Page 1 of 12

:

FAULT CODE
Associated Procedures Troubleshooting Steps
STEPS STEP 1. Check the fault codes. STEP 1A. Check to see if the fault code is active at engine start-up. STEP 2. Perform low pressure system checks. STEP 2A. Install the gauges and record inlet restriction findings. STEP 2B. Install the gauges and record fuel pressure findings. STEP 2C. Install the gauges and record air in fuel findings. STEP 2D. Install the gauges and record fuel displacement findings. STEP 2E. Check the lift pump supply voltage. STEP 3. Verify the inlet restriction and check for air in the fuel when loaded. STEP 3A. Verify the inlet restriction with the engine loaded. STEP 3B. Verify there is no air in the fuel system with the engine loaded. STEP 3C. Verify the fuel pressure at the fuel filter outlet with the engine loaded. STEP 4. Remove and inspect the overflow valve. STEP 4A. Remove and inspect the overflow valve. STEP 5. Measure the drain line restriction. Overflow valve clean Restriction less than 152 mm Hg [6 in Hg] No air found in the fuel Restriction less than 152 mm Hg [6 in Hg] Fuel pressure at fuel filter inlet less than 34 kPa [5 psi] No air found in fuel Fuel in bucket is greater than 1.33 liters [1.4 qt] Battery voltage ± 2 VDC Fault Code 368 inactive SPECIFICATIONS

Fuel pressure greater than 14 kPa [2 psi]

mk:@MSITStore:C:\Intelect\INSITE\FIS\FIS3666194.chm::/procedures/80-t05-368.htm

10/5/2010

htm 10/5/2010 . but other fault codes are active. STEP 6B. Action  Check to see if the fault code is active at engine start-up. Disable the fault code. Clear the fault codes. troubleshoot the active fault codes. Check the fuel pump gear key in use. STEP 7B. OK Fault Code 368 inactive Applicable fault code(s) NOT OK Fault Code 368 active and no other active fault codes present Go to 2A mk:@MSITStore:C:\Intelect\INSITE\FIS\FIS3666194.chm::/procedures/80-t05-368. Conditions Turn keyswitch ON. Install a pressure gauge in the drain line.Page 2 of 12 STEP 5A. STEP 6. Guided Step 1A . STEP 7A. Pressure less than 69 kPa [10 psi] Pump gear correctly engaged with camshaft gear and key undamaged Key is correct and installed correctly Fault Code 368 inactive All fault codes cleared? Guided Step 1 .Check the fault codes. Note: If Fault Code 368 is inactive. Check the fuel pump gear.  Use INSITE™ electronic service tool to read active fault codes. STEP 7. Clear the inactive fault codes. STEP 6A. Check the fuel pump static timing.Check to see if the fault code is active at engine start-up.

Note: Steps 2A through 2D can be observed and recorded with a single bump of the starter. Install a clear line at the fuel filter outlet and run the line into a bucket. bump the starter and leave the keyswitch ON.chm::/procedures/80-t05-368. Bulletin 3666193.Page 3 of 12 Guided Step 2 .Perform low pressure system checks. The lift pump will run for 25 to 30 seconds. record the inlet restriction. Go to 2B Go to 7A mk:@MSITStore:C:\Intelect\INSITE\FIS\FIS3666194. Conditions Turn keyswitch OFF. Install a pressure gauge at the fuel filter inlet. OK Restriction less than 152 mm Hg [6 in Hg] NOT OK Inlet restriction greater than 152 mm Hg [6 in Hg] Find source of excessive restriction between the lift pump inlet and fuel tank. Fix the source of excessive restriction. Guided Step 2A . With gauges and the clear line in place. ISB and QSB5. While the lift pump is running. Refer to Procedure 005-045 (Fuel Lift Pump) in Section 5 in the Troubleshooting and Repair Manual.9 Engines.Record findings for inlet restriction.htm 10/5/2010 . Action  Install a restriction gauge at the lift pump inlet.

OK No air found in the fuel NOT OK Air in fuel detected. mk:@MSITStore:C:\Intelect\INSITE\FIS\FIS3666194. record if air is found in the fuel system.Install the gauges and record fuel pressure findings. Fuel filter is restricted.chm::/procedures/80-t05-368. Conditions Turn keyswitch OFF. Action  With gauges and the clear line in place (as in Step 2A).Install the gauges and record air in fuel findings. bump the starter and leave the keyswitch ON. While the lift pump is running. The lift pump will run for 25 to 30 seconds. Replace the filter and recheck. OK Fuel pressure at fuel filter inlet less than 34 kPa [5 psi] NOT OK Fuel pressure at fuel filter inlet is greater than 34 kPa [5 psi]. Conditions Turn keyswitch OFF. The lift pump will run for 25 to 30 seconds. record the fuel pressure at the fuel filter inlet. While the lift pump is running. bump the starter and leave the keyswitch ON. Action  With gauges and the clear line in place (as in Step 2A). Go to 2C Go to 7A Guided Step 2C .Page 4 of 12 Guided Step 2B .htm 10/5/2010 .

bump the starter and leave the keyswitch ON.Check the lift pump supply voltage. Action  With gauges and the clear line in place (as in Step 2A). record the amount of fuel in the bucket after the lift pump has stopped running. Go to 2D Go to 7A Guided Step 2D .33 liters [1.Install the gauges and record fuel displacement findings.33 liter [1.chm::/procedures/80-t05-368. Action Check the lift pump voltage supply.  Disconnect the lift pump from the engine harness. Conditions   Disconnect the lift pump from the engine harness. OK Fuel in bucket is greater than 1.4 qt] Go to 3A NOT OK Fuel in bucket is less than 1. While the lift pump is running. Turn keyswitch ON. use a multimeter to measure mk:@MSITStore:C:\Intelect\INSITE\FIS\FIS3666194.htm 10/5/2010 . The lift pump will run for 25 to 30 seconds. Conditions Turn keyswitch OFF.Page 5 of 12 Find the source of air between the lift pump inlet and fuel tank. after bumping the starter.4 qt] Go to 2E Guided Step 2E .

Monitor and record the inlet restriction when mk:@MSITStore:C:\Intelect\INSITE\FIS\FIS3666194.Page 6 of 12 the voltage at pin 1 (engine harness. Bulletin 3666193. With the gauges and the clear line in place.9 Engines. Conditions  Turn keyswitch OFF. OK Battery voltage ± 2 VDC Replace the lift pump. ISB and QSB5. Refer to Procedure 005-045 (Fuel Lift Pump) in Section 5 in the Troubleshooting and Repair Manual. Guided Step 3A . Note: Lift pump will run for only 25 to 30 seconds after bumping the starter.Verify the inlet restriction and check for air in the fuel when loaded.htm 10/5/2010 .Verify the inlet restriction with the engine loaded. Install a pressure gauge at the fuel filter outlet. Refer to Procedure 005-045 (Fuel Lift Pump) in Section 5 in the Troubleshooting and Repair Manual. Bulletin 3666193. Action Install a restriction gauge at the lift pump inlet.chm::/procedures/80-t05-368. Guided Step 3 . Go to 7A Go to 7A NOT OK Inspect the voltage supply circuit.9 Engines. start the engine and put it under a load. ISB and QSB5. lift pump connector). Install the clear line between the fuel filter outlet and VP44.

Verify there is no air in the fuel system with the engine loaded. Conditions Turn keyswitch OFF. Monitor the clear line to see if there is any air in the fuel system when Fault Code 368 is active. OK No air found in the fuel NOT OK Air in fuel detected Find the source of air between the lift pump inlet and the fuel tank.htm 10/5/2010 . Go to 3C Go to 7A Guided Step 3C .chm::/procedures/80-t05-368. Go to 3B Go to 7A Guided Step 3B .Page 7 of 12 Fault Code 368 is active. OK NOT OK Inlet restriction less than 152 mm Hg [6 in Hg] Inlet restriction greater than 152 mm Hg [6 in Hg] Find source of excessive restriction between the lift pump inlet and fuel tank. Fix the source of excessive restriction.Verify the fuel pressure at the fuel filter outlet with the mk:@MSITStore:C:\Intelect\INSITE\FIS\FIS3666194. Action  With the gauges and the clear line in place (as in Step 3A) start the engine and put it under load. Note: Steps 3A through 3C can be observed and recorded with a single bump of the starter.

OK Overflow valve clean Go to 5A NOT OK Clean or replace overflow valve. Conditions Turn keyswitch OFF. ISB and QSB5. Action  With the gauges and the clear line in place (as in Step 3A). Action  Remove and inspect the overflow valve.9 Engines.Remove and inspect the overflow valve. Bulletin 3666193.htm 10/5/2010 .Remove and inspect the overflow valve. Guided Step 4A .Page 8 of 12 engine loaded.chm::/procedures/80-t05-368. Conditions Turn keyswitch OFF. Go to 7A mk:@MSITStore:C:\Intelect\INSITE\FIS\FIS3666194. OK Fuel pressure greater than 14 kPa [2 psi] Go to 6A NOT OK Fuel pressure less than 14 kPa [2 psi] Go to 4A Guided Step 4 . Refer to Procedure 006-044 (Fuel Return Overflow Valve) in Section 6 in the Troubleshooting and Repair Manual. start the engine and put it under load. Monitor and record the fuel pressure at the fuel filter outlet when Fault Code 368 is active.

OK Pressure less than 69 kPa [10 psi] NOT OK Pressure greater than 69 kPa [10 psi] Find the source of restriction in the drain line. Action  Install pressure gauge in the drain line.chm::/procedures/80-t05-368.htm 10/5/2010 .Measure the drain line restriction.Page 9 of 12 Guided Step 5 . Conditions Turn keyswitch OFF.Install pressure gauge in the drain line. Go to 6A Go to 7A Guided Step 6 . Bulletin 3666193. Guided Step 6A . Action mk:@MSITStore:C:\Intelect\INSITE\FIS\FIS3666194. Check for bends or kinks.9 Engines. Run the engine at high idle.Check the fuel pump static timing. Refer to Procedure 006-012 (Fuel Drain Line Restriction in Section 6 in the Troubleshooting and Repair Manual. Conditions  Turn keyswitch OFF. Guided Step 5A . ISB and QSB5.Check the fuel pump gear.

Action Check the fuel pump gear key in use. or pump replacement. Go to 6B Go to 7A Pump gear correctly engaged with camshaft gear and key undamaged Guided Step 6B . Verify the gear key is properly aligned in the center of the keyway and is not damaged.   Verify the key number inscribed on the key matches the number inscribed on the fuel pump data plate. before developing Fault Code 368. Check the fuel pump gear.Check the fuel pump gear key in use. OK NOT OK Pump gear incorrectly engaged with camshaft gear or key damaged Correct engagement or replace damaged key. review the vehicle claim history.chm::/procedures/80-t05-368. Conditions  Turn keyswitch OFF.   Verify the timing marks on the gear train are aligned with the engine at top dead center (TDC).Page 10 of 12 Review the vehicle claim history. service checks. If the vehicle has accumulated over several thousand miles without any engine problems. Refer to Procedure 005-037 (Fuel Pump Timing) in Section 5 in the Troubleshooting and Repair Manual.9 Engines. Verify the key is installed with the mk:@MSITStore:C:\Intelect\INSITE\FIS\FIS3666194. then proceed to Step 7.htm 10/5/2010 . ISB and QSB5. Bulletin 3666193.  Before proceeding with Step 6.

Guided Step 7A . mk:@MSITStore:C:\Intelect\INSITE\FIS\FIS3666194.Clear the fault codes. Turn keyswitch ON.chm::/procedures/80-t05-368.   Start the engine and road-test for 30 minutes.Disable the fault code.Page 11 of 12 arrow facing the pump. Go to 7A Go to 7A Guided Step 7 . Conditions Connect all components. Action   Disable the fault code. If injection pump is still under warranty and preauthorization is required contact RAPIDSERVE™ for authorization. OK NOT OK Fault Code 368 active Replace VP44 Injection Pump.Clear the inactive fault codes.  Connect INSITE™ electronic service tool. Use INSITE™ electronic service tool to verify that Fault Code 368 is inactive. OK Key is correct and installed correctly NOT OK Key is incorrect or installed incorrectly Install correct key or install key correctly.htm 10/5/2010 . Go to 7B Go to 7B Fault Code 368 inactive Guided Step 7B .

chm::/procedures/80-t05-368.Page 12 of 12 Conditions Connect all components.htm 10/5/2010 . Action  Clear the inactive fault codes.  Turn keyswitch ON. mk:@MSITStore:C:\Intelect\INSITE\FIS\FIS3666194. OK NOT OK Troubleshoot any remaining active fault codes Repair complete Appropriate troubleshooting chart All fault codes cleared Last Modified: 29-Jul-2010 Copyright © 2000-2009 Cummins Inc. All rights reserved.  Use INSITE™ electronic service tool to clear the inactive fault codes.