Diesel Engine, Truck, Heavy Equipment Service Manuals

Detroit Diesel Series 60 DDEC VI Troubleshooting Manual

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Covers: Detroit EPA07 Series 60 DDEC VI Troubleshooting
Pages: 925
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Compatibility: Windows/Mac computers

This manual provides instruction for troubleshooting DDEC VI Series 60 engines. Specifically covered in this manual are troubleshooting and repair steps that apply to DDEC VI.

The following is a list of contains contained in this Detroit Troubleshooting Manual:

1 INTRODUCTION
1.1 OVERVIEW
1.2 SCOPE AND USE OF THIS GUIDE
1.3 SAFETY PRECAUTIONS
2 LOW OIL PRESSURE
2.1 IMPROPER ENGINE OIL LEVEL
2.2 IMPROPER LUBRICATING OIL VISCOSITY
2.3 LUBRICATING OIL DILUTED WITH FUEL OIL OR ENGINE COOLANT
2.4 FAULTY OIL PRESSURE GAUGE SENSOR
2.5 ROCKER ARM SHAFT PLUGS MISSING (NEW OR REBUILT ENGINES ONLY)
2.6 RESTRICTED OIL COOLER
2.7 NONFUNCTIONAL OR STICKING OIL PRESSURE REGULATOR VALVE
2.8 DEFECTIVE BYPASS VALVE
2.9 DEFECTIVE PRESSURE RELIEF VALVE
2.10 DEFECTIVE PICKUP SCREEN TUBE AND SCREEN ASSEMBLY
2.11 DEFECTIVE CRANKSHAFT MAIN BEARING SHELLS
2.12 DEFECTIVE OIL PUMP ASSEMBLY
2.13 DETECTING INTERNAL FUEL LEAKS
3 MISFIRING CYLINDER
3.1 POOR VEHICLE GROUND
3.2 AERATED FUEL
3.3 FAULTY FUEL INJECTOR
3.4 FAULTY MOTOR CONTROL MODULE
3.5 WORN OR DAMAGED VALVE OR CYLINDER KIT
4 STARTING DIFFICULTY – ENGINE ROTATES
4.1 EMPTY FUEL TANK
4.2 LOW BATTERY VOLTAGE
4.3 CORRODED OR DAMAGED BATTERY TERMINALS
4.4 DEFECTIVE MAGNETIC SWITCH
4.5 DEFECTIVE STARTER
4.6 LOW CRANKING SPEED
4.7 FUEL SUPPLY VALVE
4.8 PLUGGED FUEL FILTER(S)
4.9 FUEL PUMP
4.10 AERATED FUEL
4.11 RESTRICTIVE AIR FILTER
4.12 LOW COMPRESSION
4.13 EXTENDED CRANK TIME

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
10.5 IMPROPER VALVE CLEARANCE OR INJECTOR HEIGHT, WORN OR
DAMAGED CAMSHAFT LOBES AND ROLLERS ……………………………. 10-8
10.6 FAULTY FUEL INJECTOR …………………………………………………………….. 10-9
11 ROUGH RUNNING OR STALLING
11.1 LOW BATTERY VOLTAGE ……………………………………………………………. 11-3
11.2 AERATED FUEL ………………………………………………………………………….. 11-4
11.3 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

12 LOW POWER
12.1 FACTORS THAT AFFECT WHEEL HORSEPOWER ………………………… 12-3
12.2 LOW HORSEPOWER INTERVIEW ………………………………………………… 12-6
12.3 AERATED FUEL …………………………………………………………………………. 12-12
12.4 HIGH FUEL PRESSURE ………………………………………………………………. 12-13
12.5 HIGH FUEL TEMPERATURE RETURN ………………………………………….. 12-16
12.6 RESTRICTED AIR CLEANER ELEMENT ……………………………………….. 12-17
12.7 RESTRICTED OR CRACKED CHARGE AIR COOLER OR LEAKING
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
18.2 ENGINE MANUFACTURER DIAGNOSTICS PARAMETER
DESCRIPTIONS ………………………………………………………………………….. 18-4

12 LOW POWER
12.1 FACTORS THAT AFFECT WHEEL HORSEPOWER ………………………… 12-3
12.2 LOW HORSEPOWER INTERVIEW ………………………………………………… 12-6
12.3 AERATED FUEL …………………………………………………………………………. 12-12
12.4 HIGH FUEL PRESSURE ………………………………………………………………. 12-13
12.5 HIGH FUEL TEMPERATURE RETURN ………………………………………….. 12-16
12.6 RESTRICTED AIR CLEANER ELEMENT ……………………………………….. 12-17
12.7 RESTRICTED OR CRACKED CHARGE AIR COOLER OR LEAKING
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
18.2 ENGINE MANUFACTURER DIAGNOSTICS PARAMETER
DESCRIPTIONS ………………………………………………………………………….. 18-4

29 SPN 110— COOLANT TEMPERATURE ABOVE OR BELOW NORMAL
OPERATING RANGE
29.1 SPN 110/FMI 0 …………………………………………………………………………….. 29-3
29.2 SPN 110/FMI 3 …………………………………………………………………………….. 29-3
29.3 SPN 110/FMI 4 …………………………………………………………………………….. 29-6
29.4 SPN 110/FMI 14 …………………………………………………………………………… 29-7
29.5 SPN 110/FMI 16 …………………………………………………………………………… 29-8
30 SPN 111 (CPC) – COOLANT LEVEL OUTSIDE NORMAL OPERATING
RANGE
30.1 SPN 111/FMI 1 …………………………………………………………………………….. 30-3
30.2 SPN 111/FMI 3 …………………………………………………………………………….. 30-5
30.3 SPN 111/FMI 4 …………………………………………………………………………….. 30-7
31 SPN 132 – AIR MASS FLOW NOT NORMAL
31.1 SPN 132/FMI1 ……………………………………………………………………………… 31-3
32 SPN 168 – BATTERY VOLTAGE OUTSIDE NORMAL OPERATING
RANGE
32.1 SPN 168/FMI 0 …………………………………………………………………………….. 32-3
32.2 SPN 168/FMI 1 …………………………………………………………………………….. 32-4
33 SPN 171 (CPC) – J1587 AMBIENT AIR TEMPERATURE SENSOR
DATA NOT RECEIVED
33.1 SPN 171/FMI 9 …………………………………………………………………………….. 33-3
33.2 SPN 171/FMI 14 …………………………………………………………………………… 33-3
34 SPN 174 – SUPPLY FUEL TEMPERATURE FAULT
34.1 SPN 174/FMI 3 …………………………………………………………………………….. 34-3
34.2 SPN 174/FMI 4 …………………………………………………………………………….. 34-5
35 SPN 175 – ENGINE OIL TEMPERATURE OUT OF NORMAL RANGE
35.1 SPN 175/FMI 3 …………………………………………………………………………….. 35-3
35.2 SPN 175/FMI 4 …………………………………………………………………………….. 35-5
35.3 SPN 175/FMI 14 …………………………………………………………………………… 35-5
36 SPN 190 – 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
38 SPN 247 (CPC) – MCM ENGINE HOURS DATA HIGHER OR LOWER
THAN EXPECTED
38.1 SPN 247/FMI 0 …………………………………………………………………………….. 38-3
38.2 SPN 247/FMI 1 …………………………………………………………………………….. 38-3
38.3 SPN 247/FMI 9 …………………………………………………………………………….. 38-4

39 SPN 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
40 SPN 412 – EGR TEMPERATURE IS OUTSIDE OF THE NORMAL
RANGE
40.1 SPN 412/FMI 3 …………………………………………………………………………….. 40-3
40.2 SPN 412/FMI 4 …………………………………………………………………………….. 40-6
40.3 SPN 412/FMI 16 …………………………………………………………………………… 40-8
40.4 SPN 412/FMI 20 …………………………………………………………………………… 40-9
41 SPN 523 (CPC) – TRANSMISSION CURRENT GEAR SIGNAL
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
45 SPN 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
47 SPN 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

49 SPN 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

59 SPN 651 – INJECTOR #1 NEEDLE VALVE NOT OPERATING
NORMALLY
59.1 SPN 651/FMI 14 …………………………………………………………………………… 59-3
60 SPN 652 – INJECTOR #2 NEEDLE VALVE NOT OPERATING
NORMALLY
60.1 SPN 652/FMI 14 …………………………………………………………………………… 60-3
61 SPN 653 – INJECTOR #3 NEEDLE VALVE NOT OPERATING
NORMALLY
61.1 SPN 653/FMI 14 …………………………………………………………………………… 61-3
62 SPN 654 – INJECTOR #4 NEEDLE VALVE NOT OPERATING
NORMALLY
62.1 SPN 654/FMI 14 …………………………………………………………………………… 62-3
63 SPN 655 – INJECTOR #5 NEEDLE VALVE NOT OPERATING
NORMALLY
63.1 SPN 655/FMI 14 …………………………………………………………………………… 63-3
64 SPN 656 – INJECTOR #6 NEEDLE VALVE NOT OPERATING
NORMALLY
64.1 SPN 656/FMI 14 …………………………………………………………………………… 64-3
65 SPN 703 (CPC) – ASG2 BACKUP LAMP
65.1 SPN 703/FMI 3 …………………………………………………………………………….. 65-3
65.2 SPN 703/FMI 4 …………………………………………………………………………….. 65-3
66 SPN 704 (CPC) – HIGH EXHAUST SYSTEM TEMPERATURE LAMP
66.1 SPN 704/FMI 3 …………………………………………………………………………….. 66-3
66.2 SPN 704/FMI 4 …………………………………………………………………………….. 66-3
67 SPN 704 – TURBO ACTUATOR CONTROL (AUX PWM #10)
67.1 SPN 704/FMI 3 …………………………………………………………………………….. 67-3
67.2 SPN 704/FMI 4 …………………………………………………………………………….. 67-4
67.3 SPN 704/FMI 5 …………………………………………………………………………….. 67-5
68 SPN 705 (CPC) – MALFUNCTION INDICATOR LAMP
68.1 SPN 705/FMI 3 …………………………………………………………………………….. 68-3
68.2 SPN 705/FMI 4 …………………………………………………………………………….. 68-3
69 SPN 706 (CPC) – ASG2 CHECK TRANS TEMP LAMP
69.1 SPN 706/FMI 3 …………………………………………………………………………….. 69-3
69.2 SPN 706/FMI 4 …………………………………………………………………………….. 69-3
70 SPN 707 (CPC) – AMBER WARNING LAMP
70.1 SPN 707/FMI 3 …………………………………………………………………………….. 70-3
70.2 SPN 707/FMI 4 …………………………………………………………………………….. 70-3
71 SPN 708 (CPC) – ASG2 CHECK TRANS LAMP
71.1 SPN 708/FMI 3 …………………………………………………………………………….. 71-3
71.2 SPN 708/FMI 4 …………………………………………………………………………….. 71-3

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
78 SPN 904 (CPC) – J1939 EBC2 MESSAGE MISSING AND FRONT
AXLE SPEED SIGNAL ERRATIC OR MISSING
78.1 SPN 904/FMI 9 …………………………………………………………………………….. 78-3
78.2 SPN 904/FMI 13 …………………………………………………………………………… 78-3
78.3 SPN 904/FMI 19 …………………………………………………………………………… 78-4
79 SPN 973 (CPC) – J1939 EBC1 MESSAGE MISSING AND ENGINE
RETARDER SELECTION SIGNAL IS ERRATIC OR MISSSING
79.1 SPN 973/FMI 9 …………………………………………………………………………….. 79-3
79.2 SPN 973/FMI 13 …………………………………………………………………………… 79-3
79.3 SPN 973/FMI 19 …………………………………………………………………………… 79-4
80 SPN 986 (CPC) – J1939 CM1 MESSAGE IS MISSING
80.1 SPN 986/FMI 9 …………………………………………………………………………….. 80-3
81 SPN 1071 – TWO-SPEED FAN (AUX PWM #6) FAULT
81.1 SPN 1071/FMI 3 …………………………………………………………………………… 81-3
81.2 SPN 1071/FMI 4 …………………………………………………………………………… 81-4
81.3 SPN 1071/FMI 5 …………………………………………………………………………… 81-5

82 SPN 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
86 SPN 1624 (CPC) – J1939 TCO1 MESSAGE IS MISSING AND
TACHOGRAPH VEHICLE SPEED SIGNAL IS ERRATIC AND MISSING
86.1 SPN 1624/FMI 9 …………………………………………………………………………… 86-3
86.2 SPN 1624/FMI 13 …………………………………………………………………………. 86-3
86.3 SPN 1624/FMI 19 …………………………………………………………………………. 86-4
87 SPN 1636 – INTAKE AIR TEMPERATURE OUTSIDE OF NORMAL
OPERATING RANGE
87.1 SPN 1636/FMI 3 …………………………………………………………………………… 87-3
87.2 SPN 1636/FMI 4 …………………………………………………………………………… 87-5
87.3 SPN 1636/FMI 20 …………………………………………………………………………. 87-6
87.4 SPN 1636/FMI 21 …………………………………………………………………………. 87-7
87.5 SPN 1636/FMI 31 …………………………………………………………………………. 87-8
88 SPN 1716 (CPC) – J1939 ERC1 MESSAGE IS MISSING
88.1 SPN 1716/FMI 9 …………………………………………………………………………… 88-3
89 SPN 1845 (CPC) – J1939 TCFG2 MESSAGE IS MISSING
89.1 SPN 1845/FMI 9 …………………………………………………………………………… 89-3
90 SPN 2623 (CPC) – PWM ACCELERATOR PEDAL GAS1 AND GAS2 SIGNAL MISSING
90.1 SPN 2623/FMI 4 …………………………………………………………………………… 90-3
90.2 SPN 2623/FMI 14 …………………………………………………………………………. 90-3
91 SPN 2629 – TURBO COMPRESSOR OUT TEMP HIGH OR LOW
91.1 SPN 2629/FMI 3 …………………………………………………………………………… 91-3
91.2 SPN 2629/FMI 4 …………………………………………………………………………… 91-6
91.3 SPN 2629/FMI 20 …………………………………………………………………………. 91-7
91.4 SPN 2629/FMI 21 …………………………………………………………………………. 91-8

92 SPN 2659 – EGR FLOW NOT NORMAL
92.1 SPN 2659/FMI 0 …………………………………………………………………………… 92-3
92.2 SPN 2659/FMI 1 …………………………………………………………………………… 92-4
93 SPN 2791 – EGR VALVE (AUX PWM #1) FAILED OR OPEN CIRCUIT
93.1 SPN 2791/FMI 3 …………………………………………………………………………… 93-3
93.2 SPN 2791/FMI 4 …………………………………………………………………………… 93-4
93.3 SPN 2791/FMI 5 …………………………………………………………………………… 93-4
93.4 SPN 2791/FMI 7 …………………………………………………………………………… 93-6
94 SPN 2795 – CAN COMMUNICATION ERROR
94.1 SPN 2795/FMI 9 …………………………………………………………………………… 94-3
95 SPN 2797 – INJECTOR #1, 2, OR 3 NEEDLE OR SPILL CONTROL
VALVE NOT OPERATING NORMALLY
95.1 SPN 2797/FMI 3 …………………………………………………………………………… 95-3
95.2 SPN 2797/FMI 4 …………………………………………………………………………… 95-4
95.3 SPN 2797/FMI 5 …………………………………………………………………………… 95-6
95.4 SPN 2797/FMI 6 …………………………………………………………………………… 95-7
96 SPN 2798 – INJECTOR #4, 5, OR 6 NEEDLE OR SPILL CONTROL
VALVE NOT OPERATING NORMALLY
96.1 SPN 2798/FMI 3 …………………………………………………………………………… 96-3
96.2 SPN 2798/FMI 4 …………………………………………………………………………… 96-4
96.3 SPN 2798/FMI 5 …………………………………………………………………………… 96-6
96.4 SPN 2798/FMI 6 …………………………………………………………………………… 96-7
97 SPN 2900 (CPC) – J1939 ETC7 MESSAGE IS MISSING
97.1 SPN 2900/FMI 9 …………………………………………………………………………… 97-3
98 SPN 3050 – ENGINE AIR FLOW ABOVE OR BELOW NORMAL
OPERATING RANGE
98.1 SPN 3050 ……………………………………………………………………………………. 98-3
99 SPN 3242 – DOC INLET TEMPERATURE SENSOR ABOVE OR
BELOW NORMAL OPERATING RANGE
99.1 SPN 3242/FMI 2, 3, 4 OR 10 …………………………………………………………. 99-3
100 SPN 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
102 SPN 3251 – DPF OUTLET PRESSURE ABOVE OR BELOW NORMAL
OPERATING RANGE
102.1 SPN 3251/FMI 0, 1 OR 16 …………………………………………………………….. 102-3

103 SPN 3471 – ELECTRONIC DOSING VALVE SENSOR ABOVE OR
BELOW NORMAL OPERATING RANGE
103.1 SPN 3471/FMI 1, 3, 4 OR 5 …………………………………………………………… 103-3
104 SPN 3480 – FUEL LINE PRESSURE SENSOR ABOVE OR BELOW
NORMAL OPERATING RANGE
104.1 SPN 3480/FMI 1, 2 OR 14 …………………………………………………………….. 104-3
105 SPN 3482 – FUEL CUTOFF VALVE SENSOR ABOVE OR BELOW
NORMAL OPERATING RANGE
105.1 SPN 3482/FMI 3, 4, 5 OR 7 …………………………………………………………… 105-3
106 SPN 3509 – MULTIPLEXER 1 CHANNEL 1 OR 2 SHORT OR OPEN
CIRCUIT HIGH
106.1 SPN 3509/FMI 3 …………………………………………………………………………… 106-3
107 SPN 3510 – MULTIPLEXER 2 CHANNEL 1 OR 2 SHORT OR 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
110 SPN 3556 – ELECTRONIC DOSING VALVE ABOVE OR BELOW
NORMAL OPERATING RANGE
110.1 SPN 3556/FMI 0 OR 1 ………………………………………………………………….. 110-3
111 SPN 3563– INTAKE 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

114 SPN 3603 (CPC) – J1939 ESS MESSAGE IS MISSING
114.1 SPN 3603/FMI 9 …………………………………………………………………………… 114-3
115 SPN 3609 – DPF INLET PRESSURE SENSOR ABOVE OR BELOW
NORMAL OPERATING RANGE
115.1 SPN 3609FMI 2, 3, 4, 10, 20 OR 21 ……………………………………………….. 115-3
116 SPN 3610 – DPF OUTLET PRESSURE SENSOR ABOVE OR BELOW
NORMAL OPERATING RANGE
116.1 SPN 3610/FMI 2, 3, 4, 14, 20 OR 21 ………………………………………………. 116-3
117 SPN 3659 – INJECTOR #1 SPILL VALVE NOT OPERATING
NORMALLY
117.1 SPN 3659/FMI 14 …………………………………………………………………………. 117-3
118 SPN 3660 – INJECTOR #2 SPILL VALVE NOT OPERATING
NORMALLY
118.1 SPN 3660/FMI 14 …………………………………………………………………………. 118-3
119 SPN 3661 – INJECTOR #3 SPILL VALVE NOT OPERATING
NORMALLY
119.1 SPN 3661/FMI 14 …………………………………………………………………………. 119-3
120 SPN 3662 – INJECTOR #4 SPILL 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
122 SPN 3664 – INJECTOR #6 SPILL VALVE NOT OPERATING
NORMALLY
122.1 SPN 3664/FMI 14 …………………………………………………………………………. 122-3
123 SPN 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
125 SPN 3798 – PROPORTIONAL VALVE BANK 2 CIRCUIT
125.1 SPN 3798/FMI 4
126 SPN 3720 – ASH LEVEL ABOVE NORMAL
126.1 SPN 3720/FMI 15 OR 16
127 SPN 4077 FUEL LINE PRESSURE SENSOR CIRCUIT FAULT
127.1 SPN 4077/FMI 3, 4 OR 14

128 SPN 4228 – VGT TEMPERATURE WARNING
128.1 SPN 4228/FMI 15
128.2 SPN 4228/FMI 16
129 DDEC VI SCHEMATICS
129.1 CRUISE CONTROL
129.2 FAN CONTROL
129.3 OPTIMIZED IDLE

SVC-MAN-0009 (6SE567)

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