dermo1 Posted April 2, 2009 Share Posted April 2, 2009 Have just installed a new fs1022 on a cummins powerd monaco coach old fs1022 had a square wif sensor plug.New fs1022 has a ovel plug installed new pig tail now has a code 428 for wif sensor. tested sensors old one about 85ohms resistance and if it is jumperd in code goes away. any one else had this problem is thare a fix Quote Link to comment Share on other sites More sharing options...
LARRY BRUDZYNSKI Posted April 3, 2009 Share Posted April 3, 2009 Was there a code before replacing the filter, or did it start after? FAULT CODE 428 Water-In-Fuel Sensor Circuit - Voltage Above Normal or Shorted to High Source Printable Version Overview CODE REASON EFFECT Fault Code : 428 PID: P097 SPN: 97 FMI: 3/3 LAMP: Amber SRT: Water-in-Fuel Sensor Circuit - Voltage Above Normal or Shorted to High Source. High voltage detected at the water-in-fuel circuit. None on performance. No water-in-fuel warning available. Water-In-Fuel Sensor Circuit SMALL | MEDIUM | LARGE Circuit Description The water-in-fuel sensor is attached to the suction-side fuel filter. The water-in-fuel sensor sends a signal to the Electronic Control Module (ECM) when a set volume of water has accumulated in the fuel filter. The water-in-fuel circuit contains two wires: a return and a signal wire. Component Location The water-in-fuel sensor is integrated into the bottom of the Original Equipment Manufacturer (OEM) supplied fuel filter. Refer to the OEM troubleshooting and repair manual for location. Shop Talk Beginning with Engine Serial Number (ESN)14039654, the temperature sensor return circuit was separated from the pressure sensor return circuit. For ESNs prior to this and with engine wiring harness Part Number 3682854, refer to the Common Pressure/Temperature Sensor Return Circuit above. For this ESN and greater or for any other engine wiring harness part number, refer to the Separate Pressure/Temperature Sensor Return Circuit above. The water-in-fuel sensor shares return wires in the engine harness with other sensors. An open return can cause multiple fault code s to be active. Before troubleshooting Fault Code 428 , check for multiple fault code s. Possible causes for this fault code include: Open return or signal circuit in the harness, connectors, sensor, or ECM. Signal wire shorted to sensor supply or battery voltage. Cautions and Warnings -------------------------------------------------------------------------------- CAUTION To reduce the possibility of damaging a new ECM, all other active fault code s must be investigated prior to replacing the ECM. 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 Part Number 3822917 - female Deutsch/AMP/Metri-Pack test lead Part Number 3823993 - 16 AWG male Deutsch test lead Part Number 3823994 - 16 AWG female Deutsch test lead. Troubleshooting Steps STEPS SPECIFICATIONS STEP 1. Check the fault code s. STEP 1A. Check for an inactive fault code . Fault Code 428 inactive? STEP 2. Check the water-in-fuel sensor and circuit. STEP 2A. Inspect the water-in-fuel sensor and connector pins. Dirty or damaged pins? STEP 2B. Check the sensor resistance. Greater than 100k ohms? STEP 2C. Check the fault code s and verify sensor condition. Fault Code 428 active? STEP 3. Check the ECM and engine harness. STEP 3A. Inspect the ECM and engine harness connector pins. Dirty or damaged pins? STEP 3B. Check the ECM response. Fault Code 429 active and Fault Code 428 inactive? STEP 3C. Check for an open circuit in the engine harness. Less than 10 ohms? STEP 3C-1. Check for an open circuit in the engine harness. STEP 3D. Check for a pin-to-pin short circuit in the engine harness. Greater than 100k ohms? STEP 3E. Check for an inactive fault code . Fault Code 428 inactive? STEP 4. Clear the fault code s: STEP 4A. Disable the fault code . Fault Code 428 inactive? STEP 4B. Clear the inactive fault code s. All fault code s cleared? -------------------------------------------------------------------------------- Guided Step 1 - Check the fault code s. -------------------------------------------------------------------------------- Guided Step 1A - Check for an inactive fault code . Conditions Turn keyswitch ON. Connect INSITE™ electronic service tool. Action Use INSITE™ to read the fault code s. Fault Code 428 inactive? Fault Code 428 inactive? YES NO No Repair No Repair Inactive or Intermittent Fault Code , Procedure 019-362 Go to 2A -------------------------------------------------------------------------------- Guided Step 2 - Check the water-in-fuel sensor and circuit. -------------------------------------------------------------------------------- Guided Step 2A - Inspect the water-in-fuel sensor and connector pins. Conditions Turn keyswitch OFF. Disconnect the water-in-fuel sensor from the sensor extension harness. Action 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 shroud broken Damaged connector locking tab Damaged wire or engine harness insulation. For general inspection techniques, refer to Component Connector and Pin Inspection, Procedure 019-361. Dirty or damaged pins? Dirty or damaged pins? YES NO A defective connection has been detected in the sensor or harness connector. Clean the connector and pins. Repair the damaged harness, connector, or pins if possible. Refer to Procedure 019-043. No Repair Go to 4A Go to 2B -------------------------------------------------------------------------------- Guided Step 2B - Check the sensor resistance. Conditions Turn keyswitch OFF. Disconnect the water-in-fuel sensor from the sensor extension harness. Action Measure the resistance between the water-in-fuel SIGNAL pin and the water-in-fuel RETURN pin at the water-in-fuel sensor connector. Refer to the wiring diagram for connector pin identification. For general resistance measurement techniques, refer to Resistance Measurements Using a Multimeter and Wiring Diagram, Procedure 019-360. Greater than 100k ohms? Greater than 100k ohms? YES NO Replace the water-in-fuel sensor. Refer to Procedure 019-127. No Repair Go to 4A Go to 2C -------------------------------------------------------------------------------- Guided Step 2C - Check the fault code s and verify sensor condition. Conditions Turn keyswitch OFF. Connect the water-in-fuel sensor to the sensor extension harness. Turn keyswitch ON. Connect INSITE™ electronic service tool. Action Use INSITE™ to read the fault code s. Fault Code 428 active? Fault Code 428 active? YES NO No Repair None. The removal and installation of the connector corrected the failure. Go to 3A Go to 4A -------------------------------------------------------------------------------- Guided Step 3 - Check the ECM and engine harness. -------------------------------------------------------------------------------- Guided Step 3A - Inspect the ECM and engine harness connector pins. Conditions Turn keyswitch OFF. Disconnect the engine harness from the ECM. Action 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 shroud broken Damaged connector locking tab Damaged wire or engine harness insulation. For general inspection techniques, refer to Component Connector and Pin Inspection, Procedure 019-361. Dirty or damaged pins? Dirty or damaged pins? YES NO A defective connection has been detected in the ECM connector or engine harness connector. Clean the connector and pins. Repair the damaged harness, connector, or pins if possible. Refer to Procedure 019-043. No Repair Go to 4A Go to 3B -------------------------------------------------------------------------------- Guided Step 3B - Check the ECM response. Conditions Turn keyswitch OFF. Disconnect the engine harness from the ECM. Turn keyswitch ON. Connect INSITE™ electronic service tool. Action Check for the appropriate circuit response after 30 seconds. Use INSITE™ to read the fault code s. Refer to the wiring diagram for connector pin identification. SMALL | MEDIUM | LARGE Fault Code 429 active and Fault Code 428 inactive? Fault Code 429 active and Fault Code 428 inactive? YES NO No Repair Call for pre-authorization. Replace the ECM. Refer to Procedure 019-031. Go to 3C Go to 4A -------------------------------------------------------------------------------- Guided Step 3C - Check for an open circuit in the engine harness. Conditions Turn keyswitch OFF. Disconnect the engine harness from the ECM. Disconnect the water-in-fuel sensor from the sensor extension harness. Action Measure the resistance between the engine harness ECM connector water-in-fuel sensor RETURN pin and the extension harness water-in-fuel sensor connector RETURN pin. Refer to the wiring diagram for connector pin identification. For general resistance measurement techniques, refer to the Resistance Measurements Using a Multimeter and Wiring Diagram, Procedure 019-360. SMALL | MEDIUM | LARGE Less than 10 ohms? Less than 10 ohms? YES NO No Repair An open return circuit has been detected in the engine harness or sensor extension harness. Repair or replace the engine harness or sensor extension harness. Refer to Procedure 019-043. Go to 3C-1 Go to 4A -------------------------------------------------------------------------------- Guided Step 3C-1 - Check for an open circuit in the engine harness. Conditions Turn keyswitch OFF. Disconnect the engine harness from the ECM. Disconnect the water-in-fuel sensor from the sensor extension harness. Action Measure the resistance between the engine harness ECM connector water-in-fuel sensor SIGNAL pin and the extension harness water-in-fuel sensor connector SIGNAL pin. Refer to the wiring diagram for connector pin identification. For general resistance measurement techniques, refer to the Resistance Measurements Using a Multimeter and Wiring Diagram, Procedure 019-360. SMALL | MEDIUM | LARGE Less than 10 ohms? Less than 10 ohms? YES NO No Repair An open signal circuit has been detected in the engine harness or sensor extension harness. Repair or replace the engine harness or sensor extension harness. Refer to Procedure 019-043. Go to 3D Go to 4A -------------------------------------------------------------------------------- Guided Step 3D - Check for a pin-to-pin short circuit in the engine harness. Conditions Turn keyswitch OFF. Disconnect the engine harness from the ECM. Disconnect the water-in-fuel sensor from the sensor extension harness. Action Measure the resistance between the water-in-fuel SIGNAL pin in the engine harness ECM connector and all other pins in the engine harness ECM connector. Refer to the wiring diagram for connector pin identification. For general resistance measurement techniques, refer to the Resistance Measurements Using a Multimeter and Wiring Diagram, Procedure 019-360. SMALL | MEDIUM | LARGE Greater than 100k ohms? Greater than 100k ohms? YES NO No Repair A pin-to-pin short circuit on the signal line has been detected in the engine harness or sensor extension harness. Repair or replace the engine harness or sensor extension harness. Refer to Procedure 019-043. Go to 3E Go to 4A -------------------------------------------------------------------------------- Guided Step 3E - Check for an inactive fault code . Conditions Connect all components. Turn keyswitch ON. Connect INSITE™ electronic service tool. Action Use INSITE™ to read the fault code s. Fault Code 428 inactive? Fault Code 428 inactive? YES NO None. The removal and installation of the connector corrected the failure. Troubleshooting procedures need to be repeated from the beginning. A failure mode should have been detected. Go to 4A Go to 1A -------------------------------------------------------------------------------- Guided Step 4 - Clear the fault code s. -------------------------------------------------------------------------------- Guided Step 4A - Disable the fault code . Conditions Connect all components. Connect INSITE™ electronic service tool. Action Start the engine and let it idle for 1 minute. Use INSITE™ to verify the fault code is inactive. Fault Code 428 inactive? Fault Code 428 inactive? YES NO No Repair Return to troubleshooting steps or contact a local Cummins Authorized Repair Location if all steps have been completed and rechecked. Go to 4B Go to 1A -------------------------------------------------------------------------------- Guided Step 4B - Clear the inactive fault code s. Conditions Connect all components. Turn keyswitch ON. Connect INSITE™ electronic service tool. Action Use INSITE™ to erase the inactive fault code s. All fault code s cleared? All fault code s cleared? YES NO No Repair Troubleshoot any remaining active fault code s. Repair complete Appropriate troubleshooting steps Quote Link to comment Share on other sites More sharing options...
Bruce Amacker Posted April 3, 2009 Share Posted April 3, 2009 First of all, I don't know squat about a Cummins, but I can make a suggestion on the diag. Does the new sensor also read 85 ohms? Check voltage at both sides of the sensor with it installed and the key on. You should have 5v or 12v VREF on one pin and a return voltage on the other pin. Check and make sure your return voltages are the same. If they are not, change the resistance by adding a resistor in series or parallel with the two pins. In series with the circuit will increase the resistance and lower the return voltage, in parallel across the pins will raise the return voltage. Buy a multi-pack of resistors at Radio Shack. A lifetime worth of resistors (50-100 resistors ranging from 10 ohms to 10 megaohms) for this kind of stuff will set you back $1-3. Good Luck! Quote Link to comment Share on other sites More sharing options...
dermo1 Posted April 3, 2009 Author Share Posted April 3, 2009 found the anser talking to fleetguard. about 2 years ago fs1022 seperator was updated with the new ovel shaped wif sensor. to get the old square sensor u wave to use a fs1003 fixes the problem. the wif sensors dont interchange the resistance in the sensors is differnt . thanks for all the help. Quote Link to comment Share on other sites More sharing options...
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