This Cummins fault 3138 document is a troubleshooting manual for an EGR orifice pressure sensor fault on CM2250 engines. It explains the circuit, diagnostic conditions, failure effects, guided checks, repair decisions, ECM calibration review, and fault clearing steps. The file is a 12-page PDF for workshop use with Cummins INSITE™ electronic service tool.
Official Cummins fault 3138 document details
| Brand | Cummins |
|---|---|
| Model coverage | ISX11.9 CM2250 and ISX15 CM2250 as shown in the procedure tables |
| System/Group | Engine Exhaust Gas Recirculation Orifice Pressure Circuit; DTCs |
| Publication no. | Bulletin Number 4022250; Bulletin Number 2883445 |
| Year/Revision | Last Modified: 11-Jun-2010; troubleshooting procedure Last Modified: 20-Jul-2010 |
| Pages | 12 |
| File size | 0.2 MB |
| Format | |
| Language | English |
Document table of contents
- Overview
- Circuit Description
- Component Location
- Conditions for Running the Diagnostics
- Conditions for Setting the Fault Codes
- Action Taken When the Fault Code is Active
- Conditions for Clearing the Fault Code
- Shop Talk
- Associated Procedures
- Troubleshooting Steps
- Guided Step 1 – Check for sensor circuit fault codes.
- Guided Step 2 – Check the EGR orifice pressure sensor and circuit.
- Guided Step 3 – Check the ECM and engine harness.
- Guided Step 4 – Check the exhaust gas recirculation flow measurement assembly.
- Guided Step 5 – Check ECM calibration and clear fault codes.
Applicable truck models
The extract identifies ISX11.9 CM2250 and ISX15 CM2250 engine applications in the associated procedure table. It covers Fault Code 3138, SPN 5019, FMI 2, described as “Engine Exhaust Gas Recirculation Outlet Pressure – Data Erratic, Intermittent or Incorrect.” The procedure applies to the EGR orifice pressure sensor mounted on the EGR mass measurement assembly near the EGR differential pressure sensor. For official brand information, visit Cummins official website.
Who needs this Cummins fault 3138 manual
Diesel technicians, fleet maintenance teams, and workshop owners need this file when diagnosing an amber CHECK ENGINE lamp or MIL related to EGR outlet pressure data. It is useful when checking sensor response, connector condition, ECM harness circuits, EGR flow measurement assembly plugging, or calibration revision status.
The diagnostic notes state that the ECM supplies 5 volts and sensor return to the EGR orifice pressure sensor, then reads a signal voltage that changes with pressure. The fault can set when the sensor value is erratic at initial key ON, while the engine is running, or incorrect at key OFF. When active, the ECM estimates EGR orifice pressure, closes the EGR valve, and can reduce engine torque if operation continues for an extended period.
Possible causes listed include a damaged EGR orifice pressure sensor, high resistance in the signal or return wiring, and plugged or restricted EGR differential pressure sensor flow ports. The guided checks use INSITE™ to identify related Fault Code 3136 and Fault Code 3137, inspect connector pins for corrosion, moisture, damaged seals, pushed-back pins, and insulation damage, then verify circuit response with the sensor or ECM connector disconnected. Later steps inspect the exhaust gas recirculation flow measurement assembly for soot buildup, cracks, and thread damage, then compare the current ECM calibration code and revision against available updates.
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