manual de instalación electrónica cummins isb,isc,isl
TRANSCRIPT
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Cummins
ISB, ISC, ISL EngineRun Harness Kit
This kit is for 1998 - 2001 EPA/CARB
automotive engines.
Manufactured by:Custom Chassis, Inc.
Wellington, OH 44090
440-647-6401
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NOTICE:Custom Chassis, Inc. (CCI) supplies this kit for
expressed purpose of Cummins ISB, ISC, and
ISL engine operation. This installation manual
provides sufficient information to achieve a
reliable and successful installation. Therefore,
CCI is not responsible for damage to engine or
related components due to poor or inappropriate
installation practices. Care should be takenwhile installing this kit to prevent personal injury.
CCI warranties the quality of this kit for
workmanship for 30 days from installation date.
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Page 1
INSTALLATION INSTRUCTIONS
Thank you for selecting this Cummins engine run harness.It will provide you with years of trouble-free use.
Before beg inning this installation, please read thoro ughly this entire instruction booklet.
The basic Cumm ins run harness provides all the required circuits for the engine to operate
properly. Due to the flexibility of the Cumm ins ECM, many more functions are available
depending upon the final engine application. Following is a list of additional circuits and/or kits
that CCI can provide.
OPTIONAL CIRCUITS
Cruise Control/ PTO Control - Includes an on/off rocker switch to turn cruise/PTO off o r in
standby. A mom entary on/off/ momentary on rocker switch for set/coast and resum e/accelerate
functions is included. This same switch sets and maintains engine speed for PTO operation.
Brake and clutch switch input is required.
Fan Clutch control - The fan is activated by one of the following: high A/C pressure, high coolant
temp, high intake mani fold temp, increase eng ine braking demand, or w ith manual switch
activation. Also included is an additional rocker to m anually override the fan con trol.
Transmission Shift Modulation Signal - Th is allows the engine to talk to an Allison electronic,
Al lison hydraulic, or Aisi n A581 automat ic t ransmission for up shifting and kick down.
Exhaust Brake Co ntrol - Includes an on/off rocker switch. This provides transmission clutch,
throttle position, and PTO interlock control.
J1587 Da ta-link Connec tor - Allows connection to Cummins computer programming and needed
for Road Relay. A cab-mounted connector is required for autom otive applications according toTMC-R P-1202. This uses the 6 pin diagnostics connector.
J1939 Da ta-link Connec tor - Allows connection to Cummins computer programming and to
interconnect between other drive train devices. This uses the 9 pin diagnostics connector.
Tachometer Signal - Provides a 12 pulses per engine revolution output signal. A com patible
tachometer can also be provided.
Start Lockout - It is used to prevent the ability to engage the starter when the engine is running.
An add itional normally closed rela y is provided to act ivate function .
Coolant Level Sensor and Harness - A sensor and shor t jumper can be provided to allow the
engine to shut down on low coolant. Required for automotive applications.
Complete Instrumentation - Any, or all gauges can be p rovided that will communicate d irectly to
the engine.
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Page 2
PRE-HARNESS INSTALLATION REQUIREMENTS
• Before beginning instal lation, verify that all parts are included in the kit. Report
any shortages or damaged parts immediately.
BASIC ISB RUN HARNESS KIT PART LIST:
Qty. Part Number Description
1 HAR-001 Main harness assembly
1 CAB-023 3' battery negative cable
1 CAB-034 4' battery positive cable
1 CAB-012 2' flat engine ground cable
1 CON-001 Throttle pedal assembly - Suspended
1 CON-004 Switch - Diagnostic, ON/OFF
1 CON-005 Switch - Diagnostic, Increment/Decrement
2 CON-007 Brackets - Rocker switch
1 CON-006 Display - 10 Lamp W arning
1 CON-003 Ignition switch assembly and two keys
20 MIS-001 Cable Ties - 10"
Note: This harness is designed to be used with a single 12 volt Group 31 battery with
3/8" stud term inals. The battery is NOT included with this kit. For additional cold
cranking power, a second battery may be necessary for cold climates. This
should be wired in parallel with the first battery. The additional battery cables are
NOT included in this kit.
• The engine MUST BE securely mounted in vehicle or power unit frame.
• Fuel lines, a ir c leaner, radiator, and CAC must be installed and plumbed.
• Transmission or dr ive unit must be mounted.
• DISCONNECT any existing e lectrical power to the engine to avoid perm anently
damaging electrical components.
Note: Use Caution to avoid personal injury or death.
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Page 3
STEP 1 - LAY OUT THE HARN ESS ROUT ING
• Route the harness so that it comes close the to ob ject it connects to. Use the
harness drawing in the Appendix as a guide. The following is the sequence of
connections on the harness:
Battery cable lugs
Start solenoid wire
Start relay
Engine power connector
Engine ECM connector
Water in fuel connector
Grid heater power cabling
Grid heater re lays
Throttle pedal connections
Ignition switch
W arning lamp panel
Diagnostic on/off switch & diagnostics increment/decrement switch
Fuse panel
• Mount harness with cable t ies or rubber coated band s ty le c lamps to avoid sharp,
rotating, or hot objects.
Note: DO NOT over tighten the cable ties as this can cut insulation and pinch the wires.
Note: If the harness passes through a firewall or pane l, use a rubber grom met to avoid
chafing the loom or harness wires.
STEP 2 - CONNECT THE ROUND PO WER CONNECTOR TO ENGINE
• The round power connector is located at the left rear corner of the engine
attached with a bracket bolted to the intake mani fold.
• Grasp the rear body of the connector and rotate it unti l i t al igns with tangs of the
matting connector. See Figure 1.
• With the rear body al igned, rotate the outer ring at the front to pull the connector
together. The connector will click when it is fully engaged.
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Page 4
Figure 1
Figure 2
STEP 3 - CONNECT THE START SOLENO ID WIRE TO THE STARTER:
• The start solenoid stud is the small stud located at the 12:00 o’clock position on
the start solenoid. See figure 2.
• Carefully place the eyelet wire on the stud. Instal l the original nut and lock
washer and tighten using a 8mm nut driver. Snug tight, but DO NOT over tighten.
• Be sure that the eye le t does not touch any o ther sur face.
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Page 5
Figure 3
STEP 4 - FRAME OR CHASSIS MOUNT T HE HARNESS START RELAY
• Find a suitable location for the relay protected from exhaust heat, water spray,
and road grime.
• Bol t or screw the relay to the frame rai l or cross member. See Figure 3.
Note: The relay should be mounted upright to avoid water from running along the wires
into the connector.
Note: Do not mount the relay to the engine as this will reduce the life of the relay. The
constant movem ent of the engine w ill cause the c ontacts to fail.
STEP 5 - FRAME OR CHASSIS MOUNT T HE CUMMINS SUPPLIED VP44 POWER R ELAY
( ISB ONLY)
• This relay is Cummins supplied and temporari ly banded to the Cummins harness
on the left side of the engine near the power connec tor. This relay must be
permanently mounted.
• Mount the VP44 power relay in the same manner as the start relay. See figure 3.
Note: The relay should be mounted upright to avoid water from running along the wiresinto the connector.
Note: Do not mount the relay to the engine as this will reduce the life of the relay. The
constant movem ent of the engine w ill cause the c ontacts to fail.
STEP 6 - INSTALL THE ECM CONN ECTOR
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Page 6
Figure 4
Figure 5
• The e ngine ECM is located on the left side middle of the engine under the intake
manifold. The OEM receptacle is the large rectangular connector located to the
left of the ECM. The connector receptacle may be covered by a yellow protective
cover.
• Remove the protect ive cover and note the indexing tangs on connector and in the
receptacle port. See figure 4.• Gently insert the connector into the receptacle and careful ly tighten the center
screw using a 4mm Allen wrench. See Figure 5.
• Carefully t ighten the center screw to approx imately 25 in-lb.
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Page 7
Figure 6
STEP 7 - ATTACH WIF (WATE R IN FILTER) CONNECT OR
• The W IF sensor recep tacle is located on the forward side of the fuel filter/water
separator. The fuel filter/water separator is located on the left side of the engine
with a bracket attached to the intake man ifold. See figure 6.
• Insert the two-p in connec tor into the receptac le .
• The connec to r w ill cli ck when fu lly ins er ted.
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Page 8
Figure 8
Figure 7
STEP 8 - CONNECT THE POW ER CABLES TO THE INTAKE HEATER T ERMINALS
• The two positive intake heater s tuds are located on the rear of the square grid
heater section on the inlet section of the intake mani fold. See Figure 7.
• A ttach one cable of the harness to each o f the posit ive s tuds .
• Remove the lock washer and nut, then install the cables and re-install the lockwasher and nut. Tighten to snug. Do not over torque.
• The opposite side of the square grid heater section has the two ground studs.
There should be a Cummins installed jumper cable connecting them together and
a short cable attached to the engine. See figure 8.
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Page 9
Figure 9
STEP 9 - MOUNT INTAK E HEATER GRID RELAYS
• F ind a su itab le location for the relay panel . I t should NOT be mounted on the
engine and away from direct heat.
• The panel should be mounted wi th the relays and fuses in an easily viewable
area. See figure 9.• The two holes in the panel allow for easy mounting to the f irewall or inner fender.
• The panel can be mounted with bolts or screws. Check the back of the mount ing
surface for obstructions bef ore drilling or screw ing.
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Page 10
Figure 10
STEP 10 - MOUNT THE ELECTRONIC THROTTLE PEDAL
• Mounting the su spended pedal (Standard).
• To determine the best pedal position hold the pedal against the firewall
while the operator operates the pedal in the seated position. Move the
pedal until the operation is smooth and comfortable. Make sure that thepedal doesn’t contact the floor or flooring material. See figure 10.
• Use a marke r to l oca te the two moun ti ng holes.
• Dri ll the two mounting holes in the fi rewall after making sure there are no
wires or other obstructions on the o pposite side of the firewall.
• The pedal must be securely mounted to f irewal l with bolts, flat washers
and lock nuts. DO NOT use screws.
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Page 11
Figure 11
- OR -
• Mounting the floor mounted pedal (optional).
• To determine the best pedal pos ition, have the operator operate the
pedal in the seated position. Move the pedal until the operation is
smooth and comfortable. See figure 11.
• Use a m arker to locate the two mounting holes.
• Dri ll the two mounting in the fi rewall after making sure there are no wires
or other obstructions on the oppos ite of the mounting surface.
• The pedal must be securely mounted wi th bolts , f lat washers and lock
nuts. DO NOT use screws.
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Page 12
Figure 12
STEP 11 - CONNECT SIX PIN CONNECTOR TO THE THROTTLE PEDAL
• Attached the six pin connector in the harness to the mating connector buil t into
the throttle pedal poten tiometer. See Figure 12.
• The connect ors wi ll cli ck when fu lly inse rted.
Note: Be careful to route the cables and ha rness away the moving parts of the pedal to avoid
jam ming the pedal.
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Page 13
Figure 13
STEP 12 - IGNITION SW ITCH INSTALLATION
• Find a suitable location for the ignition switch. I t should be located at or near
horizontal. This prevents water and debris from entering the lock tumbler.
• The recommended mounting panel thickness is 0.030" to 0.090".
• The ignit ion switch mount ing hole is 1" in diameter. Hint : Use a 7/8" hole saw.• Deb ur an d e nla rge h ole if ne ce ss ar y.
• Find and connect the six pin igni tion switch connector from the harness to the
back of the ign ition switch. See Figure 13.
• Insert the igni tion switch in the hole from the back s ide.
• Ins ta ll t he meta l panel nut and t ighten to a maximum of 50 in lbs .
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Page 14
Figure 14
STEP 13 - INSTALL THE WARNING LAMP DISPLAY
• Find a suitable location that can be easi ly seen by the operator in the operating
position.
• Using f igure 14 to create the opening and holes for mounting the warning lamp
display.• The display can be mounted on top of the panel or below for a recessed look.
• No. 10 machine screws (not inc luded) work best for mounting the panel . Do not
over tighten the screws as this will pucker the p lastic panel.
• F ind and connect the male and female 12 pin lamp connectors from the harness
to the appropriate connectors on the lamp display pigtail.
Note: This run harnes s only uses the five lower indicator lamps. The left turn, oil pressure,
volts, coolant temp, and right turn lamps are available for customer use. The harnes s has
a 12" lead in pins 6 thru 10 in each the harness connectors for customer connection. The
male connector is for power and the female connector is for ground.
DISPLAY PIN LOCATIONS
# 6 Left Turn
# 7 Oil Pressure
# 8 Volts
# 9 Coolant temperature
# 10 Right turn
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Page 15
Figure 15
STEP 14 - MOUNT DIAGNOSTIC SW ITCHES
• Find a suitable locat ion that is accessible by the operator, but is not prone to
accidental activation.
• The recommended panel mounting thickness is 0.09" to 0.19".
• Create a ho le that is 2 .02" l ong by 1 .90" high.• Assemble the rocker switches in the rocker switch bezel. The on/off switch
should be located on the left and the mom entary on/off/mom entary on switch on
the left.
• F ind the two six pin connectors in the harness for the diagnost ic switches. Feed
the connectors through the diagnostic switch hole just created. This will aid in
connecting the switches properly.
• The connector with two wires is installed on the on/off rocker swi tch. The
connector with three wires is installed on the mom entary rocker switch. Push to
seat the connectors over the spade terminals. See figure 15.
• With the connectors ins talled, push the rocker switch assembly in the mounting
hole. The assembly should snap into place.
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Page 16
Figure 16
STEP 15 - MOUNT THE FUSE BLOCKS
• The two fuse blocks can be mounted together (recommended) or separately.
• The fuse blocks should not be mounted ups ide down increasing the chance of
fuses loosening from vibration.
• The fuse blocks should me mounted in an eas ily access ible, weatherproof location. See Figure 16.
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Page 17
Figure 17
STEP 16 - CONNECT BATTERY CA BLES
Engine Ground
• Connect the flat braided engine grounding cable to an available threaded hole on
the upper engine block just above the flywheel housing and to frame m ounting
bolt or stud.• Tighten both mounting nuts securely to insure proper contact .
• Apply dielectric grease, ant i-seize, or s imilar products to both mounting points to
reduce the chances o f corrosion.
Battery Ground
• Connect the shorter (negat ive) battery cable first to one of the s tarter mount ing
bolts and then to the negative battery terminal. See figure 17.
• Tighten the s tarter bolt securely to insure proper contact.
• Also install the two ground (black heat shrink) harness terminals on the negative
battery terminal.
• Apply dielectric grease, ant i-seize, or s imilar products to both mounting points to
reduce the chances o f corrosion.
Battery Power
• Connect the longer (posit ive) battery cable f irst to large starter solenoid stud and
to the positive battery terminal. See figure 18.
• Tighten the s tarter bolt securely to insure proper contact.
• Also install the three power (red heat shrink) harness terminals on the positive
battery terminal.
• Apply dielectric grease, ant i-seize, or s imilar products to both mounting points to
reduce the chances o f corrosion.
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Page 18
Figure 18
STEP 17 - FINAL CHECKS AND SYSTEM TESTS
• Using cable ties and/or harness c lamps tie up any lose or hanging wires.
• Check al l routing to prevent chafing or pinch ing the harness.
• Check that all wiring avo ids any moving parts .
• Check al l mount ing fasteners to ensure properly t ightened.
• Turn the ignition switch to the on position and observe the fol lowings funct ions.
• The ECM powers the fuel pump and a whirring sound will continue until
the fuel pressure is met.
• With the diagnostic switch in the off posit ion, the indicator lamps
(warning, stop, service engine, wa it to start, and wat er in fuel) light up for two seconds and g o off in the given order, one after the other, to verify
they are working and wired correctly.
• I f the ECM determines the cold starting aid is needed, the wai t to s tart
lamp will remain on until the intake heaters have timed out.
• I f an act ive fault is present, one of the three warning lamps will remain on
determined by the type of fault being sensed. See the diagnostics
section in the appendix for further explanation.
• I f no faults are noted, turn the ignition to the start position to begin engine
cranking. If the engine does not start after 30 seconds, wait 1 minute for the start
to cool down. Repeat as necessary.
• The engine elect ronic subsystems and the starter motor are independent
of each other. During the cranking ph ase, with the key switch in the startposition, the ECM c ommands all the fuel needed to start the engine. THE
THROTTLE PEDAL HAS NO EFFECT WHILE CRANKING THE
ENGINE.
• While the engine is cranking, the ECM is performing additional diagnostic
and status opera tions. An active fault may cause one of the indicator
lamps to illuminate and remain lighted; which lamp is illuminated,
depends on the severity of the fault.
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APPENDIX
Table of Contents:
Section A - Wiring Schematic . . . . . . . . . . . . . A-1Section B - Harness Connector Diagram . . . . . A-2Section C - Diagnostics . . . . . . . . . . . . . . . . . . A-3Section D - Fault Code Information . . . . . . . . . A-4
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Page A-1
WIRING SCHEMATIC
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Page A-2
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Page A-3
DIAGNOSTICS
The ISB, ISC, and ISL engines have a built-in diagnostic capability which a lerts the
operator of a system problem while the engine is running by illuminating one of the
indicator lamps. The warning (yellow) lamp, when lighted warns the operator of an active
component or system fault. Whi le it denotes a failure has happened, the vehicle can be
operated. The vehicle should be serviced to solve the problem, but the situation is notconsidered an emergency. The lighted stop (red) lamp indicates a major ISB, ISC, ISL
engine problem and the vehicle should be stopped as soon as possible.
Note: The red lamp will be flashed in scenarios where engine protection shutdown
is about to shut the en gine down.
The engine protection system uses an indicator lamp to alert the operator of a coolant
temperature high, intake manifold temperature high, oil pressure low, or coolant (water)
level low condition. The lamp wi ll turn on at the occurrence and then begin blinking after
a period of time. This blinking operation is to warn the operator that something has been
active for a period of time or else the pressure or temperature cond ition has become
worse and engine shutdown is about to occur, if the shutdown feature has been enabled.
Note: The engine protection faults defined above will turn on the yellow and red
lamps depending on the severity of the fault detected with the exception of the
coolant level engine protection which will turn on the service engine lamp.
In addition to a lerting the operator of system faults, the lamps are used in the diagnostic
operation. The diagnostic mode begins when the ignition switch and diagnostic test
switch are on and the engine is not running. The yellow lamp flashes at the beginning of
a fault code sequence, the red lamp flashes the three digit code for the active fault and
yellow lamp ag ain flashes to separa te the previous red lamp seque nce from the next one.
The second d iagnostic switch allows the operator to toggle upward or downward through
the fault codes. At the conclusion of the diagnostic mode, the diagnostic test switch
should be turned off.
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Page A-4
FAULT CODE INFORMATION for ISB, ISC, ISL ENGINES
Flash
Code/
Lamp
REASON EFFECT (Only when fault code is active) APPLICATION
111*
WarningECM internal hardware error. Possible no effect or engine may run rough or not start. ISB, ISC, ISL
115*
Warning
No engine speed or position signal detected at pin No. 17 of the
engine harness.
Engine power derates.
Possible white smoke.ISB, ISC, ISL
121*
Warning
No engine speed or position signal detected at pin No. 9 of the
engine harness.
No engine speed and position backup for main speed/position
sensor.ISC, ISL
122
Warning
High voltage detected at the boost pressure sensor signal pin No.
45 of the engine harness.Engine will derate to no-boost fueling. ISB, ISC, ISL
123
Warning
Low voltage detected at boost pressure sensor signal pin No. 45
of the engine harness.Engine will derate to no-boost fueling. ISB, ISC, ISL
131
Warning
High voltage detected at throttle position signal pin No. 30 of the
OEM harness.
Engine idles when idle validation switch indicates idle and ramps up
to a default set speed when the idle validation switch indicates off
idle.
ISB, ISC, ISL
132
Warning
Low voltage det ected at throttle position signal pin No. 30 of the
OEM harness.
Engine idles when idle validation switch indicates idle and ramps up
to a default set speed when idle valida tion switch indicates off-idle.ISB, ISC, ISL
135
Warning
High voltage detected at oil pressure signal pin No. 33 of the
engine harness.
Default value used for oil pressure.
No engine protection for oil pressure.ISB, ISC, ISL
141
Warning
Low voltage detected at oil pressure signal pin No. 33 of the
engine harness
Default value used for oil pressure. No engine protection for oil
pressure.ISB, ISC, ISL
143Warning
Oil pressure signal indicates oil pressure below the low engineprotection limit.
Power and/or speed derate and possible engine shutdown if engineprotection shutdown feature is enabled.
ISB, ISC, ISL
144
Warning
High voltage detected at coolant temperature signal pin No. 23 of
the engine harness.
Default value used for coolant temperature. No engine protection for
coolant temperature.ISB, ISC, ISL
145
Warning
Low voltage detected at coolant temperature signal pin No. 23 of
the engine harness.
Default value used for coolant temperature. No engine protection for
coolant temperature.ISB, ISC, ISL
146
Warning
Coolant temperature signal indicates coolant temperature has
exceeded the minimum engine protection limit.
Power derate and possible engine shutdown if engine protection
shutdown feature is enabled.ISB, ISC, ISL
151
Stop
Coolant temperature signal indicates coolant temperature has
exceeded the engine protection limit.
Power and/or speed derate and possible engine shutdown if engine
protection shutdown feature is enabled.ISB, ISC, ISL
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FAULT CODE INFORMATION for ISB, ISC, ISL ENGINES
Page A-5
153
Warning
High voltage detected at intake manifold temperature signal pin
No. 34 of the engine harness.
Default value used for intake manifold temperature. No engine
protection for intake manifold temperature.ISB, ISC, ISL
Flash
Code/
Lamp
REASON EFFECT (Only when fault code is active) APPLICATION
154
Warning
Low voltage detected at intake manifold temperature signal pin No.
34 of the engine harness.
Default value used for intake manifold temperature. No engine
protection for intake manifold temperature.ISB, ISC, ISL
155
Stop
Intake manifold air temperature signal indicates intake manifold air
temperature is above the engine protection limit.
Power and/or speed derate and possible engine shutdown if engine
protection shutdown feature is enabled.ISB, ISC, ISL
191 A/C Clutch driver signal indicates a short to ground when
commanded on. Can not turn on A/C ISB, ISC, ISL
221
Warning
High voltage detected at ambient air pressure signal pin No. 32 of
the engine harness.Engine power derate. ISC, ISL
222
Warning
Low voltage detected at ambient air pressure signal pin No. 32 of
the engine harness.Engine power derate. ISC, ISL
234
Stop
Engine speed signal indicates engine speed has exceeded the
overspeed limit.
Fuel to injectors disabled until engine speed falls below the overspeed
limit.ISB, ISC, ISL
235
Service
Engine
Coolant level signal at pin No. 37 of the engine harness indicates
coolant level is low.
Power and/or speed derate and possible engine shutdown if engine
protection shutdown feature is enabled.ISB, ISC, ISL
241
Warning
Vehicle speed signal on pin Nos. 8 and 18 of the OEM harness has
been lost.
Engine speed limited to “Max. Engine Speed without VSS”. Cruise
control, gear-down protection and the read speed governor will not work.
Trip information data that is based on mileage will be incorrect.
ISB, ISC, ISL
242
Warning
Invalid or inappropriate vehicle speed signal indicated on pin Nos. 8
and 18 of the OEM harness indicating on intermittent connection or
possible tampering.
Engine speed limited to “Max. Engine Speed without VSS”. Cruise
control, gear-down protection and road speed governor will not work.
Trip information data that is based on mileage will be incorrect.
ISB, ISC, ISL
243 Error detected in exhaust brake relay enable circuit at pin No. 42 of the engine harness.
Exhaust brake will not work. ISB, ISC, ISL
245Error detected in fan clutch relay enable circuit at pin No. 31 (ISB)
and pin No. 41 (ISC) of the engine harness.
Electronic control module (ECM) cannot control the engine cooling fan.
Fan will remain on or off.ISB, ISC, ISL
261*
Warning
VP44 Fuel Pump Control Module indicates the fuel temperature has
exceeded the engine protection limit.Power derate. ISB
263High voltage detected at fuel temperature signal pin No. 35 of the
engine harness.Default value used for fuel temperature. Possible low power. ISC, ISL
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FAULT CODE INFORMATION for ISB, ISC, ISL ENGINES
Page A-6
264
Warning
High or low voltage detected at the fuel temperature sensor signal
circuit inside the VP44 pump controller.
Default value used for fuel temperature. Possible low power and no
engine protection for fuel temperature.ISB
265Low voltage detected at fuel temperature signal pin No. 35 of the
engine harness.Default value used fo r fuel temperature . P ossible low power. ISC, ISL
Flash
Code/
Lamp
REASON EFFECT (Only when fault code is active) APPLICATION
268*
Warning
Fuel pressure in the accumulator is not changing with engine
operating conditions.Power derate. Engine may run rough. ISC, ISL
271
Yellow
Low or no current detected on front pumping control valve return pin
No.21. (Set only during control valve click test)Low power. Poor Performance ISC, ISL
272
Warning
High current detected on front pumping control valve return pin No.
21.Low power. Poor performance. Possible damage to the ECM. ISC, ISL
273
Warning
Low or no current detected on rear pumping control valve return pin
No. 15. (Set only during control valve click test)Low power. Poor performance. ISC, ISL
274
Warning
High Current detected on rear pumping control valve return pin No.
15.Low power. Poor performance. Possible damage to the ECM. ISC, ISL
275
WarningEngine ECM has detected a failure in the front pumping element. Low power. Poor performance. ISC, ISL
276
WarningHigh current detected on injection control valve return pin No. 7.
Injection Control Valve is shut down and engine will not run. Possible
ECM damage.ISC, ISL
277*
WarningEngine ECM has detected a failure in the injection control valve. Low power. Engine may not run. ISC, ISL
278*
WarningError detected in lift pump circuit at pin 11 of the engine harness. Possible low power. Engine may die, run rough or be difficult to start. ISB, ISC, ISL
279
Warning
Low or no current detected on injection control valve return pin No.
7. (Set only during control valve click test)Low power. Engine may not run. ISC, ISL
281
WarningEngine ECM has detected a failure in the front pumping element. Possible no effect or engine power derate. ISC, ISL
282
WarningEngine ECM has detected a failure in the rear pumping element. Possible no effect or engine power derate. ISC, ISL
283
Warning
High voltage detected at main engine speed/position sensor voltage
supply pin 8 of the engine harness.
ECM will use the VP44 pump speed (ISB) or the engine position signal
(ISC,ISL) as a backup. Possible white smoke and power loss.ISB, ISC, ISL
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FAULT CODE INFORMATION for ISB, ISC, ISL ENGINES
Page A-7
284
Warning
Low voltage detected at main engine speed/position sensor voltage
supply pin 8 of the engine harness.
ECM will use the VP44 pump speed (ISB) or the engine position signal
(ISC,ISL) as a backup. Possible white smoke and power loss.ISB, ISC, ISL
285
Warning
The software has detected an error due to a parameter time-out on
the multiplexed data bus. At least one mux device will not work properly. Engine may idle only. ISB, IS C, ISL
286
Warning
The software indicates that the multiplexed data bus is not
erroneous but is invalid.Engine will idle only. ISB, ISC, ISL
Flash
Code/
Lamp
REASON EFFECT (Only when fault code is active) APPLICATION
287
Warning
The software indicates that the multiplexed data is not valid and
erroneous for the accelerator pedal sensor. Engine will idle only. ISB, ISC, ISL
288
Warning
The software indicates that the multiplexed data is not valid and
erroneous for the remote throttle.Engine will not respond to remote throttle. ISB, ISC, ISL
319
Service
Engine
Power to the real time clock has been interrupted and its setting is
no longer valid.Time stamp in ECM power down data will be incorrect. ISB, ISC, ISL
328
WarningEngine ECM has detected a failure in the rear pumping element. Low power. Engine may not run. ISB, ISC, ISL
329*
Stop
Engine ECM has detected an over pumping failure in the CAPS
pump.
Instability at idle accompanied by low power or extremely poor
performance and severe black smoke. Engine may shutdown. ISC, ISL
352
Warning
Low voltage detected at engine position sensor +5 volt supply, pin
No. 10 of the engine harness.
Default value used for sensors connected to this +5 volt supply. Engine
will derate to no-boost fueling and loss of engine protection for oil
pressure. Intake manifold pressure and coolant temperature.
ISB, ISC, ISL
361
StopContinuous power detected at VP44 fuel control valve. Fueling to injectors disabled. Engine dies. ISB
362
Warning Low voltage or no voltage detected at the VP44 fuel control valve. Engine will lose power and may shut down. ISB
363
Warning
No fuel control valve movement detected by the VP44 pump
controller.Engine power loss. ISB
364*
Warning
No communications or invalid data transfer rate detected on date
link between ECM and VP44 pump controller at pins 4 and 13 of the
engine harness.
Engine will run at a backup mode set speed when throttle is off idle. ISB
365
Warning
Low voltage detected at VP44 pump controller supply voltage
circuit.Engine may lose power and may shut down. ISB
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FAULT CODE INFORMATION for ISB, ISC, ISL ENGINES
Page A-8
366
Warning
VP44 pump controller battery voltage measurement is outside the
range between 6 and 24 volts.Engine will lose power and may shut down. ISB
367
StopVP44 pump speed/position sensor signal lost. Fueling to injectors is disabled and engine will shutdown. ISB
368
Warning
The VP44 pump can not achieve the timing value being
commanded by the ECM.Significant engine power loss. ISB
369Warning VP44 pump controller does not detect engine position pulse at pinNo. 7 of the engine harness. Significant engine power loss. Possible white smoke. ISB
Flash
Code/
Lamp
REASON EFFECT (Only when fault code is active) APPLICATION
372*
Warning
VP44 pump controller detects continuous voltage at idle select pin
No. 16 of the engine harness...OR...pump controller detects an
open circuit or short circuit to ground at idle select pin 16 of the
engine harness.
If communication is lost between the ECM and VP44 pump controller,
engine will either only idle or will be stuck at a slightly higher set speed,
regardless of throttle position.
ISB
373
Stop
High voltage detected at VP44 fuel shut off signal pin No. 6 of the
engine harness.Fueling to injectors disabled. Engine will shut down. ISB
374*
WarningVP44 pump controller has detected an internal error. Engine power derate or engine may die. ISB
376*
StopNo calibration in the VP44 pump controller. Fueling to injectors disabled. Engine will shut down. ISB
377
Warning
VP44 pump controller is not powering down when key switch power
is removed from the engine control module.Equipment batteries may be drained low during long shutdown periods. ISB
381*Warning
Error detected in cold start aid relay 1 enable circuit at pin No. 41 of the OEM harness.
Intake air heater can not be fully energized by the ECM. Possible whitesmoke and/or hard starting.
ISB, ISC, ISL
382*
Warning
Error detected in cold start aid relay 2 enable circuit at pin No. 31 of
the OEM harness.
Intake air heater can not be fully energized by the ECM. Possible white
smoke and/or hard starting.ISB, ISC, ISL
385
Warning
High voltage detected at OEM harness sensor supply pin No. 10 of
the OEM harness.Sensors connected to this +5 volts supply will not function. ISB, ISC, ISL
386
Warning
High voltage detected at the engine harness sensor +5 VDC supply
pin No. 10 of the engine harness.
Default value used for sensors connected to this +5 volts supply.
Engine will derate to no-boost fueling and loss of engine protection for oil
pressure, intake manifold temperature, and coolant temperature.
ISB, ISC, ISL
387
Warning
High voltage detected at the throttle position sensor +5 VDC supply
pin No. 29 of the OEM harness.
Engine idles when idle validation switch indicates idle and ramps up to a
default set speed when idle validation switch indicates off-idle.ISB, ISC, ISL
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FAULT CODE INFORMATION for ISB, ISC, ISL ENGINES
Page A-9
391
Warning
Error detected in VP44 power supply relay enable circuit at pin No.
43 of the engine harness.Possible no effect on performance or engine may die. ISB
415
Stop
Oil pressure signal indicates oil pressure below the very low engine
protection limit.
Power and/or speed derate and possible engine shutdown if engine
protection shutdown feature is enabled.ISB, ISC, ISL
418
WIF
Water-in-fuel signal indicates the water in the fuel filter needs to be
drained.Excessive water in the fuel can lead to severe fuel system damage. ISB, ISC, ISL
422
Warning
Voltage detected simultaneously on both the coolant level high and
low signal pins No. 27 and 37 of the engine harness ...OR... no
voltage detected on either pin. (Fault is active for Switch type
coolant level sensors only)
No engine protection for coolant level. ISB, ISC, ISL
Flash
Code/
Lamp
REASON EFFECT (Only when fault code is active) APPLICATION
429
Warning
Low voltage detected at water-in-fuel signal pin 40 of the OEM
harness.No water-in-fuel protection. ISB, ISC, ISL
431
Warning
Idle validation signals on pins No. 25 and 26 of the OEM harness
indicate no voltage detected simultaneously.No effect on performance, but loss of idle validation. ISB, ISC, ISL
432
Warning
Idle validation signal at pin No. 26 of the OEM harness indicates
the throttle is at the idle position when the throttle position signal at
pin No. 30 of the OEM harness indicates the throttle is not at the
idle position...OR...idle validation signal at pin No. 26 of the OEM
harness indicates the throttle is not at the idle position when the
throttle position signal at pin No. 30 of the OEM harness indicates
the throttle is at the idle position.
Engine will only idle. ISB, ISC, ISL
433
Yellow
Boost pressure signal indicates boost pressure is high when other
engine parameters (i.e. speed and load) indicate boost pressure
should be low.
Possible over fueling during acceleration. Increase in black smoke. ISB, ISC, ISL
434*
Warning
Supply voltage to the ECM fell below 6.0 volts for a fraction or asecond ...OR... the ECM was not allowed to power down correctly
(retain battery voltage for 30 seconds after key start)
Possible no noticeable performance effects ...OR... engine dying or hardstarting. Fault information, trip information, maintenance monitor data,
trending data, and user activated data logger data may bee inaccurate.
ISB, ISC, ISL
441
Warning
Voltage detected at ECM power supply pins No. 38, 39, and 40 of
the engine harness indicates the ECM supply voltage fell below 6
volts.
Engine will die or run rough. ISB, ISC, ISL
442
Warning
Voltage detected at ECM power supply pins 38, 39, and 40 (and pin
No. 50 for ISC, ISL) of the engine harness indicates the ECM
supply voltage is above the maximum system voltage level.
None on performance. ISB, ISC, ISL
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FAULT CODE INFORMATION for ISB, ISC, ISL ENGINES
Page A-10
443
Warning
Low voltage detected at throttle position sensor +5 volts supply pin
No. 29 of the OEM harness.
Engine idles when idle validation switch indicates idle and ramps up to a
default set speed when idle validation switch indicates off-idleISB, ISC, ISL
444
Warning
Low voltage detected at OEM harness sensor +5 volts supply pin
No. 10 of the OEM harness.
Sensors connected to this +5 volts supply (i.e. remote throttle position
sensor) will not function.ISB, ISC, ISL
449
Warning
Fuel pressure signal indicates that fuel pressure has exceeded the
maximum limit for the given engine rating.
Fuel pumping is stopped until pressure returns to normal. Possible fuel
pump damage may result.ISC, ISL
451Warning High voltage detected at fuel pressure sensor signal pin No. 46 of the engine harness. Low power, reduced performance. ISC, ISL
452
Warning
Low voltage detected at fuel pressure sensor signal pin No. 46 of
the engine harness.Low power, reduced performance. ISC, ISL
Flash
Code/
Lamp
REASON EFFECT (Only when fault code is active) APPLICATION
488
Warning
Intake manifold temperature signal indicates intake manifold
temperature is above the minimum engine protection threshold.
Power derate and possible engine shutdown if engine protection
shutdown feature is enabled.ISB, ISC, ISL
493
Warning
ECM has detected a circuit failure on the Injection Control Valve
Identifier circuit.Small power loss. ISC, ISL
515
Warning
High voltage detected at the auxiliary +5 sensor supply voltage pin
No. 49 of the engine harness.No engine protection for coolant level. ISB, ISC, ISL
516
Warning
Low voltage detected at the auxiliary +5 volts sensor supply voltage
pin 49 of the engine harness.No engine protection for coolant level. ISB, ISC, ISL
517
Warning
A mechanically stuck fuel control valve has been detected by the
VP44 fuel pump controller.Engine may shutdown. ISB
529*
Warning
Error detected in the Dual Output B circuit pin No. 1 of the engine
harness (ISC) or pin No. 21 of the engine harness (ISB).
The device being controlled by the Dual Output Driver B signal will not
function properly.ISB, ISC, ISL
539
Warning
Open circuit failure of the Injection Control Valve transorb pin No. 6
of the engine harness.Low power, possible ECM damage. ISC, ISL
551
Warning
Idle validation signals on pins No. 25 and 26 of the OEM harness
indicate voltage detected simultaneously on both pins.Engine will only idle. ISB, ISC, ISL
591
Warning
High voltage detected at the exhaust pressure sensor signal pin No.
43 of the engine harness.
Default value used for exhaust pressure. Engine will be limited to no-
boost fueling.ISL
592
Warning
Low voltage detected at the exhaust pressure sensor signal pin No.
43 of the engine harness.
Default value used for exhaust pressure. Engine will be limited to no-
boost fueling.ISL
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FAULT CODE INFORMATION for ISB, ISC, ISL ENGINES
Page A-11
593
Warning
VGT speed signal on pin No. 4 of the engine harness indicates the
VGT has exceeded the maximum limit.Reduce turbo charger speed. No fueling derate. ISL
594
Warning
VGT speed signal on pin No. 4 of the engine harness indicates the
VGT speed is below the minimum limit.No effect. ISL
599
Stop
The duel output feature is a customer specialized calibration and it
has initiated an engine shutdown based on the customer’s specified
operating conditions, engine sensor value, and/or OEM inputs to the
ECM
Engine will shutdown ISB, ISC, ISL
768
Warning
Error detected in the Output Device Driver (VGT or Transmission
Shift Modulation Signal) signal pin No. 21 on the OEM harness.Cannot control the VGT or Transmission, depending on application. ISB, ISC, ISL
779
WarningLow or no voltage detected at the OEM switch. Engine will lose power and may shut down. ISB, ISC, ISL
Note: * Indicates multiple errors can generate this fault code.
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Document # 032902
Custom Chassis, Inc.
21950 Gore O rphanage RoadWellington, OH 44090
Phone 440-647-6401
Fax 440-647-3817