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FAULT CODE 254

Fuel Shutoff Solenoid Supply Circuit

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Overview

CODE REASON EFFECT
Fault Code: 254
PID: S017
SPN: 632
FMI: 4
LAMP: Red
SRT: 00-602		 Low voltage detected at the fuel shutoff driver pin 16 of the actuator harness connector. This indicates a current draw from the electronic control module (ECM) greater than 2 amperes or a faulty ECM power supply. The ECM turns off the fuel shutoff valve supply voltage. The engine dies.

Fuel Shutoff Solenoid Circuit

Circuit Description

The fuel shutoff solenoid is a device used by the ECM to control the engine fuel supply. The ECM can shut down the engine by cutting off the power to the fuel shutoff solenoid.

Component Location

The fuel shutoff solenoid is located on the top of the fuel pump.

Shop Talk

  • Inspect the fuel shutoff supply circuit for external wires that can be spliced in to power another device. Removing any extra wires that are found in the circuit powering the fuel shutoff valve with another source other than from pin 16 of the actuator can damage the ECM internally, even if the source is close to battery voltage.
  • If there is an external shutdown system on the vehicle that uses the fuel shutoff valve for engine shutdown, make sure it has
    not failed and pulled down the voltage on the fuel shutoff circuit.
  • Inspect the engine block to chassis ground wire to make sure it is securely fastened to a clean, dry, conductive surface.
  • Check the starter solenoid (+) terminal for a loose connector or accessory wiring with damaged insulation.

Cautions and Warnings

 CAUTION 

 

To reduce the possibility of pin and harness damage, use the following test lead when taking a measurement:
Part Number 3822758 – male Deutsch/AMP/Metri-Pack test lead.
 CAUTION 

 

To reduce the possibility of damaging the new ECM, all other active fault codes must be investigated prior to replacing the ECM.

Troubleshooting Steps

STEPS SPECIFICATIONS
STEP 1. Check the fuel shutoff solenoid.
STEP 1A. Check for extra wires on the fuel shutoff solenoid post. No extra wires
STEP 1B. Check for corrosion on the solenoid post. No corrosion found
STEP 1C. Check the fuel shutoff solenoid resistance. 1 to 5 ohms for 6-VDC solenoids, 6 to 15 ohms for 12-VDC solenoids, 24 to 50 ohms for 24-VDC solenoids, 42 to 80 ohms for 32-VDC solenoids, 46 to 87 ohms for 36-VDC solenoids, 92 to 145 ohms for 48-VDC solenoids, 315 to 375 ohms for 74-VDC solenoids, 645 to 735 ohms for 115-VAC solenoids
STEP 2. Check the actuator harness.
STEP 2A. Check the actuator harness and the ECM connector pins. No damaged pins
STEP 2B. Read the fault codes. Fault Code 254 active
STEP 2C. Check for a short circuit to ground. More than 100k ohms
STEP 2D. Check for a short circuit from pin to pin. More than 100k ohms
STEP 2E. Check the continuity of the wire to the fuel shutoff valve. Less than 10 ohms
STEP 2F. Check the ECM response. Fault Code 254 inactive
STEP 3. Clear the fault codes.
STEP 3A. Disable the fault code. Fault Code 254 inactive
STEP 3B. Clear the inactive fault codes. All fault codes cleared

Guided Step 1 – Check the fuel shutoff solenoid.

Guided Step 1A – Check for extra wires on the fuel shutoff solenoid post.

Conditions

  • Turn keyswitch OFF.

Action

Check for extra wires on the fuel shutoff solenoid post.

NOTE: Powering the fuel shutoff valve with another source other than pin 16 of the actuator can damage the ECM internally, even if source is close to battery voltage.
OK NOT OK
No extra wires Remove any extra wires except for the single wire from pin 16 of actuator harness.

Guided Step 1B – Check for corrosion on the solenoid post.

Conditions

  • Turn keyswitch OFF.
  • Disconnect the fuel shutoff control wire from the fuel shutoff solenoid.

Action

Check for corrosion.

Check for corrosion on the solenoid post.
OK NOT OK
No corrosion found Clean the solenoid post and the wiring terminal.

Refer to Procedure
019-050.

Guided Step 1C – Check the fuel shutoff solenoid resistance.

Conditions

  • Turn keyswitch OFF.
  • Disconnect the actuator harness from the shutoff solenoid.

Action

Check the fuel shutoff solenoid resistance.

  • Measure the resistance from the fuel shutoff solenoid to engine block ground.

For general resistance measurement techniques, refer to the Resistance Measurements Using a Multimeter and Wiring Diagram, Procedure
019-360.
OK NOT OK
1 to 5 ohms for 6-VDC solenoids

6 to 15 ohms for 12-VDC solenoids

24 to 50 ohms for 24-VDC solenoids

42 to 80 ohms for 32-VDC solenoids

46 to 87 ohms for 36-VDC solenoids

92 to 145 ohms for 48-VDC solenoids

315 to 375 ohms for 74-VDC solenoids

645 to 735 ohms for 115-VAC solenoids

 Replace the fuel shutoff solenoid.

Refer to Procedure
019-050.

Guided Step 2 – Check the actuator harness.

Guided Step 2A – Check the actuator harness and the ECM connector pins.

Conditions

  • Turn keyswitch OFF.
  • Disconnect the actuator harness connector from the ECM.
  • Flush and clean the connector pins, use electronic contact cleaner, Part Number 3824510.

Action

Check the engine harness and the ECM connector pins for:

  • 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 on or in the connector pins
  • Connector shell broken
  • Wire insulation damage
  • Damaged connector locking tab.

For general inspection techniques, refer to Component Connector and Pin Inspection, Procedure
019-361.
OK NOT OK
No damaged pins Repair the damaged pins

Flush the dirt, debris, or moisture from the connector pins. Repair or replace the actuator harness or ECM, whichever has the damaged pins.

  • Flush the dirt, debris, or moisture from the connector pins, use electronic contact cleaner, Part Number 3824510.
  • Repair the engine connector or harness. Refer to Procedure
    019-203.
  • Replace the actuator harness. Refer to Procedure
    019-043.
  • Replace the ECM. Refer to Procedure
    019-031.
  • Replace the o-ring on the 28-pin connector if it is damaged or missing. Refer to Procedure
    019-203.

Guided Step 2B – Read the fault codes.

Conditions

  • Turn keyswitch OFF.
  • Connect all components.

Action

Read the fault codes.

  • Start the engine and let it idle for 1 minute.
  • Use INSITE™ electronic service tool to read the active fault codes.
OK NOT OK
Fault Code 254 active Repair complete.

Guided Step 2C – Check for a short circuit to ground.

Conditions

  • Turn keyswitch OFF.
  • Disconnect the actuator harness from the fuel shutoff solenoid.
  • Disconnect the actuator harness connector from the ECM.

Action

Check for a short circuit to ground.

  • Measure the resistance from pin 16 of the actuator harness connector to engine block ground.

For general resistance measurement techniques, refer to the Resistance Measurements Using a Multimeter and Wiring Diagram, Procedure
019-360.
OK NOT OK
More than 100k ohms Repair or replace the actuator harness.

  • Repair the actuator harness. Refer to Procedure
    019-203.
  • Replace the actuator harness. Refer to Procedure
    019-043.

Guided Step 2D – Check for a short circuit from pin to pin.

Conditions

  • Turn keyswitch OFF.
  • Disconnect the actuator harness from the fuel shutoff solenoid.
  • Disconnect the actuator harness connector from the ECM.

Action

Check for a short circuit from pin to pin.

  • Measure the resistance from pin 16 of the actuator harness connector to all other pins in the connector.

For general resistance measurement techniques, refer to the Resistance Measurements Using a Multimeter and Wiring Diagram, Procedure
019-360.
OK NOT OK
More than 100k ohms Repair or replace the actuator harness.

  • Repair the actuator harness. Refer to Procedure
    019-203.
  • Replace the actuator harness. Refer to Procedure
    019-043.

Guided Step 2E – Check the continuity of the wire to the fuel shutoff valve.

Conditions

  • Turn keyswitch OFF.
  • Disconnect the actuator harness from the fuel shutoff solenoid.
  • Disconnect the actuator harness connector from the ECM.

Action

Check for continuity to fuel shutoff valve.

  • Measure the resistance from pin 16 of the ECM actuator connector to fuel shutoff valve ring connector on actuator harness.

For general resistance measurement techniques, refer to the Resistance Measurements Using a Multimeter and Wiring Diagram, Procedure
019-360.
OK NOT OK
Less than 10 ohms Repair or replace the actuator harness.

  • Repair the actuator harness. Refer to Procedure
    019-203.
  • Replace the actuator harness. Refer to Procedure
    019-043.

Guided Step 2F – Check the ECM response.

Conditions

  • Disconnect the actuator harness connector from the ECM.
  • Connect jumper wire pin 27 of actuator harness connector to pin 27 of ECM actuator port.
  • Connect jumper wire pin 23 of actuator harness connector to pin 23 of ECM actuator port.
  • Connect jumper wire pin 26 of actuator harness connector to pin 26 of ECM actuator port.
  • Turn keyswitch ON.

Action

Check the ECM response.

  • Wire a 1k-ohm resistor from pin 16 to pin 9 of the actuator port of the ECM.
OK NOT OK
Fault Code 254 inactive Fault Code 254 active.

Replace the ECM. Refer to Procedure
019-031.

Guided Step 3 – Clear the fault codes.

Guided Step 3A – Disable the fault code.

Conditions

  • Connect all the components.

Action

Disable the fault code.

  • Start the engine and let it idle for 1 minute.
  • Verify Fault Code 254 is inactive.
OK NOT OK
Fault Code 254 inactive Return to the troubleshooting steps or contact a Cummins® Authorized Repair Location if all the steps have been completed and checked again.

Guided Step 3B – Clear the inactive fault codes.

Conditions

  • Connect all the components.

Action

Clear the inactive fault codes.

  • Use INSITE™ electronic service tool to erase the inactive fault codes.
OK NOT OK
All fault codes cleared Troubleshoot any remaining active fault codes.
Repair complete
Appropriate troubleshooting charts
Last Modified:  17-Jan-2007
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