Service Parts Bae TH6 Topics January, 1998 , 98T19-5 Fis Gp eign Fay 19 'sB ‘Subject Fault Code Updates T&A Manual ‘Shop Manual O&M Manval AR Marval ‘Other 9666194 This service parts topic provides updates to fault codes in the ISB Troubleshooting and Repair Manual, Bulletin No. 3666194, The effected fault codes are: Fault Code 362 — Fuel Pump Fuel Metering Valve Open Circuit Fault Code 363 — Fuel Pump Solenoid Valve Closing at Wrong time Fault Code 364 — Electronic Control Module (ECM) to Pump Communications Error Fault Code 381 — VP44 Relay Coil Supply Circuit Fault Code 365 — Fuel Pump Voltage Out of Range Error Low Fault Code 368 — Fuel Pump Cannot Reach Commanded Timing Gamoune Engine Company, Ing, Columbus, Undlana 47HO2I00E Summing Engine Company Ltd., Daventry, Horthants, England N11 SNU ears Gite: 2.55 Cone Fat How alia, Soroy KTS aL Eopragito Toso NOS arom Engine Company, ne ‘Airighs rose Page 1 of 48Pose Spee $62 98T19-5 Fault Code 362 Fuel Pump Fuel Metering Valve Open Circuit CODES REASON EFFECT Fault Code: 262 Low current or no current detected | Engine will stop or run rough. PID(P), SID(S): $251 at the VP44 fuel metering valve, SPN: 1076 FMI: 4 Lamp: None P44 Fuel Pump Circuit 75]_¥P44 +12VDC Supply Fuel 5|_—_Enaine Position Reference Signal Pump Low Idle Select [ 4 ‘VP44 Fuel Shutoff 531A WP44 Datalink (+) ; [_\vP44 Datalink ©) 7 (UShield Return é \VP44 Battery Return (.) 53 c Ca foead roel shutott Engine Harness ce Unewitched ° Battery +12VDC + of} —_ Circuit Description: This circuit is internal to the VP44 fuel pump control module (FPCM). It controls the quantity of fuel being delivered to each cylinder. Component Location: ‘The fuel metering vaive is located inside the VP44 fuel pump in the middle of the delivery valve holders.98T19-5 Fault Code 362 Page 3 TROUBLESHOOTING SUMMARY STEPS STEP 1: Check equipment voltage supply. ‘STEP 1A: Check the battery voltage, STEP 2: Check engine harness. STEP 2A: Inspect the engine harness, fuel pump, and ECM connectors. STEP 2B: Check VP44 supply resistance. STEP 2C: Check resistance in VP44 controller ground circuit. STEP 3: Check pump wiring. STEP 3A: Inspect fuel metering valve connec- tion. STEP 4: Clear the fault codes. ‘STEP 4A: Disable the fault cot STEP 4B: Clear the inactive fault codes SPECIFICATIONS SRT CODE Normal conditions: at least 12 volts in a 12 volt system During cranking: at least 8 volts, No damaged pins Less than 0.2 ohms Less than 0.2 ohms No frayed or damaged wires Fault Code 362 inactive All faults clearedFault Code 362 seT19-5 Page 4 TROUBLESHOOTING STEP STEP 1: Check equipment voltage supply. STEP 1A: Check the battery voltage. Condition: * Key switch in the "OFF" position. ‘Action Specifications/Repair Next Step Check the battery voltage. OK 2A * Measure the battery voltage from the positive | Normal conditions: (+) terminal to the negative (-) terminal. greater than 12 volts * Measure the battery voltage from the positive A : (+) terminal othe negative () terminal white. | DUFng eranking: trying to start the engine. 3 _ — NOT OK 4A Charge or replace the battery Refer to the equipment manufacturer's troubleshooting and repair manual. ont cel98T19-5 Fault Code 362 Page 5 STEP 2: Check engine harness. STEP 2A: Inspect the engine harness, fuel pump, and ECM connectors. Condition: * Key switch in the “OFF” position. * Disconnect the engine harness from the ECM. * Disconnect the engine harness from the VP44 fuel pump. Action ‘Specifications/Repair Next Step Inspect the engine harness, fuel pump, and OK 2B ECM connectors for the following: No damaged pins © bent or broken pins = A © 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 engine harness, ECM, (fuel pump, whichever has the damaged pins. ‘© Repair the engine harness. Refer to Procedures 019-250 and 019-209 in the ‘Troubleshooting and Repair Manual ISB Fuel System ISB Engines, Bulletin No. 3666194. © Replace the engine hamess. Refer to Procedure 019-043 in the Troubleshooting and Repair Manual ISB Fuel System ISB Engines, Bulletin No. 3666194. © Replace the ECM. Refer to Procedure 019-031 in the Troubleshooting and Repair Manual ISB Fuel System ISB Engines, Bulletin No. 3666194. © Replace the fuel pump. Refer to Proce- dure 005-014 in the Troubleshooting and Repair Manual ISB Engines, Bulletin No. 3666193.Fault Code 362 Page 6 STEP 2B: Check VP44 supply voltagi 98T19-5 Condition: * Key switch in the “ON" position. * Disconnect the engine harness from the fuel pump. Action Specitications/Repair Next Step Check the harness resistance, OK 20 © Measure the resistance from pin 7 of the Less than 0.2 ohms i it ea Connector, harness sg, othe postive TACT oi Rear y Fault Code 39198T19-5 Fault Code 362 Page 7 STEP 21 heck resistance in VP44 controller ground circuit. Conditio ‘© Key switch in the “OFF” position. * Disconnect the engine harness connector from the ECM. * Disconnect the engine harness from the fuel pump. Action Specifications/Repair Next Step Measure the resistance from pin 6 of VP44 connector, harness side, to engine block ground. NOTE: Clean painvdirt from block Surface you are using for ground to obtain a good reading, Less than 0.2 ohms OK NOT OK STEP 3: Check pump wiring. STEP 3) : Inspect fuel metering valve connections. Condi © Key switch in the “OFF* position. Acti Specifications/Repair Next Step Visually inspect wires from VP44 Fuel Pump | OK 4a Control Module to fuel metering solenoid for _| No frayed or damaged wires damage. NOTOK a Replace the fuel pump Refer to Procedure 005-014 in the Trouble- shooting and Repair Manual ISB Engines, Bulletin No. 3666193.Fault Code 362 98T19-5 Page 8 STEP 4: Clear the fault cod STEP 4A: Disable the fault code. Condition: * Connect all the components. Action Specifications/Repair Next Step Disable the fault code. oK 4B * Start the engine and let idle for 1 minute. Fault Code 362 inactive ° Verily that Fault Code 362 is inactive, NOT OK 1A Return to 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 the components. Action Specifications/Repair Next Step Clear the inactive fault codes. OK Repair ° Erase the inactive fault code using INSITE™. | All the faults cleared complete NOT OK Appropriate: | Troubleshoot any remaining active fault trouble- | codes. shooting chart98T19-5 Fault Code 363 Page 9 Fault Code 363 Fuel Pump Fuel Solenoid Valve Closing At Wrong Time CODES REASON EFFECT Fault Code: 363 No fuel metering valve movement | Engine power derate. PID(P), SID(S): S251 detected by the VP44 pump Engine possibly stops. SPN: 1076 controller. FM: 7 Lamp: None VP44 Fuel Pump Circuit VP44 +12VDC Supply Fuel : Engine Position Reference Signal ae Pump Low Idle Select ° 4°) vP44 Fuel Shutoff 2 VP44 Datalink (+) oe i [_\vP44 Datalink (-) 7 3 \UShield Return aa Q VP44 Battery Return (-) “a J Cp tiweaa ret Shuto Engine Harness ceed = Unswitched Battery +12VDC. O1+0 QARRRREG Circuit Description: This circuit is internal to the VP44 fuel pump and detects fuel solenoid movement. Component Location: The VP44 fuel pump is located on the back side of the gear housing on the intake side of the engine.Fault Code 363, 9-5 Page 10 a TROUBLESHOOTING SUMMARY STEPS SPECIFICATIONS SRT CODE STEP 1: Check for active fault codes. STEP 1A: Read the fault codes. Fault Code 366 inactive STEP 2: Check engine harness. STEP 2A: Inspect the engine harness, fuel No damaged pins pump, and ECM connectors. STEP 2B: Check the battery voltage. Atleast 12 volts in a 12 volt system STEP 2C: Check for open circuit. Less than 0.2 ohms STEP 2D: Check for high resistance. Less than 0.2 ohms STEP 3: Check equipment voltage supply. STEP 3A: Check alternator output. Refer to equipment repair manual ‘STEP 4: Clear the fault codes. STEP 4A: Disable the fault code. Fault Code 363 inactive STEP 4B: Clear the inactive fault codes. All faults cleared TROUBLESHOOTING STEP STEP 1: Check for active fault codes. STEP 1A: Read the fault codes. Condition: * Key switch to the “ON" position. Action Specifications/Repair Next Step Read the fault codes, OK 28 © Read the fault codes using INSITE”. Fault Code 366 inactive NOT OK Go to Fault Fault Code 366 active Code 36698T19-5 Fault Code 363, Page 1 ‘STEP 2: Check engine harness. STEP 2A: inspect the engine harness, fuel pump, and ECM connectors. Condition: * Key switch in the “OFF” position. * Disconnect the engine harness from the ECM. * Disconnect the engine harness from the VP44 fuel pump. Action Specifications/Repair Next Step Inspect the engine harness, fuel pump, and OK 2B ECM connectors for the following: No damaged pins © bent or broken pins nGTOK am * pushed back or expanded pins corroded pins moisture in or on the connector missing connector seal. Repair damaged pins Repair or replace the engine harness, ECM, or fuel pump, whichever has the damaged pins, © Repair the engine hamess. Refer to Procedures 019-209 and 019-250 in the Troubleshooting and Repair Manual |SB Fuel System ISB Engines, Bulletin No. 3666194. © Replace the engine hamess. Refer to Procedure 019-043 in the Troubleshooting ‘and Repair Manual ISB Fuel System ISB Engines, Bulletin No. 3666194. * Replace the ECM. Refer to Procedure 019-031 in the Troubleshooting and Repair Manual ISB Fuel System ISB Engines, Bulletin No. 3666194. '* Replace the VP44 fuel pump. Refer to Procedure 005-014 in the Troubleshooting ‘and Repair Manual ISB Engines, Bulletin No. 3666193. © Dry the connector by using electrical contact cleaner, Part No. 3824510,Fault Code 363 98T19-5 Page 12 STEP 2B: Check battery voltage. | Condition: * Keyewitch in the “ON" position. Action | Specifications/Repair Next Step Check battery voltage. ] 0K 2c © Measure the voltage at the battery. At least 12 volts in a 12 volt system Note: If the engine will not start, check battery voltage during cranking. Battery voltage should remain above 8 volts during cranking. NOT OK 3A Charge or replace batteries Refer to the equipment manufacturer's troubleshooting and repair manual,98T19-5 Fault Code 363, Page 13 STEP 20: Check for open circuit. Condition: * Keyswitch in the “OFF” position. * Disconnect the engine harness from the ECM. + Disconnect the engine harness from the VP44 uel pump. Action Specifications/Repair Next Step ‘Check for open circuit in VP44 controller ground | OK 3A circuit Less than 0.2 ohms © Measure the resistance from pin 6 on the harness side of the fuel pump connector to. | NOT OK reas engine block ground. aeFault Code 363, seT19-5 Page 14 STEP 2D: Check for high harness resistance. Condition: © Keyswitch in the “ON” position. * Disconnect the engine harness from the VP44 fuel pump. Action Specifications/Repair Next Step Measure VP44 supply resistance oK 4A * Measure the resistance from pin 7 on the _| Less than 0.2 ohms harness side of the VP44 connector to the - - positive (+) battery terminal NOT Or ee 391 STEP 3: Check equipment voltage supply. STEP 3A: Check alternator output. Condition: * Engine running. Action Specifications/Repair Next Step Check alternator output OK 20 * Refer to equipment manufacturers repair Refer to equipment repair manual manual 9 an Ropair or replace alternator Refer to equipment manufacturer's trouble- shooting and repair manual.ssTt98-5 Fault Code 363 Page 18 STEP 4: Clear the fault code. STEP 4A: Disable the fault code. Condition: * Connect all the components. Action Specifications/Repair Next Step Disable the fault code. 0K 48 * Verity that Fault Code $63 is inactive. Fault Code 363 inactive NOT OK 1A Retumn to 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 the components. ‘Action Specifications/Repair Next Step Clear the inactive fault codes. 0K Repair + Erase the inactive fault code using INSITE™. | All faults cleared complete NOT OK Appropriate | Troubleshoot any remaining active fault trouble- | codes. shooting chartFault Code 364 series Page 16 Fault Code 364 Electronic Control Module (ECM) to Pump Communications Error CODES REASON EFFECT Fault Code: 364 'No communications or invalid data | Engine will run in a back-up mode set PID(P), SID(S): $233 | transfer rate detected on datalink | speed whon accelerator is offi. SPN: "1077 between ECM and VP44 fuel pump FMI: 9 Control module at pins 4 and 13 of Lamp: None the engine harness. P44 Fue! Pump Circuit 751 VP44 +12VDC Supply om Fuel _—_Enuaine Position Reference Signal ao Pump Low Idle Select 4°. —WP4d Fuel Shutoff 16 25] A VPA Datalink (9) i" i [-\VP44 Datalink (>) aa e (Shield Return 03 $ VP44 Battery Return (-) “ C.—frtveaa Fuel Shute Engine Hames ih ‘3 Unswitohed Oo Battery +12VDC. + o|& ted Gircuit Description: ‘This circuit is the communications datalink between the ECM and fuel pump control module. Component Location: ‘The datalink is located wi iin the ECM and fuel pump control module. Shop Talk: * The datalink is used to communicate fueling and timing commands as well as pump status messages. If the datalink is lost, the pump will run in back-up mode based on idle signal (pin 4 at VP44 connector). * This code will be active if the VP44 power supply is inadequate. Refer to Fault Code 391 first if Fault Code 364 is active.98T19-5 Fault Code 364 Page 17 TROUBLESHOOTING SUMMARY A caution A To avoid damaging anew ECM, all other active fault codes must be investigated prior to replacing the ECM. STEPS STEP 1: Check engine harness. ‘STEP 1A: Inspect the engine harness, fuel pump, and ECM connectors. STEP 1B: Check battery voltage. STEP 1C: Check for an open circuit in VP44 ground circuit. Check for an open circuit in the VP44 datalink circuit. STEP 1: Check for a short circuit to ground in the VP44 datalink circuit. STEP 14F: Check for a short circuit from pin to pin in the VP44 datalink circuit. heck the harness resistance STEP 1 STEP 1 STEP 2: Clear the fault codes. SPECIFICATIONS SRT CODE No damaged pins 12 volts in a 12 volt system 8 volts cranking Less than 0.2 ohms Less than 10 ohms More than 100k ohms More than 100k ohms Less than 0.2 ohms Fault Code 364 inactive All faults clearedFault Code 364 98T19-5 Page 18 TROUBLESHOOTING STEP STEP 1: Check engine harness. STEP 1A: Inspect the engine harness, fuel pump, and ECM connectors. AcautionA, Pe gvold damaging a new ECM, all other active fault codes must be investigated prior to replacing the ECM. Condition: * Key switch in the “OFF” position, * Disconnect the engine harness from the ECM. * Disconnect the engine harness from the fuel pump. Action Specifications/Repair Next Step Iepea the engine hess, fal pump and OK 8 ECM connectors for the following: No damaged pins = bont or broton pis NOT OK 2A + pushod back o expanded pina Ropar he damage pins Repair or replace the engine harness, ECM, + moat Ino onthe conestr : « missing or damaged seals: ce fuel pump, whichever has the damaged * Repair the engine hamess. Refer to Procedures 019-209 and 019-250 in the ‘Toubleshooting and Repair Manual ISB Fuol System ISB Engines, Bulletin No. 3666194. * Replace the engine harness. Refer to Procedure 019-043 in the Troubleshooting ‘and Repair Manual ISB Fuel System ISB Engines, Bulletin No. 3666194 * Replace the ECM. Refer to Procedure 019-031 in the Troubleshooting and Repair Manual ISB Fuel System ISB Engines, Bulletin No. 3666194, * Replace the fuel pump. Refer to Proce- dure 005-014 in the Troubleshooting and Repair Manual ISB Engines, Bulletin No. 3666193,98T19-5 Fault Code 364 Page 19 STEP 1B: Check the battery voltage. Condition: ¢ Key switch in the “ON” position. ‘Action ‘Specifications/Repair Next Step Check the battery vollage. oK 1c * Measure the battery voltage from the positive | Normal: 12 volts in a 12 volt system battery post to the negative battery post. Cranking: 8 volts in a 12 volt system NOT OK Refer to Fault Code 391Fault Code 364 Page 20 STEP 1C: Check for open circult in the VP44 ground circuit, 98T19-5 Condi © Key switch in the “OFF” position, isconnect the engine hamess from the fuel pump. isconnect the engine harness from the ECM. * Disconnect the ECM battery return connector. Action Specifications/Repair Next Step ‘Check for an open circuit in the VP44 controller | OK ground circuit. Less than 0.2 ohms 16 © Measure the resistance from pin 8, on the Fo og harness side of the fuel pump connector, to engine block ground. Refer to Fault Code 39198T19-5 Fault Code 364 Page 21 STEP 1D: Check for an open circuit in the VP44 datalink circuit. Conditior * Key switch in the “OFF” position. * Disconnect the engine harness from the fuel pump, * Disconnect the engine harness from the ECM. Action Specifications/Repair Next Step Check for an open circuit in datalink circuit. | OK 1E ‘* Measure the resistance from pin 2 on harness | Less than 10 oh side of the fuel pump connector to pin 13 on [or oy a harness side of ECM connector. ‘* Measure the resistance from pin 1 on hamess side of the fuel pump connector to pin 4 on harness side of ECM connector. Replace the engine harness Refer to Procedure 019-043 in the Trouble- shooting and Repair Manual ISB Fuel System ISB Engines, Bulletin No, 3666194.Fault Code 364 98T19-5 Page 22 STEP 1E: Check for a short circuit to ground in the VP44 datalink circuit. Condition: * Key switch in the “OFF” position. * Disconnect the engine harness from the fuel pump control module. Action Specifications/Repair Next Step Check for a short circuit to ground in the OK 1F datalink circuit. ‘More than 100k ohms '* Measure the resistance from pin 2 on engine harness side of the fuel pump connector to | NOT OK 2A ‘engine block ground. © Measure the resistance from pin 1 on engine harness side of the fuel pump connector to engine block ground. Replace engine harness Refer to Procedure 019-043 in the Trouble- shooting and Repair Manual ISB Fuel ‘System ISB Engines, Bulletin No. 3666194.98T19-5 Fault Code 364 Page 23 STEP 1F: Check for a short circuit from pin to pin in the VP44 datalink circuit. Condition: + Key switch in the “OFF” position, * Disconnect the engine harness from the VP44 fuel pump control module. Action Specifications/Re} Next Step Check for a short from pin to pin. OK 2A ‘* Measure the resistance from pin 2 on hamess | More than 100k ohms. side of the fuel pump connector to all other or Gy on pins in the connector. ‘© Measure the resistance from pin 1 on hamess side of the fuel pump connector to all other pins in the connector. Replace engine harness Refer to Procedure 019-043 in the Trouble- shooting and Repair Manual ISB Fuel | System ISB Engines, Bulletin No. 3666194, Test All PinsFault Code 364 seT19-5 Page 24 STEP 1G: Check supply resistance. Condition: © Key switch in the “ON” position. ¢ Disconnect the VP44 connector. Action Specifications/Rep Next Step Measure the harness resistance, OK 1D * Measure the resistance from the positive (+) | Less than 0.2 ohms battery Post to pin 7 at the VP44 connector oro ras arness side. Fault Code 391. STEP 2: Clear the fault codes. STEP 2A: Disable the fault code. Condition: * Connect al the components. Action Specifications/Repair Next Step Disable the fault code. OK 2B « ‘Start the engine and let ide for 1 minute. __| Fault Code 364 inactive © Verify that Fault Code 364 is inactive. NOT OK 7A Return to troubleshooting steps or contact, your local Cummins Authorized Repair Location if all steps have been completed and checked again. STEP 2B: Clear the inactive fault codes. Condition: * Connect all the components. 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 trouble- codes. ‘shooting chart98T19-5 Fault Code 391 Page 25 Fault Code 391 P44 Relay Coil Supply Circuit CODES REASON EFFECT Fault Code: 391 Error detected in VP44 power Possible no effect on performance or PID(P), SID(S): S017 supply relay enable circuit at pin | engine may die. SPN: 632 43 of the engine hares. FM 11 Lamp: Yellow Fuel Shutoff Solenoid Circuit Fuel Shutott Fuel Pump D ECM 7 c B A P44 Relay Circuit Description: ‘The VP44 relay is used to supply voltage to the VP44 fuel pump. The ECM can shut down the engine by cutting off the power to the fuel shutoff relay circuit Component Location: This component is installed by the equipment manufacturer. Refer to the equipment manufacturer's trouble- shooting and repair manual for component location. This relay is attached to the engine harness. Shop Talk: * Inspect the VP44 relay circuit for external wires that may be spliced in to power another device. Remove any extra wires that are found in the circuit * If there is an external shutdown system on the vehicle that uses the VP44 relay circuit for engine shutdown, make sure it has not failed and pulled down the voltage on the VP44 relay circuit. * Inspect the engine block to chassis ground wire to make sure it is securely fastened to a clean, dry surface. * Check the starter solenoid '* +” terminal for a loose connector or accessory wiring with damaged insulation. * High resistance in the VP44 power supply circuit may result in an active Fault Code 964 and an engine that will not start. The troubleshooting steps for Fault Code 391 apply to other symptoms and fault codes that areFault Code 391 98T19-5 Page 26 voltage dependent. © Ifthe engine does not start, or if Fault Code 964 is active, Step 2A, Harness Resistance to VP44 relay, should be performed first. © To quickly check this circuit: 1. Check battery voltage at cranking (Greater than 8.0 volts 2. With key switch in the “ON” position, measure resistance from “ +" battery to pin No. 7 at VP44 connector (Less than 0.2 ohms) 3. Measure resistance from pin No. 6 at VP44 to ground (Less than 0.2 ohms) ‘Sources of high resistance include moisture in the power relay and fuse holder.98T19-5 Fault Code 391 Page 27 TROUBLESHOOTING SUMMARY ‘STEPS STEP 1: Check engine harness. ‘STEP 1A: Inspect the engine harness and ECM connectors. STEP 1A-1: Check battery voltage STEP 1B: Check for an open circuit in the fuel shutoff circuit. STEP 1C: Check for an open circuit in the relay ground circuit. STEP 1D: Check for an open in the ground circuit. STEP 1E: Check for a short circuit to ground. STEP 1F: Check for a short circuit from pin to pin. STEP 1G: Check the fuel shut-off voltage from the ECM. ‘SPECIFICATIONS SRT CODE No damaged pins 12 volts in 12 volt system 8 volts while cranking Less than 10 ohms Less than 10 ohms Less than 10 ohms More than 100k ohms More than 100k ohms 11 volts STEP 2: Check original equipment manufacturer's (OEM) harness. STEP 2A: Check the pump power supply circuit. STEP 2B: Measure pump power supply resis- tance. ‘STEP 2C: Measure the pump ground resis- tance. STEP 3: Clear the fault codes STEP 3A: Disable the fault code. STEP 3B: Clear the inactive fault codes. No damaged pins Less than 0.2 ohms Less than 0.2 ohms Fault Code 391 inactive All faults clearedFault Code 391 Page 28 TROUBLESHOOTING STEP STEP 1: Check engine harness. STEP 1A: Inspect the engine harness and ECM connectors. 98T19-5 ECM. AcautionA To avold damaging a new ECM, all other active fault codes must be investigated prior to replacing the © Key switch in the “OFF” position, © Disconnect the engine harness from the ECM. Action _ pushed back or expanded pins © corroded pins © moisture in or on the connector * missing or damaged seals. Specifications/Repair Next Step Check the engine harness and the ECM OK TAT connectors for the following: No damaged pins * bent or broken pins NOT OK 3A Repair the damaged pins Repair or replace the engine hamess or ECM, whichever has the damaged pins. © Repair the engine hamess. Refer to Procedure 019-250 in the Troubleshooting and Repair Manual ISB Fuel System ISB Engines, Bulletin No. 3666194. * Replace the engine harness. Refer to Procedure 019-043 in the Troubleshooting and Repair Manual ISB Fuel System ISB Engines, Bulletin No. 3666194, * Replace the ECM. Refer to Procedure 019-031 in the Troubleshooting and Repair Manual ISB Fuel System ISB Engines, Bulletin No, 9666194.9819-5 Fault Code 391 Page 29 STEP 14-1: Check the battery voltage Condition: © Key switch in the “ON” position. Action Next Step Check the battery voltage oK 1B ‘© Measure the battery voltage from the positive | Normal: 12 volts in a 12 volt system battery post to the negative battery post. Cranking: 8 volts in a 12 volt system NOT OK 3A Replace the battery.Fault Code 391 98T19-5 Page 30 STEP 1B: Check for open citcuit in the fuel shutoff cireult, Condi © Key switch in the “OFF” position, * Disconnect engine harness from the ECM. * Disconnect engine harness from OEM fuel shutoff circuit Action Specifications/Repair Next Step Check for open circuit in the fuel shutoff circuit. | OK 1G © Measure resistance from pin 43 of the engine | Less than 10 ohms hamess connector to pin C on the harness = side of the fuel shut off relay connector nor oo | Replace the engine hamess Refer to Procedure 019-043 in the Trouble- shooting and Repair Manual ISB Fuel System ISB Engines, Bulletin No. 3666194,9eT19-5 Fault Code 391 Page 31 STEP 1C: Check for open circuit in the relay ground circuit. Condition: | | * Key switch in the “OFF” position. j + Disconnect engine hamess from the ECM. * Disconnect engine harness from OEM fuel shutoff circuit. Action Specifications/Repai Next Step Check for open circuit in the relay ground OK 1D circu Less than 10 ohms * Measure the resistance from pin 29 of the NOT OK 3A engine harness connector to pin D on the tor, harness side of the fuel shut off relay connec- Replace the engine harness Refer to Procedure 019-043 in the Trouble- shooting and Repair Manual ISB Fuel System ISB Engines, Bulletin No. 3666194.Fault Code 391 Page 32 STEP 1 Check for an open in the ground circuit. 98T19-5 Condition: © Key switch in the "OFF" position. * Disconnect the engine hamess from the ECM. Action Specifications/Repair Next Step ground circuit. © Measure the resistance from pin 29 of the engine harness to battery return. Check for an open circuit in the engine harness OK Less than 10 ohms 1E NOT OK Repair or replace the engine harness or battery return connector * Replace the engine harness. Refer to Procedure 019-043 in the Troubleshooting and Repair Manual ISB Fuel System ISB Engines, Bulletin No. 9666194 * Replace the battery return connector. Refer to Procedure 019-199 in the Troubleshooting and Repair Manual 1SB Fuel System ISB Engines, Bulletin No. 3666104, 3A‘98T19-5 Fault Code 391 Page 33 STEP 1E: Check for short circuit to ground. Conditio * Key switch in the “OFF” position. © Disconnect engine harness from the ECM. ® Disconnect engine harness from OEM fuel shutoff circuit. Action Specifications/Repair Next Step Check for short circuit to ground. OK ie * Measure the resistance from pin 43 of the More than 100k ohms seaine harness connector to engine block TOK aa . Replace the engine harness Refer to Procedure 019-043 in the Trouble- shooting and Repair Manual ISB Fuel ‘System ISB Engines, Bulletin No. 3666194.Fault Code 301 98T19-5 Page 34 STEP 1F: Check for a short circuit from pin to pin. Condition ® Key switch in the “OFF* position * Disconnect engine harness from the ECM. 2 Disconnect engine harness from OEM fuel shutoff circuit. Action Specifications/Repair Next Step Check for a short circuit from pin to pin. OK 16 ® Measure the resistance from pin 43 of the _| More than 100k ohms engine harness to all other pins in the engine - harness. on ‘ Replace the engine harness Refer to Procedure 019-043 in the Trouble- shooting and Repair Manual ISB Fue! System ISB Engines, Bulletin No. 3666194, Test All Pins _ = ‘Action Specifications/Repair Next Step ‘Check for signal voltage from ECM OK 1c Wexteby cence hares sits © oro fete ‘Trouble- ‘shooting98T19-5 Fault Code 391 Page 35 STEP 2: Check +12v Pump Power Supply and Ground Circuit STEP 2A: Check the Pump Power Supply Circui Condition: * Disconnect the VP44 power relay * Key switch in the “ON” position. isconnect engine harness from VP44 connector. Action Specifications/Repair Check the OEM harness connection, VP44 power relay, and engine harness for: il Next Step OK | 2B 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 |= Repair the damage pins © Repair or replace the four pin weather- pack connector. Refer to Procedure 019-204 in the Troubleshooting and Repair Manual ISB Fuel System ISB Engines, Bulletin No. 3666194.Fault Code 391 ay Page 36 geri STEP 2B: Check +12v harness resistance to VP44 injection pump. Condition: * Key switch in the "ON" position, * Disconnect engine harness from VP44 pump. Action Specifications/Repair Next Step Check + 12v harness resistance to VP44 OK 2c injection pump. Less than 0.2 ohms © Measure the resistance from “+” battery — terminal to pin No. 7 of the VP44 connector. Nor OK 3A Repair or replace the section of the power supply circuit causing high resis- tance. Refer to the equipment manufacturer's troubleshooting and repair manual, STEP 2C: Check the resistance of the VP44 ground Condition: © Key switch in the “OFF” position. © Disconnect engine harness from the ECM. * Disconnect the engine harness from the VP44 connector. Action Specifications/Repair Next Step ‘Check the resistance of the VP44 ground OK 3A circuit. Less than 0.2 ohms © Measure the resistance from pin No. 6 at the ‘P44 connector, harness side, to the battery | NOT OK cn Repair or replace the section of ground ground terminal (3, ; circuit causing high resistance. Refer to the equipment manufacturer's troubleshooting and repair manual.98Tt9-5 Fault Code 381 Page 37 STEP 3: Clear the fault codes. STEP 3A: Disable the fault code. Condition: + Connect all the components. Action Specifications/Repair Next Step Disable the fault code, OK | 3B * Start the engine and let idle for 1 minute, _| Fault Code 391 inactive * Verity Fault Code 391 is inactive. = ri Return to the troubleshooting steps or Contact your local Cummins Authorized Repair Location if all the steps have been completed and checked again STEP 3B: 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 code using INSITE”. | All faults cleared complete NOT OK Appropriate Troubleshoot any remaining active fault trouble- codes. shooting chartsFault Code 365, T18 Page 38 cuted Fault Code 365 Fuel Pump Voltage Out of Range Error Low CODES REASON EFFECT Fault Code: 265 Low voltage detected at VP44 Possible engine stalling, low in power or PID(P), SID(S): $233 Pump controller supply voltage | running rough. SPN: "1077 circuit. Ful: 4 Lamp: None P44 Fuel Pump Circuit 7>}_WP44 +12VDC Supply — Fuel 3 _Enaine Position Reference Signal i Low Idle Select Pump }—>4 16 \VP44 Fuel Shutoff 5], VP44 Datalink (+) fe ; [_|VP44 Datalink (-) a a \ZShield Return 03 | 3 P44 Battory Return (-) -o4_VP44 Fuel Shutoff Engine Harness Ce |= Unawitehed O° ead Battery +12VDC. 4 + = o}| & led ‘000006 Description: Pot Component Location: rs Suppliod to the VP44 through a relay. When the electronic control mo: supplied from the battery, through the relay, to the fuel pump. Refer fo equipment manufacturer's repair manual. \dule (ECM) switches the relay, power98T19-5 Fault Code 365 Page 39 TROUBLESHOOTING SUMMARY STEPS SPECIFICATIONS SRT CODE STEP 1: Check engine harness. STEP_1A: Inspect the engine harness, fuel pump, and ECM connectors. heck VP44 supply resistance. theck for open circuit in VP44 controller ground circuit. STEP 1 STEP 1 Check equipment voltage supply. ‘STEP 2B: Check alternator output. STEP 3: Clear the fault codes. isable the fault code. lear the inactive fault codes. No damaged pins Less than 0.2 ohms Less than 0.2 ohms 12 volts in a 12 volt system At least 8 volts during crank- ing Refer to equipment repair manual Fault Code 365 inactive All faults clearedFault Code 365 98T19-5 Page 40 TROUBLESHOOTING STEP STEP 1: Check engine harness. STEP 1A: Inspect the engine harness, fuel pump, and ECM connectors. Condition: * Key switch in the “OFF” position. * Disconnect the engine hamess from the ECM * Disconnect the engine harness from the VP44 fuel pump. Action Specifications/Repair Next Step Inspect the engine harness, fuel pump, and | OK 1B ECM connectors for the following: | No damaged pins * bent or broken pins es x © pushed back or expanded pins © corroded pins © moisture in or on the connector © missing or damaged seals. Repair the damaged Repair or replace the engine harness, ECM, or fuel pump, whichever has the damaged pins. * Repair the engine harness. Refer to Procedures 019-209 and 019-250 in the Troubleshooting and Repair Manual ISB Fuel System ISB Engines, Bulletin No, 3666194, ‘* Replace the engine harness. Refer to Procedure 019-043 in the Troubleshooting and Repair Manual ISB Fuel System ISB Engines, Bulletin No, 3666194. * Replace the ECM. Refer to Procedure 019-031 in the Troubleshooting and Repair Manual ISB Fuel System ISB Engines, Bulletin No. 3666194. * Replace the fuel pump. Refer to Proce- dure 005-014 in the Troubleshooting and Repair Manual ISB Engines, Bulletin No. 3666199,98T19-5 Fault Code 365, Page 41 STEP 1B: Check VP44 supply voltage. Condition: ‘© Key switch in the “ON” position. ¢ Disconnect the engine hamess from the fuel pump. Action Specifications/Repair Next Step Check the voltage supplied to the fuel pump. OK 1c ‘+ Measure the voltage from pin 7 of the VP44 | Less than 0.2 ohms connector, harness side, to the positive (+) eee a NOT OK Refer to battery terminal | ae | 301Fault Code 365 98T19-5 Page 42 STEP 16: Check for open circuit in VP44 controller ground circuit. Condition: © Key switch in the “OFF” position, * Disconnect engine harness from the ECM. * Disconnect engine harness from the fuel pump control module. Action Specifications/Repair Next Step Check for open circuit in VP44 controller ground | OK 2A steut Lee than 0.2 ohme © Measure the resistance from pin 6 on the ~ hanes sooth os! pump conta module | NOT OK Refer to engine block ground. soi98T19-5 Fault Code 365 Pages STEP 2: Check equipment voltage supply. STEP 2A: Check the battery voltage. Condition: Action Specifications/Repair Next Step Check the battery voltage. OK 2B © Measure the battery voltage from the positive | 12 V System: (+) terminal to the negative (-) terminal. at least 12 VDC * Measure the battery voltage from the positive | 5,4; king: (+) terminal to the negative () terminal while | Dayna Gaming: trying to start the engine. — NOT OK 3A Charge or replace the battery Refer to the equipment manufacturer's toubleshoctng ad opal manual, Yon ® . (Q STEP 2B: Check alternator output. Conditior © Start and idle engine. Action Specifications/Repair Next Step Measure voltage output. OK 3A © Refer to the Troubleshooting and Repair Refer to the alternator manufacturer Manual ISB Engines, Bulletin No. 3666193. diagnostic instructions. NOT OK 3A Repair or replace alternator Refer to Procedure 013-001 in the Trouble- ‘shooting and Repair Manual ISB Engines,Fault Code 365, ‘98T19-5 Page 44 STEP 3: Clear the fault code. : Disable the fault code. jon: © Connect all the components. Action Specifications/Repair Next Step Disable the fault code. oK 38 ® Start the engine and let idle for 1 minute. Fault Code 365 inactive * Verity that Fault Code 965 is inactive. NOT OK 77 Return to troubleshooting steps or contact your local Cummins Authorized Repair Location if all stops have been completed and checked again. STEP 3B: Clear the inactive fault codes. Condition: © Connect all the components, Action Specifications/Repair Next Step Clear the inactive fault codes. K Repair © Erase the inactive fault code using INSITE*, | All the faults cleared ‘compiate NOT OK ‘Appropriate Troubleshoot any remaining active fault | trouble codes. shooting chart98T19-5 Fault Code 368 Page 45 Fault Code 368 Fuel Pump Cannot Reach Commanded Timing CODES I REASON EFFECT Fault Code: 368 |The VP44 pump cannot achieve | Engine power derate. PID) SID(S): $254 | the ting vale Being commandos 1078 by the electronic control module Fue (ECM) Lamp: _None P44 Fuel Pump Circuit 73L_wPa4 +12VDC Supply ra #5{__Engine Position Reference Signal oO Pump Low Idle Select 4°. —WPad Fuel Shutoff ug 5°]. Pad Datalink (+) el ; [ \wP4a Datalink (-) os Ushi >, \JShield Return fhos 3 VP44 Battery Return (-) = Ce : ‘WP44 Fuel Shutoff Engine Harness ce = Unewitched O° Battery +12VDC. + c eens Circuit Description: ‘The VP44 fuel pump uses an internal check to determine if the fuel injection pump can reach the commanded timing. Component Location: Internal to the VP44 fuel pump. Shop Talk: ® The VP44 fuel injection pump uses fuel pressure generated by an internal vane pump and a timing solenoid to vary timing. Any restriction either to the pump inlet or outlet could cause timing problems (i.e. plugged fuel filter could cause this error). * If the problem is intermittent and the fault code count increases with occurrence, operate the engine under the conditions which cause the power derate while monitoring inlet restriction at the fuel filter outlet (5 psi minimum). © Amistimed fuel pump due to an incorrect key or mistimed fuel pump gear can resulte in intermittnet lowe power land fault code 368 increasing.Fault Code 368 Pau Cos seT19-5 TROUBLESHOOTING SUMMARY STEPS SPECIFICATIONS ‘SRT CODE STEP 1: Check ECM calibration. STEP 1A: Verify the correct calibration is inthe Calibration correct ECM. STEP 2: Check for multiple fault codes. STEP 2A: Read the fault codes. Fault Codes 115, 365, and 369 are not active STEP 3: Check fuel plumbing. STEP 3A; Cheok fue! inlet pressure. Minimum § psi STEP 4: Check gear train. 3 Check for slipped gears. Key is aligned STEP 5: Clear the fault codes ‘STEP 5A; Disable the fault code. Fault Code 368 inactive ‘STEP 5B: Clear the inactive fault codes. All faults cleared TROUBLESHOOTING STEP STEP 1: Check ECM calibration. STEP 1A: Verliy the correct calibration is in the ECM. Condition: © Key switch in the “ON” position. Action Specifications/Repair Next Step Road the calibration. OK 2A © Read the calibration using INSITE™., Calibration correct NOT OK 6A Download the correct calibration STEP 2: Check for multiple fault codes. STEP 2A; Read the feult codes. Condition: © Key switch in the "ON" position. Action Specifications/Repair Next Step Read the fault codes. OK 3A © Road the fault codes using INSITE". Fault Codes 115, 365 and 369 are not active Not OK Fault Code 115, 965 or 36998T19-5 Fault Code 368 Page 47 STEP 3: Check fuel plumbing. STEP GA: Check fuel inlet pressure. | Condition: © Engine running at high idle. ¢ Connect all components. ' Action Specifications/Repair Next Step Check for high fuel inlet restriction. oK 3B | © Check to see if the restriction on the fuel inlet | Fuel pressure greater than 5 pst | to the lift pump is above specifications. Refer [~ Taco e | to Procedure 006-020 in the Troubleshooting ae i 4 Refer to i and Repair Manual ISB Engines, Bulletin No, | Troubleshoot low pressure fuel system appropriate | oeeeien | (ines, fiters, it pump). trouble- | shooting tree. STEP 3B: Check fuel pressure before and after the fuel fiter. Conditio + Engine running at high idle. * Connect all components. Action Specifications/Repair Next Step | Check fuel pressure before and after the fuel | OK an | filter. Greater than 10 psi before the filter | + Measure the fuel pressure before and after | Greater than 5 psl after the filter | the fue! filter. noTOR an Replace the fuel pump \| Refer to Procedure 005-014 in the Trouble- shooting and Repair Manual {SB Engines, Bulletin No. 3665193 | STEP 4: Check gear train. STEP 4A: Check for slipped gears. Condition: + Remove fuel pump gear access cover or front gear cover. slippage. NOTE: Key must be aligned in the center of the keyway and/or the marks on the crank= shaft, camshaft, and fuel pump gear are aligned with engine at No. 1 TOC Action Specifications/Fepair Next Step Check for slipped goars. oK 5A © Check for slipped fuel pump gear by remov- | Key Is aligned ing fuel pump gear access cover. * iFfuel pump gear has not slipped, remove |. - - front cover to inspect cam and crank gear for | NOT OK 5A | Remove gear and repair Rofer to the Troubleshooting and Repair Manual ISB Fue! System ISB Engines, Bulletin No. 3666193.Fault Code 368 98T19-5 Page 48 STEP 5: Clear the fault code, STEP 5A: Disable the fault code. Condition: © Connect all the components Action Specifications/Repair Next Step Disable the fault code. OK 5B © Start the engine and let idle for 1 minute. Fault Code 368 inactive * Verify Fault Code 368 is inactive. NOT OK A Relum to the troubleshooting steps or contact your local Cummins Authorized Repair Location if all the steps have been completed and checked again, STEP SB: 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 code using INSITE”, | All faults cleared complete NOT OK ‘Appropriate ‘Troubleshoot any remaining active fault trouble- codes, shooting chart