File: 01-105-689 FAULT CODE 689 - Crankshaft Engine Speed Sensor Error TROUBLESHOOTING SUMMARY AcautionA To reduce the possibility of damaging a new engine control module, all other active fault codes must be investigated prior to replacing the engine control module. AcautionA To reduce the possibility of pin and harness damage, use the following test leads when taking a measurement: Part Number 3824774 - Pressure sensor breakout cable, Part Number 3824776 - Pressure mnsor breakout cable, Part Number 3822758 - male Deutsch"™/AMP™/Metri-Pack™ test lead, and Part Page 1 of 13 SPECIFICATIONS SRT CODE No damaged pins Less than 10 ohms More than 100k ohms More than 100k ohms No damaged pins Less than 10 ohms More than 100k ohms More than 100k ohms No damaged pins Signal present 4.75 to 5.25-VDC Fault Code 689 inactive STEPS STEP 1: Check the engine harness. STEP 1A: Inspect the engine harness and the extension harness connector pins. STEP 1B: Check for an open circuit STEP1C: Check fora short circuit to engine block ground. ‘STEP 1D: Check for a short circuit from pin to pin, STEP 2: Check the extension hamess. STEP 2A: Inspect the extension harness and the engine control module connector pins, STEP 2B: Check for an open circult. STEP 2C: Check for a short circuit to engine block ground. STEP 2D: Check fora short circuit from pin to pin STEP 3: Check the crankshaft engine speed sensor. STEP 3A: __ Inspect the sensor and engine harness connector pins. STEP 3B: Check signal from the sensor. STEP 3C: Check sensor supply voltage. STEP 4: Clear the fault codes. STEP 4A: Disable the fault code. STEP 4B: Clear any inactive fault codes. © 2008 Cummins inc., Box 3005, Columbus, IN 47202-3005 U.S.A, AAll Rights Reserved. All fault codes cleared Printed from QuickServe® Online. Last Modified: 24-Apr-2012File: 01-105-689 Page 2 of 13 TROUBLESHOOTING STEP STEP 1: Check the engine harness. STEP 1A:___ Inspect the engine harness and the extension harness connector pins. Condition: * Place the runi/stop/auto switch in the STOP position. + Disconnect the engine harness from the extension harness. Action Specification/Repair Next Step Inspect the engine harness andthe extension | OK 1B hammess connector pis forthe folowing No damaged pins Corroded pins NOT OK 4a + 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. Use the following procedure for general inspection techniques. Refer to Procedure 049-361 in Section 19 Repair the damaged pins. + Flush the dirt, debris, or moisture from the connector pins. Use electronic contact cleaner, Part Number 3824510. + Install the appropriate connector seal ifit is damaged or missing, + Repair the engine harness. Refer to Procedure 019-208 in Section 19. + Replace the engine hamess. Refer to Procedure 019-043 in Section 19. + Repair the extension hamess. Refer to Procedure 019-208 in Section 19. + Replace the extension hamess. Refer to Procedure 019-175 in Section 19. © 2008 Cummins inc., Box 3005, Columbus, IN 47202-3005 U.S.A, All Rights Reserved. Printed from QuickServe® Online. Last Modified: 24-Apr-2012File: 01-105-689 Page 3 of 13 STEP 1B: Check for an open circuit. Condition: + Place the runistop/auto switch in the STOP position. * Disconnect the engine harness from the extension hamess. + Disconnect the engine harness from the crankshaft engine speed sensor. Action Specification/Repair Next Step Check for an open circuit, oK 1c ‘+ Measure the resistance from the crankshaft engine speed sensor SUPPLY pins on the Less than 10 ohms engine hamess inline connector to the NOT OK 4a crankshaft engine speed sensor SUPPLY pins at the engine hamess sensor connector. + Measure the resistance from the crankshaft engine speed sensor RETURN pin on the ‘engine hamess inline connector to the crankshaft engine speed sensor RETURN pin at the engine hamess sensor connector. + Measure the resistance from the crankshaft engine speed sensor SIGNAL pin on the engine hamess inline connector to the crankshaft engine speed sensor SIGNAL pin at the engine harness sensor connector. Repair or replace the engine harness. + Repair the engine harness. Refer to Procedure 019-208 in Section 19. + Replace the engine harness. Refer to Procedure 019-043 in Section 19. © 2008 Cummins inc., Box 3005, Columbus, IN 47202-3005 U.S.A, All Rights Reserved. Printed from QuickServe® Online. Last Modified: 24-Apr-2012File: 01-105-689 Page 4 of 13 STEP 1C: Check fora short circuit to engine block ground. Condition: + Place the runistop/auto switch in the STOP position. * Disconnect the engine harness from the extension hamess. + Disconnect the engine harness from the crankshaft engine speed sensor. Action Specification/Repair Next Step Check for a short circuit to engine block ground. | OK 1D ‘+ Measure the resistance from the crankshaft engine speed sensor SUPPLY pins on the More than 100k ohms engine hamess inline connector to engine block ground, NOT OK 4A + Measure the resistance from the crankshaft engine speed sensor SIGNAL pin on the engine hamess inline connector to engine + Repair the engine hamess. Refer to block ground. Procedure 019-208 in Section 19. + Replace the engine harness. Refer to Procedure 019-043 in Section 19. Repair or replace the engine harness. © 2008 Cummins inc., Box 3005, Columbus, IN 47202-3005 U.S.A, Printed from QuickServe® Online. All Rights Reserved. Last Modified: 24-Apr-2012File: 01-405-689 Page Sof 13 STEP 1D: __Gheck for a short circuit from pin to pin. Condition: + Place the runistop/auto switch in the STOP position, * Disconnect the engine hamess from the extension harness. + Disconnect the engine harness from the crankshaft engine speed sensor. Action Specification/Repair Next Step Check for a short circut from pin to pin OK 20 + Measure the resistance between the crankshaft engine speed sensor SUPPLY pins | More than 100k ohms to all other pins of the engine hamess inline connector. NOT OK 4a * Measure the resistance between the Repair or replace the engine harness. crankshaft engine speed sensor RETURN pin : to all other pins of the engine hamess inline * Repair the engine harness. Refer to Sommsctor Procedure 019-208 in Section 18. + Measure the resistance between the + Replace the engine harness. Refer to crankshaft engine speed sensor SIGNAL pin Procedure 018-043 Jp Seton 18. to all other pins of the engine hamess inline connector. © 2008 Cummins inc., Box 3005, Columbus, IN 47202-3005 U.S.A, All Rights Reserved. Printed from QuickServe® Online. Last Modified: 24-Apr-2012File: 0105-689 Page 6of 13, STEP 2: Check the extension harness. STEP 2A: Inspect the extension harness and the engine control module connector pins Condition: + Place the runistop/auto switch in the STOP position + Disconnect the extension hamess connector from the engine control module. ‘Action Specification/Repair Next Stop Inspect the extension hamess and engine control | OK 2B module connector pins forthe following ; Loose connector No damaged pine Gorroded pins Bent or broken pins NoT OK 4A 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, Use the following procedure for general inspection techniques. Refer to Procedure 019-361 in Section 19 Repair the damaged pins, + Flush the dirt, debris, or moisture from the connector pins. Use electronic contact cleaner, Part Number 3824510, + Install the appropriate connector seal ifit is damaged or missing, + Repair the extension hamess. Refer to Procedure 019-213 in Section 19. + Replace the extension hamess. Refer to Procedure 019-175 in Section 19. + Replace the engine control module, Refer to Procedure 019-031 in Section 19. © 2008 Cummins inc., Box 3005, Columbus, IN 47202-3005 U.S.A, All Rights Reserved. Printed from QuickServe® Online. Last Modified: 24-Apr-2012File: STEP 2B: 01-105-689 Check for an open circuit. Page 7 of 13 Condition: Place the run/stop/auto switch in the STOP position. Disconnect the extension harness from the engine contro! module. Connect the extension hamess to the engine harness. Connect the engine harness to the crankshaft engine speed sensor. Action Specification/Repair Noxt Step Check for an open circuit, oK 2c + Measure the resistance from the crankshaft engine speed sensor SIGNAL pin to the Less than 10 ohms RETURN pin on the extension hamess. connector. NOT OK an Repair or replace the extension harness. + Repair the extension harness. Refer to Procedure 019-213 in Section 19. + Replace the extension hamess. Refer to Procedure 019-175 in Section 19. © 2008 Cummins inc., Box 3005, Columbus, IN 47202-3005 U.S.A, all Rights Reserved. Printed from QuickServe® Online. Last Modified: 24-Apr-2012File: 01 105-689 Page 8 of 13 STEP 2C: Check for a short circuit to engine block ground. Condition: + Place the run/stop/auto switch in the STOP postion + Disconnect the extension hamess from the engine harness. + Disconnect the extension harness from the engine control module. ‘Action Specification/Repair Next Step Check for a short circuit to engine block ground. ] OK 20 + Measure the resistance from the crankshaft engine speed sensor SUPPLY pins on the More than 100k ohms extension harness connector to engine block ground. NoT ok 4a + Measure the resistance from the erankshaft | Repair or replace the extension harness engine speed sensor RETURN pin on the extension hamess connector to engine block | * Repaitthe extension hamess. Refer to oxen Procedure 019-213 in Section 19, «Tea the resistance from the erankshatt | * Replace the extension hamess. Refer to engine speed sensor SIGNAL pin on the Procedure 018-173 Jo SBbijon 18. texension harness connector to engine block ground © 2008 Cummins inc., Box 3005, Columbus, IN 47202-3005 U.S.A, All Rights Reserved. Printed from QuickServe® Online. Last Modified: 24-Apr-2012File: 01-405-689 Page 9 of 13 STEP 2D: heck for a short circuit from pin to pin. Condition: + Place the runistop/auto switch in the STOP position. + Disconnect the extension harness from the engine control module. + Disconnect the extension harness from the engine harness. Action Specification/Repair Next Step Check for a short circut from pin to pin OK 3A + Measure the resistance between the crankshaft engine speed sensor SUPPLY pins_| More than 100k ohms and all other pins on the extension hamess ‘connector. NOT OK 4a * Measure the resistance between the Repair or replace the extension hamess. crankshaft engine speed sensor RETURN pin and all other pins on the extension hamess * Repair the extension hainess. Refer to Sannacton Procedure 019-213 in Section 18. + Measure the resistance between the + Replace the extension hamess. Refer to crankshaft engine speed sensor SIGNAL pin Procedure 018-175 Jp Seton 18. and all other pins on the extension hamess connector. Test All Pins © 2008 Cummins inc., Box 3005, Columbus, IN 47202-3005 U.S.A, All Rights Reserved. Printed from QuickServe® Online. Last Modified: 24-Apr-2012File: 01-105-689 Page 10 of 13 STEP 3: Check the crankshaft engine speed sensor. STEP 3A: Inspect the sensor and engine harness connector pins. Condition: + Place the run/stop/auto switch in the STOP position. + Disconnect the engine harness connector from the crankshaft engine speed sensor. ‘Action Spocification/Repair Noxt Step Inspect the sensor and the engine harness oK 38 connector pins forthe following: ; + Loose connector No damaged pins + Corroded pins + Bent or broken pins NOT OK. 4A + Pushed back or expanded pins Repair the damaged pins, + Moisture in or on the connector sane ny form th + Missing or damaged connector seals + Flush the dit, debris, or moisture form the + Dirt or debris in or on the connector pins ‘connector, Part Number 3824510. » Connector shell broken + Install the appropriate connector seal itis, + Wire insulation damage damaged or missing + Damaged connector Reking tab + Repair the engine harness. Refer to Procedure 019-201 in Section 19, Refer to Use the following procedure for general Procedure 019-202 in Section 19 or Refer inspection techniques. Refer to Procedure to Procedure 019-205 in Section 19. 019-361 in Section 19. + Replace the crankshaft engine speed sensor. Refer to Procedure 019-038 in Section 18 STEP 3B:__ Check signal from the sensor. Condition: + Install Breakout cable, between the crankshaft engine speed sensor and the engine hamess. Connect INSITE™ olectronic service tool + Place the runistoplauto switch in the STOP position ‘Action Spocification/Repair Noxt Step Check sensor signal voltage: oK 4A + While baring the engine over, use the sensor breakout cable to measure the voltage from. Signal present the SIGNAL pin fo the RETURN pin, Signal NOT OK 3c must change from +4.0 through 5.0:VDC to +0.5 through 2.3-VDC and back, about every 60 degrees of crankshaft rotation. Signal not present © 2008 Cummins inc., Box 3005, Columbus, IN 47202-3005 U.S.A, All Rights Reserved. Printed from QuickServe® Online. Last Modified: 24-Apr-2012File: 01-105-689 STEP 3C: Check sensor supply voltage. Page 11 of 13 Condition: + Connect INSITE™ electronic service tool + Place the run/stop/auto switch in the STOP position. + Disconnect the engine harness from the crankshaft engine speed sensor. Action Specification/Repair Next Step Check the supply voltage. oK 4a + Measure the voltage from the crankshaft engine speed sensor SUPPLY pins to the 478 to 5.25-VDC crankshaft engine speed sensor RETURN pin | * Replace the crankshaft engine speed on the hamess side of the crankshaft engine sensor. Refer to Procedure 019-038 in speed sensor connector. Section 19. NOT OK 1A Return to troubleshooting steps or contact a Cummins® Authorized Repair Location if all steps have been completed and checked again. © 2008 Cummins inc., Box 3005, Columbus, IN 47202-3005 U.S.A, All Rights Reserved. Printed from QuickServe® Online. Last Modified: 24-Apr-2012File: 01-105-689 Page 12 of 13 STEP 4: Clear the fault codes. STEP 4A: Disable the fault code. Condition: + Connect all components. + Connect INSITE™ electronic service tool + Place the idle/rated switch in the IDLE position + Place the run/stop/auto switch in the RUN position and idle for 1 minute. Action Specification/Repair Next Step Disable the fault code. 0K 4B + Use INSITE™ electronic service tool to verify cu inactive that Fault Code 689 is inactive. Fault Code 689 inactive NoT OK 1A Return to troubleshooting steps or contact a Cummins® Authorized Repair Location if all steps have been completed and checked again. STEP 4B: Clear the inactive fault codes. Condition: + Connect all components. + Connect INSITE™ electronic service tool Action Specification/Repair Next Step Clear the inactive fault codes. oK Repair + Use INSITE™ electronic service tool to clear | Ai fault codes cleared complete the inactive fault codes. NOT OK Appropriate troubleshoot! ‘Troubleshoot any remaining active fault toahan codes. © 2008 Cummins inc., Box 3005, Columbus, IN 47202-3005 U.S.A, All Rights Reserved. Printed from QuickServe® Online. Last Modified: 24-Apr-2012File: 01-105-689 Page 13 of 13 © 2008 Cummins inc., Box 3005, Columbus, IN 47202-3005 U.S.A, Printed from QuickServe® Online. AAll Rights Reserved. Last Modified: 24-Apr-2012