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. This 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. |
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Copyright © 2007 DETROIT DIESEL CORPORATION |
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 same part number or with an equivalent part number. Do not use a replacement part of lesser quality. The service procedures recommended and described in 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 manual 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.
ii |
All information subject to change without notice. |
Copyright © 2007 DETROIT DIESEL CORPORATION |
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 |
2 |
LOW OIL PRESSURE |
|
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 |
2.5ROCKER ARM SHAFT PLUGS MISSING (NEW OR REBUILT ENGINES
ONLY) ...................................................................................................... |
2-7 |
2.6 RESTRICTED OIL COOLER ................................................................... |
2-9 |
2.7NONFUNCTIONAL 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 ROTATES |
|
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 TIME ...................................................................... |
4-19 |
All information subject to change without notice. |
iii |
Copyright © 2007 DETROIT DIESEL CORPORATION |
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 |
WORN OR DAMAGED VALVE OR CYLINDER KIT ................................ |
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 |
WORN OR DAMAGED VALVE OR CYLINDER KIT ................................ |
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 EXHAUST SYSTEM .................................................................. |
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 |
WORN OR DAMAGED VALVE OR CYLINDER KIT ................................ |
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 |
10.5IMPROPER 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 |
INSUFFICIENT 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 |
iv |
All information subject to change without notice. |
Copyright © 2007 DETROIT DIESEL CORPORATION |
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 |
12.7RESTRICTED OR CRACKED CHARGE AIR COOLER OR LEAKING
|
INTAKE 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 DIAGNOSTICS |
|
18.1 |
ENGINE MANUFACTURER DIAGNOSTICS DEFINITIONS ................... |
18-3 |
18.2ENGINE MANUFACTURER DIAGNOSTICS PARAMETER
DESCRIPTIONS ...................................................................................... |
18-4 |
All information subject to change without notice. |
v |
Copyright © 2007 DETROIT DIESEL CORPORATION |
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 |
20SPN 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 |
22SPN 84 (CPC) - J1939 WHEEL-BASED VEHICLE SPEED SIGNAL ERRATIC OR MISSING
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 |
25SPN 94 – FUEL 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 |
vi |
All information subject to change without notice. |
Copyright © 2007 DETROIT DIESEL CORPORATION |
SERIES 60 DDEC VI TROUBLESHOOTING GUIDE
29SPN 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 |
32SPN 168 – BATTERY VOLTAGE OUTSIDE NORMAL OPERATING RANGE
32.1 |
SPN 168/FMI 0 ......................................................................................... |
32-3 |
32.2 |
SPN 168/FMI 1 ......................................................................................... |
32-4 |
33SPN 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 - ENGINE 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 |
38SPN 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. |
vii |
Copyright © 2007 DETROIT DIESEL CORPORATION |
SERIES 60 DDEC VI TROUBLESHOOTING GUIDE
39SPN 411 — EGR DIFFERENTIAL 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 |
40SPN 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 |
|
|
ERRATIC OR MISSING |
|
41.1 |
SPN 523/FMI 19 ....................................................................................... |
41-3 |
41.2 |
SPN 523/FMI 13 ....................................................................................... |
41-3 |
42 |
SPN 524 (CPC) - J1939 ETC2 MESSAGE IS MISSING |
|
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 |
45SPN 596 (CPC) - CRUISE CONTROL ENABLE SWITCH SIGNAL ERRATIC OR MISSING
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 |
47SPN 599 (CPC) - CRUISE CONTROL SWITCHES NOT FUNCTIONING PROPERLY
47.1 |
SPN 599/FMI 4 ......................................................................................... |
47-3 |
48 |
SPN 600 (CPC) - CRUISE CONTROL COAST SWITCH SIGNAL |
|
|
ERRATIC OR MISSING |
|
48.1 |
SPN 600/FMI 13 ....................................................................................... |
48-3 |
48.2 |
SPN 600/FMI 19 ....................................................................................... |
48-3 |
viii |
All information subject to change without notice. |
Copyright © 2007 DETROIT DIESEL CORPORATION |
SERIES 60 DDEC VI TROUBLESHOOTING GUIDE
49SPN 602 (CPC) - CRUISE CONTROL ACCELERATE SWITCH SIGNAL ERRATIC OR MISSING
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. |
ix |
Copyright © 2007 DETROIT DIESEL CORPORATION |
SERIES 60 DDEC VI TROUBLESHOOTING GUIDE
59SPN 651 – INJECTOR #1 NEEDLE VALVE NOT OPERATING NORMALLY
59.1 SPN 651/FMI 14 ....................................................................................... |
59-3 |
60SPN 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 |
62SPN 654 – INJECTOR #4 NEEDLE VALVE NOT OPERATING NORMALLY
62.1 SPN 654/FMI 14 ....................................................................................... |
62-3 |
63SPN 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 |
x |
All information subject to change without notice. |
Copyright © 2007 DETROIT DIESEL CORPORATION |
|
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 SHUTDOWN |
|
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 |
78SPN 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. |
xi |
Copyright © 2007 DETROIT DIESEL CORPORATION |
SERIES 60 DDEC VI TROUBLESHOOTING GUIDE
82SPN 1072 – JAKE BRAKES STAGE 1 (AUX PWM #7) OPEN OR 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 |
SPN 1172 -TURBO COMPRESSOR IN TEMP HIGH OR LOW |
|
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 |
86SPN 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 |
87SPN 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 |
90SPN 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 |
xii |
All information subject to change without notice. |
Copyright © 2007 DETROIT DIESEL CORPORATION |
|
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 |
95SPN 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 - ENGINE AIR FLOW ABOVE OR BELOW NORMAL |
|
|
OPERATING RANGE |
|
98.1 |
SPN 3050 ................................................................................................. |
98-3 |
99SPN 3242 - DOC INLET TEMPERATURE SENSOR ABOVE OR BELOW NORMAL OPERATING RANGE
99.1 SPN 3242/FMI 2, 3, 4 OR 10 ................................................................... |
99-3 |
100SPN 3246 - DPF OUTLET TEMPERATURE SENSOR OPERATING 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 OPERATING RANGE
101.1 SPN 3250/FMI 0, 2, 3, 4, 10, 14, 31 ......................................................... |
101-3 |
102SPN 3251 - DPF OUTLET PRESSURE ABOVE OR BELOW NORMAL OPERATING RANGE
102.1 SPN 3251/FMI 0, 1 OR 16 ....................................................................... |
102-3 |
All information subject to change without notice. |
xiii |
Copyright © 2007 DETROIT DIESEL CORPORATION |
SERIES 60 DDEC VI TROUBLESHOOTING GUIDE
103SPN 3471 - ELECTRONIC DOSING VALVE SENSOR ABOVE OR BELOW NORMAL OPERATING RANGE
103.1 SPN 3471/FMI 1, 3, 4 OR 5 ..................................................................... |
103-3 |
104SPN 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 3482/FMI 3, 4, 5 OR 7 ..................................................................... |
105-3 |
106SPN 3509 - MULTIPLEXER 1 CHANNEL 1 OR 2 SHORT OR OPEN CIRCUIT HIGH
106.1 SPN 3509/FMI 3 ....................................................................................... |
106-3 |
107SPN 3510 - MULTIPLEXER 2 CHANNEL 1 OR 2 SHORT OR OPEN 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 |
110SPN 3556 - ELECTRONIC DOSING VALVE ABOVE OR BELOW NORMAL OPERATING RANGE
110.1 SPN 3556/FMI 0 OR 1 ............................................................................. |
110-3 |
111SPN 3563– INTAKE MANIFOLD 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 - ETHER START (LOW-SIDE 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 3597/FMI 3 ....................................................................................... |
113-3 |
xiv |
All information subject to change without notice. |
Copyright © 2007 DETROIT DIESEL CORPORATION |
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 |
116SPN 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 |
117SPN 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 |
119SPN 3661 - INJECTOR #3 SPILL VALVE NOT OPERATING NORMALLY
119.1 SPN 3661/FMI 14 ..................................................................................... |
119-3 |
120SPN 3662 - INJECTOR #4 SPILL VALVE 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 |
122SPN 3664 - INJECTOR #6 SPILL VALVE NOT OPERATING NORMALLY
122.1 SPN 3664/FMI 14 ..................................................................................... |
122-3 |
123SPN 3695 (CPC) - DPF REGEN 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/FMI 0, 15,16,OR 31 ................................................................ |
124-3 |
125 |
SPN 3798 - PROPORTIONAL VALVE BANK 2 CIRCUIT |
|
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 4077/FMI 3, 4 OR 14 ....................................................................... |
127-3 |
All information subject to change without notice. |
xv |
Copyright © 2007 DETROIT DIESEL CORPORATION |
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 |
xvi |
All information subject to change without notice. |
Copyright © 2007 DETROIT DIESEL CORPORATION |
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 |
1-2 |
All information subject to change without notice. |
Copyright © 2007 DETROIT DIESEL CORPORATION |
SERIES 60 DDEC VI TROUBLESHOOTING GUIDE
1.1OVERVIEW
Detroit Diesel Corporation is the world leader in diesel engines and diesel engine electronics. 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 standard 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 devices.
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.
All information subject to change without notice. |
1-3 |
Copyright © 2007 DETROIT DIESEL CORPORATION |
1.2SCOPE AND USE OF THIS GUIDE
1.2SCOPE AND USE OF THIS GUIDE
The first half of the manual contain mechanical troubleshooting procedures. The second 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 chapter.
Information can be located by 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" indicate 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 for 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.accessfreightliner.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 Diesel Customer Support Center at (313) 592–5800. Once you 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 you to stay on track.
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 resolution. The mechanical troubleshooting should be used before the electronic troubleshooting.
1-4 |
All information subject to change without notice. |
Copyright © 2007 DETROIT DIESEL CORPORATION |
SERIES 60 DDEC VI TROUBLESHOOTING GUIDE
1.2.2Electronic 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 the open. It may be that the best repair technique is to replace a complete harness. The technician should make the determination of the proper repair, with the best interest of the customer in mind.
Instructions to check terminals and connectors should include checking 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 mostly concerned with DDEC related codes. Codes associated with other components, e.g. transmissions, ECUs, ABS, etc. can be found in the related publication.
All information subject to change without notice. |
1-5 |
Copyright © 2007 DETROIT DIESEL CORPORATION |
1.3SAFETY PRECAUTIONS
1.3SAFETY PRECAUTIONS
The following safety precautions must be observed when working on a Detroit Diesel engine:
PERSONAL INJURY
To avoid injury from accidental engine startup while servicing the engine, disconnect/disable the starting system.
All engine installations, especially those within enclosed 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 the air starter system before disconnecting the air supply hose.
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All information subject to change without notice. |
Copyright © 2007 DETROIT DIESEL CORPORATION |
SERIES 60 DDEC VI TROUBLESHOOTING GUIDE
1.3.1Ether Start
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 hardware.
FIRE AND TOXICITY
Some pressurized fluid may be trapped in the system. To avoid personal injury, loosen all connections slowly to avoid contact with fluid. When required, spray fluid into a proper container. The engine starting fluid used in DDEC 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 container. The engine starting fluid used in DDEC Ether Start Systems contains extremely flammable and toxic substances.
All information subject to change without notice. |
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Copyright © 2007 DETROIT DIESEL CORPORATION |
1.3SAFETY PRECAUTIONS
1.3.2Exhaust (Start/Run Engine)
Before starting and running an engine, adhere to the following safety precautions:
PERSONAL INJURY
To avoid injury before starting and running the engine, ensure the vehicle is parked on a level surface, parking brake is set, and the wheels are blocked.
1.3.3Glasses
Select appropriate safety glasses for the job. It is especially 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 compressed air, wear adequate eye protection (face shield or safety goggles) and do not exceed 276 kPa (40 psi) air pressure.
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All information subject to change without notice. |
Copyright © 2007 DETROIT DIESEL CORPORATION |
SERIES 60 DDEC VI TROUBLESHOOTING GUIDE
1.3.4Welding
Wear welding goggles and gloves when welding or using an acetylene torch. Ensure that a metal 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 and 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 restraining 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. |
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Copyright © 2007 DETROIT DIESEL CORPORATION |
1.3SAFETY PRECAUTIONS
FIRE
To avoid injury from fire, check for fuel or oil leaks before welding or 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 infect a minor cut or opening in the skin. If 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.
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.
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All information subject to change without notice. |
Copyright © 2007 DETROIT DIESEL CORPORATION |
SERIES 60 DDEC VI TROUBLESHOOTING GUIDE
1.3.6Fuel
Keep the hose and nozzle or the funnel and container in contact with the metal of the fuel tank 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 involved in servicing away from the engine.
□Stop the engine immediately if a fuel leak is detected.
□Do not smoke or allow open flames when working 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.
All information subject to change without notice. |
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Copyright © 2007 DETROIT DIESEL CORPORATION |
1.3SAFETY PRECAUTIONS
FIRE
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
Electrical storage batteries emit highly flammable hydrogen gas when charging and continue to do so for some time after receiving a steady charge.
BATTERY EXPLOSION AND ACID BURN
To avoid injury from battery explosion or contact with 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 baking soda or lime to help neutralize the acid.
□Flush your eyes with water.
□Get medical attention immediately.
Always disconnect the battery cable before working on the electrical system.
PERSONAL INJURY
To avoid injury from accidental engine startup while servicing the engine, disconnect/disable the starting system.
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All information subject to change without notice. |
Copyright © 2007 DETROIT DIESEL CORPORATION |
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