Paccar

Reason:
VGT Actuator Driver Circuit (Motor) – Mechanical System Not Responding or Out of Adjustment. The smart VGT controller has detected incorrect stop limits, or the VGT is unable to move to the closed position.

Effect:
Possible reduced engine performance

Circuit Description:
The variable geometry turbocharger (VGT) is electronically activated by the VGT actuator. The VGT actuator is a smart device and receives information via the J1939 data link from the primary engine control module (ECM). The VGT actuator performs its own diagnostics and reports malfunctions back to the primary engine ECM, using the J1939 data link. The ECM then decodes the error message and converts it to a fault code.

Component Location:
The VGT actuator is located on the turbocharger bearing housing.

Conditions for Running the Diagnostics:
This diagnostic runs continuously when the engine is running.

Conditions for Setting the Fault Codes:
The Variable Geometry Turbocharger (VGT) actuator position could not meet the commanded position for greater than 10 seconds.

Action Taken When the Fault Code is Active:
1) The ECM illuminates the amber CHECK ENGINE lamp and/or Malfunction Indicator Lamp (MIL) after the diagnostic fails on two consecutive trips.
2) The VGT actuator will continue to attempt to meet commanded position, even when the CHECK ENGINE lamp is on.
3) Active and stationary regeneration of the diesel particulate filter will be disabled.
4) Exhaust Gas Recirculation (EGR) valve operation will be disabled.
5) Diesel exhaust fluid injection into the aftertreatment system is disabled.
6) Engine torque will be reduced if the engine is operated for an extended period of time with this fault active.

Conditions for Clearing the Fault Code:
1) To validate the repair, perform a key cycle, start the engine and let it idle for 1 minute.
2) The ECM will turn off the amber CHECK ENGINE lamp immediately after the diagnostic runs and passes.
3) For On-Board Diagnostics (OBD) engines, the ECM will extinguish the Malfunction Indicator Lamp (MIL) after three consecutive trips where the diagnostic runs and passes.
4) The Reset All Faults command in INSITE™ electronic service tool can be used to clear active and inactive faults, as well as extinguish the MIL for OBD applications.

Shop Talk:
The aftertreatment system must be inspected for potential damage after making the appropriate repair outlined in this fault code troubleshooting tree. Progressive damage to the aftertreatment system can possibly have occurred.

Possible Causes:
1) A malfunctioning turbocharger
2) A malfunctioning turbocharger actuator

Reason:
Sensor Supply 3 Circuit – Voltage Above Normal or Shorted to High Source. High voltage detected on the 5 volt sensor supply circuit to the engine speed sensor.

Effect:
Engine may run rough, may stop running, may not start, or may be difficult to start.

Circuit Description:
The sensor supply 3 circuit provides a 5 volt supply to the primary engine speed/position sensor.

Component Location:
Sensor Supply 3 originates in the engine wiring harness. It provides 5 VDC to the engine crankshaft speed/position sensor.

Conditions for Running the Diagnostics:
This diagnostic runs continuously when the keyswitch is in the ON position or when the engine is running.

Conditions for Setting the Fault Codes:
The Engine Control Module (ECM) detected the sensor supply 3 signal voltage was out of range high.

Action Taken When the Fault Code is Active:
1) The ECM illuminates the amber CHECK ENGINE lamp and/or the Malfunction Indicator Lamp (MIL) immediately when the diagnostic runs and fails.
2) The backup engine speed sensor will be used by the ECM for the engine speed signal.

Conditions for Clearing the Fault Code:
1) To validate the repair, perform a key cycle, start the engine and let it idle for 1 minute.
2) The fault code status displayed by INSITE™ electronic service tool will change to INACTIVE immediately after the diagnostic runs and passes.
3) For On-Board Diagnostics (OBD) engines, the ECM will extinguish the Malfunction Indicator Lamp (MIL) after three consecutive trips where the diagnostic runs and passes.
4) For On-Board Diagnostics (OBD) engines, the ECM will extinguish the Malfunction Indicator Lamp (MIL) after three consecutive trips where the diagnostic runs and passes.
5) The Reset All Faults command in INSITE™ electronic service tool can be used to clear active and inactive faults, as well as extinguish the MIL for OBD applications.

Shop Talk:
High voltage on the +5 volt supply wire can be caused by a short to battery voltage in the engine harness or connectors, or a damaged ECM.

Possible Causes:
1) Faulty ECM
2) Faulty circuit response
3) Inactive fault codes

Reason:
Wheel-Based Vehicle Speed – Data Erratic, Intermittent, or Incorrect. The ECM lost the vehicle speed signal or is reading an erratic value.

Effect:
Engine speed limited to Maximum Engine Speed without VSS parameter value. Cruise Control, Gear-Down Protection, and Road Speed Governor will not work.

Circuit Description:
The vehicle speed sensor senses the speed of the tailshaft gear on the vehicle’s transmission. This speed signal is then transmitted to the engine control module (ECM) and converted into a vehicle speed.

Component Location:
The vehicle speed sensor is located in the rear of the vehicle transmission. Refer to the OEM service manual for location.

Conditions for Running the Diagnostics:
This diagnostic runs continuously when the vehicle is in motion, if the feature is enabled.

Conditions for Setting the Fault Codes:
The Engine Control Module (ECM) detected a loss of vehicle speed when other engine operating conditions indicated that the vehicle should be in motion. This fault code can also become active if the calculated gear ratio and actual gear ratio do not agree while the vehicle is in motion.

Action Taken When the Fault Code is Active:
1) The ECM illuminates the amber CHECK ENGINE lamp immediately when the diagnostic runs and fails.
2) The engine speed operating range is limited to the adjustable parameter “Maximum Engine Speed without VSS”.
3) ECM powerdown will be delayed for 60 seconds after key OFF.

Conditions for Clearing the Fault Code:
1) To validate the repair, start the engine and move the vehicle so the ECM can read a vehicle speed. The vehicle may need to be driven for up to 15 minutes to get the diagnostic to run and the fault to go inactive.
2) The fault code status displayed by INSITE™ electronic service tool will change to INACTIVE immediately after the diagnostic runs and passes.
3) The ECM will turn off the amber CHECK ENGINE lamp immediately after the diagnostic runs and passes.
4) For On-Board Diagnostics (OBD) engines, the ECM will extinguish the Malfunction Indicator Lamp (MIL) after three consecutive trips where the diagnostic runs and passes.
5) The Reset All Faults command in INSITE™ electronic service tool can be used to clear active and inactive faults, as well as extinguish the MIL for OBD applications.

Shop Talk:
There are multiple types of vehicle speed sensors. Various types include magnetic pickup, data link, digital, and tachograph. Contact the OEM for the specific type installed on the vehicle.

This fault is set active when the ECM loses a vehicle speed signal when other engine conditions indicate the vehicle is moving. The fault can also become active if there is a series of clutch, service brake or throttle movements with no vehicle movement. The fault is set inactive when the ECM receives a valid vehicle speed signal.

Since the vehicle speed sensor is an OEM installed component, this troubleshooting procedure will not cover all malfunctions of the circuit due to components not under Cummins Inc. control. Sensor resistance values, data link speed sensors and tachographs are not fully covered under this procedure. For more information on those components, refer to the OEM service manual.

A damaged vehicle speed sensor or debris on the end of the sensor could cause the fault to become active. Incorrect INSITE™ electronic service tool feature and parameter settings (gear ratio, tire size, rear axle ratio, etc) will also cause the fault to become active. Feature and parameter settings under Transmission Setup and Vehicle Speed source need to be verified with the vehicle components.

NOTE: If the power is removed from the ECM within 60 seconds of key OFF and before the ECM has powered down, Fault Code 1117 may become active

Reference the appropriate OEM wiring diagram when troubleshooting circuits that utilize wiring supplied by the OEM For intermittent power supply and datalink communication issues with Aftertreatment Components, it is highly recommended that the OEM Power Distribution Center fuses and relays be thoroughly checked for loose, missing or intermittent connections.

Possible Causes:
1) Faulty OEM harness
2) Faulty ECM
3) Damaged OEM harness connector pins at the ECM
4) Open circuit in the OEM harness
5) Short circuit to ground in the OEM harness
6) Pin-to-pin short circuit in the OEM harness
7) Gear slipping on the shaft
8) Inactive fault codes

Reason:
Coolant Level – Data Valid But Below Normal Operational Range – Least Severe Level. Low engine coolant level detected.

Effect:
None on performance

Circuit Description:
The coolant level sensor is a switch and is used to measure the level of the engine coolant in the radiator top tank. The coolant level sensor is immersed in the coolant and returns a different signal voltage when immersed in coolant versus being out of coolant. The engine control module (ECM) monitors the change in the signal voltage to determine the level of the engine coolant.

Component Location:
The engine coolant level sensor is typically located in the radiator top tank or surge tank. Refer to the OEM service manual for the location.

Conditions for Running the Diagnostics:
This diagnostic runs continuously when the keyswitch is in the ON position or when the engine is running.

Conditions for Setting the Fault Codes:
The Engine Control Module (ECM) detected the coolant level sensor signal voltage is between 1.75 VDC and 3 VDC for more than 30 seconds, indicating low coolant level.

Action Taken When the Fault Code is Active:
The ECM illuminates the white MAINTENANCE lamp or flashes the amber CHECK ENGINE lamp, indicating a maintenance condition, immediately after the diagnostic runs and fails.

Conditions for Clearing the Fault Code:
1) To validate the repair, perform a key cycle, start the engine and let it idle for 1 minute.
2) The fault code status displayed by INSITE™ electronic service tool will change to INACTIVE immediately after the diagnostic runs and passes.
3) The ECM will turn off the flashing amber CHECK ENGINE lamp / MAINTENANCE lamp immediately after the diagnostic runs and passes.
4) The Reset All Faults command in INSITE™ electronic service tool can be used to clear active and inactive faults, as well as extinguish the MIL for OBD applications.

Shop Talk:
This fault code goes active when the coolant level inside the radiator top tank or surge tank drops below the sensor level. Fill the top tank with coolant.

Reference the appropriate OEM wiring diagram when troubleshooting circuits that utilize wiring supplied by the OEM.

Possible Causes:
1) Inactive fault codes
2) Faulty ECM

Reason:
Coolant Level – Data Valid But Below Normal Operational Range – Least Severe Level. Low engine coolant level detected.

Effect:
None on performance

Circuit Description:
The coolant level sensor is a switch and is used to measure the level of the engine coolant in the radiator top tank. The coolant level sensor is immersed in the coolant and returns a different signal voltage when immersed in coolant versus being out of coolant. The engine control module (ECM) monitors the change in the signal voltage to determine the level of the engine coolant.

Component Location:
The engine coolant level sensor is typically located in the radiator top tank or surge tank. Refer to the OEM service manual for the location.

Conditions for Running the Diagnostics:
This diagnostic runs continuously when the keyswitch is in the ON position or when the engine is running.

Conditions for Setting the Fault Codes:
The Engine Control Module (ECM) detected the coolant level sensor signal voltage is between 1.75 VDC and 3 VDC for more than 30 seconds, indicating low coolant level.

Action Taken When the Fault Code is Active:
The ECM illuminates the white MAINTENANCE lamp or flashes the amber CHECK ENGINE lamp, indicating a maintenance condition, immediately after the diagnostic runs and fails.

Conditions for Clearing the Fault Code:
1) To validate the repair, perform a key cycle, start the engine and let it idle for 1 minute.
2) The fault code status displayed by INSITE™ electronic service tool will change to INACTIVE immediately after the diagnostic runs and passes.
3) The ECM will turn off the flashing amber CHECK ENGINE lamp / MAINTENANCE lamp immediately after the diagnostic runs and passes.
4) The Reset All Faults command in INSITE™ electronic service tool can be used to clear active and inactive faults, as well as extinguish the MIL for OBD applications.

Shop Talk:
This fault code goes active when the coolant level inside the radiator top tank or surge tank drops below the sensor level. Fill the top tank with coolant.

Reference the appropriate OEM wiring diagram when troubleshooting circuits that utilize wiring supplied by the OEM.

Possible Causes:
1) Inactive fault codes
2) Faulty ECM

Reason:
Fan Control Circuit – Voltage Below Normal or Shorted to Low Source. Low signal voltage detected at the fan control circuit when commanded ON.

Effect:
The fan can stay on continuously or not run at all.

Circuit Description:
The fan control circuit is a device used by the engine to control the fan operation. When the engine control module (ECM) energizes the fan control circuit, the engine fan is engaged. The fan control circuit utilizes a pulse width modulated (PWM) signal. A PWM signal is a pulsed voltage signal between 0-VDC and system voltage. The frequency of the pulsed voltage signal is dependent on the application requirement. There are two types of fans supported by the fan control circuit; variable speed and ON/OFF. INSITE™ electronic service tool can be used to determine which fan type is presently set up for use. The fan control circuit varies by the OEM. OEMs can use a solenoid return that is wired to the ECM or use a return that goes to engine block or chassis ground.

Component Location:
The control solenoid location varies by OEM. Refer to the appropriate OEM service manual to determine the location.

Conditions for Running the Diagnostics:
This diagnostic runs when the keyswitch is in the ON position and when the pulse width modulated (PWM) device is getting energized or de-energized. In some cases, the diagnostics can also run at some fixed intervals.

Conditions for Setting the Fault Codes:
The Engine Control Module (ECM) detected the fan control circuit pulse width modulated (PWM) signal was not at system voltage when the pulse width modulated (PWM) signal was commanded ON.

Action Taken When the Fault Code is Active:
1) The ECM illuminates the amber CHECK ENGINE lamp immediately when the diagnostic runs and fails.
2) Fan operation will be disabled.

Conditions for Clearing the Fault Code:
1) To validate the repair, perform a key cycle, start the engine and let it idle for 1 minute.
2) The fault code status displayed by INSITE™ electronic service tool will change to INACTIVE immediately after the diagnostic runs and passes.
3) The ECM will turn off the amber CHECK ENGINE lamp immediately after the diagnostic runs and passes.
4) The Reset All Faults command in INSITE™ electronic service tool can be used to clear active and inactive faults, as well as extinguish the MIL for OBD applications.

Shop Talk:
The fan control logic can be adjusted with INSITE™ electronic service tool. There are two choices: 12 or 24 volts ON, or 0 volts ON. For proper fan operation, the fan control logic setup with INSITE™ electronic service tool must match the hardware configuration on the vehicle.

This fault code is logged when the ECM commands 12 or 24-VDC to the fan control solenoid, but the voltage on the fan control signal circuit is less than 12 or 24-VDC. The low voltage on the signal circuit usually indicates a short circuit to ground in the harness or solenoid.

If Fault Code 245 is still active after completing the following troubleshooting steps, consult the OEM service manual for procedures to check the fan control circuit for a short circuit to ground.

Reference the appropriate OEM wiring diagram when troubleshooting circuits that utilize wiring supplied by the OEM.

Possible Causes:
1) Faulty fan control solenoid and circuit
2) Internal short in the fan control solenoid
3) Pin-to-ground short circuit in the fan control solenoid
4) Faulty ECM

Reason:
Engine Crankshaft Speed/Position – Data Valid But Above Normal Operating Range – Moderately Severe Level. The engine speed has exceeded a critical limit.

Effect:
Engine will be shut down.

Circuit Description
The air shutoff valve is an optional component used to shutdown the engine in the event of an engine overspeed condition. It can be closed via a manual shutdown switch or via an ECM command.

Component Location:
The engine air shutoff valve location can vary depending on the OEM. Refer to the OEM service manual.

Conditions for Running the Diagnostics:
This diagnostic runs continuously when the keyswitch is in the ON position or when the engine is running.

Conditions for Setting the Fault Codes:
The Engine Control Module (ECM) detected the engine speed was greater than 2500 RPM for 0.25 seconds, or the operator manually tripped the engine air shutoff valve.

Action Taken When the Fault Code is Active:
1) The ECM illuminates the amber CHECK ENGINE lamp immediately when the diagnostic runs and fails.
2) The air shutoff valve closes
3) The engine will be shut down.

Conditions for Clearing the Fault Code:
1) The air shutoff valve must be reset to the open position.
2) To validate the repair, perform a key cycle, start the engine and let it idle for 1 minute.
3) The fault code status displayed by INSITE™ electronic service tool will change to INACTIVE immediately after the diagnostic runs and passes.
4) The ECM will turn off the amber CHECK ENGINE lamp immediately after the diagnostic runs and passes.
5) The Reset All Faults command in INSITE™ electronic service tool can be used to clear active and inactive faults, as well as extinguish the MIL for OBD applications.

Shop Talk:
This fault code indicates that the engine has been shut down via the engine air shutoff valve. This can occur automatically (engine overspeed condition) or manually (activating the engine air shutoff valve switch in the cab). In either case, this fault code will become active until the valve de-activated.

Possible Causes:
1) Damaged engine
2) Alternative fuel source
3) Faulty RPM reading
4) Inactive fault codes
5) Faulty ECM

Reason:
Engine Crankshaft Speed/Position – Data Valid But Above Normal Operating Range – Moderately Severe Level. The engine speed has exceeded a critical limit.

Effect:
Engine will be shut down.

Circuit Description
The air shutoff valve is an optional component used to shutdown the engine in the event of an engine overspeed condition. It can be closed via a manual shutdown switch or via an ECM command.

Component Location:
The engine air shutoff valve location can vary depending on the OEM. Refer to the OEM service manual.

Conditions for Running the Diagnostics:
This diagnostic runs continuously when the keyswitch is in the ON position or when the engine is running.

Conditions for Setting the Fault Codes:
The Engine Control Module (ECM) detected the engine speed was greater than 2500 RPM for 0.25 seconds, or the operator manually tripped the engine air shutoff valve.

Action Taken When the Fault Code is Active:
1) The ECM illuminates the amber CHECK ENGINE lamp immediately when the diagnostic runs and fails.
2) The air shutoff valve closes
3) The engine will be shut down.

Conditions for Clearing the Fault Code:
1) The air shutoff valve must be reset to the open position.
2) To validate the repair, perform a key cycle, start the engine and let it idle for 1 minute.
3) The fault code status displayed by INSITE™ electronic service tool will change to INACTIVE immediately after the diagnostic runs and passes.
4) The ECM will turn off the amber CHECK ENGINE lamp immediately after the diagnostic runs and passes.
5) The Reset All Faults command in INSITE™ electronic service tool can be used to clear active and inactive faults, as well as extinguish the MIL for OBD applications.

Shop Talk:
This fault code indicates that the engine has been shut down via the engine air shutoff valve. This can occur automatically (engine overspeed condition) or manually (activating the engine air shutoff valve switch in the cab). In either case, this fault code will become active until the valve de-activated.

Possible Causes:
1) Damaged engine
2) Alternative fuel source
3) Faulty RPM reading
4) Inactive fault codes
5) Faulty ECM

Reason:
Exhaust Gas Pressure – Data Erratic, Intermittent or Incorrect. The exhaust gas pressure sensor is reading an erratic value.

Effect:
Possible reduced engine performance

Circuit Description:
The exhaust gas pressure sensor is used to measure exhaust gas pressure in the exhaust manifold. This information is used by the engine control module (ECM) to control emissions and exhaust gas recirculation (EGR) valve operation. The ECM provides a 5 volt supply to the exhaust gas pressure sensor on the sensor supply circuit. The ECM also provides a ground on the sensor return circuit. The exhaust gas pressure sensor provides a signal to the ECM on the exhaust gas pressure sensor signal circuit. This sensor signal voltage changes, based on the pressure in the exhaust manifold.

Component Location:
The exhaust gas pressure sensor is located above the front section of the exhaust manifold and is plumbed into the exhaust manifold.

Conditions for Running the Diagnostics:
This diagnostic consists of two parts:
One part runs immediately after the keyswitch is turned OFF, and the engine coolant temperature is above 70°C or 158°F. The second part runs continuously while the engine is running.

Conditions for Setting the Fault Codes:
1) The Engine Control Module (ECM) detected the exhaust pressure reading was higher or lower than the other absolute pressure sensors when the keyswitch is OFF and the engine is not running.
2) The Engine Control Module (ECM) detected the exhaust pressure was higher or lower than expected during normal engine operation.

Action Taken When the Fault Code is Active:
1) The ECM illuminates the amber CHECK ENGINE lamp and/or the Malfunction Indicator Lamp (MIL) immediately when the diagnostic runs and fails.
2) A default value is used for the exhaust gas pressure sensor reading.
3) Exhaust Gas Recirculation (EGR) valve operation will be disabled.
4) Engine torque will be reduced if the engine is operated for an extended period of time with this fault active.

Conditions for Clearing the Fault Code:
1) To validate the repair, first ensure the engine coolant temperature is above 70°C or 158° F. Operate the engine if necessary.
2) Cycle the keyswitch to the ON position for 30 seconds, then cycle the keyswitch to the OFF position for 30 seconds. Start the engine and run it at high idle for up to 5 minutes.
3) The fault code status displayed by INSITE™ electronic service tool will change to INACTIVE immediately after the diagnostic runs and passes.
4) The ECM will turn off the amber CHECK ENGINE lamp immediately after the diagnostic runs and passes.
5) For On-Board Diagnostics (OBD) engines, the ECM will extinguish the Malfunction Indicator Lamp (MIL) after three consecutive trips where the diagnostic runs and passes.
6) The Reset All Faults command in INSITE™ electronic service tool can be used to clear active and inactive faults, as well as extinguish the MIL for OBD applications.

Shop Talk:
N/A

Possible Causes:
1) Stuck in-range exhaust gas pressure sensor reading
2) High resistance in the exhaust gas pressure sensor signal or return lines
3) Plugging or restriction in the exhaust gas pressure sensor tube
4) Leaks in the exhaust system