Symptoms Control System with CAPS Fuel System Engine ... · Start by performing Step 1...

4/27/2019 QuickServe Online | (3666271) ISC, QSC8.3, and ISL Electronic Control System Troubleshooting and Repair Manual

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Engine Performance Troubleshooting Tree - CM554 ElectronicControl System with CAPS Fuel System

Symptoms

How To Use This Tree

Shoptalk

Engine Acceleration or Response Poor

Cranking Fuel Pressure is Low

Engine Operating Fuel Pressure is Low

Engine Decelerates Slowly

Engine Difficult to Start or Will Not Start (Exhaust Smoke)

Engine Difficult to Start or Will Not Start (No Exhaust Smoke)

Engine Power Output Low

Engine Runs Rough at Idle

Engine Runs Rough or Misfires

Engine Speed Surges at Low or High Idle

Engine Speed Surges Under Load or in Operating Range

Engine Shuts Off or Dies Unexpectedly or Dies During Deceleration

Engine Starts but Will Not Keep Running

Engine Will Not Reach Rated Speed (RPM)

Intake Manifold Pressure (Boost) is Below Normal

This symptom tree can be used to troubleshoot all performance based symptoms listed above.Start by performing Step 1 troubleshooting. Step 2 will ask a series of questions and will providea list of troubleshooting steps to perform depending on the symptom. Perform the list oftroubleshooting in the sequence shown in the Specifications/Repair section of the tree.

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Troubleshooting Summary

Driveability is a term that in general describes vehicle performance on the road. Driveabilityproblems for an engine can be caused by several different factors. Some of the factors areengine-related and some are not. Before troubleshooting it is important to determine the exactcomplaint and whether the engine has a real driveability problem or if it simply does not meetdriver expectations.

Low power is a term that is used in the field to describe many different performance problems.Low power is defined as the inability of the engine to produce the power necessary to move thevehicle at a speed that can be reasonably expected under the given conditions of load, grade,wind, and so on.

Poor acceleration or response is described as the inability of the vehicle to acceleratesatisfactorily from a stop or from the bottom of a grade. It can also be the lag in accelerationduring an attempt to pass or overtake another vehicle at conditions less than rated speed andload. Poor acceleration or response is difficult to troubleshoot since it can be caused by severalfactors.

STEPS SPECIFICATIONSSTEP 1. Perform basic troubleshooting

procedures.STEP 1A. Check for activefault codes or high counts ofinactive fault codes.

Active fault codes or highcounts of inactive faultcodes?

STEP 1B. Perform basictroubleshooting checks.

All steps have been verified tobe correct?

STEP 2. Determination of enginesymptom.STEP 2A. Low power, pooracceleration, or poorresponse.

Is the engine symptom lowpower, poor acceleration, orpoor response?

STEP 2B. Engine misfire,engine speed surge, orengine speed unstable.

Is the engine symptom enginemisfire, engine speed surge,or engine speed unstable?

STEP 2C. Excessive white orblack smoke.

Is the engine symptomexcessive white or blacksmoke?

STEP 2D. Low intakemanifold pressure.

Is the engine symptom lowboost pressure?



STEPS SPECIFICATIONSSTEP 2E. Engine will not startor difficult to start, or engineshuts off unexpectedly.

Is the symptom engine willnot start or difficult to start, orengine shuts offunexpectedly?

STEP 3. No-start troubleshootingprocedures.STEP 3A. Check the ECMkeyswitch voltage.

Is the keyswitch voltage equalto battery voltage?

STEP 3B. Check the ECMbattery supply voltage.

Is the ECM battery supplyvoltage equal to the batteryvoltage?

STEP 3C. Verify the operationof cold weather starting aids.

If equipped, are cold weatherstarting aids operatingcorrectly?

STEP 3D. Check the fuel liftpump pressure.

Is the fuel lift pump pressuregreater than the specificationsoutlined in Procedure 005-045 in Section 5 in the ISC,ISCe, QSC8.3, ISL and QSL9Engines Troubleshooting andRepair Manual, Bulletin4021418?

STEP 3E. Verify fuel pressuresensor accuracy.

Is the accumulator pressurevalue less than 34.5 bar [500psi]?

STEP 3F. Check theaccumulator pressure.

Is accumulator pressuregreater than 293 bar [4250psi] while cranking?

STEP 3G. Use INSITE™electronic service tool tocheck the CPS crank state.

Does CPS state read ValidSync while cranking?

STEP 3G-1. Check andadjust speed/position sensorair gap.

Are the sensor(s) depthmeasurements withinspecification?



STEPS SPECIFICATIONSSTEP 3H. Measure gearpump pressure.

Is the fuel gear pumppressure greater than thespecifications outlined inProcedure 005-089 in Section5 in the ISC, ISCe, QSC8.3,ISL and QSL9 EnginesTroubleshooting and RepairManual, Bulletin 4021418?

STEP 3I. Perform theinjection control valve (IVC)click test.

Does the injection controlvalve pass the click test?

STEP 3J. Perform thepumping control valve (PCV)click test.

Do the pumping controlvalves pass the click test?

STEP 3K. Check thedistributor rotor timing.

Distributor rotor timing iscorrect as outlined inProcedure 005-072 in Section5 in the ISC, ISCe, QSC8.3,ISL and QSL9 EnginesTroubleshooting and RepairManual, Bulletin 4021418?

STEP 3L. Inspect the gearpump coupling for wear.

Is the gear pump drive shaftor coupling worn?

STEP 4. Fuel system troubleshootingprocedures.STEP 4A. Check for faultcodes.

Are fuel system fault codesactive?

STEP 4B. Check the CAPSfuel pump wiring.

All fuel pump wiring isundamaged and is properlyconnected?

STEP 4C. Check transorbdiode.

Does the rough running, blacksmoke, or surge complaintcontinue?

STEP 4D. Check for air in thehigh-pressure pump fuelsupply.

Is air present in the fuelsupply?



STEPS SPECIFICATIONSSTEP 4E. Measure the fuelinlet restriction.

Is the fuel inlet restriction lessthan the specificationsoutlined in Procedure 006-020 (Fuel Inlet Restriction) inthe ISC, ISCe, QSC8.3, ISLand QSL9 EnginesTroubleshooting and RepairManual, Bulletin 4021418?

STEP 4F. Measure the fuelgear pump pressure.

Is the fuel gear pumppressure greater than thespecifications outlined inProcedure 005-089 (FuelPump Gear Pump Module) inthe ISC, ISCe, QSC8.3, ISLand QSL9 EnginesTroubleshooting and RepairManual, Bulletin 4021418?

STEP 4G. Perform theinjection control valve clicktest.


STEP 4H. Perform thepumping control valve clicktest.


STEP 4I. Measure fuel drainline restriction.

Is the drain line restrictionless than specification?

STEP 4J. Perform the singlecylinder cutout test.

Can the miss or excessivesmoke be attributed to asingle cylinder?

STEP 4K. Verify the fueltemperature sensor is withinspecification.

Is the fuel temperature sensorwithin specification?

STEP 4L. Check forexcessive injector drainleakage.

Are only a few drops of fuelper minute draining from theback of the cylinder head?

STEP 4M. Pop test theinjectors.

The injector spray pattern iscorrect and the injectors popbetween 275 and 300 bar[3989 and 4351 psi]?

STEP 4N. Inspect the gearpump coupling for wear.




STEPS SPECIFICATIONSSTEP 5. Air handling troubleshooting

procedures.STEP 5A. Inspect theturbocharger blades fordamage.

Damage found onturbocharger blades?

STEP 5B. Check theturbocharger axial and radialclearances.

Are the turbocharger axialand radial bearing clearanceswithin specification?

STEP 5C. Inspect thewastegate actuator rod fortravel.

Does the wastegate actuatorrod move?

STEP 5C-1. Inspect thewastegate actuator rod fortravel.

Does the wastegate actuatorrod move?

STEP 6. Electronic featuretroubleshooting procedures.STEP 6A. Verify throttle pedaltravel.

Does the throttle position readzero when the throttle isreleased and 100 percentwhen the throttle isdepressed?

STEP 6B. Check ambient airpressure sensor accuracy (ifequipped).

Is the reading within 50.8mm-Hg [2 in-Hg] of localbarometric pressure?

STEP 6C. Check intakemanifold pressure sensoraccuracy.

Is the intake manifoldpressure reading less than102 mm-Hg [4 in-Hg]?

STEP 6D. Verify electronicfeature settings are correct.

Are the electronic features setcorrectly?

STEP 7. Base engine troubleshootingprocedures.STEP 7A. Verify overheadadjustments are correct.

Are the overhead settingswithin the reset limits?

STEP 7B. Verify engine brakeadjustment (if equipped).

Are the engine brake settingswithin the reset limits?

STEP 7C. Inspect the chargeair cooler.

Is the charge air cooler free ofcracks, holes, or otherdamage?



STEP 1. Perform basic troubleshooting procedures.

STEP 1A. Check for active fault codes or high counts of inactive fault codes.

STEP 1B. Perform basic troubleshooting checks.

STEPS SPECIFICATIONSSTEP 7D. Check air intakerestriction.

Is air intake restriction greaterthan 635 mm-H 2O [25 in-H2O]?

STEP 7E. Check exhaustrestriction.

Is exhaust back pressure lessthan 72 mm-Hg [3 in-Hg]?

STEP 7F. Check engineblowby.

Are the engine blowbymeasurements withinspecification?

STEP 7F-1. Verifyturbocharger contribution toengine blowby.

Has the total engine blowbydropped more than 30percent of the total?

Conditions : Turn keyswitch ON.

Connect INSITE™ electronic service tool.

Action Specification/Repair Next Step

Check for active fault codes.

Use INSITE™electronic service toolto read the fault codes.


YES

Go to appropriate faultcode troubleshootingprocedures.


NO

1B

Conditions : None.




STEP 2. Determination of engine symptoms.

STEP 2A. Low power, poor acceleration, or poor response.

The following items must bechecked or verified beforecontinuing:

Verify the fuel level inthe tanks, regardless ofwhat the gauge reads.

Verify there have notbeen any changes toCPL components onthe engine.

Verify fuel grade iscorrect for theapplication.

Verify the engine isoperating within therecommended altitude.

Verify engine oil is atthe correct level.

Verify engine parasiticshave not changed.

Verify engine duty cyclehas not changed.

Verify engine crankingspeed is greater than150 rpm.

Verify battery voltage isadequate.

All steps have been verifiedto be correct?

YES2A

All steps have been verifiedto be correct?

NO Repair :

Correct the failure and verifycomplaint is no longerpresent after repair.

Repair complete

Conditions : None.




STEP 2B. Engine misfire, engine speed surge, or engine speed unstable.

Interview driver and verify thecomplaint.


YES Repair :

Perform the troubleshootingsteps in the recommendedorder listed below:

Step 4 - Fuel systemchecks

Step 5 - Air handlingchecks

Step 6 - Electronicschecks

Step 7 - Base enginechecks.

Perform thetroubleshooting stepssuggested in the repairprocedure


NO

2B

Conditions : None.




STEP 2C. Excessive white or black smoke.


Is the engine symptomengine misfire, enginespeed surge, or enginespeed unstable?

YES Repair :


Step 4 - Fuel systemchecks

Step 5 - Air handlingchecks

Step 6 - Electronicschecks

Step 7 - Base enginechecks.

Perform thetroubleshooting stepssuggested in the repairprocedure.

Is the engine symptomengine misfire, enginespeed surge, or enginespeed unstable?

NO

2C

Conditions : None.




STEP 2D. Low intake manifold pressure.

Interview the driver and verifythe complaint.


YES Repair :


Step 5 - Air HandlingChecks

Step 4 - Fuel SystemChecks

Step 7 - Base EngineChecks.



NO

2D

Conditions : None.




STEP 2E. Engine will not start or difficult to start, engine shuts off unexpectedly.


Is the engine symptom LowBoost Pressure?

YES Repair :


Step 5 - Air HandlingChecks

Step 4 - Fuel SystemChecks

Step 7 - Base EngineChecks.


Is the engine symptom LowBoost Pressure?

NO2E

Conditions : None.




STEP 3. No-start troubleshooting procedures.

STEP 3A. Check the ECM keyswitch voltage.


Is the symptom engine willnot start or difficult to start,or engine shuts offunexpectedly?

YES Repair :


Step 3 - No StartChecks

Step 4 - Fuel System

Checks Step 7 - BaseEngine

Checks Step 5 - AirHandling

Checks Step 6 -Electronics Checks.


Is the symptom engine willnot start or difficult to start,or engine shuts offunexpectedly?

NO

Return to correct symptomtree.

Conditions : Disconnect the OEM harness from the ECM.

Turn keyswitch ON




STEP 3B. Check the ECM battery supply voltage.

STEP 3C. Verify the operation of cold weather starting aids.

Measure the signal voltagefrom the keyswitch inputSIGNAL wire of the OEMharness to the engine blockground.

Measure the keyswitchvoltage with the keyswitch inthe ON position and alsowith the keyswitch in theSTART position.

Reference the wiringdiagram for connector pinidentification.

Is the keyswitch voltageequal to battery voltage?

YES3B

Is the keyswitch voltageequal to battery voltage?

NO Repair :

Repair or replace the OEMpower harness or keyswitch,or check the batteryconnections.

Repair complete

Conditions : Turn the keyswitch ON.

Disconnect connector 2 from the ECM


Measure the voltage from theECM battery supply (+) to theECM battery supply (-) pins inthe OEM harness connector.

Reference the wiringdiagram for connectorpin identification.


YES

3C


NO Repair :

Repair or replace the ECMpower harness. Check thebattery connections andfuse terminals.

Repair complete



STEP 3D. Check the fuel lift pump pressure.

Conditions : None.


Make sure the intake airheater and other cold startingaids are operational, ifequipped.

Refer to Procedure 008-011(/qs3/pubsys2/xml/en/procedures/45/45-008-011-tr.html)in Section 8, in the ISC,ISCe, QSC8.3, ISL andQSL9 Troubleshooting andRepair Manual, Bulletin4021418.


If equipped, are coldweather starting aidsoperating correctly?

YES

3D

If equipped, are coldweather starting aidsoperating correctly?

NO Repair :

Repair cold weather startingaids.


Repair complete

Conditions : Refer to Procedure 005-045 (/qs3/pubsys2/xml/en/procedures/45/45-005-045-tr.html) inSection 5, in the ISC, ISCe, QSC8.3, ISL and QSL9 Troubleshooting and Repair Manual,Bulletin 4021418.

Action Specification/Repair Next StepMeasure the fuel lift pumpoutput pressure.

Refer to Procedure 005-045(/qs3/pubsys2/xml/en/procedures/45/45-005-045-tr.html)in Section 5, in the ISC,ISCe, QSC8.3, ISL and

Is the fuel lift pump pressuregreater than thespecifications outlined?

YES

3E

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STEP 3E. Verify fuel pressure sensor accuracy.

QSL9 Troubleshooting andRepair Manual, Bulletin4021418.

Is the fuel lift pump pressuregreater than thespecifications outlined?

NO Repair :

Find and repair the cause oflow lift pump pressure.Refer to Procedure 005-045(/qs3/pubsys2/xml/en/procedures/45/45-005-045-tr.html)in Section 5, in the ISC,ISCe, QSC8.3, ISL andQSL9 Troubleshooting andRepair Manual, Bulletin4021418.

Repair complete




Use INSITE™ electronicservice tool to monitoraccumulator pressure.

The engine speed must bezero for at least 1 minutebefore performing this test.

Is the accumulator pressurevalue less than 34.5 bar[500 psi]?

YES

3F

Is the accumulator pressurevalue less than 34.5 bar[500 psi]?

NO Repair :

Replace the fuel pressuresensor. Reference ServiceBulletin, CAPS FuelPressure Sensor Kit,4021293 or 4021294.

Repair complete




STEP 3F. Check the accumulator pressure.

STEP 3G. Use INSITE™ electronic service tool to check the CPS crank state.

STEP 3G-1. Check and adjust the speed/position sensor air gap.




Use INSITE™ electronicservice tool to readaccumulator pressure whilecranking the engine.


YES

3L


NO

3G

Conditions : Connect INSITE™ electronic service tool.

Turn keyswitch ON.


Check ignition coils.

Use INSITE™ electronicservice tool to monitor CPSstate while cranking theengine.


YES3H


NO Repair :

Troubleshoot the enginespeed sensor circuit. SeeFault Codes 115 and 121.

3G-1

Conditions : Install the sensors.



Action Specification/Repair Next StepCheck and adjust thespeed/position sensor airgap.

Check the air gapbetween the ESS/EPSand the camshaft ringgear. Since the EPSand ESS are mountedon the same boss, theair gap can bemeasured using theoutside sensor bore.This measurement canusually be taken withoutremoving the aircompressor.

Bar the engine over 2full revolutions (clockwise facing thefront of the engine).

Use a depth micrometerand measure thedistance from the faceof the gear housingboss to the face of thecamshaft ring gear.Record thismeasurement “A”.

Measure the gap in 45degree camshaftrotation increments. Ifthe measurements “A”varies by more than0.051 mm [0.002 in] thetone wheel is warped,or the camshaft gear iswalking.

Next measure thesensor. Use a depthmicrometer to measure


YES

3H


NO Repair :

Replace the enginespeed/position sensor(s).

Refer to Procedure 019-042(/qs3/pubsys2/xml/en/procedures/71/71-019-042.html)in Section 19, ISC, QSC8.3,and ISL Electronic ControlSystem, Troubleshootingand Repair Manual, Bulletin3666271.

Repair complete

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STEP 3H. Measure gear pump pressure.

the distance from thebottom of the sensormounting flange to thetip of the threaded endof the sensor. Recordthis as measurement“B”. The air gap can becalculated bysubtracting B from A(air gap measurementequals A minus B). Ifthe air gap is less than0.406 mm [0.016 in]add a 0.508 mm [0.020in] shim to sensor.

Minimum Air Gap:0.406 mm [0.016 in]

Maximum Air Gap:1.020 mm [0.040 in]

Conditions : Connect a fuel pressure gauge to the Compuchek™ fitting on the cam housing.




STEP 3I. Perform the injection control valve (ICV) click test.

Measure the gear pumppressure while cranking theengine.

Refer to Procedure 005-089(/qs3/pubsys2/xml/en/procedures/45/45-005-089.html)in Section 5, in the ISC,ISCe, QSC8.3, ISL andQSL9 Troubleshooting andRepair Manual, Bulletin4021418.

Is the fuel gear pumppressure greater than thespecifications. Refer toProcedure 005-089(/qs3/pubsys2/xml/en/procedures/45/45-005-089.html)in Section 5, in the ISC,ISCe, QSC8.3, ISL andQSL9 Troubleshooting andRepair Manual, Bulletin4021418?

YES Repair :

Use the following procedurein the C8.3G, C Gas Plus,and L Gas Plus EnginesTroubleshooting and RepairManual, Bulletin 3666206.Refer to Procedure 013-016in Section 13.(/qs3/pubsys2/xml/en/procedures/107/107-013-016.html)

3I

Is the fuel gear pumppressure greater than thespecifications. Refer toProcedure 005-089(/qs3/pubsys2/xml/en/procedures/45/45-005-089.html)in Section 5, in the ISC,ISCe, QSC8.3, ISL andQSL9 Troubleshooting andRepair Manual, Bulletin4021418?

NO

3K







STEP 3J. Perform the pumping control valve (PCV) click test.


Turn the keyswitch ON


Use INSITE™ electronicservice tool to perform theICV click test.



YES Repair :

Follow the electronic faultcode trees for theappropriate troubleshootingprocedure.

3J


NO Repair :

Replace the injection controlvalve stator. Refer toProcedure 019-430(/qs3/pubsys2/xml/en/procedures/71/71-019-430.html)in Section 19, in theElectronic Control SystemISC, QSC8.3, and ISLTroubleshooting and RepairManual, Bulletin 3666271.

Repair complete


Turn keyswitch ON.






STEP 3K. Check the distributor rotor timing.

Use INSITE™ electronicservice tool to perform thefront and rear PCV test.



YES Repair :

Replace the injection controlvalve module. Refer toProcedure 005-086(/qs3/pubsys2/xml/en/procedures/45/45-005-086.html)in Section 5, in the ISC,ISCe, QSC8.3, ISL andQSL9 Troubleshooting andRepair Manual, Bulletin4021418.

Repair complete


NO Repair :

Replace the accumulatormodule. Refer to Procedure005-085(/qs3/pubsys2/xml/en/procedures/45/45-005-085.html)in Section 5, in the ISC,ISCe, QSC8.3, ISL andQSL9 Troubleshooting andRepair Manual, Bulletin4021418.

Repair complete

Conditions : Turn keyswitch OFF.







STEP 3L. Inspect the gear pump coupling for wear.

Inspect the distributor rotortiming and check for a seizedrotor.


Distributor rotor timing iscorrect as outlined. Refer toProcedure 005-072(/qs3/pubsys2/xml/en/procedures/45/45-005-072.html)in Section 5, in the ISC,ISCe, QSC8.3, ISL andQSL9 Troubleshooting andRepair Manual, Bulletin4021418?

YES

3L

Distributor rotor timing iscorrect as outlined. Refer toProcedure 005-072(/qs3/pubsys2/xml/en/procedures/45/45-005-072.html)in Section 5, in the ISC,ISCe, QSC8.3, ISL andQSL9 Troubleshooting andRepair Manual, Bulletin4021418?

NO Repair :

Replace the fuel injectionpump. Refer to Procedure005-229(/qs3/pubsys2/xml/en/procedures/45/45-005-229.html)in Section 5, in the ISC,ISCe, QSC8.3, ISL andQSL9 Troubleshooting andRepair Manual, Bulletin4021418.

Repair complete


Remove the gear pump module.







STEP 4. Fuel system troubleshooting procedures.

STEP 4A. Check for fault codes.


Inspect the gear pump driveshaft coupling and shaft forwear.

Refer to Procedure 005-089(/qs3/pubsys2/xml/en/procedures/45/45-005-089.html)in Section 5 in the ISC,ISCe, QSC8.3, ISL andQSL9 Troubleshooting andRepair Manual, Bulletin4021418.


YES Repair :

Replace the gear pumpmodule. Refer to Procedure005-089(/qs3/pubsys2/xml/en/procedures/45/45-005-089.html)in Section 5, in the ISC,ISCe, QSC8.3, ISL andQSL9 Troubleshooting andRepair Manual, Bulletin4021418.

Repair complete


NO Repair :

Replace the injection controlvalve. Refer to Procedure005-086(/qs3/pubsys2/xml/en/procedures/45/45-005-086.html)in Section 5, in the ISC,ISCe, QSC8.3, ISL andQSL9 Troubleshooting andRepair Manual, Bulletin4021418.

Repair complete






STEP 4B. Check the CAPS fuel pump wiring.

STEP 4C. Check the transorb diode.

Conditions : Turn keyswitch ON



Measure the fuel pressurewhile cranking the engine.

Use INSITE™electronic service toolto read the fault codeinformation.

Check for active fuel systemfault codes related to thecomplaint.


YES Repair :

Follow the appropriatetroubleshooting tree.

Repair complete


NO4B

Conditions : Nome.


Check the injection controlvalve, pressure control valve,fuel pressure sensor, and fueltemperature sensor wiring fordamage, cuts, and looseconnections.


YES

4C


NO Repair :

Replace the malfunctioningfuel system component.

Repair complete

Conditions : Unplug the fuel pressure sensor.



STEP 4D. Check for air in the high-pressure pump fuel supply.


Unplug the fuel pressuresensor.

Does the rough running,black smoke, or surgecomplaint continue?

YES

4D

Does the rough running,black smoke, or surgecomplaint continue?

NO Repair :

Replace the transorb diode.Refer to Procedure 019-184(/qs3/pubsys2/xml/en/procedures/71/71-019-184.html)in Section 19, in theElectronic Control SystemISC, QSC8.3, and ISLTroubleshooting and RepairManual, Bulletin 3666271.

Repair complete







STEP 4E. Measure the fuel inlet restriction.

Check for air in the fuel.



YES Repair :

Locate and correct thecause of air ingestion in thefuel supply system. Sourcesof air ingestion include loosefuel filters, loose fuel linefittings, loose or cracked fueltank stand-pipes, andsevere restrictions in thefuel supply lines and filters.

Repair complete


NO4E

Conditions : Perform this check during the complaint.

Action Specification/Repair Next StepMeasure the fuel inletrestriction.


Refer to Procedure 006-020(/qs3/pubsys2/xml/en/procedures/45/45-006-020-tr.html)in Section 6, in the ISC,ISCe, QSC8.3, ISL andQSL9 Troubleshooting andRepair Manual, Bulletin402141?

YES

4F






STEP 4F. Measure the fuel gear pump pressure.

Refer to Procedure 006-020(/qs3/pubsys2/xml/en/procedures/45/45-006-020-tr.html)in Section 6, in the ISC,ISCe, QSC8.3, ISL andQSL9 Troubleshooting andRepair Manual, Bulletin4021418?

NO Repair :

Locate the cause of the highinlet restriction.Check theOEM fuel inlet plumbing,fuel filters, and lift pumpcheck valve.

Repair complete.

Conditions : Connect a fuel pressure gauge to the Compuchek™ fitting on the cam housing.

Action Specification/Repair Next StepMeasure the gear pumppressure while the engine isat the rated condition.


Is the fuel gear pumppressure greater than thespecifications outlined.Refer to Procedure 005-089(/qs3/pubsys2/xml/en/procedures/45/45-005-089.html)in Section 5, in the ISC,ISCe, QSC8.3, ISL andQSL9 Troubleshooting andRepair Manual, Bulletin4021418?

YES

4G






STEP 4G. Perform the injection control valve (ICV) click test.

Is the fuel gear pumppressure greater than thespecifications outlined.Refer to Procedure 005-089(/qs3/pubsys2/xml/en/procedures/45/45-005-089.html)in Section 5, in the ISC,ISCe, QSC8.3, ISL andQSL9 Troubleshooting andRepair Manual, Bulletin4021418?

NO Repair :

Replace the fuel gear pumpmodule. Refer to Procedure005-089(/qs3/pubsys2/xml/en/procedures/45/45-005-089.html)in Section 5, in the ISC,ISCe, QSC8.3, ISL andQSL9 Troubleshooting andRepair Manual, Bulletin4021418.

Repair complete


Turn keyswitch ON.

Action Specification/Repair Next StepUse INSITE™ electronicservice tool to perform theICV click test.

Refer to Procedure 005-078(/qs3/pubsys2/xml/en/procedures/45/45-005-078.html)in Section 5, in the ISC,ISCe, QSC8.3, ISL and


YES4H






STEP 4H. Perform the pumping control valve (PCV) click test.

QSL9 Troubleshooting andRepair Manual, Bulletin4021418.


NO Repair :

Replace the injection controlvalve stator.

Refer to Procedure 019-430(/qs3/pubsys2/xml/en/procedures/71/71-019-430.html)in Section 19, in theElectronic Control SystemISC, QSC8.3, and ISLTroubleshooting and RepairManual, Bulletin 3666271.

Repair complete


Turn keyswitch ON.

Action Specification/Repair Next StepUse INSITE™ electronicservice tool to perform thefront and rear PCV click test.



YES4I





STEP 4I. Measure fuel drain line restriction.

STEP 4J. Perform the single cylinder cutout test.


NO Repair :

Replace the accumulatormodule.


Repair complete


Perform this check during the complaint.


Check the fuel drain linerestriction.



YES4J


NO Repair :

Look for causes of highdrain line restriction, such askinked or blocked fuel lines.

Repair complete






STEP 4K. Verify the fuel temperature sensor is within specification.


Engine running at low idle.



Operate the engine at loadedconditions.

Use INSITE™electronic service toolto perform the singlecylinder cutout test todisable individualinjectors.


YES Repair :

Replace the fuel injector inthe cylinder that wasidentified using the singlecylinder cutout test.


Repair complete


NO

4K

Conditions : Turn keyswitch to the OFF position.

Disconnect the engine harness from the fuel temperature sensor.

Install the fuel pressure/temperature sensor breakout cable, Part Number 3162982





STEP 4L. Check for excessive injector drain leakage.

Check the resistance of thefuel temperature sensor.

Measure the resistancefrom pin B to pin D ofthe fuel temperaturesensor.


Is the fuel temperaturesensor within specification?

YES4L

Is the fuel temperaturesensor within specification?

NO Repair :

Replace the fueltemperature sensor.


Repair complete

Conditions : Remove the fuel injector drain banjo fitting from the back of the cylinder head.

Action Specification/Repair Next StepRun the engine at low idlewhile monitoring the amountof fuel draining from the backof the cylinder head.


YES

4M





STEP 4M. Pop test the injectors.


NO Repair :

A damaged connectionbetween the high-pressureconnector and an injectorhas been detected.

Remove all high-pressureconnectors and check forburrs or deformation aroundthe tip of the injector.


Repair complete

Conditions : Remove the injectors. Refer to Procedure 006-026(/qs3/pubsys2/xml/en/procedures/45/45-006-026-tr.html) in Section 6, in the ISC, ISCe,QSC8.3, ISL and QSL9 Troubleshooting and Repair Manual, Bulletin 4021418.

Action Specification/Repair Next StepPop test the injectors andcheck for proper spraypattern.

Refer to Procedure 006-026(/qs3/pubsys2/xml/en/procedures/45/45-006-026-tr.html)in Section 6, the ISC, ISCe,QSC8.3, ISL and QSL9Troubleshooting and RepairManual, Bulletin 4021418.


YES

4N






STEP 4N. Inspect the gear pump coupling for wear.


NO Repair :

Replace the malfunctioninginjector. Refer to Procedure006-026(/qs3/pubsys2/xml/en/procedures/45/45-006-026-tr.html)in Section 6, in the ISC,ISCe, QSC8.3, ISL andQSL9 Troubleshooting andRepair Manual, Bulletin4021418.

Repair complete


Remove the gear pump module.

Action Specification/Repair Next StepInspect the gear pump driveshaft coupling and shaft forwear.


YES Repair :

Replace the gear pumpmodule. Refer to Procedure005-089(/qs3/pubsys2/xml/en/procedures/45/45-005-089.html)in Section 5, in the ISC,ISCe, QSC8.3, ISL andQSL9 Troubleshooting andRepair Manual, Bulletin4021418.

Repair compelete





STEP 5. Air handling troubleshooting procedures.

STEP 5A. Inspect the turbocharger blades for damage.


NO Repair :

Replace the injection controlvalve. Refer to Procedure005-086(/qs3/pubsys2/xml/en/procedures/45/45-005-086.html)in Section 5, in the ISC,ISCe, QSC8.3, ISL andQSL9 Troubleshooting andRepair Manual, Bulletin4021418.

Repair complete


Remove the intake and exhaust pipes from the turbocharger.





STEP 5B. Check the turbocharger axial and radial clearances.

Inspect the compressor andturbine blades for damage orwear.

Use the followingprocedure in the B5.9G,B5.9LPG, B Gas Plus,B LPG Plus, B GasInternational, and G5.9EnginesTroubleshooting andRepair Manual, Bulletin3666164. Refer toProcedure 010-033 inSection 10.(/qs3/pubsys2/xml/en/procedures/45/45-010-033-tr.html)


YES Repair :

Replace the turbochargerassembly. Refer toProcedure 010-033(/qs3/pubsys2/xml/en/procedures/45/45-010-033-tr.html)in Section 10, in the ISC,ISCe, QSC8.3, ISL andQSL9 Troubleshooting andRepair Manual, Bulletin4021418.

Repair complete


NO5B


Action Specification/Repair Next StepCheck the turbocharger forcorrect axial and radialclearance.


Are the turbocharger axialand radial bearingclearances withinspecification?

YES

5C






STEP 5C. Inspect the wastegate actuator rod for travel..

STEP 5C-1. Inspect the wastegate actuator rod for travel.

Are the turbocharger axialand radial bearingclearances withinspecification?

NO Repair :

Replace the turbochargerassembly. Refer toProcedure 010-033(/qs3/pubsys2/xml/en/procedures/45/45-010-033-tr.html)in Section 10, in the ISC,ISCe, QSC8.3, ISL andQSL9 Troubleshooting andRepair Manual, Bulletin4021418.

Repair complete


Remove the integral boost line from the wastegate actuator.


Apply a regulated air supplyof 138 kPa [20 psi] to theactuator and check foractuator movement.

Does the wastegateactuator rod move?

YESRepair complete


NO5C-1


Remove the e-clip from the wastegate pin and disconnect the actuator rod.





STEP 6. Electronic feature troubleshooting procedures.

Apply a regulated air supplyof 138 kPa [20 psi] to theactuator and check foractuator movement.


YES Repair :

Move the wastegate leveron the turbocharger backand forth to check forsmooth operation. Replacethe turbocharger assembly ifthe wastegate is seized.


Repair complete


NO Repair :

Replace the wastegateactuator.


Repair complete





STEP 6A. Verify throttle pedal travel.

STEP 6B. Check ambient air pressure sensor accuracy (if equipped).




Use INSITE™ electronicservice tool to monitor thethrottle position while fullydepressing and releasing thethrottle pedal.

Does the throttle positionread zero when the throttleis released and 100 percentwhen the throttle isdepressed?

YES

6B

Does the throttle positionread zero when the throttleis released and 100 percentwhen the throttle isdepressed?

NO Repair :

Determine and correct thecause of the throttle pedalrestriction.

Repair complete



Action Specification/Repair Next StepStart INSITE™ DataMonitor/Logger and compareINSITE™ reading forBarometric Air Pressure tothe local barometric pressureusing the table below.

Refer to Procedure 018-028(/qs3/pubsys2/xml/en/procedures/99/99-018-028.html)

Is the reading within 50.8mm-Hg [2 in-Hg] of localbarometric pressure?

YES

6C




STEP 6C. Check intake manifold pressure sensor accuracy.

in Section V. Is the reading within 50.8mm-Hg [2 in-Hg] of localbarometric pressure?

NO Repair :

Replace the barometricpressure sensor. Seeequipment manufacturerservice information.

Repair Complete




Start INSITE™ electronicservice toolData/Monitor/Logger andread the value of intakemanifold pressure.


YES

6D


NO Repair :

Replace the intake manifoldpressure sensor. Refer toProcedure 019-061(/qs3/pubsys2/xml/en/procedures/71/71-019-061.html)in Section 19, in theElectronic Control SystemISC, QSC8.3, and ISLTroubleshooting and RepairManual, Bulletin 3666271.

Repair complete




STEP 6D. Verify electronic feature settings are correct.

STEP 7. Base engine troubleshooting procedures.

STEP 7A. Verify overhead adjustments are correct.



Action Specification/Repair Next StepUse INSITE™ electronicservice tool to verify thefollowing adjustableparameters are set correctly:

Maximum VehicleSpeed

Powertrain Protection

Rear Axle Ratio

Tailshaft Teeth

Tire Revolutions perMile

Gear-Down Protection

Cruise Control DroopSettings

Cruise ControlMaximum VehicleSpeed.

Are the electronic featuresset correctly?

YES2A

Are the electronic featuresset correctly?

NO Repair :

Use INSITE™ electronicservice tool to correctprogrammable features.

Repair complete


Remove the rocker lever cover. Refer to Procedure 003-011 Section 3 in the ISC, ISCe,QSC8.3, ISL and QSL9 Troubleshooting and Repair Manual, Bulletin 4021418.(/qs3/pubsys2/xml/en/procedures/45/45-003-011-tr.html)





STEP 7B. Verify engine brake adjustment (if equipped).

Measure the overheadsetting.

Refer to Procedure003-004 in Section 3.(/qs3/pubsys2/xml/en/procedures/45/45-003-004-tr.html)


YES7B


NO Repair :

Adjust the overheadsettings. Refer to Procedure003-004(/qs3/pubsys2/xml/en/procedures/45/45-003-004-tr.html)in Section 3, in the ISC,ISCe, QSC8.3, ISL andQSL9 Troubleshooting andRepair Manual, Bulletin4021418.

Repair complete


Remove the rocker lever cover. Refer to Procedure 003-011(/qs3/pubsys2/xml/en/procedures/45/45-003-011-tr.html) in Section 3, in the ISC, ISCe,QSC8.3, ISL and QSL9 Troubleshooting and Repair Manual, Bulletin 4021418.

Action Specification/Repair Next StepVerify the engine brakes areoperating correctly.

Measure the enginebrake settings. Refer toProcedure 020-004(/qs3/pubsys2/xml/en/procedures/45/45-020-004-tr.html) in Section20, in the ISC, ISCe,QSC8.3, ISL and QSL9Troubleshooting andRepair Manual, Bulletin4021418.

Are the engine brakesettings within the resetlimits?

YES

7C







STEP 7C. Inspect the charge air cooler.

STEP 7D. Check air intake restriction.

Are the engine brakesettings within the resetlimits?

NO Repair :

Adjust the engine brakesettings. Refer to Procedure020-004(/qs3/pubsys2/xml/en/procedures/45/45-020-004-tr.html)in Section 20, in the ISC,ISCe, QSC8.3, ISL andQSL9 Troubleshooting andRepair Manual, Bulletin4021418.

Repair complete

Conditions : Refer to Procedure 010-027 in Section 10. (/qs3/pubsys2/xml/en/procedures/45/45-010-027.html)


Inspect the charge air cooler.

Inspect the charge air coolerfor cracks, holes, ordamage.

Refer to Procedure 010-027in Section 10.(/qs3/pubsys2/xml/en/procedures/45/45-010-027-tr.html)

Is the charge air cooler freeof cracks, holes, or otherdamage?

YES

7D

Is the charge air cooler freeof cracks, holes, or otherdamage?

NO Repair :

Repair the charge air coolerassembly.

Repair complete






STEP 7E. Check exhaust restriction.

Conditions : Refer to Procedure 010-031 in Section 10. (/qs3/pubsys2/xml/en/procedures/45/45-010-031-tr.html)


Check the intake systemrestriction by installing avacuum gauge into the airintake system.

Refer to Procedure010-031 in Section 10.(/qs3/pubsys2/xml/en/procedures/45/45-010-031-tr.html)

Is air intake restrictiongreater than 635 mm H O[25 in H O]?

YES Repair :

Correct the cause of highintake air restriction. Checkfor plugged air filter orrestricted air intake piping.

Repair complete

Is air intake restrictiongreater than 635 mm H O[25 in H O]?

NO

7E

2

2

2

2

Conditions : Use the following procedure in the B5.9G, B5.9LPG, B Gas Plus, B LPG Plus, B GasInternational, and G5.9 Engines Troubleshooting and Repair Manual, Bulletin 3666164.Refer to Procedure 011-009 in Section 11. (/qs3/pubsys2/xml/en/procedures/45/45-011-009-tr.html)

Action Specification/Repair Next StepCheck the exhaust systemback pressure.

Check the exhaust systemback pressure by installing apressure gauge into theexhaust system just past theturbocharger outlet. Use thefollowing procedure in theB5.9G, B5.9LPG, B GasPlus, B LPG Plus, B GasInternational, and G5.9Engines Troubleshooting

Exhaust back pressurewithin 61 to 127 mm-Hg [2.4to 5.0 in-Hg]?

YES

7F






STEP 7E. Check exhaust restriction.

and Repair Manual, Bulletin3666164. Refer toProcedure 011-009 inSection 11.(/qs3/pubsys2/xml/en/procedures/45/45-011-009-tr.html)

Exhaust back pressurewithin 61 to 127 mm-Hg [2.4to 5.0 in-Hg]?

NO Repair :

Inspect exhaust system forsource of high restriction.Use the following procedurein the B5.9G, B5.9LPG, BGas Plus, B LPG Plus, BGas International, and G5.9Engines Troubleshootingand Repair Manual, Bulletin3666164. Refer toProcedure 011-009 inSection 11.(/qs3/pubsys2/xml/en/procedures/45/45-011-009-tr.html)

Repair complete


Action Specification/Repair Next StepCheck the exhaust systemback pressure by installing apressure gauge into theexhaust system just past theturbocharger outlet.

Refer to Procedure 011-009(/qs3/pubsys2/xml/en/procedures/45/45-011-009-tr.html) in Section11, in the ISC, ISCe,QSC8.3, ISL and QSL9Troubleshooting and

Is exhaust back pressureless than 72 mm-Hg [3 in-Hg]?

YES

7F







STEP 7F. Check engine blowby.

STEP 7F-1. Verify turbocharger contribution to engine blowby.

Repair Manual, Bulletin4021418.

Is exhaust back pressureless than 72 mm-Hg [3 in-Hg]?

NO Repair :

Inspect the exhaust systemfor the source of highrestriction.

Repair complete.

Conditions : Refer to Procedure 014-005 in Section 14. (/qs3/pubsys2/xml/en/procedures/45/45-014-005.html) in the B5.9G, B5.9LPG, B Gas Plus, B LPG Plus, B Gas International, and G5.9Engines Troubleshooting and Repair Manual, Bulletin 3666164.

Action Specification/Repair Next StepMeasure the engine blowby.

Measure the engineblowby.

Refer to Procedure014-005 in Section 14(/qs3/pubsys2/xml/en/procedures/45/45-014-005.html) in the B5.9G,B5.9LPG, B Gas Plus,B LPG Plus, B GasInternational, and G5.9EnginesTroubleshooting andRepair Manual, Bulletin3666164


YES

Return to Step 2 or contacta Cummins Inc. servicerepresentative for furtherdiagnostic andtroubleshootinginstructions.7G


NO

7F-1





Last Modified: 15-Feb-2019


Connect the appropriate orifice to the end of the blowby draft tube.

Remove the turbocharger oil drain line from the block and drain into a bucket.

Start the engine.


Load engine to rated rpm ona chassis dynamometer.

Measure the engineblowby. Refer toProcedure 014-005 inSection 14(/qs3/pubsys2/xml/en/procedures/45/45-014-005.html) in the B5.9G,B5.9LPG, B Gas Plus,B LPG Plus, B GasInternational, and G5.9EnginesTroubleshooting andRepair Manual, Bulletin3666164


YES Repair :

Replace the turbochargerassembly. Refer toProcedure 010-033 inSection 10.(/qs3/pubsys2/xml/en/procedures/45/45-010-033-tr.html)in the B5.9G, B5.9LPG, BGas Plus, B LPG Plus, BGas International, and G5.9Engines Troubleshootingand Repair Manual, Bulletin3666164.

Repair complete


NO Repair :

The engine may need to berebuilt. See the enginerebuild specifications.

Repair complete



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