Dodge Cummins Articles: 3rd Generation - TSB Articleshttps://mopar1973man.com/cummins/articles.html/3rd-generation/engine/obdii-error-codes/page/6/?d=4Dodge Cummins Articles: 3rd Generation - TSB ArticlesenP2502 Charging System Errorhttps://mopar1973man.com/cummins/articles.html/3rd-generation/engine/obdii-error-codes/p2502-charging-system-error-r286/

P2502 CHARGING SYSTEM ERROR

When Monitored and Set Condition:

When Monitored: While the engine is running.
Set Condition: The ECM cycles the voltage regulator in the generator while monitoring for a change in output voltage. If the voltage does not drop when the regulator is off, the fault is set.

POSSIBLE CAUSES

  • DIRTY OR LOOSE CONNECTIONS
  • HIGH RESISTANCE IN THE B+ CIRCUIT
  • HIGH RESISTANCE IN THE B+ CROSS OVER CABLE
  • HIGH RESISTANCE IN THE GROUND CIRCUIT
  • GENERATOR
  • ECM
  • INTERMITTENT CONDITION

DIAGNOIST PROCEDURE

NOTE: Refer to VERIFICATION TESTS for appropriate verification test procedures.

  1. Visually inspect the positive and negative connections at the battery. Visually inspect the battery negative connections at the engine block. Are the connections free of corrosion and are they tight?
    Yes --> Go To 2
    No --> Clean and/or tighten the connections. Perform POWERTRAIN VERIFICATION TEST VER - 4 (DIESEL).
  2. Measure the voltage between the B+ post of the generator and the B+ post of the battery while the engine is running. Is the voltage above .4 volts?
    Yes --> Repair the high resistance in the B+ circuit from battery to the generator. Perform POWERTRAIN VERIFICATION TEST VER - 4 (DIESEL).
    No --> Go To 3
  3. Measure the voltage between the B+ post of the generator and the B+ post of the right side battery to the left side battery while the engine is running. Is the voltage above .4 volts?
    Yes --> Repair the high resistance in the B+ cross over cable from right side battery to left side battery. Perform POWERTRAIN VERIFICATION TEST VER - 4 (DIESEL).
    No --> Go To 4
  4. Measure the voltage between the generator case and the B- post of the battery. Is the voltage above .1 volts?
    Yes --> Repair the high resistance in the ground circuit. Perform POWERTRAIN VERIFICATION TEST VER - 4 (DIESEL).
    No --> Go To 5
  5. Disconnect the Generator field harness connector.
    NOTE: Check connectors - Clean/repair as necessary.
    Measure the resistance between the generator field terminals. Is the resistance between .5 and 15 Ohms?
    Yes --> Go To 6
    No --> Replace the generator. Perform POWERTRAIN VERIFICATION TEST VER - 4 (DIESEL).
  6. Turn the ignition off. Reconnect the Generator field harness connector. Disconnect the ECM harness connectors.
    NOTE: Check connectors - Clean/repair as necessary.
    Ignition on, engine not running. Measure and record the voltage between battery positive circuits of the ECM harness connector and the battery negative circuits of the ECM harness connector. Turn the ignition off. Reconnect the ECM harness connectors. Start the engine. Use the DRBIII® to measure and record battery voltage. Compare the voltage reading from the voltmeter with that of the DRBIII®. Are the readings within 3 volts of each other?
    Yes --> Test Complete.
    No --> Replace and program the ECM in accordance with the Service Information. Perform POWERTRAIN VERIFICATION TEST VER - 4 (DIESEL).
]]>286Wed, 06 Jan 2016 22:12:37 +0000P2503 Charging System Output Lowhttps://mopar1973man.com/cummins/articles.html/3rd-generation/engine/obdii-error-codes/p2503-charging-system-output-low-r287/

P2503 CHARGING SYSTEM OUTPUT LOW

When Monitored and Set Condition:

When Monitored: While the engine is running.
Set Condition: The battery voltage exceeds target voltage by more than a calibrated value.

POSSIBLE CAUSES

  • OTHER DTC'S PRESENT
  • GENERATOR
  • FIELD DRIVER CIRCUIT SHORTED TO GROUND
  • ECM
  • INTERMITTENT CONDITION

DIAGNOSTIC PROCEDURE

NOTE: Refer to VERIFICATION TESTS for appropriate verification test procedures.

  1. With the DRBIII®, read DTCs. Is DTC P2502 set?
    Yes --> Repair other DTCs first. Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
    No --> Go To 2
  2. Disconnect the Generator field harness connector.
    NOTE: Check connectors - Clean/repair as necessary.
    Measure the resistance between the generator field terminals at the generator. Is the resistance between .5 and 15 Ohms?
    Yes --> Go To 3
    No --> Replace the generator. Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
  3. Disconnect the ECM harness connectors.
    NOTE: Check connectors - Clean/repair as necessary.
    Measure the resistance of the generator field driver circuit between the generator and battery negative. Is the resistance greater than 100 ohms?
    Yes --> Go To 4
    No --> Repair the generator field driver circuit shorted to ground. Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
  4. Measure and record the voltage between battery positive circuit of the ECM harness connector and the battery negative circuits of the ECM harness connector. Reconnect the ECM connectors. Use the DRBIII® to measure and record battery voltage. Compare the voltage reading from the voltmeter with that of the DRBIII®. Are the readings within 3 volts of each other?
    Yes --> Refer to the SYMPTOM: INTERMITTENT CONDITION Symptom (Diagnostic Procedure). Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
    No --> Replace and program the ECM in accordance with the Service Information. Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
     
]]>287Wed, 06 Jan 2016 22:13:14 +0000P2504 Charging System Output Highhttps://mopar1973man.com/cummins/articles.html/3rd-generation/engine/obdii-error-codes/p2504-charging-system-output-high-r288/

P2504 CHARGING SYSTEM OUTPUT HIGH

When Monitored and Set Condition:

When Monitored: While the engine is running.
Set Condition: Battery voltage is less than 11.5 volts for more than 8 seconds. Battery voltage must exceed 12 volts for more than 5 seconds for fault to become inactive.

POSSIBLE CAUSES

  • OTHER DTC'S PRESENT
  • DIRTY OR LOOSE CONNECTIONS
  • ADD-ON OR ACCESSORY WIRES AT BATTERY TERMINAL
  • HIGH RESISTANCE IN THE B+ CIRCUIT
  • HIGH RESISTANCE IN THE B+ CROSS OVER CABLE
  • HIGH RESISTANCE IN THE GROUND CIRCUIT
  • GENERATOR
  • ECM
  • INTERMITTENT CONDITION

DIAGNOSTIC PROCEDURE

NOTE: Refer to VERIFICATION TESTS for appropriate verification test procedures.

  1. With the DRBIII®, read DTCs. Is DTC P2502 set?
    Yes --> Repair other DTCs first. Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
    No --> Go To 2
  2. Visually inspect the positive and negative connections at the battery. Visually inspect the battery negative connections at the engine block. Are the connections free of corrosion and are they tight?
    Yes --> Go To 3
    No --> Clean and/or tighten the connections. Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
  3. Check for add-on or accessory wiring at positive (+) terminal of the battery. Are there any damaged wires at the battery?
    Yes --> Remove defective or miss wired add-on or accessory wiring from battery. Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
    No --> Go To 4
  4. Measure the voltage between the B+ post of the generator and the B+ post of the battery while the engine is running. Is the voltage above .4 volts?
    Yes --> Repair the high resistance in the B+ circuit from battery to the generator. Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
    No --> Go To 5
  5. Measure the voltage between the B+ post of the generator and the B+ post of the right side battery to the left side battery while the engine is running. Is the voltage above .4 volts?
    Yes --> Repair the high resistance in the B+ cross over cable from right side battery to left side battery. Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
    No --> Go To 6
  6. Measure the voltage between the generator case and the B- post of the battery. Is the voltage above .1 volts?
    Yes --> Repair the high resistance in the ground circuit. Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
    No --> Go To 7
  7. Disconnect the Generator field harness connector.
    NOTE: Check connectors - Clean/repair as necessary.
    Measure the resistance between the generator field terminals at the generator. Is the resistance between .5 and 15 Ohms?
    Yes --> Go To 8
    No --> Replace the generator. Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
  8. Measure and record the voltage between battery positive circuit of the ECM harness connector and the battery negative circuits of the ECM harness connector. Reconnect the ECM connectors. Use the DRBIII® to measure and record battery voltage. Compare the voltage reading from the voltmeter with that of the DRBIII®. Are the readings within 3 volts of each other?
    Yes --> Refer to the SYMPTOM: INTERMITTENT CONDITION Symptom (Diagnostic Procedure). Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
    No --> Replace and program the ECM in accordance with the Service Information. Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
]]>288Wed, 06 Jan 2016 22:13:55 +0000P2509 Powerdown Data Lost Errorhttps://mopar1973man.com/cummins/articles.html/3rd-generation/engine/obdii-error-codes/p2509-powerdown-data-lost-error-r289/

P2509 POWERDOWN DATA LOST ERROR

When Monitored and Set Condition:

When Monitored: Continuous - key on or key off.
Set Condition: Loss of voltage detected at the ECM for a calibrated amount of time.

POSSIBLE CAUSES

  • POOR CONNECTIONS AT THE BATTERIES
  • LOW BATTERY VOLTAGE
  • OPEN FUSED B+ TO ECM
  • OPEN GROUND CIRCUIT
  • BATTERY + SHORTED TO OTHER CIRCUITS
  • RETURN CIRCUIT SHORTED
  • BATTERY + SHORTED TO GROUND
  • INTERMITTENT CONDITION

DIAGNOSTIC PROCEDURE

NOTE: Refer to VERIFICATION TESTS for appropriate verification test procedures.

  1. Visually inspect the wiring at the battery for damaged wires, or corrosion. Are the connections tight and free of corrosion?
    Yes --> Go To 2
    No --> Repair the poor connections at the batteries. Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
  2. Measure the voltage between the positive and negative posts of the batteries. Is the battery voltages both above 12 volts?
    Yes --> Go To 3
    No --> Recharge or replace the battery (s). Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
  3. Turn the ignition off. Disconnect the ECM harness connectors. Turn the ignition on. Measure the resistance between the positive battery post and the ECM supply circuits. Is the resistance less than 10 Ohms?
    Yes --> Go To 4
    No --> Repair the open fused B+ circuit to ECM. Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
  4. Measure the resistance between the negative battery post and the ECM ground wire. Is the resistance less than 10 Ohms?
    Yes --> Go To 5
    No --> Repair the open ground circuit. Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
  5. Measure the resistance between the ECM supply circuits and all other circuits in the ECM harness connector, except other supply circuits. Is the resistance greater than 100k Ohms?
    Yes --> Go To 6
    No --> Repair the battery circuit short to other circuits in engine harness. Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
  6. Measure the resistance between the ECM return circuits and all other circuits in the ECM harness connector, except other return circuits. Is the resistance greater than 100k Ohms?
    Yes --> Go To 7
    No --> Repair or replace the engine harness. Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
  7. Measure the resistance between the ECM B+ supply circuit and ground. Is the resistance greater than 100k Ohms?
    Yes --> Refer to the SYMPTOM: INTERMITTENT CONDITION Symptom (Diagnostic Procedure). Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
    No --> Repair Battery + shorted to ground. Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
]]>289Wed, 06 Jan 2016 22:14:50 +0000P2607 Low Voltage At The #2 Intake Air Hater Relayhttps://mopar1973man.com/cummins/articles.html/3rd-generation/engine/obdii-error-codes/p2607-low-voltage-at-the-2-intake-air-hater-relay-r290/

P2607 LOW VOLTAGE AT THE #2 INTAKE AIR HEATER RELAY

When Monitored: When the ignition is on.
Set Condition: When the signal from the #1 intake air heater output does not match the signal from the #1 intake
air heater feedback.

POSSIBLE CAUSES

  • LOOSE CONNECTION
  • INTAKE AIR HEATER RELAY
  • SIGNAL CIRCUIT OPEN FROM RELAY TO ECM
  • SIGNAL CIRCUIT SHORTED TO BATTERY NEGATIVE
  • ECM
  • INTERMITTENT CONDITION

DIAGNOSTIC PROCEDURE

  1. Ignition on, engine not running. With the DRBIII®, actuate the #1 Intake Air Heater. Can you hear the Relay clicking?
    Yes --> Go To 2
    No --> Go To 3
  2. While the relay is clicking, wiggle the wiring harness and connectors. Does this interrupt the clicking?
    Yes --> Repair the poor connection. Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
    No --> Go To 3
  3. Turn the ignition off. Remove the Intake Air Heater #1 Relay. Check connectors - Clean/repair as necessary. Measure the resistance between the signal and return posts of the intake air heater relay. Is the resistance between 15 and 25 Ohms?
    Yes --> Go To 4
    No --> Replace the Intake Air Heater #1 relay. Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
  4. Disconnect the ECM harness connectors. Check connectors - Clean/repair as necessary. Measure the resistance of the intake air heater relay signal circuit between the ECM connector and the intake air heater relay connector. Is the resistance less than 10 Ohms?
    Yes --> Go To 5
    No --> Repair the open signal circuit from PDC to ECM harness connector. Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
  5. Measure the voltage between the signal circuit of the intake air heater relay and battery negative. Is the voltage greater than 1 volts?
    Yes --> Repair the signal circuit shorted to Battery negative. Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
    No --> Go To 6
  6. Reconnect the ECM harness connectors. Disconnect the intake air heater relay signal wire and use a jumper to connect it to battery negative. Turn the ignition on. With the DRBIII®, read DTCs. Did DTC P0542 set or P2608?
    Yes --> Refer to the SYMPTOM: INTERMITTENT CONDITION Symptom (Diagnostic Procedure). Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
    No --> Replace the ECM. Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
]]>290Wed, 06 Jan 2016 22:15:49 +0000P2608 High Voltage At The #2 Intake Air Heater Relayhttps://mopar1973man.com/cummins/articles.html/3rd-generation/engine/obdii-error-codes/p2608-high-voltage-at-the-2-intake-air-heater-relay-r291/ P2608 HIGH VOLTAGE AT THE #2 INTAKE AIR HEATER RELAY

When Monitored: When the ignition is on.
Set Condition: When the signal from the #2 Intake Air Heater output does not match the signal from the #2
Intake Air Heater feedback.

POSSIBLE CAUSES

  • LOOSE CONNECTION
  • INTAKE AIR HEATER RELAY
  • SIGNAL CIRCUIT SHORTED TO BATTERY NEGATIVE
  • ECM
  • INTERMITTENT CONDITION

DIAGNOSTIC PROCEDURE

  1. Ignition on, engine not running.

With the DRBIII®, actuate the Intake Air Heater relay.
Can you hear the Relay clicking?
Yes --> Go To 2
No --> Go To 3
2. While the relay is clicking, wiggle the wiring harness and connectors.
Does this interrupt the clicking?
Yes --> Repair the poor connection.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No --> Go To 3
3. Turn the ignition off.
Remove the Intake Air Heater Relay.
Check connectors - Clean/repair as necessary.
Measure the resistance between the signal and return posts of the intake air heater relay.
Is the resistance between 15 and 25 Ohms?
Yes --> Go To 4
No --> Replace the Intake Air Heater relay.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
4. Disconnect the ECM harness connector(s).
Check connectors - Clean/repair as necessary.
Measure the resistance between the signal circuit of the intake air heater relay and battery negative.
Is the resistance greater than 100 K ohms?
Yes --> Go To 5
No --> Repair signal circuit shorted to battery negative.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).

5. Reconnect the ECM harness connectors.
Turn the ignition on.
Disconnect the intake air heater relay signal wire.
Did DTC P0542 or 2608 set?
Yes --> Refer to the SYMPTOM: INTERMITTENT CONDITION Symptom (Diagnostic
Procedure).
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No --> Replace the ECM.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).

]]>291Wed, 06 Jan 2016 22:16:43 +0000P2609 No Voltage Drop Seen From Intake Air Heatershttps://mopar1973man.com/cummins/articles.html/3rd-generation/engine/obdii-error-codes/p2609-no-voltage-drop-seen-from-intake-air-heaters-r292/

P2609 NO VOLTAGE DROP SEEN FROM INTAKE AIR HEATERS

When Monitored and Set Condition:

When Monitored: First 15 seconds of engine operation.
Set Condition: The ECM does not detect a voltage drop on the intake air heater circuit.

POSSIBLE CAUSES

  • INTAKE AIR HEATER OPEN
  • INTAKE AIR HEATER GROUND OPEN
  • OPEN BATTERY CABLE FROM INTAKE AIR HEATER RELAY
  • BATTERY CABLE OPEN
  • #1 INTAKE AIR HEATER RELAY
  • #2 INTAKE AIR HEATER RELAY
  • INTERMITTENT CONDITION

DIAGNOSTIC PROCEDURE

NOTE: Refer to VERIFICATION TESTS for appropriate verification test procedures.

  1. Measure the resistance between the intake air heater supply and ground terminal on each intake air heater. Is the resistance less than 10 Ohms?
    Yes --> Go To 2
    No --> Replace the open Intake Air Heater.
  2. Measure the resistance of the intake air heater ground circuit between the intake air heater terminal and the intake manifold cover ground connection. Is the resistance less than 10 Ohms?
    Yes --> Go To 3
    No --> Repair the open Intake Air heater ground.
  3. Measure the resistance of the battery cable between the intake air heater and the intake air heater relay for both intake air heaters. Is the resistance less than 10 Ohms?
    Yes --> Go To 4
    No --> Repair The open or high resistance battery cable from the intake heater relay to heater.
  4. Measure the resistance of the battery cable between the battery and the intake air heater relay for both relays. Is the resistance less than 10 Ohms?
    Yes --> Go To 5
    No --> Replace the battery cable from the battery to the Intake Air Heater Relay.
  5. Disconnect the #1 intake air heater relay signal wire. Connect a jumper wire from the signal terminal of the #1 intake air heater relay to battery positive. Did the relay click when 12 volts was applied?
    Yes --> Go To 6
    No --> Replace #1 Intake Air Heater Relay.
  6. Disconnect the #2 intake air heater relay signal wire. Connect a jumper wire from the signal terminal of the #2 intake air heater relay to battery positive. Did the relay click when 12 volts was applied?
    Yes --> Refer to the SYMPTOM: INTERMITTENT CONDITION Symptom (Diagnostic Procedure).
    No --> Replace #2 Intake Air Heater Relay.
]]>292Wed, 06 Jan 2016 22:17:48 +0000