Professional Documents
Culture Documents
FAULT CODE
FAULT CODE 2359 - EGR Differential Pressure Sensor - Data Valid But Above Normal Operating Range - Moderately
Severe Level
Associated Procedures
Troubleshooting Steps
STEPS
STEP 1.
SPECIFICATIONS
Check electrical grounds.
STEP 1A. Check the engine and vehicle
grounds.
STEP 2.
STEP 3.
STEP 4.
STEP 5.
STEP 6.
mk:@MSITStore:C:\Intelect\INSITE\FIS\FIS4021477.chm::/procedures/105-t05-2359.htm
6/19/2012
Page 2 of 19
Action
Check for a loose or corroded engine, chassis, or battery
ground connection.
z
z
mk:@MSITStore:C:\Intelect\INSITE\FIS\FIS4021477.chm::/procedures/105-t05-2359.htm
6/19/2012
Page 3 of 19
z
z
YES
NO
Tighten any loose connections and clean the battery
terminals.
No Repair
Go to 2A
Action
Check for active or high counts of inactive fault codes.
z
Fault Code 2271, 2272, 2273, 2274, 2346, 2347, 2348, 2349, Fault Code 2271, 2272, 2273, 2274, 2346, 2347, 2348, 2349,
2351, 2352, 2353, or 2357 active or inactive with high
2351, 2352, 2353, or 2357 active or inactive with high
counts?
counts?
ISM02 and ISX CM870 and CM570: Fault Code 2277, 2278,
2355, or 2356 active or inactive with high counts?
ISM02 and ISX CM870 and CM570: Fault Code 2277, 2278,
2355, or 2356 active or inactive with high counts?
YES
Troubleshoot fault codes starting with the fault code
containing the highest number of counts.
NO
No Repair
Go to 3A
Guided Step 3 - Check the EGR differential pressure tubes and mounting surfaces.
mk:@MSITStore:C:\Intelect\INSITE\FIS\FIS4021477.chm::/procedures/105-t05-2359.htm
6/19/2012
Page 4 of 19
Guided Step 3A - Check the EGR differential pressure tubes, adapter, and exhaust system for visible
leaks.
Conditions
Turn keyswitch OFF.
Action
Check the EGR differential pressure tubes, adapter, and
exhaust system for visible leaks.
Leaks can be easily identified by traces of soot.
The EGR differential pressure tubes must not be removed,
however, the sensor can be removed to inspect the o-rings
between the EGR differential pressure sensor and the
adapter for proper sealing.
Use the following procedures to check for leaks:
z
YES
NO
Go to 7A
Go to 3B
Guided Step 3B - Check for proper installation of the EGR differential pressure tubes.
Conditions
z
mk:@MSITStore:C:\Intelect\INSITE\FIS\FIS4021477.chm::/procedures/105-t05-2359.htm
6/19/2012
Page 5 of 19
Action
Check the EGR differential pressure tubes for proper
installation.
Use the following procedures:
z
YES
NO
Install the EGR differential pressure tubes correctly.
Use the following procedures:
z
No Repair
z
Go to 7A
Guided Step 3C - Check for proper installation of the EGR differential pressure sensor.
Conditions
z
Action
Check the EGR differential pressure sensor for proper
installation.
Use the following procedures:
z
mk:@MSITStore:C:\Intelect\INSITE\FIS\FIS4021477.chm::/procedures/105-t05-2359.htm
6/19/2012
Page 6 of 19
YES
NO
Install the EGR differential pressure sensor correctly.
Use the following procedures:
z
No Repair
z
Go to 4A
Go to 7A
Guided Step 4 - Perform the EGR Differential Pressure Tube Diagnostic Test to establish
whether the tube(s) are plugged.
Guided Step 4A - Release the excess pressure in the EGR differential pressure tubes.
Conditions
z
Keyswitch ON.
Action
Release the excess pressure in the EGR differential
pressure tubes.
z
This procedure will release any gas in the tubes that has
expanded due to hot temperatures.
Differential pressure tube fittings tightened?
YES
NO
mk:@MSITStore:C:\Intelect\INSITE\FIS\FIS4021477.chm::/procedures/105-t05-2359.htm
6/19/2012
Page 7 of 19
No Repair
Go to 4B
Conditions:
z
z
z
z
z
z
Action
Use INSITE electronic service tool to monitor the
following parameters:
z
z
YES
NO
mk:@MSITStore:C:\Intelect\INSITE\FIS\FIS4021477.chm::/procedures/105-t05-2359.htm
6/19/2012
Page 8 of 19
No Repair
z
Go to 4C
Go to 7A
z
z
z
Action
Use INSITE electronic service tool to monitor the EGR
differential pressure sensor signal voltage.
z
z
YES
NO
Go to 7A
Go to 4D
Conditions
z
z
z
mk:@MSITStore:C:\Intelect\INSITE\FIS\FIS4021477.chm::/procedures/105-t05-2359.htm
6/19/2012
Page 9 of 19
z
z
z
Action
Verify the EGR differential pressure sensor signal voltage
to establish whether either of the differential pressure tubes
are plugged.
Use INSITE electronic service tool to monitor the
following parameters:
z
z
z
Wait for the EGR valve to fully close, then verify the
fully closed position.
Engage the PTO and raise the engine speed to
1400 50 rpm.
Monitor the EGR differential pressure sensor signal
voltage.
YES
NO
Go to 5A
mk:@MSITStore:C:\Intelect\INSITE\FIS\FIS4021477.chm::/procedures/105-t05-2359.htm
6/19/2012
Page 10 of 19
z
z
z
z
Action
Verify engine coolant temperature is greater than 67C
[154F] and intake manifold air temperature is greater than
7C [45F].
z
NO
No Repair
For ISM CM870 and CM570 Electronic Control
System, Troubleshooting and Repair Manual, Bulletin
4021381. Refer to Procedure 019-370 in Section 19.
For ISM CM875 Electronic Control System,
Troubleshooting and Repair Manual, Bulletin
4021477. Refer to Procedure 019-370 in Section 19.
For Signature and ISX CM870 Electronic Control
System, Troubleshooting and Repair Manual, Bulletin
4021334. Refer to Procedure 019-370 in Section 19.
Go to 7A
Go to 6A
Guided Step 6A - Inspect the air handling system for intake manifold, charge-air cooler, or EGR leaks.
mk:@MSITStore:C:\Intelect\INSITE\FIS\FIS4021477.chm::/procedures/105-t05-2359.htm
6/19/2012
Page 11 of 19
Conditions
z
Action
Inspect the air handling system for intake manifold, charger,
air cooler, or EGR leaks.
Use the following procedures to inspect the charge-air
cooler for leaks:
z
NO
Repair leaks.
No Repair
Go to 7A
Go to 6B
Guided Step 6B - Check the variable geometry actuator rod for correct travel.
Conditions
z
z
z
z
Action
Use INSITE electronic service tool to start the
Turbocharger Actuator Test.
z
mk:@MSITStore:C:\Intelect\INSITE\FIS\FIS4021477.chm::/procedures/105-t05-2359.htm
6/19/2012
Page 12 of 19
z
z
YES
NO
Go to 6C
Go to 6B-1
Guided Step 6B-1 - Check for turbocharger air leaks and inspect air lines.
Conditions
z
z
z
z
Action
Use INSITE electronic service tool to perform the
Turbocharger Actuator Test.
Select the Extend Actuator position.
Listen for air leaks at the following components:
z
z
z
z
z
z
z
z
mk:@MSITStore:C:\Intelect\INSITE\FIS\FIS4021477.chm::/procedures/105-t05-2359.htm
6/19/2012
Page 13 of 19
actuator.
A small amount of air can be heard from the turbocharger
control valve during the turbocharger actuator test. This is a
normal condition for the valve to achieve output regulation
pressure. Do not replace the turbocharger control valve for
this condition.
Air leaks found in the system?
YES
NO
No Repair
Go to 7A
Go to 6B-2
Guided Step 6B-2 - ISM02 and ISX CM870 and CM570: Check for air pressure at the turbocharger control
valve outlet.
Conditions
z
z
z
z
Action
Use INSITE electronic service tool to perform the
Turbocharger Actuator Test.
z
z
YES
NO
No Repair
No Repair
Go to 6B-3
Go to 6B-5
Guided Step 6B-3 - ISM02 and ISX CM870 and CM570: Check for correct air pressure at the turbocharger
control valve outlet.
Conditions
mk:@MSITStore:C:\Intelect\INSITE\FIS\FIS4021477.chm::/procedures/105-t05-2359.htm
6/19/2012
Page 14 of 19
z
z
z
z
Action
Use INSITE electronic service tool to perform the
Turbocharger Actuator Test.
Select the Retract Actuator position.
Remove the air line connection at the outlet of the
turbocharger control valve.
Install an M12 Compuchek fitting, Part Number
3824843, at the outlet of the turbocharger control
valve.
Install an air pressure gauge that is capable of
reading at least 1034 kPa [150 psi].
z
z
Pressure gauge read more than 103 kPa [15 psi] after 5
minutes?
Pressure gauge read more than 103 kPa [15 psi] after 5
minutes?
YES
NO
Go to 7A
Go to 6B-4
Action
Damage to the turbocharger can result if the proper
removal procedure is not followed.
Remove the variable geometry actuator from the
turbocharger.
Use the following procedures:
SMALL | MEDIUM | LARGE
z
mk:@MSITStore:C:\Intelect\INSITE\FIS\FIS4021477.chm::/procedures/105-t05-2359.htm
6/19/2012
Page 15 of 19
Turbocharger actuator rod travel at least 12 mm [0.472 Turbocharger actuator rod travel at least 12 mm [0.472 in]?
in]?
YES
NO
Go to 7A
Go to 7A
Guided Step 6B-5 - ISM02 and ISX CM870 and CM870: Check for air pressure at the turbocharger control
shutoff valve outlet.
Conditions
z
z
z
Action
Use INSITE electronic service
tool to perform the Turbocharger
Actuator Test.
z
mk:@MSITStore:C:\Intelect\INSITE\FIS\FIS4021477.chm::/procedures/105-t05-2359.htm
6/19/2012
Page 16 of 19
No Repair
Go to 7A
Go to 6B-6
Guided Step 6B-6 - ISM02 and ISX CM870 and CM570: Check for air pressure at the turbocharger control
shutoff valve inlet.
Conditions
z
z
z
Action
Verify the OEM air supply line is connected to the correct
port on the turbocharger control shutoff valve.
z
YES
NO
No Repair
Go to 6B-7
Go to 7A
Guided Step 6B-7 - ISM02 and ISX CM870 and CM570: Check for plugged turbocharger control shutoff
valve filter.
Conditions
z
z
mk:@MSITStore:C:\Intelect\INSITE\FIS\FIS4021477.chm::/procedures/105-t05-2359.htm
6/19/2012
Page 17 of 19
z
z
z
Action
Use INSITE electronic service tool to perform the
Turbocharger Actuator Test.
Select the Extend Actuator position.
Listen for an air leak at the turbocharger control
shutoff valve filter head.
z
z
YES
NO
Go to 7A
Go to 7A
Guided Step 6C - Use INSITE electronic service tool to perform EGR Valve/Turbocharger Operational
Test.
Conditions
z
z
z
Action
Use INSITE electronic service tool to select the EGR
Valve/Turbocharger Operational Test.
z
z
YES
NO
Replace the turbocharger.
Use the following procedures:
No Repair
mk:@MSITStore:C:\Intelect\INSITE\FIS\FIS4021477.chm::/procedures/105-t05-2359.htm
6/19/2012
Page 18 of 19
Go to 7A
Go to 7A
Action
Use INSITE electronic service tool to verify the engine
coolant temperature is greater than 67C [153F] and the
intake manifold air temperature is greater than 7C [45F].
z
z
z
NO
Return to the troubleshooting steps or contact a Cummins
Authorized Repair Location if all steps have been completed
and checked again.
No Repair
Go to 7B
Go to 1A
Action
Clear the inactive fault codes.
z
mk:@MSITStore:C:\Intelect\INSITE\FIS\FIS4021477.chm::/procedures/105-t05-2359.htm
6/19/2012
Page 19 of 19
NO
No Repair
mk:@MSITStore:C:\Intelect\INSITE\FIS\FIS4021477.chm::/procedures/105-t05-2359.htm
6/19/2012