three shift
attempts were
missed.

ON

551

Accelerator pedal idle
validation circuit,
shorted low.

ON

581

Fuel supply pump
inlet pressure sensor
circuit, shorted high.

ON

582

Fuel supply pump
inlet pressure sensor
circuit, shorted low.

ON

583

Fuel supply pump
inlet pressure low
warning.

ON

588

Engine start alarm
circuit, high voltage
when low voltage was
expected at ECM.

ON

589

Engine start alarm
circuit, low voltage
when high voltage
was expected at
ECM.

ON

595

Turbocharger
overspeed protection
fault.

14

600 SRM 1172

Fault Codes

Table 1. Error Code Descriptions (Continued)

Fault Condition Present/Maintenance Required

Fault Code Readout

Limited Operating

Conditions

Warning Light

Engine Stop

Warning Light

Maintenance

Warning Light

Fault

Code

Description

ON

596

Electrical charging
system voltage high,
warning.

ON

597

Electrical charging
system voltage low,
warning.

ON

598

Electrical charging
system voltage low,
critical.

611

Engine hot,
shutdown.

ON

775

Air system, slow leak
detected.

ON

776

Air system, fast leak
detected.

951

Cylinder power
imbalance between
cylinders.

15

NOTES

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16

TECHNICAL PUBLICATIONS

600 SRM 1172

3/05 (8/04)(7/04) Printed in United Kingdom