File: 08-t05-2387 Page 1 of 10 1RIPSIFAULIEGODE 23872 VET Actuator Driver frouit (Motor) - Mechanical System Not Responding Properly or Out of Adjustment TROUBLESHOOTING SUMMARY, STEPS ‘SPECIFICATIONS SRT CODE STEP 1: Check the fault codes and previous service history. STEP 1A: Check for active fault codes. Fault Code 2387 active or inactive with more than one count logged in the last 25 engine hours? STEP4B: Check for previous variable Actuator removed or replaced geometry turbocharger (VGT) during a recent repair event? actuator removals, STEP1C: Check for exhaust gas EGR system fault codes active? recirculation (EGR) related fault codes. STEP1D: Check exhaust restriction, Exhaust restriction greater than exhaust restriction limits for a dirty aftertreatment diesel Particulate filter (DPF)? STEP1E: Review claims history for recent ‘Turbocharger replaced in the turbocharger malfunctions. past three months for the same symptoms? STEP Check the VGT actuator, STEP 2A: Inspect the VGT actuator and Dirty or damaged pins? connector pins. STEP 2B: Inspect the VGT actuator. Gear broken or damaged on the VGT actuator? STEP2C: Inspect the turbocharger shaft Sector gear teeth not damaged movement. and movement meets the requirements when using the sector gear gauge, according to Procedure 010-134 in Section 10 in the base engine service manual? STEP Clear the fault code. STEP 3A; Progressive damage to the to the aftertreatment system, aftertreatment system detected? STEP 3B: Check if an engine control Ifa calibration update for this module (ECM) calibration fault code is available, does the update is available. ECM contain that revision or higher? STEP3C: Disable the fault codes. Fault code inactive? © 2008 Cummins Inc., Box 3005, Columbus, IN 47202-3005 U.S.A, Printed from QuickServe® Online. AII Rights Reserved. Last Modified: 28-Nov-2017TROUBLESHOOTING STEP Page 2 of 10 STEP 1: Check the fault codes and previous service history. STEP 1A: Check for active fault codes. Condition: + Turn keyewiteh ON, + Connect INSITE™ electronic service tool Action Specification/Repair Next Stop Check for active Fault Code 2387. Fault Code 2387 active or high inactive 1B + Use INSITE™ electronic service tool to read | counts? the fault codes, YES Fault Code 2387 active or high inactive 3A counts? No. Repair: No troubleshooting is necessary. Clear the inactive fault code. STEP 18: Check for previous VGT actuator removals. Condition: + NA Action Specification/Repair Next Step Check for previous replacements, Actuator removed or replaced during a 3A + Determine if the actuator has been removed or | recent repair event? replaced and Fault Code 2387 is active. YES Repair: Remove the actuator and install itin the correct position. *+ Use the following procedure in the ISB (M2150 Service Manual, Bulletin 4021878, for ISB engines. Refer to Procedure 010-134 in Section 10, + Use the following procedure in the ISC and ISL CM2150 Service Manual, Bulletin 4021869, for ISC and ISL engines. Refer to Procedure 010-134 in Section 10. Actuator removed or replaced during a 1c recent repair event? No © 2008 Cummins nc., Box 3005, Columbus, IN 47202-3005 U.S.A, All Rights Reserved. Printed from QuickServe® Online, Last Modified: 28-Nov-20175: 08-05-2387 Page 3 of 10 STEP 1C: Check for EGR-related fault codes. Condition: + Turn keyswitch ON. + Connect INSITE™ electronic service tool. Action Specification/Repair Next Step Check for active or high inactive EGR valve, EGR system fault codes active? Appropriate EGR temperature, and EGR differential pressure-related fault codes, * Use INSITE™ electronic service tool to read YES troubleshoot 1ng procedure the fault codes. restriction limits for a dirty aftertreatment DPF? No tem fault tive? 1D + Check for active or high inactive Fault Codes | EOR system fault codes act 1896, 1899, 2357, 2359, 2961, and 2962. No STEP 1D: Check exhaust restriction. Condition: + Install a pressure gauge into the exhaust system. + Turn keyswitch ON, + Operate engine at rated horsepower and rpm, Action Specification/Repair Next Step Check exhaust restriction by installing a pressure | Is exhaust restriction greater than exhaust | 3A gauge into the exhaust system, just past the restriction limits for a dirty aftertreatment turbocharger outlet. DPF? Ifa portis not found in the exhaust system, YES emove the exhaust gas temperature 1 sensor | Repair: and install the pressure gauge in the temperature | T°E°0 tne following procedure in the ISB. coteol bolt CM2150 Service Manual, Bulletin + Use the following procedure in the ISB 4021578, for ISB engines. Refer to M2150 Service Manual, Bulletin 4021578. Procedure 018-020 in Section V. Refer to Procedure 011-009 in Section 11 + Use the following procedure in the ISC + Use the following procedure in the ISC and and ISL CM2150 Service Manual, Bulletin ISL CM2150 Service Manual, Bulletin 4021569, for ISC and ISL engines, Refer 4021569, Refer to Procedure 011-008 in to Procedure 018-020 in Section V. Section 11 Is exhaust restriction greater than exhaust | 1E (©2008 Cummins Inc., Box 3005, Columbus, IN 47202-3005 U.S.A. All Rights Reserved. Printed from QuickServe® Online. Last Modified: 28-Nov-2017File: 08-t05-2387 STEP 1E: Review claims history for recent turbocharger malfunctions. Page 4 of 10 Condition: None Action Specification/Repair Next Step Review malfunctions that have occurred over the last three months to see if the engine has been in for this same symptom, Turbocharger been replaced in the past three months for the same symptoms? YES Repair: Inspect the grid heater for damage or plugging, + Refer fo Procedure 010-023 in Section 10, in the ISB CM2100 and CM2150 Service Manual, Bulletin 4021578 + Refer to Procedure 010-023 in Section 10, in the ISC and ISL. CM2150 Service Manual, Bulletin 4021569, If found damaged, replace the grid heater and inspect the air handling system for debris. Check the EGR cooler forleaks. Perform the (On-Engine Pressure Test of the EGR cooler, *+ Use the following procedure in the ISB (M2100 and CM2150 Service Manual Bulletin 4021578. Refer to Procedure 011-019 in Section 11 + Use the following procedure in the ISC and ISL CM2150 Service Manual, Bulletin 4021569. Refer to Procedure 011-019 in Section 11. Ifthe EGR cooler is not usable, replace the EGR cooler. 2h ‘Turbocharger been replaced in the past three months for the same symptoms? No 2a © 2008 Cummins Inc., Box 3005, Columbus, IN 47202-2005 U.S.A, All Rights Reserved, Printed from QuickServe® Ontine. Last Modified: 28-Nov-2017File: 08-108-2387 Page 5 of 10 STEP 2: Check the VGT actuator. STEP 2A: Inspect the VGT actuator and connector pins. Condition: + Turn keyswitch OFF + Disconnect the VGT actuator from the engine hamess. Action Specification/Repair Next Step Inspect the engine hamess and VGT actuator | Dirty or damaged pins? 3A connector pins for the fllowing: YES + Loose connector + Corroded pins Repair: + Bent or broken pins A damaged connection has been detected in + Pushed back or expanded pins the actuator connector or harness connector. + Moisture in or on the connector + Missing or damaged connector seals Clean the connector and pins + Dirt or debris on or in the connector pins Repair the damaged hamess, connector, or + Connector shell broken pins, if possible. + Wire insulation damage 7 Dad cee eae Refor to Procedure 019-043 in Section 19. Use the following procedure for general pee cua inspection techniques. Refer to Procedure + Use the following procedure in the ISB 018-361 in Section 19, CM2150 Service Manual, Bulletin 4021878. Refer to Procedure 010-124 in Section 10. + Use the foliowing procedure in the ISC and ISL CM2150 Service Manual, Bulletin 4021889. Refer to Procedure 010-134 in Section 10, Dirty or damaged pins? 2B No. © 2008 Cummins Inc., Box 3005, Columbus, IN 47202-3005 U.S.A. Printed from QuickServe® Online. All Rights Reserved. Last Modified: 28-Nov-2017Filo: 08-05-2387 STEP 28: Inspect the VGT actuator. Page 6 of 10 Condition: + Turn keyswitch OFF. + Drain the engine coolant, in Section 8 008-018 in Section 8. in Section 10. 010-134 in Section 10. + Remove the VGT actuator from the turbocharger. + Use the following procedure in the ISB CM2150 Service Manual, Bulletin 4021578, Refer to Procedure 010-134 * Use the following procedure in the ISB CM2150 Service Manual, Bulletin 4021578, Refer to Procedure 008-018 * Use the following procedure in the ISC and ISL CM2150 Service Manval, Bulletin 4021569, Refer to Procedure Use the following procedure in the ISC and ISL CM2150 Service Manual, Bulletin 4021869. Refer to Procedure Action Specification/Repair Next Step ‘Check for a broken drive gear on the VGT actuator. Gear is broken on the VGT actuator? YES Repai ‘A damaged gear has been detected on the \VGT actuator. + Replace the VGT actuator. + Use the following procedure in the ISB M2150 Service Manual, Bulletin 4021578. Refer to Procedure 010-134 in Section 10. + Use the following procedure in the ISC and ISL CM2150 Service Manual, Bulletin 4021569. Refer to Procedure 010-134 in Section 10. 2c Gear is broken on the VGT actuator? NO 2c ©2008 Cummins Inc., Box 3005, Columbus, IN 47202-3005 U.S.A. Al Rights Reserved. Printed from QuickServe® Online. Last Modified: 98-Nov-2017File: 08-05-2387 Pago 7 of 10 STEP 2C: __ Inspect the turbocharger shaft movement. Condition: * Turn Keyswitch OFF. + Remove VGT actuator om the turbocharger. Action ‘Specification/Repair Next Step Inspect the sector gear on the turbocharger for | Sector gear teeth are not damaged and 3A damaged or broken geer tooth movement meets ine requirements when Navel Using the sector gear gauge, aecording fo BOtoaet te eek oreeaause Fam Number | Procedure 010-134 n Section 101n the base moves through its operating range. Use the rains series Mania a following procedure in the ISB CM2150 Senice | YES Manual, Suletin 4021578. Refer to Procedure | Repair 040-184in Section 10 _— actuator h Use the following procedure in in the ISC and pee ctuator has been ISL Ch2180 Service Manual, Bullein 4021569, Refer to Procedure 010-134 in Section 10 Replace the VGT actuator ulessit was Note: It may take considerable force to move the already replaced in Step sector gear Ifit can be moved by hand, thisis | * Use the following procedure inthe ISB considered acceptable. Do not use any hand M2150 Service Manual, Bulletin ce 4021878, Refer to Procedure 010-194 in Section 10 . he eo cee ein i ase ere + Use the following procedure in the ISC_ fe ea fat! ulletin and ISL CM2150 Service Manual, Bulletin Refer to Procedure 010-134 in Section 10. 4021569. Refer to Procedure 010-134 in + Use the folowing procedure in the ISC and Aa ISL cM2t50 Service Manual, Bulotin 4021569, Refer to Procedure 010-134 in serena Sector gear teeth are not damaged and | 9A movement meats the requirements when Using the sector gear gauge, according to Procedure 010-134 in Section 10 in the base engine service manual? No. Repair: A turbocharger mechanical malfunction has been detected, Note: This malfunction can be caused by debris exiting the engine, causing the turbocharger nozzle to stop moving. Inspect the base engine components for damage. Replace the turbocharger assembly. + Use the following procedure in the ISB C2150 Service Manual, Bulletin 4021578. Refer to Procedure 010-033 in Section 10. + Use the foliowing procedure in the ISC and ISL CM2150 Service Manual, Bulletin 4021569. Refer to Procedure 019-033 in Section 10, Note: The VGT actuator will be reused with the new turbocharger. Do not install the actuator on the malfunctioning turbocharger. (© 2008 Cummins Ine., Box 3008, Columbus, IN 47202-3005 U.S.A. All Rights Reserved. Printed from QuickServe® Online. Last Modifie 28-Nov-2017File: 08-108-2387 STEP Clear the fault code. STEP 3A: Check for progressive damage to the aftertreatment system. Page 8 of 10 Condition: in Section 14, 014-013 in Section 14, + Perform the Snap Acceleration — Altertreatment Connected Test to test for a damaged DPF. + Use the following procedure in the ISB CM2150 Service Manual, Bulletin 4021578, Refer to Procedure 014-013, + Use the following procedure in the ISC and ISL CM2150 Service Manual, Bulletin 4021569, Refer to Procedure are found in the Calibration Information section of System ID & Dataplate in Features Parameters. Action Specification/Repair Next Step Check for progressive damage to the Progressive damage to the aftertreatment | 38 aftertreatment system system detected? Perform the Snap Acceleration Afterreaiment | YES Connected Test io test for a damaged DPF. Repair: + Use the following procedure in the 18 el an Gw2t50 Sonics Nanuel, Sutetn aozrere, | Replace he damaged aterrestment syst Refer to Procedure 014-013 in Section 14. : + Use tho following procedure in the ISC and | * Use the following procedure in the [SB ISL CM2150 Service Manual, Bulletin CM2150 Service Manual, Bulletin 4021568, Refer to Procedure 014-013 in 4021578. Refer to Procedure 011-050 in Section 14 Section 11 + Use the following procedure in the |SC and ISL CM2150 Service Manuel, Bulletin 4021569, Refer to Procedure 011-050 in Section 11 Progressive damage to the aftertreatment | 38 system detected? No STEP 3B: Check if an ECM calibration update is available. Condition: * Connect all components, + Connect INSITE™ electronic service too Action Specification/Repair Next Step Compare the ECM code and revision number in | Ifa calibration update for this fault code is | 3c the ECM to the calibration revisions listed in the | available, does the ECM contain that revision ECM Calibration Revision History for applicable | or higher? changes related to this fault code. Yes * Use INSITE™ electronic service too! to find the present ECM code and revision number in J the ECM. The ECM code and revision number | If calibration update for this fault codeis | 3c. available, does the ECM contain that revision ot higher? No Repair: If necessary, calibrate the ECM. Refer to Procedure 019-032, © 2008 Cummins Inc., Box 3008, Columbus, IN 47202-3005 U.S.A. All Rights Reserved. Printed from QuickServe® Online, Last Modified: 28-Nov-2017File: 08-05-2387 STEP 3C:___Disable the fault code. Page 9 of 10 Condition: + Connect all components. + Connect INSITE™ electronic service tool Verify that all steps have been completed, If all steps have been completed, then follow the technical escalation process. Action Specification/Repair Next Step, Disable the fault code. Fault code inactive? Repair + Operate the engine within the “Conditions for | yeg complete Clearing the Fault Code” found in the Overview section of this troubleshooting procedure. Fault code inactive? Escalate or No call for assistance Repair: (© 2008 Cummins Inc., Box 3005, Columbus, IN 47202-3005 U.S.A, All Rights Reserved. Printed from QuickServe® Oniine. Last Modified: 28-Nov-2017ertgi2019 ‘Afterreatment Testing IR! PSRC100; EXT IRIMTYP99; EXIT; !Rispsz6;stm0;exit General Information Use the following procedure for additional information on the aftertreatment system, Refer to Procedure 011-999 in Section F. (Iqs3/pubsys2/xml/en/procedures/45/45-011-999-tr- iscl07.html) The following procedure contains two main steps: Initial Check * This is an inspection step to determine the condition of the aftertreatment diesel particulate filter (DPF) without removal of the filter. The Initial Check step should be used to determine if the aftertreatment DPF has malfunctioned due to progressive damage. Test + This step of the procedure explains how to perform a stationary regeneration using an electronic service tool or an original equipment manufacturer (OEM)-provided stationary regeneration method. The Test step should only be performed when troubleshooting procedures and/or engine indicator lamps indicate this is necessary. If the aftertreatment DPF requires replacement, before | replacing: + Troubleshoot and clear all fault codes + Verify the correct fuel type is being used * Troubleshoot any oil consumption complaint + Troubleshoot any coolant consumption complaint + Inspect the diesel oxidation catalyst (DOC). Refer to Procedure 011-049 in Section 11 (/qs3/pubsys2/xml/en/procedures/45/45-011-049-tr- | iscl07.htm!) The INSITE™ electronic service tool Aftertreatment DPF || Stationary Regeneration Test can be used to: + Regenerate an aftertreatment DPF + Recover the aftertreatment diesel oxidation catalyst and aftertreatment DPF after coolant contamination