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Engine Performance Troubleshooting Tree - CM2150 Electronic Control

System
This troubleshooting procedure should be followed for the following symptoms:
• Engine Acceleration or Response Poor
• Cranking Fuel Pressure Low
• Engine Operating Fuel Pressure 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
• Smoke, Black - Excessive
• Smoke, White - Excessive
• 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) Below Normal
• Intake Manifold Pressure (Boost) Above Normal

How to Use This Troubleshooting Procedure:

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 provide a list of troubleshooting steps to perform,
depending on the symptom. Perform the list of troubleshooting in the sequence shown in the Specifications/Repair
section of the tree.

Shop Talk:
Driveability is a term that in general describes vehicle performance on the road. Driveability problems for an engine
can be caused by several different factors. Some of the factors are engine-related and some are not. Before
troubleshooting it is important to determine the exact complaint and whether the engine has a real driveability problem,
or if it simply does not meet driver 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 the vehicle 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 accelerate satisfactorily from a stop or from
the bottom of a grade. It can also be the lag in acceleration during an attempt to pass or overtake another vehicle at
conditions less than rated speed and load. Poor acceleration or response is difficult to troubleshoot since it can be
caused by several factors.
Included in this engine performance tree is information for troubleshooting engines with the exhaust gas temperature
sensor. This information is contained in Step 4.

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TROUBLESHOOTING SUMMARY

STEPS SPECIFICATIONS SRT CODE

STEP 1: Perform basic troubleshooting procedures.
STEP 1A: Check for active fault codes or Active fault codes or high
high counts of inactive fault counts of inactive fault codes?
codes.
STEP 1B: Perform basic troubleshooting All steps verified to be correct?
checks.
STEP 2: Determination of engine symptom.
STEP 2A: Low power, poor acceleration, Engine symptom - Low Power,
or poor response. Poor Acceleration, or Poor
Response?
STEP 2B: Engine misfire, engine speed Engine symptom - Engine
surge, or engine speed Misfire, Engine Speed Surge, or
unstable. Engine Speed Unstable?
STEP 2C: Excessive white or black smoke. Engine symptom - Excessive
White or Black Smoke?
STEP 2D: Low intake manifold pressure Engine symptom - Low Intake
(boost). Manifold Pressure (boost)?
STEP 2E: High intake manifold pressure Engine symptom - High Intake
(boost). Manifold Pressure (boost)?
STEP 2F: Engine will not start or difficult Engine symptom - Engine Will
to start, engine shuts off Not Start or Difficult to Start,
unexpectedly. Engine Shuts Off Unexpectedly?
STEP 3: No-start troubleshooting procedures.
STEP 3A: Verify the operation of cold Necessary cold weather starting
weather starting aids. aids operating properly?
STEP 3B: Check for other fault codes that Any fault codes that can cause a
explain a no-start condition. no-start condition become active
during cranking?
STEP 3C: Check engine speed during Engine cranking speed greater
cranking. than 150 rpm?
STEP 3D: Check the engine control Keyswitch voltage equal to
module (ECM) keyswitch battery voltage?
voltage.
STEP 3E: Check the ECM battery supply ECM battery supply voltage
voltage. equal to the battery voltage?
STEP 3F: Check fuel rail pressure to the Fuel rail pressure greater than
injectors. 300 bar [4351 psi] while
cranking?
STEP 3G: Check for fuel pressure from the Fuel pressure 560 kPa [81 psi]?
gerotor pump while cranking the
engine.
STEP 3G-1: Check the inlet fuel Restriction higher than the
restriction. specification?
STEP 3G-2: Check fuel lift pump Fuel pressure 3 bar [44 psi] after
pressure. pump operating for 30 seconds?
STEP 3G-3: Check if engine starts. Engine starts?

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STEP 3G-4: Check for proper operation Check valve near the fuel lift
of the check valve near the pump operating properly?
fuel lift pump.
STEP 3G-5: Check if the engine starts. Engine starts?
STEP 3H: Check for external fuel rail Fuel rail leakage present?
(high-pressure) leaks.
STEP 3I: Check injector solenoid Injector tester tool show a green
operation. light?
STEP 3J: Measure the injector drain flow Drain fuel flow from the fuel
from all injectors. drain block greater than the
specification?
STEP 3J-1: Isolate the injector drain Drain fuel flow from the injector
flow from each of the greater than the specification?
injectors.
STEP 3K: Use INSITE™ electronic service Fuel pump actuator click when
tool to perform a fuel pump commanded with the diagnostic
actuator click test. test in INSITE™ electronic
service tool?
STEP 3L: Measure the fuel drain flow from Drain fuel flow from the fuel
the fuel pressure relief valve. pressure relief valve greater
than the specification?
STEP 4: Exhaust gas temperature analysis.
STEP 4A: Check for exhaust gas Exhaust gas temperature
temperature sensors. sensors present?
STEP 4B: Check the cylinder temperatures Temperature sensor reading at
using an infrared thermometer. any cylinder more than 67°C or
120°F different from the
average?
STEP 4C: Check exhaust gas temperature Any of the exhaust gas
readings. temperature sensors read: For
Thermocouple: 474°C [885°F]?
For Thermistors: 600°C
[1112°F]?
STEP 4C-1: Check the engine harness Dirty or damaged pins?
and the ECM 1 and ECM 2
connectors for affected
cylinders.
STEP 4C-2: Check the exhaust gas Dirty or damaged pins?
temperature sensor
converter and engine
harness connector pins.
STEP 4C-3: Check for an open circuit in Less than 10 ohms?
the exhaust gas
temperature sensor or
sensor converter supply.
STEP 4C-4: Check for a short circuit to Greater than 100k ohms?
ground.
STEP 4D: Check for significant Temperature sensor reading at
temperature difference. any cylinder more than 45°C or
81°F different from the average?
STEP 4D-1: Check for shared Are cylinders that share a
turbochargers/air handling particular turbocharger
passages. affected?

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STEP 5: Fuel system troubleshooting procedures.

STEP 5A: Check for fault codes. Fuel system fault codes active?
STEP 5B: Measure the fuel inlet Fuel restriction above
restriction. specifications?
STEP 5C: Check stage one fuel filter head Fuel filter head check valves in
check valves for proper good condition and the
operation. passageway free of restrictions?
STEP 5D: Check injector solenoid Injector tester tool show a green
operation. light?
STEP 5E: Use INSITE™ electronic service Fuel pump actuator click when
tool to perform fuel pump commanded with the diagnostic
actuator click test. test in INSITE™ electronic
service tool?
STEP 5F: Measure the injector drain flow Drain fuel flow from the fuel
from all injectors. drain block greater than the
specification?
STEP 5F-1: Isolate the injector drain Drain fuel flow from the injector
flow from each of the greater than the specification?
injectors.
STEP 5G: Perform single cylinder cut-out Miss or excessive smoke be
test. attributed to a single cylinder?
STEP 5H: Audio check for injector Can a miss be heard from any
operation. individual injector?
STEP 6: Air handling troubleshooting procedures.
STEP 6A: Inspect the turbocharger blades Damage found on turbocharger
for damage. blades?
STEP 6B: Check the turbocharger axial Turbocharger axial and radial
and radial clearances. bearing clearance within
specification?
STEP 6C: Check air intake restrictions. Intake restriction greater than
635 mm-H2O [25 in-H2O]?

STEP 7: Electronic feature troubleshooting procedures.

STEP 7A: Verify throttle pedal travel. Throttle position read 0 percent
when the throttle is released and
100 percent when the throttle is
depressed?
STEP 7B: Check barometric pressure INSITE™ electronic service tool
sensor accuracy. reading is within 102 mm-Hg [4
in-Hg] of local barometric
pressure?
STEP 7C: Check intake manifold pressure Intake manifold pressure
sensor accuracy. reading is less than 102 mm-Hg
[4 in-Hg]?
STEP 8: Base engine troubleshooting procedures.
STEP 8A: Verify overhead adjustments are Overhead settings within the
correct. reset limits?
STEP 8B: Check exhaust restriction. Exhaust back pressure less than
75 mm-Hg [3 in-Hg]?

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TROUBLESHOOTING STEP

STEP 1: Perform basic troubleshooting procedures.

STEP 1A: Check for active fault codes or high counts of inactive fault codes.
Condition:
• Turn keyswitch ON.
• Connect INSITE™ electronic service tool.

Action Specification/Repair Next Step

Check for active fault codes. Active fault codes or high counts of inactive Repair
• Use INSITE™ electronic service tool to read fault codes? complete
the fault codes. YES
Repair:
Follow the electronic fault code trees for
troubleshooting procedures.

Active fault codes or high counts of inactive 1B

fault codes?
NO

STEP 1B: Perform basic troubleshooting checks.

Condition:
None.

Action Specification/Repair Next Step

The following items must be checked or verified All steps have been verified to be correct? 2A
before continuing: YES
• Verify fuel level in the tanks
• Verify there have not been any changes to
CPL components on the engine All steps have been verified to be correct? Repair
• Verify fuel grade is correct for application NO complete
• Verify engine is operating within the
Repair:
recommended altitude
• Verify engine oil is at the correct level Correct or repair and verify complaint is no
• Verify engine parasitics have not changed longer present after repair.
• Verify engine duty cycle has not changed
• Verify engine cranking speed is greater than
150 rpm
• Verify battery voltage is within specification.

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STEP 2: Determination of engine symptoms.

STEP 2A: Low power, poor acceleration, or poor response.
Condition:
None.

Action Specification/Repair Next Step

Interview the driver and verify the complaint. Engine symptom - Low Power, Poor Perform the
• Interview the operator. Acceleration, or Poor Response? troubleshooti
YES ng steps
suggested in
Repair: the repair
Perform the troubleshooting steps in the procedure.
recommended order listed below:
• Step 4 - Exhaust Gas Temperature
Analysis (exhaust gas temperature only)
• Step 5 - Fuel System Checks
• Step 6 - Air Handling Checks
• Step 7 - Electronics Checks
• Step 8 - Base Engine Checks.

Engine symptom - Low Power, Poor 2B

Acceleration, or Poor Response?
NO

STEP 2B: Engine misfire, engine speed surge, or engine speed unstable.
Condition:
None.

Action Specification/Repair Next Step

Interview the driver and verify the complaint. Engine symptom - Engine Misfire, Engine Perform the
• Interview the operator. Speed Surge, or Engine Speed Unstable? troubleshooti
YES ng steps
suggested in
Repair: the repair
Perform the troubleshooting steps in the procedure.
recommended order listed below:
• Step 4 - Exhaust Gas Temperature
Analysis (exhaust gas temperature only)
• Step 5 - Fuel System Checks
• Step 6 - Air Handling Checks
• Step 7 - Electronics Checks
• Step 8 - Base Engine Checks.

Engine symptom - Engine Misfire, Engine 2C

Speed Surge, or Engine Speed Unstable?
NO

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STEP 2C: Excessive white or black smoke.
Condition:
None.

Action Specification/Repair Next Step

Interview the driver and verify the complaint. Engine symptom - Excessive White or Black Perform the
• Interview the operator. Smoke? troubleshooti
YES ng steps
suggested in
Repair: the repair
Perform the troubleshooting steps in the procedure.
recommended order listed below:
• Step 4 - Exhaust Gas Temperature
Analysis (exhaust gas temperature only)
• Step 5 - Fuel System Checks
• Step 6 - Air Handling Checks
• Step 8 - Base Engine Checks.

Engine symptom - Excessive White or Black 2D

Smoke?
NO

STEP 2D: Low intake manifold pressure (boost).

Condition:
None.

Action Specification/Repair Next Step

Interview the driver and verify the complaint. Engine symptom - Low Intake Manifold Perform the
• Interview the operator. Pressure (boost)? troubleshooti
YES ng steps
suggested in
Repair: the repair
Perform the troubleshooting steps in the procedure.
recommended order listed below:
• Step 6 - Air Handling Checks
• Step 5 - Fuel System Checks
• Step 8 - Base Engine Checks.

Engine symptom - Low Intake Manifold 2E

Pressure (boost)?
NO

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STEP 2E: High intake manifold pressure (Boost).
Condition:
None

Action Specification/Repair Next Step

Interview the operator and verify the compliant. Engine symptom - High Intake Manifold Perform the
• Interview the operator. Pressure (boost)? troubleshooti
YES ng steps
suggested in
Repair: the repair
Perform the troubleshooting steps in the procedure.
recommended order listed below:
• Step 7 - Electronics Checks
• Step 5 - Fuel System Checks.

Engine symptom - High Intake Manifold 2F

Pressure (boost)?
NO

STEP 2F: Engine will not start or difficult to start, engine shuts off unexpectedly.
Condition:
None.

Action Specification/Repair Next Step

Interview the driver and verify the complaint. Engine symptom - Engine Will Not Start or Perform the
• Interview the operator. Difficult to Start, Engine Shuts Off troubleshooti
Unexpectedly? ng steps
YES suggested in
the repair
Repair: procedure.
Perform the troubleshooting steps in the
recommended order listed below:
• Step 3 - No Start Checks
• Step 5 - Fuel System Checks
• Step 6 - Air Handling Checks
• Step 7 - Electronics Checks.

Engine symptom - Engine Will Not Start or Return to

Difficult to Start, Engine Shuts Off correct
Unexpectedly? symptom
NO tree

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STEP 3: No-start troubleshooting procedures.

STEP 3A: Verify the operation of cold weather starting aids.
Condition:
• Turn keyswitch ON.

Action Specification/Repair Next Step

Check cold weather starting aids. Necessary cold weather starting aids 3B
• Refer to the Operation of Diesel Engines in operating properly?
Cold Climates, Bulletin 3379009. YES

Necessary cold weather starting aids Repair

operating properly? complete
NO
Repair:
Install or repair cold weather starting aids.
Refer to the Operation of Diesel Engines in
Cold Climates, Bulletin 3379009.

STEP 3B: Check for other fault codes that explain a no-start condition.
Condition:
• Turn keyswitch ON.
• Connect INSITE™ electronic service tool.

Action Specification/Repair Next Step

Use INSITE™ electronic service tool to read fault Any fault codes that can cause a no-start Repair
code information. condition become active during cranking? complete
• Check for fault codes that come active during YES
a unsuccessful start attempt that can be the
cause for a no-start condition. Repair:
Follow the electronic fault code trees for the
appropriate troubleshooting procedures.

Any fault codes that can cause a no-start 3C

condition become active during cranking?
NO

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STEP 3C: Check engine speed during cranking.
Condition:
• Turn keyswitch ON.
• Connect INSITE™ electronic service tool.

Action Specification/Repair Next Step

Use INSITE™ electronic service tool to monitor Engine cranking speed greater than 150 3D
engine speed and fuel rail pressure while rpm?
cranking the engine. YES
• Check engine speed during cranking.
• Monitor fuel rail pressure during cranking, (300
bar [4351 psi] minimum pressure is required to Engine cranking speed greater than 150 Repair
start the engine). rpm? complete
If lower fuel rail pressure is observed after NO
completing all sub-steps of Step 3, proceed to Repair:
Step 5 for further fuel system troubleshooting
Find and correct the cause for low cranking
procedures.
speed. Check the batteries, engine starting
motor, and accessory loads. See the Engine
Will Not Crank or Cranks Slowly
troubleshooting symptom tree in Section TS.

STEP 3D: Check the engine control module (ECM) keyswitch voltage.
Condition:
• Disconnect the engine harness from the ECM 50-pin connector.
• Turn keyswitch ON.

Action Specification/Repair Next Step

Measure the signal voltage from the keyswitch Keyswitch voltage equal to battery voltage? 3E
input SIGNAL wire of the engine harness to the YES
engine block ground.
• Measure the keyswitch voltage with the
keyswitch in the ON position and also with the Keyswitch voltage equal to battery voltage? Repair
keyswitch in the cranking position. NO complete
Refer to the circuit diagram or wiring diagram for Repair:
connector pin identification. • Repair or replace the original equipment
manufacturer (OEM) power harness. Refer
to the OEM service manual.
• Repair or replace the keyswitch. Refer to
Procedure 019-064 in Section 19.
• Check the battery connections and fuse
terminals. Refer to Procedure 013-009 in
Section 13.

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STEP 3E: Check the ECM battery supply voltage.
Condition:
• Turn keyswitch OFF.
• Disconnect the ECM power harness from the ECM.

Action Specification/Repair Next Step

Measure the voltage from the ECM battery ECM battery supply voltage equal to the 3F
SUPPLY (-) pin to the ECM battery SUPPLY (+) battery voltage?
pins in the ECM power harness connector. YES
• Measure the ECM voltage with the keyswitch
in the ON position and also with the keyswitch
in the cranking position. ECM battery supply voltage equal to the Repair
• Refer to the wiring diagram for connector pin battery voltage? complete
identification. NO
Repair:
Refer to the OEM service manual.
Repair or replace the ECM power harness.
• Check the battery connections and fuse
terminals. Refer to Procedure 013-009 in
Section 13.

STEP 3F: Check fuel rail pressure to the injectors.

Condition:
• Turn keyswitch ON.
• Connect INSITE™ electronic service tool.

Action Specification/Repair Next Step

Measure the fuel rail pressure output pressure Fuel rail pressure greater than 300 bar [4351 5B
while cranking the engine. psi] while cranking?
• The cranking speed must be greater than YES
150rpm for 30 seconds.
Fuel rail pressure greater than 300 bar [4351 3G
psi] while cranking?
NO
Repair:
Repair or replace the components
associated with the leaks in the fuel system.
Install the fuel check ball valve in the correct
direction if it was found to be installed
incorrectly.

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STEP 3G: Check for fuel pressure from the gerotor pump while cranking the engine.
Condition:
• Turn keyswitch ON.
• Connect INSITE™ electronic service tool.

Action Specification/Repair Next Step

Attempt to start the engine by engaging the Fuel pressure 560 kPa [81 psi]? 3H
engine starting motor for at least 30 continuous YES
seconds.
• Use INSITE™ electronic service tool to
monitor fuel pressure. Fuel pressure 560 kPa [81 psi]? 3G-1
NO

STEP 3G-1: Check the inlet fuel restriction.

Condition:
• Turn keyswitch ON.

Action Specification/Repair Next Step

Check the fuel restriction and stage one filter Restriction higher than the specification? Repair
restriction. YES complete
• Refer to Procedure 006-020 in Section 6.
Restriction higher than the specification? 3G-2
NO
Repair:
• If the inlet restriction is higher than
specifications, refer to the OEM service
manual to determine the source of the
high restriction.
• If the stage 1 filter restriction is higher than
specifications, replace the stage one filter.
Refer to Procedure 006-075 in Section 6.

STEP 3G-2: Check fuel lift pump pressure.

Condition:
• Turn keyswitch ON.
• Attach a fuel pressure gauge to the fuel filter head stage one filter outlet.

Action Specification/Repair Next Step

Measure the fuel lift pump output pressure. Fuel pressure 3 bar [44 psi] after pump 3G-3
• Turn keyswitch ON, but engine not operating. operating for 30 seconds?
Listen for the fuel lift pump to operate. The YES
pump will run for 30 seconds then shut off.
Repair:
• Replace the air bleed check valve. Refer
to Procedure 006-021 in Section 6.

Fuel pressure 3 bar [44 psi] after pump 3G-4

operating for 30 seconds?
NO

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STEP 3G-3: Check if engine starts.
Condition:
• Turn keyswitch ON.

Action Specification/Repair Next Step

Check if engine starts. Engine starts? Repair

• Attempt to start the engine. YES complete

Repair:
The replacement of the air bleed check valve
in the previous step corrected the problem.

Engine starts? Repair

NO complete

Repair:
• Replace the the fuel pump. Refer to
Procedure 005-016 in Section 5.

STEP 3G-4: Check for proper operation of the check valve near the fuel lift pump.
Condition:
• Turn keyswitch ON.

Action Specification/Repair Next Step

Inspect the check valve for proper operation. Check valve near the fuel lift pump operating 3G-5
• Turn keyswitch ON, but engine not operating. correctly?
YES
Repair:
• Replace the air bleed check valve. Refer
to Procedure 006-021 in Section 6.

Check valve near the fuel lift pump operating Repair

correctly? complete
NO
Repair:
• Replace the check valve near the fuel lift
pump. Refer to Procedure 006-008 in
Section 6.

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STEP 3G-5: Check if engine starts.
Condition:
• Turn keyswitch ON.

Action Specification/Repair Next Step

Check if engine starts. Engine starts? Repair

YES complete
Attempt to start the engine.
Repair:
The replacement of the air bleed check valve
in the previous step corrected the problem.

Engine starts? Repair

NO complete

Repair:
• Replace the check valve near the fuel lift
pump. Refer to Procedure 005-045 in
Section 5.

STEP 3H: Check for external fuel rail (high-pressure) leaks.

Condition:
Crank the engine to develop fuel pressure.

Action Specification/Repair Next Step

Inspect the fuel rail for leaks. Fuel rail leakage present? Repair
• Refer to Procedure 006-051 in Section 6. YES complete

Repair:
Repair fuel rail or leaking component.

Fuel rail leakage present? 3I

NO
Repair:
Connect the fuel supply lines in the correct
port.

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STEP 3I: Check injector solenoid operation.
Condition:
• Turn keyswitch ON
• Attach the Injector Tester, Part Number 2892293, to an injector.

Action Specification/Repair Next Step

Test all of the injectors using the injector tester Injector tester tool show a green light? 3J
tool. YES
• Turn keyswitch ON.
• Attach the injector tester tool to the two pin
injector connector. Refer to Procedure Injector tester tool show a green light? Repair
006-026 in Section 6. NO complete

Repair:
Replace any malfunctioning injectors. Refer
to Procedure 006-026 in Section 6.

STEP 3J: Measure the injector drain flow from all injectors.
Condition:
• Crank engine to at least 150 rpm.
• Unplug all injectors.
• Connect appropriate service tools to measure injector drain flow at the fuel drain block.

Action Specification/Repair Next Step

Measure the injector return fuel drain flow at the Drain fuel flow from the fuel drain block 3J-1
fuel drain block. greater than the specification?
• Refer to Procedure 006-026 in Section 6. YES

Drain fuel flow from the fuel drain block 3K

greater than the specification?
NO

STEP 3J-1: Isolate the injector drain flow from each of the injectors.
Condition:
• Crank engine to at least 150 rpm.
• Unplug all injectors.
• Connect appropriate service tools to measure injector drain flow at each cylinder head.

Action Specification/Repair Next Step

Measure the injector return fuel drain flow at the Drain fuel flow from the injector greater than Repair
fuel drain block. the specification? complete
• Refer to Procedure 006-026 in Section 6. YES
Repair:
Replace any malfunctioning injectors. Refer
to Procedure 006-026 in Section 6.

Drain fuel flow from the injector greater than 3K

the specification?
NO

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STEP 3K: Use INSITE™ electronic service tool to perform the fuel pump actuator click test.
Condition:
• Turn keyswitch ON.
• Connect INSITE™ electronic service tool..

Action Specification/Repair Next Step

Perform the fuel pump actuator click test Fuel pump actuator click when commanded 3L
• Use INSITE™ electronic service tool to with the diagnostic test in INSITE™
perform the fuel pump actuator click test. electronic service tool?
YES

Fuel pump actuator click when commanded Repair

with the diagnostic test in INSITE™ complete
electronic service tool?
NO
Repair:
Replace the fuel pump actuator. Refer to
Procedure 019-117 in Section 19.

STEP 3L: Measure the fuel drain flow from the fuel pressure relief valve.
Condition:
• Crank engine to at least 150 rpm.
• Unplug all injectors.
• Connect appropriate service tools to measure fuel drain flow from the fuel pressure relief valve.

Action Specification/Repair Next Step

Measure the injector return fuel drain flow at the Drain fuel flow from the fuel pressure relief Repair
fuel drain block. valve greater than the specification? complete
• Refer to Procedure 006-061 in Section 6. YES
Repair:
Replace the fuel pressure relief valve. Refer
to Procedure 006-061 in Section 6.

Drain fuel flow from the fuel pressure relief Repair

valve greater than the specification? complete
NO
Repair:
• Replace the the fuel pump. Refer to
Procedure 005-016 in Section 5.

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File: 253-ttqsk50 Page 17 of 29

STEP 4: Exhaust gas temperature analysis.

STEP 4A: Check for exhaust gas temperature sensors.
Condition:
• Check for exhaust gas temperature Sensors. Refer to Procedure 019-013 in Section 19.

Action Specification/Repair Next Step

Check for exhaust gas temperature Sensors. Exhaust gas temperature sensors present? 4C
• Refer to Procedure 019-013 in Section 19. YES

Exhaust gas temperature sensors present? 4B

NO

STEP 4B: Check cylinder temperatures using an infrared thermometer.

Condition:
• Turn keyswitch ON.
• Operate the engine at at least 50 percent load for 5 minutes.

Action Specification/Repair Next Step

Use an infrared thermometer to check cylinder Temperature sensor reading at any cylinder Repair
temperatures. Manually calculate the average of more than 67°C or 120°F different from the complete
the temperature readings. average?
• Refer to Procedure 006-026 in Section 6. YES
Repair:
Replace any malfunctioning injectors. Refer
to Procedure 006-026 in Section 6.

Temperature sensor reading at any cylinder 5A

more than 67°C or 120°F different from the
average?
NO

STEP 4C: Check exhaust gas temperature readings.

Condition:
• Turn keyswitch ON.
• Connect INSITE™ electronic service tool.

Action Specification/Repair Next Step

Check the exhaust gas temperature sensor Any of the exhaust gas temperature sensors 4C-1
readings. read:
• Use INSITE™ electronic service tool to take a • For Thermistors: 600°C [1112°F]?
datalog of all exhaust gas temperature YES
sensors.
Any of the exhaust gas temperature sensors 4D
read:
• For Thermistors: 600°C [1112°F]?
NO

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File: 253-ttqsk50 Page 18 of 29
STEP 4C-1: Check the engine harness and the ECM 1 and ECM 2 connectors for affected cylinders.
Condition:
• Turn keyswitch OFF.
• Disconnect the engine harness connector from the affected ECM connector.

Action Specification/Repair Next Step

Inspect the engine harness and ECM connector Dirty or damaged pins? 4C-4
pins for the following: YES
• Loose connector
• Corroded pins Repair:
• Bent or broken pins A damaged connection has been detected in
• Pushed back or expanded pins the engine harness connector or ECM
• Moisture in or on the connector connector.
• Missing or damaged connector seals
• Dirt or debris in or on the connector pins • Flush the dirt, debris, or moisture from the
• Connector shell broken connector pins. Use electrical contact
• Wire insulation damage cleaner, Part Number 3824510.
• Damaged connector locking tab. • Install the appropriate connector seal if it is
damaged or missing.
Use the following procedure for general • Replace the damaged section of the
inspection techniques. Refer to Procedure engine harness. Refer to Procedure
019-361 in Section 19. 019-043 in Section 19.
• Replace the ECM. Refer to Procedure
019-031 in Section 19.

Dirty or damaged pins? 4C-2

NO

STEP 4C-2: Check the exhaust gas temperature sensor and engine harness connector pins.
Condition:
• Turn keyswitch OFF.
• Disconnect the engine harness connector and all exhaust gas temperature interconnects from the exhaust gas
temperature sensors.

Action Specification/Repair Next Step

Inspect the engine harness connector and Dirty or damaged pins? 4C-4
exhaust gas temperature sensor connector pins YES
for the following:
• Loose connector Repair:
• Corroded pins A damaged connection has been detected in
• Bent or broken pins the engine harness connector or exhaust gas
• Pushed back or expanded pins temperature sensor connector.
• Moisture in or on the connector
• Missing or damaged connector seals • Flush the dirt, debris, or moisture from the
• Dirt or debris in or on the connector pins connector pins. Use electrical contact
• Connector shell broken cleaner, Part Number 3824510.
• Wire insulation damage • Install the appropriate connector seal if it is
• Damaged connector locking tab. damaged or missing.
• Replace the damaged section of the
Use the following procedure for general engine harness. Refer to Procedure
inspection techniques. Refer to Procedure 019-043 in Section 19.
019-361 in Section 19.
Dirty or damaged pins? 4C-3
NO

© 2008 Cummins Inc., Box 3005, Columbus, IN 47202-3005 U.S.A. Printed from QuickServe® Online.
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File: 253-ttqsk50 Page 19 of 29
STEP 4C-3: Check for an open circuit in the exhaust gas temperature sensor supply.
Condition:
• Turn keyswitch OFF.
• Disconnect the engine harness connector from the affected exhaust gas temperature sensor.
• Disconnect the engine harness connector from the affected ECM connector.

Action Specification/Repair Next Step

Check for an open circuit. Less than 10 ohms? 4C-4

• Measure the resistance from the exhaust gas YES
temperature sensor 5 volt SUPPLY pin of the
engine harness ECM connector to the exhaust
gas temperature sensor SUPPLY pin of the Less than 10 ohms? 4D
affected exhaust gas temperature sensor NO
connector.
Repair:
Refer to the wiring diagram for connector pin • Replace the exhaust gas temperature
identification. sensor. Refer to Procedure 019-013 in
Use the following procedure for general Section 19.
resistance measurement techniques. Refer to
Procedure 019-360 in Section 19.

STEP 4C-4: Check for a short circuit to ground.

Condition:
• Turn keyswitch OFF.
• Disconnect the engine harness connector from the affected exhaust gas temperature sensor.
• Disconnect the engine harness connector from the affected ECM connector.

Action Specification/Repair Next Step

Check for a short circuit to ground. Greater than 100k ohms? 4D

• Check the exhaust gas temperature sensor for YES
short circuit to ground.
Repair:
The exhaust gas temperature system has
suffered an in-range malfunction.
• Replace the exhaust gas temperature
sensor. Refer to Procedure 019-013 in
Section 19.

Greater than 100k ohms? 4D

NO
Repair:
• Troubleshoot all harnesses connected in
series to determine which contains the
short circuit to ground. Refer to Procedure
019-043 in Section 19.

© 2008 Cummins Inc., Box 3005, Columbus, IN 47202-3005 U.S.A. Printed from QuickServe® Online.
All Rights Reserved. Last Modified: 17-Nov-2015
File: 253-ttqsk50 Page 20 of 29
STEP 4D: Check for significant temperature difference.
Condition:
• Turn keyswitch ON and operate the engine to at least 50 percent load for 5 minutes.
• Connect INSITE™ electronic service tool.

Action Specification/Repair Next Step

Check the exhaust gas temperature sensor Temperature sensor reading at any cylinder 4D-1
readings. more than 45°C or 81°F different from the
• Use INSITE™ electronic service tool to take a average?
datalog of all exhaust gas temperature YES
sensors and take the average using INSITE™
electronic service tool Average Exhaust
Temperature Parameter. Temperature sensor reading at any cylinder 5A
more than 45°C or 81°F different from the
average?
NO

STEP 4D-1: Check for shared turbochargers/air handling passages.

Condition:
• Check the air handling layout for common turbochargers or passages for particular cylinders.

Action Specification/Repair Next Step

Check for shared turbochargers/air handling Are cylinders that share a particular 6A
passages. turbocharger affected?
• Check the engine air handling layout to YES
determine if the cylinders with a significant
temperature difference receive air from the
same turbocharger. Are cylinders that share a particular Repair
turbocharger affected? complete
NO
Repair:
Replace the injectors. Refer to Procedure
006-026 in Section 6.

STEP 5: Fuel system troubleshooting procedures.

STEP 5A: Check for fault codes.
Condition:
• Turn keyswitch ON.
• Connect INSITE™ electronic service tool.

Action Specification/Repair Next Step

Check for fault codes. Fuel system fault codes active? Repair
• Use INSITE™ electronic service tool to read YES complete
the fault code information.
• Determine if there are active fuel system fault Repair:
codes related to the complaint. Follow the electronic fault code trees for the
appropriate troubleshooting procedures.

Fuel system fault codes active? 5B

NO

© 2008 Cummins Inc., Box 3005, Columbus, IN 47202-3005 U.S.A. Printed from QuickServe® Online.
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File: 253-ttqsk50 Page 21 of 29
STEP 5B: Measure the fuel inlet restriction.
Condition:
Measure the fuel inlet restriction. Refer to Procedure 006-020 in Section 6.

Action Specification/Repair Next Step

Check for fuel inlet restriction. Fuel restriction above specifications? Repair
• Refer to Procedure 006-020 in Section 6. YES complete

Repair:
Find the correct cause of the high inlet
restriction. Look for plugged OEM fuel filters
or screens, a restricted lift pump bypass
check valve, pinched OEM fuel lines, or a
restricted stand pipe in the OEM fuel tank.

Fuel restriction above specifications? 5C

NO

STEP 5C: Check stage one fuel filter head check valves for proper operation.
Condition:
• Refer to Procedure 006-008 in Section 6.

Action Specification/Repair Next Step

Check fuel filter head check valves for proper Fuel filter head check valves in good 5D
operation. condition and the passageway free of
• The check valve prevents back-flow of fuel restrictions?
through the first stage filter during priming and YES
operation, when installed properly.
• A stuck check valve will not allow fuel flow
from the lift pump to prime the engine. Fuel filter head check valves in good Repair
condition and the passageway free of complete
restrictions?
NO
Repair:
• Refer to Procedure 006-008 in Section 6.

STEP 5D: Check injector solenoid operation.

Condition:
• Turn keyswitch ON.
• Attach the Injector Tester, Part Number 2892293, to an injector.

Action Specification/Repair Next Step

Test all of the injectors using the injector tester Injector tester tool show a green light? 5E
tool. YES
• Turn the keyswitch ON, and attach the injector
tester tool to the 2 pin injector connector.
• Refer to Procedure 006-026 in Section 6. Injector tester tool show a green light? Repair
NO complete

Repair:
Replace any malfunctioning injectors. Refer
to Procedure 006-026 in Section 6.

© 2008 Cummins Inc., Box 3005, Columbus, IN 47202-3005 U.S.A. Printed from QuickServe® Online.
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File: 253-ttqsk50 Page 22 of 29
STEP 5E: Use INSITE™ electronic service tool to perform fuel pump actuator click test.
Condition:
• Turn keyswitch ON.
• Connect INSITE™ electronic service tool.

Action Specification/Repair Next Step

Perform the fuel pump actuator click test. Fuel pump actuator click when commanded 5F
• Use INSITE™ electronic service tool to with the diagnostic test in INSITE™
perform fuel pump actuator click test. electronic service tool?
YES

Fuel pump actuator click when commanded Repair

with the diagnostic test in INSITE™ complete
electronic service tool?
NO
Repair:
Replace the fuel pump actuator. Refer to
Procedure 019-117 in Section 19.

STEP 5F: Measure the injector drain flow from all injectors.
Condition:
• Crank engine to at least 150 rpm.
• Unplug all injectors.
• Connect appropriate service tools to measure injector drain flow at the fuel drain block.

Action Specification/Repair Next Step

Measure the injector return fuel drain flow at the Drain fuel flow from the fuel drain block 5F-1
fuel drain block. greater than the specification?
• Refer to Procedure 006-026 in Section 6. YES

Drain fuel flow from the fuel drain block 5G

greater than the specification?
NO

© 2008 Cummins Inc., Box 3005, Columbus, IN 47202-3005 U.S.A. Printed from QuickServe® Online.
All Rights Reserved. Last Modified: 17-Nov-2015
File: 253-ttqsk50 Page 23 of 29
STEP 5F-1: Isolate the injector drain flow from each of the injectors.
Condition:
• Crank engine to at least 150 rpm.
• Unplug all injectors.
• Connect appropriate service tools to measure injector drain flow at each cylinder head.

Action Specification/Repair Next Step

Measure the injector return fuel drain flow at the Drain fuel flow from the injector greater than Repair
cylinder head. the specification? complete
• Refer to Procedure 006-026 in Section 6. YES
Repair:
Replace any malfunctioning injectors. Refer
to Procedure 006-026 in Section 6.

Drain fuel flow from the injector greater than 5G

the specification?
NO

STEP 5G: Perform single cylinder cut-out test

Condition:
• Turn keyswitch ON.
• Operate engine at low idle.
• Connect INSITE™ electronic service tool.

Action Specification/Repair Next Step

Perform single cylinder cut-out test. Miss or excessive smoke be attributed to a Repair
• Operate the engine at load. single cylinder? complete
• Use INSITE™ electronic service tool to YES
perform the cylinder cut-out test to disable
individual injectors. Repair:
Look for a cause of the complaint, including
valve lash and excessive crankcase pressure
that can indicate power cylinder damage or
camshaft lobe wear. If no other damage is
found, replace the fuel injector in the cylinder
that was identified using the single cylinder
cut-out test.
• Refer to Procedure 006-026 in Section 6.

Miss or excessive smoke be attributed to a 5H

single cylinder?
NO

© 2008 Cummins Inc., Box 3005, Columbus, IN 47202-3005 U.S.A. Printed from QuickServe® Online.
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File: 253-ttqsk50 Page 24 of 29
STEP 5H: Audio check for injector operation.
Condition:
• Turn keyswitch ON.
• Operate engine at low idle.

Action Specification/Repair Next Step

Perform an audio check on each injector to verify Can a miss be heard from any individual Repair
proper operation. injector? complete
• With the engine running at idle, use a YES
mechanic's stethoscope (Snap-On™, Part
Number GA111D, or similar) to identify any Repair:
individual injector improper operation. Replace any faulty injectors. Refer to
Procedure 006-026 in Section 6.

Can a miss be heard from any individual 2A

injector?
NO

STEP 6: Air handling troubleshooting procedures.

STEP 6A: Inspect the turbocharger blades for damage.
Condition:
• Turn keyswitch OFF.
• Remove the intake and exhaust pipes from the turbocharger.

Action Specification/Repair Next Step

Inspect the compressor and turbine blades for Damage found on turbocharger blades? Repair
damage or wear. YES complete
• Refer to Procedure 010-033 in Section 10.
Repair:
Replace the turbocharger assembly. Refer to
Procedure 010-033 in Section 10.

Damage found on turbocharger blades? 6B

NO

© 2008 Cummins Inc., Box 3005, Columbus, IN 47202-3005 U.S.A. Printed from QuickServe® Online.
All Rights Reserved. Last Modified: 17-Nov-2015
File: 253-ttqsk50 Page 25 of 29
STEP 6B: Check the turbocharger axial and radial clearances.
Condition:
• Turn keyswitch OFF.

Action Specification/Repair Next Step

Check the turbocharger for correct axial and Turbocharger axial and radial bearing 6C
radial clearance. clearances within specification?
• Refer to Procedure 010-033 in Section 10. YES

Turbocharger axial and radial bearing Repair

clearances within specification? complete
NO
Repair:
Replace the turbocharger assembly. Refer to
Procedure 010-033 in Section 10.

STEP 6C: Check air intake restriction.

Condition:
• Turn keyswitch OFF.
• Install a vacuum gauge or water manometer in the air intake piping.

Action Specification/Repair Next Step

Check air intake system restriction. Air intake restriction greater than 635 mm- Repair
H2O [25 in-H2O]? complete
Install a vacuum gauge into the air intake
system. Refer to Procedure 010-031 in Section YES
10.
Air intake restriction greater than 635 mm- 2A
H2O [25 in-H2O]?
NO

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File: 253-ttqsk50 Page 26 of 29

STEP 7: Electronic feature troubleshooting procedures.

STEP 7A: Verify throttle pedal travel.
Condition:
• Turn keyswitch ON.
• Connect INSITE™ electronic service tool.

Action Specification/Repair Next Step

Verify throttle pedal travel. Throttle position read 0 percent when the 7B
• Use INSITE™ electronic service tool to throttle is released and 100 percent when the
monitor the throttle position while fully throttle is depressed?
depressing and releasing the throttle pedal. YES

Throttle position read 0 percent when the Repair

throttle is released and 100 percent when the complete
throttle is depressed?
NO
Repair:
Determine and correct the cause of the
throttle pedal restriction.

STEP 7B: Check barometric pressure sensor accuracy.

Condition:
• Turn keyswitch ON.
• Connect INSITE™ electronic service tool.

Action Specification/Repair Next Step

Use INSITE™ electronic service tool to monitor INSITE™ electronic service tool reading is 7C
the barometric air pressure. within 102 mm-Hg [4 in-Hg] of local
• Compare INSITE™ electronic service tool barometric pressure?
barometric pressure readings with the local YES
barometric pressure.
INSITE™ electronic service tool reading is Repair
within 102 mm-Hg [4 in-Hg] of local complete
barometric pressure?
NO
Repair:
Replace the barometric pressure sensor.
Refer to Procedure 019-004 in Section 19.

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File: 253-ttqsk50 Page 27 of 29
STEP 7C: Check intake manifold pressure sensor accuracy.
Condition:
• Turn keyswitch ON.
• Connect INSITE™ electronic service tool.

Action Specification/Repair Next Step

Check intake manifold pressure sensor Intake manifold pressure reading is less than 8A
accuracy. 102 mm-Hg [4 in-Hg]?
• Use INSITE™ electronic service tool to YES
monitor the value of intake manifold pressure
without operating the engine.
Intake manifold pressure reading is less than Repair
102 mm-Hg [4 in-Hg]? complete
NO
Repair:
Replace the intake manifold pressure sensor.
Refer to Procedure 019-061 in Section 19.

STEP 8: Base engine troubleshooting procedures.

STEP 8A: Verify overhead adjustments are correct.
Condition:
• Turn keyswitch OFF.
Remove the rocker lever cover. Refer to Procedure 003-011 in Section 3.

Action Specification/Repair Next Step

Measure the overhead setting. Overhead settings within the reset limits? 8B
• Refer to Procedure 003-006 in Section 3. YES

Overhead settings within the reset limits? Repair

NO complete

Repair:
Adjust the overhead settings. Refer to
Procedure 003-006 in Section 3.

© 2008 Cummins Inc., Box 3005, Columbus, IN 47202-3005 U.S.A. Printed from QuickServe® Online.
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File: 253-ttqsk50 Page 28 of 29
STEP 8B: Check exhaust restriction.
Condition:
• Refer to Procedure 011-009 in Section 11.

Action Specification/Repair Next Step

Check the exhaust system back pressure. Exhaust back pressure less than 75 mm-Hg 2A
• Refer to Procedure 011-009 in Section 11. [3 in-Hg]?
YES

Exhaust back pressure less than 75 mm-Hg Repair

[3 in-Hg]? complete
NO
Repair:
Inspect exhaust system for source of high
restriction.

© 2008 Cummins Inc., Box 3005, Columbus, IN 47202-3005 U.S.A. Printed from QuickServe® Online.
All Rights Reserved. Last Modified: 17-Nov-2015
File: 253-ttqsk50 Page 29 of 29

© 2008 Cummins Inc., Box 3005, Columbus, IN 47202-3005 U.S.A. Printed from QuickServe® Online.
All Rights Reserved. Last Modified: 17-Nov-2015