What is XCMG XE490D (CM2150C-CM2150D) Fault Code 1654?

Fault Code 1654 indicates a Fuel Actuator (FCA) Circuit - Data Valid But Below Normal Operating Range condition in the Cummins CM2150 electronic control system. This code triggers when the Engine Control Module (ECM) detects that the fuel control actuator's feedback signal is reading lower than the expected operational threshold, suggesting reduced fuel delivery authority or improper valve positioning.

The Fuel Control Actuator regulates fuel rail pressure by controlling the flow from the high-pressure fuel pump on these Cummins-powered XCMG excavators. When this circuit reads below normal range, the ECM cannot accurately manage fuel delivery, directly impacting engine power output, throttle response, and emissions compliance. For used XE490D machines, this code often appears after extended operating hours when electrical connections degrade or the actuator itself experiences mechanical wear.

Common Symptoms

• Yellow warning lamp illuminated on the instrument cluster with noticeable engine power reduction (derate mode)
• Poor throttle response or hesitation during acceleration, particularly under heavy hydraulic load
• Rough idle or inconsistent engine RPM at low speeds
• Black smoke from exhaust during operation due to improper fuel metering
• Difficulty starting or extended cranking times, especially when the engine is cold

Potential Causes

The most common technical failures triggering Code 1654 on used XCMG excavators include:

• Corroded or loose electrical connectors at the fuel actuator (common failure point after 5,000+ hours due to engine bay heat and vibration)
• Damaged wiring harness between the ECM and FCA, particularly where the harness routes near the engine block or hydraulic lines (known rub point on XE490D models)
• Failed Fuel Control Actuator internal components, including worn solenoid coil or mechanical valve sticking
• Low supply voltage to the actuator caused by corroded ground connections or failing ECM power relay
• ECM calibration issues or software corruption (less common but possible after electrical system faults)

How to Troubleshoot and Fix Code 1654

Step 1: Visual Inspection Inspect the FCA connector and wiring harness for obvious damage, corrosion, or oil contamination. On used excavators, check specifically where the harness passes over the valve cover—this is a known wear point. Clean all connector pins with electrical contact cleaner and verify secure connection.

Step 2: Electrical Testing Using a digital multimeter, perform a resistance check on the FCA solenoid (typically 2-5 ohms). Check supply voltage at the actuator connector with key on, engine off (should read approximately 12V). Inspect ground circuit continuity—poor grounds are extremely common on older machines.

Step 3: Actuator Function Test Connect Cummins INSITE diagnostic software to perform an actuator response test. Monitor the FCA commanded position versus actual position—deviations greater than 10% indicate actuator failure. If electrical tests pass but the actuator fails response testing, replacement is necessary.

Step 4: Harness and ECM Verification Inspect the entire harness length for chafing or insulation damage. On used machines, replace any suspect sections rather than attempting repairs. If all components test properly, ECM reprogramming or replacement may be required.

Disclaimer: This guide provides general diagnostic information. Always consult the official XCMG service manual and Cummins troubleshooting procedures. For complex electrical diagnostics or ECM programming, professional technician assistance is recommended.