Paccar

Verify the electronic control module (ECM) calibration is correct. Check the calibration revision history found on QuickServe™ Online for applicable fixes to the calibration stored in the ECM. If necessary, calibrate the ECM. Use the following procedure in the corresponding Troubleshooting and Repair Manual for the engine being serviced.

Possible causes:

1)Crankcase ventilation filter needs to be replaced
2)Crankcase pressure sensor damage
3)Malfunctioning or misassembled closed crankcase ventilation valve
4)Frozen, plugged, or restricted crankcase ventilation hose
5)Plugged or restricted crankcase ventilation hose
6)Plugged or restricted crankcase ventilation oil drain tube or check valve
7)Plugged or restricted crankcase breather tube (rear engine-mounted crankcase ventilation filter)
8)High air intake restriction.

Depending on the breather system used, the crankcase ventilation filter will be located:

1)On top of the rocker lever cover, between the rocker lever cover and the crankcase ventilation filter cover, or
2)At the rear of the engine, encased in an external crankcase ventilation filter housing that mounts to the flywheel housing.

Both systems are closed crankcase breather systems, meaning the crankcase gases are vented into the intake system at the inlet to the turbocharger compressor.

It is important to check for plugged or restricted hoses, tubes, check valves, and filters in extreme cold ambient temperatures.

If Fault Code 556 becomes active due to a plugged filter before the maintenance interval is reached or the filter plugs frequently, see the Crankcase Gases (Blowby) Excessive troubleshooting symptom tree.

After Fault Code 556 occurs, it is important to check for progressive damage to the engine due to the high crankcase pressure. Check for oil leaking from gaskets and seats.

Possible repairs:

1)Replace the crankcase pressure sensor.
2)Replace the crankcase ventilation filter.
3)Replace the crankcase breather element.
4)Clean or replace the crankcase ventilation oil drain tubes, check valves, breather tubes, or oil separator.
5)Replace the crankcase ventilation filter.
6)Replace the damaged gasket, seal, or other component.

Verify the electronic control module (ECM) calibration is correct. Check the calibration revision history found on QuickServe™ Online for applicable fixes to the calibration stored in the ECM. If necessary, calibrate the ECM. Use the following procedure in the corresponding Troubleshooting and Repair Manual for the engine being serviced.
Possible causes:

1)Crankcase breather filter needs to be replaced
2)Crankcase pressure sensor damage
3)Plugged or restricted crankcase breather oil separator
4)Plugged or restricted crankcase breather oil drain tube or check valve
5)Plugged or restricted crankcase breather draft tube
6)Frozen, plugged, or restricted crankcase breather tube.

It is important to check for plugged or restricted hoses, tubes, check valves, oil separator, and filters in extreme cold ambient temperatures.

If Fault Code 556 becomes active due to a plugged filter before the maintenance interval is reached or the filter plugs frequently, see the Crankcase Gases (Blowby) Excessive troubleshooting symptom tree.

After Fault Code 556 occurs, it is important to check for progressive damage to the engine due to the high crankcase pressure. Check for oil leaking from gaskets and seals.

Possible repairs:

1)Replace the crankcase pressure sensor.
2)Replace the crankcase ventilation filter.
3)Replace the crankcase breather element.
4)Clean or replace the crankcase ventilation oil drain tubes, check valves, breather tubes, or oil separator.
5)Replace the crankcase ventilation filter.
6)Replace the damaged gasket, seal, or other component.

Verify the electronic control module (ECM) calibration is correct. Check the calibration revision history found on QuickServe™ Online for applicable fixes to the calibration stored in the ECM. If necessary, calibrate the ECM again. Refer to Procedure 019-032 in Section 19.

Before performing troubleshooting work, verify the vehicle’s system voltage by monitoring battery voltage in the INSITE™ electronic service tool data monitor or connecting a digital volt ohm meter to the batteries. This will help identify a potential system voltage issue. Refer to the OEM service manual for specified voltage range and troubleshooting procedures.

If the engine will not start and Fault Code 559 comes active during cranking, but no speed sensor fault codes exist, monitor rail pressure with INSITE™ electronic service tool. The procedures referred to in this troubleshooting tree will also have checks for engine no start conditions.

Before servicing any fuel system components, (such as fuel lines, fuel pump, injectors, etc.) which would expose the fuel system or internal engine component to potential contaminants prior to disassembly, clean the fittings, mounting hardware, and the area around the component to be removed. Dirt or contaminants can be introduced into the fuel system and engine if the surrounding areas are not cleaned, resulting in damage to the fuel system and engine.

If fuel pressure is low, check the following:

1)Fuel system prime (make sure that there is fuel in the tanks and that the system is primed)
2)Fuel gear pump pressure.

If fuel gear pump pressure is correct, test for system leakage:

1)High pressure pump leakage
2)Injector leakage
3)Fuel rail pressure relief valve leakage.

If Fault Code 559 is inactive and there are no existing performance complaints, it is possible that the vehicle was run out of fuel or that the fault came active if the engine was not primed following fuel filter replacement. Clear the inactive fault code.

Fault Code 559 sets when the engine is running and measured rail fuel pressure remains at least 100 Bar [1450 psi] less than commanded pressure. Once detected, Fault Code 559 will remain active until the engine is turned off or until the measured rail fuel pressure matches the commanded rail fuel pressure. When a condition exists that causes Fault Code 559 to become active, it is typical for the fault code to become active when the engine is heavily loaded and become inactive when the engine is lightly loaded.

When Fault Code 559 occurs, the fuel system has lost its ability to maintain rail fuel pressure. Causes of this fault include:

1)Fuel inlet restrictions
2)Fuel filter plugging
3)Fuel gear pump output low
4)Fuel gear pump pressure regulator sticking or leaking
5)High pressure pump capacity decay (high leakage to drain from the high pressure pump)
6)Fuel rail pressure relief valve leaks to drain
7)Fuel rail pressure relief valve opens at too low a pressure
8)Injector fuel circuit leaks to drain
9)Pressure sensor reads more than 100 bar lower than actual pressure
10)Air in the fuel.

A few bubbles exiting the line during the test is expected. A foamy appearance is an indication of a leak that allows air to enter, a severe inlet restriction that causes cavitation, or a system that is not yet primed. If fuel inlet restriction is not excessive, the source of air entry could be isolated to one of the following: suction fuel lines, OEM fuel lines, suction-side fuel filter assemblies, or stand-pipe(s) in the fuel tank(s).

The fuel rail pressure sensor can be checked. When checking the fuel rail pressure sensor accuracy, make sure the high-pressure fuel rail is not pressurized. The fuel pump, high-pressure fuel lines, and fuel rail contain very high-pressure fuel. Do not loosen any fittings while the engine is running. Wait at least 10 minutes after shutting down the engine before loosening any fittings in the high-pressure fuel system, to allow the pressure to decrease to a lower level. There could be a significant amount of time waiting on the rail to depressurize completely to 0. It could be necessary to manually relieve the pressure from the high pressure fuel rail.

Intermittent ECM power supply connections can cause Fault Code 559. If the engine is running with an active Fault Code 559 and Fault Codes 449, 1911, or 2311 are not present, check the ECM power supply for intermittent connections or battery issues. Fault Code 1117 can also be active if this fault condition exits.

Inactive Fault Code/Exhausted Troubleshooting Tree:

Troubleshooting inactive Fault Code 559 can be very difficult. The fault code must be active for any of the outlined procedures in which the engine is operated during the test. For engines with high counts of inactive Fault Code 559 or if the troubleshooting tree has been exhausted, operate the engine on a chassis dynamometer or a diagnostic road test to duplicate the fault code. The most common causes of intermittent Fault Code 559 that are difficult to create are leaking high-pressure connectors that only leak when the engine and the fuel are hot, intermittent fuel supply restrictions such as debris floating in the fuel tank, and a fuel pressure relief valve that opens prematurely. Check the High Pressure Connector (HPC) and connector torque and torque to specification if necessary. Operate the engine on a chassis dynamometer or conduct a diagnostic road test to duplicate the fault code. Use INSITE™ electronic service tool to log fuel system parameters during testing.

Possible repairs:

1)Add fuel to the fuel tank or perform repairs to the vehicle’s tank or fuel gauge.
2)Repair the fuel leak.
3)Make sure the fuel pump pressure into the filter is within specification.
4)If the pump is OK, replace the fuel filter and prime the fuel system.
5)If the fuel inlet restriction is too high, check the OEM fuel lines from the tank for proper size. Make certain there are no kinks or bends in the fuel lines and the fuel lines are not clogged.
6)Replace the fuel pump.
7)If no issues are found, replace the suction side fuel filter and prime the fuel system.
8)Replace the injector of the cylinder that is contributing to the high return flow.
9)Replace the high-pressure fuel pump.
10)Replace the rail fuel pressure relief valve.
11)Repair the tampering
12)Check drain line restriction.
13)After replacing the fuel pump actuator, measure the fuel pump flow again. If the flow is not within specification, replace the high-pressure fuel pump.
14)Replace the ECM.

The fuel system is designed to run on clean fuel. It has two fuel filters to maintain this cleanliness. Carelessness in handling and storage of fuel system components during the repair can subject the precision components to damaging debris. Before servicing any fuel system components (such as fuel lines, fuel pump, injectors, etc.), clean the fittings, mounting hardware, and the area around the component to be removed. Store the components in a clean environment. Keep all fuel port openings and line ends covered so that no dirt can enter. Use the following procedure in the ISC and ISL CM2150 Service Manual, Bulletin 4021569, or the ISLe CM2150 Service Manual, Bulletin 4021630.

Fault Code 559 sets when the engine is running and measured rail fuel pressure remains at least 250 bar [3625 psi] less than commanded pressure. Once detected, Fault Code 559 will remain active until the engine is turned OFF or until the measured rail fuel pressure matches the commanded rail fuel pressure. When a condition exists that causes Fault Code 559 to become active, it is typical for the fault code to become active when the engine is heavily loaded and become inactive when the engine is lightly loaded.

Possible causes:

1)Fuel inlet restrictions (filters, low pressure fuel lines, OEM plumbing, etc.)
2)Sticking check valve in ECM cooling plate
3)Fuel gear pump output low
4)Fuel gear pump pressure regulator stuck open (this can result in hard start and/or no-start complaints)
5)High-pressure pump capacity decay (high leakage to drain from the high-pressure pump)
6)Fuel rail pressure relief valve leaks to drain
7)Fuel rail pressure relief valve opens at a pressure too low (Fault Code 3727 detects this condition)
8)Injector fuel circuit leaks to drain (injector body, high-pressure connectors, etc.)
9)Air in the fuel or suction leaks at gear pump shaft seal (can result in hard start and/or no start complaints)
10)Fuel level is below the suction line in the fuel tank
11)Restricted fuel screen, located in the banjo bolt, at the high-pressure fuel pump inlet, if equipped
12)External fuel leaks.

If Fault Code 559 is inactive and there are not any existing performance complaints, it is possible the vehicle was run out of fuel or the fault became active if the engine was not primed following fuel filter replacement. However, if the customer reports that the fault code becomes active during engine operation, the steps in this fault code diagnostic tree can be used to identify the cause and make a repair.

If the engine will not start and Fault Code 559 becomes active during cranking, and no speed sensor fault codes exist, it is most likely that the engine is not developing rail pressure during cranking. Possibly, the engine is not primed, gear pump pressure is too low, or the high-pressure fuel system components have excessive leakage to drain. The procedures referred to in this troubleshooting tree also have checks for engine no start conditions.

The steps of this fault code tree assume that the fault condition is repeatable (this does not necessarily mean that the fault code is active with the engine at idle). The troubleshooting has been designed to isolate the problem into four categories:

1)Other more precise fault codes exist (example: electrical circuits faults).
2)Isolate the high-pressure system; determine if the high-pressure system has high leakage.
3)Isolate the low pressure system; determine if the low pressure system works correctly. The system must first be primed. Then, it is important to note that checks of gear pump pressure and inlet restriction involves using a special service tool that causes the flow rate to increase to a rated flow. Fuel gear pump pressure and/or inlet restriction can not be accurately measured without a method of increasing the flow (i.e. using the special service tool or operating the engine at full power).
4)Verify the ECM calibration is correct. Check the calibration revision history found on QuickServe™ Online for applicable fixes to the calibration stored in the ECM. If necessary, calibrate the ECM. Refer to Procedure 019-032 in Section 19.

Troubleshooting inactive Fault Code 559 can be difficult. For engines with high counts of inactive Fault Code 559, or if the troubleshooting tree has been exhausted, operate the engine on a chassis dynamometer or conduct a diagnostic road test to duplicate the fault code. Be certain to have a fuel pressure gauge installed at the pressure filter outlet side during the test.

If the accuracy of the fuel rail pressure sensor is being questioned, a key ON accuracy check can be performed. When checking the fuel rail pressure sensor accuracy, make sure the high-pressure fuel rail is not pressurized. The fuel pump, high-pressure fuel lines, and fuel rail contain very high-pressure fuel. Do not loosen any fittings while the engine is running. Once the engine is keyed OFF, there could be a significant amount of time waiting for the fuel to depressurize to 0 bar [0 psi]. It is necessary to manually relieve the pressure from the high-pressure fuel rail by loosening the pump-to-rail line at the rail. At key ON, a depressurized rail pressure sensor should read 0 ± 43 bar [624 psi].

Possible repairs:

1)Repair or replace the malfunctioning low-pressure system component as necessary and perform the low-pressure system check again to verify the issue has been corrected.
2)Replace the fuel pump actuator.
3)Tighten the injector high-pressure connector.
4)Replace the high-pressure connector and injector for the cylinder that is causing the high injector return flow.
5)Cap off additional injectors to identify the source of high injector return flow. Replace the high-pressure connector and injector for the cylinder(s) causing the high injector return flow.
6)Replace the fuel rail pressure relief valve.
7)Replace the high-pressure fuel pump head.
8)If the fuel pump head damage or stuck plungers are found, replace the fuel pump head.
9)If fuel pump head plungers are broken and/or internal camshaft housing damage is found, replace the fuel pump assembly.
10)Tighten the injector high-pressure connector
11)Replace the high-pressure connector and injector for the cylinder that is causing the high injector return flow.
12)Replace the rail fuel pressure relief valve.
13)Remove the fuel tank and clean out all debris.
14)If the engine shuts down or stalls more than 30 seconds after startup, replace the ECM cooling plate check valve.
15)Replace the fuel pump actuator housing.
16)Replace the fuel pump actuator.
17)Replace the ECM cooling plate check valve.
18)Replace the rail fuel pressure relief valve.
19)If necessary, calibrate the ECM.

Verify the electronic control module (ECM) calibration is correct. Check the calibration revision history found on Quickserve® Online for applicable fixes to the calibration stored in the ECM. If necessary, recalibrate the ECM.

The ECM monitors the voltage level on this circuit. If it detects a voltage when the signal is commanded off, it records this fault code.

Possible causes:

1)Open circuit in the starter lockout relay, OEM harness, or connectors
2)Short circuit to a voltage source in the OEM harness or relay.

Possible repairs:

1)Replace the starter lockout relay.
2)Clean, repair, or replace the OEM harness.
3)Repair or replace the OEM harness.
4)Replace the ECM.

Verify the electronic control module (ECM) calibration is correct. Check the calibration revision history found on QuickServe® Online for applicable fixes to the calibration stored in the ECM. If necessary, recalibrate the ECM.

The ECM monitors the voltage level on this circuit. If it detects a low voltage when the signal is commanded on, it records this fault code. This fault code can be caused by a short circuit to ground in the starter lockout relay, OEM harness, or connectors.

Possible repairs:

1)Replace the starter lockout relay.
2)Clean, repair, or replace the OEM harness.
3)Repair or replace the OEM harness.
4)Replace the ECM.

Verify the electronic control module (ECM) calibration is correct. Check the calibration revision history found on QuickServe® Online for applicable fixes to the calibration stored in the ECM. If necessary, calibrate the ECM.

This fault code is part of the Alternator Failure Warning feature. The ECM can increase idle speed and deactivate the idle decrement switch if idle speedup is enabled. View the Alternator Failure Warning feature settings with INSITE™ electronic service tool. Disabling the Alternator Failure Warning feature will also disable this fault code.

Make sure the ECM battery supply (+) is coming directly from the battery and not the starter.

Possible causes:

1)Overcharged batteries caused by a malfunctioning alternator or regulator.

Possible repairs:

1)Tighten the battery connections and clean the battery terminals.
2)Charge or replace the battery.
3)Repair or replace the alternator, regulator, and/or OEM wiring to the alternator.

Verify the electronic control module (ECM) calibration is correct. Check the calibration revision history found on QuickServe® Online for applicable fixes to the calibration stored in the ECM. If necessary, recalibrate the ECM.

This fault code is part of the Alternator Failure Warning feature. The ECM can increase idle speed and deactivate the idle decrement switch if Idle Speedup is enabled. View the Alternator Failure Warning feature settings using the INSITE™ electronic service tool. Disabling the Alternator Failure Warning feature will also disable this fault code.

Make sure the ECM unswitched battery supply is coming directly from the battery and not the starter.

Possible causes:

1)Undercharged batteries caused by a malfunctioning alternator or regulator
2)High-current devices on the vehicle such as citizens band radio amplifiers, numerous exterior lights, or other accessories.

Possible repairs:

1)Tighten the battery connections and clean the battery terminals.
2)Charge or replace the battery.
3)Repair or replace the alternator and/or OEM wiring to the alternator.
4)Repair or replace the battery harness.
5)Repair or replace the OEM power harness.
6)Repair or replace the OEM power harness.

Verify the electronic control module (ECM) calibration is correct. Check the calibration revision history found on QuickServe® Online for applicable fixes to the calibration stored in the ECM. If necessary, calibrate the ECM. Use the corresponding service manual for the engine bening serviced.

This fault code is part of the Alternator Failure Warning feature. The ECM can increase idle speed and deactivate the idle decrement switch if Idle Speedup is enabled. View the Alternator Failure Warning feature settings with INSITE™ electronic service tool. Disabling the Alternator Failure Warning feature will also disable this fault code.

Make sure the ECM battery supply (+) is coming directly from the battery and not the starter.

Possible causes:

1)Undercharged batteries caused by a malfunctioning alternator or regulator.

Possible repairs:

1)Tighten the battery connections and clean the battery terminals.
2)Charge or replace the battery.
3)Repair or replace the alternator and/or OEM wiring to the alternator.
4)Repair the battery power connector.
5)Repair or replace the OEM harness.