Code 386 Repair

7/28/2019 Code 386 Repair

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Associated Procedures

Troubleshooting Steps

FAULT CODE

STEPS SPECIFICATIONS

STEP 1. Check the fault codes.

STEP 1A. Check to see if the faultcode is active at engine start-up.

Fault Code 368 inactive

STEP 2. Perform low pressure systemchecks.

STEP 2A. Install the gauges andrecord inlet restriction findings. Restriction less than 152 mm Hg [6 inHg]

STEP 2B. Install the gauges andrecord fuel pressure findings.

Fuel pressure at fuel filter inlet less than34 kPa [5 psi]

STEP 2C. Install the gauges andrecord air in fuel findings.

No air found in fuel

STEP 2D. Install the gauges andrecord fuel displacement findings.

Fuel in bucket is greater than 1.33 liters[1.4 qt]

STEP 2E. Check the lift pump

supply voltage.

Battery voltage 2 VDC

STEP 3. Verify the inlet restriction and checkfor air in the fuel when loaded.

STEP 3A. Verify the inlet restrictionwith the engine loaded.

Restriction less than 152 mm Hg [6 inHg]

STEP 3B. Verify there is no air inthe fuel system with the engineloaded.

No air found in the fuel

STEP 3C. Verify the fuel pressure

at the fuel filter outlet with theengine loaded.

Fuel pressure greater than 14 kPa [2

psi]

STEP 4. Remove and inspect the overflowvalve.

STEP 4A. Remove and inspect theoverflow valve.

Overflow valve clean

STEP 5. Measure the drain line restriction.

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10/5/2010mk:@MSITStore:C:\Intelect\INSITE\FIS\FIS3666194.chm::/procedures/80-t05-368.htm


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Guided Step 1 - Check the fault codes.

Guided Step 1A - Check to see if the fault code is active at engine start-up.

STEP 5A. Install a pressure gaugein the drain line.

Pressure less than 69 kPa [10 psi]

STEP 6. Check the fuel pump static timing.

STEP 6A. Check the fuel pumpgear.

Pump gear correctly engaged withcamshaft gear and key undamaged

STEP 6B. Check the fuel pumpgear key in use.

Key is correct and installed correctly

STEP 7. Clear the fault codes.

STEP 7A. Disable the fault code. Fault Code 368 inactive

STEP 7B. Clear the inactive faultcodes.

All fault codes cleared?

Conditions

Turn keyswitch ON.

Action

Check to see if the fault code is active atengine start-up.

Use INSITE electronic service tool toread active fault codes.

Note: If Fault Code 368 is inactive, but otherfault codes are active, troubleshoot theactive fault codes.

OK NOT OK

Fault Code 368 inactive Fault Code 368 active and no other activefault codes present

Appl icable fault code(s) Go to 2A

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Guided Step 2 - Perform low pressure system checks.

Guided Step 2A - Record findings for in let restriction.

Conditions

Turn keyswitch OFF.

Action

Install a restriction gauge at the lift pumpinlet.

Install a pressure gauge at the fuel filterinlet.

Refer to Procedure 005-045 (Fuel Lift Pump)in Section 5 in the Troubleshooting andRepair Manual, ISB and QSB5.9 Engines,Bulletin 3666193.

Install a clear line at the fuel filter outlet andrun the line into a bucket.

With gauges and the clear line in place,bump the starter and leave the keyswitchON. The lift pump will run for 25 to 30seconds. While the lift pump is running,record the inlet restriction.

Note: Steps 2A through 2D can be observedand recorded with a single bump of thestarter.

OK NOT OK

Restriction less than 152 mm Hg [6 in Hg] Inlet restriction greater than 152 mm Hg [6 inHg]

Find source of excessive restriction betweenthe lift pump inlet and fuel tank.

Fix the source of excessive restriction.

Go to 2B Go to 7A

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Guided Step 2B - Install the gauges and record fuel pressure findings.

Guided Step 2C - Install the gauges and record air in fuel findings.

Conditions

Turn keyswitch OFF.

Action

With gauges and the clear line in place (asin Step 2A), bump the starter and leave thekeyswitch ON.

The lift pump will run for 25 to 30 seconds.While the lift pump is running, record the fuelpressure at the fuel filter inlet.

OK NOT OK

Fuel pressure at fuel filter inlet less than 34kPa [5 psi]

Fuel pressure at fuel filter inlet is greater than34 kPa [5 psi].

Fuel filter is restricted.

Replace the filter and recheck.

Go to 2C Go to 7A

Conditions

Turn keyswitch OFF.

Action

With gauges and the clear line in place (as

in Step 2A), bump the starter and leave thekeyswitch ON.

The lift pump will run for 25 to 30 seconds.While the lift pump is running, record if air isfound in the fuel system.

OK NOT OK

No air found in the fuel Air in fuel detected.

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Guided Step 2D - Install the gauges and record fuel displacement findings.

Guided Step 2E - Check the lif t pump supply voltage.

Find the source of air between the lift pumpinlet and fuel tank.

Go to 2D Go to 7A

Conditions

Turn keyswitch OFF.

Action

With gauges and the clear line in place (asin Step 2A), bump the starter and leave thekeyswitch ON.

The lift pump will run for 25 to 30 seconds.While the lift pump is running, record theamount of fuel in the bucket after the liftpump has stopped running.

OK NOT OK

Fuel in bucket is greater than 1.33 liters [1.4qt]

Fuel in bucket is less than 1.33 liter [1.4 qt]

Go to 3A Go to 2E

Conditions

Disconnect the lift pump from the

engine harness. Turn keyswitch ON.

Action

Check the lift pump voltage supply.

Disconnect the lift pump from theengine harness, after bumping thestarter, use a multimeter to measure

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Guided Step 3 - Verify the inlet restriction and check for airin the fuel when loaded.

Guided Step 3A - Verify the inlet restrict ion with the engine loaded.

the voltage at pin 1 (engine harness,lift pump connector).

Note: Lift pump will run for only 25 to 30seconds after bumping the starter.

OK NOT OK

Battery voltage 2 VDC

Replace the lift pump. Refer to Procedure005-045 (Fuel Lift Pump) in Section 5 in theTroubleshooting and Repair Manual, ISB andQSB5.9 Engines, Bulletin 3666193.

Inspect the voltage supply circuit.

Go to 7A Go to 7A

Conditions

Turn keyswitch OFF.

Action

Install a restriction gauge at the lift pumpinlet.

Install the clear line between the fuel filteroutlet and VP44.

Install a pressure gauge at the fuel filteroutlet. Refer to Procedure 005-045 (Fuel LiftPump) in Section 5 in the Troubleshootingand Repair Manual, ISB and QSB5.9Engines, Bulletin 3666193.

With the gauges and the clear line in place,start the engine and put it under a load.Monitor and record the inlet restriction when

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Guided Step 3B - Verify there is no air in the fuel system with the engineloaded.

Guided Step 3C - Verify the fuel pressure at the fuel filter outlet with the

Fault Code 368 is active.

Note: Steps 3A through 3C can be observedand recorded with a single bump of thestarter.

OK NOT OK

Inlet restriction less than 152 mm Hg [6 in Hg] Inlet restriction greater than 152 mm Hg [6 inHg]

Find source of excessive restriction betweenthe lift pump inlet and fuel tank.

Fix the source of excessive restriction.

Go to 3B Go to 7A

Conditions

Turn keyswitch OFF.

Action

With the gauges and the clear line in place(as in Step 3A) start the engine and put itunder load.

Monitor the clear line to see if there is anyair in the fuel system when Fault Code 368is active.

OK NOT OK

No air found in the fuel Air in fuel detected

Find the source of air between the lift pumpinlet and the fuel tank.

Go to 3C Go to 7A

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engine loaded.

Guided Step 4 - Remove and inspect the overflow valve.

Guided Step 4A - Remove and inspect the overflow valve.

Conditions

Turn keyswitch OFF.

Action

With the gauges and the clear line in place(as in Step 3A), start the engine and put itunder load.

Monitor and record the fuel pressure at thefuel filter outlet when Fault Code 368 isactive.

OK NOT OK

Fuel pressure greater than 14 kPa [2 psi] Fuel pressure less than 14 kPa [2 psi]

Go to 6A Go to 4A

Conditions

Turn keyswitch OFF.

Action

Remove and inspect the overflow valve.

Refer to Procedure 006-044 (Fuel Return

Overflow Valve) in Section 6 in theTroubleshooting and Repair Manual, ISBand QSB5.9 Engines, Bulletin 3666193.

OK NOT OK

Overflow valve clean Clean or replace overflow valve.

Go to 5A Go to 7A

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Guided Step 5 - Measure the drain l ine restriction.

Guided Step 5A - Install pressure gauge in the drain line.

Guided Step 6 - Check the fuel pump static timing.

Guided Step 6A - Check the fuel pump gear.

Conditions

Turn keyswitch OFF.

Action

Install pressure gauge in the drain line.

Refer to Procedure 006-012 (Fuel Drain LineRestriction in Section 6 in theTroubleshooting and Repair Manual, ISBand QSB5.9 Engines, Bulletin 3666193.

Run the engine at high idle.

OK NOT OK

Pressure less than 69 kPa [10 psi] Pressure greater than 69 kPa [10 psi]

Find the source of restriction in the drain line.

Check for bends or kinks.

Go to 6A Go to 7A

Conditions

Turn keyswitch OFF.

Action

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Guided Step 6B - Check the fuel pump gear key in use.

Review the vehicle claim history.

Before proceeding with Step 6, reviewthe vehicle claim history. If the vehiclehas accumulated over severalthousand miles without any engine

problems, service checks, or pumpreplacement, before developing FaultCode 368, then proceed to Step 7.

Check the fuel pump gear.

Verify the timing marks on the geartrain are aligned with the engine at topdead center (TDC). Refer to Procedure005-037 (Fuel Pump Timing) inSection 5 in the Troubleshooting andRepair Manual, ISB and QSB5.9Engines, Bulletin 3666193.

Verify the gear key is properly alignedin the center of the keyway and is notdamaged.

OK NOT OK

Pump gear correctly engaged with camshaftgear and key undamaged

Pump gear incorrectly engaged with camshaftgear or key damaged

Correct engagement or replace damagedkey.

Go to 6B Go to 7A

Conditions

Turn keyswitch OFF.

Action

Check the fuel pump gear key in use.

Verify the key number inscribed on thekey matches the number inscribed onthe fuel pump data plate.

Verify the key is installed with the

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Guided Step 7 - Clear the fault codes.

Guided Step 7A - Disable the fault code.

Guided Step 7B - Clear the inactive fault codes.

arrow facing the pump.

OK NOT OK

Key is correct and installed correctly Key is incorrect or installed incorrectly

Install correct key or install key correctly.

Go to 7A Go to 7A

Conditions

Connect all components. Turn keyswitch ON. Connect INSITE electronic service

tool.

Action

Disable the fault code.

Start the engine and road-test for 30minutes.

Use INSITE electronic service tool toverify that Fault Code 368 is inactive.

OK NOT OK

Fault Code 368 inactive Fault Code 368 active

Replace VP44 Injection Pump. If injectionpump is still under warranty and pre-authorization is required contactRAPIDSERVE for authorization.

Go to 7B Go to 7B

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Last Modified: 29-Jul-2010

Copyright 2000-2009 Cummins Inc. All rights reserved.

Conditions

Connect all components. Turn keyswitch ON.

Action

Clear the inactive fault codes.

Use INSITE electronic service tool toclear the inactive fault codes.

OK NOT OK

All fault codes cleared Troubleshoot any remaining active faultcodes

Repair complete Appropriate troubleshooting chart

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Code 386 Repair

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