Repair Menual Controlksysten 0886.9 Engines Se VolumeTroubleshooting and Repair Manual Electronic Control System ISB and QSB5.9 Engines Volume Il Copyright® 1999 Bulletin No. 3666194-01 ‘Cummins Engine Company, Inc. Printed 5/99 All rights reservedPee eee Foreword This manual provides instructions for troubleshooting and repairing this engine in the chassis. Component and assembly rebuild procedures are provided in the engine shop manual. Reter to Section i - Introduction for instructions ‘on how to use this manual. Read and follow all safety instructions. Refer to the WARNING in the General Safety Instructions In Section | = Introduction. ‘The manual is organized to guide a service technician through the logical steps of identifying and correcting problems: ‘elated to the engine. This manual does not cover vehicle or equipment problems. Consult the vehicle or equipment manutacturer for repair procedures. A series of specific service manuals (tor example: Shop, Specifications, and Alternative Repair) are available and can be ordered by filing out and mailing the Literature Order Form located in Section L - Service Literature. ‘The repair procedures used in this manual are recommended by Cummins Engine Co., Ine. Some service procedures require the use of special service tools. Use the correct tools as described. ‘Cummins Engine Company, ine. encourages the user of this manual to report errors, omissions, and recommendations, for improvement. Please use the postage paid, pre-addressed Literature Survey Form in the back of this manual for communicating your comments, ‘The specifications and rebuild information in this manual are based on the information in effect at the time of printing. ‘Cummins Engine Company, Inc. reserves the right to make any changes at any time without obligation. It differences are found between your engine and the information in this manual, contac! a Gummins Authorized Repair Location Cr call 1-800-DIESELS (1-800-343-7957) toll free in the U.S. and Canada. “The latest technology and the highest quality components are used to manufacture Cummins engines. When re- placement parts are needed, we recommend using only genuine Cummins or ReCon® exchange parts. These parts, can be identified by the following trademarks: COe i aa 4 errTable of Contents Section © resin o oe 2 ‘Troubleshooting Fault Codes .... Idx on xIsB Section | - Introduction General Safety Instructions. Important Sataty Notice Introduction Section i Section Contents Page FaIs Page tb Section I - Introduction THIS PAGE LEFT INTENTIONALLY BLANK.1sB General Safety Instructions Section i - Introduction : Page i-t General Safety Instructions Important Safety Notice A WARNING A Improper practices or carelessness can cause burns, cuts, mutilation, asphyxiation or other bodily injury or feath. Read and understand all of the safaty precautions and warnings before performing any repait. This list contains the ‘general safety precautions that must be followed to provide personal safety. Special safety precautions are included in the procedures when they apply. + Make sure the work area surrounding the product is dry, well it, ventilated, free from clutter, toase tools, parts, ignition sources and hazardous substances. Be aware of hazardous conditions that can exist. Always woar protective glasses and protective shoes when working, Rotating parts can cause cuts, mutilation of strangulation. Do not wear loose-fiting or tom clothing. Remove all jewelry when working. Disconnect the battery (negative [-] cable frst) and discharge any capacitors before beginning any repait work. Disconnect the air starting moto if equipped to prevent accidental engine stating. Puta "Do Not Operate’ tag in the operator's compartment or on the controls. * Use ONLY the proper engine barring techniques for manually otating the engine. Do not attempt to rotate the crankshaft by pulling or prying on the fan. This practice can cause serious personal injury, property damage, or damage to the fan blade(s) causing premature fan failure. * Ian engine has boon operating and the coolant is hot, allow the engine to coo! before you slowly loosen the filler cap and relieve the pressure trom the cooling system. + Do not work on anything that is supported ONLY by lifting jacks or a hoist, Always use blocks or proper stands to suppor the product Before performing any service work. * Relieve all pressure in the air oil, fuel and the cooling systems before any lines, fittings, or related items are romaved of disconnected. Be alert for possible pressure when disconnecting any device from a system that Utiizes pressure. Oo not check for pressure leaks with your hand. High pressure ol! or fuel can cause personal injury. + To prevent suttocation and frostbite, wear protective clothing and ONLY ‘disconnect fuel and liquid refrigerant (freon) lines in a well ventilated area, To protect the environment, quid refrigerant systems must be properly ‘emptiad and filled using equipment that prevents the release of refrigerant gas (luorocarbons) into the almo- sphere. Federal law requires capturing and recycling retrigerant. + TO avoid personal injury, use a hoist or get assistance when liting components that weigh 29 kg [50 Ib] or more. Make sure all iting devices such as chains, hooks, or slings are In good condition and are of the correct capacity Make sure hooks are positioned correctly. Always use a spreader bar when necessary. The lifting hooks must fot be side-loaded. ‘+ Corrosion inhibitor, a component of SCA and lubricating ol, contains alkali. Do not get the substance in your ‘eyes. Avoid prolonged or repeated contact with skin. Do not swallow internally. in case of contact, immodiately ‘wash skin with soap and water. In case of contact, immediataly flood eyes with large amounts of water for a ‘minimum of 15 minutes. IMMEDIATELY CALL A PHYSICIAN. KEEP OUT OF REACH OF CHILDREN. ‘+ Naptha and Methyl Ethy! Ketone (MEK) are flammable materials and must be used with caution. Follow the mmanulaturer's instructs te provide compet safety when using thse materia, KEEP OUT OF REACH OF HILDREN. + To avoid burns, be alert for hot parts on products that have just been turned off, and hot fluids in lines, tubes, and compartments. + Always use fools that are in good condition. Make sure you understand how to use them before performing any service work. Use ONLY genuine Cummins or Cummins ReCon® replacement parts. ‘+ Always use the same fastener part number (or equivalent) when replacing fasteners. Do not use a fastener of {asser quality if repiacements are necessary. + Do not perform any repair when fatigued or after consuming alcohol or drugs that can impair your functioning + Some state and federal agencies in the United States of America have determined that used engine oil can be carcinogenic and can cause reproductive toxicity. Avoid inhalation of vapors, ingestion, and prolonged contact with used engine olGeneral Safety Instructions IsB Page 2 Section | - Introduction NOTES1s ‘Section TF - Troubleshooting Fault Codes Page TF-a Section TF - Troubleshooting Fault Codes Section Contents Fault Code 111 Electronic Control Module (ECM) Microprocessor Fault Code 115 Engine Speed Sensor (ESS) Circuit Fault Code 122 or 123 .... Intake Manifold Pressure Sensor Circuit. Fault Code 131 of 132, ‘Accelerator Position Sensor Circuit Fault Code 133 .... ‘Remote Throttle Position Sensor Fault Code 134... Remote Throttie Position Sensor Fault Code 135 or 141 ‘il Pressure Sensor Circuit. Fault Code 143... Oil Pressure - Engine Protection Fault Code 144 or 145 Coolant Temperature ‘Circuit Fault Code 146 ‘Coolant Temperature - Engine Protection. Fault Code 151 Coolant Temper Fault Code 153 or 154 Intake Manifold Air Temperature Sensor Circuit. Fault Code 155, Intake Manifold Air Temperature Sensor: Fault Code 191 ‘ir Conditioner Clutch Suppiy Circuit Fault Code 211 Fault Code 236 ... Engine Overspeed Circuit... Fault Code 235 .. Engine Coolant Level Fault Code 241 ... Vehicle Speed Sensor Circuit Fault Code 242 . Vehicle Speod Fault Code 243 .... Exhaust Brake Suppiy Circuit Fault Code 245 .... ‘Engine Fan Clutch Fault Code 261 ... Fuel Temperature Sensor Circuit Fault Code 264, 261, 966, 367, 374, 376, oF 617 ‘VP44 Internal Fair... Fault Code 278 ..... ‘Litt Pump Circuit Fault Code 283 or 284 Engine Speed Senso 10 Protection Circuit ply CieIsp Page TF-b Section TF - Troubleshooting Fault Code: : Page Fault Code 287 Trt Fault Code 288 .. TRH Fault Code 297 TF-205 OEM Pressure Sensor Circuit. TF-205, Fault Code 298 ..... : Tree OEM Pressure Sensor Circui TR 212 Foult Code 319 Fault Code 349 .... ae ‘Auxiliary Speed or Auxiliary Pressure input Error. Fault Code 382 oF 386 .. ‘Sensor Supply Circuit. Fault Code 362 . Fuel Pump Fuel Solenoid Vaive Ciosing at Wrong Time. Fault Code 364 ... Electronic Control Fault Code 365 ...... Fuel Pump Voitage Out of Range Error Low. Fault Code 368 ..... Fuel Pump Cari Noi Reach Commanded Timing Fault Code 369 .... Fuel Pump To Engine Synchronization Pulse Not Recognized. Fault Code 372 Idle Select HighiLow Fault Code 373... P44 Fuel Pump Fue! Shut Gif Error Fault Code 375 ... Electronic Controi Module (EGM) Fuel Gaiibration Corrupted. Fault Code 377 Fuel Pump Power Fieiay Stuck-Or Fault Code 381 or 382 ... Intake Air Heater Relay Circuit. Fault Code 385 oF 444... Remote Accelerator Supply Fault Code 387 or 443. Accelerator Position Sensor Circuit Fault Code 391. P44 Feelay Cail Sup Fault Code 415 .... Oil Pressure - Engine Protection. Fault Code 418... Water-in-Fuel Sensor Circuit. Fault Code 422 ...... Coolant Level Sensor Circuit... Fault Code 429... Water-In-Fual (Wie) Sensor Cicc Fault Code 431 or 551 Idle Validation Switch (iWS) Gircut Fault Code 432 ‘Accelerator Pei Fault Code 433IsB Section TF - Troubleshooting Fault Codes Page TF-c Intake Manifold Pressure Sensor Circuit. Fault Code 434 ...... ‘Unswitched Battery Suppiy Circuit Fault Code 441 .. . Unewitched Battery Suppiy Circuit. Fault Code 442 .... Unswitched Battery Supply Fault Code 489 ‘Auxiliary Speed or Auxiliary Pi Fault Code 515 or 516... ‘Coolant Level Sensor Gircui Fault Code 526 ... ‘Switched Droop Seiection Fault Code 527... ‘Dual-Output Driver A. Fault Code 528 ‘Alternate (Switched) Torque Cu Fault Code 529 ...... Dual-Ouiput Driver B.. Fault Code 599 Fault Code 611 .. Fault Code 76: ‘Output Device Driver (Tiansmission Shift Modulation)... Information Fault CodesPage TF-d IsB ‘Section TF - Troubleshooting Fault Codes. THIS PAGE LEFT INTENTIONALLY BLANK.'sB Information Fault Codes ‘Section TF - Troubleshooting Fault Codes Page TF-1 Information Fault Codes - Information Fault Codes have simple, corrective actions and no fault code troubleshooting tree. = SRT 00-394 applies to all of the Information Fault Codes listed below. “After correcting the condition that caused the fault, let the engine warm up, then let the engine run for 1 minute to inactivate the fault code, Then, use INSITE™ to clear the fault code. Fault Code 211 .dicates that the vehicle's electronic control unit (VECU), provided by the OEM, detected an active fault in the vehicle's control system. Effect: None on performance. Corrective Action: Refer to the OEM for proper repair procedure. Clear inactive fault code using INSITE™ after OEM problem is corrected. Fault Code 287 SRT: SID; S091, SPN; 91, FMI; 2/19 Reason: The OEM vehicle electronic control unit (VECU) detected a fault with its accelerator pedal. Effect: The engine will only idle. Corrective Action: Refer to the OEM troubleshooting and repair manual. Troubleshoot the accelerator pedal con- nected to the OEM supplied vehicle electronic control unit (VECU). Fault Code 288 Lamp: Yellow SRT: SID; $029, SPN; 29, FMI; 2/19 ‘The OEM vehicle electronic control unit (VECU) detected a fault with its remote throttle. Effect: The engine will only idle. Corrective Action: Refer to the OEM troubleshooting and repair manual. Troubleshoot the remote throttle pedal connected to the OEM supplied vehicle electronic control unit (VECU). Fault Code 319 Lamp: Maintenance or none ‘SRT: Reason: Real-time clock lost power. Unswitched battery power to the ECM has been interrupted. Effect: None on performance. Data in the ECM will not have accurate time and date information Corrective Action: Set real-time clock using RoadRelay” (if equipped) or by using INSITE™. Fault Code 599 Lamp: Red SRT: Reason: The dual-output feature in this customer-apecialized calibration has initiated an engine shutdown based on ‘operating conditions, engine sensor values, or OEM inputs to the ECM. Effect: Engine will shut down, Corrective Action: The dual-output feature is contained only in customer-specialized calibrations. The feature can be set up to shut down the engine based on operating conditions, engine sensor values, or OEM inputs to the ECM. The two OEM inputs are OEM switch input and OEM pressure input. The technician must contact Cummins Engine Company to determine the dual-output feature’s con- figuration to understand which parameters and what parameter values) re causing the engine to shut down.Fault Code 611 IsB Page TF-2 Section TF - Troubleshooting Fault Codes Fault Code 611 Lamp: None SRT: Reason: The engine was shut down with the kayswitch before proper engine cooldown. Effect: No action is taken by the ECM, Corrective Action: Hot shutdowns damage engine components and shorten engine life. Refer to the engine operation and maintenance manual for proper cooldown techniques.isa Fault Code 111 ‘Section TF - Troubleshooting Fault Codes Page TF-3 Fault Code 111 Electronic Control Module (ECM) Microprocessor ‘CODES REASON, EFFECT Fault Code: 111 EGM internal hardware error. Possible no effect or engine may run PID), SIDIS): $254 rough or not start. SPN: 620 FMI: 12 Lamp:_Yellow ECM Microprocessor Circuit Description: The ECM is a computer that is responsible for engine control, diagnostics, and user features. Component Location: ‘ire BOM is located On the left side of the engine block, behind the fuel filter Shoy : Fri laut cede can be caused only by an intomal ECM problem. Repairs are not possible for the ECM.Fault Code 111 1sB Page TF-4 Section TF - Troubleshooting Fault Codes TROUBLESHOOTING SUMMARY A caution A ‘To avoid damaging a new ECM, all other active fault codes must be investigated prior to replacing the ECM. STEPS STEP 4: Check the fault codes. ‘STEP 1A: Read the fault codes. STEP 1B: Check the inactive counts of Fault Code 111. STEP 2: Clear the fault codes. STEP 2A: Disable the fault code. ‘STEP 2B: Clear the inactive fault codes. ‘SPECIFICATIONS ‘SRT CODE Fault Code 11 Inactive Fault is inactive and no erformance-related com- plaints are associated with this fault Fault Code 111 inactive All faults cleared TROUBLESHOOTING STEP STEP 1: Check the fault codes. STEP 1A: Read the tault codes. AcauTiOnA Fe gvold damaging 2 new ECM, all other active fault codes must be Investigated prior to replacing the Condition: ‘+ Connect all components. + Turn keyswitch to the ON position. Action Specifications/Repair Next Step Read the fault codes. OK 1B ‘+ Flead the fault codes using INSITE™. Fault Code 111 inactive NOT OK 2A Replace the ECM Refer to Procedure 019-031.1sB ‘Section TF - Troubleshooting Fault Codes STEP 1B: Check the inactive counts of Fault Code 111. Fault Code 111 Page TF-5 AcautionA, Je,mold damaging a new ECM, al othr ative felt codes must be investigated prior to replacing the Condition: * Tur keyswitch to the ON position. Action Specifications/Repair Next Step ‘Check the inactive counts of Fault Code 111. | OK 2A * Read the inactive counts of Fault Code 111 | Fault is inactive and no pertormance- using INSITE™, related complaints are associated with this fault. NOT OK 2A Replace the ECM Reter to Procedure 019-051. STEP 2: Clear the fault codes. STEP 2A; Disable the fault code. # Connect all components. ‘Action Specifications/Repair Next Step Disable the fault code. , OK 28 + Start the engine, and let ide for 1 minute. | Fault Code 111 inactive * Verify that Fault Code tt NOT OK on Return to the troubleshooting steps, or contact your local Cummins Authorized Repair Location if al the steps have been |e completed and checked again. ‘STEP 2B: Clear the inactive fault codes. Condition: + Connect all components. + Turn keyswitch to the ON position. Action Specifications/Repair Next Step Clear the inactive fault codes. oK Repair + Erase the inactive fault code using INSITE™. | All faults cleared complete NOT OK ‘Appropriate ‘Troubleshoot any remaining active fault troubleshoot- codes. jing chartFault Code 115, 'sB Page TF-6 Section TF - Troubleshooting Fault Codes Fault Code 115 Engine Speed Sensor (ESS) Circuit ‘CODES REASON, EFFECT Fault Code: 115 | No engine speed signal detected _| Engine power derate. PID(P), SID(S): P190 at pin 17 of the engine hamess. —_| Possible white smoke. SPN: | 190 FMI: 2 Lamp: Yellow Engine Speed Sensor (ESS) Circuit oO Engine Speed Sensor Circuit Description: ‘The engine speed sensor provides engine speed information to the electroni¢ control module (ECM). The sensor must be powered up by (+) 5 VDC,to oparate. The sensor generates its signals by sensing the movement of target teeth machined into a tone whee! that is mounted to the crankshaft. The tone wheel has 35 teeth and a gap where the 36th tooth would be placed. This missing tooth indicates that cylinder 1 (and 6) is at top dead center. Component Location: ‘The engine speed sensor is located on the intake side of the engine block, at crahkshaft level, between cylinders 4and 6. Shop Talk: ‘This fault code will also cause a fuel derate. This could be the cause of a low-power complaint. Also, this fault code can cause starting probiems in cold weather.1sB Section TF - Troubleshooting Fault Codes Fault Code 115 Page TF-7 TROUBLESHOOTING SUMMARY A caution A ‘To avoid damaging a new ECM, all other active fault codes must be investigated prior to replacing the ECM. A caution A To avoid pin and harness damage, use the following test leads when taking a measurement: Part No. 3822758 - male AMP/Metri-Pack test lead. STEPS SPECIFICATIONS SRT CODE STEP 4: Check for multiple fault codes, STEP 1A: Read faults. Fault Code 283 or 284 Inactive STEP 2: Check the engine harness. STEP 2A: Inspect the engine harness and the No damaged pins ECM connectors. STEP 2B: Check for an open circuit. Less than 10 ohms STEP 2C: Check for a short circuit to ground. More than 100k ohms STEP 2D: Check for a short circuit from pin to More than 100k ohms pin, STEP 3: Check the ESS. STEP 3A: Inspect the ESS and engine hamess No damaged pins ‘connectors. STEP 3B: Check ESS supply voltage. 4.75 to 5.25 VDC STEP 3C: Check for signal from the ESS. Signal present Inspect the nose of the sensor. No damage found STEP 4: Clear the fault codes. STEP 4A: Disable the fault codes. Fault Code 115 inactive STEP 4B: Clear the inactive fault codes. All fault codes cleared TROUBLESHOOTING STEP STEP 1: Check for multiple fault codes. STEP 1A: Read the fault codes. Condition: + Turn keyswitch to the ON position. Action Specifications/Repair Next Step Flead the fault codes. OK 2A * Read the fault codes using INSITE™ Fault Code 283 or 284 inactive NOT OK Refer to Fault Code 289 or 284 active Fault Code 283 or 284Fault Code 115 Page TF-8 STEP 2: Check the engine harness. IsB Section TF - Troubleshooting Fault Codes STEP 2A: Inspect the engine harness and the ECM connectors. ‘* Turn keyswitch to the OFF position. * Disconnect the engine harness from the ECM. AcAUTIONA Begvold damaging a now ECM, al other active fault codes must be investigated prior to replacing the Condition: * Pushed back or expanded pins * Corroded pins * Moisture in or on the connector ‘+ Missing or damaged seals. Action Specifications/Repair Next Step Inspect the engine harness and the ECM ‘0K 2B connector pins for the following: No damaged pins * Bont or broken pins rrr aa Repair the damaged pins Repair or replace the engine hamess or ECM, whichever has the damaged pins. * Repair the engine harness. Refer to Procedure 019-250. * Replace engine harness. Refer to Proce- ‘dure 019-043. * Replace ECM. Refer to Procedure 019-031.1sB Section TF - Troubleshooting Fault Codes STEP 2B: heck for an open circuit. AcautionA, To avoid pin and harness damage, use the following test lead when taking a measurement: Part No. 3822758 - male AMP/Metri-Pack test lead. Fault Code 115, Page TFS Condi = Tum keyswitch to the OFF position, ‘= Disconnect the engine harness from the ECM. * Disconnect the engine harness from the ESS. Action Specifications/Repair Next Step. ‘Check for an open circuit in the +5:VDC supply ire and the signal wire. ‘+ Measure the resistance from pin 8 of the ‘engine harness connector to pin A on the harness side of the ESS connector. ‘+ Measure the resistance from pin 18 of the engine harness connector to pin B on the harness side of the ESS connector. ‘= Measure the resistance from pin 17 of the ‘engine harness connector to pin C on the harness side of the ESS connector. OK Less than 10 ohms 2c NOT OK Replace the engine harness Refer to Procedure 019-043, 4AFault Code 115, isp Page TF-10 Section TF - Troubleshooting Fault Codes. STEP : Check for a short circuit to ground. AcaUTIONA To avoid pin and harness damage, use the following test lead when taking a measurement: Part No. 3622758 - male AMP/Metri-Pack test lead. Condi * Tum keyswitch to the OFF position, ‘+ Disconnect the engine harness from the ECM. * Disconnect the engine harnoss from the ESS. Action Specifications/Repai Next Step ‘Check for a short circuit to ground. oK 2 * Measure the resistance from pin 8 of the More than 100k ohms ‘engine harness connector to the engine block ground ‘+ Measure the resistance from pin 18 of the ~ engine harness connector to the engine block | NOT OK 4A ‘ground. Roplace the engine hare ‘+ Measure the resistance from pin 17 of the __| Refer to Procedure 019-043, ‘engine harness connector to the engine block ground,1sB Fault Code 115, Section TF - Troubleshooting Fault Codes Page TF-11 STEP 2D: Check for a short cirouit from pin to pin. AcauTionA To avoid pin and harness damage, use the following test I Part No. 8822758 - male AMP/Metri-Pack test lead. Condition: + Tum Keyswitch to the OFF position, ‘* Disconnect the engine harness from the ECM, * Disconnect the engine harness from the ESS. \d when taking a measurement: Action | Specifications/Repair Next Step ‘Check for a short circuit from pin to pin. OK 3A + Measure resistance from pins 8, 17, and 18 of | More than 100k hms. tho engine harness connector to all other pins inthe connector pn® | Nor OK «” Replace the engine harn Refer to Procedure 019-043. Test All Pins 2Fault Code 115, Page TR-12 STEP 3: Check the ESS. STEP 3A: Inspect the ESS and the engit 1sB Section TF - Troubleshooting Fault Codes harness connectors. Condition: © Tum Keyswitch to the OFF position, Disconnect the engine harness from the ESS. * Connect the engine harness to the ECM. Pushed back or expanded pins Cotroded pins Moisture in or on the connector ‘+ Missing or damaged seals, Repair the damaged pins Repair or replace the engine harness or ‘sensor, whichever has the damaged pins. ‘+ Repair the engine harness. Refer to Procedure 019-203. ‘+ Replace the engine harness. Refer to Procedure 019-043. ‘+ Replace the ESS. Refer to Procedure 019-042, Action Specifications/Repair Next Step Inspect the ESS and the engine harness. OK 3B ‘connector pins for the following: No damaged pins * Bent or broken pins nora aa1sB Fault Code 115, ‘Section TF - Troubleshooting Fault Codi Page TF-13 STEP 3B: Check ESS supply voltage. Condition: * Tum keyswitch to the ON position. = Disconnect the engine harness from the ESS. Action Specifications/Repair Next Step, ‘Check ESS supply voltage. OK 3c ‘© Measure the voltage from pin Ato pin B on | (++) 4.75 to 5.25 VDC the harness side of the ESS connector. NOFOK 7 Replace the ECM Refer to Procedure 019-031,Fault Code 115 Page TF-14 STEP 3C: Check for a signal from the ESS. {sB Section TF - Troubleshooting Fault Codes Condition: ‘+ Turn keyswitch to the ON position. ‘Install breakout cable, Part No. 382475, between the ESS and the engine hamess. NOTE: Negative (-) lead of multimeter should bbe connected to pin B and the positive (+) lead to pin C. Action Specifications/Repair | Next Step Check for a signal from the ESS. OK 3D * Measure the voltage from pin C to pin B on Signal present the breakout cablo while baring the engine ‘over! the signal is present, the voltage will fluctuate borween less than (+) 0.5 VBC and | greater than (+) 4.5 VDC as the engine is NOT OK 4A Barred over slomy Replace the ESS Refer to Procedure 019.042. STEP 3D: Inspect the nose of the sensor. Condition: * Tum keyswitch to the OFF position. ‘+ Remove sensor from engine. Rofer to Procedure 019-042. crankshaft tone wheel gear. ‘+ Inspect for sensor swelling, ‘+ Check for properly installed tone wheel Replace the engine speed sensor Refer to Procedure 019-042, Action Specifications/Repair | Next Step ‘Inspect the nose of the sensor for damage or | OK. 4a debris. No damage found ‘+ Inspect for metal debris on sensor tip. ‘ inspect for damage on the sensor caused by | NOT OK | a'sB Section TF - Troubleshooting Fault Codes STEP 4: Clear the fault codes. ‘STEP 4A; Disable the fault codes. Condition: = Connact all components. ‘+ Turn Keyswitch to the ON position. Fault Code 115 Page TF-15 Action Specifications/Repair Next Step Disable the fault codes. ‘= Start the engine, and let idle for 1 minute. + Verify Fault Code 115 is inactive. 0K Fault Code 118 inactive 4B NOT OK Return to the troubleshooting steps, or contact your local Cummins Authorized Repair Location if all the steps have been completed and checked again. 2A, = Connect all components. + Tum keyswitch to the ON position. Action Specifications/Repair Next Step Clear the inactive fault codes. OK Repair * Erase the inactive fault codes using INSITE™. | All fault codes cleared complete NOT OK “Appropriate Troubleshoot any remaining active fault codes. troubleshoot: ing chartsFault Code 122 or 123 IsB Pago TF-16 Section TF - Troubleshooting Fault Codes Fault Code 122 or 123 Intake Manifold Pressure Sensor Circuit CODES REASON EFFECT Fault Code: 122 or 123 | FC 122: High voltage detected at | Engine will derate to no-boost fueling. PID(P), SID(S): P102 the boost pressure sensor signal SPN: 102 pin 45 of the engine harness. FMI: 3 or 4 FC 128: Low voltage detected at fae wit the boost pressure sensor signal pin 45 of the engine harness. Intake Manifold Pressure Sensor Circuit Intake Manifold Pressure Sensor Return _—*Mtake Manifold Pressure Signal| ECM ie —— CL] 2 Kj A: 7 ~*~ 10 Intake Manifold Pressure Engine Harness Sensor +5VDC Supply Intake Manifold Pressure Sensor Circuit Description: The intake manifold pressure sensor monitors intake manifold pressure and passes information to the electronic control module (ECM) through the engine harness. Ifthe intake manifold pressure becomes too high, it will cause a derate condition. Component Location: ‘Fie intake manifold pressure sonsor is located on the rear ofthe intake air manifold in the second port on the side of the head to the right of the fuel filter.1s8, Fault Code 122 or 123 Section TF - Troubleshooting Fault Codes Page TF-17 jo TF-4 Shop Talk: = Determine it engine is being overfueled ‘© Confirm that the correct intake manifold pressure sensor part number is being used. ‘* Confirm that the correct turbocharger is being used. itis suspected that cold intake air is the cause of the high intake manifold pressure, test the engine with warm intake air. * Inspect the intake mar circuit Check for high restriction in the intake alr manifold due to a shutdown device in the manifold (if the vehicle equipped with one). Do not remove this device. Ifthe engine is operated in a flammable atmosphere, the device is an essential safety feature. Id pressure sensor circuit for signs of tampering. Remove any extra wires from theFault Code 122 or 123 Page TF-18 Is Section TF - Troubleshooting Fault Codes. TROUBLESHOOTING SUMMARY A caution A To avoid pin and har 5 damage, use the following test leads when taking @ measurement: Part No. 3822758 - male AMP/Metti-Pack test lead. A caution A ‘To avoid damaging a new ECM, all other active fault codes must be Investigated prior to replacing the ECM. STEPS STEP 1: Check for multiple fault codes. ‘STEP 1A: Read the fault codes. STEP 2: Check for mechanical failure. ‘STEP 2A: Verify proper turbocharger operation. ‘STEP 3: Check the engine harness. ‘STEP 3A: Inspect the engine harness and the ECM connector pins. STEP 3B: Check for an open circuit. STEP 3C: Check for a short circuit to ground. STEP 3D: Check for a short circuit from pin to pin. SPECIFICATIONS ‘SRT CODE Fault Codes 352 and 386 are not active Positive intake manifold pres- ‘sure from turbocharger and wastegate not stuck closed No damaged pins Less than 10 ohms More than 100k ohms More than 100k ohms: STEP 4: Check the intake manifold pressure sensor. STEP 4A: Inspect the intake manifold pressure sensor and engine harness connec- tor pins. STEP 4B: Check the intake manifold pressure supply voltage. STEP 4C: Check the intake manifold pressure signal voltage. STEP 5B: Clear the inactive fault codes. No damaged pins (+) 4.75 to 5.28 VOC (+) 0.42 to 0.58 VDC Fault Code 122 or 123 inactive All faults codes clearedFault Code 122 or 123 1sB Section TF - Troubleshooting Fault Codes Page TF-19 TROUBLESHOOTING STEP STEP 1: Check for multiple fault codes. STEP 1A! Read the fault codes. Condition: ‘+ Tum keyswitch to the ON position. Action Specifications/Repair Next Step Read the fault codes, OK 2A ‘+ Read fault codes using INSITE™. Fault Codes 352 and 386 are not active NOTE: If multiple temperature or pressure | NOT OK. Fault Code fault codes exist, this procedure should not | Possible sensor failure 352 bbe followed. | Shor circuit to ground in sensor +5-VDC ‘common supply, or short circuit from pin to bin STEP 2: Check for mechanical failure. STEP 2A: Verify proper turbocharger operation. Condition: ‘= Tum keyswitch to the OFF position Action ‘Specifications/Repair Next Step \Verity proper turbocharger operation. Check for | OK 3A positive intake manifold pressure using a Positive intake manifold pressure from mechanical gauge. turbocharger and wastegate not stuck- closed zs NOT OK 5A Low intake manifold pressure Correct the base engine malfunction ‘causing low intake manifold pressure. Refer to the Troubleshooting and Repair Manual, ISB Engines, Bulletin No, 3866193.Fault Code 122 or 123 Page TF-20 STEP 3: Check the engine harness 1sB Section TF - Troubleshooting Fault Codes STEP 3A: Inspect the engine harness and the ECM connector pins. Acaurion A, Te.gvoid damaging a new ECM, al other active fault codes must be Investigated prior to replacing the ECM. Condition: ‘+ Tum keyswitch to the OFF position. = Disconnect the engine hamess from the ECM. Pushed back or expanded pins ‘* Corroded pins ‘+ Moisture in or on the connector ‘+ Missing or damaged seals. Action Specifications/Repair Next Step Inspect the engine harness and the ECM OK 3B connector pins for the following: No damaged pins ‘© Bent or broken pins rrorrd 7 Repair the damaged pins Repair or replace the engine harness or ECM, whichever has the damaged pins. ‘* Repair the engine harness. Refer to Procedure 019-250. ‘+ Replace the engine harness. Refer to Procedure 019-043. ‘+ Replace the ECM, Refer to Procedure 019-031.isB Fault Code 122 or 123 Section TF - Troubleshooting Fault Codes Page TF-21 STEP 3B: Check for an open circuit. —— ‘AcautionA To avoid pin and harness damage, use the following test lead when taking a measurement: Part No. 3822758 - male AMP/Metri-Pack/Deutsch test lead. Condition: ‘¢ Turn keyswitch to the OFF position. ‘= Disconnect the intake manifold pressure sensor from the engine harness. + Disconnect the engine haess from the ECM. Action ‘Specifications/Repair Next Step ‘Check for an open circuit OK 3c + Measure the resistance from pin 45 on the —_| Less than 10 ohms fongine harness connector to pin C on the : hamess side of the intake manifold pressure | NOT OK * Maier connectbe Replace the engine harness. | Refer to Procedure 019-043.Fault Code 122 or 123 1sB Page TF-22 Section TF - Troubleshooting Fault Codes. STEP 3C: Check for a short circuit to ground. AcauTionA, Tr avoid pia and namess damage, use the folloning tet lead when taking 9 measurement Part No. 6822750 = mele AMP/Metr-Pack/Deutach teet lead. : Condition: * Tum keyswitch to the OFF position. * Disconnect the intake manifold pressure sensor from the engine harness. * Disconnect the engine hamess from the ECM. Action Specifications/Repair Next Step Check for a short circuit to ground. OK 3D * Measure the resistance from pin 45 on the —_| More than 100k ohms harness side of the engine harness connector to engine block ground. siorok ie Replace the engine harness Refer to Procedure 019-043.isB Fault Code 122 or 123 Section TF - Troubleshooting Fault Codes Page TF-23 STEP 3D: Check for a short circuit from pin to pin. AcauTionA, To avoid pin and harness damage, use the following test lead when taking a measurement: Part No. 3822758 - male AMP/Metr|-Pack test lead. Condition: + Tum Keyswitch to the OFF position, + Disconnect the engine harness from the intake manifold pressure sensor. + Disconnect the engine harness from the ECM, Action Specifications/Repair Next Step (Check for a short circuit from pin to pin. oK 48 ‘+ Measure the resistance from pins 45 and 10 | More than 100k ohms on the harness side of the engine hamess Gr oq cA F to all other pins i connector to all ther pie in the engine Ruploce Gis engine harsees Refer to Procedure 019-043,Fault Code 122 or 123 Page TF-24 IsB Section TF - Troubleshooting Fault Codes STEP 4: Check the intake manifold pressure sensor. STEP 4A: Inspect the intake manifold pressure sensor and engine harness connector pin: Condition: ‘* Turn keyswitch to the OFF position. + Disconnect the en 12 harness from the intake manifold pressure sensor. Pushed back or expanded pins Corroded pins Moisture in or on the connector Missing or damaged seals. Action Specifications/Repair Next Step Inspect the engine harness and the sensor OK 4B connector for the following: No damaged pins ‘© Bent or broken pins nOFOK = Repair the damaged pins Repair or replace the intake manifold pressure sensor or the engine hamess, whichever has damaged pins. * Repair the engine harness. Refer to Procedure 019-203, * Replace the engine harness. Refer to Procedure 019-043. ‘+ Replace the intake manifold pressure sensor. Refer to Procedure 019-061.IsB Section TF - Troubleshooting Fault Codes STEP 4B: Check the intake manifold pressure supply voltage. Fault Code 122 or 123 Page TF-25 Condition: ‘+ Tur keyswitch to the ON position. ‘engine harness, ‘© Connect the intake manifold pressure sensor breakout cable, Part No, 3824775, between the sensor and the Action Specifications/Repair Next Step ‘Check the intake manifold pressure supply ‘OK 40, voltage, (+) 4.75 to 5.25 VDC * Measure the voltage from pin A to pin B of NOT OK 5A the i ni ure sensor circuit. the intake manifold pressure sensor cicuit, | POT ne engine harness Refer to Procedure 019-043,Fault Code 122 or 123 Page TP-26 STEP 4C: Check the intake manifold pressure signal voltage. 'sB Section TF - Troubleshooting Fault Codes Condition: ‘* Turn keyswitch to the ON position. engine harness. ‘* Connect the intake manifold pressure sensor breakout cable, Part No. 3824775, between the sensor and the ‘Action ‘Specifications/Repair Next Step Chock he rake mania prosou signal” OK oA voltage. (+) 0.42 to 0,58 VDC iter os tastenpabnuee a re NOT OK mA ett mantel precueeoncorcicat, [MOTOR Sener! He racers eter i B Ac STEP 5: Clear the fault cod Ter, S; Cigar the foul codes Condition: © Connect all components. 1 GantRofenc tthe ON postion. ‘Action ‘Specifications/Repair Next Step Diabet el cade x 7 See ie creed tide fort minute | Rest Code 122 or 129 inactive 2 Many tet ut code aber 3 eins, rome = Return to troubleshooting steps, or contact your local Cummins Authorized Repair Location if all steps have been completed and checked again.sp Fault Code 122 or 123 Section TF - Troubleshooting Fault Codes Page TF-27 STEP 5B: Clear the inactive fault codes. Condition: * Connect all components + Turn Keyswitch to the ON position. Action ‘Specifications/Repair Next Step Clear the inactive fault codes. OK Repair * Erase the inactive fault codes using INSITE™. | All faults codes cleared complete NOT OK “Appropriate TFoubleshoot any remaining active fault troubleshoot- codes. ing chartsFault Code 131 or 132 TF-28 IsB Page Section TF - Troubleshooting Fault Codes Fault Code 131 or 132 Accelerator Position Sensor Circuit ‘CODES REASON, EFFECT Fault Code: 131 or 182 | FC 131: High voltage detected at | Engine idles when idle validation switch PID(P), SID(S): POST accelerator position signal pin 30 _| indicates idle and ramps up to at a default SPN: 091 of the OEM harness. set speed when tho idle validation switch FMI: 3or4 indicates offidle, FC 12: Low voltage detected at ‘accelerator position signal pin 30 of the OEM harness. Lamp: Yellow ‘Accelerator Position Sensor Circuit Accelerator Position Accelerator Position +5VDC Supply\,___ Signal = OEM Harness APS \ i "ECM 25 Accelerator Position [7 > 8 26 Return Sanh Common Ground itch Si Accelerator Switeh Stanat sete Validation Switch Signal Pedal & (2 Circuit Descriptio ‘The accelerator position sensor is attached to the accelerator pedal. The accelerator position sensor sends a signal to the electronic control module (ECM) when the driver pushes on the accelerator pedal. The accelerator position circuit contains three wires: a + §-VDC supply wire (pin 29), a return ground (pin 19), and a signal wire (pin 30). NOTE: The connector pin latters shown for the accelerator pedal wiring in these troubleshooting steps are ‘examples of representative sensors. The connector pin assignments can vary with equipment manufacturer, But the base troubleshooting logic will still apply. Component Location: ‘The accelerator positionis Fault Code 131 or 132 Section TF - Troubleshooting Fault Codes ‘Page TF-29 Shop Tall if all wiring and sensor checks look in good order then replace the accelerator position sensor and the idie validation switch circult wires between the accelerator pedal and the ECM with new wires. Run the wires through, for around, the bulkhead without using the bulkhead connector. Test the truck with the test wires in place. If the fault goes away, replace the OEM harness. Seal the openings in the bulkhead around the connector and wires to prevent toxic and noxious fumes from entering the operator area. NOTE: The threo wires in the accelerator position sensor circuit must be twisted together. The same applies for the three wires in the idle validation switch circuit. NOTE: If pin 19 (return) and pin 30 (signal) are reversed, throttle position will only read 50 percent.Fault Code 131 or 132 isp Page TF-30 Section TF - Troubleshooting Fault Codes TROUBLESHOOTING SUMMARY A caution A To avoid pin and harness damage, use the following test leads when taking a measurement: Part No. 3822758 - male Deutsch/Metri-Pack test lead Part No. 3823995 - male Weather-Pack test lead Part No. 3823996 - female Weather-Pack test lead. A caution A ‘To avold damaging a new ECM, all other active fault codes must be Investigated prior to replacing the ECM. STEPS SPECIFICATIONS ‘SRT CODE STEP 1:-Check the accelerator position sensor. STEP 1A: Inspect the OEM harness and the ac-_ No damaged pins celerator position sensor connector pins. STEP 1B: Check the accelerator position sen- 2000 to 3000 ohms sor resistance. STEP 1C: Check the resistance between sensor _ Released: 1500 to 3000 ohms Pins. Depressed: 200 to 1500 ohms NOTE: Measure when the pedal is NOTE: Released resistance dopressed and released, must be at least 1000 ohms more than deprossed resistance STEP 1D: Check for a short circuit to ground in More than 100k ohms the sensor +5-VDC supply. STEP 1E: Check for a short circuit to ground in More than 100k ohms the sensor signal wire. STEP 2: Check the OEM harness. ‘STEP 2A: Inspect the harness and the ECM No damaged pins connector pins. STEP 2B: Check for an open circuit in the sup- _—_Less than 10 ohms ply, signal, and return wires of the OEM harness. STEP 2C: Check for a short circuit between the More than 100k ohms +5-VDC supply wire and any other wire in the OEM harness. STEP 2D: Check for a short circuit between the More than 100k ohms accelerator position signal wire and any other wire In the OEM harness. ‘STEP 2E: Check for a short circuit between the More than 100k ohms +5-VDC supply and return wires. (Fault Code 132 only). ‘STEP 2F: Check for a short circuit to ground in More than 100k ohms the accelerator position sensor signal circuit (Fault Code 132 only).Ise Fault Code 131 or 132 Section TF - Troubleshooting Fault Codes Page TF-31 STEP 3: Check the ECM. ‘STEP 3A: Check the accelerator position sup- (+) 4.75 to 5.25 VDC ply voltage. STEP 4: Clear the fault code. ‘STEP 4A: Disable the fault code. Fault Code 131 or 132 Inactive ‘STEP 4B: Clear the inactive fault codes. All faults cleared TROUBLESHOOTING STEP STEP 1: Check the accelerator position sensor. STEP 1A: Inspect the OEM harness and the accelerator position sensor connector pins. Condition: ‘= Tum keyswitch to the OFF position. * Disconnect the OEM harness from the accelerator position sensor, Action ‘Specifications/Repair Next Step Inspect the OEM harness and the accelerator | OK 1B position sensor connector pins for the following: | Ne damaged pins ‘* Bont or broken pins nGroK an + Pushed back or expanded pins * Corroded pins ‘= Moisture in or on the connector ** Missing or damaged seals. Repair the damaged pins Repair or replace the OEM hamess or sensor, whichever has the damaged pins. + Repair tho OEM harness. Refer to Procedure 019-203 or 019-206. + Replace the OEM harness. Refer to Procedure 019-071. ‘+ Replace the accelerator position sensor. Refer to OEM troubleshooting and repair manual.IsB Section TF - Troubleshooting Fault Codes “ACAUTIONA, To avoid pin and harness damage, use the following test lead when taking a measurement: Part No. 3823996 - female Weather-Pack test lead. Condition: * Turn keyswitch to the OFF position. Disconnect the OEM harness from the accelerator position sensor. Action Specifications/Repair Next Step Check for an open or short circuit between pins in the acclerator position sensor ‘© Measure the resistance from pin C (pin A) to pin A (pin C) on the sensor side of the accelerator position sensor when the acoel- erator pedal is released and when it is depressed, NOTE: Install the 6-pin, Part No. 3824892, or the 3pin, Part No, 3823255, repair connector conto the accelerator position sensor. NOTE: The pin letters shown above are for the integrated sensor switch (ISS) and letters shown in brackets are for pedals with sepa- rate idle validation and accelerator sensors, OK 1c 2000 to 3000 ohms NOT OK a8 Replace the accelerator position sensor Refer to the OEM troubleshooting and repai manuel.IsB Fault Code 131 or 192 Section TF - Troubleshooting Fault Codes Page TF-33 STEP 1G; Check the resistance between sensor pins AcautionA, use the following test lead when taking a measurement: Pack test lead. To avoid pin and harness damay Part No. 3823996 - female Weather Condition: Turn keyswitch to the OFF position. + Bedale BEM hanes to th aceloaor potion ner Action Specifications/Reps Next Step | Crack he rotanc paween sorsorpna | OK . Rote: Nosure non te peal depress | Released: 1500 to 9000 ohms Marlee Bapresca 250 'e 1800 chime * Mavs in) cme sngar 9a oho.” | NOTE: leased rossiance must be al eat accelerator position sensor. a ” - NOTE: na ne Cin, Pr No, 9624892 or Me spin op concn Pathe S808855, Wonteomacorin secteow roster Garo = c Benaes te costars p NOTE: The pin laters shown above are for | Refrts te GEM toalesnoang an opal Motmogeted senor swish SS) ardte | mau Ser hewn in rch rr pal nth Sour ie vldator and ecco aFault Code 131 or 132 Page TF-34 1s Section TF - Troubleshooting Fault Codes STEP 1D: Check for a short circuit to ground in the sensor +5 VDC supply. Condition: ‘+ Turn keyswitch to the OFF position. * Disconnect the OEM harness from the accelerator position sensor, the Spin, Part No, 3823255, repair connector into the accelerator position sensor. NOTE: The pin letters shown above are for the integrated sensor switch (ISS) and the letters shown in brackets are for pedals with separate idle validation and accelerator sensors. Action ‘Specifications/Repair Next Step ‘Check for a short circuit to ground in the sensor | OK 1€ +5-VDC suppl, More than 100k ohms ‘+ Measure the resistance trom pin © (pin A) on the sensor side of the accelerator position seneor to engine block ground. NOTE: Install the 6-pin, Part No, 3824892, or NOT OK aA Replace the accelerator position sensor Refer to the OEM troubleshooting and repair manual.1sB Fault Code 131 or 132 Section TF - Troubleshooting Fault Codes Page TF-35, STEP 1E: Check for a short circu to ground in the sensor signal wire. [ Condition: + Tum keyswitch to the OFF position. * Disconnect the OEM harness from the accelerator position sensor Action Specifications/Repair Next Step Check for a short circuit to ground in the signal | OK 2A wire More than 100k ohms + Measure the resistance from pin B (pin B) on the sensor side of the accelerator position sensor to engine block ground NOTE: Install the 6pin, Part No. 9824892, or [WOT OK A the Spin, Part No. 3823255, repair connector | Replace the accelerator position sensor into the accelerator position sensor Refer to the OEM troubleshooting and repair NOTE: The pin letters shown above are for ‘manual. the integrated sensor switch (18S) and letters showin in brackets are for pedals with sapa- fate idle validation and accelerator sensors.Fault Code 131 or 132 Page TF-36 STEP 2: Check the OEM harness. STEP 2A: Inspect the OEM harness ar Isp Section TF - Troubleshooting Fault Codes the ECM connector pins. Condition: * Tum keyswitch to the OFF position. * Disconnect the OEM harness from the ECM. Corroded pins ‘Moisture in or on the connector Missing or damaged seals. Repair or replace the OEM harness or ECM, whichever has damaged pins. * Repair the OEM harness. Refer to Procedure 019-250, * Replace the OEM harne Procedure 019-071 * Replace the ECM. Refer to Procedure 019-031, Refer to Action Specifications/Repair Next Step Inspect the harness and the ECM connector | OK 2B pins for the following: No damaged pins + Bent or broken pins : i NOT OK an Pushed back or expanded pins apairihs darned gine1sB Fault Code 131 or 132 Section TF - Troubleshooting Fault Codes Page TF-37 STEP 28: Check for an open circuit in the supply, signal, and return wires of the OEM harness. ACAUTIONA, To avoid pin and harness damage, use the following test leads when taking @ measurement: Part No. 3822758 - male Deutsch/Metri-Pack test lead Part No. 3823985 - male Weather-Pack test lead. Condition: = Turn keyswitch to the OFF position, Disconnect the OEM harness from the accelerator position sensor. ‘+ Disconnect the OEM harness from the ECM. Action Next Step | ‘Cheek for an open circuit in the supply, signal, | OK 20 and return wires of the OEM hamess. Less than 10 ohms ‘= Measure the resistance trom pin 29 of the ‘OEM harness connector to pin C (pin A) on the harness side of the accelerator position sensor. ‘+ Measure the resistance from pin 30 of the (OEM harness connector to pin B (pin B) on the harness side of the accelerator position sensor. NOT OK 48 + Measure the resistance from pin 19 of the _| Replace the OEM hamess ‘OEM hamess connector to pin A (pin C) on | Refer to Procedure 019-071, the harness side of the accelerator position sensor, NOTE: The pin letters shown above are for the integrated sensor switch (ISS), and letters shown in brackets are for pedals with sepa- rate idle validation and accelerator sensors.Fault Code 131 or 132 Page TF-38 STEP 2C: Check for a short circuit between +5-VDC supply wire and any other wire in the OEM harness. Section TF - Troubleshooting Fault Codes To avoid pin and harness di Part No. 3822758 - male Dé tei AcauTiOnA, mage, use the following test lead when taking a measurement: tschvMotri-Pack test lead. : Condition: ‘+ Turn keyswitch to the OFF position, * Disconnect the OEM harness from the ECM. ‘+ Disconnect the OEM harness from the accelerator position sensor. ‘© Measure the resistance from pin 29 to all other pins in the OEM harness connector. Action Specifications/Repair Next Step ‘Check for a short circuit from the +5-VDC OK 2D supply wire to any other wire in the OEM More than 100k ohms. harness. NOT OK 4A Replace the OEM harness Refer to Procedure 019-071.1s Foult Code 131 or 132 Section TF - Troubleshooting Fault Codes Page TF-39 STEP 2D: Check for a short circuit between accelerator position signal wire and any other wire In the ‘GEM harness. AcAuTIONA, To avo pn ang harness damage, use tho folowing fat lad when taking a measurement: Part No, 5822758 - male DeutachiMetrt- Pack teat lead. Condition: ‘+ Turn keyswitch to the OFF position ‘+ Disconnect the OEM harness from the accelerator position sensor. ‘= Disconnect the OEM harness from the ECM. Action Specifications/Repair Next Step Check for a short circuit between the accelera- | OK 2E te poston sgl ie and ay oer egal | Mor than 100k ohm the OEM hares. "Neu ereasance rom pin aot an [MOTOR “A ‘other pins in OEM harness connector. Refer to Pr jure 019-071.Fault Code 131 or 132 IsB Page Te40 Section TF - Troubleshooting Fault Codes STEP 2E: Check for a short circuit between the +5-VDC supply and return wires (Fault Code 132 only). AcauTionA ‘To avoid pin and harness damage, use the following test lead when taking » measurement: Part No. 3822758 - male Deutsch/Metri-Pack test lead. Condition: ‘+ Tum keyswitch to the OFF position, ‘* Disconnect the OEM harness from the accelerator position sensor, * Disconnect the OEM harness from the ECM. Action Specifications/Repair Next Step Check for a short circuit between the +5-VDC_ | OK 2F supply and return wires. More than 100k ohms ‘© Measure the resistance from pin 29 of the ‘OEM harness connector to engine block ground. NOT OK 4A Replace the OEM harness Refer to Procedure 019-071.Isp Fault Code 131 or 132 Section TF - Troubleshooting Fault Code: Page TF-4t STEP 2F: Check for a short circuit to ground of the accelerator position sensor signal (Fault Code 132 only). AcauTionA, To avoid pin and harness damage, use the following test lead when taking a measuremer Part No. 3822758 - male Deutsch/Metri-Pack test lead. Condition: * Tum keyswitch to the OFF position sonnect the OEM harness from the accelerator position sensor. connect the OEM harness from the ECM. Action ‘Specifications/Repair Next Step Check for a short circuit to ground of the oK 26 accelerator position sensor signal circuit More than 100k ohms ‘© Measure the resistance from pin 30 of the NOT OK 4A poled ‘connector to engine block Ropioes ths Ged tarnce : Refer to Procedure 019-071.Fault Code 131 or 132 Page TPs Section TF - Troubleshooting Fault Codes STEP 3: Check the ECM. STEP 3A; Check the accelerator position supply voltage. ACAUTIONA Bgvola damaging 8 new ECM, el other active fault codes must be investigate prior to replacing the Condition: * Connect the OEM harness to the accelerator isconnect the OEM hamess from the ECM. ‘+ Turn keyswitch to the ON position, position sensor. Action | Specifications/Repair Next Step ‘Check the accelerator position supply voltage. | OK 48 ‘+ Measure the voltage from pin 19 t0 pin 29 in| (+) 4.75 to §.25 VDC the OEM port of the ECM. T wot ox "A Replace the ECM Rofer to Procedure 019-031 STEP 4: Clear the fault code. STEP 4A: Disable the fault cod Condition: + Connect all components. Action Specifications/Repair Next Step Disable the fault code. OK 4B + Tum the keyswitch to the ON position, and | Fault Code 131 or 132 inactive depress the accelerator pedal to full position. ior oy an Release the pedal, and turn the keyswitch to - the OFF position Return to troubleshooting stops, or contact ven ia your focal Cummins Authorized Repair Very that Fault Code 181 or 192 is inactive. | [cation if all steps have been completed | and checked again. Condition: * Connect all components. + Turn keyswitch to the ON position. Action Specifications/Repair | Next Step Clear the inactive fault codes. oK Ropair * Erase the inactive fault codes using INSITE. | All faults cleared complete NOT OK ‘Appropriate Troubleshoot any remaining active fault troubleshoot: codes. ing chart1sB Fault Code 133, ‘Section TF - Troubleshooting Fault Codes Page TF-43 Fault Code 133 Remote Throttle Position Sensor CODES REASON. EFFECT Fault Code: 133 High voltage detected at the Engine will not respond to remote throttle PID(P), SID(S): PO29 remote throttle position signal input SPN: '29 circuit FM 3 Lamp: Red Remote Throttle Position Sensor Circuit Remote Throttle Position Remote Throttle +5VDC Supply Position Signal Remote tfi0 TPS Ea Ae vas a ECM Remote Throttle OEM Harness Position Return Circuit Description: {Fre tere thats pada provides the driver's throte command othe electronic contol module (ECM) through the OEM harness and the original equipment manufacturer's (OEM) interface harness, The ECM uses this signal to determine the fueling command. Component Location: ‘Tho remote tnvtle posal location varies with each OEM. Reter to the OEM manual Shop Talk: ‘The throttle position sensor is a potentiometer. The resistance specifications of the throttle position sensor is as follows: * Between supply and return = 2000 to 3000 ohms * Between supply and signal: Released = 1500 to 3000 ohms; depressed = 200 to 1500 ohms Note: If the throttle or throttle position sensor is changed, oF after a calibration download, cycle the throttle pedal {keyswitch in the ON position) through its complete travel three times. This procedure calibrates the new throttle with the ECM. * The remote throttle enable switch must be tumed on for the remote throttle to operate. ‘+ Possible causes of this fault code include an open circuit in the return wire, short circuit to +5 VDC or 12 VDC, defective remote throttle position sensor or a failed ECM power supply.Fault Code 133 'sB Page TR-44 Section TF - Troubleshooting Fault Cod TROUBLESHOOTING SUMMARY A caution A ‘To avoid pin and harness damage, use the following test leads when taking a measurement: Part No. 3823996 - female Weathor-Pack test lead Part No. 3822758 - mate Deutsch/Cannon/Metri-Pack test lead. A caution A other active fault codes must be investigated prior to replacing the ECM. To avoid damaging a new ECM, STEPS ‘SPECIFICATIONS SRT CODE STEP 1: Isolate the remote throttle position sensor circuit. ‘STEP 1A: Inspect the OEM harness and sensor No damaged pins connector pins. heck for active fault codes. Fault Code 131 inactive jisconnect the remote throttle con- Fault Code 133 inactive nector; check if fault code deacti- vates. STEP 2: Check the remote throttle position sensor. Inspect the hamess and the remote No damaged pins throttle position sensor connector pins. sheck the remote throttle position 250 to 3000 ohms resistance. Released: 1500 to 3000 ohms Depressed: 250 to 1500 ohms Released resistance must be at least 1000 ohms more than depressed resistance STEP 3: Check the OEM harness. STEP SA: Inspect the harness and the ECM No damaged pins connector pins. STEP 3B: Check for a short circuit between the 250 to 3000 ohms +5-VDC supply and return wires. heck for an open circuit in the re- Less than 10 ohms turn wire. heck the resistance inthe +5-VDC ‘More than 100k ohms supply wire and signal wire circuit, theck for a short circuit between the More than 100k ohms, remote throttle position signal wire and the supply wire In the OEM har- ne STEP SF: Check for a short circuit between the More than 100k ohms remote throttle position signal and another signal wire or the switch supply wire.1sB Section TF - Troubleshooting Fault Codes Fault Code 133 Page TF-46 STEP 4: Clear the fault code. ‘STEP 4A: Disable the fault code. Fault Code 133 inactive STEP 4B: Clear the inactive fault codes. All faults cleared TROUBLESHOOTING STEP STEP 1: Isolate the remote throttle position sensor circuit. STEP 1A: Inspect the OEM harness and sensor connector pins. Condition: ‘+ Turn keyswitch to the OFF position, ‘* Disconnect the OEM harness from the remote throttle position sensor, Action Specifications/Repair Next Step Inspect the OEM harness and the remote OK 1B throtle position sensor connector pins for: No damaged pins ‘+ Bent or broken pins Pushed back or expanded pins NOT OK ae + Corroded pins Repair the damaged pins ‘+ Moisture in or on the connector Repair or replace the OEM harness or = ‘sensor, whichever has the damaged pins. Missing or damaged seals. ‘© Repair the OEM harness. Refer to Procedure 019-203. + Replace the OEM harness. Refer to Procedure 019-071 + Replace the remote throttle position sensor. Refer to OEM troubleshooting and repair manual. STEP 1B: Check for active fault codes, Condition: + Connect all the components. + Turn keyswitch to the ON position Action Specifications/Repair Next Step Check for active fault codes. Tox 10 * Check for active fault codes using INSITE™. | Fault Codes 131, 192, and 952 are active NOT OK an Fault Code 191 inactive Disconnect the remote throttle connector; check if fault code deactivates. 1 * Disconnect the romote thratilo connector. Action Specifications/Repair Next Step Check for fault code deactivates OK 2A * Chock for inactive fault codes using INSITE™. | Fault Code 133 active NOT OK Go to Fault Go to Fault Code 131 Code 131 Replace the remote throttle position sensor. Refer to OEM troubleshooting and repair manual.Fault Code 133 Page TF-45 is Section TF - Troubleshooting Fault Cod STEP 2: Check the remote throttle position sensor. STEP 2 Inspect the harness and the remote throttle position sensor connector pins. Condition ‘+ Turn Keyswitch to the OFF position. * Disconnect the OEM harness from the remote throttle position sensor. Pushed back or expanded pins Corroded pins Moisture in or on the connector Missing or damaged seals. Repair the damaged pins Repair or replace the OEM hamess or ‘sensor, whichever has the damaged pins. ‘+ Repair the OEM harness, Refer to Procedure 019-203. ‘+ Roplace the OEM harness. Refer to Procedure 019-071 ‘+ Replace the remote throttle position sensor. Refer to OEM troubleshooting and repair manual ‘Action Specifications/Repair Next Step inspect the harness and the remote throttle | OK 28 position sensor connector pins for: No damaged pins Bent or broken pins NOT OK 4A1sB Fault Code 133 Section TF - Troubleshooting Fault Codes Page TF-47 STEP 21 theck the remote throttle position resistance. ‘AcauTionA To avoid pin and harness damage, use the following test lead when taking a measuremer Part No. 3823996 - female Weather-Pack test lead. Condition: * Tum keyswitch to the OFF position. * Disconnect the OEM harness from the remote throttle position sensor. Action ‘Specifications/Repair Next Step ‘Cheok for an open or shor circuit between pins | OK 20 in the remote throttle position sensor. 250 to 3000 ohms *"Maasure the raistance between the +5VOC Troe = supply and the remote throttle position sensor return on the seneor side of the ernote Soacneat a tuetnaet tone ante throtle poston sensor when the rermate : throte ie reloased and when itis depressed, | Refer to the OEM troubleshooting and repair manualFault Code 133 Page TF-48 STEP 2C: Section TF - Troubleshooting Fault Codes heck the resistance between sensor pins. To avold pin and harness damat ‘AcautionA , use the following test lead when taking a measurement: Part No. 3823996 - female Weather-Pack test lead. Conditior ‘© Turn keyswitch to the OFF position. ‘+ Disconnect the OEM harness from the remote throttle position sensor. | Repiace the remote throttle position | sensor | Retr tothe OEM troubleshooting and ropair [manual Action Specifications/Repair _| Next Step ‘Check the resistance between sensor pins. 3A NOTE: Measure when the pedal is depressed and released. Depressed: 250 to 1500 ohms ‘= Moasure the resistance between the +5-VDC 7 ae fg, | Released resistance must be at least 1000 ‘supply and the signal wire on the sensor side | F be oF te rornote threrto positon senor hms more than depressed resistance. NOT OK 4aIsB_ Fault Code 133 Section TF - Troubleshooting Fault Codes Page TF-49 STEP 3: Check the OEM harness. STEP 3A: Inspect the harness and the ECM connector pins. ACAUTIONA, Tego aamaging a new ECM, al other active fault codes must be Investigated prior to replacing the Condition: ‘+ Tum keyswitch to the OFF position. * Disconnect the OEM harness from the ECM. ‘Disconnect the OEM harness from the remote throttle. Action Speci Next Step Inspect the harness and the ECM connector | OK 38 pins for: No damaged pins ‘+ Bent or broken pins ROTOR 7 fate kor expand Sno comes, © Moisture in or the Repair or replace amness or , ewan Seana whore tse Sage pa smn hee case ps Repu ne OEM Lr oc tee Reps he OE FepiceFault Code 133 is Page TF-50 Section TF - Troubleshooting Fault Codes 4 STEP 9B: Check for a short circult between the +5-VDC supply and return wires. ‘AcaurionA, Jp avoid pin and harnese damage, use the following test lead when taking a measurement: Part No. 3822758 - male Deutach/Cannon/Metri-Pack test lead. Condition: = Tum keyswitch to the OFF position. * Connect the OEM harness to the remote throttle position sensor. * Connect the OEM harness to the bulkhead connector. ‘= Disconnect the OEM harness from the ECM. Action ‘Specifications/Repair Next Step ‘Check the resistance between the +5-VDC OK 3c supply and return wires. 2000 to 3000 ohms ‘+ Measure the resistance between pin 10 and ; NOT OK 4A pin 20 in the OEM harness when the remote | POT, reptece the OEM harness de eee jfer to the OEM troubleshooting and repair manuel,Iss Section TF - Troubleshooting Fault Codes: STEP 3C: Check for an open circuit in the return wire. Fault Code 133 Page TF-51 To avoid Part No. Condition: * Tum keyswiteh to the OFF position, and harness damago, * Disconnect the OEM harness from the ECM. ‘AcautionA, pi @ the following test lead when taking a measurement: 1822788 - male Deutach/Cannon/Metri-Pack test lead. * Disconnect the OEM harness from the remote throttle position sensor. Action ___ Specifications/Repair Next Step ‘Check for an open circuit in the return wire. | OK | 30 * Measure the resistance from pin 20 of the _| Less than 10 ohms ‘OEM harness connector to pin of the remote throttle position sensor connector. NOL OK ae Repair or replace the OEM harness Refer to the OEM troubleshooting and repair manual.Fault Code 133 1s Page TF-52 Section TF - Troubleshooting Fault Cod STEP 3D: Check the resistance In the +5-VDC supply wire and the signal wire circuit. AcautionA, To avoid pin and harness damage, use the following test lead when taking a measurement: Part No. 3822758 - male Deutsch/Cannon/Metr-Pack test lead. Condition: * Tum keyswitch to the OFF position * Connect the OEM harness to the remote throttle position sensor. * Connect the OEM harness to the bulkhead connector. + Disconnect the OEM harness from the ECM. Action Specifications/Repair Next Step Check the resistance in the +5:VDC supply | OK 3 wire and the signal wire circuit. Released: 1500 to 3000 ohms ‘+ Measure the resistance between pin 10 and _| Depressed: 250 to 1500 ohms pin 9 when the remote throttle is released and or og Tan when itis depressed. Repat of reploes OE Refer to the OEM troubleshooting and repair ‘manual.1s ‘Section TF - Troubleshooting Fault Codes Fault Code 133 Page TF-53 STEP 3E: Check for a short clrcult between the remote throttle position signal wire and the supply wire in the OEM harness. ACAUTIONA, ‘o avoid pin and hamess damage, use the following test lead when taking a measurement: Part No. 3822758 - male Deutsch/Cannon/Metri-Pack test lead. Condition: ‘= Turn keyswitch to the OFF position. ‘= Disconnect the OEM harness from tho ECM. ‘* Disconnect the OEM hamess from the remote throttle position sensor. Action | ‘+ Moasure the resistance from pin 9 of the ‘OEM hamess connector to pin B of the emote thtottie position sensor connector. Specifications/Repair [ Next Step ‘Check for a short circuit between the remote OK oF throttle position signal wire and the supply wire | More than 100k ohm: inthe OEM hares, TT x Repair or replace the OEM harness Rfer to the OEM troubleshooting and repair manual.Fault Code 133 Page TF-54 Ist Section TF - Troubleshooting Fault Codi STEP 3F: Check for a short circuit between the remote throttle position signal and supply wire to all ‘other wires in the OEM harness connector. Condition: ‘+ Turn keyswitch to the OFF position. ‘+ Disconnect the OEM harness from the ECM, *# Disconnect the negative (-) battery terminal. * Discannect the OEM harness from the remote throttle position sensor. ‘© Measure the resistance from pin 9 and pin 10, of the OEM harness connector to all oth pins in the OEM harness connector. Repair or replace the OEM harness Refer to the OEM troubleshooting and repair manual, Action Specifications/Repair Next Step Check for a short circuit between the remote | OK aA throttle position signal and supply wire to all | More than 100k ohms other wires in the OEM harness connector. NOR GIE mr STEP 4: Clear the fault codes. STEP 4A: Disable the fault code. Condition: * Connect all the components. + Turn keyswitch to the ON position. Action ‘Specifications/Repalt Next Step Disable the fault code, ‘+ Turn the keyswitch to the ON position and depress the remote throttie to full position three times. Release the remote throttle and turn the keyswitch to the OFF position. + Start the ongine, and let it idle for 1 minute, * Using INSITE™, verify that the Fault Code 133, is inactive. OK Fault Code 133 inactive 48 NOT OK Return to troubleshooting steps, or contact your local Cummins Authorized Repair Location if all staps have been completed and checked again. 1A1sB “ault Code 133 Section TF - Troubleshooting Fault Codes Page TF-55 STEP 4B: Clear the inactive fault codes. Condition: * Connect alt the components. ‘+ Turn keyswitch to the ON position. ‘Action Specifications/Repair Next Step ‘Clear the inactive fault codes, ‘OK Repair + Erase the inactive fault codes using INSITE™. | All faults cleared complete NOT OK ‘Appropriate ‘Troubleshoot any remaining active fault troubleshoot- codes. ing chartFault Code 134 ' Page TF-56 Section TF - Troubleshooting Fault Cod Fault Code 134 Remote Throttle Position Sensor ‘CODES REASON EFFECT Fault Code: 134 Low voltage detected at the remote | Engine will not respond to remote throttle PID(P), SID(S): PO29 throttle position signal circuit input. SPN: '29 FMI: 4 Lamp: Red Remote Throttle Position Sensor Circult Remote Throttle Position Remote Throttle +5VDC Sem Position Signal Remote FA8 TPS aos rar / 7 ECM Remote Throttle OEM Harness ~——_—" Position Return Circuit Descrip The remote throttle pedal provides the driver's throttle command to the electronic control module (ECM) through the original equipment manufacturer's (OEM) harness and the OEM interface harness. The ECM uses this signal to determine the fuoling command. Component Location: ‘The remote throttle pedal location varies with each OEM. Refer to the OEM manual. Shop Tall ‘The romote throttle position sensor is a potentiometer. The resistance specifications of the throttle position sensor is as follows: ‘+ Between supply and return = 2000 to 3000 ohms * Between supply and signal; Released = 1500 to 3000 ohms; depressed = 200 to 1500 ohms NOTE: If the remote throttle position sensor Is changed, or after a calibration download, cycle the throttle pedal (Keyswitch in the ON position) through its complete travel three times. This procedure calibrates the new remote throttle with the ECM. * Tho remote throttle enable switch must be turned on for the remote throttle to operate. Possible causes of this fault code include an open circuit in the supply wire, short circuit to ground in the supply oF signal wires, defective remote throttle position sensoy, or a failed ECM power supply.1s Section TF - Troubleshooting Fault Codes Fault Code 134 Page TF-57 TROUBLESHOOTING SUMMARY A caution A ‘To avoid pin and harness damage, use the following test leads when taking a measurement: Part No. 3822758 - male Deutsch/Cannon/Metri-Pack test lead Part No. 3823996 - female Weather-Pack test lead. A caution A ‘To avoid damaging a new ECM, all other active fault codes must be investigated prior to replacing the ECM. STEPS SPECIFICATIONS SRT CODE STEP 1: Isolate the remote throttle position sensor circuit. STEP 1A: Inspect the OEM harness and sensor connector pins. STEP 1B: Check for active fault codes. STEP 1C: Disconnect the remote throttle con- nector; check if fault code deactl- vates. No damaged pins Fault Code 132 inactive Fault Code 134 inactive STEP 2: Check the remote throttle position sensor. ‘STEP 2A: Inspect the harness and the remote throttle position sensor connector pins. Check the remote throttle position resistance. Check for short circuit to ground on the remote throttle sensor +5-VDC ‘supply wire. STEP 2D: Check for a short circuit to ground on the remote throttle sansor signal wire, STEP 3: Check the OEM harness. ‘STEP 3A: Inspect the harness and the ECM connector pins. ‘STEP 3B: Check for an open circuit in the sup- ply or signal wires of the OEM hai ness. STEP 3C: Check for a short circuit to ground of the remote throttle position sensor +5:VDC supply circuit. STEP 3D: Check for a short circuit to ground of the remote throttle position sensor signal circuit. STEP 3E: Check for a short circuit between the remote throttle position +5-VDC sig- nal wire and any other wire in the OEM harness. No damaged pins 2000 to 3000 ohms More than 100k ohms. More than 100k ohms No damaged pins Less than 10 ohms More than 100k ohms More than 100k ohms More than 100k ohmsFault Code 134 Page TF-58 STEP SF: Check for a short circuit between the remote throttle position signal wire ind the other signal wire in the OEM harness. STEP 4: Clear the fault codes. STEP 4A: Disable the fault code. STEP 4B: Clear the inactive fault codes. ISB Section TF - Troubleshooting Fault Codes More than 100k ohms: Fault Code 134 All faults cleared active TROUBLESHOOTING STEP Isolate the remote throttle position sensor circuit. inspect the OEM harness and sensor connector pins. ‘= Turn Keyswitch to the OFF position. + Disconnect the OEM harness from the remote throttle position sensor. Action Specifications/Repair Next Step Inspect the OEM harness and the remote oK 1B throttle position sensor connector pins for: No damaged pins ‘* Bont or broken pins — '* Pushed back or expanded pins nor ok : - © Gorroded pine Repair the damaged pins Repair or replace the OEM harness oF ‘= Moisture in or on the connector = Missing or damaged seals. ‘sensor, whichever has the damaged pins. = Repair the OEM hamess. Refer to Procedure 019-203. ‘+ Roplace the OEM harness. Refer to Procedure 019-071, ‘+ Replace the remote throttle position ‘sensor. Refer to OEM troubleshooting and repair manual. STEP 1B: Check for active fault codes. Conditio ‘+ Connect all the components. + Turn keyswitch to the ON position. Action Specifications/Repair Next Step ‘Check for active fault codes. OK 1c © Check for active fault codes using INSITE™. | Fault Code 132 active NOT OK 4A Fault Code 132 inactiveIsB Foult Code 134 ‘Section TF - Troubleshooting Fault Codes Page TF.59 STEP 1C: Disconnect the remote throttle connector Condition: * Disconnect the remote throttle connector. Action Specifications/Repai Next Step ‘Check for fauit code deactivates, OK 2A * Check for inactive fault codes using INSITE~, | Fault Code 134 active NOT OK 4a Fault Code 134 inactive Replace the remote throttle position sensor. Refer to OEM troubleshooting and repair manual, heck the remote throttle position sensor. \: Inspect the harness and the remote throttle position sensor connector pins. Conditio ‘+ Tum keyswitch to the OFF position, Lt Disconnect the OEM harness trom the remote throttle position sensor. Action Specifications/Repair Next Step Inspect the harness and the remote throttle 28 position sensor connector pins for: Bent or broken pins ae * Pushed back or expanded pins * Corroded pins * Moisture in or on the connector ‘+ Missing or damaged seals, Repair the damaged pins Repair or replace the OEM harness or sensor, whichever has the damaged pins. ‘© Repair the OEM harness. Refer to Procedure 019-203. = Replace the OEM harness. Refer 1o Procedure 019-071. ‘+ Replace the remote throttle position sensor. Refer to OEM troubleshooting and repair manualFault Code 134 1s Page TF-60 Section TF - Troubleshooting Fault Codes STEP 2B: Check the remote throttle position resistance. ‘AcauTionA e ‘To avoid pin and hamess damage, use the following test lead when taking a measurement: Part No. 5623906 - female Weather-Pack test lead. Condition: * Turn keyswitch to the OFF position. * Disconnect the OEM harness from the remote throttle position sensor. Action Specifications/Repalr Next Step ‘Check for an open or short circuit between pins | OK 2c in the remote throttie position sensor. 2000 to 3000 ohms ‘+ Measure the resistance between the +5-VDC NOT OK 4a ‘supply and the remote throttle position sensor return on the sensor side of the remote pe eee ee throttie position sensor when the remote a throtle fs reloased and when iis depressed. | Refer to the OEM troubleshooting and repair manual.IsB Section TF - Troubleshooting Fault Codes Fault Code 134 Page TF-61 STEP 2C: Check for short circuit to ground on the remote throttle sensor +5-VDC supply wire. To avold pin and harness damat Part No. 3823996 - female Wea! Condition: ‘= Tur keyswitch to the OFF position, ACAuTIONA, , use the following test lead when taking a measurement: r-Pack test lead. * Disconnect the OEM harness from the remote throttle position sensor. throttle position sensor and the chassis. ‘ground. Action Specifications/Repair Next Step ‘Check for short circuit to ground on the remote | OK 2D throttle sensor +5-VDC supply. More than 100k ohms ‘+ Measure the resistance between the +5-VDC Figr ox 7 ‘supply on the sensor side of the remote Replace the remote throttle position ‘sensor Refer to the OEM troubleshooting and repair manual.Fault Code 134 IsB Page TF-62 Section TF - Troubleshooting Fault Codes STEP 2D: Check for a short circuit to ground of the sensor signal wire. ‘AcauTionA, Tp avo pin and harness damage use the following tot ead when taking a measurement: Past No. S822750 = male DeutschvCannon/Met'-Pack test load. Condition: + Tum keyswitch to the OFF postion. + Disconnect the OEM harness from the remote throttle postion sensor. Action Specifications/Repalr Next Step Check for a short circuit fo ground of the sensor | OK 3A signal wire More than 100k ohms ‘+ Measure the resistance between the signal NOT OK 4A wire on the sensor side of the remote thrttle postion sengor andthe chassis ground, | Replace the remote throttle postion Refer to the OEM troubleshooting and repair manual. STEP 3: Check the OEM harness. ‘STEP 3A: Inspect the harness, bulkhead connector, and the ECM connector pins. “AcauTionA, Tpqvoid damaging a new ECM, al other active fault codes must be investigated prior to replacing the Condition: ‘+ Turn keyswitch to the OFF position. ‘* Disconnect the OEM harness from the ECM. * Disconnect the GEM harness from the remote throttle position sensor. Action Specifications/Repair Next Step inspect the harness andthe ECM connector | OK 3B pins for: No damaged pins + Bent or broken pins S H i NOT OK aA Pushed back or expanded pins Noam daesed sive * Corroded pins BS Mcanes far cng comieoie Repair or replace the OEM hamoss or ECM, Seno cunasooale whichever has the damaged pins. * Repair the OEM harness. Refer to Procedure 019-250. ‘+ Replace the OEM harness. Refer to Procedure 018.071 ‘* Replace the ECM. Refer to Procedure 019.031IsB Fault Code 134 Section TF - Troubleshooting Fault Codes TF STEP 9B: Check for an open circuit in the supply or signal wires of the OEM harness. AcAuTIONA, Je avoid pin and harness damage, use the following test lead when taking a measurement: Part No. 8822758 - male Doutsch/Cannon/Metri-Pack test lead. Condition: ‘= Turn keyswitch to the OFF position, ‘+ Disconnect the OEM harness to the remote throttle position sensor. + Disconnect the OEM harness from the ECM, Specifications/Repair Next Step ‘Check for an open circuit in the supply or signal | OK ac ‘wires of the OEM harness. Less than 10 ohms ‘© Measure the resistance between pin 10 of the ‘OEM harness and the +5-VDC supply on the harness side of the remote throttle position | NOT OK aA sensor, ‘+ Measure the resistance between pin 9 of the OEM harness and the signal wire on the harness side of the remote throttle position sensor. Repair or replace the OEM harness Refer to the OEM troubleshooting and repair manual,IsB, Section TF - Troubleshooting Fault Codes STEP 3C: Check for a short cireult to ground in the remote throttle position sensor +5-VDC supply circuit. ‘AcaurionA, To avoid Part No. 3822758 - male Doutscl in and harness damage, use the followin chicannon'Wetn-Pa test lead when taking a measurement: test lead. Condition: ‘+ Turn keyswitch to the OFF position. * Disconnect the OEM harness to the remote throttle position sensor. ‘* Disconnect the OEM harness from the ECM. Action Specifications/Repair Next Step Check for a short circuit to ground in the remote | OK. =D throttle position sensor +5-VDC supply circuit. | More than 100k ohms ‘+ Measure the resistance between the pin 10 of Tr o mr the OEM harness and the chassis ground. Repair or replace the OEM harness Refer to the OEM troubleshooting and repair manual1sB Section TF - Troubleshooting Fault Codes. Fault Code 134 Page TR-65 STEP 3D: Check for a short circuit to ground of the remote throttle position sensor signal circult, To avoid pin and harness dam: Part No, 3822758 - mal ‘AcautionA, Je, use the followir jannon/Metri-Pacl test lead when taking a measurement: test lead. Condition ‘Turn keyswitch to the OFF position. ‘= Disconnect the OEM harness from the ECM. ‘+ Disconnect the OEM harness to the remote throttle position sensor. Action Specifications/Repair Check for a short circuit to ground in the remote throttle position sensor signal circu. * Measure the resistance between pin 9 of the OEM hares and the chassis ground. OK More than 100k ohms, NOT OK Repair or replace the OEM harness. Refer to the OEM troubleshooting and repair manual, xFault Code 134 Is Page TF-66 Section TF - Troubleshooting Fault Codes STEP 9E: Check for a short circuit between +5-VDC supply wire and any other wire in the OEM harness. ‘AcautionA Jo avoid pin and hamese damage, use the following test lead when taking # measurement: Part No. 3822758 - male Doutsch/Cannon/Metri-Pack test lead. Condition: ‘¢ Turn Keyswitch to the OFF position. # Disconnect the OEM harness from the remote throttle position sensor. * Disconnect the OEM harness from the ECM. * Disconnect the OEM negative (-) battery terminal. Action Specifications/Repair Next Step ‘Check for a short circuit between +5 VDC oK OF supply wire and any other wire in the OEM More than 100k ohms harness. bnoreK wa ‘© Measure the resistance between the pin 10 and all other pins in the OEM harness connector. Repair or replace the OEM hamess Refer to the OEM troubleshooting and repair manual,1sB Section TF - Troubleshooting Fault Codes Fault Code 134 Page TF-67 STEP 3F: Check for a short circuit between remote throttle position signal wire and any other wire in the OEM harness. To avoid pin and harness dam: Part No. 3822758 - male Deu! ACAUTIONA Je, use the followi VCannon/Metri-Pac test lead when taking a measurement: test lead. Condition: ‘+ Tum keyswitch to the OFF position. ‘other pins in the OEM harness connector. * Disconnect the OEM harness from the remote throttle position sensor ‘+ Disconnect the OEM harness from the ECM. + Disconnect the OEM nogative () battery terminal. Action Specifications/Repair Next Step (Check for a short circuit between remote throttle | OK aA position signal wire and any other wire in the | More than 100k ohms ‘OEM harness. ‘+ Measure the resistance between pin 9 and all | NOT OK - Repair or replace the OEM harness Refer to the OEM troubleshooting and repair manual,Fault Code 134 Page TF-68 STEP 4: Clear the fault code. STEP 4A: Disable the fault code. isB Section TF - Troubleshooting Fault Codes Condition: + Connect all the components. * Tum keyswitch to the ON position. Action Specifications/Rep: Next Step Disable the fault code OK 4B * Tum the keyswitch to the ON position, and | Fault Code 134 inactive depress the remote throtte to full position three times. Release the remote throttle, and | NOT OK 1A turn the Keyswitch to the OFF position. Feturn to troubleshooting steps, or contact * Start the engine, and let it idle for 1 minute, | Your local Cummins Authorized Repair *+ Using INSITE", verity that the Fault Gode 194 | Location if all steps have been completed is inactive. and checked again. STEP 4B: Clear the inactive fault codes. Condition: + Connect ail the components, + Tum keyswitch to the ON position. Action ‘Specifications/Repair Next Step lear the inactive fault codes. OK Repair «Erase the inactive fault codes using INSITE™. | All faults cleared complete NoT OK ‘Appropriate ‘Toubleshoot any remaining active fault _| troubleshoot = rllIsB Section TF - Troubleshooting Fault Codes Fault Code 135 or 141 Fault Code 135 or 141 Page TF-69 Oil Pressure Sensor Circuit CODES REASON, EFFECT Fault Code: 135 0r 141 | FC 135: High voltage dotected at _ | Default value used for oll pressure. PID(P), SID(S): P100 oll pressure sensor signal pin 33 of | No engine protection for oil pressure. SPN: "100 the engine harness. FMI: Sor 4 7 FC 141: Low voltage detected at cil Pee pressure sensor signal pin 33 of the engine harness. Oll Pressure Sensor Circuit Oil Pressure Oil Pressure }4— +5VDC Supply Signal ECM et 10 © i——|33 5 7119 ll Préssure Return ECM-Engine Harness, Oil Pressure Sensor 4 Circuit Descript 16 oll pressure sensor is used by the electronic control module (ECM) to monitor the lubricating oil pressure. ‘The ECM monitors the voltage on the signal pin and converts this to a pressure value. The oil pressure value is, used by the ECM for the engine protection system. Component Location: The oll pressure sensor is located on the engine block, below and to the right of the ECM Shop Talk: * If Fault Code 143 or 415 is not present, the problem is not related to the engine lubrication system. ‘+ INSITE can be used to monitor the oil pressure signal voltage going into the ECM.Fault Code 135 or 141 Page TF IsB Section TF - Troubleshooting Fault Codes TROUBLESHOOTING SUMMARY A caution AC ‘To avold pin and harness damage, use the following test lead when taking a measurement: Part No. 3822758 - male AMP/Met Pack test lead. A caution A To avoid damaging anew ECM, STEPS STEP 1: Check for multiple fault codes. ‘STEP 1A: Read the fault codes. STEP 2: Check the oil pressure sensor. STEP 2A: Inspect the engine harness and oil pressure sensor connector pins. STEP 2B: Check the oil pressure sensor supply voltage. STEP 2C: Check the oil pressure sensor signal voltage. STEP 3: Check the engine harness. ‘STEP 3A: Inspect engine harness and ECM connector pins. STEP 3B: Check for an open circuit. STEP 3C: Check tor a short circult to ground. STEP 3D: Check for a short circuit from pin to pin. STEP 4: Clear fault codes. STEP 4A: Disable the fault code. ‘STEP 4B: Clear tho inactive fault codes. | other active fault codes must be investigated prior to replacing the ECM. SPECIFICATIONS SRT CODE Fault Codes 952 and 386 Inac- tive No damaged pins (+) 4.75 to 5.25 VOC (+) 0.40 to 0,60 voc No damaged pins Less than 10 ohms More than 100k ohms More than 100k ohms Fault Code 135 or 141 inactive All faults cleared1s Section TF - Troubleshooting Fault Codes Fault Code 135 or 141 Page TF-71 TROUBLESHOOTING STEP STEP 1: Check for multiple fault codes. ‘STEP 1A: Read the fault codes. Condition: ‘+ Turn keyswitch to the ON position. Action Specifications/Repair Next Step. Fad the fault codes. OK 2A * Read the fault codes using INSITE*. Fault Codes 352 and 386 inactive NOTE: If multiple temperature or pressure | NOT OK Fault Code fault codes exist, this procedure should not | Possible sensor failure, a short circuit to 952 bbe followed. ground in the sensor +5-VDC common supply, of a short circuit from pin to pin. STEP 2: Check the oil pressure sensor. STEP 2A: Inspect the engine harness and the oll pressure sensor connector pins. Condition: = Tur keyswitch to the OFF position ‘= Disconnect the engine harness from the oi pressure sensor. Action Specifications/Repair Next Step Inspect the oil pressure sensor and the engine | OK 2B harness connector pins for the following: No damaged pins * Bent or broken pins Not ox 7 + Pushed back or expanded pins + Corraded pins ‘+ Moisture in or on the connector ‘+ Missing or damaged seals. | Repair the damaged pins Repair or replace the oil pressure sensor or ‘the engine harness, whichever has dam- aged pins. ‘= Repair the engine harness. Refer to Procedure 019-203. ‘= Replace the engine harness. Refer to Procedure 019-043, '* Replace the oil pressure sensor. Refer to Procedure 019-066.Fault Code 195 or 141 Page TF-72 STEP 2B: Chock the oll pressure sensor supply voltage. IsB Section TF - Troubleshooting Fault Codes Condition: ‘© Turn keyawitch to the ON position. '* Disconnect the engine harness from the oil pressure sensor. + install oil pressure sensor breakout cable, Part No, 3824775, Action Specifications/Repair Next Step ‘Check the oil pressure sensor supply voltage. | OK 20 * Measure the voltage fram pin Ato pin Bon | (+) 4.75 to 5.25 VDC the harness side of the oil pressure sensor connector, NOTE: Pressure sensor breakout cable kit, | NOT OK ~*~ Part No. 3824775 of kit 3824773, is available to assist with this step.IsB Section TF - Troubleshooting Fault Codes Fault Code 135 or 141 Page TF-73 STEP 20: Check the oil pressure sensor signal voltage. Condition: ‘+ Tum keyswitch to the ON position; engine not running. += Install oil pressure sensor breakout cable, Part No. 3824775. Action Specifications/Repair | Next Step ‘Check the oll pressure sensor signal voltage. | OK 3A + Measure the voltage trom pin C to pin Bot | (+) 0.40 to 0.60 VDC the breakout cable. OTK are Replace the oil pressure sensor Refer to Procedure 019-066,Fault Code 135 or 141 Page TF-74 STEP 3: Check the engine harness. IsB Section TF - Troubleshooting Fault Codes STEP 3A: Inspect the engine harness and the ECM connector pins. Pushed back or expanded pins Corroded pins Moisture in or on the connector Missing or damaged seals. Repair the damaged pins pair or replace the engine harness or ECM, whichever has the damaged pins + Repair the engine harness. Refer to Procedure 019-250. + Replace the engine harness. Refer to Procedure 019.048. ‘+ Roplace the ECM. Refer to Procedure 019-031 AcauTionA, Te.qvold damaging a new ECM, all other active fault codes must be investigated prior to replacing the ‘Condition: '* Turn keyswitch to the OFF position. + Disconnect the engine harness from the ECM. Action Specifications/Repair Next Step Inspect the engine hamess and the ECM oK Ey ‘connector pins forthe following: No damaged pins * Bent 0 pi ent or broken pins Nore mIsB Fault Code 135 or 141 Section TF - Troubleshooting Fault Codes Page TF-75 STEP 3B: Check for an open circuit. AcautionA ‘To avoid pin and harness damage, use the following test lead when taking a measurement: Part No, 8822758 - male AMP/Metri-Pack test lead. Condition: + Tum keyswitch to the OFF position. * Disconnect the engine harness from the oil pressure sensor. ‘* Disconnect the engine harness from the ECM. Action Specifications/Repair Next Step Check for an open circuit. ‘OK 3c * Measure the resistance from pin $3 of the _| Less than 10 ohms engine harness connector to pin C on the harness side of the oil pressure sensor ‘connector. ‘+ Measure the resistance from pin 10 of the engine hamess connector to pin A on the NOT OK 4a harness side of the oil pressure sensor Replace the engine harness connector. Refer to Procedure 019-043. ‘+ Measure the resistance from pin 19 of the engine harness connector to pin B on the harness side of the oll pressure sensor connector.Fault Code 136 or 141 Page TF-76 STEP 3C: Check for a short circuit to ground. IsB Section TF - Troubleshooting Fault Codes avold plo and harness 4 rt No. 3822758 - male AMP/ AcAUTIONA use the following test lead when taking a measurement: trhPack test lead. Condition: ‘+ Turn keyswitch to the OFF position. ‘= Disconnect the engine harness from the ECM. * Disconnect the engine harness from the oil pressure sensor. engine harness connector to engine block ground. ‘* Measure the resistance from pin 19 of tho engine harness connector to engine block ground. Replace the engine harness Refer to Procedure 019-043. Action ‘Specifications/Repair Next Step ‘Check for a short circuit to ground, oK 2 ‘* Measure the resistance from pin 33 of the | More than 100k ohms engine hamess connector to engine block round. ‘= Measure the resistance from pin 10 of the NOT OK 4A1sB Fault Code 135 of 141 Section TF - Troubleshooting Fault Codes Page TF-77 STEP 3D: Check for a short circuit from pin to pin. ACAUTIONA, To avoid pin and harness damage, use the following test lead when taking a measurement: Part No. 3822758 - male Deutsch/Cannon/Metri-Pack test lead. Condition: ‘= Tum keyswitch to the OFF position. ‘+ Disconnect the engine harness from the ECM. ‘+ Disconnect the engine harness from the oil pressure sensor. Action Specifications/Repair Next Step Check for a short circuit from pin to pin, oK 4a ‘+ Measure the resistance from pin 33 of the | More than 100k ohms engine harness connector to all other pins in| Replace the ECM. Refar to Procedure the engine harness connector. 019-031 NOT OK aA Replace the engine harness Refer to Procedure 019-043. somataFault Code 135 or 141 Page TF-78 STEP 4: Clear the fault cod STEP 4A: Disable the fault code Condition: + Connect all components. + Turn keyswitch to the ON position, Ise Section TF - Troubleshooting Fault Codes codes. as =| Action ‘Specifications/Repair Next Step * Start the engine, and let idle for 1 minute. Fault Code 135 or 141 inactive Seen art ead pun pe venion| tg te: postion) contact your local Cummins Authorized set your el Cuming Ata Reva cae le to a Condition: eee ‘Action ‘Specitications/Repair Next Step Clear the inactive fault codes. OK Repair SEE et eee cee rere ‘NOT OK Appropriate nor oct care tl | omen ing charts8 Section TF - Troubleshooting Fault Codes Fault Code 143 Fault Code 143 Page TF-79 Oil Pressure - Engine Protection CODES REASON. EFFECT Fault Code: 143 PID(P), SID(S); P10 SPN: 100 FMI: 1 Lamp: Yellow Oil pressure signal indicates oil pressure below the low engine protection limit. Power and/or speed derate and possible engine shutdown if engine protection shutdown feature enabled, Oil Pressure Sensor Circuit Oil Pressure Oil Pressure Sensor Oil Pressure 4. +5VDC Supply Signal ECM rr \ 7 10 4 ¢: i433 8 119 Oil Préssure i Renee Engine Harness ECM-Engine Harness a Circuit Description: ‘The oll pressure sensor is used by the electronic control module (ECM) to monitor the lubricating oil pressure. ‘The ECM monitors the voltage on the signal pin and converts this to a pressure value. The oil pressure value is used by the ECM for the engine protection system. Component Location: The oll pressure sensor is located on the engine block, below and to the right of the ECM. Shop Talk: = Confirm that the oil pressure sensor supply voltage is between (+) 4.5 and 5.25 VDC at the sensor. * Verity, with the driver, the engine speed at which the fault occurs. If the engine is being operated at too low of a speed under load, the oll pressure can drop below the engine protection limits.Fault Code 143 1sB Section TF - Troubleshooting Fault Codes Page TF-80 TROUBLESHOOTING SUMMARY STEPS SPECIFICATIONS SRT CODE STEP 1: Check the sensor accuracy. ‘STEP 1A: Verify the sensor accuracy with a ‘Sensor reading Is correct mechanical gauge. STEP 2: Clear the fault code. jisable the fault code. Fault Code 143 inactive the inactive feult codes. All faults cleared TROUBLESHOOTING STEP STEP 1: Check the sensor accuracy. STEP 1A: Verify the sensor accuracy with a mechanical gauge. Condition: + Turn keyswitch to the ON position. Action ‘Specifications/Repair Next Step Verify the sensor accuracy with a mechanical | OK 2A gauge. ‘The sensor reading is correct * Connect a mechanical oil pressure gauge to | Refer to the Troubleshooting and Repair the engine. Manual, ISB Engines, Bulletin No. 3666189, ‘+ Connect INSITE™ to vehicle datalink. + Start the engine, and compare the oll pres- sure reading on the service tool monitor screen to the reading on the mechanical oil NOT OK Fault Code eee Fault Code 141 active 141 NOTE: It necessary, rev the engine up to to see differences in the STEP 2: Clear the fault code ‘STEP 2A; Disable the fault code Condition: * Connect ail the components. * Tu keyswitch to the ON position. Action Next Step | Disable the fault code OK 28 + Start the engine, and let it idle for 1 minute. | Fault Code 143 inactive * Verily Faut Code 143 is inactive, NOT OK ia NOTE: If the fault was at a particular speed, | Return to the troubleshooting steps, or run the engine at that speed to verity the | contact your local Cummins Authorized problem has been corrected. Repair Location if all the steps have been completed and checked again.1sB Section TF - Troubleshooting Fault Codes STEP 2B: Clear the inactive fault codes. Condition: = Connect all the components, + Tum Keyswitch to the ON position. Action Specifications/Repair Next Step Clear the inactive fault codes. OK Repair ++ Erase the inactive fault code using INSITE™. | All faults cleared complete NOT OK | Appropriate “Troubleshoot any remaining active fault troubleshoot codes. ing chartFault Code 144 or 145 IsB Section TF - Troubleshooting Fault Codes eas F882 Fault Code 144 or 145 Coolant Temperature Sensor Circuit oo REASON erreor Fat Code: 4497148] FO 144 Fighvotag dooce’ | Deut avo ved for engine coolant PID(P), SID(S): P110 ‘the coolant temperature signal pin | temperature. Sen no Be ctino onginehamoes No ogi potcton for cola tempor: Fa or FO 145: Lm volage deoctee at | - ‘the coolant temperature signal pin Both engine hamoss | Coolant Temperature Sensor Circuit Coolant Temperature ‘Sensor Signal. \ B> Ss ea A> Lp A?) ECM ~ 23 Coolant Temperature Sensor Return Coolant Temperature Sensor Circuit Descript ‘The coolant temperature sensor is usad by the ECM to monitor the temperature of the engine coolant. The coolant temperature is used by the ECM for the engine protection system, timing, and fueling control. Component Location: ‘The coolant temperature Sensor is located to the front of the thermostat housing.ult Code 144 or 145 isp ‘Section TF - Troubleshooting Fault Codes Page TF-83 Shop Talk: {Fhe Sensor feading will match tothe fllowing table Ifthe sensor is functioning property. Temperature (°C) ‘Temperature [°F] Resistance (ohms) ° 32 30k to 36K 25 7 9k to 11k 50 1e2 3k t0 4k 75 167 1960 to 1500 212 600 10 675 100Fault Code 144 or 145, IsB Page TF-84 Section TF - Troubleshooting Fault Codes TROUBLESHOOTING SUMMARY A warning & ‘Wait until the coolant temperature is below 50° C [120°F] before removing the coolant system pressure cap or the coolant temperature sensor. Failure to do so can cause personal injury from heated coolant ‘spray. A caution A ‘To avoid pin and harness damage, use the following test leads when taking a measurement: Part No. 3822758 - male AMP/Metri-Pack test lead Part No. 3823256 - female Metri-Pack test lead. A caution A I other active fault codes must be investigated prior to replacing the ECM. ‘To avoid damaging anew ECM, ‘STEPS SPECIFICATIONS SRT CODE STEP 1: Check the fault codes. ‘STEP 1A: Read the fault codes. Fault Codes 952 and 386 are inactive STEP 2: Check the coolant temperature sensor. ‘STEP 2A: Inspect the engine harness and cool No damaged pins ant temperature sensor connector pins. ‘STEP 2B: Check the resistance of the coolant 175 to 244k ohms temperature sensor. STEP 2C: Check for a short circuit to ground in More than 100k ohms cootant temperature sensor. STEP 3: Check the engine harness. ‘STEP 3A: Inspect the harness and the ECM No damaged pins ‘connector. ‘STEP 3B: Check for an open circuit Less than 10 ohms STEP 3C: Check for a short circuit to ground. More than 100k ohms, ‘STEP 3D: Check for a short circuit from pin to More than 100k ohms. pi STEP 4: Clear the fault codes. STEP 4A: Disable the fault code. Fault Code 144 or 145 inactive Clear the inactive fault codes. All faults cleared1sB Fault Code 144 or 145 Section TF - Troubleshooting Fault Codes Page TF-85 TROUBLESHOOTING STEP @ STEP 1: Check for multiple fault codes. STEP 1A: Read the fault codes. Condition: ‘+ Turn keyswitch to the ON position. Action Specifications/Repair Next Step Read the fault codes. ‘OK 2a * Read the fault codes using INSITE™. Fault Codes 352 and 986 inactive NOT OK Refer to Possible sensor failure, short circuit to Fault Codes. ground in the sensor +5-VDC common 352 and 386 supply, oF a short circult from pin to pin, or an open circuit in the sensor common [ ground. STEP 2: Check the coolant temperature sensor. STEP 2A: Inspect the engine harness and coolant temperature sensor connector pins. Condition: ‘Turn keyswitch to the OFF position. Disconnect the engine harness from the coolant temperature sensor L Action Specifications/Repair Next Step inpec to ares ane sont conecor | OK 28 pins for the following: No damaged pins @ | eertcrbcton pes nee x 5 Pusad bak or panded pins Beran the damaged pine + Notre na on he conrotr Reparoreplcs he rare naan oe fone nears cosa rr Soendeas epee wore Bec beer eee fei cree tail iat he serpin corce sa | goueFault Code 144 or 145 Page TF-86 IsB Section TF - Troubleshooting Fault Codes STEP 2B: Check the resistance of the coolant temperature sensor. To avoid pin and harness dar Part No, 3823266 - female Metri-Pack t AcAuTionA 6, use the following test lead when taking a measurement: Condition: ‘* Turn koyswitch to the OFF position. + Disconnect the engine harness from the coolant temperature sensor. the coolant temperature sensor. Action Specifications/Repair Next Step ‘Check the resistance of the coolant temperature | OK 2c jensor. 175 to 244k ohms + Measure the resistance from pin A to pin Bol Tur oq aa Replace the coolant temperature sensor Refer to Procedure 019-019. P.N. 3823256 (part of 3822926)IsB Fault Code 144 or 145 Section TF - Troubleshooting Fault Codes Page TF-87 STEP 20: Check for a short circuit to ground in the coolant temperature sensor. AcauTionA, Bold pin and hdiness damage, use the following test lead when taking 2 measurement: Part No. 3823256 - female Metri-Pack test lead. Condition: ‘+ Turn keyswitch to the OFF position ‘+ Disconnect the engine harness from the coolant temperature sensor. ‘Action Specifications/Repair Next Step ‘Check for a short circuit to ground. OK 3A ‘+ Measure the resistance from pin A of the | More than 100k ohms Geokant temperature sensor to engine lock Noy ox a Replace the coolant temperature sensor Roter to Procedure 019-019. PN. 3823256 (part of 3822926)Fault Code 144 or 145 Isp Page TF-88 Section TF - Troubleshooting Fault Codes. STEP 3: Check the engine harness. STEP 3A: Inspect the engine harness and the ECM connector pins. AcautionA, Ze.svold damaging a new ECM, al other active fault codes must be Investigated prior to replacing the Condition: * Tum keyswitch to the OFF position. ‘# Disconnect the engine harness from the ECM. Action Specifications/Repair Next Step Inspect the engine harness and the ECM OK ‘3B connector pins for the following: No damaged pins = Bent or broken pins Pushed back or expanded pins Corroded pins ‘Moisture in or on the connector Missing or damaged seals. NoT OK an Repair the damaged pins Repair or replace the engine harness or ECM, whichever has the damaged pins. ‘+ Repair tho engine harness. Refer to Procedure 019-250. ‘+ Replace the engine harness. Refer to Procedure 019-043. ‘* Replace the ECM. Refer to Procedure 019-031,188 Fault Code 14 ‘Section TF - Troubleshooting Fault Codes STEP 3B: Check for an open circuit. AcauTionA, Tp mvold pin and harness damage, use the following test lead when taking a measurement: Part No. 8822758 - male AMP/Metri-Pack test lead. Condition: ‘+ Tum keyswitch to the OFF position. ‘+ Disconnect the engine harness from the coolant temperature sensor * Disconnect the engine harness from the ECM. Action Specifications/Repair [ Next Step ‘Check for an open circuit. 0K 3c * Measure the resistance from pin 19 of the | Less than 10 ohms engine harness to pin A on the harness side of the coolant temperature sensor connector, [NOT OK aA + Measure the resistance from pin 23 of the | Replace the engine harness tengine harness to pin B on the harness side | Refer to Procedure 019-043, of the coolant temperature SensorFault Code 144 or 145 isB Page TF-90 Section TF - Troubleshooting Fault Codes STEP 3C: Check for a short circuit to ground, ‘AcaurionA Te gvold pin and harness damage, use the folowing test lead when taking 2 measurerhent: Part No. 822758 - male AMP/Metri-Pack test lead. Condition: * Turn Keyswitch to the OFF position. ‘+ Disconnect the engine harness from the coolant temperature sensor. ‘= Disconnect the engine harness from the ECM. Action Specifications/Repair [ Next Step ‘Check for a short circuit to ground. OK | 3D ‘+ Measure the resistance from pin 23 of the | More than 100k ohms engine harness to engine block ground. ‘+ Measure the resistance from pin 19 of the heplocs aie cragine Warnes a engine harness to engine block ground. Replace the engine harnesisp Fault Code 144 or 145 Section TF - Troubleshooting Fault Codes Page TF-91 STEP 3D: Check for a short circuit from pin to pin. AcauTionA, To avold pin and harness damage, use the following test lead when taking a measurement: Part No. 3822758 - male AMP/Metri-Pack test lead. Condition: ‘© Turn keyswitch to the OFF position * Disconnect the engine harness from the coolant temperature sensor. + Disconnect the engine harness from the ECM. Action Specifications/Repair Next Step ‘Cheek for a short circuit from pin to pin. oK 4A * Measure the resistance from pin 23 of the | More than 100k ohms engine harness to all other pins in the engine harness, NOT OK A ‘+ Measure the resistance from pin 19 of the | Replace the engine harness engine hamess to all other Refer to Procedure 019-043. hamess.Fault Code 144 or 145 Page TF-92 ‘STEP 4; Clear the fault code. STEP 4A: Disable the fault code. IsB Section TF - Troubleshooting Fault Codes Condition: * Connect all components. + Turn keyswitch to the ON position. Action ‘Specifications/Repair Next Step Disable the fault code, ‘OK 3 * Start the engine, and let idle for | minute. _| Fault Code 144 or 145 inactive * Verity that Fault Code 144 or 145 is inactive, Ro oy aa Rotur to the troubleshooting steps, or contact your local Cummins Authorized Fopair Location if all the steps have boon Completed and checked again. 7 STEP 4B: Clear the inactive fault codes. ‘Condition: + Connect all the components. + Turn keyswitch to the ON position.* Action Specifications/Repair Next Step ‘Clear the inactive fault codes. OK Repair + Erase the inactive fault code using INSITE, | All faults cleared complete NOT OK ‘Appropriate ‘Troubleshoot any remaining active fault troubleshoot- codes. ing chart1sB Fault Code 146 Section TF - Troubleshooting Fault Codes Page TF-93 Fault Code 146 Coolant Temperature - Engine Protection CODES REASON. EFFECT Fault Code: 146 ‘Coolant temperature signal Power derate and possible engine shut- PID(P), SIDS): P10 indicates coolant temperature has | down if engine protection shutdown feature SPN: "110 exceeded the minimum engine is enabled. FMI: 0 protection limit. Lamp: Yellow Coolant Temperature Sensor Circuit Coolant Temperature Sensor Signal B> ‘Ss p28 io we iti Coolant Temperature Sensor Return Coolant Temperature Sensor Circuit Description: ‘The coolant temperature sensor (CTS) is used by the electronic cantrol module (ECM) to manitor the temperature ofthe engine coolant. The coolant temperature is used by the ECM for the engine protection system and the timing ‘and fueling control. Component Location: ‘The coolant temperature sensor Is located on top of the thermostat housing. Shop Talk: Make Sure the airtiow through the radiator is not obstructed.Fault Code 146 isp Page TF:94 Section TF - Troubleshooting Fault Codes ‘TROUBLESHOOTING SUMMARY STEPS SPECIFICATIONS SRT CODE STEP 1: Check the sensor accuracy. STEP 1A: Verify the sensor accuracy with a Sensor reading Is correct thermocouple or similar temperature probe. STEP 2: Clear the fault codes. STEP 2A: Disable the fault code. Fault Code 146 inactive STEP 2B: Clear the inactive fault codes, All faults cleared ‘TROUBLESHOOTING STEP STEP 1; Check the sensor accuracy. STEP 1A: Verity the sensor accuracy with a thermocouple or similar temperature probe. Condition: + Turn keyswiteh to the ON position. Action Specifications/Repair Next Step Verify the sensor accuracy with a thermocouple | OK aA or similar temperature probe. Sensor reading is correct * Connoct the temperature probe to the engine | Refer to the Troubleshooting and Repair noar the coolant temperature sensor Manual, ISB Engines, Bulletin No, 2666193. + Connect INSITE™ to the vehicle datalink, * Compare the coolant temperature reading on =rEtE the service tool monitor soreen tothe reacing | SOT OK ing ince 2A ory Hie ternps|etule probe: Replace the coolant temperature sensor. NOTE: Ita temperature measuring device is _| Refer to Procedure 019-018, not available, answer “OK” to this step. STEP 2: Clear the fault codes. STEP 2A: Disable the fault code. Condition: + Connect ail the components. + Turn keyswitch to the ON position ‘Action Specifications/Repair Next Step Disable the fault code OK 28 * Start the engine, and let idle for 1 minute. | Fault Code 146 inactive * Using INSITE, verify Fault Code 146 is NORGE ore inactive, Return to the troubleshooting steps, or contact your local Cummins Authorized Repair Location if all the steps have been completed and checked again.IsB Fault Code 146 Section TF - Troubleshooting Fault Codes Page TF-35 STEP 2B: Clear the inactive fault codes. Condition: * Connect all the components. + Turn keysuitch to the ON position, ‘Action Sper Next Step Clear the inactive fault codes. OK Repair + Erase the Inactive fault code using INSITE™. | All fault codes cl complete WoT OK ‘Appropriate ‘Troubleshoot any remaining active fault troubleshoot. codes. ing chartFault Code 151 IsB Page TF-96 Section TF - Troubleshooting Fault Codes Fault Code 151 Coolant Temperature - Engine Protection ‘CODES REASON, EFFECT Fault Code: 151 Coolant engine temperature signal | Power and/or speed derate and possible PID), SID(S): indicates coolant temperature has | engine shutdown if engine protection FMI: ‘exceeded the engine protection | shutdown feature is enabled. Lamp: Red lit. Coolant Temperature Sensor Circuit Coolant Temperature Sensor Signal 7 \ ros 23 rat = ad] a Coolant Temperature Sensor Return ECM Coolant Temperature Sensor Circuit Description: ‘The coolant temperature sensor is used by the electronic control module (ECM) to monitor the temperature of the engine coolant. The coolant temperature is used by the ECM for the engine protection system, timing, and fueling control, Component Location: ‘Tie cholant tomperalure Soneor Is located on the engine in the thermostat housing area, Shop Talk: Make sure the airflow through the radiator is not obstructed.IsB Section TF - Troubleshooting Fault Codes Fault Code 151 Page TF-97 TROUBLESHOOTING SUMMARY STEPS SPECIFICATIONS SRT CODE STEP 4: Check the sensor accuracy. ‘STEP 1A: Verity the sensor accuracy with Sensor reading Is correct thermocouple or similar temperature probe. STEP 2: Clear the fault code. STEP 2A: Disable the fault code. Hear the inactive fault codes. TROUBLESHOOTING STEP STEP 1; Check the sensor accuracy. ‘STEP 1A: Verity the sensor accuracy with a thermocouple or similar temperature probe. Condition: + Tum keyswitch to the ON position. ‘Action ‘Specifications/Repair Next Step Verity the sensor accuracy with @ thermocouple | OK 2A or similar temperature probe. Sensor reading is correct * Connect the temperature probe to the engine | Refer to the Troubleshooting and Repair rear the coolant temperature sensor. Manual, ISB Engines, Bulletin No. 3666193. * Connect INSITE™ to the vehicle datalink. * Compare the coolant temperature reading on the service too! monitor screen to the reading “Fault Code | fala NOT OK Fault Code om ie are eer Refer to Fault Code 145. 145 NOTE: If temperature measuring device is not available, answer “OK’ to this step.Fault Code 181 Page TF-98 STEP 2: Clear the fault code. STEP 2A: Disable the fault code, Section TF - Troubleshooting Fault Cod. IsB Condition: + Connect all the components. Action Specifications/Repair Next Step Disable the fauit code. ‘OK 2B * Start the engine, and let idle for 1 minute. _| Fault Code 181 inactive * Veri 151 is inactive. Verity Fault Code 151 is inacti roa 7m Return to the troubleshooting steps. or contact your local Cummins Authorized Repair Location if all the steps have been completed and checked again. 1 Minute {dle STEP 2B: Clear the inactive fault codes. Condition: * Connect all the components. Action Specifications/Repair Next Step Clear the inactive fault codes. OK Repair * Erase the inactive fault codes using INSITE™. | All fault codes cleared complete NOT OK ‘Appropriate ‘Toubleshoot any remaining active fault trouble- codes. shooting chart1sB ‘Section TF - Troubleshooting Fault Codes Fault Code 153 or 154 Fault Code 153 or 154 Intake Manifold Air Temperature Sensor Circuit Page TF-99 ‘CODES REASON EFFECT Fault Code: 158 or 154 PID(P), SIDIS): P105 SPN: 105 FM: Sor 4 Lamp: Yellow FC 153: High voltage detected at take manifold temperature signal pin 34 of the engine harness. FC 154: Low voltage detected at Intake manifold temperature signal pin 34 of the engine harness. Default value used for intake manifold temperature. No engine protection for intake manifold temperature. Intake Manifold Alr Temperature Sensor Circult Intake Air Temperature Sensor Signal — BD Intake Air Temperature Sensor Ae AD a Intake Air Temperature Sensor Return + Engine Harness as Circuit Description: ‘The intake manifold air temperature sensor is used by the ECM to monitor the engine intake air temperature. The intake manifold aie temperature signal is used by the ECM for engine protection system, cold start aid, timing, and fueling control. Component Location: $fhe intake manifold at Temperature sensor is located on the side ofthe intake manifold at tho rear ofthe head.Fault Code 153 or 154 0 Page TF IsB Section TF - Troubleshooting Fault Codes. THUNB stunning propery, compare the reading he following table. Temperature (°C) ‘Temperature [7F]_ Fiesistance (ohms) ° 32 80k to 38K. 25 7 9k to 11k 50 122 3k to 4k 75 167 1950 to 1500 100 212 600 to 6751sB Section TF - Troubleshooting Fault Codes Fault Code 153 or 154 Page TF-101 TROUBLESHOOTING SUMMARY A caution A ‘To avoid pin and harness damage, use the following test leads when taking a me Part No, 3823256 - female Metri-Pack test Part No. 3822758 - male Deutsch-Pack test lead. rement: A caution A ‘Te avoid damaging anew ECM, all other active fault codes must be investigated prior to replacing the ECM. ‘STEPS STEP 1: Check for multiple fault codes. ‘STEP 1A: Check for active fault codes. ‘SPECIFICATIONS SRT CODE Fault Codes 352 and 386 inac- tive STEP 2: Check the intake manifold temperature sensor. ‘STEP 2A: Inspect intake manifold temperature ‘sensor and engine harness connec- tor pins. STEP 2B: Check the sensor resistance. ‘STEP 2C: Check for a short circuit to ground. STEP 3: Check engine harness. STEP 3A: Inspect harness and ECM connector. STEP 9B: Check for an open circuit. short circuit to ground. STEP 3D: Check for a short circult from pin to pin. STEP 4: Clear fault codes. STEP 4A: Disable the fault code. ‘STEP 4B: Clear the inactive fault codes. No damaged pins 175 to 244k ohms More than 100k ohms No damaged pins Less than 10 ohms ‘More than 100k ohms ‘More than 100k ohms, Fault Code 153 or 154 inactive All faults clearedFault Code 153 or 154 Page TF-102 TROUBLI STEP 1: Check for multiple fault codes. STEP 4A: Check for active fault code 1sB Section TF - Troubleshooting Fault Codes ESHOOTING STEP L Condition: * Tum keyswitch to the ON position, Action Specifications/Repair Next Step ‘Check for active fault codes. OK 2a + Read the fault codes using INSITE™. Fault Codes 352 and 386 inactive NOT OK Refer to Possible sensor failure, a short circuit to Fault Code ‘ground in the sensor +5-VDC common 352 or 386 supply, @ short circuit from pin to pin, or an [Lepen circuit on the sensor common ground. STEP 2: Check the intake manifold temperature sensor. STEP 2A: Inspect the intake manifold temperature sensor and the engine hamess connector pins. Condition: = Tum keyswitch to the OFF position, * Disconnect the engine harness from the intake manifold temperature sensor. * Bent or broken pins ‘+ Pushed back or expanded pins Corroded pins ‘+ Moisture in or on the connector ‘+ Missing or damaged seals. Action Specifications/Repair Next Step Inspect the intake manifold temperature sensor | OK 2B {and the engine harness connector pins for the | No damaged pins following: NOTOK 77 Repair the damaged pins Repair of replace the intake manifold temperature sensor or the engine harness, whichever has the damaged pins. + Repair the engine harness. Refer to Procedure 019-202. ‘+ Replace the engine harness. Refer to Procedure 019-043. ‘+ Replace the intake manifold temperature sensor. Refer to Procedure 019-059.isB Section TF - Troubleshooting Fault Codes sor resistance. ‘To avoid pin and harness dam: Part No. 3822758 Fault Code 183. AcAuTIONA, use the following test leads when taking a measurement: Deutsch-Pack test lead Part No. 3823256 - 2-pin Metri-Pack repair terminal. or 154 Page TF-103, Condition ‘+ Turn keyswitch to the OFF position ‘Disconnect the engine harness from the intake manifold air temperature sensor. the intake manifold air temperature sensor. Action Specifications/Repair Next Step ‘Check the resistance of the intake manifold air | OK 20 temperature sensor. 175 ohms to 244k ohms ‘+ Measure the resistance from pin A to pin Bot Tor ox Pry Replace the intake manifold temperature sensor Refer to Procedure 019-059.Fault Code 153 or 154 Page TF-104 STEP 2C: Check for a short circuit to ground. To avoid Part No. Part No. 3823256 - 2-pin Metri-Pack repair te IsB Section TF - Troubleshooting Fault Codes AcAUTIONA in, and harness damage, use the following test leads when taking a measurement: 922750 - male Deutach-Pack test lead Condition: ‘¢ Turn keyswitch to the OFF position. * Disconnect the engine harness from the intake manifold air temperature sensor Action Specifications/Repair Next Step Check for a short circuit to ground. OK 3A ‘© Measure the resistance from pin A of the More than 100k ohms Intake mano temperature senser'©eraine Nor OK ry Replace the intake manifold temperature ‘sensor | Reter to Procedure 019-059, )Isp Section TF - Troubleshooting Fault Codes STEP 3: Check the engine harness. Fault Code 153 or 154 ‘STEP 3A: Inspect the engine harness and the ECM connector pins. Page TF-105 To avoid damaging a new ECM, ECM. ACAUTIONA, Il other active fault codes must be investigated prior to replacing the eo Condition ‘+ Tum keyswitch to the OFF position. + Disconnect the engine harness from the ECM. ‘* Pushed back or expanded pins * Corroded pins ‘+ Moisture in or on the connector ‘+ Missing or damaged seals. Action Specifications/Repai Next Step Inspect the engine harness and the ECM OK 3B connector pins for the following No damaged pins * Bent Bent or broken pins morn oe Repair the damaged pins Repair or replace the engine harness or ECM, whichever has the damaged pins. * Repair the engine harness. Reter to Procedure 019-250. * Replace the engine hamess. Refer to Procedure 019-043, * Replace the ECM. Refer to Procedure 019-031Fault Code 153 or 154 Page TF-106 STEP 3B: Check for an open circuit. IsB Section TF - Troubleshooting Fault Codes To avoid pin and harness dama Part No. 3822758 - male Deutsch-Pack test lead. caution, use the following test lead when taking a measurement: Condi «Tum keyswitch to the OFF position. + Disconnect the engine harness from the ECM. ‘+ Disconnect the engine harness from the intake manifold air temperature sensor. ‘+ Measure the resistance from pin 34 of the engine harness to pin B an the harness side of the intake manifold air temperature sensor connector. Replace the engine hamess Refer to Procedure 019.043, Action Specifications/Repair Next Step ‘Check for an open circuit. OK 3c ‘+ Measure the resistance from pin 19 of the _| Less than 10 ohms engine harness to pin A on the harness side of the intake manifold alr temperature sensor connector, NOT OK aA Aisp Fault Code 153 or 154 Section TF - Troubleshooting Fault Codes Page TF-107 STEP 3C: Check for a short circuit to the ground. ACAUTIONA To avoid pin and harness damage, use the following test lead when taking a measurement: Part No. 5822758 - male Deutsch-Pack test lead. Condition: ‘+ Tur keyswitch to the OFF position. * Disconnect the engine harness from the intake manifold air temperature sensor. isconnect the engine harness from the ECM. Action Specifications/Repair Next Step Check for a short circuit to ground. OK — 3D '* Measure the resistance from pin 19 of the | More than 100k ohms ‘engine harness connector to engine block ‘ground. NOT OK aA flees perms we ac osonae | MOT OS) engine hamess connector to engine block —_| eter to Procedure 019-043, ground,Fault Code 153 or 154 1sB Page TF-108 ‘Section TF - Troubleshooting Fault Codes STEP 3D: Check for @ short cirult from pin to pin. AcautionA, use the following test lead when taking measurement: lead. To avoid pin and harness damay Part No. 3822758 - male Deutsch-Pack te Condition: + Tum keyswitch to the OFF position ‘+ Disconnect the engine harness from the intake manifold air temperature sensor, + Disconnect the engine harness from the ECM. Action Specifications/Repair Next Step Chack for a short circuit from pin to pin. ‘OK ry = Measure the resistance from pin 19 of the _| More than 100k ohms. engine hamess to all other pins in the engine harness. NOT OK aA ‘+ Measure the resistance from pin 34 of the | Replace the engine harness engine harness to all other pins in the engine | Refer to Procedure 019-043. harness.($8 Section TF - Troubleshooting Fault Codes Fault Code 153 or 154 Page TF-109 STEP 4: Clear the fault code, STEP 4A; Disable the fault code. Condition: ‘* Connect all components. ‘+ Turn keyswitch to the ON position. Action ‘Specifications/Repair Next Step Disable the fault code. OK 4B * Start the engine, and let idle for 1 minute. _| Fault Code 183 or 154 Inactive + Verity that Fault Code 153 or 154 is inactive. ior OK i Return to the troubleshooting steps, or ‘contact your local Cummins Authorized Repair Location if all steps have been completed and checked again. STEP 4B: Clear the Inactive fault codes. Condition: * Connect all components. + Turn keyswitch to the ON position. ‘Action ‘Specifications/Repair Next Step Clear the inactive fault codes, 0K Repair ‘© Erase the inactive fault code using INSITE™. | All the faults cleared complete NOT OK ‘Appropriate Troubleshoot any remaining active fault troubleshoot codes. ing chartFault Code 155 IsB Page TF-110 Section TF - Troubleshooting Fault Codes Fault Code 155 Intake Manifold Air Temperature Sensor - Engine Protection Circuit ‘CODES REASON. EFFECT Fault Code: 185 Intake manifold air temperature | Speed derate and possible engine shut- PID(P), SIDIS): F105 signal indicates the intake manifold | down if engine protection shutdown feature SPN: "105, air temperature is above the {is enabled. FMI: 0 ‘engine protection limit. Lamp: Red Intake Manifold Air Temperature Sensor Circuit Intake Air Temperature Sensor Signal \ a 4 oo 34 BD) 7 it | 19 | rs y << Intake Air Temperature he Harness. Sensor Return Intake Air Temperature Sensor (Cadence Circuit Description: The intake manifold air temperature sensor is used by the electronic control module (ECM) to monitor the temperature of the engine intake air. The intake air temperature is used by the ECM for the engine protection __ system, cold start aids, and the timing and fueling control. Component Location: ‘The intake manifold temperature sensor is located on the side of the intake manifold toward the rear of the cylinder head. ‘Shop Talk: = Make Sure the engine compartment temperature does not get too high (above 93.3°C [200°F)). ‘+ Make sure the intake manifold temperature sensor is not located near any extreme heat sources, ‘+ Possible causes: = clogged, dirty, inadequate capacity air cleaner element. Refer to Procedures 010-060 through 010-063 in the ‘Troubleshooting and Repair Manual, ISB Engines, Bulletin No. 3666193. = intake restriction. Refer to Procedure 010-059 in the Troubleshooting and Repair Manual, |S8 Engines, Bulletin No, 3666193.'s8 Fault Code 155, Section TF - Troubleshooting Fault Codes Page TF-111 TROUBLESHOOTING SUMMARY STEPS SPECIFICATIONS SRT CODE STEP 1: Check the sensor accuracy. STEP 1A: Verity the sensor accuracy with a Sensor reading is correct thermocouple or similar temperature probe. STEP 2: Clear the fault code. Fault Code 185 inactive All faults cleared ‘TROUBLESHOOTING STEP STEP 1: Check the sensor accuracy. STEP 1A: Verify the sensor accuracy with a thermocouple or similar temperature probe. Condition: += Tum keyswitch to the ON position Action Specifications/Repair Next Stey Verity the sensor accuracy with a thermocouple | OK 2A oF similar temperature probe. Sensor reading is correct within 5°F * Connect the temperature probe to the engine | Locate and repair the cause of high intake ‘near the intake manitold air tamporature manifold air temperature (refer to the Shop sensor. “Talk section of this fault code for the correct + Connect INSITE™ to the datalink, procedure). + Pun the engine, and compare the intake ‘manifold temperature sensor reading on INSITE™ monitor screen to the reading from the temperature probe. NOTE: If a temperature measuring device is | NOT OK Fault Code not available, answer “OK" to this step. Sensor reading incorrect 184 NOTE: Roadings may need to be checked while engine is operating at normal tempera ture conditions (180°F coolant).Fault Code 155 Page TF-112 ‘STEP 2: Clear the fault code. STEP 2A: Disable the fault code. Condition ‘+ Connect all the components. + Tum keyswitch to the ON position. 1sB Section TF - Troubleshooting Fault Codes Action Specifications/Repair Next Step Disable the fault code. OK 28 + Start the engine, and let ide for 1 minute. _ | Fault code 155 inactive and did not + Load and operate engine to typical operating | reoccur. temperature (180°F coolant) NOT OK 1A + Verity Fault C Nony Fault Code 155 is inactive and did net) return to the troubleshooting steps, of contact your local Cummins Authorized Repair Location if all the steps havo beon comploted and checked again. ‘Connect all the components. + Turn keyswitch to the ON postion. Action ‘Specitications/Repair Next Step Clear the inactive faut codes. oK Repair * Erase the inactive fault code using INSITE™. | All faults cleared completo NOT OK ‘Appropriate Troubleshoot any remaining active fault | troubleshoot- codes, ing chart1sB Section TF - Troubleshooting Fault Codes Fault Code 191 Air Conditioner Clutch Supply Circuit Fault Code 191 Page TF-113 Air Conditioner Clutch ‘CODES REASON EFFECT Fault Code: 191 ‘Air conditioner clutch signal ‘Can not turn on air conditioner. PID(P), SID(S): POSO Indicates @ short to ground when SPN: 878 ‘commanded on. FM tt Lamp: Air Conditioner Clutch Supply Cireult Air Conditioner Clutch Supply 23 Pin Connector ECM +12 VDC. / ae Circuit Description: {Fhe air conditioner cluich solenoid is a device used by the electronic control module (ECM) to contol the air conditioner by sending a signal to open oF close the air conditioner clutch solencid, Component Location: Refer to an original equipment manufacturer's (OEM) diagram for the location of the air conditioner clutch solenoid. Shop Talk: Air conditioner clutch solenoid could be malfunctioning due to a failed engine hamess or a bad ground on the alr conditioner clutch connector.Fault Code 191 Page TF-114 IsB ‘Section TF - Troubleshooting Fault Codes TROUBLESHOOTING SUMMARY A caution A ‘To avoid pin and harness damage, use the following test leads when taking a measurement: Part No. 3822758 - male Deutsch/AMP/Motri-Pack test lead Part No. 3823993 - mate Deutsch test lead Part No. 3823994 - female Deutsch test lead. A caution A ‘To avoid damaging anew ECM, all other active fault codes must be investigated prior to replacing the EC! STEPS STEP 1: Check the air conditioner clutch. STEP 1A: Inspect and test the air conditioner clutch and air conditioner clutch re- ley (if equipped). STEP 2: Check the engine harness. STEP 2A: Inspect the engine harness, air con- ditioner clutch relay, and the ECM connectors. STEP 2B: Check for an open circuit. STEP 2C: Check for a short circuit to ground. STEP 2D: Check for a short circuit from pin to pin. STEP 3: Check the OEM harness. ‘STEP 3A: Inspect the engine harness and OEM harness connectors. STEP 3B: Check for an open circuit. STEP 3C: Check for a short circuit to ground. STEP 3D: Check for a short circuit from pin to pin. STEP 4: Clear the fault codes. SPECIFICATIONS SRT CODE Air conditioner clutch and re- lay within specifications No damaged pins Less than 10 ohms More than 100k ohms More than 100k ohms No damaged pins Less than 10 ohms More than 100k ohms More than 100k ohms Fault Code 191 inactive All faults cleared1sB Fault Code 191 Section TF - Troubleshooting Fault Codes Page TF-115, TROUBLESHOOTING STEP STEP 1: Check the air conditioner clutch. ‘STEP 1A; Check the air conditioner clutch and air conditioner clutch relay (if equipped). Condition: ‘+ Turn keyswitch to the OFF position. ‘* Disconnect the OEM harness {rom the air conditioner clutch or air conditioner clutch relay. Action ‘Specifications/Repair Next Step Check the alr conditioner clutch for: OK 2A = Damaged pins Air conditioner clutch within specitica- ‘© Open or short circuits tions: ‘© Excessive current draw (power air conditioner NOT OK aA clutch directly from battery) ‘+ Perform this test in accordance with the OEM | Repair or replace the alr condition instructions, aun Refer to the OEM troubleshooting and repair manual, STEP 2: Check the engine harness. STEP 2A: Inspect the engine harness and the ECM connectors. ACAUTIONA, Il other active fault codes must be investigated prior to replacing the To avoid damaging a new ECM, ECM, Condition: ‘+ Turn keyswitch to the OFF position, ‘* Disconnect the engine harness from the ECM. ‘= Disconnect the engine harness from the 23-pin OEM harness connector. Action Specifications/Repair Next Step Inspect the engine harness and the ECM OK 2B connectors for: No damaged pins * Bent or broken pina : * Pushed back or expanded pins NOT OK i 7 Repair the damaged pins ok ee Repair or replace the engine harness, or + Moisture In or on the connector a clues eeasenee aeas ECM, whichever has the damaged pins. ‘= Repair the engine harness. Refer to Procedures 019-250 and 019.223. ‘+ Replace the engine harness. Refer to Procedure 019-043. * Replace the ECM. Refer to Procedure 019-031Fault Code 191 1sB Page Trat16 Section TF - Troubleshooting Fault Codes STEP 28: Check for an open eircult. ‘AcautionA To avoid », use the following test leads when taking a measurement: Pan No. VAMP /Motr-Pack test lead Part No. 3823994 - female Deutsch lead. Condition: ‘+ Tusn keyswitch to the OFF position. + Disconnect the engine hamess from the ECM. * Disconnect the engine harness trom the 23-pin OEM harness connector. 23-pin OEM harness connector. Replace the engine harness Reter to Procedure 019-043. Action Specifications/Repair Next Step Check for an open circuit. oK 20 * Measure the resistance from pin 21 of the | Less than 10 ohms ‘engine harness connector to pin J of the NOROK a1sB Section TF - Troubleshooting Fault Codes STEP 2C: Check for a short circuit to ground. Fault Code 191 Page TR-117 To avoid pin and harne: use tt ‘AcaonA, dat {following test lead when taking a measurement: Part No. 3822758 - male Deutsch/AMP/Metri-Pack test lead. Condition: ‘= Tur keyswitch to the OFF position. ' Disconnect the engine harness from the ECM. + Disconnect the en, @ harness from the 23-pin OEM hamess connector. Action Specifications/Repair Next Step (Check for a shor circuit to ground. oK 2D + Measuro tho resistance from pin 21 in the | More than 100k ohms engine harness to engine block ground, nNoTOK mz Replace the engine harness Refer to Procedure 019-043,Fault Code 191 IsB Page TF-118 Section TF - Troubleshooting Fault Codes STEP 20: Check for a short circuit from pin to pin. AcauTionA “To avoid pin and harness damage, use the following test lead when taking measurement: Part No, 5822758 = male AMP/Cannon/Deutsch/MeWr-Pack test load | Condition: + Turn Keyswitch to the OFF positon * Disconnect the engine hamess from the ECM. + Disconnect the engine harness from the 23-pin OEM harness connector. ‘Action Specifications/Repair Next Step Cheek for a short circuit between pins. OK aA + Measure the resistance from pin 21 to all | More than 100k ohms ‘other pins in the connector. ard 7 Replace the engine harness Refer to Procedure 019-043,Is Fault Code 191 Section TF - Troubleshooting Fault Cod Page TF-119 STEP 3: Check the OEM harness. STEP 3A; Inspect the OEM harness. Condition: + Turn keyswitch to the OFF position * Disconnect the OEM harness from the air conditioner clutch solenoid or relay. + Disconnect the engine harness from the 23-pin OEM harness connector. Action Next Step inspect the OEM harness and 23-pin connector | OK 38 No damaged pins + Bent or broken pins * Pushed back or expanded pins NoT ok , 4A cee Repair the damaged pins 5 pine , + te on come eel teal * Missing or damaged seal cenettioner + Repair the OEM harness, Refer to Procedure 019-225 or 019-202. + Replace the OEM harness. Refer to Procedure 019-071 + Replace the air conditioner clutch relay. Refer to the OEM troubleshooting and repair manual. STEP 3B: Chock for an open circult. AcautionA, To avoid pin and harness damage, use the following test lead when taking a measurement: Part No, 8623998 ~ male Deutech tect lead. Condition: + Tur keyswitch to the OFF position. + Disconnect the OEM harness from the air concitioner clutch solenoid or relay. + Disconnect the engine harness from the 23-pin OEM harness connector. Action Specifications/Repair Next Step ‘Check for an open ciroult, OK 36 + Measure the resistance from pin J of the | Less than 10 ohms 23-pin connector on the OEM side to the air i NOT OK 4A itioner clutch solenoid or rel Eeebeebcbe ected bececlbeet tases Replace the OEM harness Refer to Procedure 019-071,Fault Code 191 1sB Page TF-120 Section TF - Troubleshooting Fault Codes STEP 3C: Check for a short circuit to ground In the OEM harness. AcautionA, Je avoid pin and harass damage, use the following test lead when taking # measurement: Part No. 3823993 - male Deutsch test lead. Condition: ‘= Tum keyswitch to the OFF position. ‘= Disconnect the OEM harness from the air conditioner clutch solenoid or relay. * Disconnect the engine harness from the 23-pin OEM harness connector. Action Specifications/Repair Next Step ‘Check for a shor circuit 1o ground in the OEM | OK 2D harness. More than 100k ohms + Measure resistance from pin J of the 28-pin 7 NOT OK an OEM harness connector to ground, Mens iis Oca marcas Refer to Procedure 019-071.isp Fault Code 191 Section TF - Troubleshooting Fault Codes Page TF-121 STEP 3D: Check for a short circuit from pin to pin. AcauTionA, ‘To avoid pin and harness damage, use the following test lead when taking a measurement: Part No. 5623999" male Deutsch iestleade ad Condition: + Turn keyswitch to the OFF position * Disconnect the OEM harness from the air conditioner clutch solenoid or relay + Disconnect the engine harnoss from the 23-pin OEM hamese connector. Action Specifications/Repair Next Step Check for a shor circuit from pin to pin inthe | OK 4A (OEM harness. More than 100k ohms ‘* Measure resistance from pin J of the 23-pin OEM harness connector to all other pins in| NOT OK o he es conador Replace the OEM harness Refer to Procedure 019-071. Test All Pins Disable the fault code. Condition: + Connect all the components. ‘= Turn keyswitch to the ON position. = Action Specifications/Repair Next Step Disable the fault code. OK 4B ‘= Start the engine, and let idle for 1 minute, _| Fault Code 191 inactive + Using INSITE™, verify Fault Coc i Using INSITE. very Fault Code 191 Io MOTIOK, Ty Return to the troubleshooting steps, or ‘contact your local Cummins Authorized Repair Location if all steps have boon | completed and checked again.STEP 4B: Clear the inactive fault codes. Isp Section TF - Troubleshooting Fault Codes Condition: Connect all the components. codes. ‘* Turn keyswitch to the ON position. ‘Action ‘Specifications/Repair Next Step Clear the inactive fault codes. Repair + Erase the inactive fault codes using INSITE™ Appropriate Troubleshoot any remaining active fault ‘roubleshoot- ing chart1sB Fault Code 234 Section TF - Troubleshooting Fault Codes Page TF-123 Fault Code 234 Engine Overspeed Circuit CODES REASON EFFECT Fault Code: 234 Engine speed signal indicates Fuel to the injectors disabled until the PID(P), SID(S): P80 engine speed has exceaded the | engine speed falls below the overspeed SPN: 190 ‘overspeed iimit. limit, FMI: o i Lamp: Red Engine Overspeed Circuit Engine Si Engine Speed Input Signal frput etre ee “ Cf Se ++svoc yw we Circuit Description: The engine speed sensor provides engine speed information to the electronic control module (ECM). The sensor must be powered up by +5 VDC to operate. The sensor generates its signals by sensing the movementof target teeth cast into a tone wheel that is mounted to the crankshaft. The tone wheel has 35 teeth and a gap where the 36th tooth would be placed. This missing tooth indicates that cylinder No. 1 (and No. 6) is at top dead center. Component Location: ‘The anging sped sensor is located on the intake side of the engine block, at orankshattlovel, Between cylinders No. 4 and No. 8. ECMFault Code 234 Page TF-124 Section TF - Trouble TROUBLESHOOTING SUMMARY Awarnine & It flammable vapors are detected, shut down the engine, ventilate the area, and do not restart the engine until the source of the vapors is located and repaired. A coution A I the engine speed stays above 3700 rpm, the engine must be shut off immediately. A caution A ‘To avold damaging anew ECM, all other active fault codes must be investigated prior to replacing the ECM. STEPS SPECIFICATIONS SRT CODE STEP 1: Identify the reason for overspeed. ‘STEP 1A: Check for proper operating condi- Not motoring downhill tions, ‘STEP 1B: Check for an alternate fuel source, No alternate fuel source STEP 1C: Check the rpm with INSITE™ service Correct rpm reading tool monitor mode. STEP 1D: Check for an active fault at low rpm, Inactive fault at low rpm STEP 2: Clear the fault code. STEP 2A: Disable the fault code. Fault Code 234 Inactive 2B: Clear the Inactive fault codes. All faults cleared TROUBLESHOOTING STEP STEP 1: Identity the reason for overspeed. 'STEP 1A: Check for proper operating conditions. Condition: + Tum keyswitch to the OFF position. Action Specifications/Repair Next Step ‘Check for proper operating conditions, OK 1B * Check if the engine was motoring downhill _| Not metoring dewnhill when the fault was logged. on Electronics are OK. Check the engine for damage due to overspeed condition.1sB Section TF - Troubleshooting Fault Code: STEP 1B: Check for an alternate fuel sourc Fault Code 234 Page TF-125 (AWARNING A, It flammable vapors are detected, shut down the engine, ventilate the area, and do not restart the engine Until the source of the vapors is located and repaired. Condition: + Turn keyawitch to the OFF position, Action Specifications/Repair Next Step Check for an alternate fuel source. OK 1c © Check if the driver reported a fuet-controlled | No alternate fuel source ‘event where the engine rapidly accelerated © aor OK Ty ‘oF past overspeed limit without accelerator ; Input to cause speed increase, then followed | Locate the alternate fuel source Ta shats engine cllsaE * Locate any alternate fuel sources, such as S Chesk tie lnicle Gece or cones ot operating the engine noar flammable flammable vapors, and check the turbo- oot blown turbocharger seals, and 60 charger seas to very there are no oilleaks. | | J tne nase engine for damage du to the overspeed condition. STEP 1C: Check the rpm with the INSITE” service tool monitor mode. AcautionA If the engine speed stays above 3700 rpm, the engine must be shut off immediately. Condition: + Pun the engine. * Connect service too! to the vehicle datalink, Action Specifications/Repair Next Step Check the rpm with the monitor mode. OK 1D * Monitor the engine using INSITE”. Correct rpm reading | NOTE: Compare the engine speed reading on | NOT OK 2A INSITE™ to a mechanical tachometer or the | Inspect the engine speed sensor dash tachometer. Check the engine speed sensor as outlined for Fault Code 115, Inspect the engine for damage due to the overspeed condition.Fault Code 234 Page TF-126 STEP 1D: Check for an active fault at low rpm. AcAUTIONA Taprold damaging the new ECM, all other active fault codes must be Investigated prlor to replacing the IsB Section TF - Troubleshooting Fault Codes Condition: + Turn Keyswitch to the ON position. iE Action Specifications/Repair [ Next Step Check for an active fault code at low rpm: oK 2A Check for active Fault Code 234 when the Inactive fault code at tow rpm engine is not running above 3700 rpm. aoreR a Replace the ECM + Refer to Procedure 019-031, STEP 2: Clear the fault code. STEP 2A: Disable the fault code. Condition: * Connect all the components. + Turn keyswitch to the ON position. ‘Action Specifications/Repair Next Step Disable the fault code, OK 28 * Start the engine, and operate in the condition | Fault Code 294 inactive that previously exited th overspeed NOT OK Ga ven iradie oi Return to the troubleshooting steps, or pote betel beri contact your local Cummins Authorized Repair Location if all the steps have been compieted and checked again. STEP 2B: Clear the inactive fault codes. Condition: * Connect all the components + Tur keyswitch to the ON postion Action Specifications/Repair Next Step Clear the inactive fault codes. OK Repair + Erase the inactive faut code using INSITE™. | All faults cleared complete NOT OK ‘Appropriate Troubleshoot any remaining active faut | troubleshoot codes. ing chartis8 Fault Code 235 Section TF - Troubleshooting Fault Codes Page TF-127 Fault Code 235 Engine Coolant Level - Engine Protection ‘CODES REASON. EFFECT Fault Code: 235 ‘Coolant jevel signal at pin 37 of the | Power and/or speed derate and possible PIDIP), SIDS: PITT ‘engine harness indicates coolant | engine shutdown if engine protection SPN: ttt level is low. shutdown feature is enabled. FMI: 4 Lamp: Maintenance Engine Coolant Level - Engine Protection Coolant Level High Signal Engine Coolant Level Return Harness | ECM N._ lor Bi 73119 C7 cou i BI i437 oO ia 49 Coolant Level Coolant Level Sensor —+5VDC Supply iron Circuit Description: ‘The coolant level sensor monitors the coolant level within the coolant system and passes information to the electronic contro! module (ECM) through the engine harness. Because this sensor is so complex, do not use a ‘multimeter to check it, I the radiator coolant level drops below a certain level, a progressive power andlor speed derate will occur. Engine can, perhaps, shut down if engine protection shutdown feature is enabled. Component Loca ‘The coolant level sensor is located in the radiator top tank or surge tank. Shop Talk: This is an OEM supplied component and can vary in location. + Ia shorting plug is used in the coolant level circuit, verity that it is wired correctly. ‘+ Make sure the coolant level sensor is located in the middle of the tank rather than off to one side where the coolant level can change when the vehicle turns toward a comer, ‘+ Make sure the correct ECM code is in the ECM. Calibrating the ECM with the incorrect DO option can cause Fault Code 235 to be active since some OEMs use different sensors that require special calibrations. * Sterling Trucks utilize ECM pin A22 for coolant level sensing through a 2-pin sensor; refer to SPT 98719-46.Fault Code 235 IsB Page TF-128 Section TF - Troubleshooting Fault Codes TROUBLESHOOTING SUMMARY A Warning & ‘Wait until the coolant temperature is below 50°C [120°F] before removing the coolant system pressure cap or the coolant temperature sensor. Failure to do 80 can cause personal injury from heated cool A caution A Do not add cold coolant to a hot engine. Castings can be damaged. Allow engine to cool to below 50°C [120°F] before adding coolant. A caution A To avoid damaging a new ECM, all other active fault codes must be inves! A caution A To avoid pin and harness damage, use the following test lead when taking a measurement: Part No. 3823758 - male Deutsch/AMP/Metri-Pack test lead Part No. 3823993 - male Deutsch test lead Part No. 3823995 - male Weather-Pack test lead. ted prior to replacing the ECM. STEPS SPECIFICATIONS ‘SRT CODE STEP 1: Verify the coolant level. STEP 1A: Check the coolant tevel. Coolant level normal STEP 2: Check the coolant level sensor. ‘STEP 2A: Confirm the fault is still active with Fault stil active the engine running. STEP 3; Check for multiple fault codes. ‘STEP 3A: Read fault codes. Fault Code 385 or 444 inactive STEP 4: Check OEM pigtail harness. STEP 4A: Inspect the coolant level sensor, ‘OEM pigtail hamess, and engine har ness connector. No damaged pins STEP 4B: Check for open circuits. Less than 10 ohms STEP 4C: Check for short circuits to ground. More than 100k ohms STEP 4D: Check for short circuits from pin to ‘More than 100k ohms bin. STEP 5: Check engine harness. STEP 6A: Inspect the engine harness and ECM No damaged pins connectors. STEP 5B: Check for short circuits to ground. More than 100k ohms STEP 5C: Check for short circuits from pin to. More than 100k ohms Pin.1sB Fault Code 235 Section TF - Troubleshooting Fault Codes Page TF-129 STEP 5D: Check for open circuit. Less than 10 ohms STEP SE: Check sensor supply voltage. (+) 4.75 to 5.25 VDC STEP 6: Clear the fault code. ‘STEP 6A: Disable the fault code. Fault Code 235 inactive F the inactive fault codes. All faults cleared TROUBLESHOOTING STEP STEP 1: Verify the coolant level. STEP 1A: Check the coolant level. WARNING, Wait until the coolant temperature is below 50°C (120°F] before removing the coolant system pressure cap or the coolant temperature sensor. Failure to do so Can cause personal injury from heated coolant spray. AcautionA, Do not add cold coolant to a hot engine: Castings can be damaged. Allow engine to cool to below 50°C. [120°F] before adding coolant, Condition: Action Specifications/Repair Next Step ‘Check coolant level OK 2A + Remove the radiator cap, and inspect coolant | Coolant level Is normal ee NOT OK @A ‘Add coolant to the radiator NOTE: Make sure the coolant has the STEP 2: Check the coolant level sensor. STEP 2A: Confirm the fault is still active with the engine running. Condition: + Turn keyswitch to the ON position. Action Specifications/Repair Next Step Confirm the fault is stil active with the engine | OK 3A running. Fault code still active + Start the engine, and let idle for at least 1 minute, NOT OK 6A ‘Read the fault codes using INSITE™. Fault Code 235 inactiveFault Code 235 Page TF-130 STEP 3: Check for multiple fault codes. STEP 3A: Read fault codes. isB Section TF - Troubleshooting Fault Codes Condition: + Turn keyswitch to the ON position, Action i Specifications/Repair Next Step Read the fault codes. OK 4A ‘* Read the fault codes using INSITE™, Fault Code 385 or 444 inactive NOT OK Refer to Fault Code 385 or 444 active Fault Code 985 or 444 STEP 4: Check OEM pigtail harness. STEP 4A: Inspect the coolant level sensor, OEM pigtail harness, and engine harness connectors. Condition: ‘+ Tum keyswitch to the OFF position. ‘* Pushed back or expanded pins * Cortoded pins ' Moisture in or on the connectors * Missing or damaged seals. Repair the damaged pins ‘* Repair the coolant level sensor. Refer to the OEM troubleshooting and repair ‘manual. ‘+ Repair the OEM pigtail hamess. Refer to the OEM troubleshooting and repair manual ‘+ Repair the engine harness. Refer to Procedure 019-043. ‘= Disconnect the coolant level sensor, OEM pigtail harness, and engine harness. Action Specifications/Repair Next Step Inspect the coolant level sensor, OEM pigtail | OK 6 hares, and engine harness connectors for: | No damaged pins. * Bent or broken pins a onisp Section TF - Troubleshooting Fault Codes STEP 4B: Check for open circuits. AWARNINGA, Wait unti the coolant tomperature ia below 50°C [120°F] before removing the coolant system pressure cap or the coolant temperature sensor. Failure to do so can cause personal Injury from heated coolant spray. AcautionA, To avold pin and harness damage, use the following test leads when taking a measurement: Part No. 3823993 - male Deutsch test lead Part No. 3823995 - male Weather-Pack test lead. Condition: + Turn keyswitch to the OFF position. ‘+ Disconnect the engine harness from the coolant level sensor and OEM pigtail harness. Action Specifications/Repair Next Step ‘Cheek for an open cirout. OK a * Measure the resistance from pin Cto pin. | Less than 10 ohms + Measure the resistance from pin Bio pin. | yor ox an ‘+ Measure the resistance from pin D to pin D. . ‘ ; Repair or replace the OEM pigtall harness Measure the resistance from pin Ato pin A. | Fete to the OEM troubleshooting and repair manual.Fault Code 235 Isp Page TF-132 Section TF - Troubleshooting Fault Codes STEP 4C: Check for short circuits to ground. AWARNINGA, Wait unt the caotant tomperature is Below 50°C [120°F] before removing the coolant system pressure cap or the coolant temperature sensor. Failure to do so can cause persanal injury from ‘coolant prey. AcAUTIONA, To avoid pin and harness damage, use the following test lead when taking a measurement: Part No. 3823993 - male Deutsch test l Conditior ‘+ Turn keyswitch to the OFF position. * Disconnect the engine hamess from the coolant level sensor and OEM pigtail harness. Action Specifications/Repair Next Step Check for short circuits to ground. OK 4D ‘+ Measure the resistance from pin A to ground. | More than 100k ohms + Measure the resistance from pin B to ground. Nor ox a . the . Measure the resistance from pin C to ground. | peor or replace the OEM pigtail harness Refer to the OEM troubleshooting and repair manual N1sB Fault Code 235 Section TF - Troubleshooting Fault Codes Page TF-133 STEP 4D: Check for short circuits from pin to pin. AWARNINGA, - Walt until the coolant temperature is below 50°C [120°F] before removing the coolant system pressure weal yi the Coolant temperature sensor. Fallure to do so can cause personal injury from heated coolant spray. AcautionA To avoid pin and harness damage, Part No. 3823993 - male Deutsct ‘Condition: ‘© Turn Keyswitch to the OFF position. Disconnect the engine harness from the coolant level sensor and OEM pigtail harness. xd when taking a measurement: the following test I iead. ‘Action ‘Specifications/Repair Next Step ‘Check for short circuits from pin to pin. ‘OK 5A ‘© Measure the resistance from pin A to all othor | More than 100k ohms pins. ‘+ Measure the resistance from pin B to all other | ~ a NOT OK 6A + Measure the resistance from pin C to all other | Repair or replace the OEM pigtail harness pins. Refer to the OEM troubleshooting and repair + Measure the resistance from pin D to all other | manual ins. Test All PinsFault Code 235 {sp Page TF-134 Section TF - Troubleshooting Fault Codes STEP 5: Check engine harness. STEP SA: Inspect the engine harness and ECM connectors. AcautionA, Fe gvoid damaging # new ECM, all other active fault codes must be investigated prior to replacing the Condition: + Turn Keyswitch to the OFF position. ‘+ Disconnect the engine hamess from the engine control module (ECM). ‘+ Disconnect the engine hamess from the OEM pigtail harness. Action Specifications/Repair Next Step Inspect the engine harness and ECM connec- | OK 3B tors for the following: No damaged pins ‘+ Bont or broken pins nOROK ok Pushed back or expanded pins ‘Corroded pins - e Repair damaged pins Repair or replace the engine harness, ECM, Moisture in or on the connector ‘or coolant level sensor, whichever has the Missing connector seal danenal eine ‘+ Repair the engine harness. Refer to Procedures 019-204 and 019-250. * Replace the engine harness. Refer to Procedure 019.043. ‘* Replace the ECM. Refer to Procedure 019.031. * Dry the connector using electrical contact, cleaner, Part No, 3824510. STEP 5B: Check for short cireuits to ground. AWARNINGA, Wait unl the coolant temperature is below 50°C {320°F] before removing the coolant system pressure cap or the coolant temperature sensor. Failure to do so can cause personal injury from heated coolant Spray. AcAUTIONA To avoid pin and harness damage, use the following test lead when taking a measurement: Part No. 9623758 - male Deutson/AMPrMetr-Pack test lead Condition: + Turn Keyswitch to the OFF position. isconnect the engine harness from the coolant level sensor and OEM pigtail harness. seonnest the engine harness from the ECM. Action Specifications/Repair Next Step ‘Check for short circuits to ground. oK 5c '* Measure the resistance from pin 49 to engine | More than 100k ohms block ground. s ‘+ Measure the resistance from pin 27 to engine | NoT OK oA block ground. Repair or replace the engine hamess ‘+ Measure the resistance from pin 37 to engine | Refer to Procedure 019-043. block ground.198 Fault Code 235 Section TF - Troubleshooting Fault Codes Page TF-135, STEP 5C: Check for short circuits from pin to pin. AWARNINGA, Wait until the coolant temperature is below 50°C [120°F] before removing the coolant system pressure Cap or'the coolant temperature sensor. Failure to do a0 Gan cause personal injury from heated coolant spray. AcauTionA, ‘To avoid pin and harness damage, use the following test lead when taking a measurement: Part No. 3822758 - male AMP/Metri-Pack test lead. Condition: + Turn keyswtch to the OFF postion. + Disconnect the engine harness trom the coolant level sensor and OEM pigtail harness. + Disconnect the engine harness from the ECM. Action Specifications/Repair Next Step ‘Check for short circuits from pin to pin. OK 30 + Measure the resistance from pin 49 to all —_| More than 100k ohms other pins. ‘+ Measure the resistance from pin 27 to all ‘other pins. NOT OK 6A ‘+ Measure the resistance from pin 37 0 all —_| Repair or replace the engine hamess other pins. Refer to Procedure 019-043, + Moasure the resistance from pin 18 to all ther pins,Fault Code 235 Page TF-136 STEP 5D: Check for open circuit. Isp ‘Section TF - Troubleshooting Fault Codes Condition: * Tum Keyswitch to the OFF position, * Disconnect the engine harness from the ECM. * Disconnect the engine harness from the coolant level sensor. Action Specifications/Repair Next Step Check for open circuit in the coolant level ‘sensor circuit. * Measure the resistance from pin B on tho harness side of the coolant level sensor Circuit to pin 19 of the engine harness connector. ‘+ Measure the resistance from pin D on the harness side of the coolant level sensor Circuit to pin 27 of the engine harness connector. ‘+ Measure the resistance from pin A on the harness side of the coolant level sensor ‘circuit to pin 37 of the engine harness. connector. ‘+ Measure the resistance from pin C on the harness side of the coolant level sensor Circuit to pin 49 of the engine harness. connector. OK Less than 10 ohms NOT OK Replace the engine harness Refer to Procedure 019-043,1sB Section TF - Troubleshooting Fault Codes STEP SE: Check sensor supply voltage. Fault Code 235 Page TF-137 AcauTionA To avoid pin and harn Part No. 822758 - male AMP/Metri-Pack test lead. damage, use the following test lead when taking a measurement: Condition: ‘+ Turn keyswitch to the ON position. * Disconnect the engine harness from the coolant level sensor. * Connect the engine harness to the ECM. Action Specifications/Repair Next Step Check sensor supply voltage. OK 6A ‘© Measure the voltage from pin C of the sensor | (+) 4.76 to 5.25 VOC connector, hamess side, to engine block Replace coolant level sensor. Refer to ground. Procedure 019-017. NOT OK 6A Replace the ECM Refer to Procedure 019-031isable the fault code. IsB Section TF - Troubleshooting Fault Codes Condition: * Connect all the components. ‘+ Tum keyswitch to the ON position. ‘Action Specifications/Repair Next Step Disable the fait code. ok 8 + Start the engine, and tet it idle for 1 minute, | Fault code 238 inactive * Verity aut i Vority Fault Code 236 is inactive, NOT OK 77 Foturn tothe troubleshooting steps, or contact your focal Cummins Authorized Repair Location if all the steps have been completed and checked again. STEP 6B: Clear tho inactive fault codes. Condition: + Connect all the components. + Tuin keyswitoh to the ON position ‘Action Specifications/Repair Next Step Clear the inactive faut codes. °K Repair + Erase the inactive fault code using INSITE™. | All faults cleared complete NoT OK Appropriate TToubieshoot any remaining active fault _| troubleshoot- codes. ing chantIsB Fault Code 241 Section TF - Troubleshooting Fault Codes Page TF-139 Fault Code 241 Vehicle Speed Sensor Circuit ‘CODES REASON EFFECT Fault Code: 241 Vehicle speed signal on pins @ and | Engine speed limited to "Max. Engine PID(P), SID(S): P84 18 of the original equipment ‘Speed without Vehicle Speed Sensor” SPN: | 084 manufacturer's (OEM) harnoss has | Cruise control, gear-down protection and FMI: 2 been lost. road speed governor will not work. Tip Lamp: Yellow information data that are based on mileage will be incorrect. Vehicle Speed Sensor Circult Vehicle Speed To Vehicle Speedometer Sensor Signal >A De ECM Da 8 B 7 18 Vehicle Speed Sensor Return OEM Harness Circuit Description: The vehicle speed sensor (VSS) uses two separate coils of wire (some applications use a single-coil sensor) to count gear teeth as they pass in front of the sensor. One cail is used by the electronic control module (ECM) to sense vehicle speed. The other coil is sometimes used by the OEM to send a vehicle speed signal to the ‘speedometer. Component Location: ‘Te VES ls most Commonly installed inthe rear ofthe transmission, ‘Shop Talk: * Disconnect the vehicle speed sensor connector that connects to the OEM speedometer, or trip recorder, and move the truck. If the fault goes inactive, there is probably electrical noise being fed into the vehicle speed ‘sonsor circuit from the OEM device, * Verify the vehicle speed sensor wires in the OEM harness are twisted-pairs, + Check brake switch operation with INSITE™. Fault could be caused by rear-wheel lockup without brake Indication to ECM. ‘+ Verity the speed sensor is installed properly and its locking nut has not vibrated loose.Fault Code 241 Page TF-140 'sB Section TF - Troubleshooting Fault Codes TROUBLESHOOTING SUMMARY A caution A To avoid pin and harness damage, use the following test leads when taking a measurement: Part No. 3822758 - male AMP/Metri-Pack/Deutsch test lead Part No. 3823996 - female Weather-Pack test lead. A caution A To avoid damaging a new ECM, ‘STEPS STEP 1: Check the VSS. ‘STEP 1A: Inspect the OEM harness and the 180r connectors, STEP 1B: Check for proper adjustment (it ad- justable). STEP 1C: Check for the correct sensor resis tance. STEP 1D: Check for a short circuit to ground. STEP 1E: Check for a short circult between coils (if two coils exist). STEP 2: Check the OEM harness. STEP 2A: Inspect the harness and the ECM connectors. Check for correct circult resistance. Check for a short circuit to ground. Check fora short circuit trom pin to pin. STEP 3: Check the OEM components. ‘STEP 3A: Check for an external recording de- vice. STEP 3B: Check for a transmission tallshaft gear slipping on the shaft. STEP 3C: Check for interference on the OEM harness. STEP 3C-1: Disable the fault code. STEP 4: Clear the fault code. ‘STEP 4A: Disable the fault code, ‘STEP 4B: Clear the Inactive fault codes. Il other active fault codes must be investigated prior to replacing the ECM. ‘SPECIFICATIONS SRT CODE No damaged pins 1/2 to 3/4 tum out from gear for threaded type of sensor 750 to 1500 ohms. More than 10M ohms More than 10M ohms No damaged pins 750 to 1500 ohms More than 100k ohms More than 100k ohms No external device Gear attached properly Fault Code 241 inactive Fault Code 241 inactive Fault Code 241 Inactive All faults cleared188 Fault Code 241 Section TF - Troubleshooting Fault Codes, Page TF-141 TROUBLESHOOTING STEP STEP 1: Check the VSS. STEP 1A; Inepect the OEM harness and the sensor connectors. Condition: * Turn keyswiteh to the OFF position, '* Disconnect the OEM harness from the VSS. ‘Action ‘Specifications/Repair Next Step Inspect the OEM harness and the sensor OK 1B connectors for the following: No damaged pins * Bent or broken pins ou NOT OK 4A S coneeea ween Repair the damaged pins Smee Ge os eee Repair or replace the OEM harness or = ie ae sensor, whichever has the damaged pins. oe '* Repair the OEM harness. Refer to Procedure 019.202. + Replace the OEM harness. Refer to Procedure 019-071. + Replace the VSS. Refer to Procedure 019.090 or 019-081. STEP 18: Check the VSS for the proper adjustment (if adjustable). Conditios + Tun keyswitch to the OFF position. + Disconnect the OEM harness trom the VSS. Action Specifications/Repair Next Step ‘Check the VSS for the proper adjustment (if OK 1c adjustable) 1/2 to 3/4 of a turn out from the gear NoT OK 4A ‘Adjust the VS Refer to Procedure 019-080 or 019-091.Fault Code 241 isB Page TF-142 Section TF - Troubleshooting Fault Codes STEP 1C: Check for the correct sensor resistance. AcavrionA, To avoid pin and harness damage, use the foll Part No. 3823996 - female Weathor-Pack test | ng test lead when taking a measurement: Condition: * Tum keyswitch to the OFF position, * Disconnect the OEM harness from the VSS. Action Specifications/Repair Next Step ‘Check the vehicle speed sensor for the correct | OK 1D resistance, 780 to 1600 ohms ‘+ Measure the resistance from pin A to pin B for each VSS connector on the sensor side, | NOT OK a Fleplace the VSS Refer to Procedure 019-090 or 019-091.IsB Section TF - Troubleshooting Fault Codes STEP 1D: Check for a short circuit to ground. Fault Code 261 Page TF-143 * Turn Keyswitch to the OFF position ‘ACAUTIONA, To avoid pin and harness damage, use the following test lead when taking a measurement: Part No, 5823996 - female Weather-Pack test load, Condition: * Disconnect the OEM harness from the vehicle speed sensor. ‘sensor side of the other VSS connector to engine block ground. Action Specifications/Repair Next Step ‘Check the VSS for a short circuit to ground. OK 1€ ‘+ Measure the resistance from pin A on the More than 10M ohms ‘sensor side of one of the VSS connectors to engine block ground. NOT OK aA ‘+ Measure the resistance from pin Aon the | Replace the VSS. Retor to Procedure 019-080 or 019-091.Fault Code 261 isp, Page TRetad Section TF - Troubleshooting Fault Cod STEP 1E: Check for a short circuit between coils {If two coils exist). AcauTIONA, ‘o avold pin and harness damage, use the following test lead when taking a measurement: Part No, 8623996 - female Wei ck test lead Condition: + Turn keyswich fo the OFF postion * Disconnect the OEM harness from the VSS. Action Specifications/Repair Next Step ‘Check the VSS for a short circult between coils. | OK 2A * Measure the resistance from pin Aon the | More than 10M ohms ‘sensor side of one of the VSS connectors to pin A of the other connector. nor Ok 7 Replace the VSS Refer to Procedure 019-090 or 019-091,1sB Section TF - Troubleshooting Fault Codes STEP 2: Check the OEM harness. STEP 2 Inspect the harness and the ECM connectors. Fault Code 241 TR-145 Condition: ‘= Turn Keyswitch to the OFF position, ‘= Disconnect the OEM harness from the ECM. Missing or damaged seals, Action ‘Specifications/Repair Next Step Inspect the harness and the ECM connectors | OK 2 | for the following: No damaged pins * Bent or broken pins ‘+ Pushed back or expanded pins not. or be * Gorroded pins Repair the damaged pins hel o secre Repair or replace the OEM hamess or ECM, Se ea ce whichever has the damaged pins. ‘+ Repair the OEM harness, Refer to Procedure 019-250. ‘+ Fleplace the OEM harness. Refer to Procedure 019-071 ‘+ Replace the ECM. Refer to Procedure 019-031.Fault Code 241 IsB Page TR-146 Section TF - Troubleshooting Fault Codes STEP 2B: Check for the correct circuit resistance. ‘AcauTionA, To avoid pin and harness damage, use the following test lead when taking a measurement: Part No. 8822758 - male AMP/Metri-Pack test lead. Condition: ‘+ Turn keyswitch to the OFF position. * Disconnect the OEM harness from the ECM. ‘+ Connect the OEM harness to the VSS. Action Specifications/Repair Next Step ‘Check for the correct circuit resistance. OK 2c ‘© Check the OEM harness for the proper 750 to 1500 ohms resistance between pin 8 and pin 18 of the OEM harness connector. Ner Ok hs Replace the OEM harness Refer to Procedure 019.071ce Fault Code 241 Section TF - Troubleshooting Fault Codes Page Tr-1a7 STEP 2C: Check for a short circuit to ground. ‘AcautionA, Jp svold pin and harness damage, use the following test lead when taking a measurement: Part No. 3822758 - male AMP/Metri-Pack/Deutsch test lead. Condition: ‘= Turn keyswitch to the OFF position, '* Disconnect the OEM harness from the VSS. ‘= Disconnect the OEM harness from the ECM. Action Specifications/Repair Next Step Check the harness for a short circuit to ground. | OK 2 * Measure the resistance trom pin 8 of he | Mere than 100k ohms OEM hamess connector to engine block ground. NoT OK 4A + Measure the resistance trom pin 18 of the | Replace the OEM harness ‘OEM hamess connector to engine block eter to Procedure 012-071 ground.Fault Code 241 Page TF-148 Section TF - Troubleshooting Fault Codes. STEP 2D: Check for a short circuit from pin to pin. To avoid pin and harness damage, use the foll Part No. 3822758 - male AMP/Metri-Pack test le Condition: * Turn keyswitch to the OFF position. ‘* Disconnect the OEM harness from the VSS. ‘* Disconnect the OEM harness from the ECM, ‘AcaurionA, ving test lead when taking a measurement: ‘Action Specifications/Repair Next Step ‘Check for a short circuit trom pin to pin. oK 3A * Measure the resistance trom pins 8 and 18 to | More than 100k ohms all other pins in the OEM hamess connector | aor ox 7A Replace the OEM harness. Refer to Procedure 019-071. STEP 3: Check OEM components. STEP 3A: Check for an external recording device. Condition: + Turn keyswiteh to the OFF position. Action Specifications/Repair Next Step ‘Check for an external recording device or oK 3B similar devices attached to the vehicle speed —_| No external device sensor circuit. ORO aa Disconnect device from circuit1s Fault Code 241 Section TF - Troubleshooting Fault Codes ‘Page TF-149 STEP 9B: Check for the transmission tallshatt gear slipping on its shatt. Condition: “Turn Keyswitch to the OFF positon + VSS removed. Action ‘Specifications/Repair Next Step ‘Check for the transmission tailshaft gear OK 3c slipping on its shaft. Gear attached properly * Check to make sure the transmission gear inside the sensor mounting is nat slipping on | NOT OK bust the shaft, Do this by trying to spin tho gear | Repair transmission gear Oe dee Foor othe OEM treubleshosting and repair heck for Interference on the OEM harness. = Connect all the components. Action ‘Specifications/Repair Next Step Check for interference on the OEM harness. | OK aA * Install a pair of twisted jumper wires from the | Fault Code 241 inactive VSS to the ECM. Connect the wires from pin | There is an Interference on the OEM ‘Aan the hamess side of the VSS connector | harness. Locate and remove the source of to pin 8 on the OEM harness connector, and | interference. from pin B on the harness side of the VSS connector to pin 18 of the OEM harness connector. NOT OK act + Disconnect the speedometer connector at the | Replace the VSS. vss. fet to Procedure 019.090 or 019.081 + Drive the vehicle. The vehicle speed must | Relor #9 Procedure : exceed 10 mph. STEP 3C-1: Disable the fault code. AcautionA, ‘Te avold damaging a new ECM, all other fault codes must be investigated prior to replacing the ECM. Condition: + Connect all the components. Action Specifications/Repair Next Step Disable the fault code. ‘OK 48 * Drive the vehicle. The vehicle speed must | Fault Code 241 inactive exceed 16 kph [10 mph}. a it NoT OK a8 Verity Fault Code 241 is inactive. Nee oe uae Refer to Procedure 019-031.Fault Code 241 Page TF-150 STEP 4: Clear the fault code. STEP 4A: Disable the fault code. isa Section TF - Troubleshooting Fault Codes. Condition: ‘* Connect all the components. + Tum Keyswitch to the ON position. Action ‘Specifications/Repair Next Step Disable the fault code. oK 48 * Drive the vehicle, The vehicle speed must Fault Code 241 inactive exceed 16 kph [10 mph} NOroR Z Return to the troubleshooting steps, oF Contact your local Cummins Authorized Repair Location if ail the steps have been completed and checked again, STEP 4B: Clear the inactive fault codes. Conditi + Connect ail the components. + Turn Keyswitch to the ON position, Action Specifications/Repair Next Step ‘Clear the inactive fault codes. oK Repair + Erase the inactive fault code using INSITE™. | All faults cleared complete NoT OK Appropriate Troubleshoot any remaining active fault twoubleshoot codes, ing chart1s Fault Code 242 ‘Section TF - Troubleshooting Fault Codes Page TF-151 Fault Code 242 Vehicle Speed Sensor (VSS) Circuit cones REASON I errECT Faun Gowe: 202 invaid or appropriate venice” | Engine speed lirifed to "Maximum Engine PID(P), SID(S): POB4 speed signal detected on pins 8 ‘Speed without Vehicle Speed Sensor" for SPN oae Seto the cngnel equpment | the duration of te valid signal, Cr Fu 10 tranufasturrs (GEM) move” | eonl goasdonn protection, and the 08d (aime: tow Inaatig.anrmitent connec. | Speed governor wil not nor piforme- ton or poole tamporag Sodas tate based om mileage wl be incon Vehicle Speed Sensor Circult To Vehicle sort sera Soa i 5 Ecm Sa sl B ie Vehicle Speed Sensor Return OEM Harness, Circuit Descripti ‘The vehicle speed sensor (VSS) uses two separate coils of wire (some applications use a single-coil sensor) to count gear teeth as they pass in front of the sensor. One coil is used by the electronic contro! module (ECM) to sense vehicle speed. The other coil is sometimes used by the OEM to send a vehicle speed signal to the speedometer. Component Location: ‘The VSS is most Gommoriy installed in the rear ofthe transmission,Fault Code 242 Ise Page TF-152 ‘Section TF - Troubleshooting Fault Codes: Shop Talk: Verify that the feature settings for VSS antitampering (Fault Code 242), application type and automatic transmission are set correctly. I any of these are set incorrectly, Fault Code 242 could occur erroneously. NOTE: Driving techniques, such as driving for extended periods of time in lower gears, could lg Fault Code 242. = Fault Code 242 can be logged if the driver attempts to defeat the road speed governor by repeatedly cycling the keyswitch. ‘+ Interview the driver to discover what occurred when the fault code was logged. Explain the driver actions that can cause Fault Code 242 to be logged. ‘When deactivating the fault, verify that the vehicle is stopped and the engine is shut down. Verify that the keyswitch has been cycled and has remained in the ON position for 30 seconds after the invalid signal has been corrected. This fault will remain active until the keyswitch is cycled and the ECM sees zero vehicle speed and zero engine speed for 30 seconds.isB Fault Code 242 Section TF - Troubleshooting Fault Codes Page TF-153 TROUBLESHOOTING SUMMARY STEPS SPECIFICATIONS SRT CODE STEP 1: Vorify that the feature settings are set correctly. ‘STEP 1A: Verify that the customer wants VSS ‘Customer wants VSS antitampering (Fault Code 242) antitampering (Fault Code 242) enabled. ‘enabled ‘STEP 1B: Verity that automatic transmission is Automatic transmission set ‘set correctly for application. correctly STEP 1C: Verity that application type is set Application type set correctly correctly for application. STEP 2: Look for signs of tampering. STEP 2A: Inspect the VSS. No signs of tampering de- tected STEP 2B: Inspect OEM VSS circuit. No signs of tampering de- tected STEP 2C: Monitor vehicle speed. Electronic service tool dis- plays correct speed STEP 2C-1: Verify the vehicle speed. Vehicle speed accurate for present gear STEP 3: Clear the fault code. STEP 3A: Disable the fault code. Fault Code 242 Inactive STEP 3B: Clear the inactive fault codes. All faults cleared TROUBLESHOOTING STEP STEP 1: Verify that the feature settings are set correctly. ‘STEP 4A: Verify that the customer wants VSS antitampering (Fault Code 242) enable Condition: + Tum keyswitch to the OFF position. Action Specifications/Repair Next Step Verify that the customer wanis VSS antitamper- | OK 18 ing (Fault Code 242) enabled. Talk to the awner | Customer wants VSS antitampering (Fault of the vehicle to soe if this feature is required | Code 242) enabled for the application of this vehicle. ore an ‘Adjust the feature setting to its correct value using INSITE™.Fault Code 242 ISB Page Tr-184 Section TF - Troubleshooting Fault Codes STEP 1B: Verify that automatic transmission is set correctly tor application. Condition: Action ‘Specifications/Repair Next Step. Verify that automatic transmission is set cor | OK ic rectly tor application. Automatic transmission set correctly * Verify that this feature Is activated if an automatic transmission is used, or deacti-. | NOT OK 3A Yated if a manual transmission is used, using | Adjust the feature setting to its correct value bret using INSITE™. STEP 1C: Vority that application type Is set correctly for application. Condition: ‘Action Specifications/Repair Next Step Verity that application type is set correctly for | OK 2A application. Application type set correctly + Verity that this feature setting is set correctly for the application in which this vehicle is used, using INSITE™ NOT OK 3A NOTE: Driving for extended periods in lower _| Adit the feature seting tots corect value {gears is considered an on/off highway fon application STEP 2: Look for signs of tampering. STEP 2A; Inspect the VSS. Condition: ‘Action Spe Next Step Inspect the VSS for: OK 2B *+ Improper mounting of the VSS No signs of tampering detected at or with * VSS improperly connected to OEM harness | the vehicle speed sensor = * Other external device connected In place of Gr ox ax vss * Any evidence that tampering with the VSS has taken place. SS is improperly installed, connected, ‘or has been tampered with * Correctly install and connect the VSS to the OEM harness. Refer to Procedure (019-090 or 019-091 + Remove any tampering device.1s ‘Section TF - Troubleshooting Fault Codes Fault Code 242 Page TF-155 STEP 2B: Inspect the OEM VSS circult. Condition: Action Specifications/Repair Next Step Inspect the OEM VSS circuit for: oK 20 "Broken, cut, or incorrect routing of the VSS _| No signs of tampering detected with the wires VSS leads or the OEM harness + Any devices connected in series or parallel = with the VSS NOT OK 3A + Any other wires addes to the VSS circuit Repair or replace the OEM harness * Any evidence that tampering with the VSS. | Refer to Procedure 019-071. it has taken place. STEP 2C: Monitor the vehicle speed. Condition: Action Specifications/Repair Next Step. ‘Monitor vehicle speed: To check the vehicle | OK 2c speed, use INSITE™ Electronic service tool displays correct © Verify that the vehicle speed is zero when the | speed vehicle is stationary and the engine is running. | * Drive the vehicle, or run on a chassis dyna- # NOT OK 3A mometer. Compare the vehicle speed read by the electronic service tool to the speedometer | Electronic service tool and speedometer igalths deh do not match. Verity the VSS parameters are adjusted NOTE: If the dash is an electronic dash that | correctly in the ECM. Check the VSS and uses the ECM to obtain vehicle speed the OEM harness in Steps 2A and 2B erform a road test, and use a stopwatch and | above, Repair any problems found, road mile markers to determine the true vehicle speed. STEP 20-1: Verify the vehicle speed. Condition: Action Specifications/Repair Next Step Verify that the speed reporied by the electronic | OK Fault Code service tool is accurate or reasonable for the | Vehicle speed accurate for present gear _| 241 PRESENT gear. (.e.,40 mph in top gear is or oq ae probably inaccurate.) Vehicle speed read by electronic service tool is Inaccurate Verity VSS parameters are adjusted cor- rectly in the ECM. Check VSS and OEM harness in Steps 2A and 2B above. Repair any problems found.Fault Code 242 Page TF-156 STEP 3: Clear the fault code. ‘STEP 3A: Disable the fault code. Section TF - Troubleshooting Fault Codes Condition: + Connect all the components. Action Specifications/Repair Next Step Disable the fault code. oK 38 + “Turn the keyswitch to the OFF position, Fault Code 242 inactive * Tur the tayoich tthe ON positon (80 n0t yor ox 7 Return to troubleshooting steps, or contact NOTE: Vehicle speed and engine speed must | your local Cummins Authorized Repair be zero for at least 30 seconds to disable the | Location if all steps have been completed fault code. end checked agein. STEP 9B: Clear the inactive fault codes. Condition: + Connect all te components, + Tum keyswitch to the ON position. Action ‘Specifications/Repair Next Step Cloar the inactive fault codes. OK Repair * Erase the inactive fault codes using INSITE”. | All faults cleared complete NOT OK Appropriate Troubleshooting any remaining active fault | troubleshoot codes, ing chart188 Fault Code 243 Section TF - Troubleshooting Fault Codes Page Tr-187 Fault Code 243 Exhaust Brake Supply Circuit CODES REASON EFFECT Fault Code: 243, Error detected in exhaust brake | Exhaust brake will not work. PID), SIDI): P121 relay enable circuit at pin 42 of the SPN: ‘513 engine harness. FMI: 4 Lamp: Exhaust Brake Relay Supply Circuit Exhaust Brake Signal 23 Pin Connector ECM 2 S) 1 +> 97 42 I, Engine Harness ol * Circuit Description: ‘Fh electronic carol module (ECM) enables the exhaust brake by sending a signal othe relay that controls tho ‘exhaust brake under certain conditions. Component Location: Refer to the original equipment manutacturer’s (OEM) diagram for the location of the engine brake,Fault Code 243, Is Page TF-158 Seotion TF - Troubleshooting Fault Code: TROUBLESHOOTING SUMMARY A caution A To avoid pin and harness damage, use the following test lead when taking a measurement: Part No. 3822758 - male Deutsch/Cannon/Metri-Pack test lead Part No. 3823994 - female Deutsch test lead Part No. 3823993 - male Deutsch test lead. A caution A To avoid damaging a new ECM, all other active fault codes must be investigated prior to replacing the ECM. STEPS ‘SPECIFICATIONS SRT CODE STEP 14: Check the engine harness. ‘STEP 1A: Inspect the engine harness, exhaust No damaged pins brake, and ECM connectors. STEP 1B: Check for an open circult, Less than 10 ohms. STEP 1C: Check for an short circuit to ground. More than 100k ohms STEP 1D: Check for a short clroult from pin to More than 100k ohms pin. STEP 2: Check the OEM harness. ‘STEP 2A: Inspect the engine harness and OEM ——_No damaged pins harness connectors. STEP 2B: Check for an open circuit. Less than 10 ohms STEP 2C: Check for a short circuit to ground. More than 100k ohms STEP 2D: Check for a short clreuit from pin to More than 100k ohms Fault Code 243 inactive ‘STEP 3B: Clear the inactive fault codes. All faults cleared1sB Section TF - Troubleshooting Fault Codes TROUBLESHOOTING STEP STEP 1: Check the engine harness. engine harness and ECM connectors. STEP 1A: Inspect the Fault Code 243 Page TF-159 “AcauTionA, ‘To avoid damaging the ECM, all other active fault codes must be investigated prior to replacing the ECM. Condition: ‘= Turn keyswitch to the OFF position. ‘* Disconnect the engine harness from the ECM. * Disconnect the engine harness from the OEM 23-pin connector. ‘+ Pushed back or expanded pins Corroded pins ‘* Moisture in or on the connector ‘* Missing or damaged seals. Action Specifications/Repair Next Step Inspect the engine harness and the ECM ‘OK 1B connectors for: No damaged pins ‘* Bent or broken pins norok aa Repair the damaged pins Repair or replace the engine harness or ECM, whichever has the damaged pins. + Repair the engine harness. Refer to Procedures 019-250 and 019-228. + Replace the engine harness. Refer to Procedure 019-043. ‘+ Replace the ECM. Refer to Procedure 019.031IsB Section TF - Troubleshooting Fault Codes Code 243, Page TF-160 STEP 4B: Check for an open eircult. AcautionA, To avoid pin and harness damage, use the following test leads when taking a measurement: Part No. 3822758 - male DeutschiCannon/Metrl-Pack test lead Part No. 3823994 - female Deutsch test lead, Condition: * Turn keyswitch to the OFF position. isconnect the engine harness from the ECM. ‘+ Disconnect the engine harness from the OEM 23-pi 1ector, Action Specifications/Repair Next Step Check for an open circuit. OK 1c ‘+ Measure the resistance from pin 42 of the | Less than 10 ohms EOM connector to pin O of the 23-pin OEM harese connector. no Net OF 7 Replace the engine harness Refer to Procedure 019-043.IsB Fault Code 243 Section TF - Troubleshooting Fault Codes Page TF-161 STEP 1C: Check for a short circult to ground. ACAUTIONA, To avoid pin and harness damage, uso the following test lead when taking a measurement: Part No. 8822758 - male Deutsch/Cannon/AMP/Metri-Peck test lead. AcautionA, Tp gvold damaging a new ECM, all other active fault codes must be Investigated prior to repiacing the Condition: ‘= Tum keyswitch to the OFF position. '* Disconnect the engine harness from the ECM. ‘© Disconnect the engine harness from the OEM 23-pin connector. ‘Action Specifications/Repair Next Step ‘Check for a short circuit to ground, OK 1D = Measure the resistance from pin 42 inthe _| More than 100k ohms engine harness to engine block ground. NOT OK aa Replace the engine harness Refer to Procedure 019-043.Foult Code 243 a Page TF-162 Section TF - Troubleshooting Fault Codes STEP 1D: Check for a short circuit between pins. AcauTionA, ‘Te avoid pin and harness damage, use the following test lead when taking a measurement: Part No. 3822758 - male Deutsch/Cannon/Metri-Pack test lead. Condition: * Tum keyswitch to the OFF position. ‘* Disconnect the engine harness from the ECM. + Disconnect the engine harness from the OEM 23-pin connector. Action Specifications/Repair Next Step ‘Check for a short circuit between a OK 2A ‘* Moasure the resistance from pin 42 to all _| More than 100k ohms ‘ther pins in the ECM connector NoreK x Replace the engine harness Refer to Procedure 019.043,isp Section TF - Troubleshooting Fault Codes Fault Code 243 Page TF-163 STEP 2: Check the OEM harness. inepect the engine harness and OEM harness connectors. n: + Turn Keyswitch to the OFF position. + Disconrect the OEM harness from the engine harness at the 23-pin connector. * Disconnect the OEM harness from the exhaust brake. Action Specifications/Repalr Next Step Inspect the OEM harness, 23>pin connector, and | OK 28 the exhaust brake connector for: No damaged pins * Bent or broken pins NoT OK 3A : K ceed eee Repair the damaged pins © Moisture in or on the connector Repair or ropiace the OEM hamess or Wicca eamased anole exhaust brake connectors, whichever have | damaged pins. * Repair the OEM harness. Refer to Procedures 019.223 and 019-202. «+ Replace the OEM harness. Refer to Procedure 019-071 + Repair the exhaust brake connector. Refer to the OEM troubleshooting and repair manual STEP 2B: Check for an open circuit. ACAUTIONA, ‘To avoid pin and hamess damage, use the following test lead when taking a measurement: Part No, 9823993 - male Deutsch test leod. Condition: * Turn keyswitch to the OFF position. * Disconnect the OEM harness from the engine hamess at the 23-pin connector. * Disconnect the OEM harness from the exhaust brake Action Speeifications/Repair Next Step Cheek for an open circu, OK 20 + Measure the resistance from pin © of the | Lese than 10 ohms 2apin OEM connector on the OEM side to NOT OK 3A 3 brake c pin 1 of the exhaust brake connector. art Reler to Procedure 019-071Fault Code 243 - Page TF-168 Section TF - Troubleshooting Fault Codes STEP 2C: Check for a short circult to ground. Condition: * Tum keyswitch to the OFF position + Disconnect the OEM harness from the engine harness at the 2-pin connector. * Disconnect the OEM harness from the exhaust brake, Action Specifications/Repair Next Step ‘Check for a short circuit to ground. OK 2D ‘+ Measure the resistance trom pin O of the More than 100k ohms 22-pin connector tothe engine block ground. For ox on Replace the OEM harness Refer to Procedure 019-071.Ise Fault Code 243 Section TF - Troubleshooting Fault Codes Page TF-165 STEP 2D: Check for a short clrcult from pin to pin. ‘AcautionA, use the following test lead when taking a measurement: test lead. To avoid pin and harness dam: Part No. 8823993 - male Deut Condition: ‘* Turn keyswitch to the OFF position. * Disconnect the OEM harness from the engine harness at the 23-pin connector. * Disconnect the OEM harness from the exhaust brake. Action Specitications/Repair Next Step (Check for a short circuit from pin to pin. OK 3A ‘* Measure the resistance from pin O of the More than 100k ohms 2pin OEM connector to a other pins In 1h8 Tor OK Pry Replace the OEM harness Refer to Procedure 019-071. Test All Pins STEP 3: Clear the fault codes. STEP 3A: Disable the fault codes. Condition: ‘* Connect all the components. + Turn keyswitch to the ON position. Action ‘Specifications/Repair Next Step Disable the fault code. OK 3B ‘ Start the engine, and let idle for 1 minute, _| Fault Code 243 inactive + Using INSITE*, verity Fault Code 243 is inactive. NoT OK 1A Return to the troubleshooting steps, or ‘contact your local Cummins Authorized Repair Location if all steps have been completed and checked again.Fault Code 243 Page TF-166 STEP 3B: Clear the inactive fault codes. IsB Section TF - Troubleshooting Fault Codes Condition: * Connect ail the components. + Turn keyswitch to the ON position, codes. Action Specifications/Repair Next Step Clear the inactive fault codes, OK Repair ‘+ Erase the inactive fault codes using INSITE, | All faults cleared complete NOT OK ‘Appropriate ‘Troubleshoot any remaining active fault troubleshoot ing chart1s8 Fault Code 245 Section TF - Troubleshooting Fault Codes Page TF-167 Fault Code 245 Engine Fan Clutch Supply Circuit ‘CODES REASON, EFFECT Fault Code: 245 Error detected in fan clutch relay | Electronic control module (ECM) can not PID(P), SID(S): $033 ‘enable circuit at pin 31 of the control the engine cooling fan. Fan will SPN: | 647 engine harness. remain either on or off FMI 4 Lamp: Engine Fan Clutch Supply Circult Fan Clutch Supply 23 Pin Connector +12 VDC ECM 3t Fan Clutch Circuit Description: ‘The fan cluich solencid is a device used by the ECM to control the engine fan by sending a signal to open or close the fan clutch solenoid. Component Location: Reefer to an original equipment manufacturer's (OEM) diagram for the location of the fan clutch solenoid. Shop Talk: = Fan clutch solenoid could be malfunctioning due to a failed engine harness or a bad ground on the fan clutch connector. ‘* Use INSITE” to make sure that on/off fan feature is enabled and the right ON voltage is chosen,Fault Code 245 Page TF-168 TROUBLESHOOTING SUMMARY A caution A To avoid pin and harness damage, use the following test lead when taking a measurement: Part No. 3822758 - male Deutsch/AMP/Metri-Pack test lead Part No, 3823993 - male Deutsch test lead Part No. 3823994 - female Deutsch test lead. A caution A To avoid damaging new ECM, all other active fault codes must be investigated prior to replacing the ECM. STEPS ‘STEP 1: Check the fan clutch. STEP 1A: Inspect and test the fan clutch and fan clutch relay (it equipped). STEP 2: Check the engine harness. ‘STEP 2A: Inspect the engine harness, fan clutch relay, and ECM connectors. Check for an open circuit. Check for a short circuit to ground. Check for a short circuit from pin to pin, STEP 3: Check the OEM harness. STEP 3A: Inspect the engine harness and OEM harness connectors. ‘STEP 3B: Check for an open circult. STEP 3C: Check for a short circuit to ground. ‘STEP 3D: Check for a short circuit from pin to pin. STEP 4: Clear the fault codes. STEP 4A: Disable the fault code. ‘STEP 4B: Clear the inactive fault codes, SPECIFICATIONS SRT CODE Fan clutch and relay within specifications: No damaged pins Less than 10 ohms More than 100k ohms. More than 100k ohms. No damaged pins Less than 10 ohms More than 100k ohms ‘More than 100k ohms Fault Code 245 inactive All faults clearedIsB Section TF - Troubleshooting Fault Codes Fault Code 245, Page TF-169 TROUBLESHOOTING STEP STEP 1: Check the fan clutch STEP 1A: Check the fan clutch and fan clutch relay (if equipped) Condition: Tum Keyswitch to the OFF position. + Disconnect the OEM harness from the fan clutch of fan clutch relay. Action Specifications/Repair Next Step ‘Check the fan clutch for OK 2A ‘* Damaged pins Fan clutch within specifications = Open or short circuits NOT OK * Excessive current draw (power fan clutch directly from battery) instructions. ‘+ Perform this test in accordance with the OEM Repair or replace the fan clutch Refer to OEM troubleshooting and repair manual. STEP 2: Check the engine harness. STEP 2A: Inspect the engine harness and the ECM connectors. + Turn keyswitch to the OFF position, “Acaution A, Z2,gvold damaging a new ECM, al other active fault codes mus be Investigated prior to replacing the Condition: * Disconnect the engine harness from the ECM. * Disconnect the engine harness from the 23-pin OEM harness connector Pushed back or expanded pins Corroded pins Moisture in or on the connector Missing or damaged seals. Action ins/Re} Next Step Inspect the engine harness and the ECM OK 2B connectors for: No damaged pins * Bent of broken pins jorOK: aA Repair the damaged pins Repair or replace the engine harness, or ECM, whichever has the damaged pins. ‘© Repair the engine harness. Refer to Procedures 019-250 and 019-223. ‘« Replace the engine harness. Refer to Procedure 019-043. ‘+ Replace the ECM. Refer to Procedure 019-031.Fault Code 245 188 Page TF-170 Section TF - Troubleshooting Fault Codes STEP 2B: Check for an open circuit. AcaurionA, To avoid pin and harness damage, use the following test leads when taking a measurement: Part No. 3822751 jutsch/AMP/Metri-Pack test lead Part No. 3823994 - female Deutsch lead. Condition: ‘+ Turn keyswitch to the OFF position. ‘* Disconnect the engine harness from the ECM. + Disconnect the engine hamess from the 23-pin OEM harness connector. Action Specifications/Repair Next Step Check for an open circuit, OK 2c * Measure the resistance from pin 31 of the | Less than 10 ohms engine harness connector to pin N of the 23-pin OEM harness connector. NOT OK an Replace the engine harness Refer to Procedure 019-043.IsB Section TF - Troubleshooting Fault Codes STEP 2C: Check for a short circuit to ground. Fault Code 245 Page TF-171 AcauTionA, To avoid pin and harness damage, use the following test lead when taking a measurement: Part No, 8822788 - male Deutsch/AMP/Metri-Pack test I Condition: ‘= Turn Keyswitch to the OFF position. ‘+ Disconnect the engine harness from the ECM. * Disconnect the engine harness from the 23-pin OEM harness connector Action Specifications/Repair Next Step ‘Check for a short circuit to ground. oK ire the resistance from pin 31 inthe | More than 100k ohms: 2D harness to engine block ground. mores Replace the engine harness Refer to Procedure 019-043, aAFault Code 245, 'sB Page TF-172 Section TF - Troubleshooting Fault Codes STEP 2D: Check for a short circuit from pin to pin. ‘AcauTionA, ‘To avold pin and harness damage, use the following test lead when taking a measurement: Part No. 3822758 - male AMP/Cannon/Deutsch/Metri-Pack test lead. Condition: Turn keyswitch to the OFF position. Disconnect the engine harness from the ECM. © Disconnect the engine harness from the 23-pin OEM harness connector. Action Specifications/Repair Next Step Check for a short circuit batwoen pins. OK 3A * Measure the resistance from pin 31 to all More than 100k ohms ‘other pins in the connector. NOT OK aA Replace the engine harness. Refer to Procedure 019-043.1sB Fault Code 245 Section TF - Troubleshooting Fault Codes Page TF-173 STEP 3: Check the OEM harness. STEP 3A: Inspect the OEM harness. Condition: ‘= Turn keyswitch to the OFF position. ‘* Disconnect the OEM harness from the fan clutch relay. * Disconnect the engine harness from the 23-pin OEM harness connector. Action Specifications/Repair Next Step Inspect the OEM hamess and 23-pin connector | OK 3B for: No damaged pins Bent or broken pins NoT OK re Pushed back or expanded pins ‘+ Corroded pins * Moisture in or on the connector * Missing or damaged seals. Repair the damaged pins Repair or replace the OEM harness or fan clutch relay, whichever has damaged pins. © Repair the OEM harness. Refer to Procedure 019-223 or 019-202. * Replace the OEM harness. Refer to Procedure 019-071. ‘+ Fleplace the fan clutch relay. Refer to the OEM troubleshooting and repair manual.Fault Code 245 'sB Page TF-174 Section TF - Troubleshooting Fault Codes STEP 3B: Check for an open circuit. ‘AcauTionA, , use the following test lead when taking a measurement: test lea To avoid pin and harness di Part No. 3823993 - male Deut Condition: ‘+ Turn keyswitch to the OFF position, ‘+ Disconnect the OEM harness from the fan clutch solenoid or relay. isconnect the engine harness from the 23-pin OEM harness connector Action Specifications/Repair Next Step Check for an open circuit. OK 3G ‘+ Measure the resistance from pin N of the Less than 10 ohms 23-pin OEM hamess connector to the fan clutch solenoid or relay. ee a Replace the OEM harness Rofer to the Procedure 019-071Is Fault Code 245 Section TF - Troubleshooting Fault Codes Page TF-175 STEP 2C: Check for a short circuit to ground in the OEM harness. AcautionA To avold pin and harness damage, use the following test lead when taking a measurement: Part No. 3823993 - male Deutsch test lead. Condition: + Tum koyswitch to the OFF position. + Disconnect the OEM harness from the fan clutch solenoid or relay ‘+ Disconnect the engine harness from the 23-pin OEM harness connector. Action ‘Specifications/Repair Next Step Check for a short circuit 0 ground inthe OEM | OK 3 harness. More than 100k ohms Measure resistance from pin N of the 28-pin 7 NOT OK aA OEM hamess connector to ground Roses ue Geka Refer to Procedure 019-071.Fault Code 245, tsp Page TF-176 Section TF - Troubleshooting Fault Codes STEP 30: Check for a short cicult from pinto pin. AcautionA, To avoid pin and harness damage, use the following test lead when taking a measurement: Part No. 3823993 - male Deutsch test lead. Condition: = Tum keyswitch to the OFF position, ‘* Disconnect the OEM harness from the fan clutch solenoid or relay. ‘+ Disconnect the engine hamess from the 23-pin OEM harness connector Action Specifications/Repair [ Next Step Check for a short circuit from pin to pin in the | OK 4A ‘OEM harness, More than 100k ohms * Measure resistance from pin N of the 23-pin = 7 NOT OK an OEM harness connector to all other pins in | TOO ne Oew harness ee Refer to Procedure 019-071, Test All Pins ~ oes ‘STEP 4: Clear the fault codes. ‘STEP 4A: Disable the fault code. Condition: * Connect all the components. + Turn keyswitch to the ON position. Action ‘Specifications/Repair | Next Step Disable the fault code. OK 4B + Start the engine, and let idle for 1 minute. | Fault Gode 245 inactive * Using INSITE™, verity Fault Code 245 1s NoToe an eee Return to the troubleshooting steps, or contact your local Cummins Authorized Repair Location if all steps have boon completed and checked again.Fault Code 245 IsB Section TF - Troubleshooting Fault Codes Page TF-177 STEP 48: Clear the inactive fault codes. Condition: ‘+ Connect all the components. ‘* Turn keyewitch to the ON position. ‘Action ‘Specifications/Repair | Next Step Clear the inactive fault codes. ‘OK Repair ‘+ Erase the inactive fault codes using INSITE™. | All faults cleared complete NOT OK “Appropriate ‘Troubleshoot any remaining active fault troubleshoot codes. ing chartFault Code 261 'sB Page TF-178 ‘Section TF - Troubleshooting Fault Codes Fault Code 261 Fuel Temperature Sensor Circuit ‘CODES REASON EFFECT Fault Code: 261 Fuel temperature signal indicates | Power derate. PID), SIDS): P174 fue! temperature has exceeded the SPN: 174 engine protection timit andior FMI: 0 «| PUMP protection limit, Lamp: Yellow P44 Fuel Pump Circuit Description: The fuel temperature sensor is located in the VP44 fuel pump. Fuel temperature information is passed to the electronic control module (ECM) through the controller area network (CAN) datalink. Component Location: ‘The fuel temperature sensor is located in the VP44 fuel pump.IsB Fault Code 261 Section TF - Troubleshooting Fault Codes Page TF-179 TROUBLESHOOTING SUMMARY STEPS SPECIFICATIONS SRT CODE STEP 1; Check the sensor accuracy. STEP 1A: Verlty the sensor accuracy with a Sensor reading correct thermocouple or similar temperature probe STEP 2: Clear the fault code. STEP 2A: Disable the fault code. Fault Code 261 inactive STEP 2B: Clear the inactive fault codes. All faults cleared TROUBLESHOOTING STEP ‘STEP 1: Check sensor accuracy. STEP 1A: Verify the sensor accuracy with a thermocouple or similar temperature probe. Condition: * Allow the engine to cold soak (for 22 hours, if possible) + Turn keyswitch to the ON position. Action ‘Specifications/Repair Next Step Verify the sensor accuracy with a thermocouple | OK 2A oF similar tomporature probe. Sensor reading is correct * Place a thermocouple or similar temperature | Locate and repair the cause of high fuel probe (thermometer kit, Part No, 3822668, | temperature. Refer to the Troubleshooting an be used) in the outlet tap of the fuel fiter | and Ropair Manual, ISB Engines, Bulletin head No, 3666198. + Connect INSITE” to the engine datatink ‘+ Compare the fuel temperature sensor reading on the INSITE™ monitor screen to the reading from the temperature probe. * Load and operate the engine to typical operating temperature (180°F), and compare the fuel temperature sensor reading on the INSITE™ monitor seroen to the reading from | NOT OK 2A the temperature probe. Replace the VP44 pump NOTE: Readings should vary no more than _| Refer to Procedure 005-014 in the Trouble- 25°F between INSITE” and the temperature | shooting and Repair Manual, ISB Engines, | probe when the engine is warm or withia °F | Bulletin No. 3666193. ‘when the engine is cold. NOTE: If @ temperature measuring device is not available, answer "OK" to this stop. Readings need to be checked while engine is ‘operating at the concitions at which the fault occurred.