Detroit Series 60 DDEC V Troubleshooting Manual

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Covers: Detroit Series 60 DDEC V Troubleshooting & Diagnostics
Pages: 751
Format: PDF files (zipped)
File size: 33mb
Compatibility: Windows/Mac computers

This troubleshooting manual describes procedures to diagnose the Detroit Series 60 engine with DDEC V (5) electronic controls. In this manual you will find detailed step-by-step instructions and accurate illustrations to aid with troubleshooting the Series 60 DDEC V engine. View the manual on your computer or print off pages as needed.

Topics in the Detroit Series 60 DDEC V Troubleshooting Manual:

Series 60 DDEC V Troubleshooting
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 Oil Pressure Gauge Line Obstructed
2.6 Rocker Arm Shaft Plugs Missing (New or Rebuilt Engines Only)
2.7 Restricted Oil Cooler
2.8 Nonfunctional or Sticking Oil Pressure Regulator Valve
2.9 Defective Bypass Valve
2.10 Defective Pressure Relief Valve
2.11 Defective Pickup Screen Tube and Screen Assembly
2.12 Defective Crankshaft Main Bearing Shells
2.13 Defective Oil Pump Assembly
2.14 Detecting Internal Fuel Leaks
3 Misfiring Cylinder
3.1 Poor Vehicle Ground
3.2 Aerated Fuel
3.3 Faulty Fuel Injector
3.4 Faulty Electronic Control Unit
3.5 Worn or Damaged Valve or Cylinder Kit
4 Starting Difficulty (Engine Rotates)
4.1 Electronic Control Unit Wiring Harness
4.2 Empty Fuel Tank
4.3 Low Battery Voltage
4.4 Corroded or Damaged Battery Terminals
4.5 Defective Magnetic Switch
4.6 Defective Starter
4.7 Low Cranking Speed
4.8 Fuel Supply Valve
4.9 Plugged Fuel Filter(S)
4.10 Fuel Pump
4.11 Aerated Fuel
4.12 Restrictive Air Filter
4.13 Low Compression
5 No Start (Engine Will Not Rotate)
5.1 Discharged Battery
5.2 Defective Magnetic Switch
5.3 Defective Starter
5.4 Internal Engine Damage
6 Excessive Oil Consumption
6.1 Miscalibrated Dipstick
6.2 External Oil Leaks
6.3 Leaking Oil Cooler Core
6.4 Defective Air Compressor
6.5 Defective Turbocharger
6.6 Worn or Damaged Valve or Cylinder Kit
7 Excessive Crankcase Pressure
7.1 Obstruction or Damage to Rocker Cover Breather
7.2 Defective Air Compressor
7.3 Defective Turbocharger
7.4 Worn or Damaged Valve or Cylinder Kit
8 Excessive Exhaust Smoke (Black or Gray)
8.1 Improper Grade of Fuel Oil
8.2 Restricted Air Cleaner Element
8.3 Restricted or Cracked Charge Air Cooler
8.4 Faulty Exhaust System
8.5 Faulty Fuel Injector
8.6 Defective Turbocharger
9 Excessive Blue Smoke
9.1 Defective Turbocharger
9.2 Worn or Damaged Valve or Cylinder Kit
10 Excessive White Smoke
10.1 Improper Grade of Fuel
10.2 Defective Fuel Pump
10.3 Aerated Fuel
10.4 Improper Injector Calibration Setting (DDEC V Engines Only)
10.5 Improper Valve Clearance or Injector Height, Worn or Damaged Camshaft Lobes and Rollers
10.6 Faulty Fuel Injector
10.7 Faulty Electronic Control Unit
11 Rough Running or Stalling
11.1 Low Battery Voltage
11.2 Aerated Fuel Oil
11.3 Insufficient Fuel Oil Flow
11.4 High Fuel Oil Temperature Return
11.5 Improper Injector Calibration Setting (DDEC V Engines Only)
11.6 Low Compression Pressure
12 Low Power Concern
12.1 Factors That Affect Wheel Horsepower
12.2 Low Horsepower Interview
12.3 Aerated Fuel
12.4 High Fuel Pressure
12.5 High Fuel Temperature Return
12.6 Restricted Air Cleaner Element
12.7 Restricted or Cracked Charge Air Cooler or Leaking Intake Manifold
12.8 Faulty Exhaust System
12.9 High Inlet Air Temperature
12.10 High Altitude Operation
12.11 Incorrect Camshaft Timing
12.12 Verification of Power With Chassis Dynamometer
13 High Engine Coolant Temperature
13.1 Improper Engine Coolant Level
13.2 Insufficient Radiator Air Circulation
13.3 Faulty Pressure Control Cap
13.4 Defective Coolant Hoses
13.5 Fan Belts Are Incorrectly Adjusted
13.6 Inoperative Thermo-Modulated Fan
13.7 Faulty Thermostats
13.8 Faulty Water Pump
13.9 Combustion Gases in Coolant
13.10 Abnormal Radiator Coolant Flow
14 Low Coolant Temperature
14.1 Faulty Thermostats
15 Poor Fuel Economy
15.1 Software Version
16 Air Compressor
16.1 Air Compressor Troubleshooting
17 DDEC System
17.1 DDEC System–How It Works
17.2 Connectors
17.3 Wires and Wiring
17.4 Conduit and Loom
17.5 Tape and Taping
18 Diagnostic Codes
18.1 DDEC Diagnostic Codes
18.2 Reading the Diagnostic Codes
18.3 First Step for Diagnosing a Fault Within the DDEC System
18.4 Code Descriptions
19 Basic Knowledge Required / Testing / Service Tools
19.1 Basic Knowledge Required
19.2 Before Troubleshooting
19.3 Servicing DDEC Connectors
19.4 Service Tools
19.5 Diagnostic and Reprogramming Tools
19.6 Explanation of Abbreviations and Terms
20 Intermittent Fault
20.1 Intermittent Code or a Symptom and No Codes
20.2 Engine Cranks But Will Not Start
20.3 Erratic Performance and No Codes
20.4 Amber Warning Lamp and Red Stop Lamp Fault
20.5 No Data to Diagnostic Data Reader
20.6 Diagnostic Request Switch Inoperative
20.7 Cruise Control Inoperative
20.8 Fan Operational Concern (On/Off Type)
20.9 Fan Operational Concern (Variable Speed Type)
20.10 Engine Brake Inoperative
20.11 Miscellaneous Digital Input Fault
20.12 Miscellaneous Digital Output Fault
20.13 Fire Truck Pressure Governor Fault
20.14 Troubleshooting Electronic Fire Commander
20.15 Optimized Idle Feature Does Not Function
20.16 Transmission Interface Fault
20.17 Maintenance Alert System
20.18 Exhaust Gas Recirculation System Basic Checks for Series 60 Engines
21 Flash Code 11 – VSG Voltage Low
21.1 Description of Flash Code 11
21.2 Troubleshooting Flash Code 11, PID 187/FMI 4
22 Flash Code 12 – VSG High
22.1 Description of Flash Code 12
22.2 Troubleshooting Flash Code 12, PID 187/FMI 3
23 Flash Code 13 – CLS/ECL Sensor Voltage Low/EGR Valve High
23.1 Description of Flash Code 13
23.2 Troubleshooting Flash Code 13, PID 111/FMI 4
23.3 Troubleshooting Flash Code 13, PID 111/FMI 6
23.4 Troubleshooting Flash Code 13, PID 146/FMI 6
24 Flash Code 14 – Coolant or Oil Temp Sensor High
24.1 Description of Flash Code 14
24.2 Troubleshooting Flash Code 14, PID 110/FMI 3
24.3 Troubleshooting Flash Code 14, PID 175/FMI 3
25 Flash Code 15 – Coolant or Oil Temp Sensor Low
25.1 Description of Flash Code 15
25.2 Troubleshooting Flash Code 15, PID 110/FMI 4
25.3 Troubleshooting Flash Code 15, PID 175/FMI 4
26 Flash Code 16 – CLS/ECL Sensor Voltage High
26.1 Description of Flash Code 16
26.2 Troubleshooting Flash Code 16, PID 111/FMI 3
26.3 Troubleshooting Flash Code 16, PID 111/FMI 5
26.4 Troubleshooting Flash Code 13, PID 146/FMI 5
27 Flash Code 21 – TPS/AP Sensor High
27.1 Description of Flash Code 21
27.2 Troubleshooting Flash Code 21, PID 91/FMI 3
28 Flash Code 22 – TPS/AP Sensor Low
28.1 Description of Flash Code 22
28.2 Troubleshooting Flash Code 22, PID 91/FMI 4
29 Flash Code 23 – Supply Fuel Temp Sensor High
29.1 Description of Flash Code 23
29.2 Troubleshooting Flash Code 23, PID 174/FMI 3
30 Flash Code 24 – Supply Fuel Temp Sensor Low
30.1 Description of Flash Code 24
30.2 Troubleshooting Flash Code 24, PID 174/FMI 4
31 Flash Code 26 – Auxiliary Shutdown Active
31.1 Description of Flash Code 26
31.2 Troubleshooting Flash Code 26, SID 25, 61/FMI 11
32 Flash Code 27 – Intake Air Temp Sensor High
32.1 Description of Flash Code 27
32.2 Troubleshooting Flash Code 27, PID 172/FMI 3
33 Flash Code 28 – Intake Air Temp Sensor Low
33.1 Description of Flash Code 28
33.2 Troubleshooting Flash Code 28, PID 172/FMI 4
34 Flash Code 29 – TCI / TCO Temperature Low
34.1 Description of Flash Code 29
34.2 Troubleshooting Flash Code 29, PID 351/FMI 4
34.3 Troubleshooting Flash Code 29, PID 404/FMI 4
35 Flash Code 31 – Engine Brake Fault or Auxiliary Output #12–17
35.1 Description of Flash Code 31
35.2 Troubleshooting Flash Code 31, SID 51, 52/FMI 3, 4
35.3 Troubleshooting Flash Code 31, Sid260, 261, 262, 263, 264, 265/FMI 3, 4
36 Flash Code 32 – CEL/AWL / SEL/RSL Fault
36.1 Description of Flash Code 32
36.2 Troubleshooting Flash Code 32, SID 238, 239/FMI 3, 4
37 Flash Code 33 – TBS/IMP Sensor High
37.1 Description of Flash Code 33
37.2 Troubleshooting Flash Code 33, PID 102/FMI 3
38 Flash Code 34 – TBS/IMP Sensor Low
38.1 Description of Flash Code 34
38.2 Troubleshooting Flash Code 34, PID 102/FMI 4
39 Flash Code 35 – OPS/EOP Sensor High
39.1 Description of Flash Code 35
39.2 Troubleshooting Flash Code 35, PID 100/FMI 3
40 Flash Code 36 – OPS/EOP Sensor Low
40.1 Description of Flash Code 36
40.2 Troubleshooting Flash Code 36, PID 100/FMI 4
41 Flash Code 37 – FRS/Fuel Restriction Sensor Voltage High
41.1 Description of Flash Code 37
41.2 Troubleshooting Flash Code 37, PID 95/FMI 3
42 Flash Code 38 – FRS/Fuel Restriction Sensor Voltage Low
42.1 Description of Flash Code 38
42.2 Troubleshooting Flash Code 38, PID 95/FMI 4
43 Flash Code 39 – EGR Valve / VNT Vane Fault
43.1 Description of Flash Code 39
43.2 Troubleshooting Flash Code 39, SID 147/FMI 12
43.3 Troubleshooting Flash Code 39, SID 146, 147/FMI 2, 12, 7, 14, 11
44 Flash Code 41 – Missing TRS/CKP Pulses or Extra SRS/CMP Pulses
44.1 Description of Flash Code 41
44.2 Troubleshooting Flash Code 41, SID 21/FMI 0
45 Flash Code 42 – Missing SRS/CMP Pulses or Extra TRS/CKP Pulses
45.1 Description of Flash Code 42
45.2 Troubleshooting Flash Code 42, SID 21/FMI 1
46 Flash Code 43 – Coolant Level Low
46.1 Description of Flash Code 43, PID 111/Fmi1
46.2 Troubleshooting Flash Code 43, PID 111/Fmi1
47 Flash Code 44 – Coolant or Oil Temp High
47.1 Description of Flash Code 44
47.2 Troubleshooting Flash Code 44, PID 105, 110, 172, 175/FMI 0, 14
48 Flash Code 45 – Engine Oil Pressure Low
48.1 Description of Flash Code 45
48.2 Troubleshooting Flash Code 45. PID 100/FMI 1
49 Flash Code 46 – Battery Voltage Low
49.1 Description of Flash Code 46
49.2 Troubleshooting Flash Code 46, PID 168/FMI 1
50 Flash Code 47 – Air / Fuel Pressure High
50.1 Description of Flash Code 47
50.2 Troubleshooting Flash Code 47, PID 106, 102/FMI 0
51 Flash Code 48 – Air / Fuel / EGR Pressure Low or EGR / TCI / TCO Temperature Low
51.1 Description of Flash Code 48
51.2 Troubleshooting Flash Code 48, PID 94, 412, 411, 351, 404/FMI 1
52 Flash Code 49 – TCO or TCI Temperature High
52.1 Description of Flash Code 49
52.2 Troubleshooting Flash Code 49, PID 351, 404/FMI 0, 14
53 Flash Code 51 – TCO or TCI Temperature Circuit Failed High
53.1 Description of Flash Code 51
53.2 Troubleshooting Flash Code 51, PID 351/FMI 3
53.3 Troubleshooting Flash Code 51, PID 404/FMI 3
54 Flash Code 52 – ECM/ECU Fault
54.1 Description of Flash Code 52
54.2 Troubleshooting Flash Code 52, SID 254/FMI 12
55 Flash Code 53 – ECM/ECU Memory Fault
55.1 Description of Flash Code 53
55.2 Troubleshooting Flash Code 53, PID 253/FMI 12/2
56 Flash Code 54 – VSS Fault
56.1 Description of Flash Code 54
56.2 Troubleshooting Flash Code 54, PID 84/FMI 12
57 Flash Code 55 – J1939 Data Link Fault
57.1 Description of Flash Code 55
57.2 Troubleshooting Flash Code 55, SID 231/216/FMI 12/14
58 Flash Code 56 – J1587 Data Link Fault
58.1 Description of Flash Code 56
58.2 Troubleshooting Flash Code 56, SID 250/Fmi12
59 Flash Code 58 — Cruise Control Input Fault
59.1 Description of Flash Code 58
59.2 Troubleshooting Flash Code 58
60 Flash Code 61 – Injector Response Long
60.1 Description of Flash Code 61
60.2 Troubleshooting Flash Code 61, SID 1/2/3/4/5/6/FMI 0
61 Flash Code 62 – Auxilary Output #1, #2, #5–11 Fault
61.1 Description of Flash Code 62
61.2 Troubleshooting Flash Code 62, SID 26, 40, 53, 54, 55, 56, 257, 258, 259/FMI 3, 4
62 Flash Code 63 – PWM Fault
62.1 Description of Flash Code 63
62.2 Troubleshooting Flash Code 63, SID 57–60/FMI 0/1/3/4/7
63 Flash Code 64, Turbo Speed
63.1 Description of Flash Code 64
63.2 Troubleshooting Flash Code 64, PID 103/FMI 8/0
64 Flash Code 65 – Air Filter Restriction Input Voltage High or Low
64.1 Description of Flash Code 65
64.2 Troubleshooting Flash Code 65, PID 107/FMI 3
64.3 Troubleshooting Flash Code 65, PID 107/FMI 4
65 Flash Code 66
65.1 Description of Flash Code 66, PID 99/FMI 3/4
66 Flash Code 68 – Idle Validation Fault
66.1 Description of Flash Code 68
66.2 Troubleshooting Flash Code 68, SID 230/FMI 5/6
67 Flash Code 71 – Injector Response Short
67.1 Description of Flash Code 71
67.2 Troubleshooting Flash Code 71, SID 1/2/3/4/5/6/FMI 0
68 Flash Code 72 – Vehicle Overspeed
68.1 Description of Flash Code 72
68.2 Troubleshooting Flash Code 72, PID 84/FMI 0/11
69 Flash Code 73 — Air Filter Restriction High
69.1 Description of Flash Code 73
69.2 Troubleshooting Flash Code 73, PID 107/FMI 0
70 Flash Code 74 — OI Safety Loop
70.1 Description of Flash Code 74
70.2 Troubleshooting Flash Code 74, PID 70/FMI 4
71 Flash Code 75 – Battery Volt High
71.1 Description of Flash Code 75
71.2 Troubleshooting Flash Code 75
72 Flash Code 77 – Exhaust Back Pressure Fault and Several Information Codes
72.1 Description of Flash Code 77
72.2 Troubleshooting Flash Code 77, PID 81, FMI 3
72.3 Troubleshooting Flash Code 77, PID 81, FMI 4
73 Flash Code 81 – Oil Level or Exhaust Temp Circuit Failed High
73.1 Description of Flash Code 81
73.2 Troubleshooting Flash Code 81, PID 411/FMI 3
73.3 Troubleshooting Flash Code 81, PID 412/FMI 3
73.4 Troubleshooting Flash Code 81, PID 98/FMI 3
73.5 Troubleshooting Flash Code 81, PID 173/FMI 3
74 Flash Code 82 – Oil Level or Exhaust Temp Circuit Failed Low
74.1 Description of Flash Code 82
74.2 Troubleshooting Flash Code 82, PID 411/FMI 4
74.3 Troubleshooting Flash Code 82, PID 412/FMI 4
74.4 Troubleshooting Flash Code 82, PID 98/FMI 4
74.5 Troubleshooting Flash Code 82, PID 173/FMI 4
75 Flash Code 83 – EGR Temp or EGR Delta-Pressure
75.1 Description of Flash Code 83
75.2 Troubleshooting Flash Code 83, PID 411/FMI 0
75.3 Troubleshooting Flash Code 83, PID 412/FMI 0
76 Flash Code 86 – PSG Sensor High
76.1 Description of Flash Code 86, PID 73, 108/FMI 3
76.2 Troubleshooting Flash Code 86, PID 73, 108/FMI 3
77 Flash Code 87 – PSG Sensor Low
77.1 Description of Flash Code 87, PID 73/FMI 4
77.2 Troubleshooting Flash Code 87, PID 73/FMI 4
78 Flash Code 89 – AECL Sensor Fault or Fuel Inlet Restriction High
78.1 Description of Flash Code 89, PID 111/FMI 12 & PID 95/FMI 0
78.2 Troubleshooting Flash Code 89, PID 111/12
78.3 Troubleshooting Flash Code 89, PID 95/FMI 0
79 Engine Harness
79.1 Troubleshooting the Engine Harness
80 Vehicle Interface Harness
80.1 Troubleshooting the Vehicle Interface Harness +5 Volt Supply
81 Engine Wiring Schematics
81.1 Engine Harness
81.2 Injector Harness Wiring Schematic
81.3 EGR Temperature Sensor, Delta P Sensor, Temperature Sensors, Pressure Sensors, and Speed Sensors Schematics
81.4 VPOD, Injector, and MAS Schematic
81.5 VPOD, Coolant, Oil Temperature, EGR, and VNT VPOD Schematic
82 Vehicle Wiring Schematics
82.1 Vehicle Interface Harness
82.2 Cruise Control
82.3 Electronic Fire Commander
82.4 Ether Start
82.5 Optimized Idle
82.6 Pressure Sensor Governor
83 DDEC Pro-Link/DDR Operation
83.1 DDEC Pro-Link Operation
83.2 Diagnostic Codes
83.3 Cylinder Cutout Sequence
83.4 Injector Calibration Update
83.5 Reprogram Calibration
83.6 Snapshot Sequence
83.7 Print Function

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