SSS CELECT PLUS Troubleshooting
Contents
1. ee gt _a a a a aaaoa aoumnnnueunququu0 LEE accelerator position sensor Action e Measure resistance from pin 18 of the OEM harness connector to all other pins in the connector e Measure the resistance from pin 11 of the OEM harness connector to all other pins in the connector Repair or replace the OEM harness Refer to the OEM Troubleshooting and Repair Manual Guided Step 3 Check the ECM Guided Step 3A Check the accelerator position supply for proper voltage Conditions e Connect the OEM harness to the accelerator position sensor e Disconnect the OEM harness connector from the ECM SMALL MEDIUM LARGE e Turn keyswitch ON Action e Measure the voltage from pin 18 to pin 19 in the OEM port of the ECM Page 11 of 15 30 04 09 6 33 PM Po OK NOTOK Cd 4 75 to 5 25 VDC Replace the ECM Refer to Procedure 019 031 in the Troubleshooting and Repair Manual Industrial CELECT Plus System Bulletin 3666130 Go to 3B Go to 4A 9 Guided Step 3B Check for the appropriate ECM response A CAUTION A To avoid pin and harness damage use the following test lead when performing this procedure Part Number 3822917 female Deutsch AMP Metri Pack test lead Conditions e Disconnect the OEM harness connector from the ECM e Install Part Number 3822917 as a jumper wire between pin 11 and pin 18 of the OEM ECM port e Turn keyswitch ON SMALL MEDIU2. cable Conditions e Turn keyswitch OFF e Install the breakout cable Part Number 3824892 to the SSS e Do not connect the breakout cable to the OEM harness SMALL MEDIUM LARGE Action e With the accelerator pedal released on idle measure the resistance from pin 3 APS signal to pin 4 APS return on the breakout cable Page 6 of 15 30 04 09 6 33 PM Note Resistance value should be the same as the Idle Resistance Value stamped on the SSS cover 20 ohms Correct resistance value Replace the SSS Refer to the OEM Troubleshooting and Repair Manual Guided Step 2 Check the OEM harness Guided Step 2A Inspect the harness and the ECM connector pins A CAUTION A To avoid damaging a new ECM all other active fault codes must be investigated prior to replacing the ECM Conditions e Turn keyswitch OFF e Disconnect the OEM harness connector from the ECM e Disconnect the OEM harness from the bulkhead connector e Disconnect the OEM harness from the accelerator position sensor e Flush and clean the connector pins using electronic contact cleaner Part Number 3824510 Page 7 of 15 30 04 09 6 33 PM Action bent or broken pins pushed back or expanded pins corroded pins moisture in or on the connector missing or damaged seals dirt or debris in or on the connector pins No damaged pins Repair the damaged pins Repair or replace the OEM harn
3. 30 04 09 6 33 PM Overview EFFECT Low voltage detected at the accelerator position signal Severe derate pin 11 of the OEM harness connector power and speed SRT 00 084 Accelerator Position Sensor Circuit Accelerator Position Accelerator Position Return Signal Accelerator Position 5VDC Supply Accelerator Position Sensor SMALL MEDIUM LARGE Circuit Description The accelerator position sensor signals the Electronic Control Module ECM when the accelerator is depressed The circuit contains three wires 5 VDC supply wire 18 return wire 19 and signal wire 11 Component Location Page 1 of 15 30 04 09 6 33 PM The accelerator position sensor APS is located on the accelerator pedal Shop Talk If all wiring and sensors check good replace the APS circuit wires between the accelerator pedal and the ECM with new wires Run them through or around the bulkhead without using the bulkhead connector Test with these wires If fault clears replace the OEM harness Seal the bulkhead openings around the wires to prevent toxic noxious fumes from seeping into the cab Test voltage levels of the SSS with breakout cable Part Number 3824892 The ECM and accelerator pedal must be calibrated to each other for proper engine response Required when a new accelerator pedal is installed replaced an ECM is replaced a new calibration is downloaded to the ECM or the accelerator pedal wiring is disco
4. M LARGE Action e Read the fault codes using Compulink Part Number 3823549 Echek Part Number 3824437 or INSITE Part Number 3824638 Po OK NTONK Fault Code 132 inactive Fault Code 131 active Replace the ECM Refer to Procedure 019 031 in the Troubleshooting and Repair Manual Page 12 of 15 30 04 09 6 33 PM Industrial CELECT Plus System Bulletin 3666130 Go to 3C Go to 4A eee eee Guided Step 3C Check ECM signal pin resistance A CAUTION A To avoid pin and harness damage use the following test lead when taking a measurement Part Number 3822917 female Deutsch AMP Metri Pack test lead Conditions e Turn keyswitch OFP e Disconnect the OEM harness connector from the ECM Action e Measure the resistance from pin 11 of the ECM OEM port to pin 19 in the ECM OEM port use test lead Part Number 3822917 Less than 100k ohms Go to 4A Go to 4A gt on SSe__owaoa LWOoees sn wy o0n0n 0C0s20 OOOO Page 13 of 15 30 04 09 6 33 PM Guided Step 4 Clear the fault code Guided Step 4A Disable the fault code Conditions e Connect all the components Action e Start the engine and let it idle for one 1 minute e Verify Fault Code 132 is inactive Fault Code 132 inactive Return to the troubleshooting steps or contact your local Cummins Authorized Repair Location if all the steps have been completed and checked again eT Guided Step 4B Clear the ina
5. ctive fault codes Conditions e Connect all the components Action Page 14 of 15 30 04 09 6 33 PM e Erase the inactive fault codes using Compulink Part Number 3823549 Echek Part Number 3824437 or INSITE Part Number 3824638 All faults cleared Troubleshoot any remaining active fault codes Repair complete Appropriate troubleshooting chart El Last Modified 27 Oct 2003 C Page 15 of 15
6. ess or ECM whichever has the damaged pins e Flush the dirt debris or moisture from the connector pins using electronic contact cleaner Part Number 3824510 Refer to Procedure 019 203 in the Troubleshooting and Repair Manual Industrial CELECT Plus System Bulletin 3666130 Repair the OEM harness Refer to Procedure 019 203 in the Troubleshooting and Repair Manual Industrial CELECT Plus System Bulletin Number 3666130 023666130 Replace the OEM harness Refer to the OEM Troubleshooting and Repair Manual Replace the ECM Refer to Procedure 019 031 in the Troubleshooting and Repair Manual Industrial CELECT Plus System Bulletin 3666130 Replace the o ring on the 28 pin connector if it is damaged or missing Refer to Procedure 019 203 in the Troubleshooting and Repair Manual Industrial CELECT Plus System Bulletin 3666130 Go to 2B Go to 4A 9 Guided Step 2B Check for continuity in circuit rs ee Page 8 of 15 30 04 09 6 33 PM Conditions e Turn keyswitch OFP e Connect bulkhead connector e Disconnect the Accelerator Position Sensor e Disconnect the OEM harness connector from the ECM Action e Inspect wiring to APS check wiring diagram for color code e Measure the resistance from pin 18 of the OEM harness connector to 5 VDC supply pin at the APS connector e Measure the resistance from pin 11 of the OEM harness connector to the signal pin of the APS connector e Mea
7. ness damage use the following test lead when taking a measurement Part Number 3822917 female Deutsch AMP Metri Pack test lead Troubleshooting Steps STEP 1 Check the accelerator pedal STEP 1A Verify the accelerator Sensor connected position sensor is connected to the OEM harness Page 3 of 15 30 04 09 6 33 PM STEP 1B Inspect the harness and No damaged pins the accelerator position sensor connector pins STEP 1C Measure the idle resistance Correct resistance value value STEP 2 Check the OEM harness STEP 2A Inspect the harness and No damaged pins the ECM connector pins STEP 2B Check for continuity in Less than 10 ohms Circuit STEP 2C Check for a short circuit to More than 100k ohms ground STEP 2D Check for a short circuit More than 100k ohms STEP 3 Check the ECM STEP 3A Check the accelerator 4 75 to 5 25 VDC position supply for proper voltage STEP 3B Check for the appropriate Fault Code 132 inactive Fault Code 131 ECM response active STEP 3C Check ECM signal pin Less than 100k ohms resistance STEP 4 Clear the fault code STEP 4A Disable the fault code Fault Code 132 inactive STEP 4B Clear the inactive fault All faults cleared codes Guided Step 1 Check the accelerator pedal Guided Step 1A Verify the accelerator position sensor is connected to the OEM harness Conditions e Turn keyswitch OFF Page 4 of 15 30 04 09 6 33 PM Action e Verify tha
8. nnected while keyswitch ON With keyswitch ON slowly push the accelerator to the floor and release do this three times This recalibrates the ECM and accelerator pedal Note The three wires in the accelerator position sensor circuit must be twisted together Cautions and Warnings A CAUTION A To avoid pin and harness damage use the following test leads when taking a measurement Part Number 3822758 male Deutsch AMP Metri Pack test lead Part Number 3822917 female Deutsch AMP Metri Pack test lead Part Number 3824892 accelerator position sensor breakout cable A CAUTION A To avoid pin and harness damage use the following test lead when taking a measurement Part Number 3824892 accelerator position sensor breakout cable A CAUTION A To avoid damaging a new ECM all other active fault codes must be investigated prior to replacing the ECM Page 2 of 15 30 04 09 6 33 PM A CAUTION A To avoid pin and harness damage use the following test lead when taking a measurement Part Number 3822758 male Deustch AMP Metri Pack test lead A CAUTION A To avoid pin and harness damage use the following test lead when taking a measurement Part Number 3822758 male Deutsch AMP Metri Pack test lead A CAUTION A To avoid pin and harness damage use the following test lead when performing this procedure Part Number 3822917 female Deutsch AMP Metri Pack test lead A CAUTION A To avoid pin and har
9. sure the resistance from pin 19 of the OEM harness connector to the return pin of the APS connector Less than 10 ohms Repair or replace the APS wiring Refer to the OEM Troubleshooting and Repair Manual Go to 2C Go to 4A COE ass anii Guided Step 2C Check for a short circuit to ground A CAUTION A To avoid pin and harness damage use the following test lead when taking a measurement Part Number 3822758 male Deustch AMP Metri Pack test lead Page 9 of 15 30 04 09 6 33 PM PIN 11 18 Conditions e Turn keyswitch OFF e Disconnect the OEM harness connector from the ECM e Disconnect the OEM harness from the accelerator position sensor SMALL MEDIUM LARGE Action e Measure the resistance from pin 18 of the OEM harness to engine block ground e Measure the resistance from pin 11 of the OEM harness to engine block ground More than 100k ohms Repair or replace the OEM harness Refer to the OEM Troubleshooting and Repair Manual a Guided Step 2D Check for a short circuit A CAUTION A To avoid pin and harness damage use the following test lead when taking a measurement Part Number 3822758 male Deutsch AMP Metri Pack test lead Conditions Test All Pins e Turn keyswitch OFF m e Disconnect the OEM harness connector PIN 11 18 from the ECM e Disconnect the OEM harness from the SMALL I MEDIUM LARGE Page 10 of 15 30 04 09 6 33 PM
10. t the accelerator position sensor is connected to the OEM harness Sensor connected Go to 1B Go to 4A CC Guided Step 1B Inspect the harness and the accelerator position sensor connector pins Conditions e Turn keyswitch OFF e Disconnect the OEM harness from the accelerator position sensor e Flush and clean the connector pins using electronic contact cleaner Part Number 3824510 Action bent or broken pins pushed back or expanded pins corroded pins moisture in or on the connector missing or damaged seals dirt or debris in or on the connector pins No damaged pins Repair the damaged pins Repair or replace the OEM harness or sensor whichever has the damaged pins e Flush the dirt debris or moisture from the Page 5 of 15 30 04 09 6 33 PM connector pins using electronic contact cleaner Part Number 3824510 e Repair the engine harness Refer to Procedure 019 201 and 019 202 in the Troubleshooting and Repair Manual Industrial CELECT Plus System Bulletin 3666130 e Replace the OEM harness Refer to the OEM Troubleshooting and Repair Manual e Replace the accelerator position sensor Refer to the OEM Troubleshooting and Repair Manual Go to 1C Go to 4A EEE Guided Step 1B Measure the idle resistance value A CAUTION A To avoid pin and harness damage use the following test lead when taking a measurement Part Number 3824892 accelerator position sensor breakout
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