Detroit Diesel Engine 60 DDEC VI Troubleshooting Guide

Download

Page 1

Page 2

Page 3

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.

Page 4

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.

Page 5

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.

Page 6

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.

Page 7

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.

Page 8

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.

Page 9

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.

Page 10

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.

Page 11

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.

Page 12

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.

Page 13

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.

Page 14

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.

Page 15

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.

Page 16

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

Page 17

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

Page 18

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.

Page 19

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

Page 20

All information subject to change without notice.

Page 21

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.

Page 22

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.

Page 23

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.

Page 24

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.

Page 25

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.

Page 26

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.

Page 27

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.

Page 28

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.

Page 29

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.

Page 30

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.

Page 31

1.3.8 Fire

SERIES 60 DDEC VI TROUBLESHOOTING GUIDE

Keep a charged ﬁre extinguisher within reach. Ensure you have the proper type of exti

nguisher on

hand.

FIRE

To avoid injury from ﬁre, keep a ﬁre extinguisher near the grinding machine in c ase excessive heat should ignite the oil.

1.3.9 Cleaning A gent

Avoid the use of carbon tetrachloride as a cleaning agent because of the harmful vapors that it releases. Ensure the work area is adequately ventilated. Use protective gloves, goggles or face shield, and apron.

PERSONAL INJURY

To avoid inju ry from harmful vapors or skin contact, do not use carbon tetrachloride as a cleanin

g agent.

1.3.10 Diagnostic Equipment

For mobile applications, Detroit Diesel Diagnostic Link 7.0 (DDDL 7.0) must be used by personnel other than the vehi vehicle while an assistant performs the diagnostic evaluations.

To avoid injury from los s operator of a DDEC equipped engine must not use or read any diagno stic tool while the vehicle/vessel is moving.

cle operator. The vehicle operator must maintain control of the

PERSONAL INJURY

of vehicle/vessel control, the

All information subject to change without notice.

Page 32

1.3 SAFETY PRECAUTIONS

1.3.11 Working on a Running Engine

When working on an engine that is running, accidental contact with the hot exhaust ma

nifold can cause severe burns. Remain alert to the location of the rotating fan, pulleys and belts. Avoid making contact across the two terminals of a battery which can result in severe arcing, or battery explosion.

PERSONAL INJURY

To avoid injury from rotating belts and fans, do not remove and discard safety guards.

PERSONAL INJURY

To avoid injury when working near or on an operati

ng engine, remove loose items of clothing and jewelry. Tie back o r contain long hair that could be caught in any moving part causing injury.

All information subject to change without notice.

Page 33

SERIES 60 DDEC VI TROUBLESHOOTING GUIDE

1.3.12 Optimized Idle

Optimized Idle must be turned on by the factory via order entry or mainframe setup.

UNEXPECTED ENGINE START

To avoid injury from an unexpected startup of an engine equipped with the Optimize d Idle system, remove the starter relay from the relay holder.

PERSONAL INJURY

To avoid injury from accidental engine startup, replace a defective ECM with an ECM programmed with identic inputs and outputs.

1.3.13 Fluoroelastomer

Fluoroelastomer (Viton®) parts such a normal design conditions.

To avoid injury from chemical bur shield and neoprene or PVC gloves when handling ﬂuoroelastomer O-rings or seals that have been degraded by excessive heat. Discard glo ﬂuoroelastomer parts.

A potential hazard may oc

cur if these components are raised to a temperature above 600°F ( 316°C) (in a ﬁre for example). Fluoroelastomer will decompose (indicated by charring or the appearance of a black, sticky mass) and produce hydroﬂuoric acid. This acid is e xtremely corrosive and, if touched by bare skin,

may cause severe burns (the symptoms could be delayed for several hours).

s O-rings and seals are perfectly safe to handle under

CHEMICAL BURNS

ns, wear a face

ves after handling degraded

All information subject to change without notice.

Page 34

1.3 SAFETY PRECAUTIONS

All information subject to change without notice.

Page 35

2 LOW OIL PRESSURE

Section Page

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 SH AFT PLUGS MISSING (NEW OR

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

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

2.7 NONFUNCTIONAL OR STICKING OI

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

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

2.9 DEFECTIVE PRESSURE REL

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

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

2.12 DEFECTIVE OIL PUM

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

P ASSEMBLY .......................................................

IEF VALVE ...............................................

L PRESSURE REGULATOR

REBUILT ENGINES

2-13

2-16

Page 36

All information subject to change without notice.

Page 37

2.1 IMPROPER ENGINE OIL LEVEL

SERIES 60 DDEC VI TROUBLESHOOTING GUIDE

To determine if improper engine oil level is causing low oil pressure, perform the fo

llowing steps:

1. Ensure that the vehicle is parked on level ground.

2. Check the engine oil level; refer to appropriate service manual, preventive maintenance chapter.

[a] If the engine oil level is correct, check lubricating oil viscosity; refer to section 2.2.

[b] If the engine oil level is incorrect, refer to section 2.1.1.

2.1.1 Low Engine Oil Level Resolution

Perform the following steps for low engine oil level:

1. Fill engine oil pan to correct level; refer to appropriate service manual, preventive maintenance chapter.

2. Verify low engine oil resolution; refer to s

ection 2.1.1.1.

2.1.1.1 Test for Proper Engine Oil Level

Perform the following steps to determine if properly ﬁlled oil pan resolved low oil pressure:

1. Connect Detroit Diesel Diagnostic Link (DDDL 7.0) to check the oil pressure.

2. Start and vary engine speed between

1800 - 2100 rpm.

3. Check DDDL 7.0 for oil pressure reading.

[a] If DDDL 7.0 indicates oil pressure greater than or equal 241 kPa (35 psi) at 1800

rpm, shut down the engine and

disconnect DDDL 7.0. Refer to section 6 to diagnose

the cause for the low oil level.

[b] If D DDL 7.0 indicates oil pressure less than 241 kPa (35 psi), at 1800 rpm, shut

down the engine and disco

nnect DDDL 7.0. Check oil pressure using a mechanical

gage; refer to section 2.1.2.

2.1.2 Check Oil Pressure with a Mechanical Gauge

Check as follows:

1. Remove the oil pre

2. Connect a mechanical oil pressure gage to oil pressure sending unit port on the engine.

3. Start the engine. Verify that the engine speed is between 1800 and 2100 rpm.

[a] If the oil pres

[b] If oil pressure is less than 241 kpa (35 psi),refer to section 2.2.

ssure sending unit from the engine.

sure is greater than or equal to 241 kpa (35 psi), refer to section 2.4.

All information subject to change without notice.

Page 38

2.2 IMPROPER LUBRICATING OIL VISCOSITY

To determine if improper lubricating oil viscosity is causing low oil pressure, per

form the

following steps:

1. Acquire a lubricating oil sample from the engine oil pan.

2. Submit oil sample f or an ASTM test analysis.

[a] If engine oil sample meets ASTM speciﬁcations, check to determine if lubricating

oil is diluted with fuel or coolant; refer to section 2.3.

[b] If engine oil sample did not meet ASTM speciﬁcations, re

fertosection2.2.1.

2.2.1 Lubricating Oil Replacement

Perform the following steps to replace engine oil:

1. Drain and reﬁll engine with new lubricating oil; refer to appropriate service manual, preventive maintenance chapter.

2. Verify lubricating oil replacement, refer to section 2.2.1.1.

2.2.1.1 Test Engine with Replaced Lubricating Oil

Perform the following steps to determine if replaced lubricating oil resolved low oil pressure:

1. Connect to DDDL 7.0.

2. Start and run engine speed at 1800 rpm.

3. Check DDDL 7.0 for the for oil pressure reading.

[a] If DDDL 7.0 indicates oil pre

ssure greater than or equal 241 kPa (35 psi) at 1800 rpm, shut down the engine and disconnect DDDL 7.0. No further troubleshooting is required.

[b] If DDDL 7.0 indicates oil

pressure less than 241 kPa (35 psi) at 1800 rpm, shut down the engine and disconnect DDDL 7.0. Check the lubricating oil for fuel and water dilution; refer to section 2.3.

All information subject to change without notice.

Page 39

SERIES 60 DDEC VI TROUBLESHOOTING GUIDE

2.3 LUBRICATING OIL DILUTED WITH FUEL OIL OR ENGINE COOLANT

To determine if lubricating oil is diluted with fuel oil or engine coolant is causing

low oil pressure,

perform the following steps:

1. Acquire a lubricating oil sample from the engine oil pan.

2. Examine the lubricating oil sample for presence of engine coolant o

rfueloil.

[a] If coolant or fuel oil are not present, check for a faulty oil pressure gage,

refer to section 2.4.

[b] If water or fuel oil are present, refer to section 2.3.1.

2.3.1 Contaminated Lubricating Oil Resolution

Perform the following steps to resolve contaminated lubricating oil:

1. Drain engine oil pan, refer to appropriate service manual, preventive maintenance chapter.

2. Reﬁll engine crankcase with new oil; refer t

o appropriate service manual, preventive

maintenance chapter.

3. Verify lubricating oil replacement; refer to section 2.3.1.1.

2.3.1.1 Test Replaced Lubricating Oil

Perform the following steps to dete

rmine if replaced lubricating oil resolved low oil pressure:

1. Connect to DDDL 7.0.

2. Start and run the engine speed at 1800 rpm.

3. Visually examine DDDL 7.0 fo

r oil pressure reading.

[a] If DDDL 7.0 indicates oil pressure greater than or equal 241 kPa (35 psi) at 1800

rpm, shut down the engine and disconnect DDDL 7.0. Refer to section 2.13 to determine the cause for t

he diluted oil.

[b] If DDDL 7.0 indicates oil pressure less than 241 kPa (35 psi) at 1800 rpm, shut

down the engine and disconnect DDDL 7.0. Check for faulty oil pressure gage; refer to section 2.4

All information subject to change without notice.

Page 40

2.4 FAULTY OIL PRESSURE GAUGE SENSOR

To determine if a faulty oil pressure gage sensor is causing low oil pressure, perfor following steps:

1. Connect to DDDL 7.0.

2. Start and vary the engine speed between 1800 - 2100 rpm.

3. Visually examine DDDL 7.0 for oil pressure reading.

[a] If DDDL 7.0 indicates oil pressure greater than or equal 241 kPa (35 psi) at 1800

rpm, shut down the engine and disconnect DDDL 7.0, refer

to OEM for the correct

operation of the oil gage.

[b] If D DDL 7.0 indicates oil pressure less than 241 kPa (35 psi) at 1800 rpm, shut

down the engine; refer to section 2.4.1.

2.4.1 Oil Pressure Gage Sensor Replacement

Perform the following steps to replace the oil pressure gage sensor:

1. Remove and replace the oil pressure gage sensor; refer to OEM guidelines.

2. Verify replaced oil pressure gage senso

2.4.1.1 Test the Engine with Replaced Oil P

r; refer to section 2.4.1.1.

ressure Gage Sensor

mthe

Perform the following steps to determine if replaced oil pressure gage sensor resolved low oil pressure:

1. Connect to DDDL 7.0.

2. Start and run engine speed at 1800 rpm.

3. Visually examine DDDL 7.0 for oil pressure reading.

[a] If DDDL 7.0 indicates oil

pressure greater than or equal 241 kPa (35 psi) at 1800 rpm, shut down the engine and disconnect DDDL 7.0. No further troubleshooting is required.

[b] If DDDL 7.0 indicate

s oil pressure less than 241 kPa (35 psi) at 1800 rpm, shut down

the engine and disconnect DDDL 7.0. Refer to section 2.5.

All information subject to change without notice.

Page 41

SERIES 60 DDEC VI TROUBLESHOOTING GUIDE

2.5 ROCKER ARM SHAFT PLUGS MISSING (NEW OR REBUILT ENGINES ONLY)

If engine is not new or has not been rebuilt, refer to section 2.6.

To determine if a missing rocker arm shaft plugs are causing low oil pressure, perform the following steps:

1. Remove the rocker arm cover, (two piece, three piece); refer to appro

priate ser vice

manual, engine chapter.

2. Visually inspect the rocker arm shaft for missing or leaking shaft plugs.

[a] If the shaft plugs are present and a re not leaking, check t

he oil cooler for restriction;

refer to section 2.6.

[b] If the shaft plugs are missing, refer to section 2.5.2.

[c] If the shaft plugs are leaking, refer to section 2.5.

2.5.1 Leaking Rocker Arm Shaft Plug Repair

Perform the following steps to repair leaking rocker arm shaft plugs:

1. Remove damaged shaft plugs; refer to appropriate service manual, engine chapter.

2. Inspect rocker arm shaft for damage. refer to appropriate service manual, engine chapter.

3. Install new shaft plugs; refer to appropriate service manual, engine chapter.

NOTE:

Shaft plug must be installed 1.0 - 1.3 mm (0.040 -0.050 in.) below surface using J–36236.

If damage is found, replace the rocker arm shaft;

4. Install rocker arm cover; ref

er to appropriate service manual, engine chapter.

5. Verify repair made to the rocker s haft plugs; refer to section 2.5.2.1.

2.5.2 Missing Rocker Arm Shaft Plug Repair

Perform the following steps to repair missing rocker arm shaft plugs:

1. Inspect rocker arm sha refer to appropriate service manual, engine chapter.

2. Install new shaft plugs; refer to appropriate service manual, engine chapter.

NOTE:

Shaft plug must be installed 1.0 - 1.3 mm (0.040 -0.050 in.) below surface using J–36236.

3. Install rocker a

All information subject to change without notice.

rm cover; refer to appropriate service manual, engine chapter.

ft for damage. If damage is found, replace the rocker arm shaft;

Page 42

2.5 ROCKER ARM SHAFT PLUGS MISSING (NEW OR REBUILT ENGINES ONLY)

4. Verify repair made to the rocker shaft plugs; refer to section 2.5.2.1.

2.5.2.1 Test Engine with Repaired Rocker Shaft Plugs

Perform the following steps to determine if repaired rocker shaft plugs resolve

1. Connect to DDDL 7.0.

2. Start and run engine speed at 1800 rpm.

3. Check DDDL 7.0 for oil pressure reading.

[a] If DDDL 7.0 indicates 241 kPa (35 psi) or more at 1800 rpm, shut down the engine

and disconnect DDDL 7.0. No further troubleshooting is required.

[b] If DDDL 7.0 indicates less than 241 kPa (35 psi) at 180

0 rpm, shut down the engine

and disconnect DDDL 7.0. Check the oil cooler for restriction; refer to section 2.6.

d low oil pressure:

All information subject to change without notice.

Page 43

2.6 RESTRICTED OIL COOLER

SERIES 60 DDEC VI TROUBLESHOOTING GUIDE

To determine if a restricted oil cooler is causing low oil pressure, perform the foll

owing steps:

1. Connect to DDDL 7.0.

2. Start and run the engine at 1800 rpm.

3. Run the engine at 1800 rpm with a no-load for approximately 5 minutes

, allowing the

engine coolant to reach normal operating range, 88 - 96°C (190 - 210°F).

[a] If DDDL 7.0 is indicating a lubricating oil temperature less than or equal to 110°C

(230°F). Shut down the engine, disconnect DDDL 7.0, and

check pressure regulator

valve; refer to section 2.7.

[b] If DDDL 7.0 is indicating a lubricating oil temperature greater than 110°C (230°F).

Shut down the engine and repair oil cooler; refer to s

ection 2.6.1.

2.6.1 Oil Cooler Repair

Perform the following steps to repair the oil cooler:

1. Remove and repair oil cooler, refer to appropriate service manual, lubrication system chapter.

2. Clean the oil cooler; refer to appropriate service manual, lubrication system chapter.

3. Inspect the oil cooler for damage; refer to appropriate service manual, lubrication system chapter.

4. Install repaired oil cooler; refer to appropriate service manual, lubrication system chapter.

5. Verify repair of oil cooler; refer to section 2.6.1.1.

2.6.1.1 Test Engine with Repaired Oil Cooler

Perform the following ste

1. Connect to DDDL 7.0.

2. Refer to section1.3 for the exhaust caution before proceeding. Start and run the engine at 1800 rpm.

3. Run the engine through its operating range with no-load for approximately 5 minutes, allowing the engine coolant to reach normal operating range, 88 - 96°C ( 190 - 210°F).

[a] If DDDL 7.0 is ind

(230°F) at 1800 rpm, disconnect DDDL 7.0 and shut down the engine. No further troubleshooting is required.

[b] If DDDL 7.0 is

1800 rpm, shut down the engine and disconnect DDDL 7.0. Check pressure regulator valve; refer to section 2.7.

ps to determine if oil cooler repair resolved low oil pressure:

icating a lubricating oil temperature less than or equal to 110°C

indicating a lubricating oil temperature greater than 110°C (230°F) at

All information subject to change without notice.

Page 44

2.7 NONFUNCTIONAL OR STICKING OIL PRESSURE REGULATOR VALVE

To determine if a nonfunctional or sticking regulator valve is causing low oil press

ure, perform

the following steps:

1. Remove the oil pressure regulator; refer to appropriate service manual, lubrication system chapter.

2. Inspect the oil pressure regulator; refer to appropriate service manual, lubrication system chapter.

[a] If the regulator valve moves freely in the valve body; see Figur

e 2-1. reinstall the oil pressure regulator assembly; refer to appropriate service manual, lubrication system chapter. Check the bypass valve, refer to section 2.8.

[b] If the regulator valve will not move freely in the val

ve body, r efer to section 2.7.1.

1. Pin 5. Valve

2. Pressure Relief Valve Pin Location 6. Spring

3. Pressure Regulator P

4. Valve Body

Figure 2-1 Oil Pressure Regu

in Location

7. Spring Seat

lator

All information subject to change without notice.

Page 45

SERIES 60 DDEC VI TROUBLESHOOTING GUIDE

2.7.1 Oil Pressure Regulator Valve Repair

Perform the following steps to repair the oil pressure regulator valve:

1. Disassemble the pressure regulator valve and replace damaged components; refer to appropriate service manual, lubrication system chapter.

2. Assemble the pressure regulator valve; refer to appropriate servi

ce manual, lubrication

system chapter.

3. Verify repair of the regulator valve; refer to section 2.7.1.1.

2.7.1.1 Test Engine with Repaired Oil Pressure Regulator Valve

Perform the following steps to determine if repaired o pressure:

1. Connect to DDDL 7.0.

2. Start and run engine speed at 1800 rpm.

3. Visually examine DDDL 7.0 for oil pressure reading.

[a] If DDDL 7.0 indicates 241 kPa (35 psi) or more at 1800 rpm, shut down the engine

and disconnect DDDL 7.0. No further trou

[b] If DDDL 7.0 indicates less than 241 kPa (35 psi) at 1800 rpm, shut down the engine

and disconnect DDDL 7.0; check bypass valve; refer to section 2.8.

il pressure regulator valve resolved low oil

bleshooting is required.

All information subject to change without notice.

Page 46

2.8 DEFECTIVE BYPASS VALVE

To determine if a defective bypass valve is causing low oil pressure, perform the fol

lowing steps:

1. Remove the oil ﬁlter adaptor; refer to appropriate service manual, lubrication system chapter.

2. Inspect the oil ﬁlter adaptor; refer to appropriate service manual

, lubrication system

chapter.

[a] If no damage is found with the oil ﬁlter adaptor components, reinstall the oil ﬁlter

adaptor; refer to appropriate service manual, lubrication sy

stem chapter. Check

pressure relief valve, refer to section 2.9.

[b] If damage is found with the oil ﬁlter adaptor components; refer to section 2.8.1.

2.8.1 Oil Filter Adaptor Repair

Perform the following steps to repair the oil

1. Disassemble the oil ﬁlter adaptor; refer to appropriate service manual, lubrication system chapter.

2. Assemble the oil ﬁlter adaptor; refer to a chapter.

NOTE:

Always replace the copper washer whe

ﬁlter adaptor:

ppropriate service manual, lubrication system

never the adaptor plug is removed.

3. Install repaired oil ﬁlter adaptor; refer to appropriate service manual, lubrication system chapter.

4. Verify repairs made to the oil

2.8.1.1 Test Engine with Repaired Oi

ﬁlter adaptor; refer to section 2.8.1.1.

l Filter Adaptor

Perform the following steps to determine if repaired oil pressure regulator valve resolved low oil pressure:

1. Connect to DDDL 7.0.

2. Start and vary the engine speed between 1800 -2100 rpm.

3. Visually examine DDDL 7.0 for oil pressure reading.

[a] If DDDL 7.0 indicat

es 241 kPa (35 psi) or more at 1800 rpm, shut down the engine

and disconnect DDDL 7.0. No further troubleshooting is required.

[b] If DDDL 7.0 indicates less than 241 kPa (35 psi), shut down the engine and

disconnect DDD

L 7.0, c heck pressure relief valve; refer to section 2.9.

All information subject to change without notice.

Page 47

SERIES 60 DDEC VI TROUBLESHOOTING GUIDE

2.9 DEFECTIVE PRESSURE RELIEF VALVE

To determine if a defective pressure relief valve is causing low oil pressure, perfo

rm the following

steps:

1. Remove the pressure relief valve; refer to appropriate service manual, lubrication system chapter.

2. Inspect the oil pressure relief valve; refer to appropriate service manual, lubrication system chapter.

[a] If the relief valve moves freely in the valve body, reinstall th

e oil pressure relief valve; refer to appropriate service manual, lubrication system chapter. Check the pickup tube and screen assembly for defects, refer to section 2.10.

[b] If the relief valve will not move freely in the valve b

ody, refer to section 2.9.1.

2.9.1 Pressure Relief Valve Repair

Perform the following steps to repair the pressure relief valve:

1. Disassemble the pressure relief valve and replace damaged components; refer to appropriate service manual, lubricatio

2. Assemble and install the pressure regulator valve; refer to appropriate service manual, lubrication system c hapter.

n system chapter.

3. Verify repair of the regulator val

2.9.1.1 Test Engine with Repaired Relie

ve; refer to section 2.9.1.1.

f Valve

Perform the following steps to determine if repaired relief valve resolved low oil pressure:

1. Connect to DDDL 7.0.

2. Start and run engine speed

at 1800 rpm.

3. Visually examine DDDL 7.0 for oil pressure reading.

[a] If DDDL 7.0 indicates 241 kPa (35 psi), or more at 1800 rpm, shut down the engine

and disconnect DDDL 7

.0. No further troubleshooting is required.

[b] If DDDL 7.0 indicates less than 241 kPa (35 psi), at 1800 rpm, shut down the engine

and disconnect DDDL 7.0, check pickup tube and screen assembly; refer to section

2.10.

All information subject to change without notice.

Page 48

2.10 DEFECTIVE PICKUP SCREEN TUBE AND SCREEN ASSEMBLY

To determine if a defective pickup screen tube or screen assembly is causing low oil p perform the following steps:

1. Remove pickup screen tube and screen assembly; refer to appropriate service manual, lubrication system chapter.

2. Visually inspect pickup screen tube and screen assembly; refer to appropriate service manual, lubrication system chapter.

[a] If no stress cracks, twisted screen tube, or cracked ﬂange gask

ets are found, check

crankshaft main bearings; refer to section 2.11.

[b] If stress cracks, twisted screen tube, or cracked ﬂange gaskets are found,

refer to section 2.10.1.

2.10.1 Pickup Screen Tube and Screen Assembly Repair

Perform the following steps to repair the pickup screen tube and screen assembly:

1. Replace all damaged components identiﬁed during inspection and install; refer to appropriate service manual, lubricatio

2. Verify repairs to pickup screen tube and screen assembly; refer to section 2.10.1.1.

n system chapter.

ressure,

2.10.1.1 Test Engine with Repaired Pickup Screen Tube and Screen Assembly

Perform the following steps to determine if repaired pickup screen resolved low oil pressure:

1. Connect to DDDL 7.0.

2. Start and run engine speed at 1800 rpm.

3. Visually examine DDDL 7.0 for oil pressure reading.

[a] If DDDL 7.0 indicates 241

and disconnect DDDL 7.0. No further troubleshooting is required.

[b] If DDDL 7.0 indicates less than 241 kPa (35 psi) at 1800 rpm, shut down the engine

and disconnect DDDL

kPa (35 psi), or more at 1800 rpm, shut down the engine

7.0, check crankshaft main bearings; refer to section 2.11.

All information subject to change without notice.

Page 49

SERIES 60 DDEC VI TROUBLESHOOTING GUIDE

2.11 DEFECTIVE C RANKSHAFT MAIN BEARING SHELLS

To determine i f defective crankshaft main bearing shells are causing low oil pressu

re, perform

the following steps:

1. Check main bearing to crankshaft journal clearances; refer to appropriate service manual, engine chapter.

[a] If main bearing shell-to-journal clearance is within 0.040 - 0.151 mm (0.0016 -0.006

in.), check oil pump assembly; refer to section 2.12.

[b] If main bearing shell-to-journal clearance is not within 0.04

0 - 0.151 mm (0.0016

-0.006 in.), refer to section 2.11.1.

2.11.1 Crankshaft Main Bearing Shell Repair

Perform the following steps to repair crankshaft main bearing shells:

1. Remove and replace defective crankshaft mai

n bearing shells; refer to appropriate service

manual, engine chapter.

2. Verify crankshaft main bearing shells repair: refer to section 2.11.1.1.

2.11.1.1 Test Engine with New Crankshaft Main Bearing Shells

Perform the following steps to deter

mine if repaired relief valve resolved low oil pressure:

1. Connect to DDDL 7.0.

2. Start and run engine between 1800 rpm.

3. Visually examine DDDL 7.0 for

oil pressure reading.

[a] If D DDL 7.0 indicates 241 kPa (35 psi), at 1800 rpm, shut down the engine and

disconnect DDDL 7.0. No further troubleshooting is required.

[b] If DDDL 7.0 indicates less

than 241 kPa (35 psi) at 1800 rpm, shut down t he engine

and disconnect DDDL 7.0. Check the oil pump assembly; refer to section 2.11.

All information subject to change without notice.

Page 50

2.12 DEFECTIVE OIL PUMP ASSEMBLY

To determine if a defective oil pump is causing low oil pressure, perform the followi

ng steps:

1. Remove the oil pump assembly; refer to appropriate service manual, lubrication system chapter.

2. Manually rotate the oil pump drive gear.

[a] If the drive gear rotates freely in the pump housing, call the Detroit Diesel Customer

Support Center 313–592–5800.

[b] If the drive gear did not rotate freely; refer to section

2.12.1.

2.12.1 Oil Pump Assembly Repair

Perform the following steps to repair the oil pump assembly:

1. Disassemble the oil pump assembly and replace worn or damaged components as required; refer to appropriate service manual, lubric

ation system chapter.

2. Reassemble the oil pump; refer to appropriate service manual, lubrication system chapter.

3. Verify oil pump repair; refer to section 2.12.1.1.

2.12.1.1 Test Engine with Repaired Oil Pump Assembly

Perform the following steps to dete

rmine if repaired relief valve resolved low oil pressure:

1. Connect to DDDL 7.0.

2. Start and run the engine speed at 1800 rpm.

3. Visually examine DDDL 7.0 fo

r oil pressure reading.

[a] If DDDL 7.0 indicates 241 kPa ( 35 psi) at 1800 rpm, shut down the engine and

disconnect DDDL 7.0. No further troubleshooting is required.

[b] If DDDL 7.0 indicates les

s than 241 kPa (35 psi) at 1800 rpm, shut down the engine and d isconnect DDDL 7.0; call the Detroit Diesel Customer Support Center (313–592–5800).

All information subject to change without notice.

Page 51

SERIES 60 DDEC VI TROUBLESHOOTING GUIDE

2.13 DETECTING INTERNAL FUEL LEAKS

Used lube oil analysis can identify a potential source of engine trouble before it oc

curs. A program such as the Detroit Diesel Oil Analysis Program is recommended for monitoring crankcase oil in all engines. One of the most serious conditions used oil analysis can uncover is the presence of excessive fuel in the lube oil which should not exce

ed 2.5% maximum of oil volume, reference Detroit Diesel's Publication 7SE270 “Engine Requirements for Lubricating Oil, Fuel and Filters.” While used oil analysis can uncover the presence of excessive fuel in the lube oil, other methods must be used to determine its source. A par

ticularly effective test involves

the use of special test fuel containing dye additives.

2.13.1 Prepare Test Fuel

The use of ﬂuorescent dye(J–28431–B) is effective in fuel leak detection and should be the technician's choice in preparing a test fuel mixtur

e. However, if a “Black light“ or ﬂuorescent dye

are not available, red LTO 1140 may be substituted.

To pr epa re ﬂuorescent dye (J–28431–B), mix 118 ml (four ounces) of ﬂuorescent dye additive with 15.1 liters (four gallons) of diesel fue

l in a clean container m arked with the words “Test Fuel”.

To prepare Red LTO 1140, mix 59 ml (two ounces) of Red LTO 1140 dye additive with 18.9 liters (ﬁve gallons) of diesel fuel in a clean container marked with the words “Test Fuel”.

2.13.1.1 Fuel Leak Tests (E3 Injectors Installed/Engine Off)

To locate a leaking injector the tests

below should be completed in the sequence indicated and stopped at a point when the leaking injector is diagnosed. If a leaking injector is found, do not arbitrarily replace more than that injector, as multiple injector malfunctions are rare on the same engine.

All information subject to change without notice.

Page 52

2.13 DETECTING INTERNAL FUEL LEAKS

NOTE:

During fuel pressure testing (engine off, 5 minutes at 345 kPa [50 psi]) fuel leakage w

ill be evident at the injector body/plunger spring seat area see Figure 2-2. Factory tests have shown that accumulatio n of fuel at each injector, approximately a tablespoon may be evident during these tests. Evidence of fuel in this area is expected, as there

is no other place for it to go when the injector cavities are pressurized, forcing fuel between the injector body and plunger.

1. Acce ptable Fuel Leakage

Figure 2-2 Acceptable-Fuel Leakage Between injector Plunger and Body

2.13.1.2 Fuel Pressure Test

Since there is no known fuel leak tester available in the commercial market today, one must be fabricated. Use the following guidelines to help in fabricating:

□ Although test fuel can be pressurized by variety of methods, Detroit Diesel recommends

an air/fuel accumulator design capable of safely withstanding a minimum pressure of 345 kPa (50 psi).

□ The tester should have a capacity of 9.5 liters (2.5 gallons) of test fuel and provide for

contamination free storage of the test fuel when not in use.

□ Regulated shop air may be used to charge the accumulator tank and maintain a constant

test fuel pressure.

□ A shut-off valve should be installed at the accumulator outlet to start and stop pressurization

during the test sequence.

All information subject to change without notice.

Page 53

SERIES 60 DDEC VI TROUBLESHOOTING GUIDE

PERSONAL INJURY

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

PERSONAL INJURY

To avoid injury from tank rupture or a sudden air hose failure, do not use unregulated air pressure or an accumulator tank with an inadequate pre ssure rating.

Fuel Leak Tester

1. Fill fuel system tester with the ﬂuorescent or red dye fuel mixture approximately 9.5 liters (2.5 gallons).

2. Charge tester (outlet valve closed) with shop air regulated at 345 kPa (50 psi).

3. Hook-up the tester to the engine fuel system. There are two options for fuel tester to engine hook-up as determined by the eas

□ Option 1–Remove the fuel line from the outlet side of the fuel pump and connect the

e of access.

fuel system testers line in this fuel hose ﬁtting. This hook-up location will require the fuel system shut-off valve to rema

in in the open position during testing. About

3.8 liters (1 gallon) of test fuel will be necessary to charge the engine's fuel system from this hook-up location. Test fuel will not harm the engine's fuel ﬁlters and may remain in the fuel system at the c

□ Option 2–Remove the fuel line from the outlet side of the fuel by-pass ﬁlter adapter

onclusion of testing.

and connect the fuel testers line in this fuel hose ﬁtting. It is recommended that the fuel system shut-off valve be p

laced in the closed position before removing the engine

fuel line and remain closed until reinstalled. About 1.9 liter (0.5 gallon) of test fuel

will be necessary to charge the engine's fuel system from this hook-up location.

4. Remove rocker cover and d

isconnect the fuel outlet line at a convenient location between the cylinder head and the fuel tank. Install an a ppropriate size pipe plug (loose) in the fuel outlet line end and place it in a container to catch the fuel while priming the cylinder head. If equipped, Jak

e Brakes® should be removed to allow for the visual examination

of the injectors during fuel leak testing.

5. Slowly open the fuel tester's shut-off valve and charge the cylinder head fuel galley. When test fuel is ﬂowing

from the fuel return line and air has been purged from the system,

tighten the pipe plug at the engine fuel outlet line ﬁtting.

6. With the fuel tester shut-off valve completely open and the cylinder head galley pressurized t

o 345 kPa (50 psi), visually monitor the overhead using a black light for ﬁve minutes if the test time goes beyond ﬁve minutes it will become more difﬁcult to determine the faulty injector due to expected leakage at the injector plunger/body. Pay

All information subject to change without notice.

Page 54

2.13 DETECTING INTERNAL FUEL LEAKS

special attention to any leaks at the injector body, high and low pressure body plugs, see Figure 2-3and see Figure 2-5, injector nut to body and nut to tube seals see Figur

2-4, and stop valve cover see Figure 2-6.

NOTE:

Injector plunger/body leakage at the follower spring area is normal and

expected during

this test.

NOTE:

The ﬁgures that follow do not illustrate amount of fuel leakage but rath

er its origin or location. If injector(s) are removed and reinstalled in the head, the injector nut 'O' ring seals should be replaced with n ew parts.

1. Fuel Leakage at Low Pressure Body Plug

Figure 2-3 Unacceptable-Fuel Leakage at Low Pressure Body Plug

All information subject to change without notice.

Page 55

SERIES 60 DDEC VI TROUBLESHOOTING GUIDE

1. Fuel Le akage at Injector Nut-to-Tube 'O' Ring Seal

Figure 2-4 Unacceptable-Fuel Leakage at Injector Nut-toTube 'O' Ring Seal

1. Fuel Leakage at High Pressure Body Plug and or

Body Crack

Figure 2-5 Unacceptable-Fuel Leakage at High Pressure B ody Plug and

or Body Crack

All information subject to change without notice.

Page 56

2.13 DETECTING INTERNAL FUEL LEAKS

1. Fuel Leakage at Injector Stop Valve Cover

Figure 2-6 Unacceptable-Fuel Leakage at Injector Stop Valve Cover

7. Correct the cause of any abnormal fuel leaks.

8. Bleed the pressure from the accumulator tank and remove the pipe plug from the fuel outlet line. Reinstall the fuel outlet line in the engine's fuel system. Disconnect the fuel tester and reinstall the fuel inlet line in the engine's fuel system.

9. Completely open the engine's fuel shut-off valve and assure that all fuel connections are tight. Reinstall the rocker cover and start engine to purge the air from the fuel system. If the engine fails to start, it may be necessary to prime the fuel system.

All information subject to change without notice.

Page 57

3 MISFIRING CYLINDER

Section Page

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

Page 58

All information subject to change without notice.

Page 59

3.1 POOR VEHICLE GROUND

SERIES 60 DDEC VI TROUBLESHOOTING GUIDE

To determine if poor vehicle ground is causing the cylinder to misﬁre, perform the fo

1. Remove alternator belt.

2. Start the engine.

3. Run the engine through operating range.

4. Listen for engine misﬁring.

[a] If the engine is not misﬁring, refer to section 3.1.1. Shut down the engine.

[b] If the engine is still misﬁring, check for aerated fuel

; refer to section 3.2.

3.1.1 Negative Lead Repair

Perform the following steps for negative lead repair:

1. Shut down the engine.

2. Remove negative lead(s) at frame ground stu

3. Clean ground stud; refer to O EM guidelines.

4. Clean negative lead(s) terminal lugs with low grit sandpaper.

5. Repair any loose or damaged lead(s)

, using the splice method or rosin core solder.

d near battery box.

llowing steps:

6. Install negative lead(s) to frame ground stud; refer to OEM guidelines.

7. Install alternator belt. Tighten belt to:

[a] If installing a new belt, tight

en to 170 N·m (125 lb).

[b] If installing a used belt, tighten to 135 N·m (100 lb).

[c] If a belt tension gage is not available, adjust the belt tension so that a ﬁrm push with

the thumb, at a point midw

ay between the two pulleys, will depress the belt 12.70 -

19.05 mm (0.500 -0.750 in.).

NOTE:

When installing or adj

usting an accessory drive belt, be sure the bolt at the accessory

adjusting pivot point is properly tightened, as well as the bolt in the adjusting slot.

NOTE:

Drive belts (Vee and

poly-vee) should be replaced every 2,000 hours or 160,000 km

(100,000 miles).

8. Verify negative lead repair; refer to section 3.1.1.1.

All information subject to change without notice.

Page 60

3.1 POOR VEHICLE GROU ND

3.1.1.1 Veriﬁcation of Repair for Negative Lead

Perform the following steps to determine if negative lead repair resolved the misﬁr condition:

1. Refer to section3.1 for exhaust caution before preceding. Start engine.

2. Run engine speed up to the occurrence of the misﬁring.

3. Listen for misﬁring cylinder.

[a] If the engine is not misﬁring, no further troubleshooting is required. Shut down

the engine.

[b] If the engine is misﬁring, check for aerated fuel. Shut down the engine;

refer to section 3.2.

ing cylinder

All information subject to change without notice.

Page 61

3.2 AERATED FUEL

SERIES 60 DDEC VI TROUBLESHOOTING GUIDE

To determine if aerated fuel is causing the cylinder to misﬁre, perform the followin

gsteps:

1. Disconnect the fuel line return hose from the ﬁtting located at the fuel tank.

2. Place the opened end of fuel line into a suitable container.

3. Start the engine.

4. Run the engine at 1000 rpm.

5. Visually check to see if air bubbles are rising to the surface of the f uel within the container.

[a] If a ir bubbles are present, r efer to section 3.2.1.

[b] If air bubbles are not present, check for improper calibration setting. Shut down

the engine.

3.2.1 Aerated Fuel Repair

Perform the following steps for air in fuel r

1. Shut down engine.

2. Tighten all fuel line connections between fuel tank and fuel pump; refer to OEM guidelines.

3. Visually inspect all fuel lines between fuel tank and fuel pump for leaks.

epair:

4. Replace any damaged components; refer to appropriate service manual, fuel system chapter.

5. Verify repair of fuel lines:

[a] If no air in the fuel return, refer t o section 3.2.1.1.

[b] If air in the rule return, l

3.2.1.1 Test the Engine with Rep

ocate and repair. Then refer to section 3.2.1.1.

air for Aerated Fuel

Perform the following steps to determine if the aerated fuel repair resolved the misﬁring cylinder condition:

1. Refer to section3.

2 for exhaust caution before preceding. Start engine.

2. Run engine at 1000 rpm.

3. Listen for misﬁring cylinder.

[a] If the engine i

s not misﬁring, no further troubleshooting is required. Shut down

the engine.

[b] If the engine is misﬁring,, shut down the engine and check for improper injector

setting.

All information subject to change without notice.

Page 62

3.3 FAULTYFUELINJECTOR

3.3 FAULTY FUEL INJECTOR

To determine if a faulty fuel injector is causing the cylinder to misﬁre, perform the

following steps:

1. Connect to DDDL 7.0.

2. Start the engine.

3. From the Select Menu, scroll to select ENGINE and press the ENTER key

4. Scroll to FUEL INJECTOR INFO (CUTOUT) and press the ENTER key.

5. Scroll to select NEW TEST and press the ENTER key.

6. Scroll to select RPM SETTING FOR CCO TEST NORMAL and scr

oll to select 1000

and press the ENTER key.

7. Scroll to select AUTO and press the ENTER key. Wait for END OF TEST.

NOTE:

If an injector cannot be cutout, you will see an ERROR message. Press FUNC to exit the cylinder cutout function, press the FUNC key.

8. Scroll the list to review the results of the c

ylinder cutout test. To ﬁnd suspect injectors, look for a cylinder with a value that is within 0.2 degrees of the NO CUTOUT PULSE WIDTH, by comparing the CUTOUT PULSE WIDTH values to the NO CUTOUT PULSE WIDTH values.

[a] If any CUTOUT PULSE WIDTH values are within 0.2 degrees of the NO CUTOUT

PULSE WIDTH, shut down the engine and refer to section 3.3.1.

[b] If any CUTOUT PULSE WIDTH values a

re not within 0.2 degrees of the NO

CUTOUT PULSE WIDTH, shut down the engine and refer to section 3.4.

3.3.1 Faulty Fuel Injector Repair

Perform the following steps for faulty fuel injector assembly(s):

1. Remove and replace inje

ctor assembly(s) whose values are within 0.2 degrees of the NO

CUTOUT PULSE WIDTH; refer to the appropriate service manual, fuel system chapter.

2. Verify replaced injector assembly(s), refer to section 3.3.1.1.

3.3.1.1 Veriﬁcation of Repair for Faulty Fuel Injector

Perform the follow cylinder condition:

1. Refer to section3.3 f or the exhaust caution before preceding. Start the engine.

2. Run the engine s

ing steps to determine if the replaced fuel injector(s) resolved the misﬁring

peed up to the occurrence of the misﬁring.

3. Listen for misﬁring cylinder.

All information subject to change without notice.

Page 63

SERIES 60 DDEC VI TROUBLESHOOTING GUIDE

[a] If the engine is not misﬁring, shut down the engine. No further troubleshooting is

required.

[b] If the engine is misﬁring, shut down the engine and check for a faulty Electronic

Control Unit (MCM); refer to section 3.4.

3.4 FAULTY MOTOR CONTROL MODULE

To determine if a faulty MCM is causing the cylinder to misﬁre, per

form the following:

1. Remove the thru-bolts holding the MCM to the engine; refer to the a ppropriate service manual, fuel system chapter.

2. Remove the MCM from the engine and tag the MCM for core r

eturn.

3. Obtain a new reprogrammed MCM.

4. Inspect the MCM isolators for any damage. Replace if necessary, refer to the appropriate service manual, fuel system chapter.

5. Install the MCM to the engine using thru-bolts; refer to the appropriate service m anual, fuel system chapter.

6. Torque the MCM thru-bolts to 23 - 27 N·m (1

7 - 20 lb·ft).

7. Install the 120–pin Engine Harness connector to the MCM.

3.4.1 Faulty MCM Repair

No repair authorized for MCM.

3.4.1.1 Veriﬁcation of Repair for Faulty MCM

Perform the following step

s to determine if the new MCM resolved the misﬁring cylinder

condition:

1. Start the engine.

2. Run the engine speed up

to the occurrence of the misﬁring.

3. Listen for misﬁring cylinder.

[a] If the engine is not misﬁring, shut down the engine. No further troubleshooting is

required.

[b] If the engine is misﬁring, shut down the engine and check for worn or damaged

valves and cylinder kits; refer to section 3.5.

All information subject to change without notice.

Page 64

3.5 WORNORDAMAGEDVALVEORCYLINDERKIT

Loss of compression in Series 60 engines may result from a variety of sources, includ

ing worn or broken ﬁre or compression rings, holes in pistons, leaky valves, scored or worn cylinder walls, leaky or broken gaskets and cracked cylinder heads or cylinder liners. The detection and elimination of the cause or causes of cylinder pressure losses is

vital to engine life and efﬁcient operation. To assist the mechanic in effectively measuring the l oss of cylinder pressure, and locating the source of abnormal leaks in individual cylinders, the following test procedure has been developed.

1. Move the vehicle requiring test to the chassis dynamometer; refer to OEM guidelines.

2. Disconnect air compressor; refer to the appropriate service manual, special equipment chapter.

3. Start the engine.

4. Run the engine and bring the engine coolant temperature to normal operating range.

5. Run vehicle to full load and rated speed.

6. Attach a manometer calibrated to read in kPa (in. H

O), to the oil dipstick opening.

7. Measure and record crankcase pressure. For crankcase pressure guidelines refer to Service Information Letter 02 TS-20 found on th

e DDC extranet.

8. Shut down engine.

9. Remove the vehicle from the chassis dynamometer.

10. Review the crankcase pressure

[a] If the crankcase pressure was greater than 1.25 kPa (5 in. H

[b] If the crankcase pressure was less than 1.25 kPa (5 in. H

compression test. Refer

test results.

to section 3.5.1.2.

O); refer to section 3.5.1.

O); perform a cylinder

11. Compare the cylinder compression test results to speciﬁcations.

[a] If cylinder pressure is below speciﬁcations, refer to section 3.5.1.

[b] If cylinder pressu

re is within speciﬁcation, call Detroit Diesel Customer Support

Center (313-592-5800).

3.5.1 Worn or Damag ed Valve or Cylinder Kit Repair

Perform the following steps for worn or damaged valve or cylinder kit:

1. Remove cylind

2. Inspect the cylinder head for worn or damaged valves; refer to the appropriate service manual, engine chapter. For repair and replacement procedures, refer to the appropriate service man

er head; refer to the appropriate service manual, engine chapter.

ual, engine chapter.

3. Inspect the cylinder kit components for worn or damaged liners, pistons or piston rings; refer to the appropriate service manual, engine chapter.

All information subject to change without notice.

Page 65

SERIES 60 DDEC VI TROUBLESHOOTING GUIDE

4. Veriﬁcation of repairs made to cylinder valve(s) or cylinder kit components is required; refer to section 3.5.1.1.

3.5.1.1 Veriﬁcation of Repair for Worn or Damaged Valve or Cylinder Kit

Perform the following steps to determine if the repaired valve or cylinder kit resolved the misﬁring cylinder condition:

1. Refer to section3.5 for the exhaust caution before preceding. St

2. Run the engine speed up to the occurrence of the misﬁring.

3. Listen for misﬁring cylinder.

[a] If the engine is not misﬁring, no further troubleshoo

[b] If the engine is misﬁring, call the Detroit Diesel Customer Support Center

313–592–5800.

3.5.1.2 Cylinder Compression Test

Perform the following steps for a compress

PERSONAL INJURY

To avoid injury from inhaling engine exhaust, a lways operate the engine in a well-ventil exhaust is toxic.

1. Start and run the engine unt

il normal operating temperature is reached. Stop the engine.

ion test on a Series 60 Engine:

ated area. Engine

art the engine.

ting is required.

2. Disconnect the batteries.

3. Disconnect the fuel pump feed line from the fuel tank. Place a suitable container under the line to catch the sp

illing fuel. Turn the ¼ turn valve off on the outlet ﬁtting of the

secondary fuel ﬁlter.

4. Disconnect the fuel supply line to the cylinder head. Place a suitable container under the line to catch the sp

illed fuel. Disconnect the fuel return line from the doser valve and place

a suitable container under the line to catch the spilled fuel.

All information subject to change without notice.

Page 66

3.5 WORNORDAMAGEDVALVEORCYLINDERKIT

EYE INJURY

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

NOTICE:

All the fuel must be removed from the cylinder head before removing injectors. This prevents the fuel from enterin

gthe cylinder and causing cylinder wall lube oil wash down or a hydrostatic lock at startup.

5. Blow low pressure regulated air no more than 207 kPa (30 psi ) into the inlet ﬁtting for 20 to 30 seconds or until all the fuel is purged from the head.

6. Clean and remove the rocker cover, it is no

t necessary to remove the bottom rocker cover.

If equipped with Jake Brakes remove the Jake Brake assembly.

7. Remove all the rocker shaft m ounting bolts and nut from the front or rear rocker shaft assembly. Using rocker arm lifter (J–

35996–A), see Figure 3-1, lift the assembly straight

up and off of the head and place in a clean area on the bench.

Figure 3-1 Rocker Arm/Sh

aft Assembly Removal/Installation

8. Use tool J-47808 to remove the 4–pin electrical connection from the injector.

9. Disengage the locking tang on the harness plug connection, grasp the connector and gently pul

litfromthesocket.

10. Remove the injector hold down clamps.

All information subject to change without notice.

Page 67

SERIES 60 DDEC VI TROUBLESHOOTING GUIDE

NOTICE:

Use extreme care when handling injectors to avoid costly damage by dropping or mishandling. Always install new O-rings when replacing injectors.

11. Remove the three injectors to be tested from the cylinder head.

12. Place the compression test adaptors (J-47373) into the injector holes. It is recommended to have three test adaptors (J-47373) when performing this r

outine.

13. Install the injector hold down clamps and torque hold down bolts to 58-66 N·m (43-49 lb·ft).

14. Carefully remove the shaft from the rocker arm as

sembly by slowly pulling it out of the

assembly. Place the shaft on the bench. Do not disturb the stack-up of the rocker a rm sets.

15. Remove the three injector rocker arms and replace with spacers (J–38768–5) .

16. Lubricate the shaft with clean engine o

il. With sleeves in place, carefully reinstall the shaft

through each rocker arm shaft. Make sure cup plug end faces inboard.

17. Install the modiﬁed rocker arm shaft assembly on the head. If the engine is equipped with a Jake Brake®, use non-Jake Brake ro

cker arm shaft bolts 8929129. Torque the three bolts

and the nut to 102-108 N·m (75-80 lb·ft).

NOTE:

Verify that the bolt holes for th

e rocker shafts are clean as not to hydro lock the bolts

causing damage to the cylinder head.

18. Disconnect both connectors at the valve cover for the injectors.

NOTE:

Disconnect both connectors at the valve cover for the i njectors.

PERSONAL INJURY

To avoid injury when wor

king on or near an operating engine, wear protective clothing, eye protection, and hearing protection.

All information subject to change without notice.

Page 68

3.5 WORNORDAMAGEDVALVEORCYLINDERKIT

PERSONAL INJURY

To avoid injury from hot surfaces, wear protective g loves , or allow engine to cool before removing any component.

ENGINE EXHAUST

To avoid injury from inhaling engine exhaust, always operate the engine in a well-ventilated area. Engine exhaust is toxic.

19. Attach cylinder compression gauge (J–6692–B) to the ﬁrst adaptor. See Figure 3-2.

Figure 3-2 Attach Cylinder Compressi

on Gauge J 6692–B

20. Reconnect the batteries.

21. Crank the engine over using the starter motor 5 compression strokes record the compression reading

on the gauge.

NOTE:

Verify that the batteries voltage does not g o low enough to affect engine cranking speed. If the cranking spe

ed is affected then the results will be inaccurate. If needed connect a

battery charge to maintain battery voltage.

22. The compression reading should be 3102-3793 kPa ( 450-550 psi) with no two cylinders differingbymo

re than 276 kPa (40 psi). If compression readings are below speciﬁcations,

repeat step 20 to be certain of the reading.

All information subject to change without notice.

Page 69

SERIES 60 DDEC VI TROUBLESHOOTING GUIDE

23. After testing all three cylinders, r emove bolts from the modiﬁed rocker arm shaft assembly and, using rocker arm lifter (J–35996), lift the assembly straight up and off the cy

linder

head. Place in a clean area on the bench.

24. Carefully remove the shaft from the rocker arm assembly, remove the three rocker arm sleeves. Replace the three injector rocker arms. Lubricate the sha

ft with clean engine oil

and carefully reinstall through each rocker arm.

25. Remove the injector hold down clamps discard the hold down bolt and remove the compression test adaptors from the cylinder head.

26. Using new sealing rings and injector hold down bolt install the injectors back into the cylinder head and torque to speciﬁcations; Torque bolt to 50 Nm (37 lb ft) Loosen the bolt 60 degrees ( 1/6 of a turn or one bolt ﬂat) Do not fully l

oosen the bolt. Torque the bolt to

35 Nm (26 lb ft) Tighten the bolt an additional 90 degrees.

27. Replace the completed rocker arm shaft assembly on the engine and torque nut and bolts to speciﬁcations torque to 102-108 N•m (75-80 l

b•ft)

28. Repeat steps 4b-26 for the rear 3 cylinders

29. Install upper valve cover, insuring that the bolt hole are clear of dirt and o il as not to damage the lower rocker cover.

30. Check test results

All information subject to change without notice.

Page 70

3.5 WORNORDAMAGEDVALVEORCYLINDERKIT

All information subject to change without notice.

Page 71

4 STARTING DIFFICULTY – ENGINE ROTATES

Section Page

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

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

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

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

4-12

Page 72

All information subject to change without notice.

Page 73

4.1 EMPTY FUEL TANK

SERIES 60 DDEC VI TROUBLESHOOTING GUIDE

To determine if an empty fuel tank is causing starting difﬁculty, determine the amou

nt of fuel in

fuel tank; refer to OEM guidelines.

1. If fuel is at recommended level, check for a weak battery; refer to section 4.2.

2. If fuel is below recommended level, refer to section 4.1.1.

4.1.1 Low Fuel Level Resolution

Perform the following steps to resolve low fuel level:

1. Fill fuel tank to full; refer to OEM guidelines.

2. Verify fuel tank reﬁll; refer to section 4.1.1.1.

4.1.1.1 Test Engine with Filled Tank

To determine if a ﬁlled fuel tank resolved starting difﬁculty, attempt to start and run the engine.

1. If the engine starts and runs, no further troubleshooting is required. Shut down the engine.

2. If the engine fails to start and run, check t

he battery; refer to section 4.2.

4.2 LOW BATTERY VOLTAGE

To determine if a weak battery is causing starting difﬁculty, perform the following steps:

1. Measure the battery voltage; refer to OEM guidelines.

2. Analyze your ﬁndings.

[a] If voltage is between 10.5 - 14 volts (21 - 26 volts for a 24 volt system), check the

terminals; refer to section 4.3.

[b] If voltage is less than 10.5

volts (21 volts for a 24 volt system), replacement is

necessary; refer to section 4.2.1.

4.2.1 Battery Replacement

Perform the following steps for battery repair:

1. Remove and replace

2. Verify battery replacement; refer to section 4.2.1.1.

the battery; refer to OEM guidelines.

All information subject to change without notice.

Page 74

4.3 CORRODED OR DAMAGED BATTERY TERMINALS

4.2.1.1 Test Engine with Replaced Battery

Perform the following steps to determine if the battery replacement resolved start

1. Attempt to start and run the engine.

[a] If the engine starts and runs, no further troubleshooting is required. Shut down the

engine.

[b] If the engine fails to start and run, check the terminals; refer to section 4.3.

4.3 CORRODED OR DAMAGED BATTERY TERMINALS

Corroded or damaged terminals may cause starting difﬁculties.

4.3.1 Corroded or Damaged Battery Terminal Repair

To determine if corroded or damaged terminals i

1. Visually inspect terminals for corrosion or damage.

[a] If corrosion or damage is not found, check the magnetic switch; refer to section 4.4.

[b] If corrosion or damage is found, repair is n

2. Repair or replace any corroded or damaged terminals; refer to OEM guidelines.

s causing starting difﬁculty:

ecessary;gotostep2.

ing difﬁculty:

3. Verify repair of corroded or damaged terminals; refer to section 4.3.1.1.

4.3.1.1 Test with Repaired Battery Terminals

Perform the following steps to

1. Attempt to start and run the engine.

[a] If the engine starts and runs, no further troubleshooting is required. Shut down the

engine.

[b] If the engine fails to start and run, check the magnetic switch; refer to section 4.4.

determine if the repair resolved starting difﬁculty:

All information subject to change without notice.

Page 75

SERIES 60 DDEC VI TROUBLESHOOTING GUIDE

4.4 DEFECTIVE MAGNETIC SWITCH

To determine if a defective magnetic switch is causing starting difﬁculty:

1. Start e ngine.

2. Clamp a heavy gauge battery jumper cable between the two large studs of the magnetic switch. See Figure 4-1.

Figure 4-1 Basic Cranking Circuit

[a] If the engine cranked with the jumper cable in place, the magnetic switch must be

replaced; refer to section 4.4.1.

[b] If the engine did not crank with the jumper cable in place, check the starter;

refer to section 4.5.

4.4.1 Magnetic Switch Replacement

Replace the magnetic switch; refer to OEM guidelines then verify magnetic switch replacement; refer to section 4.4.1.1

4.4.1.1 Test Engine w ith Replaced Magnetic Switch

Refer to section4.4 for the exhaust caution before proceeding. To determine if the magnetic switch replacement resolved starting difﬁculty, attempt to start and run the engine.

1. If the engine starts and runs, no further troubleshooting is required. Shut down the engine.

2. If the engine fails to start and run, check the starter; refer to section 4.5.

All information subject to change without notice.

Page 76

4.5 DEFECTIVE STARTER

To determine if a defective starter is causing starting difﬁculty, perform the foll

1. Place the red lead of a voltmeter to the solenoid "BAT'' terminal, see Figure 4-2.

1. Black Voltmeter Lead 4. Harness Tube

2. Starter Ground Terminal Lug 5. Volt Ohm Meter

3. Red Voltmeter Lead

owing steps:

Figure 4-2 Cranking Motor Available Volta

ge Test

2. Place the black voltmeter lead to the starter ground terminal, see Figure 4-1.

3. Engage the starter switch.

4. View the voltage reading

on the meter.

[a] If the voltage is less than speciﬁcation while cranking the engine, replacement is

necessary; refer to section 4.5.1.

[b] If the voltage is to

speciﬁcation while cranking the engine, check the cranking speed;

refer to section 4.6.

4.5.1 Starter R ep lacemen t

Perform the following steps for starter replacement:

1. Replace the st

2. Verify replacement of starter; refer to section 4.5.1.1.

arter; refer to the appropriate service manual, electrical equipment chapter.

All information subject to change without notice.

Page 77

SERIES 60 DDEC VI TROUBLESHOOTING GUIDE

4.5.1.1 Test Engine with Replaced Starter

Perform the following steps to determine if the replaced starter resolved starting

difﬁculty:

1. Attempt to start and run the engine. If the engine starts and runs, no further troubleshooting is required. Shut down the engine.

2. If the engine fails to start and run, check the cranking speed; refer

to section 4.6.

4.6 LOW CRANKING SPEED

To determine if low cranking speed is causing starting difﬁculty, perform the following steps:

1. Install a tachometer to the engine.

2. Record engine revolution while cranking the engine; r

efer to OEM for guidelines.

[a] If the cranking speed is greater than 100 rpm, check the fuel supply valve;

refer to section 4.7.

[b] If the cranking speed is less than 100 rpm; re

fer to section 4.6.1.

4.6.1 Low Cranking Speed Repair

Perform the following steps for low cranking speed repair:

1. Drain the engine oil; refer to the appropriate service manual, preventive maintenance engine chapter.

2. Remove oil ﬁlter(s); refer to the appropriate service manual, preventive maintenance chapter.

3. Inst all new oil ﬁlter(s); re

fer to the appropriate service manual, preventive maintenance

chapter.

4. Reﬁll the lubrication system with new oil; refer to the appropriate service manual, preventive maintenance c

hapter.

5. Verify low cranking speed repair; refer to section 4.6.1.1.

4.6.1.1 Test Engine with Replaced O il

To determine if the replaced oil resolved starting difﬁculty, attempt to start and run the engine.

1. If the engine star

2. If the engine fails to start and run, check the fuel supply valve; refer to section 4.7.

ts and runs, no further troubleshooting is required. Shut down the engine.

All information subject to change without notice.

Page 78

4.7 FUEL SUPPLY VALVE

To determine i f the fuel supply valve is causing starting difﬁculty, check that fuel

supply valve

is open; refer to OEM guidelines.

1. Check that fuel supply valve.

2. Is the valve open?

[a] If the fuel supply valve is open, check the fuel ﬁlters; refer to section 4.8.

[b] If the fuel supply valve is closed, repair is necessary; refer to section 4.7.1.

4.7.1 Fuel Supply Valve Repair

Perform the following steps for fuel supply valve repa

1. Open the closed valve; refer to the appropriate service manual, fuel system chapter.

2. Prime the fuel system; refer to the appropriate service manual, operation and veriﬁcation chapter.

3. Verify fuel supply valve repair; refer to section 4.7.1.1.

ir:

4.7.1.1 Test Engine with Fuel Supply Valve Op en

To determine if opening the fuel supply valve resolved starting difﬁculty, attempt to start and run the engine.

1. If the engine starts and runs, no further troubleshooting is required. Shut down the engine.

2. If the engine fails to start and run, check the fuel ﬁlters; refer to section 4.8.

All information subject to change without notice.

Page 79

4.8 PLUGGED FUEL FILTER(S)

SERIES 60 DDEC VI TROUBLESHOOTING GUIDE

To determine if a plugged fuel ﬁlters i s causing starting difﬁculty, perform the fol

1. Disconnect the fuel line return hose from the ﬁtting located at the fuel tank.

2. Place the opened end of fuel line into a ﬁve gallon container.

3. Start the engine.

4. Run the engine at 1000 rpm.

5. Clock fuel rate for one minute.

6. Measure the amount of fuel ﬂowed into the container.

[a] If the fuel ﬂow is greater than 3.8 L/min (1 gal/min), check for air in fuel;

refertosection4.10.

[b] If the fuel ﬂow is less than 3.8 L/m in (1 gal/min), r

eplace the fuel ﬁlters;

refertosection4.8.1.

4.8.1 Plugged Fuel Filter(s) Replacement

Perform the following steps to replace fuel ﬁlter(s):

1. Replace the fuel ﬁlter; refer to the chapter.

appropriate service manual, preventive maintenance

lowing steps:

2. Test the engine to determine if starting has been improved; refer to section 4.8.1.1.

4.8.1.1 Test Engine with Replaced Fuel Filters

To determine if the replaced exhaust caution before proceeding. Attempt to start and run the engine.

1. If the engine starts and runs, no further troubleshooting is required. Shut down the engine.

2. If the engine fails to sta

fuel ﬁlters resolved the starting difﬁculty, refer to section4.8 for the

rt and run, check the fuel pump; refer to s ection 4.9.

All information subject to change without notice.

Page 80

4.9 FUEL PUMP

To determine if the fuel pump is causing starting difﬁculty, perform the following s

1. Insert a piece of wire through the pump ﬂange drain hole, see Figure 4-3.

Figure 4-3 Fuel Pump Flange Drain Hole Location

2. Crank the engine momentarily and feel for wire vibration.

teps:

[a] If the wire did not vibrate, determine if the drive hub or coupling should be replaced;

refertosection4.9.1.

[b] If the wire did vibrate, check for aerated fuel. Refer to section 4.10.

4.9.1 Drive Hubs and Coupling Replacement

Perform the following steps for drive hub or coupling replacement:

1. Replace the drive hub or co

upling; refer to the appropriate service manual, fuel system

chapter.

2. Test the engine to determine if s tarting has been improved; refer to section 4.9.1.1.

4.9.1.1 Engine Test with Replaced Drive Hubs or Replaced Coupling

To deter mine if r e run the engine.

1. If the engine starts and runs, no further troubleshooting is required. Shut down the engine.

2. If the engine fa

placed drive hubs or coupling resolved starting difﬁculty, attempt to start and

ils to start and run, check for aerated fuel; refer to section 4.10.

All information subject to change without notice.

Page 81

4.10 AERATED FUEL

SERIES 60 DDEC VI TROUBLESHOOTING GUIDE

To determine if aerated fuel is causing starting difﬁculty, perform the following s

teps:

1. Disconnect the fuel line return hose from the ﬁtting located at the fuel t ank; refer to OEM guidelines.

2. Place the opened end of the fuel line into a suitable container.

3. Start the engine.

4. Run the engine at 1000 rpm.

5. Visually check to see if air bubbles are rising to the sur

face of the fuel within the container.

[a] If air bubbles are present, repair is necessary; refer to section 4.10.1.

[b] If air bubbles are not present, check for a restrictive air ﬁlter. Shut down the engine;

refertosection4.11.

4.10.1 Aerated Fuel Resolution

Perform the following steps for aerated fuel resolution:

1. Shut down engine.

2. Tighten all fuel line connections b guidelines.

etween fuel tank and fuel pump; refer to O EM

3. Visually inspect all fuel lines between fuel tank and fuel pump for leaks.

4. Replace damaged components as r

equired; refer to OEM guidelines.

5. Verify aerated fuel resolution; refer to section 4.10.1.1.

4.10.1.1 Test Engine with Aerated Fuel Resolution

Refer to section4.10 for exhaust caution before proceeding. Perform the following steps to determine if aerated fue

1. Attempt to start and run the engine. If the engine starts and runs, no further troubleshooting is required. Shut down the engine.

2. If the engine fails t

l resolution resolved starting difﬁculty:

o start and run, check for a restrictive air ﬁlter; refer to section 4.11.

All information subject to change without notice.

Page 82

4.11 RESTRICTIVE AIR FILTER

To determine if a restrictive air ﬁlter is causing starting difﬁculty, perform the f

ollowing steps:

1. Remove the air ﬁlter element; refer to OEM guidelines.

2. Attempt to start and run the engine.

[a] If the engine starts and runs, no f urther troubleshooting is requir

ed. Shut down the

engine.

[b] If the engine fails to start and run, refer to section 4.11.1.

4.11.1 Air Filter Replacement

Perform the following steps for air ﬁlter replacement

1. Visually inspect the air ﬁlter for clogging and replace as necessary; refer to OEM guidelines.

2. Visually inspect gaskets for deterioratio guidelines.

3. Visually inspect air inlets for restrictions and clean as necessary; refer to OEM guidelines.

4. Verify air ﬁlter replacement; refer to s

ection 4.11.1.1.

n and replace as necessary; refer to OEM

4.11.1.1 Test Engine with Replaced Air Filt

Refer to section 4.11 for the exhaust before proceeding. Perform the following steps to determine if the replaced air ﬁlter resolved starting difﬁculty:

1. Attempt to start and run the e

ngine. If the engine starts and runs, no further troubleshooting

is required. Shut down the engine.

2. If the engine fails to start and run, check compression; refer to section 4.12.

All information subject to change without notice.

Page 83

4.12 LOW COMPRESSION

SERIES 60 DDEC VI TROUBLESHOOTING GUIDE

To determine if low compression is causing starting difﬁculty, perform the followi

ng steps:

1. Perform a cylinder compression test. Refer to section 4.12.1.2.

2. Compare cylinder compression test results to speciﬁcations.

[a] If cylinder pressure is below speciﬁcations; refer to section 4.12

.1.

[b] If cylinder pressure is within speciﬁcations, call Detroit Diesel Customer Support

Center (313-592-5800).

4.12.1 Low Compression Repair

Perform the following steps for low compression repai

1. Remove cylinder head; refer to the appropriate service manual, engine chapter.

2. Inspect the cylinder head for worn or damaged valves; refer to the appropriate service manual, engine chapter.

3. Replace damaged valves; refer to the appropriate service manual, engine chapter.

4. Inspect the cylinder kit components for worn or damaged liners, pistons or piston rings; refer to the appropriate service manual

, engine chapter.

5. Verify repairs made to cylinder head valve(s) or cylinder kit components; refer to section

4.12.1.1.

All information subject to change without notice.

Page 84

4.12 LOW COMPRESSION

4.12.1.1 Test Engine with R epaired Cylinder Head Valve(s), and Cylind er Kit

Perform the following steps to determine if the cylinder head valve and cylinder k

it repair

resolved starting difﬁculty:

1. Attempt to start and run the engine. If the engine starts and runs, no f urther troubleshooting is required. Shut down the engine.

2. If the engine fails to start and run, call the Detroit Diesel Customer Support Center at 313–592–5800.

4.12.1.2 Cylinder Compression Test

Perform the following steps for a compression test on

PERSONAL INJURY

To avoid injury from inhaling engine exhaust, always operate the engine in a well-ventilated area exhaust is toxic.

1. Start and run the engine until norma

l operating temperature is reached. Stop the engine.

a Series 60 Engine:

. Engine

2. Disconnect the batteries.

3. Disconnect the fuel pump feed line from the fuel tank. Place a suitable container under the line to catch the spilling

fuel. Turn the ¼ turn valve off on the outlet ﬁ tting of the

secondary fuel ﬁlter.

4. Disconnect the fuel supply line to the cylinder head. Place a suitable container under the line to catch the spilled f

uel. Disconnect the fuel return line from the doser valve and place

a suitable container under the line to catch the spilled fuel.

All information subject to change without notice.

Page 85

SERIES 60 DDEC VI TROUBLESHOOTING GUIDE

EYE INJURY

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

NOTICE:

All the fuel must be removed from the cylinder head before removing injectors. This prevents the fuel from enterin

gthe cylinder and causing cylinder wall lube oil wash down or a hydrostatic lock at startup.

5. Blow low pressure regulated air no more than 207 kPa (30 psi ) into the inlet ﬁ tting for 20 to 30 seconds or until all the fuel is purged f rom the head.

6. Clean and remove the rocker cover, it is no

t necessary to remove the bottom rocker cover.

If equipped with Jake Brakes r emove the Jake Brake assembly.

7. Remove all the rocker shaft mounting bolts and nut from the front or rear rocker shaft assembly. Using rocker arm lifter (J–

35996–A), see Figure 4-4, lift the assembly straight

up and off of the head and place in a clean area on the bench.

Figure 4-4 Rocker Arm/Sh

aft Assembly Removal/Installation

8. Use tool J-47808 to remove the 4–pin electrical connection from the injector.

9. Disengage the locking tang on the harness plug connection, grasp the connector and gently pul

l it from the socket.

10. Remove the injector hold down clamps.

All information subject to change without notice.

Page 86

4.12 LOW COMPRESSION

NOTICE:

Use extreme care when handling injectors to avoid costly damage by dropping or mishandling. Always install new O-rings when replacing injectors.

11. Remove the three injectors to be tested from the cylinder head.

12. Place the compression test adaptors (J-47373) into the injector holes. It is recommended to have three test adaptors (J-47373) when performing this r

outine.

13. Install the injector hold down clamps and torque hold down bolts to 58-66 N·m (43-49 lb·ft).

14. Carefully remove the shaft from the rocker arm as

sembly by slowly pulling it out of the

assembly. Place the shaft on the bench. Do not disturb the stack-up of the rocker arm sets.

15. Remove the three injector rocker arms and replace with spacers (J–38768–5) .

16. Lubricate the shaft with clean engine o

il. With sleeves in place, carefully reinstall the shaft

through each rocker arm shaft. Make sure cup plug end faces inboard.

17. Install the modiﬁed rocker arm shaft assembly on the head. If the engine is equipped with a Jake Brake®, use non-Jake Brake ro

cker arm shaft bolts 8929129. Torque the three bolts

and the nut to 102-108 N·m (75-80 lb·ft).

NOTE:

Verify that the bolt holes for th

e rocker shafts are clean as not to hydro lock the bolts

causing damage to the cylinder head.

18. Disconnect both connectors at the valve c over for the injectors.

NOTE:

Disconnect both connectors at the valve cover for the injectors.

PERSONAL INJURY

To avoid injury when wor

king on or near an operating engine, wear protective clothing, eye protection, and hearing protection.

All information subject to change without notice.

Page 87

SERIES 60 DDEC VI TROUBLESHOOTING GUIDE

PERSONAL INJURY

To avoid injury from hot surfaces, wear protective gloves, or allow engine to cool before removing any component.

ENGINE EXHAUST

To avoid injury from inhaling engine exhaust, a lways operate the engine in a well-ventilated area. Engine exhaust is toxic.

19. Attach cylinder compression gauge (J–6692–B) to the ﬁrst adaptor. See Figure 4-5.

Figure 4-5 Attach Cylinder Compressi

on Gauge J–6692–B

20. Reconnect the batteries.

21. Crank the engine over using the starter motor 5 compression strokes record the compression reading

on the gauge.

NOTE:

Verify that the batteries voltage does not go low enough to affect engine cranking speed. If the cranking spe

ed is affected then the results will be inaccu rate. If needed connect a

battery charge to main tain battery voltage.

22. The compression reading should be 3102-3793 kPa (450-550 psi) with no two cylinders differingbymo

re than 276 kPa (40 psi). If compression readings are below speciﬁcations,

repeat step 20 to be certain of the reading.

All information subject to change without notice.

Page 88

4.12 LOW COMPRESSION

23. After testing all three cylinders, remove bolts from the modiﬁed rocker arm shaft assembly and, using rocker arm lifter (J–35996), lift the assembly straight up and off the cy

linder

head. Place in a clean area on the bench.

24. Carefully remove the shaft from the rocker arm assembly, remove the three rocker arm sleeves. Replace the three injector rocker arms. Lubricate the sha

ft with clean engine oil

and carefully reinstall through each rocker arm.

25. Remove the injector hold down clamps discard the hold down bolt and remove the compression test adaptors from the cylinder head.

oosen the bolt. Torque the bolt to

35 Nm (26 lb ft) Tighten the bolt an additional 90 degrees.

27. Replace the completed rocker arm shaft assembly on the engine and torque nut and bolts to speciﬁcations torque to 102-108 N•m (75-80 l

b•ft)

28. Repeat steps 4b-26 for the rear 3 cylinders

29. Install upper valve cover, insuring that the bolt hole are clear of dirt and oil as not to damage the lower rocker cover.

30. Check test r esults

All information subject to change without notice.

Page 89

4.13 EXTENDED CRANK TIME

SERIES 60 DDEC VI TROUBLESHOOTING GUIDE

There are no fault codes present and the engine ﬁnally starts after an extended crank

time.

4.13.1 Fuel Level/Leaks Check

Check as follows:

1. Visually inspect fuel tank for proper fuel level; if the tank is low/empty, ﬁll the t ank and verify repair, If fuel level is OK, go to next step.

2. Visually inspect the entire fuel system for leaks and damage. Repair as necessary. If no leaks are found, check fuel pressure. Refer to section 4.13.1.1, “Fuel Pressure Test.”

4.13.1.1 Fuel Pressure Test

Check as follows:

1. Verify that there is ample fuel in the fuel tank; if the tank is low, ﬁll the tank with ultra low sulfur fuel.

2. Remove the supply fuel temperature sending

3. Attach a calibrated fuel gauge capable of reading 0-551 kPa (0-80 psi) to the fuel pump port. Crank-start the engine and record the fuel pressure gauge reading.

unit from the fuel pump.

[a] If the pressure is 0-60 kPa (0-10 psi

) within 20 seconds of cranking, refer to section

4.13.1.2, “No or Low Fuel Pressure Test.”

[b] If pressure is below 420 kPa (61 psi) with the engine running, refer to section

4.13.1.2, “No or Low Fuel Pres

sure Test.”

[c] If pressure is above 490 kPa (71 psi) with the engine running, refer to section

4.13.1.3, “High Fuel Pressure Test.”

4.13.1.2 No or Low Fuel Pressure Te st

Check as follows:

1. Remove the fuel suction line going to the fuel pump.

2. Tee in a vacuum gauge into the pump and the line. Start/Crank the engine over.

3. Is the reading on the

gauge greater than 6-12 in. H

[a] If yes, check the suction line from the fuel pump to the fuel tank for a restriction

(bent, kinked, or internally collapsed). If there is no damage check fuel ﬁlter, get customer appro

val to replace the ﬁlters.

[b] If no, go to step 4.

4. Replace the fuel pressure regulator and retest the fuel pressure. If the fuel pressure is still not within s

pecs, refer to section 4.13.1.4, “Fuel Pump Test.”

All information subject to change without notice.

Page 90

4.13 EXTENDED CRANK TIME

4.13.1.3 High Fuel Pressure Test

Check as follows:

1. Tee in a pressure gauge into the return line after the fuel pressure regulator.

2. Start the engine and m onitor the gauge.

3. Is the pressure reading on the gauge above 3 psi?

[a] If yes, check the fuel return line for damage (kinked, internally collapsed, or bent

closed) If damaged, repair as needed.

[b] If no, replace the fuel pressure regulator.

4.13.1.4 Fuel Pump Test

Check as follows:

1. Remove the fuel pump from the engine.

2. Crank the engine over and visually inspect t

he air compressor shaft.

[a] If air compressor shaft is not turning, verify air compressor operation. Refer t o the

Bendix web site at http:\\www.bendix.com or call the Bendix Technical Assistance Center at 1-800-AIR-BRAKE, (1-800-247

-2725).

[b] If air compressor shaft is turning, replace the fuel pump.

All information subject to change without notice.

Page 91

SERIES 60 DDEC VI TROUBLESHOOTING GUIDE

4.14 CRANK NO START

The engine cranks but does not start.

Check for the following:

□ Low Fuel Level □ Air Inlet and Exhaust Restrictions □ No RPM While Cranking (using DDDL 7.0) □ Low Cranking Speed □ No or Low Fuel Pressure □ Defective Fuel Pump □ High Fuel Pressure □ Engine Timing Off □ Low Compression

4.14.1 Low Fuel Level and Air Inlet and Exhaust Restrictions

Check as follows:

1. Check for low fuel level.

[a] isually inspect fuel tank for proper fuel level; if low/empty, ﬁll the tank and verify

repairs.

[b] If fuel level is acceptable, go to the next step.

2. Check the air inlet and exhaust restrictions.

[a] Visually inspect the air intake and exhaust system for restrictions; if found, repair

as necessary and verify repairs.

[b] If no damage is found, go to No RPM Data Received via DDDL 7.0, refer to section

4.14.2.

4.14.2 No RPM Data Received via DDDL 7.0

Check No RPM data received via DDDL 7. go to Low Cranking Speed, minimum crank speed 80 RPM, refer to section 4.14.3, “Low Cranking Speed”).

1. Disconnect the MCM 120–pin conne

2. Install breakout box J-48475 and use cables J-48583.

3. Measure the resistance between pins 44 and 45 of the MCM 120 pin connector.

0 while cranking (if R PM is present while cranking,

ctor.

[a] If the resistance is less 140

Ω,gotostep4.

[b] If the resistance is greater than 140 Ω,gotostep6.

4. Disconnect the CMP Sensor.

5. Measure the resistanc

All information subject to change without notice.

e between pins 44 and 45 on the breakout box.

Page 92

4.14 CRANK NO START

[a] If the resistance is less than 3 Ω, repair short between MCM pins 42 and 43 the

CMP Sensor.

[b] If the resistance is greater than 3 Ω replace the CMP Sensor.

6. Disconnect the CMP Sensor.

7. Install a jumper wire between pins 1 and 2 on the CMP harness connect

or.

8. Measure the resistance between pins 44 and 45 on the breakout box.

[a] If the resistance is greater than 3 Ω,gotostep9.

[b] If the resistance is less than 3 Ω, replace the CMP Sensor.

9. Measure resistance between pin 44 on the breakout box and pin 1 on the harness side of the CMP connector.

[a] If the resistance is less than 3 Ω, r epair open on wi

re between pins 45 of the MCM

120–pin connector and pin 2 on the CMP connector.

[b] If the resistance is greater than 3 Ω, repair the open wire between pin 44 of the MCM

120–pin connector and pin 1 on the harnes

s side of the CMP connector.

4.14.3 Low Cranking Speed

Start troubleshooting by checking the battery voltage as follows:

1. Check the batteries by removing the surface charge from the batteries.

[a] Turn the ignition OFF.

[b] Turn ON the headlights for two to three minutes.

2. Check the battery voltage.

[a] If the battery voltage is

not below 1 2 volts, refer to section 4.14.3.1, “Battery Cable

Voltage Drop Test.”

[b] If the battery voltage is below 12 volts, charge the batteries then proceed with the

next step.

3. Check the condition of the batteries individually; refer to diagnostics in the OEM manual.

[a] If all the batteries are good, go to the next step.

[b] If the batteries

are not good, replace them and go to the next step.

4. Reconnect the batteries.

5. Start the engine. Does the engine start normally?

[a] If yes, chec

k the charging system diagnostics in the OEM manual.

[b] If no, refer to section 4.14.3.1, “Battery Cable Voltage Drop Test.”

All information subject to change without notice.

Page 93

SERIES 60 DDEC VI TROUBLESHOOTING GUIDE

4.14.3.1 Battery Cable Voltage Drop Test

Check as follows:

1. Disable the engine from starting by disconnecting the MCM 120–pin connector. This allows cranking without starting the engine.

2. Attach a long jumper lead from the battery negative post to the negat

ive lead of the

voltmeter.

3. Connect the positive lead of the voltmeter to the three locations listed below, measuring voltage at each point, one at a time while the starter is crankin

[a] Starter solenoid battery terminal

[b] Starter motor terminal on the starter solenoid

[c] Starter ground terminal

4. Connect the volt meter to the battery positive and negative terminals. Measure voltage when cranking the engine.

5. Compare the battery voltage to reading ta

keninstep4tothevoltagereadingtaken

in step 3.

6. Is there more t hat a one volt difference between the battery voltage ( go to step 4) and the voltage at the battery terminal on

the starter solenoid ( go to step 3[a])?

[a] If yes, repair bad connection or wire between the battery positive terminal and the

battery terminal on the starter solenoid.

[b] If no, go to the next step.

7. Is there more than one volt difference between the batteries and the starter m otor terminal on the starter solenoid?

[a] If yes, refer to the OEM ma

nual for starter diagnostics.

[b] If no, go to the next step.

8. Is there more than one volt difference between the battery negative terminal and the starter ground ter

minal?

[a] If yes, repair bad connection or wire between the battery negative terminal and the

starter ground terminal.

[b] If no, refer to st

All information subject to change without notice.

arter diagnostics in the OEM manual.

Page 94

4.14 CRANK NO START

4.14.4 No or Low Fuel Pressure/Leaks

Visually inspect the entire fuel system for leaks. If leaks are found, repair as nece

ssary. If no leaks

are found, check the fuel pressure. Refer to section 4.14.4.1.

4.14.4.1 Fuel Pressure Test

Test as follo ws:

1. Verify that there is ample fuel in the tanks, if tanks are low ﬁll wit

2. Remove the supply fuel temperature sending unit from the fuel pump.

3. Attach a calibrated gauge capable of reading 0-551 kPa (0-80 psi) to the fuel pump port. Crank or start the engine and record the reading on the g

auge.

[a] If pressure is 0-60 kPa (0-10 psi) within 20 seconds of cranking, refer to section

4.14.4.2, “No or Low Fuel Pressure Test.”

[b] If pressure is below 420 kPa (61 psi) with the e

ngine running, refer to section

4.14.4.2, “No or Low Fuel Pressure Test.”

[c] If pressure is above 490 kPa (71 psi) with the engine running, refer to section

4.14.4.3, “High Fuel Pressure Test.”

[d] If pressure is between 420–490 kPa (61 -71 psi) with the engine running,

refer to section 12.1112.11, “Incorrect Camshaft Timing.”

h Ultra Low Sulfur Fuel.

4.14.4.2 No or Low Fuel Pressure Test

Check as follows:

1. Remove the fuel suction line going to the fuel pump.

2. Tee in a vacuum gauge into the pump and the line. Start/Crank the engine over.

3. Is the reading on the gauge

greater than 6-12 in.H

[a] If yes, check the suction line from the fuel pump to the fuel tank for a restriction

(bent, kinked, or internally collapsed). If there is no damage check fuel ﬁlter, get customer approval to

replace the ﬁlters.

[b] If no, go to step 4.

4. Replace the fuel pressure regulator and r etest the fuel pressure. If the fuel pressure is still not within specs

, refer to section 4.14.4.4, “Fuel Pump Test.”

All information subject to change without notice.

Page 95

SERIES 60 DDEC VI TROUBLESHOOTING GUIDE

4.14.4.3 High Fuel Pressure Test

Check as follows:

1. Tee in a pressure gauge into the return line after the fuel pressure regulator.

2. Start the engine and monitor the gauge.

3. Is the pressure reading on the gauge above 3 psi?

[a] If yes, check the fuel return line for damage (kinked, internally collapsed, or bent

closed) If damaged repair as needed.

[b] If no, replace the Fuel Pressure Regulator.

4.14.4.4 Fuel Pump Test

Check as follows:

1. Remove the fuel pump from the engine.

2. Crank the engine over and visually inspect t

he air compressor shaft.

[a] If air compressor shaft is not turning, verify air compressor operation. Refer to the

Bendix web site at http:\\www.bendix.com or call the Bendix Technical Assistance Center at 1-800-AIR-BRAKE, (1-800-247

-2725).

[b] If air compressor shaft is turning, replace the f uel pump.

4.14.5 Engine Timing

Check Cam timing, refer to section 12.11, “Incorrect Camshaft Timing” in the EPA07 Series 60 Service Manual (6SE2007).

4.14.6 Low Compression

Perform DDDL 7.0 compression test service routine, based on results then perform Manual Compression Test, (refer to section 4.12.1.2).

All information subject to change without notice.

Page 96

4.14 CRANK NO START

All information subject to change without notice.

Page 97

5 NO START - ENGINE WILL NOT ROTATE

Section Page

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

Page 98

All information subject to change without notice.

Page 99

5.1 DISCHARGED BATTERY

SERIES 60 DDEC VI TROUBLESHOOTING GUIDE

To determine if a discharged battery is causing the engine not to start, measure and r

ecord the

voltage at the b attery terminals; refer to OEM guidelines.

1. If the voltage recorded is below OEM speciﬁcations and the engine failed to start, replacement is necessary; refer to section 5.1.1.

2. If the voltage recorded is at recommended OEM speciﬁcations and the engine failed to start, check the magnetic switch; refer to section 5.2.

5.1.1 Discharged Battery Resolution

Perform the following steps for battery replacement:

1. Replace the battery; refer to OEM guidelines.

2. Verify replacement of the battery; refer to section 5.1.1.1.

5.1.1.1 Test Engine with New Battery

To determine if the new battery resolved the

1. If the engine starts and runs, no further troubleshooting is required. Shut down the engine.

2. If the engine fails to start or run, check the magnetic switch; refer to section 5.2.

no start condition, attempt to start and run the engine.

All information subject to change without notice.

Page 100

5.3 DEFECTIVE STARTER

5.2 DEFECTIVE MAGNETIC SWITCH

To determine if a defective magnetic switch is causing no start:

1. Start engine.

2. Clamp a heavy gage battery jumper cable between the two large studs of the magnetic switch; see Figure 5-1.

Figure 5-1 Basic Cranking Circuit

[a] If the engine cranked with the jumper cable in place, the magnetic switch must be

replaced; go to step 3.

[b] If the engine did not crank with the jumper cable in place, check the starter;

refer to section 5.3.

3. Replace the magnetic switch. Refer to OEM guidelines.

4. Verify magnetic switch replacement; refer to section 5.2.1.

5.2.1 Test Engine with New Magnetic Switch

Refer to section 5.2 for exhaust caution before proceeding. To determine if the magnetic switch replacement resolved the no start condition, attempt to start and run the engine.

1. If the engine starts and runs, no further troubleshooting is required. Shut down the engine.

2. If the engine fails to start or run, check the starter; refer to section

All information subject to change without notice.