Double Empty Container Handler TROUBLESHOOTING SANY TROUBLESHOOTING 6 TROUBLESHOOTING .. 6.1 Precautions 6.2 Troubleshooting Procedures... 6.3 Common Troubleshooting 6.3.1 Troubleshooting the engine system... 6.3.2 Troubleshooting the transmission system 6.3.2.1 Overview... 6.3.2.2 Troubleshooting procedures 6.3.2.3 Troubleshooting table 6.3.3 Troubleshooting the drive axle and brake system..... 6.3.4 Troubleshooting the drive axle and brake system..... 6.3.5 Troubleshooting the steering system 6.3.6 Troubleshooting the spreader system. 6.3.7 Troubleshooting the mast system... . 6.3.8 Troubleshooting the air conditioning system. 6.3.9 Troubleshooting the hydrautic system 6.3.10 Troubleshooting the electrical 6.3.10.1 Troubleshooting the electrical system 6.3.10.2 Troubleshooting the cable harness... 6.3.10.3 Troubleshooting table 6.4 Engine Error Codes..... 6.4.1 VOLVO engine error codes. 6.4.2 CUMMINS engine error codes 6.4.3 YUCHAI engine error codes 6.5 Transmission Error Codes 6.6 Machine Error Codes...» 6.6.1 Machine Error Codes... @sany Safety, Operation and Maintenance Manual-June 2019 otTROUBLESHOOTING Double Empty Container Handler Read and understand all safety precautions and instructions in this manual before reading any} other manuals provided with this machine and before operation or maintaining it. Failure to do) this could result in death or serious injury. 62 ‘Safety, Operation and Maintenance Manual-June 2019 @sanyDouble Empty Container Handler TROUBLESHOOTING 6. TROUBLESHOOTING 6.1 Precautions If two or more personnel are engaged in the repair or maintenance meanwhile, they should ‘come to an agreement about the operation procedures before the work. Prior to the repair ‘or maintenance, they should firstly notice oth- er personnel involved in it. Troubleshooting is aimed to find out the causes of failures and repair the machine to avoid further malfunction, The key to detect the failures is to understand the structure and functions of machine, ‘Asking to the operators for knowing the possi- ble reasons of failures is a shortcut for troubleshooting. 6.2 Troubleshooting Procedures You can perform the following 6 basic steps to find out the failure cause and work out the cor- responding sollution: 1. Read this manual in detail to get a general knowledge about related system and its oper- ating principle as well as the structure, func- tion and technical specification of system components 2. Consul the driver Before checking, you should consult relevant personnel (the driver) for all the failure details. * The current operation condition of the ma- chine (Does the machine operate properly) * When is the failure found and what is the machine working at that time * The failure development. Does the failure get worse or occur for the priority time * What other failures did the machine have before @sany Safety, Operation and Maintenance Manual-June 2019 63TROUBLESHOOTING Double Empty Container Handler For example, which components have been repaired or replaced * What have been done and what was the re- sult after the failure occurred * Can the failure be repeated 3, Check before starting * Before per forming trouble diagnosis, check the running record and operation mainte- nance record for any irregular or improper operation or maintenance. * Check if any part of the machine is abnor- mal such as: the lacking or leaking of oil and water; loosening pipe, wire or circuit; abnormal crack, ete. * In addition, check the electrical system such as battery voltage. Check whether power wire connecting end Is loose or burnt. Use multimeter to check whether fuse is burnt or not. 4. Operate machine in person (trial run) * After making sure that there is no failure in the above third item, start the machine ac- cording to standard operating methods to inspect and confirm the failure cause. If the failure cannot be confirmed, stop the engine and get further failure details from) the driver. 5, Perform trouble diagnosis * Review the information in this manual NOTE: It should be noticed that displayed error code may not indicate the current machine failure due to those temporary electrical fail- ures stored in the controller. Therefore, "re- peated tial” is required to erase the error codes accumulated in controller memory and confirm whether the error code is dis- played after “repeated trial’. In other words, this failure can be repeated. 64 ‘Safety, Operation and Maintenance Manual-June 2019 @sanyDouble Empty Container Handler TROUBLESHOOTING 6.Find the possible causes * Before coming to a conclusion, check the most possible cause again and try to con- firm the real cause of the failure. Make a proper repair schedule according to your conclusion. 6.3 Common Troubleshooting 6.3.1 Troubleshooting the engine system Table 6-1 Failure Symptom] __ Possible Causes ‘Suggested Actions Reference Too low temperature Completely preheat the Insufficient preheating tme | engine - of engine Blocked air filter or air Sheek the ar ake . Hard to startthe | intake pipe v ‘aI ‘ blockage. engine see "Fuel Fastin ol creult off4el | check the fuel system, system’ on ys page 5-45 Insufficient starting voltage Check the voltage of battery. The engine is over rewing The EDC fuel control unitis faulty Check the fuel control unit. The corrugated pipes have cracks and air leakage The quality of pipe itself Replace it. The rotation speed of engine is hot stable The EDC fuel control unit is faulty Check the fuel control unit. Engine stops No fuel in tank Check if fuel is used up. Blockage in fuel pipe Check if fuel oil circuit is blocked unexpectedly ‘Airentering infuel pipe | CheCkiffuel enters into the ; 9 pipe fuel pipe. Engine , Insufficient coolant in water | Check if the coolant of see “Coolant overheating oF | tank ter tank is sufficient. level, checkin running hot an water tank is sufficient. . fT @sany Safety, Operation and Maintenance Manual-June 2019 65TROUBLESHOOTING Double Empty Container Handler Table 6-1 (continue) Failure Symptom Possible Causes Suggested Actions Reference and topping up” on page 5-54 Malfunction of thermostat Check the thermostat. The fan belt is loose Check if the fan belt is loosened. See “Drive belt, ‘checking and changing (engine option VOLVO)’ on page 5-32 ‘The water pump is damaged Check water pump. There is oil in water but no water in oil The engine oil cooler is damaged Check if engine oil cooler is damaged. If yes, replace it. The cylinder head has crack The quality of cylinder head Replace the cylinder head Insufficient coolant Check if the coolant is sufficient. See “Coolant level, checking and topping up” on page 5-54 The lubrication oit [The cylinder gasket or __| Check ifoylinder gasket or levelinoil pan | cylinder head has crack _| cylinder head has erack rises ; unexpectedly and | The evlinder liners Check if the cylinder liner is J water enters oil _| Sa™maged damaged. The oillevelis toolow | Ref the lubrication ol E See “Oil filter, Lubrication oil | The olfteris blocked _| Replace the fiter. changing’ on pressure is too page 5-42 low The lubrication oil is too ‘See "Engine oil, Replace the lubrication oil. | changing’ on thin page 5-40 The watertank | The water tank is damaged | Replace it. refer to “Shop has leak Manual The engine oll The engine oil cooler is fer to “Sh cooler has bs Replace it refer to "Shop, leakage (gearbox) damaged Manual’ The power of The fuel supply is Check if the fuel oil circuit engine is not - 3 insufficient is unblocked. sufficient 66 Safety, Operation and Maintenance Manual-June 2019 @sanyDouble Empty Container Handler TROUBLESHOOTING Table 6-1 (continue) Failure Symptom Possible Causes ‘Suggested Actions Reference The fuel quality cannot Use accopted fuel - meet requirements See “Turboch The air intake pipe is Check ifthe air intake pipe |" ocnerser and blast pipe, damaged is blocked. i checking” on page 5-61 The speed of engine is automatically decreased The fuel supply is not smooth Check if the fuel oil circuit is blocked. The pre-filter and filter elements for engine diesel are blocked The diesel is too dirty Chang the diesel. The diesel tank is dirty Clean fuel tank. The exhaust pipe The exhaust pipe is Replace the pipe. damaged of engine has leakage The lange of exhaust pipe | ighten the hange is loosened See “Drive belt, checking and chan The engine fan | The quality ofbettitself | Replace bet ues beltis broken VOLvo)" on page 5-32 The belt is too tight ‘Adjust the tension of belt 7 The wear clearance The engine has | Between valve and valve | Replace the valve. : blue smoke sleeve becomes large The rings are worn Replace the piston rings. : Itis hard to speed | The EDC fuel control unit | Check EDC fuel control . up the engine | has fault unit The engine The seal of superch supercharger has | The seal of superchargeis | Repiace the seal : damaged oil leakage Safely, Operation and Maintenance Manual-June 2019 o7 @sanyTROUBLESHOOTING Double Empty Container Handler Table 6-1 (continue) Failure Symptom Pos: le Causes Suggested Actions Reference The indication of fuel gauge is incorrect The fuel gauge or oil level | Check the fuel gauge and sensor is damaged oil level sensor. The oil seal at the front end of The quality of sealitself | Replace it. - engine crankshaft 6.3.2 Troubleshooting the transmission system 6.3.2.1 Overview When troubleshooting a “ transmission” prob- lem, it should be kept in mind that the trans- mission is only the central unit of a group of related power-train components. Proper oper- ation of the transmission depends on the con- dition and correct functioning of other components of the group. Therefore, to prop- erly diagnose a suspected problem in the transmission, it is necessary to consider the transmission fluid, charging pump, torque converter, transmission assembly, oil cooler, filter, connecting hoses, and controls, includ- ing the engine, as a complete system. Torque converter transmission troubles fall i to three general categories: mechanical, hy- draulic and electrical problems. In addition to the mechanical and electrical components, all of which must be in the proper condition and funct ioning cor rect ly, the cor rect functioning of the hydraulic circuit is most important. Transmission fluid is the “life blood” of the transmission. It must be supplied in an ad- equate quantity and delivered to the system at the correct pressures to ensure converter op- eration, to engage and hold the clutches from 9, and to cool and lubricate the working components. 68 ‘Safety, Operation and Maintenance Manual-June 2019 @sanyDouble Empty Container Handler TROUBLESHOOTING 6.3.2.2 Troubleshooting procedures Step 1: Stall test Use a stall test to identify transmission, con verter, or engine problems. 1.Park the machine against a solid barrier, such as a wall, and / or apply the parking brake and block the wheels. 2.Put the gear selector at forward (or reverse, as applicable) gear. 3. Select the highest speed. 4.With the engine running, slowly increase ‘engine speed to approx. 1/2 throttle and hold until transmission (converter outlet) oil tem- perature reaches the operating range. Do not operate the converter at stall condition longer than 30 seconds at one| time, shift to neutral for 15 seconds and| repeat the procedure until _desired| temperature is reached. —_Excessive| temperature (120°C/250°F maximum) will cause damage to the transmission clutches, fluid, converter, and seals. ‘Step 2: Transmission pressure checks Transmission problems can be isolated by the use of pressure tests. When the stall test indi- cates slipping clutches, measure clutch pack pressure to determine if the slippage is due to low pressure or clutch plate friction material failure. In addition, converter charging pressure and transmission lubrication pressure may also be measured. @sany Safety, Operation and Maintenance Manual-June 2019 69TROUBLESHOOTING Double Empty Container Handler Step 3: Mechanical and electrical checks: Prior to checking any part of the system for hydraulic function (pressure testing), make the following mechanical and electrical checks: * Check the parking brake for correct adjustment. * Be sure all lever linkage is properly con nected and adjusted in each segment and at all connecting points. * The controls are actuated electrically. Check the wiring and electrical components. * Be sure that all components of the cooling system are in good condition and operating correctly. The radiator must be clean to maintain the proper cooling and operating temperatures for the engine and transmis- sion. Air clean the radiator, if necessary. * The engine must be operating correctly. Be sure that it is correctly tuned and adjusted to the correct idle and max. noload gov- erned speed specifications. Step 4: Hydraulic check Also, before checking the transmission clutches, torque converter, charging pump, and hydraulic circuit for pressure and rate of oll flow, it is important to make the following transmission fluid check Check oil level in the transmission. The trans- mission fluid must at full level. All clutches and the converter as well as its fluid circuit hoses must be fully charged (filled) at all times. NOTE: 6-10 ‘Safety, Operation and Maintenance Manual-June 2019 @sanyDouble Empty Container Handler TROUBLESHOOTING Be careful that the machine does not move unexpectedly when the engine and converter are operating at stall RPM 6.3.2.3 Troubleshooting table Table 6-2 Failure Symptom Possible Causes ‘Suggested Actions Reference Low oil pressure See “Transmission Check the oil level. oil level, Insufficient oil checking” on Slipping of clutch page 5-68 Damage of charge pump | Check the charge pump. 2 Wear of the clutch Replace the clutches. refer to “Shop @sany abrasion sheet Manual” ‘See Check the level of “Transmission Low or high oil level i ne ‘i re si or oil level, lubrication ol checking” on High oil page 5-68 temperature Wom charge pump Check the charge pump. - Sa Step the clutch in braking and check ifthe clutch - release when braking ‘switch is operating ‘Abnormal meshing of gear | Check the meshing of gear. Too much noise | Abrasion or damage of __| Replace the damaged or : bearing abraded bearing, See “Transmission Low oil level Check the oil level oil level, Inadequate oil che inadequate oil nage 568 pressure displayed by oil | Damage of charge pump _| Check the charge pump. - Pressure gauge | Damage of the clutch Check the presssure- . pressure-adjusting valve | adjusting valve. Damage of the clutch oil-_| Replace the damaged . sealing part sealing part. The gearbox can _| Fault in control unit of Check the signal of control : not switch gears _| gearbox unit of gearbox. Safety, Operation and Maintenance Manual-June 2019 onTROUBLESHOOTING Double Empty Container Handler Table 6-2 (continue) Failure Symptom Possible Causes ‘Suggested Actions Reference Check if the solenoid coil of gearbox solenoid valve is - blown. Check ifthe valve core is 7 blocked. The gear can not be shifted manually: The contact is faulty Check the contact. - Faulty of control lever See “Attaching Excessive The mounting bolts are batter vibration and a 9 Tighten the mounting bolts. | propeller shaft, noise in cab 7 checking" on page 5-63 6.3.3 Troubleshooting the drive axle and brake system Table 6-3 Failure Symptom Suggested Actions Reference Oil pressure of braking See “Oil system is low Check ifthe brake oilhas | jeakage of drive The force of ET leakage. ae a Beebe i faking oil circuit has air service brake is eapoeabee Not sufficient The brake components are | Check the brake cheat” on worn out components. page 5-71 Check ifthe fan of cooling Too much The oil temperature of | system can rotate orfan | referto “Shop foomuch noise | braking system is high flanks are damaged, Manual” Replace itif necessary. Failure of brake valve Adjust the distance of : brake valve. No service brake | Faiure of brake Check te clearance of or the service brake sheet brake functions | Failure of pressure relay _| Clean or replace it. - peg Failure of accumulator Check the accumulator. See” on page Failure of gear pump Replace it. gfe 0 “Shop Manual" 6-12 ‘Safety, Operation and Maintenance Manual-June 2019 @sanyDouble Empty Contal ner Handler TROUBLESHOOTING Table 6-3 (continue) Failure Symptom Possible Causes Suggested Actions Reference Failure of brake valve Clean or replace it. refer to “shop group Manual’ No parking brake or the parking brake functions bad Failure of parking brake Clean the parking brake. Failure of solenoid valve Clean the solenoid valve or replace it. High oil return back pressure Check the oil return pipe. Failure of brake valve Clean or replace it. refer to “Shop Manual” 6.3.4 Troubleshooting the drive axle and brake system Table 6-4 Failure Symptom] Possible Causes Suggested Actions Reference Oil pressure of braking See “Oil system is low Check ifthe brake oilhas | jeakage of drive The force of leakage. axle and brake service brake is _| Braking oil circuit has air components, not sufficient The brake components are | Check the brake checking’ on worn out components. page 5-71 Too much noise The oil temperature of ‘Check if the fan of cooling system can rotate or fan refer to “Shop bad Failure of accumulator Check the accumulator. braking system is high _| flanks are damaged. Manual” Replace itif necessary. ‘Adjust the distance of Failure of brake valve just the dietance of - brake valve, Check the cl f Failure of brake wok ihe erearance oF - brake sheet. No service brake | Failure of pressure relay _| Clean orreplace it. - or the service See "Brake brake functions system accumulator, checking” on page 5-119 refer to “Shop Failure of gear pum} Replace it. gearpume p Manuat” @sany Safety, Operation and Maintenance Manual-June 2019 613TROUBLESHOOTING Double Empty Container Handler Table 6-4 (continue) Failure Symptom Pos: le Causes. Suggested Actions Reference Failure of brake valve group Clean or replace it. refer to “Shop Manual” No parking brake or the parking brake functions bad Failure of parking brake Clean the parking brake. Failure of solenoid valve Clean the solenoid valve or replace it High oil return back pressure Check the oil return pipe. Failure of brake valve Clean or replace it. refer to “Shop Manual” 6.3.5 Troubleshooting the steering system Table 6-5 Fallure Symptom | __ Possible Causes ‘Suggested Actions Reference Insufficient oll supply Check the system refer to “Shop pressure. Manual” Failure of hydraulic Ineffective or steering gear Clean and replace it. : impossibbleto | Fo steer erious leakage of steering Replace the sealing parts. . cylinder Damping hole of low ; amplifier is clogged Cheat - 6.3.6 Troubleshooting the spreader system Table 6-6 Failure Symptom | __ Possible Causes ‘Suggested Actions Reference No pressure in the system Damaged overflow valve or relief valve Replace the overflow valve orrelief valve, Valve core is blocked Clean it No output of oil pump Check the oil pump feed to oil circuit No spreader Electrical failure Replace the circuit. Solenoid valve is damaged Replace the solenoid movements valve. The valve core is blocked _| Clean the valve core. - 6-14 ‘Safety, Operation and Maintenance Manual-June 2019 @sanyDouble Empty Container Handler TROUBLESHOOTING Table 6-6 (continue) Failure Symptom Possible Causes ‘Suggested Actions Reference Only a few of Bad connection caused by wiring fault Cheek and fix the fault. The corresponding solenoid valve is clamped Clean the solenoid valve. The coil of solenoid valve Replace the coil - spreader is damaged eplace the coil functions are effective The controller of spreader] Replace the spreader refer to “Shop is damaged controller. Manual’ Check and repair it. Fault in button of joystick | Replace the joystick if - necessary The power supply fuse of see ‘Fuses, spreader control device is | Replace the fuse. chang blown page 5-132 The hoses of general cil supplying valve have some | Inspect and fix i. - No movement of | malfunction the spreader General oil supplying valve has some malfunction Check and resume it. Replace the general oil supplying valve if necessary. ‘Spreader controller is damaged Replace it. refer to "Shop Manual” The yellow indicator ight blinks or illuminates all the time when the spreader is not seated Wrong induction distance of seated sensor Adjust the distance. ‘Seat sensor is damaged Replace the sensor. The yellow indicator light is damaged Replace the indicator light. refer to “Shop Manual” The red indicator light does not biink or illuminate Wrong induction distance of unlock sensor Adjust the distance. Unlock sensor is damaged | Replace the sensor. : when the - spreader is The red indicator lights | pebtace the indicator light. | Teferto “Shop unlocked damaged Manual” The green Wrong induction distance | ast the distance. indicator light | of lock sensor does not biink Hoes not Dlink OF | 1 ock sensor is damaged _| Replace the sensor. - illuminate when Safely, Operation and Maintenance Manual-June 2019 5 @sanyTROUBLESHOOTING Double Empty Container Handler Table 6-6 (continue) Failure Symptom Possible Causes Suggested Actions Reference the spreaderis | The green indicator light is | ooace tho indicator light. | "fr to“Shop locked damaged Manual’ 6.3.7 Troubleshooting the mast system Table 6-7 Fault Causes of faults Methods Reference The mast sways | Too much side gap of outer | Adjust the sliding block in . too much mast outer mast. Te The spreader foo much side gap ‘Adjust the siding block in support sways too | between spreader and 2 inner mast. much inner mast Malfunction of oil pump _| Repair or replace it. - Malfunction of multi-way Clean or replace it. - valve Malfunction of logic valve or the electromagnetic valve that is controlled by Mast unable to lift | logic valve Clean or replace it. - or descend Malfunction ofthe oll cult | ee ctace the gear pump or | refer to “Shop controlled by multi-way , relief valve. Manual valve Malfunction of overflow _| Replace the sealing . valve elements. Replace the elect Electrical malfunction piace the electrical : elements. Malfunction of overflow | Crean or replace it refer to “Shop valve Manual Mast descends —_ | Malfunction of logic valve automatically or the electromagnetic Clean or replace it. - valve that is controlled by logic valve 616 Safety, Operation and Maintenance Manual-June 2019 @sanyDouble Empty Container Handler TROUBLESHOOTING Table 6-7 _(conlinue) Fault Causes of faults Methods Reference Power supply fuse of mast S60 eam “ Replace the fuse. changing’ on No operation of | control circu is blown " one the mast page 5-132 Circuit maifunction Check and repairit. No lifting movement of mast Check and synchronize the after normal operation; Mast able to lift when safety bypass tumed off Spreader not fully or incompletely locked locking action of spreader; lock or unlock the spreader completely. 6.3.8 Troubleshooting the air conditioning system No refrigeration effect Fuse of condenser burns out Table 6-8 Failure Symptom | Possible Causes Suggested Actions Reference Gab temperature is lower | set a lower temperature. - than the set temperature pe High temperance Turn on the refrigeration Changes during one day | mode after the temperature - 9 ‘9 YJ is getting higher. Belt is loose Tighten the belt Check ifthe inserting fuse in | see “Fuses, electric cabinet is blown. if | changing’ on yes. change the fuse page 5-132 Check if the fuse is fixed. Check if the plug-in part of controller and condenser coil has good contact effect. Plug-in part of condenser clutch coil is loose Insert the plug-in part again. Coil is too tight or plug-in part has poor contact effect Fix the coil terminals, Refrigerant is leaking ‘Turn off the refrigeration mode, Check the condenser for leakage. See “Leakage or lack of oil in condenser, @sany Safety, Operation and Maintenance Manual-June 2019 617TROUBLESHOOTING Double Empty Container Handler Table 6-8 (continue) Failure Symptom | Possible Causes ‘Suggested Actions Reference checking” on page 5-111 Inform SANY to deal with it : Most of the air outlets are | Adjust the cab temperature. blocked Open all the air outlets. Bad sealing of cab Close all the windows and Poor refrigeration doors. effect See Refrigerant is not enough | Fill in refrigerant. Refrigerant, filing’ on page 5-110 eeurauee Check the output, grounding and connecting wire of engine is loose or . conditioner. Connect the ruptured wire again Small air volume see "Fuses, ornoair —_| Fuse is blown Change the fuse changing” on page 5-132 Speed governing resistance of evaporator | Inform SANY to deal with it. - is damaged Low air pressure and fe Filter is dirt Clean the fit ° refrigeration effect y feat the filter. is poor 6.3.9 Troubleshooting the hydraulic system Table 6-9 Failure Symptom | Possible Causes Suggested Actions Reference Failure of cooler Replace it refer to “Shop Manual Hydraulic motor of cooling Replace the hydraulic refer to “Shop High oil cirouit is damaged motor. Manual’ temperature Oil supply of loop feed Replace the back pressure pump is not enough spring. Inter drainage of reversing | Replace the reversing . valve is faulty valve. 6-18 Safety, Operation and Maintenance Manual-June 2019 @sanyDouble Empty Container Handler TROUBLESHOOTING Table 6-9 (continue) Failure Symptom Possible Causes ‘Suggested Actions Reference Low flow of cooler Clean the cooler. a Outer radiator fins are too dirty Wash the outer radiator fins, Hydraulic oil of substandard quality Hydraulic oll of substandard viscosity Replace the hydraulic oil. See “Hydraulic oil, changing” on page 5-116 Long-term use of hydraulic oil without fitting or Periodical filtration. replacing it See “Oil return aT The constant entrance of | Replace the filter core filter element, lycraulic O'S | dust, sand and other debris | periodically. replacing” on polluted and page S117 deteriorated s High temperature; oxidation metamorphism See “Hydraulic Entry of water and air, asa | Replace the hydraulic oil. | oil, changing result of cavitation, on page 5-116 erosion, etc. See “Air filter element, Clogged filter Clean it or replace it. changing” on page 5-115 Damaged or distorted i Replace the sealing parts, - Leaking of sealing parts 2 hydraulic oil Joints and pipelines are | siahten the loose parts . loose see "Fuses, The fuse of cooling system | Replace the fuse. changing’ on is bumt page 5-132 The temperature switch is The hydraulic or | damaged Replace the switch. - brake cooling Tho conta ov system does 0a | rong the cool Replace the contact. cool automaticaly | °otoling the cooling feplace the contact. - system is fused Fallure of cooler solenoid | Reniace it Ec valve Failure of cooler motor _| Replace it. Safety, Operation and Maintenance ManualJune 2019 619 @sanyTROUBLESHOOTING Double Empty Container Handler 6.3.10 Troubleshooting the electrical 6.3.10.1 Troubleshooting the electrical system The causes for faults in electrical control sys- tem are generally complicated. The real causes for faults should be diagnosed only based on careful observation, research, ex- periments and rich practical experiences. When the causes are diagnosed, eliminate them in sequence from easy to difficult. 6.3.10.2 Troubleshooting the cable harness NOTE: Perform troubleshooting for all cables in the same way to avoid damage to control units, components or measuring equipment 1. Study the circuit diagram in question. Check where the suspected cable is connected and if'so where itis spliced. 2. Turn off the main electric power. 3. Unplug the connector at the control unit or component in question. 4, Check if there is open circuit NOTE: ‘Some components cannot be checked without power supply to the components. In such an event, proceed to point 5 * a. Measure the resistance between connec- tions for the component in the connector at the control. unit or the component in question. * b, The resistance must correspond with the ‘component. Otherwise there may be an open circuit or short circuit in cable harness and / or the component. 6-20 ‘Safety, Operation and Maintenance Manual-June 2019 @sanyDouble Empty Container Handler TROUBLESHOOTING 5. Check if there is short circuit to frame: * a. Unplug the connector at both the control unit and the component in question. * b, Measure the resistance of one lead at a time. Measure between the lead and a frame-connected part of the machine. * c. The multimeter should show endless resistance. 6.3.10.3 Troubleshooting table Table 6-10 Failure Symptom Possible Causes Suggested Actions | Reference see “Troubleshoot Open circuit or short circuit | Check and fix it ing the cable harness" on page 6-20 Non-operation of | Magnet rusted ‘Scrub the magnet. - magneticvalve | So col abrasion or sealing | Replace the spool or aging seal ring. Severe al carbon pollution in| sub the magnet the valve Failure of defiection spring __| Replace the spring, - Airejection from | iiure of magnetic valve Replace the valve. magnetic valve see “Troubleshoot. Open circuit ‘Check and fix it. ing the cable harness” on Water level switch page 6-20 alarms for full tank | of of structure of water level Replace the switch, - switch The water level switch is Reinstall the switch reversely installed ‘einstall the switch. see “Troubleshoot: Open circuit Check and fix it ing the cable No indication of hamness” on fuel level page 6-20 Reverse connection of power Reconnect the lines : line and signal line 621 @sany Safety, Operation and Maintenance Manual-June 2019TROUBLESHOOTING Double Empty Container Handler Table 6-10 (continue) Failure Symptom Possible Causes Suggested Actions | Reference Line abrasion, there is contact Inaccuracy of fuel resistance between signal line | Check and fix it. - level indication and power line Failure of sensor Replace the sensor. - see “Troubleshoot- Non-operation of || Failure of circuit Check and fix it. ing the cable temperature hamess” on switch page 6-20 ‘Switch damaged Replace the switch - ‘Adjusted value of temperature Repl - Raul switch is inaccurate coum temperature - ‘switch The temperature switen is Check and fix it. - deffective see “Troubleshoot- Non-operation of || Failure of circuit Check and fix it. ing the cable pressure switch harness" on page 6-20 ‘Switch damaged Replace the switch. ‘Adjusted value of pressure Readjust it . Faulty of pressure | Switch is inaccurate ‘switch - ‘The pressure switch is Replace it i defective see “Troubleshoot- Open circuit Check and fix it. ing the cable No signal of hamess” on pressure sensor page 6-20 Reverse connection of signal Reconnect the lines. - line and power line Line abrasion: there is contact resistance between signal line Faulty of pressure | ang its housing, orpower line | Check and fx it . sensor signal and its housing The sensor is defective Replace it. Incorrect signal of throttle, Start the engine and run it Reverse connection of power line of pedal and ground wire Check and fix it. 6-22 ‘Safety, Operation and Maintenance Manual-June 2019 @sanyDouble Empty Container Handler TROUBLESHOOTING Table 6-10 _ (continue) Failure Symptom Possible Causes Suggested Actions | Reference at its max. speed. Step on the throttle, but the rotate speed decreases The rocker switch is damaged | Replace it - 308) No operation of “Troubleshoot- rocker switch The lead is peeled Check and fix it. ing the cable harness” on page 6-20 The bulb is damaged Replace the bulb. > see No indicator light “Troubleshoot Failure of circuit Check and fix it. ing the cable harness’ on page 6-20 The connection iron of contactor does not fall when the power is off The contact spring is too soft ‘Adjust the elasticity of spring. The bottom plate is eneven Remove the protruding part. The connection iron or mechanical part is clamped Recover it to be flexible. The contacts are fused together Replace the contact. The contact of cotactor does not close fully when the power is on The contact spring is too soft Adjust the elasticity of spring Contact of relay is hot Its load exceeds the max. volume Find out the reason and eliminate the failure. The contact moves too much Replace the contact. The contact is serious burt Replace the contact. The contact pressure is inadequate Replace the contact. Poor contact of relay The contact is covered with dust, dirt or is blown Find out the reason and eliminate the failure. @sany Safety, Operation and Maintenance Manual-June 2019 623TROUBLESHOOTING Double Empty Container Handler Table 6-10 (continue) Failure Symptom Possible Causes ‘Suggested Actions | Reference ‘Adjust the elasticity of The contact spring is too soft | spring. Replace it as : necessary. The contact is wrong Replace the contacts. - There are sparks ‘Adjust the elasticity of onthe contact | The contact springs too soft | spring. Replace it as - when the relay is necessary. closed The contact is burnt, poor Repiace it contact Pool connection of armature | Clean the connection : and iron core surface. Abnormal noise of Replace the contact DC contactor Large pressure of contact spring and contactor if pressure necessar ny. The contacts are fused Replace the contacts or . Battery switch | together switch cannot be disconnected __| The mechanical partis Repair it to make it . clamped flexible, see “Troubleshoot- Non-operation of || Open circuit Check aid fix it. ing the cable preheater harness” on page 6-20 Heater damaged Replace it = see Short circuit of horn power “Troubleshoot ircull Dw The hom alarms Check and fix it. ing the cable wire and control power line ° all the time when m hamess” on the power is on page 6-20 The contact of relay controling | peniace the relay the hom is fused The contact head is loose Retighten the contact. The fuse of contol rout ‘See “Fuses, Press down the. | Are TCMLIS | Replace the fuse. changing’ on wiper button, but [oo page 5-132 the wiper motor is The zero wire is not connected Re-connect the zero not starting in the control circuit wire. heck the relay, an The start relay is damaged Check the relay, and - replace it as necessary. 624 Safety, Operation and Maintenance Manual-June 2019 @sanyDouble Empty Container Handler TROUBLESHOOTING Table 6-10 (continue) Failure Symptom Pos: le Causes Suggested Actions Reference The wiper button ic deffective ‘Check the button, and replace it as necessary. see “Troubleshoot- Sound & light The leadis peeled oropen | ona ck and fit ing the cable alarm does not circuit hamess” on work page 6-20 The alarm is damaged Replace it. - see “Troubleshoot. Open circuit ‘Check and fix it. ing the cable harness” on page 6-20 The fuse of power supply is See Fuses, Non-operation of | blown Replace the fuse. changing” on display when the page 5-132 system is see powered “Troubleshoot Failure of circuit ‘Check and fix it. ing the cable hamess’ on page 6-20 ‘Check and recover the Endless loop of program - program. The controller is damaged Replace the controlter. : The contact head is loose Retighten the contact. - ‘See “Fuses, The fuse of control circuit is - Replace the fuse. changing” on blown page 5-132 Rotate the ignition switch, but the engine does not start The gear selector is not at neutral position Rotate the gear selector to neutral position. The start relay is damaged ‘Check the relay, and replace it as necessary. The ignition switch is deffective (Check the switch, and replace it as necessary. Rotate the ignition switch, but the start relay and Pool contact of ignition switch Find out the reason and eliminate the failure. @sany Safety, Operation and Maintenance Manual-June 2019 625TROUBLESHOOTING Double Empty Container Handler Table 6-10 (continue) Failure Symptom Possible Causes Suggested Actions | Reference start contractor do See ‘Fuses, 3s _| Replace the fi bs hot work The fuse of control cirouit i Replace the fuse body | changing” on lown pt page 5-132 “The lead and contact head are | Find out the reason and . loose, pool contact eliminate the failure. The contact head of relay or Find out the reason and contactor is loose, the loop is " - eliminate the failure. ineffective ov pre pecal 7 ioones ts | Make the pedal to . and unable tobe stepped toits | move smoothly. Engine speed bottom. cannot reach to Make the output signal Incorrect throttle output signal $ the rated speed PUsENA | tobe 1.6-3.8V. The connector is loose orthe _| Check the connector . wire is dropped and wire. ae tne engine is ms pe peo Speke ‘ Make the pedal to. . started, and the | and unable tobe stepped tots | rere nat, gearis selected, | bottom. the machine cannot move with | There is parking signal Press down the parking . the gear signal button. see “Troubleshoot- The travelling Failure of the ground wire Check and fix it. ia the cable speed is not eogee page 6-20 displayed and the machine can only travel at 1st gear The speed sensor is damaged Replace it. ‘The circuit board is damaged Replace the channel, or if necessary, replace the frequency divider. Inaccurate measurement of weight Reverse connection of rod and rodless chamber pressure _| Reconnect them. : sensors Pressure sensor is damaged _| Replace it. - The connector is loose or the wire is dropped Check the connector and wire. Wrong alarm of forward over- tuning protection Uneven road Make the road even. Wrong distance of proximity switch Adjust the distance. 6-26 ‘Safety, Operation and Maintenance Manual-June 2019 @sanyDouble Empty Container Handler TROUBLESHOOTING Table 6-10 (continue) Failure Symptom Pos: le Causes Suggested Actions Reference Proximity switch is damaged Replace it The connector is loose or the wire is dropped Check the connector and wire. Cab cannot be moved The ignition switch is tured off Tur on the ignition switch, Solenoid valve is damaged Check the solenoid valve. The connector is loose or the wire is dropped Check the connector and wire. Counterweight cannot be moved The ignition switch is turned off ‘Tum on the ignition switch, Solenoid valve is damaged Check the solenoid valve. The connector is loose or the wire is dropped Check the connector and wire. The menus cannot be displayed normally with distorted figures, ‘Too much redundancy data Refresh the page. The screen is disturbed by magnetism Eliminate the interference source. The screen is damaged Replace the screen. see Shock and ne | ‘THoubleshoot Canbus failure reck and recoverthe | ing the cable belle harness” on The data page 6-20 terminal displayed on the | Canbus terminal resistance iS |r sace the resistance screen is damaged abnormal we “Troubleshoot- The lead is peeled Check and recoverthe | ing the cable wire. harness” on page 6-20 Theft f Sh See “Fuses, bi 'e fuse of power supply 'S | Replace the fuse. changing” on own page 5-132 Na one of — [Failure of controller Check it. 5 controller Check and recover the Failure of program . program. Controller damaged Replace the controller. - Safely, Operation and Maintenance Manual-June 2019 627 @sanyTROUBLESHOOTING Double Empty Container Handler Table 6-10 (continue) Failure Symptom Possible Causes ‘Suggested Actions Reference Failure of input or output circuit Check the circuit. see “Troubleshoot- ing the cable harness" on page 6-20 No operation of extended block The fuse of power supply is. blown Replace the fuse. See “Fuses, changing” on page 5-132 Failure of extended block Check and recover the communication circuit. ‘Communication fault between engine and controler Failure of the communication cirouit Check if the circuit is disconnected or if there is water in circuit Communication fault between controller and 1/0 Failure of the communication circuit Check if the circuit is disconnected or if there is water in circuit, Communication fault between controller and display Failure of the communication circuit Check if the circuit is disconnected or if there is water in circuit, Failure of terminal resistor Check if the terminal resistor is burnt or poorly connected. Check if the terminal resistor is on its plug Communication fault between controller and length & angle sensor Failure of the communication cirouit Cheek if the circuit is disconnected or if there is water in circuit, Failure of terminal resistor Check if the terminal resistor is burnt or poorly connected. Check if the terminal resistor is in its plug, or replace the sensor. 6.4 Engine Error Codes 6.4.1 VOLVO engine error codes For the detailed information, see: “VOLVO ENGINE MANUAL” 6-28 ‘Safety, Operation and Maintenance Manual-June 2019 @sanyDouble Empty Container Handler TROUBLESHOOTING Table 6-11 Engine Error Codes Code Possible Failure suggest Acton No. Causes symptom 1 No faults 2.1 | 97 |Waterinfuel | Waterinfuel | None hey the primary fuel Low coolant 1. Check the coolant level 22 | 111 |Coolantievel |") Engine stopped | 2. Check the function of coolant level monitor. + Short crcut 1. Check that the coolant Coolant level | to positive (+) level sensor cable nol 23 | at | coon Heawers None damaged. 2. Check the function of sensor coolant level sensor. 1. Check that the sensor connector is correctly 1. No signal installed 2. Abnormal 2. Check that the engine frequency sree Yer | speed sensor cable is not Flywheel | 3. “intermittent” damaged. 24 | 637 | soeed sensor | signal fromthe | 2ndruns 3. Check that the engine sensor roughly when | speed sensor is correctly 4, Faultin starts installed in the flywheel sensor housing. 4. Check the function of engine speed sensor. 1. Check that the engine speed sensor connector is correctly installed, tno signa | Enaine takes | 2, Check thatthe engine : longerto start | speed sensor cable is not Camshaft | 2. Abnormal 25 | 636 | drive speed | frequency than normal. | damaged. Engine runs _| 3. Check that the engine sensor 3. Fault in normally when | speed sensor is correctly sensor’ running. installed in the upper timing gear cover. 4. Check the function of engine speed sensor. eee ‘After the engine has 26 | 190 | Engine speed one, None stopped, look for the reason for the high speed @sany Safely, Operation and Maintenance Manual-June 2019 29TROUBLESHOOTING Double Empty Container Handler Table 611. Engine Error Codes (continue) Code] SPN Possible Failure Description Suggested Actions No. | Code Causes Symptom 1, Engine goes toidle 4. Check that the 2. Ifyourelease | potentiometer has been speed 1.Shorted to | the accelerator | connected correctly i positive (+)or | firstandthen | 2. Check that the cable potentiometer " 28 | 608 negative(-) | pressitdown | hamess to the connected to au 2. Fault in again, the potentiometer has not sensor engine canbe | been damaged forcedtorun | 3. Check the using the idle _| potentiometer function contact. 1. Check the indicator 41. Short circuit cables for breaks and Indicator for | 2. Open circuit short circuits 29 | 97 waterin fuel | 3. Faultin None 2. Check the function of indicator indicator. Change it as necessary 1. Shor crcut 7. Check that the oil pressure sensor cable is to positive (+) or ar | 100 [Olpressure | Por N not damaged. sensor ( round) 6 one 2. Check that the oil iM pressure sensor is 2. Open circuit correctly connected 1. Check that the boost temperature sensor connector is correctly installed 1. Shor circuit 2. Check that the boost Boost to positive (+) or ao | 105 |e erature |nevative N temperature sensor cable mperature ( round) (-) fone is not damaged. sensor a 3. Check that the boost 2. Open circuit temperature sensor is correctly installed. 4. Check the function of boost temperature sensor. 1. Short circuit Cacant | topostve oor | Eehestnais,_ | 1. check hatin coolant 33°] 110 | temperature | negative temperature senegy, when the connector is correctly baliaal (round) ©) T engine is hot. | installed 2. Open circuit 6-30 Safely, Operation and Maintenance Manual-June 2019 DsanyDouble Empty Container Handler TROUBLESHOOTING Table 6-11 Engine Error Codes (continue) Code No. Possible Causes Symptom Suggested Actions 2, Check that the coolant temperature sensor cable is not damaged. 3, Check that the coolant temperature sensor is correctly installed. 4. Check the function of coolant temperature sensor. 1. Check that the boost. pressure sensor connector is correctly installed 1. Short circuit Engine smokes | 2. Check that the boost Boost to positive (+) or | more than pressure sensor cable is 3.4 | 106 | pressure negative normally during | not damaged. sensor (ground) (-) acceleration/ | 3, Check that the boost 2. Open circuit | load increase. pressure sensor is correctly installed 4. Check the function of boost pressure sensor. Engine control module reduces | 1. Check the function of engine power _| turbocharger compressor. Boost Boost pressure | (unless the 2. Check the function of pressure too high protection has _| boost pressure sensor. been shut off | 3. Check fuel volume / with the VODIA_ | injector. diagnostic tool). 35 | 106 1. Check that the fuel pressure sensor connector is correctly installed. 41. Short circuit 2. Check that the fuel to positive (+) or pressure sensor cable is negative None not damaged. (ground) (-) 3. Check that the fuel 2. Open circuit pressure sensor is, correctly installed. 4. Check fuel pressure sensor function. Fuel pressure sensor 36 | 94 @sany Safety, Operation and Maintenance Manual-June 2019 631TROUBLESHOOTING Double Empty Container Handler Table 6-11 Engine Error Codes (continue) Code | SPN Possibl Failure 8 Description oss ‘Suggested Actions No. | Code Causes Symptom 1. Check that the cable 4. Short circuit hamess to the oil oll to positive (+) or temperature sensor has 3.7 | 175 | temperature | negative None not been damaged. sensor (ground) (-) 2. Check that the oil 2. Open circuit temperature sensor has been connected correctly. 1. Check ifitis possible to low increase pressure with the 3.8 | 94. | Fuel pressure hel None hand pump. , 2. Check the fuel filter. 3, Check the fuel pre-fiter. 1. Faully alterator Batt ao | ts |Batery 2 Fauty None Check the supply voltage voltage, EMS from the control unit. battery, battery cables 1. The engine cannot be 4. Check that connections 1.Shor circuit | started to the ignition key have not Start output/ | to positive (+) or | 2, The enaine | pen aemayed, 46 | 677 |Startmotor |negative(-) _| starts 2 Check thet ae relay 2. Activated for | immediately tooton ane th hamess to the ignition key ‘a alee has not been damaged. ignition is turned on Engine can only 4.8h heck that the start 520 | Stop input Shor circuit i stopped with | Check that the starter 48 to negative (-) switch connections are not 195 | EMS the auxiliary 2. Open circuit damaged. stop. 1. The engine cannot be 41. Check that connections 1. Short circuit 2 The to the ignition key have not 5.2 | 520 | Starterinput |tonegative() | te. engine | been damaged. 194 |.cIU 2.Aclvated for | TAM ay 2. Check that the cable too long ee fe ely hamess to the ignition key ren the has not been damaged. ignition is tured on 632 Safety, Operation and Maintenance Manual-June 2019 @sanvDouble Empty Container Handler TROUBLESHOOTING Table 6-11 Engine Error Codes (continue) Code] SPN Possible Failure ous Description ons Suggested Actions No. | Code Causes symptom 1. Engine can only be stopped with the auxiliary stop, 2. Engine stops. +. shortereutt | faultis, 41. Check that the starter displayed for 40 | switch connections are not Stop input | Ne9@tV8 ©) | seconds and | damaged 2 ircuit - 53] 970 | ou Open circuit | te engine can | 2. Check that the ignition 3. Activated for a notbe started | switch cable is not ‘9 during this time. | damaged. When a fault is active, the engine can be started but not stopped. 1. Preheating 4. Short circuit | can not be 1. Check that the relay | to positive (+) or | activated. input cable is not Preheat , 54 | 626 a eating | negative 2.Preheating | damaged y (ground) (-) relay is 2. Check the function of 2. Open circuit | constantly relay. connected Oillevel We 57. | 98 | Oillevel evel Is tog oS Waring Check the oil leve! low indication 1. Warning indication 2. The engine control module | 1. Check the oil level. on Oiltemperature | limtsengine | 2. Check the oi 58 | 175 | ernperature |istoe oh output (unless | temperature. i 9 protection has | 3. Check the function of oil been turned off | temperature sensor. with the diagnosis tool vopia) 4. Short creull 4. Check that the cable to positive (+) or Oil level harness to the oil level 59 | 98 negative None sensor sensor has not been (ground) (-) damaged. 2. Open circuit ged. @sany Safety, Operation and Maintenance Manual-June 2019 633TROUBLESHOOTING Double Empty Container Handler Table 6-11 Engine Error Codes (continue) ae Si | aeteg || FECES ae ‘Suggested Actions No. | Code Causes Symptom 2. Check the function of oil level sensor. 1. Check the coolant level. 2. Check the intercooler Engine control | (cleanliness). module reduces | 3. Check if there is air in Coolant engine power _| the cooling system. 1 | 0 [Solent temperature is | (ufless the 4. Check the pressure cap temperature |e high protection has | on the expansion tank been shut off 5. Check the function of with the VODIA. | coolant temperature diagnostic too)). | sensor. 6. Check the function of thermostat. Engine control 1. Check the coolant level. module reduces | 2. Check the intercooler rigine power moon fooon___ [roms Gentes 62 105 temperature is . temperature | 05 high protection has _| temperature sensor the been shut off function of. with the VODIA | 4. Check the function of diagnostic tool). | thermostat. 1. Check that the 8-pin Instruments and | Connector is not damaged. Data link Faulty data link s 2. Check that the cables. 64 | 639 | cany, clu | (CAN), CIU warning lights | Setween the CiU and the stop working. engine management unit are not damaged. Internal fault in contro! module. Engine not 1. Check that the 8-pin ‘operating: connector is not damaged. engine cannot | 2. Check that the cables 2017/PSID_ | Data link (CAN), be started. between the CIU and the 65 639 Engine engine management unit 201 EMS 2 operating are not damaged engine idles and | 3. Check that sleeves 11 can only be and 12 in the connector on stopped with the | the CIU are not damaged auxiliary stop (AUX-stop). 634 Safely, Operation and Maintenance Manual-June 2019 DsanyDouble Empty Container Handler TROUBLESHOOTING Table 6-11 Engine Error Codes (continue) Code] SPN] eccription | _Possiole Failure =a No. | Code Causes symptom Engine control | 1. Check the cil level. module reduces | 2. Check that the air filters engine power _| are not blocked, 66 | 100 | onprossure | 2lpressureis |(unlessine | 3. Check system pressure to0 tow protection has _| valves and safety valves in been shut off _ | the oil system. with the VODIA. | 4. Check the function of ol diagnostic tool). | pressure sensor. Engine stopped. 500 | Piston Piston cooling Linda isae- Check that the oil pressure 67 cooling pressure is too in the engine exceeds 175 192 | pressure low engine speed | ipa (25.4 psi) below 1000 rpm. 1. Check that the piston cooling pressure sensor contact is correctly 1. Short circuit installed. 520 cooing to positive (+) or 2, Check that the cable 68 negative None harness to the piston 192 | pressure ‘ pressur (ground) (-) cooling pressure sensor 2. Open circuit has not been damaged. 3. Check the function of piston cooling pressure sensor. 1. Short circuit 1 Cheol ee supply tonegative (-) voltage from the control Battery 2. Faulty Problems in unit. 69 | 158 | voltage, cru | alternator engine starting, | 2. Check the battery. 3. Faulty battery 3. Check the alternator. or battery 4, Check the 8-pin contact, cables 7. Check that the injector Le cables are not damaged rigine runs 1. Electrical ; 2. Check that the injector fault on 5 oylinders. | connections are not 74} 651 | Mecter 2. Faulty 2.Abnormal | damaged orlinder #1 | compression or | SCund 3, Check fuel supply injector 8 Reduced | pressure Performa! 4, Check the valve clearance @sany Safety, Operation and Maintenance Manual-June 2019 635)TROUBLESHOOTING Double Empty Container Handler Table 6-11 Engine Error Codes (continue) Code] SPN Possible Failure Description ‘Suggested Actions No. | Code Causes Symptom 5. Do a compression test and check cylinder #1 1. Check that the injector cables are not damaged 2. Check that the injector 41. Engine runs , 1. Electrical connections are not on 5 cylinders, Injector, fault 2,Abnormal | Samaged- 72 | 652 | Oinserq2 |2Fauly Seana 3. Check fuel supply compression or pressure. 3. Reduced injector 4. Check the valve performance. clearance. 5, Do.a compression test and check cylinder #2 1. Check that the injector cables are not damaged 2. Check that the injector 4. Engine runs 1. Electrical connections are not on $ cylinders. fault damaged. 73 | 653 | inector 2. Fault 2 Abnormal | 3. Check fuel suppl cylinder#3 | 2 Faulty sound. . pPly compression or pressure. 3. Reduced injector 4, Check the valve performance. clearance. 5. Do a compression test and check cylinder #3 1. Check that the injector cables are not damaged. 2. Check that the injector 4. Engine runs 1. Electrical connections are not on 8 cylinders. fault damaged. 7.4 | 654 | Miector 2. Fault 2 Abnormal | 3. Check fuel suppl cylinder#a | 2 Faully sound. 7 Ply compression or | 5°O ogg | pressure. injector 4, Check the valve performance, clearance. 5. Do.a compression test and check cylinder #4 1. Electrical 1, Engine uns | 4 Check that the injector con 5 cylinders, fault cables are not damaged 75 | 655 | necior 2. Fault 2 Abnormal | 2. Check thatthe injector cylinder#s | PUY sound. v compression or connections are not 3. Reduced injector damaged. performance. 6-36 Safely, Operation and Maintenance Manual-June 2019 @sanvDouble Empty Container Handler TROUBLESHOOTING Table 6-11 Engine Error Codes (continue) Code] SPN Possible Failure Description Suggested Actions No. | Code Causes symptom 3, Check fuel supply pressure. 4, Check the valve clearance. 5, Do a compression test and check cylinder #5. 1. Check that the injector cables are not damaged 2. Check that the injector 41. Engine runs 1. Electrical : connections are not on 5 cylinders Injector, a 2. Abnormal | damaged. 76 | 656 | Sinderne | 2-Faulty sound 3, Check fuel supply compression or pressure, ‘ 3. Reduced injector 4. Check the valve performance, clearance 5. Do a compression test and check cylinder #6. crankcase The engine is_ | 1. Check whether the cates | crankcase shut down (ifthe | crankcase ventilation is z1 | 159 [pressure |ventlation protection has | blocked. : frapaso. | PFessure too [not been shut | 2, Check whether cylinder high off by the liner, piston or piston rings 952VE) parameter tool). | are worn or damaged. 1. Check that the crankcase ventilation pressure sensor contact is Crankcase correctly installed ventilation | * Short circuit 2, Check that the cable to positive (+) or ze | 159 [Pressure | RBar ‘ harness to the crankcase : sensor ( an wry lone ventilation pressure (TAD950- : ‘Open circuit sensor has not been 952VE) Ps damaged. 3, Check the funetion of crankcase vent pressure sensor. Intemal EGR hanes eet Engine control i Check tec as | 2791 | (TAD950- module reduces | Naess (boost pressure 952VE) press engine power. | S&S0") sensor) 2. Check the IEGR. @sany Safety, Operation and Maintenance Manual-June 2019 637TROUBLESHOOTING Double Empty Container Handler Table 6-11. Engine Error Codes (continue) ae Si | aeteg || FECES ae ‘Suggested Actions No. | Code Causes Symptom 2, Mechanical fault on the IEGR 1. Faulty values in pressure and boost pressure sensors. 2. Faultfor oll | 4. Check that the cable pressure and | hamess to oil pressure 620) | ower supply |‘-Shorteut | boost pressure | and boost pressure sensor 93 | r07er | POmer SUPP | 2. Fauttin sensor. has not been damaged. 1080 sensor 3.Lowengine | 2. Check the oil pressure output and boost pressure 4.The sensors. instrument displays zero oil pressure and boost pressure. 1. Cheok thatthe 8-pin connector is not damaged. Faulty data 2. Check that the cables 9.2 | 608 | fink (st587) | Faulty data link | None. between the CIUIDCU and the engine management unit are not damaged, 1. Faulty values in oil pressure and boost pressure 2 Pautforoit | 7 check that the cable “| | hamess to ol pressure 41. Shortcut Pooet areeeure | 2nd boost pressure sensor ag | 620! | Power supply | 9 Eatin oost Pressure | 5 not been damaged 1079 | to sensor sensor. sensor 3 Lowengine | 2: Check the ol pressure output and boost pressure Pi sensors. instrument displays zero oil pressure and boost pressure. 6-38 Safely, Operation and Maintenance ManualJune 2019 DsanyDouble Empty Container Handler TROUBLESHOOTING Table 6-11 Engine Error Codes (continue) Code] SPN Possibl Failure ous Description — Suggested Actions No. | Code Causes Symptom 1. Internal fault 1. Re-program the control Data set in control Engine does not | ™odule 9.8 | 630 | eeu, | madulle Se MO" 2. tthe fault remains, | | 2, Programming change the control clu faulty module 1. Faulty EEPROM, CIU ee runs ‘© Fault in 2. Faulty flash Se da he unit 28 | 629 }controtunit, |memory,ciu | 2 Engine goes }e-program the uni ’ : toidle. 2. Change the CIU unit. clu 3. Fault in 3. Engine can control module, | © ra tay clu Memory fault in engine Engine might _ 2.9 | 639 | Memory taut | re ment | roe Re-program the unit system 1. Internal fault Data set internal faul 1, Re-program the control in control Engine does not | Todule 99 | 630 EPROM. module sa 1908 NOt | 9 if the fault remains, Ewe 2. Programming | S@"- change the control faulty module 1. Engine Control Internal fault in| misfires. 99 | 629 Change the contro! unit module EMS | control module | 2. Engine does 3 not start. 6.4.2 CUMMINS engine error codes For the detailed information, see: “CUMMINS ENGINE MANUAL". @sany Safety, Operation and Maintenance Manual-June 2019 639)TROUBLESHOOTING Double Empty Container Handler Table 6-12 Engine Error Codes Code Description Failure Symptom Suggested Actions ‘SPN/FMI Ei d limited maine speed limited _ | 1. Check the cabling between Vehicle Speed Sensor | to max. engine speed. 84/2 control unit and component. Circuit - data incorrect | Road speed governer 2. Check the sensor. will not work Vehicle Speed Sensor ene speee mie’ i, | t= Check the cabling between 84/10 | Circuit-tampering has | Pome ee ovemner control unit and component. been detected eons 2. Check the sensor. will not work SAE Ji939 Engine may only idle ot 1g. | Multiplexing or engine will not Use diagnostic menu to find the Accelerator Pedal —_| accelerate to ful incorrect segment. Sensor System Error_| speed Accelerator Pedal _| Severe derate in 1. Check the cabling betws Circuit shorted high | engine: Limp home 2 che thes no ‘S| capability only. - Check the sensor. Severe derate in Accelerator Pedal 4. Check the cabling between power output of the 91/4 | Position Sensor control unit and component. engine. Limp home Circuit - shorted low 2. Check the sensor. capability only. None on per formanc Wate{\? Fuel Sensor per 1. Check the cabling between 97/3 | Circuit shorted nigh |®NOWater-in-uel | contro! unt and component warning available. | 2. Check the sensor. None on performance | 4. Check the cab Water in Fuel Sensor be feck the cabling between 9718 ee entod iow, |e Nowatersin-ue! | control unit and component warming available. _| 2. Check the sensor. High Maintenance power, rain water from the fuel. starting Progressive power 4100/1 [Engine Oil Pressure | derate increasing in | Check the engine il level, top Low — critical severity from time _| up asneeded after alert Engine Oil Pressure _ | None on performance. | 4. Check the cabling between 4100/2. | Sensor Circuit-data | No engine protection | control unit and component. incorrect for oil pressure. 2. Check the sensor. Engine OilPressure | None on performance. | 1. Check the cabling between 4100/3 | Sensor Circuit - No engine protection | control unit and component. shorted high for oil pressure. 2. Check the sensor. 6-40 Safety, Operation and Maintenance Manual-June 2019 @sanyDouble Empty Container Handler TROUBLESHOOTING Table 6-12. Engine Error Codes (continue) Code Description Failure Symptom Suggested Actions SPN/FMI ym Engine Oil Pressure _ | None on performance. | 1. Check the cabling between 100/4 | Sensor Circuit - No engine protection | control unit and component. shorted low for oil pressure. 2. Check the sensor. Engine Oil Pressure Check the engine oil level, top N rf 100178 | Low— warning fone on Performance. | up as needed Intake Manifold 1, Check the cabling between 102/2 | Pressure Sensor Engine power derate. | control unit and component. Circuit - data incorrect 2. Cheek the sensor. Intake Manifold 1, Check the cabling between Derate in power 4102/3. | Pressure Sensori#1 | oe engine, Circuit - shorted high control unit and component. 2, Check the sensor. Intake Manifold berate poner 1. Check the cabling between 102/4 | Pressure Sensor #1 control unit and component. output of the engine. Cirouit - shorted low 2, Check the sensor. 1, Check the coolant level in the Intake Manifold Progressive power _| engine, top up as needed. 4105/0 | Temperature #1 High - | 2"@te increasing in| 2, Check thatthe charge-air critical severity from time cooler is clean, clean as needed. after alert, 3. Check that fan belts are intact. 4. Check the sensor. Intake Manifold Possible white smoke, Temperature Sensor | No engine protection | ": Check the cabling between 10513. | #4 circut- shorted | forintake manifold air | onvol unt and component high temperature. ck the See Intake Manifold Possible white smoke. 1 105/4 | Temperature Sensor | Noengine protection | 7. Check the cabling between #1 Circut-shorted | for intake manifold air | Comwolunt and component low temperature. feck the sensor. “Ambient Air Pressure 7. Check the cabling between 108/2 | Sensor Circuit-data | Engine power derate. | control unit and component. incorrect 2. Check the sensor. “Ambient Air Pressure 1, Check the cabling between 108/3 | Sensor Circuit — Engine power derate. | control unit and component shorted high 2. Check the sensor. “Ambient Air Pressure 1, Check the cabling between 10814 | Sensor Circuit - Engine power derate. | control unit and component. shorted low 2. Check the sensor. @sany Safety, Operation and Maintenance Manual-June 2019 641TROUBLESHOOTING Double Empty Container Handler Table 612. Engine Error Codes (continue) Code Description Failure Symptom Suggested Actions SPN/ FMI 1. Check the coolant level 2. Check that the radiator is Progressive power | G2" Engine Coolant tote worecen iy | 3: Checkif there is air in coolant 110/0 | Temperature High — a system, severity from time critical 4, Check the cap on the after alert. expansion tank. 5. Check the sensor. 6. Check the thermostat Engine Coolant Possible white smoke. | + Cock the cabling betwe eck the cabling between No engine protection 110/3 | Temperature Sensor |" eh cont control unit and component, Circuit - shorted high q 2. Check the sensor. temperature Possible white smoke. Engine Coolant No engine protection | ‘= Cheek the cabling between 110/4 | Temperature Sensor | 5 control unit and component. for engine coolant Circuit - shorted low 2. Check the sensor. temperature 1. Check the coolant level 2. Check that the radiator is Progressive power | 2” Engine Coolant dercte mncrensngin | 3:Checkif there is airin cootant 110/16 | Temperature High — severity from ee system, warning 4, Check the cap on the after alert expansion tank 6. Check the sensor. 6. Check the thermostat Pi roaressive power | 4. Check the coolant level in the Engine Coolant Level | derate increasing in m4 engine, top up as needed, Low - critical severity from time 2. Check the sensor. after alert. Electical Charging | inated unter 4167/1 | System Voltage Low - Y | Check batteries and alternator. erred ove low battery voltage condition is corrected Electtical Charging | Amber waming BMP. | +. Check uses. 167 / 16. System Voltage High - | MUMINAIGA UN NISN | 2. Check batteries and warning level batlery voltage alternator. condition is corrected Electrical Charging | amber lamp will ight 467/18 | System Voltage Low - Check batteries and altemator. warning evel until ow battery 6-42 Safely, Operation and Maintenance Manual-June 2019 @sanyDouble Empty Container Handler TROUBLESHOOTING Table 6-12 Engine Error Codes (continue) Code spwrrm | Desetietion Failure Symptom Suggested Actions voltage condition is corrected Possible electrical | 1. Check fuses rea /1e | Batlery #1 Voltage | Gamage to all 2. Check batteries and High - warning electrical components. | alternator. Engine may stop 1. Check fuses 168/18 Patery #1 Voltage | Cnning or be difficult | 2. Check batteries and ‘ow - warning tostart alternator. Fuel injection disabled 490/9. | Engine Speed High |untilengine speed | Ease off throttle or select higher critical fails below the gear. overspeed limit Engine can exhibit misfire as control Engine Speed / switches from the einuneiedl or | Primary othe backup | 1. Check the cabling between 190/2 speed sensor. Engine | control unit and component. two signals from the magnetic pickup sensor power is reduced 2. Check the sensor. while the engine operates on the backup speed sensor. Real Time Clock - i | 25112) | cower interrupt None on performance. ‘Accelerator Pedal Idle 1. Check the cabling between 58/2 | Validation Circuit- | Engine will only idle. | control unit and component. data incorrect 2. Check the sensor. ‘Accelerator Pedal Idle 1. Check the cabling between 5568/4 | Validation Circuit- | Engine will only idle. | control unit and component. shorted low 2. Check the sensor. ‘Accelerator Pedal Idle 1. Check the cabling between 558/13 | Validation Circuit - out | Engine will only idle. | control unit and component. of calibration 2. Check the sensor. Possible no noticeable performance effects or Fuel Pump Control | engine dying orhar —_| 1. Check fuses. 627/2 | Module, Electronic —_| starting. Fault 2. Check batteries and Calibration Code Error | information, trip alternator. information, and maintenance monitor @sany Safety, Operation and Maintenance Manual-June 2019 643TROUBLESHOOTING Double Empty Container Handler Table 612. Engine Error Codes (continue) Code Description Failure Symptom Suggested Ac SPN/ FMI a data can be inaccurate Engine Control 629/12. | Module — critical Engine may not start. | Check the control unit. internal failure Possible no noticeable performance effects or engine dying or har starting. Fault Re the 30/2 | Engine Control ani program the software in Module — data lost ‘ control unit engine. information, and maintenance monitor data can be inaccurate. ‘One or more SAE J1939 multiplexed devices |... sisgnostic menu to find 639/9 | Multiplexing PGN _| will not operate incorrect segment. Timeout Error properly, One or more symptoms will occur. AE J1 Atleast SAE 1989 Rees, Use diagnostic menu to find 639/13. | Multiplexing multiplexed device will incorrect segment. Configuration Error _| not operate properly Extemal Speed Input a Unt | Primary or secondary | 1. Check the cabling between 644/2 pI engines may be shut | control unit and component Sychronization) - data down. 2. Check the sensor, incorrect Fan Clutch Grout. | Tefan may stay on | 7. Check the cabling between 64714 continuously ornot | control unit and component. shorted low run at all 2. Check the sensor. Injector Solenoid 1. Check the cabling between Engine can misfire or 651/5 | Valve Cylinder #1 control unit and component. possibly run rough. Circuit - open circuit 2. Check the sensor. Injector Solenoid 1 Check he cabling b Valve Cylinder #1 reck the cabling between 651/7 | Crcuit out of Engine will shut down. | control unit and component. Tejustmant 2. Check the sensor. Injector Solenoid i i Engine can misfire or | © Check the cabling between 652/5 | Valve Cylinder #2 control unit and component. possibly run rough. Circuit = open circuit 2. Check the sensor. 644 Safely, Operation and Maintenance Manual-June 2019 @sanyDouble Empty Container Handler TROUBLESHOOTING Table 6-12 Engine Etror Codes (continue) Code Y ; Description Failure Symptom Suggested Actions SPN/ FMI Injector Solenoid + Check he cabling b Valve Cylinder #2 eck the cabling between 652/7 Engine will shut down. | control unit and component Circuit - out of 2. Check the sensor. adjustment Injector Solenoid 1. Check the cabling between Engine can misfire or 653/5 | Valve Cylinder #3 control unit and component. possibly run rough Circuit - open circuit 2. Check the sensor. Injector Solenoid + Check he cabling betwe. Valve Cylinder #3 . reck the cabling between 653 /7 Engine will shut down. | control unit and component. Circuit - out of 2. Check the sensor. adjustment Injector Solenoid i i Engine can misfire or_| 1 Check he cabling between 654/5 | Valve Cylinder #4 control unit and component. possibly run rough Circuit - open circuit 2. Check the sensor. Injector Solenoid + Check the canting b Valve Cylinder #4 eck the cabling between 654/7 Engine will shut down. | control unit and component. Circuit - out of 2. Check the sensor. adjustment Injector Solenoid 5 1. Check the cabling between gine can misfire or 855/5 | Valve Cylinder #5 control unit and component. possibly run rough. Circuit— open circuit 2. Check the sensor. Injecto r Solenoid Valve Cylinder #5 1. Check the cabling between 65517 en out of Engine will shut down. | control unit and component iment 2. Check the sensor. Injector Solenoid Engine can misfire or | *- Check the cabling between 8656/5 | Valve Cylinder #6 control unit and component. possibly run rough Circuit - open circuit 2. Check the sensor. Injector Solenoid u 1. Check the cabling between Valve Cylinder #6 656/7 Engine will shut down. | control unit and component Circuit - out of 2. Check the sensor. adjustment Auxilary Equipment [ie engine power | 1 Check he cabling between 703/11, | Sensor input #3 deat | control unit and component (OEM Switch) 2. Check the sensor. Remote Accelerator | Remote accelerator | 1. Check the cabling between 9741/3 | Pedal Position Sensor | will not operate control unit and component Circuit - shorted high Remote accelerator 2, Check the sensor. @sany Safety, Operation and Maintenance Manual-June 2019 645,TROUBLESHOOTING Double Empty Container Handler Table 6-12 Engine Error Codes (continue) Code eis run Description Failure Symptom ‘Suggested Actions position will be set to zero percent. Remote accelerator Remote Accelerator _| will not operate. 1. Check the cabling between 974/4 | Pedal Position Sensor | Remote accelerator _| control unit and component. Circuit shorted low | position will be set to | 2, Check the sensor. zero percent. The engine will not respond to the remote SAE J1939 throttle. Engine may | 1. Check the cabling between 974/19 | Multiplexing Remote | only idle. The primary | control unit and component. Throttle Data Error | or cab accelerator _—_| 2. Check the sensor. may be able to be used. Engine Speed/ Position Sensor #1 1. Check the cabling between 1043/3. | (Crankshaft) Supply | Engine will only idle. | control unit and component. Voltage Circuit - 2. Check the sensor. shorted high Engine Speed/ Position Sensor #1 1. Check the cabling between 1043/4 | (Crankshaft) Supply _ | Engine will only idle. control unit and component. Voltage Circuit - 2. Check the sensor. shorted low ‘Sensor Supply 1. Check the cabling between 1079/3. | Voltage #1 Circuit Engine power derate. | control unit and component. -shorted high 2. Check the sensor. ‘Sensor Supply 1. Check the cabling between 1079/4 | Voltage #1 Circuit- | Engine power derate. | control unit and component. shorted low 2. Check the sensor. Engine will run poorly High Fuel Pressure | but will be severely 1347/3. | Solenoid Valve #1 derated. Fuel pressure | - Circuit - shorted high | wi be higher than commanded. 6-46 Safety, Operation and Maintenance Manual-June 2019 @SANYDouble Empty Container Handler TROUBLESHOOTING Table 6-12 Engine Error Codes (continue) Code Description Failure Symptom Suggested Actions SPN/ FMI ym Engine will run poorly High Fuel Pressure | at dle. Engine will 1347/4 | Solenoid Valve #1 | have low power. Fuel. | ~ Circuit v- shorted low | pressure will be higher than commanded Fuel Pumping 1347/7 | Element #1 (Front)- | Enoine wilnotrunor | mechanically stuck | Power. 6.4.3 YUCHAI engine error codes For the detailed information, see: “YUCHAI ENGINE MANUAL” Table 6-13 Engine Error Codes SPN a 5 Description Possible Causes Suggested Actions Code 1. Check ifthe plug of fuel pressure sensor is connected correctly. 2. Check ifthe circuit of fuel pressure sensor is in good condition. 1. Short circuit of positive | 3. Check if the fuel pressure sensor is oy _ | Fuetpressure | pole (+) ornegative pole () | installed correctly sensor 2. Open circuit 4. Check the function of fuel pressure 3. Low pressure of oil supply | sensor. 5. Check if the manual pump can be used to increase the pressure 6. Check the fuel pre-fiter. 7. Check the fuel fiter. 1 Waterin fue 1. Drain the main fuel fier Water in fuel [ater in fue! 2. Check ifthe cable of indicator is short 2. Short circuit 97 |orindicator [7° t circuit or open circuit malfunction | 9 oon 3. Check the function of indicator. - Indicator error Replace it if necessary. Lubrigating ot | 1: to™!ubricatng ollevel_ | > a ihohemental evel ‘ 08 rr 9°" | 2. short circuit of positive |? Check ne hamess fo Wbncating ol leveland [pote (e)ornegave poe ()_| eve storie good condtion sensor Heiatee- eck the function of lubricating oil level sensor. @sany Safety, Operation and Maintenance Manual-June 2019 647TROUBLESHOOTING Double Empty Container Handler Table 6-13. Engine Error Codes (continue) SPN Code Description Possible Causes ‘Suggested Actions 100 Lubricating oil pressure sensor 1. Short circuit of positive pole (+) or negative pole (-) 2. Open circuit 1. Check if the harness to lubricating oil pressure sensor is in good condition 2. Check if the lubricating oil pressure sensor is connected correctly. 3. Check the lubricating oil level. 4, Check if the lubricating oil filter is clogged. 5. Check the pressure valve and safety valve of lubrication system. 6. Check the function of lubricating oil pressure sensor. 102 ‘Supercharged pressure sensor 1. Short circuit of positive pole (+) or negative pole (-) 2, Open circuit 3. High supercharged pressure 1. Check if the plug of supercharged air pressure sensor is connected correctly. 2. Check if the circuit of supercharged air pressure sensor is in good condition. 3. Check if the supercharged air pressure sensor is installed correctly 4. Check the function of supercharged air pressure sensor. 5. Check the function of turbocharger. 6. Check the fuel amount / pump nozzle 105 Supercharged air temperature and sensor 1, High supercharged air temperature 2. Short circuit of positive pole (+) or negative pole (-) 3. Open circuit 1. Check the coolant level 2. Check the intercooler. 3. Check the function of coolant temperature sensor. 4. Check the function of thermostat. 5. Check if the plug of supercharged air temperature sensor is connected correctly, 6. Check if the circuit of supercharged air temperature sensor is in good condition, 7. Check if the supercharged air temperature sensor is installed correctly 8. Check the function of supercharged air temperature sensor. 107 Air filter pressure 1. Short circuit of positive pole (+) or negative pole (-) 2. Open circuit 1. Check if the plug of air filter is connected correctly. 2. Check if the circuit of air fiter is in good condition. 6-48 Safety, Operation and Maintenance Manual-June 2019 @sanyDouble Empty Container Handler TROUBLESHOOTING Table 6-13. Engine Error Codes (continue) SPN | Description Possible Causes Suggested Actions Code 3. Check ifthe air iter is installed correctly 4. Check the function of ar filter. 1. Check the coolant level 2. Check the intercooler. 3, Check if there is air in the cooling system. 4, Check the pressure cap on expansion water tank. ont 1. High coolant temperature: | 6. Check the function of coolant 110 [temperature |2-Shetteicuitofposive | temperature sensor. pole (+) or negative pole (-) | 6. Check the function of thermostat. and sensor | 3 Qpen circuit 7. Check if the plug of coolant temperature sensor is connected correctly 8. Check ifthe circuit of coolant temperature sensor is in good condition. 9. Check if the coolant temperature sensor is installed correctly 1. Check the coolant level Low coolant | 1. High coolant temperature | > Check the function of coolant level a |levelor 2.Short circuit ofpositive | S00" sengor pole (+) 3. Check if the circuit of coolant level malfunction | 3. Sensor malfunction sensor isn good condition, 1. Short circuit ofnegative 1 4 check the power supply voltage of pole () control unit tse | Battery 2. Malfunction of charging | oOo tne attony. voltage (SPN) | generator 3. Check the charging generator. 3. Malfunction ofbatteryor | + Check tne spin alee battery cables 1. Check ifthe cable hamess of lubricating oil temperature sensor isin good condition 1, Short circuit of positive | > Check ifthe lubricating oil - pole (+) or negative pole (-) 175. | Lubricating ol | Oe mattunetion temperature sensor is installed temperature | 3 High lubricating oil correctly Siddledlel 3. Check the lubricating oil level. 4. Check the lubricating oil temperature. 5. Check the functions of lubricating oil temperature sensor. @sany Safely, Operation and Maintenance Manual-June 2019 49TROUBLESHOOTING Double Empty Container Handler Table 613 Engine Error Codes (continue) SPN Possible Causes Suggested Actions Code ‘Stop the machine to check the causes 190 | rotate speed | {igh engine rotate speed | Frist engine rotate speed 1. Check ifthe potentionmeteris installed correctly. Malfunction of 2. Check ifthe cable harness to engine rotate | 1. Short circuit of positive __ | potentionmeteris in good condition. eos | Speed pole (+) or negative pole (-) | 3. Check the function of potentionmeter. potentionme | 2, Sensor malfunction 4, Check ifthe &-pin plug is in good tertoClU or | 3. Data line malfunction _| condition data line 5. Check ifthe cable hamess betweeen CIU and engine control unit is in good condition 1. Check ifthe cable hamess of lubricating oil pressure sensor and 20 | Powersupply |1,Short circuit ceed eenon Pressure sensor is in ofsensor | 2. Sensor malfunction 2. Check the lubricating oil pressure sensor and supercharged air pressure sensor. P 1. Short circuit of positive __| 1. Check if the cable of relay input is in ‘ower supply 626 | Srrotay (Sen) | Pole (*) or negative pole (-)_ | good condition. 2. Sensor malfunction 2. Check the function of relay. 1 Inner malfunction of control unit 2. Malfunction of electrical g29 | Control unit removable (eePROM) 4. Re-programme the contro! unit. malfunction eee et naen 2. Replace the CIU unit memory, CIU 4, Malfunction of control unit, clu Data allection | 1: !nner malfunction of 4. Re-programme the control unit 630 ° control unit 2. Replace the control unit when memorizer een 2. Program malfunction _| necessary. 1. Check if the plug of engine rotate speed sensor is connected correct ‘Camshaft 1. No signal eres if the cable of engine ‘Busts 636 | speed sensor | 2, Abnormal frequency Fae Gensoria in good soca malfunction | 3. Sensor maltunction 3 check I the envine rotate speed sensoris installed correctly 6-50 ‘Safely, Operation and Maintenance Manual-June 2019 @sanvDouble Empty Container Handler TROUBLESHOOTING Table 6-13. Engine Error Codes (continue) ‘SPN Description Possible Causes ‘Suggested Actions Code 4. Check the function of engine rotate speed sensor. 1. Check if the plug of engine rotate speed sensor is connected correctly 1. No signal 2. Check if the cable of engine rotate Flywheel 2. Abnormal frequency speed sensor is in good condition. 637 | rotate speed | 3. Sensor sends out 3. Check if the engine rotate speed sensor ‘interval’ signals sensor is installed correctly in the 4. Sensor malfunction flywheel cover. 4. Check the function of engine rotate speed sensor. 1. Reprogramme the contro! unit. 2. Check if the 8-pin connector is in good condition. Memorizer 3. Check if the cable hamess between £39 | malfunction | Memorizer malfunction CIU and engine control unit is in good condition. 4, Check if the plug hole 11 and 12 on CIU plug are in good condition. Cylinder 1 651 | (spn) 652 ~ 7 1. Check if the cable of pump nozzle is in good condition. 653 Cylinder 3 1. Electrical malfunction 2. Check if the connector of pump (SPN) 2. Difference of compressed | nozzle is in good condition, Cylinder 4 Pressure or malfunction of _ | 3. Check the fuel supply pressure 654 | (SPN) pump nozzle 4. Check the clearance of air valve. 5. Test the compressed pressure and ess | C¥linder 5 check the cylinder. (SPN) Cylinder 6 858 | (SPN) 1. Shor circuit of negative _ | * Check ifthe power supply switch is evr on pote (+) nanan ble of power supp! eck if the cable supply 2. Too long operating ime | itch is in good condition, 1. Short circuit ofnegative _ | 1. Check if the power supply switch is 970 | Stopinputto | pole (-) connected well. clu 2. Too long operating time 3. Open circuit 2, Check ifthe cable of power supply ‘switch is in good condition. @sany Safety, Operation and Maintenance Manual-June 2019 651TROUBLESHOOTING Double Empty Container Handler Table 6-13. Engine Error Codes (continue) PN € Description Possible Causes ‘Suggested Actions Code 1. Short circuit of negative _| + Checkifthe power supply switch is 5201 | Startinputto | oie (.) connected well 94 jou 2. Check if the cable of power supply 2. Too long operating time | «itch isin good condition 1. Short circuit of negative 5201 | Stopinoutto | ore (2 Check if the power supply switch is 95 | EMS 2, Too long operating time _| Connected well 6.5 Transmission Error Codes For the detailed information, see: “DANA TRANSMISSION MANUAL". Table 6-14 Tranmission Error Codes Code No. Description Limitation Suggested Actions 00.50 | Memory error in control Transmission in Contact SANY distributors for unit transmission locked neutral position | more information 00.51 | Memory error in control_| Transmission in Contact SANY distributors for 51 | unit transmission locked neutral position | more information 00.52 | Memory error in contral_| Transmission in Contact SANY distributors for unit transmission locked neutral position | more information. 90.59 __| Memory errorin contro_| Transmission in Contact SANY distributors for unit transmission locked neutral position | more information. Signal from sensor oll 1. Check cabling to sensor oll zoso | Pressure indicates low | Transmission in pressure. 80 | oil pressure when there | locked neutral position | 2. Check sensor oil pressure should be pressure (with engine on / off) Signal from sensor oil 1. Check cabling to sensor oll go.61 | Pressure indicates low | Transmission in pressure. ‘81 | oilpressure when there | locked neutral position | 2. Check sensor oil pressure should be pressure (with engine on / off) Electrical malfunction 20.62 Control unit activates | Perform checks according to sensor oil pressure error code 50.XX 90.63 _| Electrical matfunction | Transmission in solenoid valve drive | locked neutral position 30.64 _ | Electrical matfunction | Transmission in solenoid vaive drive _| locked neutral position 652 Safety, Operation and Maintenance Manual-June 2019 @sanyDouble Empty Container Handler TROUBLESHOOTING Table 6-14 Tranmission Error Codes (continue) Code No. Descri tion Suggested Actions 20,65 | Solenoid valve drive | Transmission in . “8° | reacts too slow locked neutral position Controlunit saves | 1. Check cabling to control stored information to | unit 30.04 Low battery voltage flash memory and 2. Check alternator, battery restarts to clear and cabling between battery memory and alternator. Control unit receives reduced proportional _| 1. Check voltage feed 30.05 | Highbattery voltage —_| control precision 2. Ifauxiliary start equipment is depending on reduced | connected, disconnect it PWM work cycle Ret tage to foomWolunitreceives | aus toed 31.00 | Reference voltage to | et enor feck voltage fee sensors is too low 2. Check control unit signals Reference voltage to | Contolunitrecelves | c vottage feed 31.01 | sensor isto high reduced sensor 2. Check control unt id signals . Check control unit Check cabling to gear selector Incorrect direction fr i goog | MeerTectdirection from | Controtunitiocks | ith regards to forward and gear selector transmission in neutral reverse signal Control unit does not aog ) IRe2trect gear selection | allow change of range, | Check cabiing o gear selector from gear selector however, operation of ‘| with regards to signal range machine is possible 1. Check transmission with Contolunitndicates_ | Pose to understand it anc if 42.04 | Actual gear ratio too low | that one or several at is the case, which clutch is clutches are slipping | SlPPing 2. Check the set transmission ratio for the control unit, 1. Check transmission with 4205 |hon that one or several _ | Hats tne case, which cluchis I clutches are slipping | Sl'PPing 2. Check the set transmission ratio for the control unit. 1. Check cabling to sensor Signal from sensor Control unit indicates | temperature torque converter. 43.03 | engine rpm and cil ontrol unit indicates | temps ra : temperature the error 2, Check sensor temperature torque converter. @® sany ‘Safety, Operation and Maintenance Manual-June 2019 653