steps specifications srt code step 1: check the ......2011/09/01 · step 2b: check the resistance...

© 2008 Cummins Inc., Box 3005, Columbus, IN 47202-3005 U.S.A. Printed from QuickServe® Online.All Rights Reserved. Last Modified: 16-Dec-2010

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TROUBLESHOOTING SUMMARY

CAUTIONTo reduce the possibility of pin and harness damage, use the following test leads when taking a measurement:PartNumber 3822758 - male AMP™/Deutsch™/Metri-Pack™ test leadPart Number 3823993 - male Deutsch™/Metri-Pack™test lead.

CAUTIONTo reduce the possibility of damaging a new ECM, all other active fault codes must be investigated prior to replacing theECM.

STEPS SPECIFICATIONS SRT CODESTEP 1: Check the injection control valve.

STEP 1A: Record and clear the inactive faultcodes.

All inactive fault codes cleared.

STEP 1B: Check for codes after performing aclick test.

Fault Code 276 or 277 logged, or nofault codes present.

STEP 2: Check the injection control valve.STEP 2A: Inspect the injection control valve

stator connector for damaged pins.No damaged pins.

STEP 2B: Check the resistance of the injectioncontrol valve stator.

0.1 to 1.0 ohms.

STEP 2C: Check for a short circuit to groundin the injection control valve stator.

More than 100k ohms.

STEP 3: Check the engine wiring harness.STEP 3A: Inspect the engine wiring harness

and the ECM connector pins.No damaged pins.

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 3C-1: Check for a short circuit toground.


STEP 3D: Check for a short circuit from pin topin.


STEP 4: Check the ECM ground circuit.STEP 4A: Check the negative (-) battery

connection for corrosion.Connection is tight and corrosionfree.

STEP 4B: Check the resistance of the ECMground circuit.

Less than 10 ohms.

STEP 4C: Inspect the 23-pin OEM connector. No damaged or loose connections.

STEP 4D: Check the resistance of the OEMground circuit.

Less than 10 ohms.

STEP 5: Clear the fault codes.STEP 5A: Disable the fault code. Fault Code 276 inactive.

STEP 5B: Clear the inactive fault codes. All fault codes cleared.


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TROUBLESHOOTING STEP

STEP 1: Check the injection control valve.STEP 1A: Record and clear the inactive fault codes.

Condition:• Connect all components.• Turn keyswitch ON.• Connect INSITE™ electronic service tool.

Action Specification/Repair Next Step

Record and clear the inactive fault codes.• Use INSITE™ electronic service tool to clear the

inactive fault codes.

OK

All inactive fault codes cleared.

1B

NOT OK

All inactive fault codes not cleared.

5B

STEP 1B: Check for codes after performing a click test.

Condition:• Turn keyswitch ON.• Connect INSITE™ electronic service tool.


Use INSITE™ electronic service tool to run thesolenoid click test on the injection control valve.• Listen for a strong, steady, audible click when

activating the test and while wiggling theinjection control valve stator wires.

OK

Fault Code 276 or 277 logged, or no faultcodes present.

2A

NOT OK

Injection control valve stops clicking or doesnot click while wiggling wires.

Injection control valve clicks erratically duringwiggling of wires.

Replace the injection control valve stator.Refer to Procedure 019-430 in Section 19.

5A


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STEP 2: Check the injection control valve.STEP 2A: Inspect the injection control valve stator connector for damaged pins.

Condition:• Turn keyswitch OFF.• Disconnect the engine wiring harness from the injection control valve.


Inspect the injection control valve connector forthe following:• Loose connector• Corroded pins• Bent or broken pins• Pushed back or expanded pins• Moisture in or on the connector• Missing or damaged connector seals• Dirt or debris in or on the connector pins• Connector shell broken• Wire insulation damage• Damaged connector locking tab.

Use the following procedure for general inspectiontechniques. Refer to Procedure 019-361 in Section19.

OK

No damaged pins.

2B

NOT OK


5A


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STEP 2B: Check the resistance of the injection control valve stator.

Condition:• Turn keyswitch OFF.• Disconnect the engine wiring harness from the injection control valve stator.


Check the resistance of the injection control valvestator.• Measure the resistance between pin 1 and pin

2 of the injection control valve stator connector.

Use a wiring diagram and the following procedurefor general resistance measurement techniques.Refer to Procedure 019-360 in Section 19.

OK

0.1 to 1.0 ohms.

2C

NOT OK


5A


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STEP 2C: Check for a short circuit to ground in the injection control valve stator.

Condition:• Turn keyswitch OFF.• Disconnect the engine wiring harness from the injection control valve stator.


Check for a short circuit to ground in the injectioncontrol valve stator.• Measure the resistance from pin 1 of the

injection control valve stator connector tochassis ground.

• Measure the resistance from pin 2 of theinjection control valve stator connector tochassis ground.


OK


3A

NOT OK


5A


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STEP 3: Check the engine wiring harness.STEP 3A: No damaged pins.

Condition:• Turn keyswitch OFF.• Disconnect the engine wiring harness from the ECM.• Disconnect the engine wiring harness from the injection control valve stator.


Inspect the engine wiring harness and the ECMconnector pins for the following:• Loose connector• Corroded pins• Bent or broken pins• Pushed back or expanded pins• Moisture in or on the connector• Missing or damaged connector seals• Dirt or debris in or on the connector pins• Connector shell broken• Wire insulation damage• Damaged connector locking tab.


OK

No damaged pins.

3B

NOT OK

Repair the damaged pins.

Repair or replace the engine wiring harness orECM, whichever has the damaged pins.• Repair the engine wiring harness. Refer to

Procedure 019-201 in Section 19. Refer toProcedure 019-205 in Section 19. Refer toProcedure 019-204 in Section 19.

• Replace the engine wiring harness. Refer toProcedure 019-043 in Section 19.

• Call for authorization to replace the ECM.Upon receipt of authorization, replace theECM. Refer to Procedure 019-031 in Section19.

5A


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STEP 3B: Check for an open circuit.

Condition:• Turn keyswitch OFF.• Disconnect the engine wiring harness from the ECM.• Disconnect the engine wiring harness from the injection control valve.


Check for an open circuit in the injection controlvalve circuit of the engine harness.• Measure the resistance from pin 7 of the engine

wiring harness to pin 1 of the injection controlvalve connector.

• Measure the resistance from pin 6 of the enginewiring harness to pin 2 of the injection controlvalve connector.


OK

Less than 10 ohms.

3C

NOT OK

Replace the engine wiring harness. Refer toProcedure 019-043 in Section 19.

5A


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STEP 3C: Check for a short circuit to ground.



Check for a short circuit to ground.• Measure the resistance from pin 6 of the engine

wiring harness connector to chassis ground.• Measure the resistance from pin 7 of the engine

wiring harness connector to chassis ground.


OK


3D

NOT OK 3C-1

STEP 3C-1: Check for a short circuit to ground.

Condition:• Turn keyswitch OFF.• Disconnect the engine wiring harness from the ECM.• Disconnect the engine wiring harness from the injection control valve stator.• Disconnect the transient suppressor.


Check for a short circuit to ground.• Measure the resistance from pin 6 of the engine

wiring harness connector to chassis ground.• Measure the resistance from pin 7 of the engine

wiring harness connector to chassis ground.

OK


Replace the transient suppressor.• Refer to Procedure 019-184 in Section 19.

5A

NOT OK

Replace the engine wiring harness.• Refer to Procedure 019-043 in Section 19.

5A


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STEP 3D: Check for a short circuit from pin-to-pin.



Check for a short circuit from pin to pin.• Measure the resistance from pin 6 of the engine

wiring harness connector to all other pins in theconnector and to the transient suppressor case.

• Measure the resistance from pin 7 of the enginewiring harness connector to all other pins in theconnector and to the transient suppressor case.


OK


4A

NOT OK

• Short circuit from pin 6 to pin 7 or totransient suppressor case. Replace thetransient suppressor. Refer to Procedure019-184 in Section 19.

• Short circuit from pin 6 or pin 7 to any otherpins. Replace the engine wiring harness.Refer to Procedure 019-043 in Section 19.

5A


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STEP 4: Check the ECM ground circuit.STEP 4A: Check the negative (-) battery connection for corrosion.

Condition:• Turn keyswitch ON.


Check the negative (-) battery connection forcorrosion and that all connections are tight.

Check the negative (-) battery connection forcorrosion and that all connections are tight.

OK

Connection is tight and corrosion free.

4B

NOT OK

Tighten the connection.• Tighten the loose connection and clean the

terminal. Refer to the OEM service manual.

5A


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STEP 4B: Check the resistance of the ECM ground circuit.

Condition:• Turn keyswitch OFF.• Disconnect the engine wiring harness from the ECM.


Check for an open circuit in the ECM groundcircuits.• Measure the resistance from pin 20 to the

negative (-) battery terminal.• Measure the resistance from pin 28 to the



negative (-) battery terminal.


OK

Less than 10 ohms.

Replace the injection control valve module.Use the following procedure in theTroubleshooting and Repair Manual, ISC,ISCe, QSC8.3, ISL and QSL9 Engines, Bulletin4021418. Refer to Procedure 005-078 inSection 5.

5A

NOT OK

Ground wire open in either engine or OEMharness.

4C


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STEP 4C: Inspect the 23-pin OEM connector.

Condition:• Turn keyswitch OFF.• Disconnect the engine wiring harness from the battery supply at the 23-pin OEM connector.


Inspect the 23-pin OEM connector on both thebattery side and harness side for the following:• Loose connector• Corroded pins• Bent or broken pins• Pushed back or expanded pins• Moisture in or on the connector• Missing or damaged connector seals• Dirt or debris in or on the connector pins• Connector shell broken• Wire insulation damage• Damaged connector locking tab.


OK

No damaged pins or loose connections.

4D

NOT OK

Repair or replace the damaged pins.

Refer to Procedure 019-207 in Section 19.

5A


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STEP 4D: Check the resistance of the OEM ground circuit.

Condition:• Turn keyswitch OFF.• Disconnect the engine wiring harness from the 23-pin Deutsch™ connector.


Check the resistance of the OEM ground circuit.• Measure the resistance from pins E, F, H, P, and

W of the battery return connector to thenegative (-) battery terminal.


OK

Less than 10 ohms.

Replace the engine wiring harness. Refer toProcedure 019-043 in Section 19.

5A

NOT OK

Repair or replace the OEM wiring harness.

5A

STEP 5: Clear the fault codes.STEP 5A: Disable the fault code.



Disable the fault code.• Start the engine and let it idle for 1 minute, then

increase the engine rpm above 1800 rpm, thengo back to idle three consecutive times.

• Use INSITE™ electronic service tool to verifyFault Code 276 is inactive.

OK

Fault Code 276 inactive.

5B

NOT OK

Return to the troubleshooting steps or contacta Cummins® Authorized Repair Location if allsteps have been completed and checkedagain.

1A


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STEP 5B: Clear the inactive fault codes.



Clear the inactive fault codes.• Use INSITE™ electronic service tool to clear the

inactive fault codes.

OK

All fault codes cleared.

Repaircomplete

NOT OK

Troubleshoot any remaining active faultcodes.

Appropriatetroubleshooting chart


File: 71-t05-276 of 15

steps specifications srt code step 1: check the ......2011/09/01 · step 2b: check the resistance...

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