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2019 Cummins 5.9L & 6.7L Common Rail Diesel Class
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Cummins 5.9l & 6.7l Common Rail Diesel Class

When: Tuesday, July 30, 2019, 8:30 AM  - 12:00 PM

Instructed by: Wally Mouradian from the Automotive Training Group (ATG) 


Come to this class to skip the hours of trying to find tests or system descriptions in repair information. Technicians new to diesels will avoid the painful lessons, and experienced diesel technicians will be saying, “Wow, that’s a lot easier!”


Bosch fuel systems and Cummins engines come together to create some confusing (and often invisible) Dodge/Ram repair information. Cummins designed the engines, but Dodge wrote the repair information. See the problem? Very little practical diagnostic information was ever published, and what there is lacks any explanation of the purpose of each test, or a clear direction to go with the results. But we have a solution!

This manual and class were designed specifically to give technicians a clear diagnostic path for engine management and emissions concerns. We spent months collecting and comparing technical information to fill in the holes, and then diagnosed and repaired these vehicles to validate everything we found. This manual is the only place you’ll find explanations that not only tell you which tests to run in what order and what the test results should be, but why, and what your options are when a test fails.

Cummins Low Power Example The capture below shows a test drive for a low power complaint on a Cummins 5.9L. At low loads and speeds, the fuel pressure regulator (FCA solenoid) is almost normal at 32%, and the rail pressure is close to the desired (‘SET’) pressure. However, at higher speeds and loads (cursor), the high pressure was 10,000 PSI less than the set point! The FCA solenoid command dropped to 0% to increase fuel flow to the high pressure pump pistons, but it wasn’t enough. 

Low Fuel Pressure @ Speed & Load

 

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That’s a simple enough example – it’s obvious that there’s a high pressure problem, but now what? It could be caused by any of the faults below. Which fault gets tested first? There’s no OEM flow chart for ‘low power’.

  • Low pressure pump or in-tank restriction
  • Clogged fuel filter
  • High pressure CP3 transfer pump
  • Cascade overflow valve
  • FCA solenoid failure

Physical CP3 pump damage/wear Leaking injector(s) balls (high return rate) Loose injector transfer tube nuts Blown pressure limiting valve However, the list above is not the point of this manual and seminar. The value is in gaining the ability to navigate all of these possible causes in the least amount of time. We’ve provided decision-making indicators for each step so you don’t miss anything, and our primary focus is on tests that don’t require much, if any, disassembly.

Key Point: Our ‘first test’ defined the problem category. It’s even more valuable when the test passes, because then you know that nothing in the category is at fault. One test drive, and you know that you don’t have to test ANYTHING on that list!

Other Engine Management & Emissions Systems:  This diagnostic philosophy works great for other systems as well, and for many newer systems, these skills are mission-critical.

System coverage includes:

  • No-starts, hard-starts and stalling
  • Surging, hesitation, slow idle return and racing engines
  • Misfire diagnostics
  • Turbocharger mechanical & closed loop controls
  • Fuel: High, low, and return systems
  • EGR flow management, cooling, throttling, and bypassing
  • DPF regeneration & issues
  • Practical DOC & NAC diagnostics
  • SCR/DEF message clearing issues

 

Instructor Wally Mouradian 


Instructor for the class will be Wally Mouradian from the Automotive Training Group (ATG). Wally has over 35 years of automotive experience including working as a repair technician and owning a service station. He is an ASE Certified and a L1 Certified Master Technician and graduate of Denver Automotive and Diesel College. Wally was a member of the Service Technicians Society (STS) and served as vice president of Automotive Service Association Broward County Chapter. He has 14 years of automotive training experience and is a representative for EASE Diagnostics.

The Automotive Training Group (ATG), Inc. is a privately held, employee owned corporation based in San Diego, California. In January of 2004, ATG acquired the product development, training, and sales legacy of JENDHAM, Inc., and Mitchell’s training division, in order to continue offering industry leading training and information products. ATG’s primary mission is to develop and deliver advanced drivability training seminars for the automotive and diesel aftermarket. ATG currently conducts over 450 seminars each year. They visit most major cities three to four times a year with a new seminar topic each time.