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 1MCM/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.
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.
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.
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, today’s technicians must become
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.
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.
1.2.1Mechanical 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
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.
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
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.
1.3.3Glasses
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.
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
Toavoidinjury fromarc welding,gaswelding,or
cutting, wear required safety equipment such as an arc
welder’s face plate or gas welder ’s goggles, welding
gloves,protectiveapron,longsleeveshirt,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
To avoid injury from fire, check for fuel or oil leaks before
welding o r carrying an open flame near the engine.
1.3.5Pressurized 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.
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
To avoid injury from fire, contain and eliminate leaks of
flammable fluids as they occur. Failure to eliminate leaks
could result in fire.
1.3.7Batteries
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 theengine,disconne
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.
1.3.9Cleaning 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.
1.3.10Diagnostic 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
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.
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.
al
1.3.13Fluoroelastomer
Fluoroelastomer (Viton®) parts such a
normal design conditions.
Toavoidinjuryfromchemicalbur
shield andneoprene orPVC gloveswhen 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
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.
2.2.1Lubricating 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.
2.2.1.1Test 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.
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.
2.6.1Oil 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.
2.6.1.1Test 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
2.7NONFUNCTIONAL OR STICKING OIL PRESSURE REGULATOR VALVE
2.7NONFUNCTIONAL 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
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.
2.9.1Pressure 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
2.9.1.1Test 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
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.
2.13.1Prepare 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”.
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.
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 2-2Acceptable-Fuel Leakage Between injector Plunger and Body
2.13.1.2Fuel 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
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 notuse unregulatedair pressureor 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
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
e
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 2-3Unacceptable-Fuel Leakage at Low Pressure Body Plug
Figure 2-6Unacceptable-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.
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.
3.3.1Faulty 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.
3.3.1.1Verification 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
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.
2
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.
2
O); perform a cylinder
2
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).
3.5.1Worn 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.
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 3-1Rocker 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
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.
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.
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 4-1Basic 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.
4.4.1Magnetic Switch Replacement
Replace the magnetic switch; refer to OEM guidelines then verify magnetic switch replacement;
refer to section 4.4.1.1
4.4.1.1Test 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.
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.
4.11.1Air 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
4.11.1.1Test Engine with Replaced Air Filt
er
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.
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 4-4Rocker 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
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.
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.
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 oil as not to
damage the lower rocker cover.
There are no fault codes present and the engine finally starts after an extended crank
time.
4.13.1Fuel 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.”
4.13.1.1Fuel 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.”
4.13.1.2No 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.”
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
g.
[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
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 5-1Basic 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.
5.2.1Test 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