Conditions

• Turn keyswitch OFF.

Action

• Interview the operator using the appropriate complaint prompt sheet. Refer to Procedure t00-004

• If necessary to duplicate the complaint, verify the complaint on the dyno, during a road test or operating the engine under load under similar conditions.

• Verify that there are no derates, gear down protection or load based speed control occurring or enabled.

Specification

• If the complaint cannot be verified, then proceed to the Repair section.

Linked Solutions

• None

Conditions

• Turn keyswitch OFF.

Action

• Visually inspect the vehicle intake system for blockage or damage.

• Visually inspect the air filter to make sure it is not plugged.

Specification

• If the intake air filter is plugged, then a restricted intake air filter has been detected.

Linked Solutions

• None

Conditions

• Turn keyswitch OFF.

Action

• Inspect the air intake system for leaks. Refer to Procedure 010-024

Specification

• If a leak is found, then proceed to the Repair section.

Linked Solutions

• None

Conditions

• Turn keyswitch OFF.

Action

• Remove the exhaust gas pressure sensor tube. Refer to Procedure 011-027

• Inspect the exhaust gas pressure sensor tube(s) for cracks and thread damage. Refer to Procedure 011-027

• Inspect the inside of the tube(s) and sensor adapter for debris or soot buildup. Refer to Procedure 011-027

Specification

• If plugging or damage is found, then proceed to the Repair section.

Linked Solutions

• None

Conditions

• Turn keyswitch OFF.

Action

• Inspect the exhaust system for leaks. Refer to Procedure 010-024

Specification

• If a leak is found, then proceed to the Repair section.

Linked Solutions

• None

Conditions

• Turn keyswitch OFF.

Action

• Remove the EGR differential pressure sensor tubes. Refer to Procedure 011-026

• Visually inspect the EGR differential pressure sensor tubes for restrictions.

• Remove the EGR venturi tube. Refer to Procedure 011-025

• Visually inspect the EGR venturi tube for restrictions.

Specification

• If damage or restrictions are found, then proceed to the Repair section.

Linked Solutions

• None

Conditions

• Engine running at idle.

• Connect the recommended Cummins® electronic service tool or equivalent.

Action

• Use the recommended Cummins® electronic service tool or equivalent.

• Perform the Cylinder Cutout Test.

Specification

• If engine fails the cylinder cutout test, before replacing the fuel injector, verify the overhead valve lash measurements are correct for the suspect cylinder and adjust if needed.

Linked Solutions

• None

Conditions

• Turn keyswitch ON.

Action

• Measure the fuel pump gear pump outlet pressure at idle and at high idle. Refer to Procedure 005-016

• If engine will not start, then perform the check during cranking. Refer to Procedure 005-016

Specification

• If the fuel pump gear pump outlet pressure is not within specification, then proceed to Linked Solutions section.

Linked Solutions

• Fuel filter restriction

• Air in fuel check

• Fuel Inlet Restriction check

• Fuel lift pump check

• Fuel shutoff valve is malfunctioning

• Fuel pump gear pump is malfunctioning

Conditions

• Turn keyswitch OFF.

Action

• Perform the Fuel Filter Restriction Test. Refer to Procedure 006-015

Specification

• If the differential pressure does not meet specification, then a plugged or blocked fuel filter has been detected.

Linked Solutions

• None

Conditions

• Turn keyswitch OFF.

• Verify adequate fuel level in the tank

Action

• Allow the engine to reach operating temperature.

• If engine will not start, then perform the check during cranking.

• Inspect for air being ingested into the fuel. Refer to Procedure 006-003

Specification

• If air is present in the fuel flow, then a damaged fuel supply line, loose or damaged fuel filter, or a loose connection has been detected.

Linked Solutions

• None

Conditions

• Turn keyswitch OFF.

Action

• Measure the fuel inlet restriction. Refer to Procedure 006-020

Specification

• If the engine will not start, continue with published troubleshooting.

• If the fuel inlet restriction is not within specification, then proceed to the Repair section.

Linked Solutions

• None

Conditions

• Turn keyswitch ON.

Action

• Listen for fuel lift pump operation.

• If the fuel lift pump does not operate after turning the keyswitch ON, then measure the resistance in the fuel lift pump circuit. Refer to Procedure 019-397

• Measure the lift pump pressure. Refer to Procedure 005-236

Specification

• If the resistance is not within specification, then proceed to the Repair section.

• If the fuel lift pump pressure is not within specification, then a malfunctioning fuel lift pump has been detected. Refer to Procedure 005-236

Linked Solutions

• None

Conditions

• Turn keyswitch OFF.

• Disconnect the fuel shutoff valve from the engine wiring harness.

Action

• Measure the fuel shutoff valve resistance. Refer to Procedure 005-043

Specification

• If the fuel shutoff valve solenoid resistance does not meet specification, then a malfunctioning fuel shutoff valve solenoid has been detected.

Linked Solutions

• None

Conditions

• Turn keyswitch OFF.

Action

• Verify all preceding linked solution verifications have been performed.

Specification

• If all preceding linked solution verifications have been performed and all were within specification, then proceed to the Repair section.

Linked Solutions

• None

Conditions

• Turn keyswitch OFF.

Action

• Visually inspect the charge air cooler hoses for possible air leaks.

• Pressure test the charge air cooler to check for leaks. Refer to Procedure 010-027

Specification

• If a leak is found, then proceed to the Repair section.

Linked Solutions

• None

Conditions

• Turn keyswitch OFF.

Action

• Perform the Timing Actuator Flow Test. Refer to Procedure 005-239

Specification

• If the Timing Actuator Flow Test is not within specification, then proceed to the Repair section.

Linked Solutions

• None

Conditions

• Turn keyswitch OFF.

Action

• Swap the fueling actuators.

• Run the engine at idle.

Specification

• If the symptom follows the fueling actuator, then a malfunctioning fueling actuator has been detected.

Linked Solutions

• None

Conditions

• Turn keyswitch OFF.

• Remove the intake and exhaust connections from the turbocharger.

Action

• Visually inspect the turbocharger compressor and turbine seals. Refer to Procedure 010-145

• Visually inspect the compressor wheel retaining nut for signs of dust ingestion. Refer to Procedure 010-145

• Visually inspect the turbocharger compressor and turbine blades for damage or wear. Refer to Procedure 010-145

• Measure the radial and axial clearance of the turbocharger wheel. Refer to Procedure 010-145

• Inspect the turbocharger shroud plate. Refer to Procedure 010-145

Specification

• If any of the checks are not within specification, then a malfunctioning turbocharger has been detected.

Linked Solutions

• None

Conditions

• Turn keyswitch OFF.

• Drain the engine coolant. Refer to Procedure 008-018

• Disconnect the variable geometry turbocharger actuator from the engine wiring harness.

• Remove the variable geometry turbocharger actuator from the turbocharger. Refer to Procedure 010-134

Action

• Inspect the pins and connectors for damage. Refer to Procedure 019-361

• Visually inspect the variable geometry turbocharger pinion gear on the actuator for seizure, excessive wear, or damaged teeth. Refer to Procedure 010-134

• Visually inspect the variable geometry turbocharger sector gear for excessive wear, damaged teeth, or a broken shaft. Refer to Procedure 010-134

• Inspect the variable geometry turbocharger sector gear for correct travel. Refer to Procedure 010-134

• Inspect the turbocharger shroud plate. Refer to Procedure 010-145

Specification

• If the variable geometry turbocharger actuator movement does not meet requirements, then a malfunctioning variable geometry turbocharger actuator has been detected.

• If the variable geometry turbocharger sector gear does not meet requirements, then a malfunctioning turbocharger has been detected.

Linked Solutions

• None

Conditions

• Turn keyswitch ON.

• Connect the recommended Cummins® electronic service tool or equivalent.

Action

• Use the recommended Cummins® electronic service tool or equivalent.

• Verify the Percent Accelerator Pedal value being displayed.

Specification

• If the accelerator pedal does not read 100 percent with the accelerator pedal depressed and 0 percent when released, then a malfunctioning accelerator pedal has been detected.

Linked Solutions

• None

Conditions

• Reconnect previously disconnected components.

• Turn keyswitch ON.

• Connect the recommended Cummins® electronic service tool or equivalent.

Action

• Use the recommended Cummins® electronic service tool or equivalent.

• Perform the Aftertreatment Diesel Particulate Filter Regeneration Analyzer Test. Refer to Procedure 014-027

Specification

• If the Aftertreatment Diesel Particulate Filter Regeneration Analyzer Test does not pass, then reset the search to Aftertreatment Diesel Particulate Filter Regeneration Analyzer Did Not Pass. Only select the solution title that matches the error messages in the recommend Cummins® electronic service tool or equivalent.

• If the Aftertreatment Diesel Particulate Filter Regeneration Analyzer Test will not start, then reset the search to Aftertreatment Diesel Particulate Filter Regeneration Analyzer Did Not Start.

• If the Aftertreatment Diesel Particulate Filter Regeneration Analyzer Test does not complete, then reset the search to Aftertreatment Diesel Particulate Filter Regeneration Analyzer Did Not Complete.

Linked Solutions

• None

Conditions

• Connect all components.

• Turn keyswitch ON.

• Connect the recommended Cummins® electronic service tool or equivalent.

Action

• Use the recommended Cummins® electronic service tool or equivalent to find the current ECM code and revision number in the ECM.

• Compare the ECM code and revision number in the ECM to the calibration revision listed in the ECM calibration revision history for applicable changes.

Specification

• If the ECM does not contain the appropriate calibration revision or higher, calibrate ECM.

Linked Solutions

• None