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Electronic Control System Gas Plus Engines – FAULT CODE 566

Engine Cylinder Number 6 Knock – Data Valid but Above Normal Operational Range – Most Severe Level

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Overview

CODE REASON EFFECT
Fault Code: 566
PID: S095
SPN: 1357
FMI: 0
LAMP: Red
SRT: 

Engine Cylinder Number 6 Knock – Data Valid but Above Normal Operational Range – Most Severe Level.

Engine power derate.

Knock Sensor Circuit
SMALL | MEDIUM | LARGE

Circuit Description

The knock sensor is an accelerometer which measures high frequency vibrations. The electronic control module (ECM) processes the voltage signals from the knock sensor to check for an elevated signal during the combustion cycle for each cylinder. In this way, one sensor can be used for multiple cylinders.

Component Location

Knock sensor 1 is located on the side of the engine, on the block, above the air compressor on C and L engines. The B series engine has the knock sensor located on the cylinder head intake cover capscrew. The front knock sensor mounting surface on the C and L engine block has two identically sized holes. The knock sensor is mounted on the lower hole and the top hole is used on some products for p-clip mounting.

Shop Talk

The knock sensors are located on the cylinder block and cylinder head. There are two sensors. Knock sensor 1 monitors cylinders 1, 2, and 3; and knock sensor 2 monitors cylinders 4, 5, and 6. The vehicle keyswitch
must be cycled before full power will be restored after a knock induced derate.

The knock sensors measure the high frequency vibration of the engine due to combustion knock. Knock may occur if the engine is supplied low quality fuel or operated at excessive temperatures. Other sources of high frequency vibration may also cause knock faults to be logged. This may include gear driven accessories such as air compressors or hydraulic pumps, driveline vibration, or a rough running engine due to low fuel pressure.

When the conditions exist, knock faults typically will occur when operated at full power such as during wide open throttle acceleration or during a stall test on an automatic transmission. As such, faults will likely be inactive at idle.

Troubleshooting Steps

STEPS SPECIFICATIONS
STEP 1. Check for fault codes.  
  STEP 1A. Check for an active fault code. Fault Code 572 active?
  STEP 1B. Check for existing fault codes other than knock fault codes. Active fault codes other than knock fault codes?
  STEP 1C. Check for an active fault code. Fault Code 566 active?
STEP 2. Check the knock sensor and related components.  
  STEP 2A. Inspect the knock sensor and sensor connector. Any knock sensor damage?
  STEP 2B. Check for an ignition related problem. Ignition system operating properly?
  STEP 2C. Check the turbocharger wastegate. Is the turbocharger wastegate functioning properly?
  STEP 2D. Check the overhead adjustment. Overhead adjustment within specification?
  STEP 2E. Check the air compressor timing. Air compressor timed correctly?
  STEP 2F. Check for cylinder damage. Evidence of damage?
STEP 3. Check ECM calibration and clear fault codes.  
  STEP 3A. Check to see if an ECM calibration update is available. If a calibration update for this fault code is available, does the ECM contain that revision or higher?
  STEP 3B. Disable the fault code. Fault Code 566 inactive?

Guided Step 1 – Check for fault codes.

Guided Step 1A – Check for an active fault code.

Conditions

  • Turn keyswitch ON
  • Connect INSITE™ electronic service tool.

Action

Start the engine and operate the engine in the condition in which the knock fault occurred.

  • Use INSITE™ electronic service tool to read the fault codes.

Fault Code 572 active?
YES NO
No Repair No Repair
Reference Fault Code 572

Guided Step 1B – Check for existing fault codes other than knock fault codes.

Conditions

  • Turn keyswitch ON.
  • Connect INSITE™ electronic service tool.

Action

Start the engine and operate the engine in the condition in which the knock fault occurred.

  • Check for existing fault codes other than knock fault codes.
  • Use INSITE™ electronic service tool to read the fault codes.

Active fault codes other than knock fault codes?
YES NO
No Repair No Repair
Troubleshoot applicable fault code(s)

Guided Step 1C – Check for an active fault code.

Conditions

  • Turn keyswitch ON.
  • Connect INSITE™ electronic service tool.

Action

Start the engine and operate the engine in the condition in which the knock fault occurred.

  • Use INSITE™ electronic service tool to read the fault codes.

Fault Code 566 active?
YES NO
No Repair No Repair

Guided Step 2 – Check the knock sensor and related components.

Guided Step 2A – Inspect the knock sensor and sensor connector.

Conditions

  • Turn keyswitch OFF.
  • Knock sensor 1 disconnected from the engine harness.

Action

Inspect the knock sensor for the following:

  • Damage to the sensor face
  • Damage to the mounting stud or bolt
  • Poor installation, such as incorrect torque
  • Loose connector
  • Corroded pins
  • Bent or broken pins
  • Pushed back or expanded pins
  • Moisture in or on the connector
  • Missing or damaged connector seals
  • Dirt or debris in or on the connector pins
  • Connector shell broken
  • Wire insulation damage
  • Damaged connector locking tab.

Note: Washers or p-clips can
not be mounted with the knock sensor.

Use the following procedure for general inspections techniques.
Refer to Procedure 019-361 in Section 19.

Any knock sensor damage?
YES NO

An incorrectly mounted or damaged knock sensor has been detected.

 No Repair

Guided Step 2B – Check for an ignition related problem.

Conditions

  • Turn keyswitch OFF.

Action

Check for an ignition-related problem:

  • Reference the Ignition System troubleshooting procedures in the Engine Performance Troubleshooting Tree in Section TT.

Ignition system operating properly?
YES NO
No Repair

An ignition related problem has been detected.

Repair or replace the damaged components.

Use the following procedure in the C8.3G, C Gas Plus, and L Gas Plus Engines Troubleshooting and Repair Manual, Bulletin 3666206.
Refer to Procedure 013-012 in Section 13.

Use the following procedure in the C8.3G, C Gas Plus, and L Gas Plus Engines Troubleshooting and Repair Manual, Bulletin 3666206.
Refer to Procedure 013-016 in Section 13.

Use the following procedure in the B5.9G, B5.9LPG, B Gas Plus, B LPG Plus, B Gas International, and G5.9 Engines Troubleshooting and Repair Manual, Bulletin 3666164.
Refer to Procedure 013-012 in Section 13.

Use the following procedure in the B5.9G, B5.9LPG, B Gas Plus, B LPG Plus, B Gas International, and G5.9 Engines Troubleshooting and Repair Manual, Bulletin 3666164.
Refer to Procedure 013-016 in Section 13.

Guided Step 2C – Check the turbocharger wastegate.

Conditions

  • Turn keyswitch OFF.

Action

Check the turbocharger wastegate for proper operation.

Is the turbocharger actuator functioning properly?
YES NO
No Repair

A damaged turbocharger actuator has been detected.

Replace the actuator.

Guided Step 2D – Check the overhead adjustment.

Conditions

  • Turn keyswitch OFF.

Action

Check the overhead adjustment:

Overhead adjustment within specification?
YES NO
No Repair

Adjust the overhead.

Guided Step 2E – Check the air compressor timing.

Conditions

  • Turn keyswitch OFF.

Action

Check the air compressor timing:

Air compressor timed correctly?
YES NO
No Repair

An incorrectly timed air compressor has been detected.

Set the air compressor timing.

Guided Step 2F – Check for cylinder damage.

Conditions

  • Turn keyswitch OFF.
  • Cylinder 6 spark plug removed.

Action

Inspect for cylinder damage.

  • Use a borescope to inspect cylinder 6 for knock damage.

Evidence of damage?
YES NO

Replace the damaged components.

  • Reference the C8.3G, C Gas Plus, and L Gas Plus Engines Troubleshooting and Repair Manual, Bulletin 3666206
  • Reference the B5.9G, B5.9LPG, B Gas Plus, B LPG Plus, B Gas International, and G5.9 Engines Troubleshooting and Repair Manual, Bulletin 3666164.
 No Repair

Guided Step 3 – Check ECM calibration and clear fault codes.

Guided Step 3A – Check to see if an ECM calibration update is available.

Conditions

  • Connect all components.
  • Connect INSITE™ electronic service tool.

Action

Compare the ECM code and revision in the ECM to the calibration revisions listed in the ECM Calibration Revision History for applicable changes related to this fault code.

  • Use INSITE™ electronic service tool to find the ECM code and revision number. The ECM code and revision number is found in the Calibration Information section of System ID and Dataplate in Features and Parameters.

If a calibration update for this fault code is available, does the ECM contain that revision or higher?
YES NO
No Repair

If necessary, calibrate the ECM. Refer to Procedure
019-032 in Section 19.

Guided Step 3B – Disable the fault code.

Conditions

  • Connect all components.
  • Connect INSITE™ electronic service tool.

Action

Disable and clear the fault code.

  • Operate the engine in the condition in which the knock fault occurred.
  • Use INSITE™ electronic service tool to verify Fault Code 566 is inactive.

Fault Code 566 inactive?
YES NO
No Repair

Return to the troubleshooting steps or contact a Cummins® Authorized Repair Location if all steps have been completed and checked again.
Repair complete

Last Modified:  25-Jun-2009
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