Detroit Diesel Engine 60 DDEC VI Troubleshooting Guide

SERIES 60 DDEC VI TROUBLESHOOTING GUIDE

ENGINE EXHAUST

Consider the following before servicing engines:

TRADEMARK INFORMATION

DDC®, Detroit Diesel®, DDEC®, Diagnostic Link®, Optimized Idle®, Optimized Idle®, Pro-Link®, and Series 60® are registered trademarks of Detroit Diesel Corporation. All other trademarks used are the property of their respective owners.

MCM/CPC WARNING

Figure 1 MCM/CPC Replacement Warning

SOFTWARE UPGRADES

NOTE:

These engines are equipped with DaimlerChrysler software. T his software generally assures optimal engine performance. The installation of software upgrades may cause minor changes in features and engine performance.

ABSTRACT

This manual provides instruction for troubleshooting DDEC® VI Series 60® engines.

Speciﬁcally covered in this manual are troubleshooting and repair steps that apply to the DDEC VI.

All information subject to change without notice.

SERIES 60 DDEC VI TROUBLESHOOTING GUIDE

SAFETY INSTRUCTIONS

To reduce the chance of personal injury and/or property damage, the instructions contained in this troubleshooting manual must be carefully observed. Proper service and repair are important to the safety of the service technician and the safe, reliable operation of the engine.

If part replacement is necessary, the part must be replaced with one of the s ame part number or with an equivalent part number. Do not use a replacement part of lesser quality. The service procedures recommended and described i n this manual are effective methods of performing repair. Some of these procedures require the use of specially designed tools. Accordingly, anyone who intends to use a replacement part, procedure or tool which is not recommended, must ﬁrst determine that neither personal safety nor the safe operation of the engine will be jeopardized by the replacement part, procedure or tool selected.

It is important to note that this m anual contains various hazard notices labeled “Warnings, “Cautions" and "Notices" that must be carefully observed in order to reduce the risk of personal injury during repair, or the possibility that improper repair may damage the engine or render it unsafe. It is also important to understand that these “Warnings,” "Cautions" and "Notices" are not exhaustive. It is impossible to warn personnel of all the possible hazardous consequences that might result from failure to follow these instructions.

A LETTER TO THE TECHNICIANS

Technicians today are required to have computer skills, excellent comprehension of the written word and possess an extensive diagnostic understanding of the various technological systems and components. Technicians today must perform at a higher level of efﬁciency and competency than their predecessors and at the same time furnish professional quality support.

As the leader in engine computer systems and technology, Detroit Diesel Corporation remains focused on providing excellence in products, service support and training. As products become more and more advanced, technicians must become specialized in multiple areas. This manual is designed with that thought in mind. The Detroit Diesel 2007 Electronics Controls Troubleshooting Guide will provide you with concentrated information that will allow you to excel in 2007 Electronics Controls technology.

All information subject to change without notice.

SERIES 60 DDEC VI TROUBLESHOOTING GUIDE

TABLE OF CONTENTS

1 INTRODUCTION

1.1 OVERVIEW .............................................................................................. 1-3

1.2 SCOPE AND USE OF THIS GUIDE ........................................................ 1-4

1.3 SAFETY PRECAUTIONS ........................................................................ 1-6

2LOWOILPRESSURE

2.1 IMPROPER ENGINE OIL LEVEL ............................................................ 2-3

2.2 IMPROPER LUBRICATING OIL VISCOSITY .......................................... 2-4

2.3 LUBRICATING OIL DILUTED WITH FUEL OIL OR ENGINE COOLANT 2-5

2.4 FAULTY OIL PRESSURE GAUGE SENSOR .......................................... 2-6

2.5 ROCKER ARM SHAFT PLUGS MISSING (NEW OR REBUILT ENGINES

ONLY) ...................................................................................................... 2-7

2.6 RESTRICTED OIL COOLER ................................................................... 2-9

2.7 NONFUNCTIONAL OR STICKING OIL PRESSURE REGULATOR

VALVE ...................................................................................................... 2-10

2.8 DEFECTIVE BYPASS VALVE .................................................................. 2-12

2.9 DEFECTIVE PRESSURE RELIEF VALVE ............................................... 2-13

2.10 DEFECTIVE PICKUP SCREEN TUBE AND SCREEN ASSEMBLY ....... 2-14

2.11 DEFECTIVE CRANKSHAFT MAIN BEARING SHELLS .......................... 2-15

2.12 DEFECTIVE OIL PUMP ASSEMBLY ....................................................... 2-16

2.13 DETECTING INTERNAL FUEL LEAKS ................................................... 2-17

3 MISFIRING CYLINDER

3.1 POOR VEHICLE GROUND ..................................................................... 3-3

3.2 AERATED FUEL ..................................................................................... 3-5

3.3 FAULTY FUEL INJECTOR ....................................................................... 3-6

3.4 FAULTY MOTOR CONTROL MODULE ................................................... 3-7

3.5 WORN OR DAMAGED VALVE OR CYLINDER KIT ................................ 3-8

4 STARTING DIFFICULTY – ENGINE ROTATE S

4.1 EMPTY FUEL TANK ................................................................................ 4-3

4.2 LOW BATTERY VOLTAGE ...................................................................... 4-3

4.3 CORRODED OR DAMAGED BATTERY TERMINALS ............................ 4-4

4.4 DEFECTIVE MAGNETIC SWITCH .......................................................... 4-5

4.5 DEFECTIVE STARTER ............................................................................ 4-6

4.6 LOW CRANKING SPEED ........................................................................ 4-7

4.7 FUEL SUPPLY VALVE ............................................................................. 4-8

4.8 PLUGGED FUEL FILTER(S) .................................................................... 4-9

4.9 FUEL PUMP ............................................................................................ 4-10

4.10 AERATED FUEL ..................................................................................... 4-11

4.11 RESTRICTIVE AIR FILTER ..................................................................... 4-12

4.12 LOW COMPRESSION ............................................................................ 4-13

4.13 EXTENDED CRANK T IME ...................................................................... 4-19

All information subject to change without notice.

SERIES 60 DDEC VI TROUBLESHOOTING GUIDE

4.14 CRANK NO START .................................................................................. 4-21

5 NO START - ENGINE WILL NOT ROTATE

5.1 DISCHARGED BATTERY ........................................................................ 5-3

5.2 DEFECTIVE MAGNETIC SWITCH .......................................................... 5-4

5.3 DEFECTIVE STARTER ............................................................................ 5-5

5.4 INTERNAL ENGINE DAMAGE ................................................................ 5-6

6 EXCESSIVE OIL CONSUMPTION

6.1 EXTERNAL OIL LEAKS ........................................................................... 6-3

6.2 LEAKING OIL COOLER CORE ............................................................... 6-4

6.3 DEFECTIVE AIR COMPRESSOR ........................................................... 6-6

6.4 DEFECTIVE TURBOCHARGER ............................................................. 6-8

6.5 WORNORDAMAGEDVALVEORCYLINDERKIT ................................ 6-9

7 EXCESSIVE CRANKCASE PRESSURE

7.1 OBSTRUCTION OR DAMAGE TO ROCKER COVER BREATHER ........ 7-3

7.2 DEFECTIVE AIR COMPRESSOR ........................................................... 7-4

7.3 DEFECTIVE TURBOCHARGER ............................................................. 7-6

7.4 WORNORDAMAGEDVALVEORCYLINDERKIT ................................ 7-7

8 EXCESSIVE EXHAUST SMOKE - BLACK OR GRAY

8.1 IMPROPER GRADE OF DIESEL FUEL .................................................. 8-3

8.2 RESTRICTED AIR CLEANER ELEMENT ............................................... 8-4

8.3 RESTRICTED OR CRACKED CHARGE AIR COOLER .......................... 8-5

8.4 FAULTY E XHAUST SYS TEM .................................................................. 8-7

8.5 FAULTY FUEL INJECTOR ....................................................................... 8-8

8.6 DEFECTIVE TURBOCHARGER ............................................................. 8-9

9 EXCESSIVE BLUE SMOKE

9.1 DEFECTIVE TURBOCHARGER ............................................................. 9-3

9.2 WORNORDAMAGEDVALVEORCYLINDERKIT ................................ 9-5

10 EXCESSIVE WHITE SMOKE

10.1 IMPROPER GRADE OF FUEL ................................................................ 10-3

10.2 DEFECTIVE FUEL PUMP ....................................................................... 10-4

10.3 AERATED FUEL ..................................................................................... 10-6

10.4 IMPROPER INJECTOR CALIBRATION SETTING .................................. 10-7

10.5 IMPROPER VALVE CLEARANCE OR INJECTOR HEIGHT, WORN OR

DAMAGED CAMSHAFT LOBES AND ROLLERS .................................. 10-8

10.6 FAULTY FUEL INJECTOR ....................................................................... 10-9

11 ROUGH RUNNING OR STALLING

11.1 LOW BATTERY VOLTAGE ...................................................................... 11-3

11.2 AERATED FUEL ...................................................................................... 11-4

11.3 INSUFF ICIENT FUEL FLOW ................................................................... 11-4

11.4 HIGH FUEL TEMPERATURE RETURN .................................................. 11-6

11.5 IMPROPER INJECTOR CALIBRATION SETTING .................................. 11-8

11.6 LOW COMPRESSION PRESSURE ........................................................ 11-8

All information subject to change without notice.

SERIES 60 DDEC VI TROUBLESHOOTING GUIDE

12 LOW POWER

12.1 FACTORS THAT AFFECT WHEEL HORSEPOWER .............................. 12-3

12.2 LOW HORSEPOWER INTERVIEW ......................................................... 12-6

12.3 AERATED FUEL ..................................................................................... 12-12

12.4 HIGH FUEL PRESSURE ......................................................................... 12-13

12.5 HIGH FUEL TEMPERATURE RETURN .................................................. 12-16

12.6 RESTRICTED AIR CLEANER ELEMENT ............................................... 12-17

12.7 RESTRICTED OR CRACKED CHARGE AIR COOLER OR LEAKING

INTA KE MANIFOLD ................................................................................. 12-18

12.8 FAULTY EXHAUST SYSTEM .................................................................. 12-20

12.9 HIGH INLET AIR TEMPERATURE .......................................................... 12-21

12.10 HIGH ALTITUDE OPERATION ................................................................ 12-22

12.11 INCORRECT CAMSHAFT TIMING ......................................................... 12-24

12.12 POWER VERIFICATION WITH CHASSIS DYNAMOMETER ................. 12-25

13 HIGH ENGINE COOLANT TEMPERATURE

13.1 IMPROPER ENGINE COOLANT LEVEL ................................................. 13-3

13.2 INSUFFICIENT RADIATOR AIR CIRCULATION ..................................... 13-5

13.3 FAULTY PRESSURE CONTROL CAP .................................................... 13-6

13.4 DEFECTIVE COOLANT HOSES ............................................................. 13-7

13.5 FAN BELTS ARE INCORRECTLY ADJUSTED ....................................... 13-8

13.6 INOPERATIVE THERMO-MODULATED FAN ......................................... 13-9

13.7 FAULTY THERMOSTATS ....................................................................... 13-10

13.8 FAULTY WATER PUMP ........................................................................... 13-11

13.9 COMBUSTION GASES IN COOLANT .................................................... 13-13

13.10 ABNORMAL RADIATOR COOLANT FLOW ............................................ 13-19

14 LOW COOLANT TEMPERATURE

14.1 FAULTY THERMOSTATS ....................................................................... 14-3

15 POOR FUEL ECONOMY

15.1 SOFTWARE VERSION ............................................................................ 15-3

16 AIR COMPRESSOR

16.1 AIR COMPRESSOR TROUBLESHOOTING ........................................... 16-3

17 DDEC VI SYSTEM

17.1 DDEC VI SYSTEM--HOW IT WORKS ..................................................... 17-3

17.2 MOTOR CONTROL MODULE ................................................................ 17-3

17.3 COMMON POWERTRAIN CONTROLLER ............................................. 17-11

17.4 WIRES AND WIRING .............................................................................. 17-21

17.5 CONDUIT AND LOOM ............................................................................. 17-35

17.6 TAPE AND TAPING ................................................................................. 17-36

17.7 SENSORS ................................................................................................ 17-37

17.8 INSTRUMENT PANEL LAMPS ................................................................ 17-51

18 ENGINE MANUFACTURER DIAGNOSTIC S

18.1 ENGINE MANUFACTURER DIAGNOSTICS DEFINITIONS ................... 18-3

18.2 ENGINE MANUFACTURER DIAGNOSTICS PARAMETER

DESCRIPTIONS ...................................................................................... 18-4

All information subject to change without notice.

SERIES 60 DDEC VI TROUBLESHOOTING GUIDE

19 SPN 27 - EGR VALVE POSITION CIRCUIT FAULT

19.1 SPN 27/FMI 3 ........................................................................................... 19-3

19.2 SPN 27/FMI 4 ........................................................................................... 19-4

19.3 SPN 27/FMI 7 ........................................................................................... 19-7

20 SPN 51 - INTAKE THROTTLE VALVE ABOVE OR BELOW NORMAL

OPERATING RANGE

20.1 SPN 51/FMI 2, 3 OR 4 ............................................................................. 20-3

21 SPN 70 (CPC) - J1939 PARK BRAKE SWITCH SIGNAL ERRATIC

OR MISSING

21.1 SPN 70/FMI 13 ......................................................................................... 21-3

21.2 SPN 70/FMI 19 ......................................................................................... 21-3

22 SPN 84 (CPC) - J1939 WHEEL-BASED VEHICLE SPEED SIGNAL

ERRATICORMISSING

22.1 SPN 84/FMI 13 ......................................................................................... 22-3

22.2 SPN 84/FMI 19 ......................................................................................... 22-3

23 SPN 84 (CPC) – VEHICLE SPEED SENSOR

23.1 SPN 84/FMI 2 ........................................................................................... 23-3

23.2 SPN 84/FMI 3 ........................................................................................... 23-3

23.3 SPN 84/FMI 4 ........................................................................................... 23-4

23.4 SPN 84/FMI 6 ........................................................................................... 23-4

23.5 SPN 84/FMI 8 ........................................................................................... 23-5

24 SPN 91 (CPC) – ACCELERATOR PEDAL SENSOR FAULT

24.1 SPN 91/FMI 2 ........................................................................................... 24-3

24.2 SPN 91/FMI 3 ........................................................................................... 24-4

24.3 SPN 91/FMI 4 ........................................................................................... 24-5

25 SPN 94 – FU EL COMPENSATION PRESSURE SENSOR CIRCUIT

FAULT

25.1 SPN 94/FMI 3 OR 4 ................................................................................. 25-3

26 SPN 100 — ENGINE OIL PRESSURE OUTSIDE OF NORMAL

OPERATING RANGE

26.1 SPN 100/FMI 1 ......................................................................................... 26-3

26.2 SPN 100/FMI 3 ......................................................................................... 26-4

26.3 SPN 100/FMI 4 ......................................................................................... 26-6

26.4 SPN 100/FMI 18 ....................................................................................... 26-8

27 SPN 103 – TURBO NO REVOLUTION

27.1 SPN 103/FMI 0 ........................................................................................ 27-3

27.2 SPN 103/FMI 1 ........................................................................................ 27-4

27.3 SPN 103/FMI 4 ......................................................................................... 27-5

28 SPN 108 - BAROMETRIC PRESSURE SENSOR CIRCUIT FAULT

28.1 SPN 108/FMI 3 ......................................................................................... 28-3

28.2 SPN 108/FMI 4 ......................................................................................... 28-3

All information subject to change without notice.

SERIES 60 DDEC VI TROUBLESHOOTING GUIDE

29 SPN 110 — COOLANT TEMPERATURE ABOVE OR BELOW NORMAL

OPERATING RANGE

29.1 SPN 110/FMI 0 ......................................................................................... 29-3

29.2 SPN 110/FMI 3 ......................................................................................... 29-3

29.3 SPN 110/FMI 4 ......................................................................................... 29-6

29.4 SPN 110/FMI 14 ....................................................................................... 29-7

29.5 SPN 110/FMI 16 ....................................................................................... 29-8

30 SPN 111 (CPC) – COOLANT LEVEL OUTSIDE NORMAL OPERATING

RANGE

30.1 SPN 111/FMI 1 ......................................................................................... 30-3

30.2 SPN 111/FMI 3 ......................................................................................... 30-5

30.3 SPN 111/FMI 4 ......................................................................................... 30-7

31 SPN 132 - AIR MASS FLOW NOT NORMAL

31.1 SPN 132/FMI1 .......................................................................................... 31-3

32 SPN 168 – BATTERY VOLTAGE OUTSIDE NORMAL OPERATING

RANGE

32.1 SPN 168/FMI 0 ......................................................................................... 32-3

32.2 SPN 168/FMI 1 ......................................................................................... 32-4

33 SPN 171 (CPC) - J1587 AMBIENT AIR TEMPERATURE SENSOR

DATA NOT RECEIVED

33.1 SPN 171/FMI 9 ......................................................................................... 33-3

33.2 SPN 171/FMI 14 ....................................................................................... 33-3

34 SPN 174 – SUPPLY FUEL TEMPERATURE FAULT

34.1 SPN 174/FMI 3 ......................................................................................... 34-3

34.2 SPN 174/FMI 4 ......................................................................................... 34-5

35 SPN 175 – ENGINE OIL TEMPERATURE OUT OF NORMAL RANGE

35.1 SPN 175/FMI 3 ......................................................................................... 35-3

35.2 SPN 175/FMI 4 ......................................................................................... 35-5

35.3 SPN 175/FMI 14 ....................................................................................... 35-5

36 SPN 190 - E NGINE SPEED HIGH

36.1 SPN 190/FMI 2 ......................................................................................... 36-3

37 SPN 191 (CPC) - J1939 ETC1 MESSAGE MISSING AND

TRANSMISSION OUTPUT SHAFT SPEED SIGNAL ERRATIC OR MISSING

37.1 SPN 191/FMI 9 ......................................................................................... 37-3

37.2 SPN 191/FMI 13 ....................................................................................... 37-3

37.3 SPN 191/FMI 19 ....................................................................................... 37-4

38 SPN 247 (CPC) – MCM ENGINE HOURS DATA HIGHER OR LOWER

THAN EXPECTED

38.1 SPN 247/FMI 0 ......................................................................................... 38-3

38.2 SPN 247/FMI 1 ......................................................................................... 38-3

38.3 SPN 247/FMI 9 ......................................................................................... 38-4

All information subject to change without notice.

SERIES 60 DDEC VI TROUBLESHOOTING GUIDE

39 SPN 411 — EGR DIFFERENT IA L PRESSURE OR DELTA P SENSOR

CIRCUIT OUTSIDE OF NORMAL OPERATING RANGE

39.1 SPN 411/FMI 0 ......................................................................................... 39-3

39.2 SPN 411/FMI 3 ......................................................................................... 39-4

39.3 SPN 411/FMI 4 ......................................................................................... 39-6

39.4 SPN 411/FMI 13 ....................................................................................... 39-8

40 SPN 412 - EGR TEMPERATURE IS OUTSIDE OF THE NORMAL

RANGE

40.1 SPN 412/FMI 3 ......................................................................................... 40-3

40.2 SPN 412/FMI 4 ......................................................................................... 40-6

40.3 SPN 412/FMI 16 ....................................................................................... 40-8

40.4 SPN 412/FMI 20 ....................................................................................... 40-9

41 SPN 523 (CPC) - TRANSMISSION CURRENT GEAR SIGNAL

ERRATICORMISSING

41.1 SPN 523/FMI 19 ....................................................................................... 41-3

41.2 SPN 523/FMI 13 ....................................................................................... 41-3

42 SPN 524 (CPC) - J1939 ETC2 MESSAGE IS M ISSING

42.1 SPN 523/FMI 9 ......................................................................................... 42-3

43 SPN 527 (CPC) - J1939 CCVS MESSAGE MISSING

43.1 SPN 527/FMI 9 ......................................................................................... 43-3

44 SPN 558 (CPC) - IDLE VALIDATION SWITCH

44.1 SPN 558/FMI 1 ......................................................................................... 44-3

44.2 SPN 558/FMI 3 ......................................................................................... 44-3

44.3 SPN 558/FMI 4 ......................................................................................... 44-5

45 SPN 596 (CPC) - CRUISE CONTROL ENABLE SWITCH SIGNAL

ERRATICORMISSING

45.1 SPN 596/FMI 13 ....................................................................................... 45-3

45.2 SPN 596/FMI 19 ....................................................................................... 45-3

46 SPN 597 (CPC) - SERVICE BRAKE SWITCH SIGNAL ERRATIC OR

MISSING

46.1 SPN 597/FMI 13 ....................................................................................... 46-3

46.2 SPN 597/FMI 19 ....................................................................................... 46-3

47 SPN 599 (CPC) - CRUISE CONTROL SWITCHES N OT FUNCTIONIN G

PROPERLY

47.1 SPN 599/FMI 4 ......................................................................................... 47-3

48 SPN 600 (CPC) - CRUISE CONTROL COAST SWITCH SIGNAL

ERRATICORMISSING

48.1 SPN 600/FMI 13 ....................................................................................... 48-3

48.2 SPN 600/FMI 19 ....................................................................................... 48-3

All information subject to change without notice.

SERIES 60 DDEC VI TROUBLESHOOTING GUIDE

49 SPN 602 (CPC) - CRUISE CONTR OL ACCELERATE SWITCH SIGNAL

ERRATICORMISSING

49.1 SPN 602/FMI 13 ....................................................................................... 49-3

49.2 SPN 602/FMI 19 ....................................................................................... 49-3

50 SPN 609 - MCM FAULT (ERRONEOUS DATA)

50.1 SPN 609/FMI 12 ....................................................................................... 50-3

50.2 SPN 609/FMI 14 ....................................................................................... 50-4

51 SPN 615 (CPC) - J1939 DM1 MESSAGE FROM TRANSMISSION

MISSING

51.1 SPN 615/FMI 9 ......................................................................................... 51-3

52 SPN 625 - CAN FAULT

52.1 SPN 625/FMI 2 ........................................................................................ 52-3

52.2 SPN 625/FMI 9 ........................................................................................ 52-5

53 SPN 628 (CPC) - MULTIPLE FAULTS

53.1 SPN 628/FMI 13 (ALL FAULT DESCRIPTIONS) ..................................... 53-3

53.2 SPN 628/FMI 14 ....................................................................................... 53-3

54 SPN 629 (CPC) - MULTIPLE FAULTS

54.1 SPN 629/FMI 2 ......................................................................................... 54-3

54.2 SPN 629/FMI 12 ....................................................................................... 54-4

55 SPN 630 (CPC) - MULTIPLE FAULTS

55.1 SPN 630/FMI 14 ....................................................................................... 55-3

56 SPN 636 — CRANKSHAFT POSITION SENSOR OUTSIDE OF

NORMAL OPERATING CONDITIONS

56.1 SPN 636/FMI 1 ......................................................................................... 56-3

56.2 SPN 636/FMI 3 ......................................................................................... 56-4

56.3 SPN 636/FMI 4 ......................................................................................... 56-6

56.4 SPN 636/FMI 7 ......................................................................................... 56-7

56.5 SPN 636/FMI 8 ......................................................................................... 56-9

56.6 SPN 636/FMI 14 ....................................................................................... 56-11

57 SPN 641 - SMART REMOTE ACTUATOR 5 (VGT) ABNORMAL

OPERATION

57.1 SPN 641/FMI 7 ......................................................................................... 57-3

57.2 SPN 641/FMI 8 ......................................................................................... 57-5

57.3 SPN 641/FMI 9 ......................................................................................... 57-6

57.4 SPN 641/FMI 11 ....................................................................................... 57-7

57.5 SPN 641/FMI 14 ....................................................................................... 57-9

57.6 SPN 641/FMI 31 ....................................................................................... 57-12

58 SPN 647 - SINGLE-SPEED FAN (LOW-SIDE DIGITAL OUTPUT #3)

FAULT

58.1 SPN 647/FMI 3 ......................................................................................... 58-3

58.2 SPN 647/FMI 4 ......................................................................................... 58-4

58.3 SPN 647/FMI 5 ......................................................................................... 58-5

All information subject to change without notice.

SERIES 60 DDEC VI TROUBLESHOOTING GUIDE

59 SPN 651 – INJECTOR #1 NEEDLE VALVE NOT OPERATING

NORMALLY

59.1 SPN 651/FMI 14 ....................................................................................... 59-3

60 SPN 652 – INJECTOR #2 NEEDLE VALVE NOT OPERATING

NORMALLY

60.1 SPN 652/FMI 14 ....................................................................................... 60-3

61 SPN 653 – INJECTOR #3 NEEDLE VALVE NOT OPERATING

NORMALLY

61.1 SPN 653/FMI 14 ....................................................................................... 61-3

62 SPN 654 – INJECTOR #4 NEEDLE VALVE NOT OPERATING

NORMALLY

62.1 SPN 654/FMI 14 ....................................................................................... 62-3

63 SPN 655 – INJECTOR #5 NEEDLE VALVE NOT OPERATING

NORMALLY

63.1 SPN 655/FMI 14 ....................................................................................... 63-3

64 SPN 656 – INJECTOR #6 NEEDLE VALVE NOT OPERATING

NORMALLY

64.1 SPN 656/FMI 14 ....................................................................................... 64-3

65 SPN 703 (CPC) - ASG2 BACKUP LAMP

65.1 SPN 703/FMI 3 ......................................................................................... 65-3

65.2 SPN 703/FMI 4 ......................................................................................... 65-3

66 SPN 704 (CPC) - HIGH EXHAUST SYSTEM TEMPERATURE LAMP

66.1 SPN 704/FMI 3 ......................................................................................... 66-3

66.2 SPN 704/FMI 4 ......................................................................................... 66-3

67 SPN 704 - TURBO ACTUATOR CONTROL (AUX PWM #10)

67.1 SPN 704/FMI 3 ......................................................................................... 67-3

67.2 SPN 704/FMI 4 ......................................................................................... 67-4

67.3 SPN 704/FMI 5 ......................................................................................... 67-5

68 SPN 705 (CPC) - MALFUNCTION INDICATOR LAMP

68.1 SPN 705/FMI 3 ......................................................................................... 68-3

68.2 SPN 705/FMI 4 ......................................................................................... 68-3

69 SPN 706 (CPC) - ASG2 CHECK TRANS TEMP LAMP

69.1 SPN 706/FMI 3 ......................................................................................... 69-3

69.2 SPN 706/FMI 4 ......................................................................................... 69-3

70 SPN 707 (CPC) - AMBER WARNING LAMP

70.1 SPN 707/FMI 3 ......................................................................................... 70-3

70.2 SPN 707/FMI 4 ......................................................................................... 70-3

71 SPN 708 (CPC) - ASG2 CHECK TRANS LAMP

71.1 SPN 708/FMI 3 ......................................................................................... 71-3

71.2 SPN 708/FMI 4 ......................................................................................... 71-3

All information subject to change without notice.

SERIES 60 DDEC VI TROUBLESHOOTING GUIDE

72 SPN 709 (CPC) - RED STOP LAMP

72.1 SPN 709/FMI 3 ......................................................................................... 72-3

72.2 SPN 709/FMI 4 ......................................................................................... 72-3

73 SPN 711 (CPC) - DPF REGEN LAMP

73.1 SPN 711/FMI 3 ......................................................................................... 73-3

73.2 SPN 711/FMI 4 ......................................................................................... 73-3

74 SPN 713 (CPC) - TOP2 LOCKOUT SOLENOID

74.1 SPN 713/FMI 3 ......................................................................................... 74-3

74.2 SPN 713/FMI 4 ......................................................................................... 74-3

74.3 SPN 713/FMI 5 ......................................................................................... 74-3

74.4 SPN 713/FMI 7 ......................................................................................... 74-3

75 SPN 714 (CPC) - TOP2 SHIFT SOLENOID

75.1 SPN 714/FMI 3 ......................................................................................... 75-3

75.2 SPN 714/FMI 4 ......................................................................................... 75-3

75.3 SPN 714/FMI 5 ......................................................................................... 75-3

76 SPN 715 (CPC) - VEHICLE POWER SHU TDOWN

76.1 SPN 715/FMI 3 ......................................................................................... 76-3

76.2 SPN 715/FMI 4 ......................................................................................... 76-3

76.3 SPN 715/FMI 5 ......................................................................................... 76-3

77 SPN 723 – CAMSHAFT POSITION SENSOR FAULT

77.1 SPN 723/FMI 3 ......................................................................................... 77-3

77.2 SPN 723/FMI 4 ......................................................................................... 77-5

77.3 SPN 723/FMI 8 ......................................................................................... 77-6

77.4 SPN 723/FMI 14 ....................................................................................... 77-7

78 SPN 904 (CPC) - J1939 EBC2 MESSAGE MISSING AND FRONT

AXLE SPEED SIGNAL ERRATIC OR MISSING

78.1 SPN 904/FMI 9 ......................................................................................... 78-3

78.2 SPN 904/FMI 13 ....................................................................................... 78-3

78.3 SPN 904/FMI 19 ....................................................................................... 78-4

79 SPN 973 (CPC) - J1939 EBC1 MESSAGE MISSING AND ENGINE

RETARDER SELECTION SIGNAL IS ERRATIC OR MISSSING

79.1 SPN 973/FMI 9 ......................................................................................... 79-3

79.2 SPN 973/FMI 13 ....................................................................................... 79-3

79.3 SPN 973/FMI 19 ....................................................................................... 79-4

80 SPN 986 (CPC) - J1939 CM1 MESSAGE IS MISSING

80.1 SPN 986/FMI 9 ......................................................................................... 80-3

81 SPN 1071 - TWO-SPEED FAN (AUX PWM #6) FAULT

81.1 SPN 1071/FMI 3 ....................................................................................... 81-3

81.2 SPN 1071/FMI 4 ....................................................................................... 81-4

81.3 SPN 1071/FMI 5 ....................................................................................... 81-5

All information subject to change without notice.

SERIES 60 DDEC VI TROUBLESHOOTING GUIDE

82 SPN1072–JAKEBRAKESSTAGE1(AUXPWM#7)OPENOR

SHORT

82.1 SPN 1072/FMI 4 ....................................................................................... 82-3

82.2 SPN 1072/FMI 5 ....................................................................................... 82-4

83 SPN 1073 – JAKE BRAKE STAGE 2 (AUX PWM #13) OPEN OR

SHORT

83.1 SPN 1073/FMI 4 ....................................................................................... 83-3

83.2 SPN 1073/FMI 5 ....................................................................................... 83-4

84 SPN1172-TURBOCOMPRESSORINTEMPHIGHORLOW

84.1 SPN 1172/FMI 2 ....................................................................................... 84-3

84.2 SPN 1172/FMI 3 ....................................................................................... 84-3

84.3 SPN 1172/FMI 4 ....................................................................................... 84-6

85 SPN 1590 (CPC) - J1939 ACC1 MESSAGE FROM ADAPTIVE CRUISE

CONTROL IS MISSING

85.1 SPN 1590/FMI 9 ....................................................................................... 85-3

86 SPN 1624 (CPC) - J1939 TCO1 MESSAGE IS MISSING AND

TACHOGRAPH VEHICLE SPEED SIGNAL IS ERRATIC AND MISSING

86.1 SPN 1624/FMI 9 ....................................................................................... 86-3

86.2 SPN 1624/FMI 13 ..................................................................................... 86-3

86.3 SPN 1624/FMI 19 ..................................................................................... 86-4

87 SPN 1636 – INTAKE AIR TEMPERATURE OUTSIDE OF NORMAL

OPERATING RANGE

87.1 SPN 1636/FMI 3 ....................................................................................... 87-3

87.2 SPN 1636/FMI 4 ....................................................................................... 87-5

87.3 SPN 1636/FMI 20 ..................................................................................... 87-6

87.4 SPN 1636/FMI 21 ..................................................................................... 87-7

87.5 SPN 1636/FMI 31 ..................................................................................... 87-8

88 SPN 1716 (CPC) - J1939 ERC1 MESSAGE IS MISSING

88.1 SPN 1716/FMI 9 ....................................................................................... 88-3

89 SPN 1845 (CPC) - J1939 TCFG2 MESSAGE IS MISSING

89.1 SPN 1845/FMI 9 ....................................................................................... 89-3

90 SPN 2623 (CPC) - PWM ACCELERATOR PEDAL GAS1 AND GAS2

SIGNAL MISSING

90.1 SPN 2623/FMI 4 ....................................................................................... 90-3

90.2 SPN 2623/FMI 14 ..................................................................................... 90-3

91 SPN 2629 - TURBO COMPRESSOR OUT TEMP HIGH OR LOW

91.1 SPN 2629/FMI 3 ....................................................................................... 91-3

91.2 SPN 2629/FMI 4 ....................................................................................... 91-6

91.3 SPN 2629/FMI 20 ..................................................................................... 91-7

91.4 SPN 2629/FMI 21 ..................................................................................... 91-8

All information subject to change without notice.

SERIES 60 DDEC VI TROUBLESHOOTING GUIDE

92 SPN 2659 - EGR FLOW NOT NORMAL

92.1 SPN 2659/FMI 0 ....................................................................................... 92-3

92.2 SPN 2659/FMI 1 ....................................................................................... 92-4

93 SPN 2791 – EGR VALVE (AUX PWM #1) FAILED OR OPEN CIRCUIT

93.1 SPN 2791/FMI 3 ....................................................................................... 93-3

93.2 SPN 2791/FMI 4 ....................................................................................... 93-4

93.3 SPN 2791/FMI 5 ....................................................................................... 93-4

93.4 SPN 2791/FMI 7 ....................................................................................... 93-6

94 SPN 2795 - CAN COMMUNICATION ERROR

94.1 SPN 2795/FMI 9 ....................................................................................... 94-3

95 SPN 2797 - INJECTOR #1, 2, OR 3 NEEDLE OR SPILL CONTROL

VALVE NOT OPERATING NORMALLY

95.1 SPN 2797/FMI 3 ....................................................................................... 95-3

95.2 SPN 2797/FMI 4 ....................................................................................... 95-4

95.3 SPN 2797/FMI 5 ....................................................................................... 95-6

95.4 SPN 2797/FMI 6 ....................................................................................... 95-7

96 SPN 2798 - INJECTOR #4, 5, OR 6 NEEDLE OR SPILL CONTROL

VALVE NOT OPERATING NORMALLY

96.1 SPN 2798/FMI 3 ....................................................................................... 96-3

96.2 SPN 2798/FMI 4 ....................................................................................... 96-4

96.3 SPN 2798/FMI 5 ....................................................................................... 96-6

96.4 SPN 2798/FMI 6 ....................................................................................... 96-7

97 SPN 2900 (CPC) - J1939 ETC7 MESSAGE IS MISSING

97.1 SPN 2900/FMI 9 ....................................................................................... 97-3

98 SPN 3050 - E NGINE AIR FLOW ABOVE OR BELOW NORMAL

OPERATING RANGE

98.1 SPN 3050 ................................................................................................. 98-3

99 SPN 3242 - DOC INLET TEMPERATURE SENSOR ABOVE OR

BELOW NORMAL OPERATING RANGE

99.1 SPN 3242/FMI 2, 3,

100 SPN 3246 - DPF OUT

4 OR 10 ...................................................................

LET TEMPERATURE SENSOR OPERATING

99-3

ABOVE OR BELOW NORMAL

100.1 SPN 3246/FMI 0, 2, 3, 4, 10, 14, 31 ......................................................... 100-3

101 SPN 3250 - DPF INLET TEMPERATURE SENSOR ABOVE OR BELOW

NORMAL OPER

ATING RANGE

101.1 SPN 3250/FMI 0, 2, 3, 4, 10, 14, 31 ......................................................... 101-3

102 SPN 3251 - DPF OUTLET PRESSURE ABOVE OR BELOW NORMAL

OPERATING RANGE

102.1 SPN 325

1/FMI 0, 1 OR 16 .......................................................................

102-3

All information subject to change without notice.

SERIES 60 DDEC VI TROUBLESHOOTING GUIDE

103 SPN 3471 - ELECTRONIC DOSING VALVE SENSOR ABOVE OR

BELOW NORMAL OPERATING RANGE

103.1 SPN 34 71/FMI 1, 3, 4 OR 5 ..................................................................... 103-3

104 SPN 3480 - FUEL LINE PRESSURE SENSOR ABOVE OR BELOW

NORMAL OPERATING RANGE

104.1 SPN 3480/FMI 1, 2 OR 14 ....................................................................... 104-3

105 SPN 3482 - FUEL CUTOFF VALVE SENSOR ABOVE OR BELOW

NORMAL OPERATING RANGE

105.1 SPN 34 82/FMI 3, 4, 5 OR 7 ..................................................................... 105-3

106 SPN 3509 - MULTIPLEXER 1 CHANNEL 1 OR 2 SHORT OR OPEN

CIRCUIT HIGH

106.1 SPN 3509/FMI 3 ....................................................................................... 106-3

107 SPN 3510 - MULTIPLEXER 2 CHANNEL 1 OR 2 SHORT OR OPE

CIRCUIT HIGH

107.1 SPN 3510/FMI 3 ....................................................................................... 107-3

108 SPN 3510 – ACCELERATOR PEDAL SUPPLY OUTSIDE OF NORMAL

OPERATING RANGE

108.1 SPN 3510/FMI 2 ....................................................................................... 108-3

108.2 SPN 3510/FMI 3 ....................................................................................... 108-5

108.3 SPN 3510/FMI 4 ....................................................................................... 108-6

109 SPN 3511 - MULTIPLEXER 3 CHANNEL 1 0R 2 SHORT OR OPEN

CIRCUIT HIGH

109.1 SPN 3511/FMI 3 ....................................................................................... 109-3

110 SPN 3556 - ELECTRONIC DOSING VALVE ABOVE OR BELOW

NORMAL OPERATING RANGE

110.1 SPN 3556/FMI 0 OR 1 ............................................................................. 110-3

111 SPN 3563– INTAKE MANI

FOLD PRESSURE OUTSIDE NORMAL

RANGE

111.1 SPN 3563/FMI 0 ....................................................................................... 111-3

111.2 SPN 3563/FMI 1 ....................................................................................... 111-4

111.3 SPN 3563/FMI 3 ....................................................................................... 111-5

111.4 SPN 3563/FMI 4 ....................................................................................... 111-6

111.5 SPN 3563/FMI 20 ..................................................................................... 111-8

111.6 SPN 3563/FMI

21 .....................................................................................

111-12

112 SPN 3588 - ET

HER START (LOW-S IDE DIGITAL OUTPUT #8) FAULT

112.1 SPN 3588/FMI 3 ....................................................................................... 112-3

112.2 SPN 3588/

FMI 4 .......................................................................................

112-4

112.3 SPN 3588/FMI 5 ....................................................................................... 112-5

113 SPN 3597 - PROPORTIONAL VALVE BANK 1 CIRCUIT

113.1 SPN 359

7/FMI 3 .......................................................................................

All information subject to change without notice.

113-3

SERIES 60 DDEC VI TROUBLESHOOTING GUIDE

114 SPN 3603 (CPC) - J1939 ESS MESSAGE IS MISSING

114 .1 SPN 3603/FMI 9 ....................................................................................... 114-3

115 SPN 3609 - DPF INLET PRESSURE SENSOR ABOVE OR BELOW

NORMAL OPERATING RANGE

115 .1 SPN 3609FMI 2, 3, 4, 10, 20 OR 21 ........................................................ 115-3

116 SPN 3610 - DPF OUTLET PRESSURE SENSOR ABOVE OR BELOW

NORMAL OPERATING RANGE

116 .1 SPN 3610/FMI 2, 3, 4, 14, 20 OR 21 ....................................................... 116-3

117 SPN 3659 – INJECTOR #1 SPILL VALVE NOT OPERATING

NORMALLY

117 .1 SPN 3659/FMI 14 ..................................................................................... 117-3

118 SPN 3660 - INJECTOR #2 SPILL VALVE NOT OPERATING

NORMALLY

118 .1 SPN 3660/FMI 14 ..................................................................................... 118-3

119 SPN 3661 - INJECTOR #3 SPILL VALVE NOT OPERATING

NORMALLY

119 .1 SPN 3661/FMI 14 ..................................................................................... 119-3

120 SPN 3662 - INJECTOR #4 SPILL VA LVE NOT

OPERATING

NORMALLY

120.1 SPN 3662/FMI 14 ..................................................................................... 120-3

121 SPN 3663 - INJECTOR #5 SPILL VALVE NOT OPERATING

NORMALLY

121.1 SPN 3663/FMI 14 ..................................................................................... 121-3

122 SPN 3664 - INJECTOR #6 SPILL VALVE NOT OPERATING

NORMALLY

122.1 SPN 3664/FMI 14 ..................................................................................... 122-3

123 SPN 3695 (CPC) - DPF RE

GEN MUX SWITCH MESSAGES NOT

OPERATING NORMALLY

123.1 SPN 3695/FMI 9 ....................................................................................... 123-3

123.2 SPN 3695/FMI 13 ..................................................................................... 123-4

123.3 SPN 3695/FMI 14

.....................................................................................

123-4

123.4 SPN 3695/FMI 19 ..................................................................................... 123-5

124 SPN 3719 - SOOT LEVEL ABOVE NORMAL

124.1 SPN 3719/FM

125 SPN 3798 - P

I 0, 15,16,OR 31 ................................................................

ROPORTIONAL VALVE BANK 2 CIRCUIT

124-3

125.1 SPN 3798/FMI 4 ....................................................................................... 125-3

126 SPN 3720 - ASH LEVEL ABOVE NORMAL

126.1 SPN 3720/FMI 15 OR 16 ......................................................................... 126-3

127 SPN 4077 FUEL LINE PRESSURE SENSOR CIRCUIT FAULT

127.1 SPN 40

All information subject to change without notice.

77/FMI 3, 4 OR 14 .......................................................................

127-3

SERIES 60 DDEC VI TROUBLESHOOTING GUIDE

128 SPN 4228 - VGT TEMPERATURE WARNING

128.1 SPN 4228/FMI 15 ..................................................................................... 128-3

128.2 SPN 4228/FMI 16 ..................................................................................... 128-4

129 DDEC VI SCHEMATICS

129.1 CRUISE CONTROL ................................................................................. 129-3

129.2 FAN CONTROL ........................................................................................ 129-4

129.3 OPTIMIZED IDLE ..................................................................................... 129-10

All information subject to change without notice.

1 INTRODUCTION

Section Page

1.1 OVERVIEW .............................................................................................. 1-3

1.2 SCOPE AND USE OF THIS GUIDE ........................................................ 1-4

1.3 SAFETY PRECAUTIONS ........................................................................ 1-6

All information subject to change without notice.

1.1 OVERVIEW

SERIES 60 DDEC VI TROUBLESHOOTING GUIDE

Detroit Diesel Corporation is the world leader in diesel engines and diesel engine e

lectronics. DDC has made technological leaps in engine performance and fuel economy. Today, we build the most dependable electronically controlled diesel engine in the industry.

Detroit Diesel Electronic Controls VI (DDEC®) provides two industry s

tandard serial data links: SAE Standards J1587 and J1939. SAE Standard J1587 provides two way communications for the diagnostic equipment and vehicle displays. SAE Standard J1939 provides control data to other vehicle systems such as transmissions and traction control devic

es.

specialized in multiple areas. This

manual is designed with that thought in mind.

Our goal at Detroit Diesel is to be the most customer focused and most responsive engine manufacturer in the world.

All information subject to change without notice.

1.2 SCOPE AND USE OF THIS GUIDE

The ﬁrst half of the manual contain mechanical troubleshooting procedures. The sec

ond half

contains instructions for troubleshooting the electronic controls.

This manual is divided into numbered chapters. Each chapter begins with a table of contents. Pages and illustrations are numbered consecutively within each chapt

er.

Information can be located b y using the table of contents at the front of the manual or the table of contents at the beginning of each chapter.

Instructions to "Contact Detroit Diesel Customer Service Center" in

dicate that at the time of this publication, all known troubleshooting checks have been included. Review any recent Service Information Bulletins (SIB) or Service Information letters before calling.

It is also suggested that other DDC outlets be contacted. e.g

. if you are a dealer or user, contact

your closest DDC Distributor.

Ensure you have the engine serial number when you call. The phone number f or Detroit Diesel Customer Service Center is 313-592-5800.

Instructions in this manual may suggest replacing a non DDC component. It may be required to contact the supplier of the component, e.g. truck manufacturer for a TPS concern, to obtain approval to replace the component.

Important: To ensure you receive updates to this manual should the need arise, you must ﬁll out

the Information Card in the front of this manual. Service Information Bulletins are issued via the DDC extranet. Visit DDCDIRECT at www.access

freightliner.com.

NOTE:

It is absolutely critical that you understand the EGR system to be qualiﬁed to offer any type of proper diagnostics. Do not waste

time trying to troubleshoot a DDC product, you are not qualiﬁed to troubleshoot. Your company may incur wasted labor hours. If you are qualiﬁed to perform a troubleshooting task and have spent more than one hour on that task, STOP, and contact the Detroit Di

esel Customer Support Center at (313) 592–5800. Once yo u have discussed your options with a customer support center person, you can perform the required tests and evaluations. Please keep in contact with your customer support person. Doing so allows

youtostayontrack.

1.2.1 Mechanical Troubleshooting

Each chapter has a fault as the title (i.e. Excessive White Smoke). The next level within the chapter is the probable cause/symptom of the fault. Following this are the resolution and veriﬁcation of the resolu electronic troubleshooting.

tion. The mechanical troubleshooting should be used before the

All information subject to change without notice.

SERIES 60 DDEC VI TROUBLESHOOTING GUIDE

1.2.2 Electronic Troubleshooting

The DDEC VI system allows for an increased processor speed and increased memory.

Instructions for repair in this manual are generic. For example, "Repair Open" is used to advise the technician that a particular wire has been determined to be broken. In some cases it may not be best to try and locate t he open. It may be that the best repair techn complete harness. The technician should make the determination of the proper repair, with the best interest of the customer in mind.

ique is to replace a

Instructions to check terminals and connectors should include chec

king for proper contact tension. Using a mating terminal, a modest force should be required to remove a terminal from its mate. Replace terminals with poor tension.

After completing any repair, always clear fault codes that

may have been generated during the

troubleshooting process.

NOTE:

Be aware that troubleshooting in this manual is most

ly concerned with DDEC related codes. Code s associated with other components, e.g. transmissions, ECUs, ABS, etc. can be found in the related publication.

All information subject to change without notice.

1.3 SAFETY PRECAUTIONS

The following safety precautions must be observed when working on a Detroit Diesel e

PERSONAL INJURY

To avoid injury from accidental engine startup while servicing the engine, disconnect/disable the starting system.

All engine installations, especially those within encl

osed spaces, should be equipped with an

exhaust discharge pipe so that exhaust gases are delivered into the outside air.

PERSONAL INJURY

To avoid injury from the sudden release of a high

-pressure hose connection, wear a face shield or goggles. Bleed the air from t he air starter system before disconnecting the air supply hose.

ngine:

All information subject to change without notice.

1.3.1 Ether Start

SERIES 60 DDEC VI TROUBLESHOOTING GUIDE

The DDEC Ether Start System is a fully-automatic engine starting ﬂuid system used to

assist a DDEC equipped diesel engine in cold starting conditions. The amount of ether is properly controlled to optimize the starting process and prevent engine damage. DDEC will control ether injection using standard sensors to control the ether injection har

dware.

FIRE AND TOXICITY

Some pressu rized ﬂuid may be trapped in the system. To avoid personal injury, loosen all connections slowly to avoid contact with ﬂuid. When required, spray ﬂuidintoa proper container. The engine starting ﬂuidusedinDDEC Ether Start Systems contains extremely ﬂammable and toxic substances.

FIRE AND TOXICITY

To avoid personal injury, spray the ﬂuid from the bottom of the valve into an appropriate con tainer. The engine starting ﬂuid used in DDEC Ether Start Systems c

ontains extremely

ﬂammable and toxic substances.

All information subject to change without notice.

1.3 SAFETY PRECAUTIONS

1.3.2 Exhaust (Start/Run Engine)

Before starting and running an engine, adhere to the following safety precautions:

PERSONAL INJURY

To avoid injury b efore starting and running the engine, ensure the vehicle is parked on a leve l surface, parking brake is set, and the wheels are blocked.

1.3.3 Glasses

Select appropriate safety glasses for the job. It is es

pecially important to wear safety glasses when

using tools such as hammers, chisels, pullers or punches.

EYE INJURY

To avoid injury from ﬂying debris when using c air, wear adequate eye protection (face shield or sa fety goggles) and do not exceed 276 kPa (40 psi) air pressure.

ompressed

All information subject to change without notice.

1.3.4 Welding

SERIES 60 DDEC VI TROUBLESHOOTING GUIDE

Wear welding goggles and gloves when welding or using an acetylene torch. Ensure tha

tametal shield separates the acetylene and oxygen tanks. These must be securely chained to a cart.

PERSONAL INJURY

To avoid injury from arc welding, gas welding, or cutting, wear required safety equipment such as an arc welder’s face plate or gas welder ’s goggles, welding gloves, protective apron, long sleeve shirt, head protection, and safety shoes. Always perform welding or cutting operations in a well ventilated area. The gas in oxygen/acetylene cylinders used in gas welding an

d cutting is under high pressure. If a cylinder should fall due to careless handling, the gage end could strike an obstruction and fracture, resulting in a gas

leak leading to ﬁre or an explosion. If a cylinder should fall resulting in the gage end breaking off, the sudden release of cylinder pressure will turn the cylinder

into a dangerous projectile. Observe the following precautions when using oxygen/acetylene gas cylinders :

□ Always wear required safety shoes . □ Do not handle tanks in a careless manner or with greasy

gloves or slippery hands.

□ Use a chain, bracket, or other re s

training device at all

times to prevent gas cylinders from falling.

□ Do not place gas cylinders on their sides, but stand

them upright when in use.

□ Do not drop, drag, roll, or strike a cylinder forcefully. □ Always close valves completely when ﬁnished welding

or cutting.

All information subject to change without notice.

1.3 SAFETY PRECAUTIONS

FIRE

To avoid injury from ﬁre, check for fuel or oil leaks before welding o r carrying an open ﬂame near the engine.

1.3.5 Pressurized Fluids

Be extremely careful when dealing with ﬂuids under pressure. Fluids under pressure can have enough force to penetrate the skin. These ﬂuids can infec injured by escaping ﬂuid, see a doctor at once. Serious infection or reaction can result without immediate medical treatment.

PERSONAL INJURY

To avoid injury from the sudden release of a high-pressure hose connection, wear a face shield or goggles.

t a minor cut or opening in the skin. If

PERSONAL INJURY

To avoid injury from penetrating ﬂuids, do not put your hands in front of ﬂuid under pressure.

Fluids under

pressure can penetrate skin and clothing.

All information subject to change without notice.

1.3.6 Fuel

SERIES 60 DDEC VI TROUBLESHOOTING GUIDE

Keep the hose and nozzle or the funnel and container in contact with the metal of the fu when refueling.

FIRE

To avoid injury from ﬁre, keep all potential ignition sources away from diesel fuel, including open ﬂames, sparks, and electrical resistance heating elements. Do not smoke when refueling.

The following cautions should be followed when ﬁlling a fuel tank:

FIRE

To avoid injury from ﬁre caused by heated diesel-fuel vapors:

□ Keep those people who are not directly inv

olved in

servicing away from the engine.

□ Stop the engine immediately if a fuel leak is detected. □ Do not smoke or allow open ﬂames when worki

ng on

an operating engine.

□ Wear adequate protective clothing (face shield,

insulated gloves and apron, etc.).

□ To prevent a buildup of potentially volatile vapors, keep

the engine area well ventilated during operation.

el tank

All information subject to change without notice.

1.3 SAFETY PRECAUTIONS

To avoid injury from ﬁre, contain and eliminate leaks of ﬂammable ﬂuids as they occur. Failure to eliminate leaks

could result in ﬁre.

1.3.7 Batteries

FIRE

Electrical storage batteries emit h ighly ﬂammable hydr do so for some time after receiving a steady charge.

BATTERY EXPLOSION AND ACID BURN

To avoid injury from battery explosion or conta battery acid, work in a well ventilated area, wear protective clothing, and avoid sparks or ﬂames near the battery. If you come in contact with battery acid :

□ Flush your skin with water. □ Apply b aking soda or lime to help neutralize the acid. □ Flush your eyes with water. □ Get medical attention imme d iately.

Always disconnect the battery cable befo

re working on the electrical system.

PERSONAL INJURY

ogen gas when charging and continue to

ct with

To avoid injury from accidental engine startup while servicing the engine, disconne

ct/disable the starting

system.

All information subject to change without notice.

+ 895 hidden pages