Cummins ISB, QSB 5.9L VP44 Electronic Troubleshooting & Repair Manual

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Covers: Cummins ISB 5.9, QSB 5.9 Electronic Control System (VP44 fuel system, prior to 2003)
Pages: 956
Format: PDF
Compatibility: Windows/Mac/Tablet
File size: 27mb
Notes: Instant digital download only

This manual contains Cummins ISB5.9 and QSB5.9 Electronic Control and Fuel System troubleshooting and repair instructions. Includes Cummins ISB5.9-44 and QSB5.9-44 wiring diagrams.  This manual covers the electronic control system only. Engine mechanical troubleshooting and repair is sold separately.

Topics in the Cummins ISB, QSB 5.9-44 Electronic Control System Troubleshooting and Repair Manual:

General Safety Instructions
General Repair Instructions
General Cleaning Instructions
Acronyms and Abbreviations

Engine Identification
Engine Diagrams

Electronic Controlled Fuel System
Service Tools and Hardware – Overview

Information Fault Codes
Electronic Control Module (ECM)
Engine Speed Sensor (ESS)
Intake Manifold Pressure Sensor Circuit
Intake Manifold Pressure Sensor Circuit
Accelerator Position Sensor Circuit
Accelerator Position Sensor Circuit
Remote Throttle Position Sensor
Remote Throttle Position Sensor
Oil Pressure Sensor Circuit
Oil Pressure Sensor/Switch Circuit Choice
Oil Pressure Sensor Circuit
Oil Pressure Switch Circuit
Oil Pressure Sensor/Switch Circuit Choice
Oil Pressure Sensor Circuit
Oil Pressure Switch Circuit
Coolant Temperature Sensor Circuit
Engine Coolant Temperature 1 Sensor Circuit
Coolant Temperature – Engine Protection
Coolant Temperature – Engine Protection
Intake Manifold Air Temperature Sensor Circuit
Intake Manifold Air Temperature Sensor Circuit
Intake Manifold Air Temperature Sensor – Engine Protection Circuit
Air Conditioner Clutch Supply Circuit
Ambient Air Pressure Sensor Circuit
Ambient Air Pressure Sensor Circuit
Engine Overspeed Circuit
Engine Coolant Level – Engine Protection
Vehicle Speed Sensor Circuit
Vehicle Speed Sensor (VSS
Exhaust Brake Supply Circuit
Engine Fan Clutch Supply Circuit
Fuel Temperature Sensor Circuit
VP44 Fuel Temperature Sensor Error
Lift Pump Circuit Choice
Lift Pump Circuit
Lift Pump Circuit
Engine Speed Sensor Supply
Engine Speed Sensor Supply
J1939 Datalink Multiplexing
J1939 Datalink Multiplexing
Pressure Sensor Circuit
Pressure Sensor Circuit
Auxiliary Speed or Auxiliary Pressure Input Error
Sensor Supply Circuit
VP44 Fuel Valve Control High Current
VP44 Fuel Valve High Current Error
VP44 Fuel Pump Control Valve Feedback Error
Electronic Control Module (ECM
Fuel Pump Voltage Out of Range Error Low
VP44 Fuel Pump Voltage Measurement Error
VP44 Fuel Pump Speed/Position Sensor Signal Lost
VP44 Fuel Pump Can Not Reach Commanded Timing
VP44 Fuel Pump To Engine Synchronization Pulse Not Recognized
Idle Select High/Low
VP44 Fuel Pump Fuel Shut Off Error
VP44 Fuel Pump Calibration Error
Electronic Control Module (ECM
VP44 Fuel Pump rpm and Fuel Error
Fuel Pump Power Relay Stuck-On
Intake Air Heater Relay Circuit
Intake Air Heater Relay Circuit
Intake Air Heater Relay Circuit
Sensor Supply Circuit
Accelerator Position Sensor Circuit
VP44 Relay Coil Supply Circuit
Oil Pressure Sensor/Switch Circuit Choice
Oil Pressure Sensor Circuit
Oil Pressure Switch Circuit
Water-In-Fuel Sensor Circuit
Coolant Level Sensor Circuit
Water-In-Fuel (WIF
Idle Validation Switch (IVS
Accelerator Pedal Circuit (ISS
Intake Manifold Pressure Sensor Circuit
Unswitched Battery Supply Circuit
Unswitched Battery Supply Circuit
Unswitched Battery Supply Circuit
Accelerator Position Sensor Circuit
Remote Accelerator Supply Circuit
Intake Manifold Air Temperature Sensor – Engine Protection Circuit
Auxiliary Speed or Auxiliary Pressure Input Error
Coolant Level Sensor Circuit
VP44 Fuel Pump Valve Feedback Error
Switched Droop Selection Circuit
Dual-Output Driver A
Alternate (Switched
Dual-Output Driver B
Output Device Driver (Transmission Shift Modulation
Input – Engine Protection

Troubleshooting Procedures and Techniques
Troubleshooting Symptom Charts
Engine Acceleration or Response Poor
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 Shuts Off Unexpectedly or Dies During Deceleration
Engine Speed Surges at Low or High Idle
Engine Speed Surges Under Load or in Operating Range
Engine Speed Surges in PTO or Cruise Control
Engine Starts But Will Not Keep Running
Engine Will Not Reach Rated Speed (RPM
Engine Will Not Shut Off
Fault Code Warning Lights Stay On (No Apparent Reason
Fault Code Warning Lamps Do Not Illuminate
Fuel Consumption Excessive
Fuel In Coolant
Fuel in the Lubricating Oil
Low Idle Adjust Switch Does Not Work
PTO or Cruise Control Does Not Operate
Smoke, Black — Excessive
Smoke, White — Excessive
ECM – No Communication Troubleshooting Tree
Service Tools
Wiring Harness Repair Kit
Battery Ground Circuit
Clutch Pedal Position Switch
Clutch Pedal Position Switch Circuit
Engine Coolant Level Sensor
Engine Coolant Temperature Sensor
Cruise Control or PTO ON/OFF Switch
Cruise Control or PTO ON/OFF Switch Circuit
Cruise Control or PTO Set/Resume Select Switch
Cruise Control or PTO Set/Resume Select Switch Circuit
Diagnostic Test Mode Switch
Diagnostic Test Mode Switch Circuit
Electronic Control Module (ECM
ECM Calibration Code
Engine Brake ON/OFF Switch
Engine Brake ON/OFF Switch Circuit
Engine Position Sensor (EPS)
Engine Speed Sensor (ESS)
Engine Wiring Harness
Fan Control Circuit
Fault Lamp
Fault Lamp Circuit
Idle Adjust Switch
Idle Adjust Switch Circuit
Idle Validation Switch
Idle Validation Switch Circuit
Intake Manifold Air Temperature Sensor
Intake Manifold Air Temperature Sensor Circuit
Intake Manifold Pressure Sensor
Key Switch Battery Supply Circuit
Engine Oil Pressure Sensor
Wiring Harness
Programmable Features and Parameters Not Correct
Remote PTO Switch Circuit
Remote PTO Switch
Tachometer Circuit
Accelerator Pedal or Lever Position Sensor
Accelerator Pedal or Lever Position Sensor Circuit
Unswitched Battery Supply Circuit
Brake Pedal Position Switch
Brake Pedal Position Switch Circuit
Vehicle Speed Sensor, Digital Input
Vehicle Speed Sensor, Magnetic Pick Up
Vehicle Speed Sensor Circuit
Engine Speed Sensor Circuit
Water in Fuel Sensor
Cold Start Aid Circuit
Data Link Circuit, SAE J1939
Data Link Circuit, SAE J1587
Maintenance Lamp
Maintenance Lamp Circuit
VP44 Amp Connector
Ring Terminal
Fuse, Harness In-Line
Connector, Butt Splice
Weather Pak Connector Series
Metripack Connector Series
AMP Connector Series
Deutsch DRC Connector Series
Deutsch DT Connector Series
Deutsch DTM and DTP Connector Series
Deutsch HD10 Connector Series
Deutsch HDP20 and HD30 Connector Series
ITT Cannon Connector Series
AMP VP44 Connector Series
Packard Relay Connector
Ford™ Connector Series
D-Sub Miniature Connector Series
Bosch® Actuator and Sensor Connector Series
Bosch® ECM Injector Driver Connector Series
Bosch® ECM Actuator and Sensor Connector Series
Bosch® ECM Connector Series
Framatome Connector Series
Augat Connector Series
Connector, 23-Pin
Connector, 50-Pin
Power Train Protection Switch
Power Train Protection Switch Circuit
Two-Speed Axle Switch
Two-Speed Axle Switch Circuit
A/C Cycle Switch
A/C Cycle Switch Circuit
A/C On/Off Switch
A/C On/Off Switch Circuit
A/C Clutch Circuit
Accelerator Interlock Switch
Accelerator Interlock Switch Circuit
Cab Switchable Governor Switch
Cab Switchable Governor Switch Circuit
Switched Maximum Operating Speed Switch
Switched Maximum Operating Speed Switch Circuit
Multi Unit Synchronization Switch
Multi Unit Synchronization Switch Circuit
Multi Unit Synchronization Complement Switch
Multi Unit Synchronization Complement Switch Circuit
Intermediate Speed Control 1 Switch
Intermediate Speed Control 1 Switch Circuit
Intermediate Speed Control 2 Switch
Intermediate Speed Control 2 Switch Circuit
Intermediate Speed Control Validation/Intermediate Speed Control 3 Switch
Intermediate Speed Control Validation/Intermediate Speed Control 3 Switch Circuit
Boost Power Switch
Boost Power Switch Circuit
Alternate Torque Switch
Alternate Torque Switch Circuit
Alternate Idle Speed Switch
Alternate Idle Speed Switch Circuit
Auxiliary/Tailshaft Governor Switch
Auxiliary/Tailshaft Governor Switch Circuit
Alternate Droop Switch
Alternate Droop Switch Circuit
Variable Intermediate Speed Switch
Variable Intermediate Speed Switch Circuit
Connector, 4-Pin Relay
Multimeter Usage
Resistance Measurement Using a Multimeter
Component Connector and Pin Inspection
Inactive or Intermittent Fault Code
ECM ROM Boot
Engine Datalinks
Bosch™ Aftertreatment DEF Controller Connector
Specifications

Fault Code Troubleshooting
Fault Code 111
Electronic Control Module (ECM) Microprocessor
Fault Code 115
Engine Speed Sensor (ESS) Circuit
Fault Code 122 or 123
Intake Manifold Pressure Sensor Circuit
Fault Code 131or132
Accelerator Position Sensor Circuit
Fault Code 133
Remote Throttle Position Sensor
Fault Code 134
Remote Throttle Position Sensor
Fault Code 135 or 141
Oil Pressure Sensor Circuit
Fault Code 143
Oil Pressure – Engine Protection
Fault Code 144 or 145
Coolant Temperature Sensor Circuit
Fault Code 146
Coolant Temperature – Engine Protection
Fault Code 151
Coolant Temperature – Engine Protection
Fault Code 153 or 154
Intake Manifold Air Temperature Sensor Circuit
Fault Code 155
Intake Manifold Air Temperature Sensor· Engine Protection Circuit
Fault Code 191
Air Conditioner Clutch Supply Circuit
Fault Code 211
Fault Code 234
Engine Overspeed Circuit
Fault Code 235
Engine Coolant Level – Engine Protection
Fault Code 241
Vehicle Speed Sensor Circuit
Fault Code 242
Vehicle Speed Sensor (VSS) Circuit
Fault Code 243
Exhaust Brake Supply Circuit
Fault Code 245
Engine Fan Clutch Supply Circuit
Fault Code 261
Fuel Temperature Sensor Circuit
Fault Code 264, 361, 366, 367, 374, 376, or 517
VP44 Internal Failure
Fault Code 278
lift Pump Circuit
Fault Code 283 or 284
Engine Speed Sensor Supply
Fault Code 287
Fault Code 288
Fault Code 297
OEM Pressure Sensor Circuit
Fault Code 298
OEM Pressure Sensor Circuit
Fault Code 319
Fault Code 349
Auxiliary Speed or Auxiliary Pressure Input Error
Fault Code 352 or 386
Sensor Supply Circuit
Fault Code 362
Fuel Pump Fuel-Metering Val\le Open Circuit
Fault Code 363
· Fuel Pump Fuel Solenoid Valve Closing at Wrong Time
Fault Code 364
Electronic Control Module (ECM) to Pump Communications Error
Fault Code 365
Fuel Pum·p Voltage Out of Range Error Low
Fault Code 368
Fuel Pump Cari Not Reach Commanded Timing
Fault Code 369
Fuel Pump To Engine Synchronization Pulse Not Recognized
Fault Code 372
Idle Select High/low
Fault Code 373
VP44 Fuel Pump Fuel Shut Off Error
Fault Code 375
Electronic Control Module (ECM) Fuel Calibration Corrupted
Faull Code 377
Fuel Pump Power Relay Stuck-On
Fault Code 381 or 382
Intake Air Heater Relay Circuit
Fault Code 385 or 444
Remote Accelerator Supply Circuit
Fault Code 387 or 443
Accelerator Position Sensor Circuit
Fault Code 391
VP44 Relay Coil Supply Circuit
Fault Code 415
Oil Pressure – Engine Protection
Fault Code 418
Water-In-Fuel Sensor Circuit
Fault Code 422
Coolant level Sensor Circuit
Fault Code 429
Water-In-Fuel (WIF) Sensor Circuit
Fault Code 431 or 551
Idle Validation Switch (IVS) Circuit
Fault Code 432
Accelerator Pedal Circuit (ISS)
Fault Code 433

Intake Manifold Pressure Senscr Circuit
Un switched Battery Supply Circuit
Fault Code 441
Unswitched Battery Supply Circuit
Fault Code 442
Unswitched Battery Supply Circuit
Fault Code 488
Intake Manifold Air Temperature Sensor – Engine Protection Circuit
Fault Code 489
Auxiliary Speed or Auxiliary Pressure Input Error
Fault Code 515 or 516
Coolant Level Senscr Circuit
Fault Code 524
Switched Droop Selection Circuit
Fault Code 527
Dual-Output Driver A
Fault Code 528
Alternate (Switched) Torque Curve Switch Circuit
Fault Code 529
Dual-Output Driver B
Fault Code 599
Fault Code 611
Fault Code 768
Output Device Driver (Transmission Shift Modulation)
Information Fault Codes

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