Detroit Diesel Series 60 DDEC VI Troubleshooting Manual Download Page 16 | Manualshive

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1.2

SCOPE AND USE OF THIS GUIDE

1.2

SCOPE AND USE OF THIS GUIDE

The

fi

rst 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

fi

ll 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.

1.2.1

Mechanical Troubleshooting

Each chapter has a fault as the title (i.e. Excessive White Smoke). The next level within the
chapter is the probable cause/symptom of the fault. Following this are the resolution and
veri

fi

cation of the resolution. The mechanical troubleshooting should be used before the

electronic troubleshooting.

All information subject to change without notice.

1-4

PRELIMINARY 6SE567 0512

Copyright © 2005 DETROIT DIESEL CORPORATION

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Summary of Contents for Series 60 DDEC VI

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Page 3: ...engine in an enclosed area vent the exhaust to the outside Do not modify or tamper with the exhaust system or emission control system 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 ...

Page 4: ...cedure 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 exhaus...

Page 5: ...t pages and are posted on the World Wide Web www detroitdiesel com svc sibinex htm Revisions to this manual will be sent marked with a revision bar see Example 2 Sections containing revisions will have added information in the page footer compare Examples 1 and 2 All information subject to change without notice PRELIMINARY 6SE567 0512 Copyright 2005 DETROIT DIESEL CORPORATION iii ...

Page 6: ...DDEC VI SERIES 60 TROUBLESHOOTING GUIDE All information subject to change without notice iv PRELIMINARY 6SE567 0512 Copyright 2005 DETROIT DIESEL CORPORATION ...

Page 7: ...PN 27 FMI 0 1 2 14 3 5 4 SPN 84 VEHICLE SPEED SENSOR 4 1 SPN 84 FMI 3 4 3 4 2 SPN 84 FMI 4 4 4 5 SPN 86 ADAPTIVE CRUISE CONTROL FAULT 5 1 SPN 86 FMI 14 5 3 6 SPN 91 ACCELERATOR PEDAL SENSOR FAULT 6 1 SPN 91 FMI 2 6 3 6 2 SPN 91 FMI 3 6 4 6 3 SPN 91 FMI 4 6 5 7 SPN 100 ENGINE OIL PRESSURE OUTSIDE OF NORMAL OPERATING RANGE 7 1 SPN 100 FMI 1 7 3 7 2 SPN 100 FMI 2 7 4 7 3 SPN 100 FMI 3 7 5 7 4 SPN 100...

Page 8: ... FMI 1 12 4 13 SPN 174 SUPPLY FUEL TEMPERATURE FAULT 13 1 SPN 174 FMI 3 13 3 13 2 SPN 174 FMI 4 13 5 14 SPN 175 ENGINE OIL TEMPERATURE OUT OF NORMAL RANGE 14 1 SPN 175 FMI 2 14 3 14 2 SPN 175 FMI 3 14 4 14 3 SPN 175 FMI 4 14 6 15 SPN 411 EGR DIFFERENTIAL PRESSURE OR DELTA P SENSOR CIRCUIT OUTSIDE OF NORMAL OPERATING RANGE 15 1 SPN 411 FMI 0 15 3 15 2 SPN 411 FMI 1 15 4 15 3 SPN 411 FMI 3 15 5 15 4...

Page 9: ...6 FMI 4 22 6 22 4 SPN 636 FMI 7 22 7 22 5 SPN 636 FMI 8 22 9 23 SPN 651 INJECTOR 1 NEEDLE VALVE NOT OPERATING NORMALLY 23 1 SPN 651 FMI 5 23 3 23 2 SPN 651 FMI 10 23 6 24 SPN 652 INJECTOR 2 NEEDLE VALVE NOT OPERATING NORMALLY 24 1 SPN 652 FMI 5 24 3 24 2 SPN 652 FMI 10 24 6 25 SPN 653 INJECTOR 3 NEEDLE VALVE NOT OPERATING NORMALLY 25 1 SPN 653 FMI 5 25 3 25 2 SPN 653 FMI 10 25 6 26 SPN 654 INJECTO...

Page 10: ...32 3 32 2 SPN 709 FMI 4 32 5 32 3 SPN 709 FMI 5 32 6 33 SPN 714 ETHER START LOW SIDE DIGITAL OUTPUT 8 FAULT 33 1 SPN 714 FMI 3 33 3 33 2 SPN 714 FMI 4 33 4 33 3 SPN 714 FMI 5 33 5 34 SPN 723 CAMSHAFT POSITION SENSOR FAULT 34 1 SPN 723 FMI 3 34 3 34 2 SPN 723 FMI 4 34 5 34 3 SPN 723 FMI 8 34 6 34 4 SPN 723 FMI 14 34 7 35 SPN 975 TWO SPEED FAN AUX PWM 6 FAULT 35 1 SPN 975 FMI 3 35 3 35 2 SPN 975 FMI...

Page 11: ...RANGE 41 1 SPN 3563 FMI 0 1 2 41 3 41 2 SPN 3563 FMI 3 41 6 41 3 SPN 3563 FMI 4 41 7 42 SPN 3659 INJECTOR 1 SPILL VALVE NOT OPERATING NORMALLY 42 1 SPN 3659 FMI 5 42 3 42 2 SPN 3659 FMI 10 42 6 43 SPN 3660 INJECTOR 2 SPILL VALVE NOT OPERATING NORMALLY 43 1 SPN 3660 FMI 5 43 3 43 2 SPN 3660 FMI 10 43 5 44 SPN 3661 INJECTOR 3 SPILL VALVE NOT OPERATING NORMALLY 44 1 SPN 3661 FMI 5 44 3 44 2 SPN 3661 ...

Page 12: ...ALLY 47 1 SPN 3664 FMI 5 47 3 47 2 SPN 3664 FMI 10 47 6 48 CPC DIGITAL OUTPUTS SPN FMI 48 1 CPC DIGITAL OUTPUT FAULT CODES 48 3 48 2 TROUBLESHOOTING THE CPC DIGITAL OUTPUTS 48 3 All information subject to change without notice x PRELIMINARY 6SE567 0512 Copyright 2005 DETROIT DIESEL CORPORATION ...

Page 13: ...1 INTRODUCTION Section Page 1 1 OVERVIEW 1 3 1 2 SCOPE AND USE OF THIS GUIDE 1 4 1 3 SAFETY PRECAUTIONS 1 6 ...

Page 14: ...All information subject to change without notice 1 2 PRELIMINARY 6SE567 0512 Copyright 2005 DETROIT DIESEL CORPORATION ...

Page 15: ...ic 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...

Page 16: ... 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 ...

Page 17: ...ir 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 B...

Page 18: ...e exhaust system or emission control system 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...

Page 19: ...ressurized 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 cont...

Page 20: ...s start and operate an engine in a well ventilated area If operating an engine in an enclosed area vent the exhaust to the outside Do not modify or tamper with the exhaust system or emission control system 1 3 3 Glasses 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 inju...

Page 21: ...less 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 han...

Page 22: ... 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 penet...

Page 23: ...n 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 pot...

Page 24: ...tery 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...

Page 25: ...and apron PERSONAL INJURY To avoid injury from harmful vapors or skin contact do not use carbon tetrachloride as a cleaning agent 1 3 10 Diagnostic Equipment For mobile applications Detroit Diesel Diagnostic Link 7 0 DDDL 7 0 must be used by personnel other than the vehicle operator The vehicle operator must maintain control of the vehicle while an assistant performs the diagnostic evaluations PER...

Page 26: ...a battery which can result in severe arcing or battery explosion PERSONAL INJURY To avoid injury from rotating belts and fans do not remove and discard safety guards PERSONAL INJURY To avoid injury when working near or on an operating engine remove loose items of clothing and jewelry Tie back or contain long hair that could be caught in any moving part causing injury All information subject to cha...

Page 27: ...er normal design conditions CHEMICAL BURNS To avoid injury from chemical burns wear a face shield and neoprene or PVC gloves when handling fluoroelastomer O rings or seals that have been degraded by excessive heat Discard gloves after handling degraded fluoroelastomer parts A potential hazard may occur if these components are raised to a temperature above 600 F 316 C in a fire for example Fluoroel...

Page 28: ...1 3 SAFETY PRECAUTIONS All information subject to change without notice 1 16 PRELIMINARY 6SE567 0512 Copyright 2005 DETROIT DIESEL CORPORATION ...

Page 29: ...e 2 1 DDEC VI SYSTEM HOW IT WORKS 2 3 2 2 MOTOR CONTROL MODULE 2 4 2 3 COMMON POWERTRAIN CONTROLLER 2 13 2 4 WIRES AND WIRING 2 25 2 5 CONDUIT AND LOOM 2 39 2 6 TAPE AND TAPING 2 40 2 7 SENSORS 2 41 2 8 INSTRUMENT PANEL LAMPS 2 54 ...

Page 30: ...All information subject to change without notice 2 2 PRELIMINARY 6SE567 0512 Copyright 2005 DETROIT DIESEL CORPORATION ...

Page 31: ...roller CPC The connection to the vehicle is made via a CAN interface which digitally transmits the nominal values e g torque engine speed specification etc and the actual values e g engine speed oil pressure etc 2 1 1 Harnesses There are two major harness the Engine Harness EH and the Vehicle Interface Harness VIH The Engine Harness is installed at the factory and is delivered connected to all eng...

Page 32: ...odes being logged 2 2 1 Engine Harness The MCM has a 120 pin connector Engine Harness which is factory installed It also has a 21 pin connector which is the responsibility of the OEM The pinouts for the 120 pin connector are listed in Table 2 1 Table 2 2 Table 2 3 and Table 2 4 The pinout for the 21 pin connector is listed in Table 2 5 All information subject to change without notice 2 4 PRELIMINA...

Page 33: ...cyl 1 pin 4 15 NC 16 Needle Control Valve cyl 4 pin 2 17 Needle Control Valve Common cyl 4 5 6 pin 1 18 Needle Control Valve cyl 6 pin 2 19 NC 20 Needle Control Valve cyl 5 pin 2 21 NC 22 Needle Control Valve cyl 2 pin 2 23 Needle Control Valve Common cyl 1 2 3 pin 1 24 Needle Control Valve cyl 3 pin 2 25 NC 26 Needle Control Valve cyl 1 pin 2 27 NC 28 NC 29 DOC Outlet Temp Sensor 30 DPF Outlet Pr...

Page 34: ...MP SRS 45 CMP SRS 46 NC 47 Fan Speed 48 NC 49 NC 50 Sensor Ground 51 Turbo Speed Sensor 52 Sensor Ground 53 NC 54 Engine Oil Pressure Sensor 55 Sensor Ground 56 NC 57 NC 58 Sensor Power Supply 59 NC 60 EGR Valve Position Table 2 2 MCM Connector Series 60 2 of 4 C Sample All information subject to change without notice 2 6 PRELIMINARY 6SE567 0512 Copyright 2005 DETROIT DIESEL CORPORATION ...

Page 35: ... Temperature Sensor 78 NC 79 NC 80 NC 81 NC 82 Sensor Supply 83 EGR Temperature Sensor 84 Fuel Compensation Pressure Sensor 85 Sensor Supply 86 Turbo Compressor In Temp 87 Intake Manifold Pressure Sensor 88 Sensor Ground 89 DOC Inlet Temp Sensor 90 Intake Air Throttle Valve Table 2 3 MCM Connector Series 60 3 of 4 C Sample All information subject to change without notice PRELIMINARY 6SE567 0512 Co...

Page 36: ...6 Intake Air Temperature Sensor 107 NC 108 Engine Oil Temperature Sensor 109 EGR Delta Pressure Sensor 110 Engine Coolant Temp Sensor 111 Fuel Line Pressure Sensor 112 Turbo Compressor Out Temp 113 NC 114 Sensor Ground 115 DPF Outlet Temp Sensor 116 NC 117 Sensor Power Supply 118 DPF Inlet Pressure Sensor 119 NC 120 NC Table 2 4 MCM Connector Series 60 4 of 4 C Sample All information subject to ch...

Page 37: ...uting is different The 120 pin connector and the 21 pin connector must be tie wrapped to the brackets as shown in the following drawing for the Series 60 engine see Figure 2 2 Figure 2 2 Series 60 Engine 120 pin Connector and 21 pin Connector Tie wrapped to Brackets All information subject to change without notice PRELIMINARY 6SE567 0512 Copyright 2005 DETROIT DIESEL CORPORATION 2 9 ...

Page 38: ... 15 KL30 Battery 21 16 CAN1GND Not Used 21 17 Not Used 21 18 KDiag_S Not Used 21 19 CAN1L Engine CAN 21 20 KL50 Crank Start Input 21 21 START_B Crank Activation Output Front Looking into the Pins on the Harness Table 2 5 21 Pin Connector to the MCM Part Tyco Amp Part Number DDC Part Number Connector 1 355222 2 A 024 545 91 26 2 5 mm Contact strip form A 001 982 02 26 2 5 mm Contact single A 000 98...

Page 39: ...Solenoid Control 31 17 DOC Outlet Temp Sensor Exhaust Gas Temperature in Front of Particulate Trap X 31 18 DOC Inlet Temp Sensor X 31 19 DPF Outlet Temp Sensor Exhaust Gas Temperature After Particulate Trap X 31 20 Full Heater Ground 2 31 21 Spare 31 22 Power Supply X 31 23 Fan Speed X 31 24 Sensor Ground 3V X 31 25 Spare 31 26 Spare 31 27 TCI Temp X 31 28 Sensor Ground 5V X 31 29 Sensor Supply 2V...

Page 40: ...er Connector 967363 1 A 008 545 31 26 Terminal 0 5 1 0 mm 1 929974 4 A 019 545 95 26 Seals GXL insulation 828921 1 Cavity Plugs 828922 1 Backshell 965636 1 A 000 545 99 35 Table 2 8 31 pin MCM Pigtail Connector Part Numbers All information subject to change without notice 2 12 PRELIMINARY 6SE567 0512 Copyright 2005 DETROIT DIESEL CORPORATION ...

Page 41: ...in the connector pin outs for truck vocational transit bus and crane applications The CPC is the interface between the MCM and the vehicle equipment for engine control and manages other vehicle equipment functions See Figure 2 3 Figure 2 3 The Common Powertrain Controller All information subject to change without notice PRELIMINARY 6SE567 0512 Copyright 2005 DETROIT DIESEL CORPORATION 2 13 ...

Page 42: ...systems Other electrical system wires should ideally be at least three feet away from the VIH and should not be parallel to the VIH This will eliminate coupling electromagnetic energy from other systems into the VIH See Figure 2 4 for the CPC dimensions Figure 2 4 CPC Dimensions NOTE The CPC should be mounted with the connectors pointing down All information subject to change without notice 2 14 P...

Page 43: ...ntrol units for example synchronization controllers for more than one genset air compressor controls From this data instructions are computed for controlling the engine and transmitted to the MCM via the proprietary data link 2 3 1 Environmental Conditions Temperature vibration and water intrusion must be considered 2 3 1 1 Temperature The ambient operating temperature range is 40 F to 185 F 40 C ...

Page 44: ...he OEM supplied Vehicle Interface Harness VIH connects the CPC to the MCM and other vehicle systems see Figure 2 6 Figure 2 6 Vehicle Interface Harness All information subject to change without notice 2 16 PRELIMINARY 6SE567 0512 Copyright 2005 DETROIT DIESEL CORPORATION ...

Page 45: ...with drain wire and 30 twists per meter The insulation is rated to 105 C Termination resistors for the Engine CAN link are located in the CPC and MCM 2 3 2 1 Frequency Input The CPC has one frequency input on the VIH that can accept a variable reluctance sensor A typical frequency input functions is the Vehicle Speed Sensor VSS Requirements for a variable reluctance signal interface are listed in ...

Page 46: ...total maximum current draw for their installation Table 2 10 Maximum Average Current Draw The current draw for a CPC configuration is listed in Table 2 11 Configuration Condition Current Ignition Off 1 mA CPC Ignition On and Engine Stopped 120 mA Table 2 11 Current Draw for CPC Configuration The current draw for a MCM is listed in Table 2 12 Configuration Condition Current Ignition Off 1 mA MCM Ig...

Page 47: ...See Figure 2 7 Figure 2 7 Main Power Supply Shutdown NOTE Switches must remain closed for 30 seconds after ignition is off for the MCM and CPC to write non volatile data NOTE It is recommended that both the positive and negative battery leads be disconnected All information subject to change without notice PRELIMINARY 6SE567 0512 Copyright 2005 DETROIT DIESEL CORPORATION 2 19 ...

Page 48: ... connected directly to the battery for isolation purposes 2 3 4 Fuses A Battery fuse and an ignition circuit fuse must be provided by the vehicle wiring harness Blade type automotive fuses are normally utilized however manual or automatic reset circuit breakers which meet the following requirements are also acceptable The fuse voltage rating must be compatible with the CPC MCM s maximum operating ...

Page 49: ... derating characteristics are listed in Table 2 13 and Table 2 14 of Rated Fuse Current Minimum Blow Time Maximum Blow Time 100 100 hours 135 1 minutes 30 minute 200 6 seconds 40 seconds Table 2 13 Fuse Current and Blow Time Temperature of Rated Fuse Current 40 C 110 max 25 C 100 120 C 80 min Table 2 14 Fuse Temperature and Current 2 3 5 Connectors There are three 18 pin connectors and one 21 pin ...

Page 50: ...0mm wire single A 013 545 76 26 CPC socket 1 0 2 5mm wire single 1 968873 3 A 013 545 78 26 CPC socket 1 0 2 5mm wire strip 1 968851 3 Table 2 17 Connector 3 21 pin Connector Key A Part Tyco Amp Part Number DDC Part Number CPC 18 Pin Connector C Key 6 968974 2 A 018 545 68 26 CPC socket 0 5 1 0mm wire single A 013 545 76 26 CPC socket 1 0 2 5mm wire single 1 968873 3 A 013 545 78 26 CPC socket 1 0...

Page 51: ... conveniently positioned in a well protected location facilitating subsequent Detroit Diesel Diagnostic Link 7 0 DDDL 7 0 usage i e reprogramming diagnostics etc NOTE REQUIRED The J1939 data link must be wired to this connector The components listed in Table 2 22 are required to incorporate a SAE J1939 J1587 Data Link in a VIH for diagnostic and reprogramming devices Component DDC Part Number Deut...

Page 52: ... 8 Wiring for 9 pin Data Link Connector The SAE J1587 J1708 Data Link must be twisted pairs The twists are a minimum of 12 turns per foot 305 mm The maximum length for the SAE J1587 J1708 Data Link is 130 ft 40 m All information subject to change without notice 2 24 PRELIMINARY 6SE567 0512 Copyright 2005 DETROIT DIESEL CORPORATION ...

Page 53: ...ecommend using any type of terminal lubricant or grease compounds These products may cause dirt or other harmful substances to be retained in the connector DDC has not tested these products and cannot stand behind their use NOTICE Insulation must be free of nicks Tape conduit loom or a combination thereof must be used to protect the wires Refer to section 2 6 and refer to section 2 5 All wires mus...

Page 54: ...ded into the connector These connectors are push to seat connectors with cylindrical terminals The diagnostic connector terminals are gold plated for clarity NOTICE Improper selection and use of crimp tools have varying adverse effects on crimp geometry and effectiveness Proper installation of terminals require specialized tools Do not attempt to use alternative tools The crimp tool to use in Deut...

Page 55: ... and insert the lock clip 4 Position the contact so that the crimp barrel is 1 32 of an inch above the four indenters See Figure 2 9 Crimp the cable Figure 2 9 Setting Wire Gage Selector and Positioning the Contact 5 Grasp the contact approximately one inch behind the contact crimp barrel Hold the connector with the rear grommet facing you See Figure 2 10 Figure 2 10 Pushing Contact Into Grommet A...

Page 56: ...ector 2 4 4 2 Deutsch Terminal Removal The appropriate size removal tool should be used when removing cables from connectors The proper removal tools are listed in Table 2 24 Tool Kent Moore Part Number Removing 12 AWG J 37451 Removing 16 18 AWG J 34513 1 Table 2 24 Removal Tools for Deutsch Terminals All information subject to change without notice 2 28 PRELIMINARY 6SE567 0512 Copyright 2005 DETR...

Page 57: ...Position 2 Slide the tool along the cable into the insert cavity until it engages and resistance is felt Do not twist or insert tool at an angle See Figure 2 13 Figure 2 13 Removal Tool Insertion 3 Pull contact cable assembly out of the connector Keep reverse tension on the cable and forward tension on the tool All information subject to change without notice PRELIMINARY 6SE567 0512 Copyright 2005...

Page 58: ...with durable insulation is considered to be acceptable 2 4 5 1 Clipped and Soldered Splicing Method The tools required are listed in Table 2 25 Tool Part Number Heat Gun Sn 60 solder with rosin core flux Wire Stripper Kent Moore J 35615 or equivalent Splice Clips commercially available Wire size dependent Heat Shrink Tubing Raychem HTAT or equivalent Table 2 25 Recommended Splicing Tools The crite...

Page 59: ...leads with a commercially available clip and hand tool See Figure 2 15 Figure 2 15 Securing the Leads With a Clip 3 Use a suitable electronic soldering iron to heat the wires Apply the solder to the heated wire and clip not to the soldering iron allowing sufficient solder flow into the splice joint All information subject to change without notice PRELIMINARY 6SE567 0512 Copyright 2005 DETROIT DIES...

Page 60: ...he tools required are listed in Table 2 27 Tool Part Number Heat Gun Wire Stripper Kent Moore J 35615 or equivalent Splice Clips commercially available Wire size dependent Heat Shrink Tubing Raychem HTAT or equivalent Terminal Crimper for Metri Pack 280 12 AWG Kent Moore J 38125 6 Terminal Crimper for Metri Pack 280 18 AWG Kent Moore J 39848 Terminal Crimper for Weather Pack Kent Moore J 35606 Ter...

Page 61: ...ee Figure 2 17 B NOTICE Any terminal that is cracked or ruptured is unacceptable as malfunctions may occur 5 Visually inspect the splice clip for cracks rupture or other crimping damage Remove and replace damaged clips before proceeding 6 Pull on wire to ensure the splice integrity The criteria listed in Table 2 28 must be met Wire Gage Must Withstand Applied Load 14 AWG 45 lb 200 N 16 AWG 27 lb 1...

Page 62: ...mance Replace wire to avoid having splices closer than 12 in 3 m apart 8 Loop the lead back over the spliced joint and tape See Figure 2 16 Figure 2 17 Splicing Straight Leads Alternate Method 1 All information subject to change without notice 2 34 PRELIMINARY 6SE567 0512 Copyright 2005 DETROIT DIESEL CORPORATION ...

Page 63: ...ng straight leads is 1 Locate broken wire 2 Remove insulation as required be sure exposed wire is clean and not corroded 3 Slide a sleeve of glue lined shrink tubing Raychem HTAT or equivalent long enough to cover the splice clip on the wire and overlap the wire insulation about 25 in 6 mm on both sides see Figure 2 18 A 4 Insert one wire into splice clip until it butts against the splice clip Sto...

Page 64: ...o splices that have more than one lead in or out 9 Loop the lead back over the spliced joint and tape See Figure 2 16 Figure 2 18 Splicing Straight Leads Alternate Method 2 All information subject to change without notice 2 36 PRELIMINARY 6SE567 0512 Copyright 2005 DETROIT DIESEL CORPORATION ...

Page 65: ...lice NOTICE The heat shrink wrap must overlap the wire insulation about 25 in 6 mm on both sides of the splice 1 Select the correct diameter to allow a tight wrap when heated 2 Heat the shrink wrap with a heat gun do not concentrate the heat in one location but apply the heat over the entire length of shrink wrap until the joint is complete 3 Repeat step 2 to apply a second layer of protection if ...

Page 66: ... at least a 2 5 in 65 mm separation between splices Figure 2 19 The Correct and Incorrect Method of Staggering Multiple Splices NOTICE A minimum of two layers of heat shrink tubing extending 25 in 6 mm past the splice must be used to complete the splice 2 Heat shrink a minimum of two layers of heat shrink tubing 3 Tape the spliced wires to each other Refer to section 2 5 All information subject to...

Page 67: ... place with conduit outlet rings or tape 2 5 1 Criteria for Conduit and Loom Due to the wide variety of operating conditions and environments it is the responsibility of the OEM to select a conduit that will survive the conditions of the specific applications Flame retardant convoluted polypropylene conduit or equivalent may be used for most installations Heat retardant nylon conduit or oil water ...

Page 68: ...ant and weather resistant may be used NOTICE Black vinyl electrical tape should not be used in applications where the temperature exceeds 176 F 80 C In applications where temperature exceeds 176 F 80 C vinyl electrical tape should not be used For these applications adhesive cloth backed flame retardant polyethylene or fiber glass tape Delphi PM 2203 Polikan 165 or equivalent is recommended 2 6 2 T...

Page 69: ...s Variable Capacitance Used to monitor manifold and oil gallery pressures Variable Resistance Potentiometer Used to sense throttle position Switch Used to signal coolant level Table 2 30 Sensor Types The sensors integrated into the Engine Harness are factory installed refer to section 2 7 1 The sensors integrated into the Vehicle Interface Harness are installed by the OEM refer to section 2 7 2 Al...

Page 70: ...st system of the vehicle Located before the DOC that is within the after treatment device DOC Temperature Out Temperature measured between the DOC and the DPF in the after treatment assembly located in the exhaust system of the vehicle Engine Coolant Temperature Sensor ECT Sensor Senses coolant temperature for functions such as engine protection fan control and engine fueling EGR Temperature Senso...

Page 71: ...DE See Figure 2 20 for the location of the sensors for the DOC and DPF Figure 2 20 Sensor Location for the DOC and DPF All information subject to change without notice PRELIMINARY 6SE567 0512 Copyright 2005 DETROIT DIESEL CORPORATION 2 43 ...

Page 72: ...to section 2 7 3 Turbo Compressor In Temperature Sensor 23527831 Senses the temperature of the turbo compressor inlet Refer to section 2 7 4 Vehicle Speed Sensor VSS Senses vehicle speed for Cruise Control and Vehicle Speed Limiting Refer to section 2 7 5 Available in some applications Table 2 32 Function and Guidelines for OEM installed Sensors NOTE The OEM harness must be securely fastened every...

Page 73: ...40 to 257 F 40 to 125 C Exposure to temperatures beyond this range may result in unacceptable component life or degraded sensor accuracy Figure 2 21 Engine Coolant Level Sensor Specifications The connector listed in Table 2 33 is a Metri Pack 280 series push to seat connector Coolant Level Sensor Connector Connector P N 15300027 Terminal P N 12077411 Seal P N 12015323 Secondary Lock P N 15300014 T...

Page 74: ...lustration see Figure 2 22 Polarity of the ground and signal must be correct for proper operation Figure 2 22 Engine Coolant Level Sensor Installation for CPC All information subject to change without notice 2 46 PRELIMINARY 6SE567 0512 Copyright 2005 DETROIT DIESEL CORPORATION ...

Page 75: ...line flows The insulated portion of the probe should be inserted into the coolant 1 2 in or more past the inside wall of the tank See Figure 2 23 Figure 2 23 Engine Coolant Level Sensor Location Top of Radiator Tank Determine proper location for low coolant level sensor while running the drawdown test It must actuate a warning before the satisfactory drawdown level is reached The ECL Sensor compon...

Page 76: ... Connector Kit 15300027 Metri Pack Terminals 12077411 Secondary Lock 15300014 Wire Seal 12015323 Terminal 12103881 Table 2 35 ECL Sensor Installation Kit 3 8 in NPTF P N 23515398 The sensor must be enabled with VEPS or the DRS as listed in Table 2 36 Parameter Group Parameter Options Default 13 Cool Level Sensor Input Enable 0 Disabled 1 Dual Level Probe Sensor IMO fixed threshold 2 Single Level P...

Page 77: ...s 60 produces a signal representing the temperature of the turbo compressor inlet See Figure 2 24 and Figure 2 25 Figure 2 24 Turbo Compressor In Temperature Sensor Figure 2 25 Turbo Compressor In Temperature Sensor Installation All information subject to change without notice PRELIMINARY 6SE567 0512 Copyright 2005 DETROIT DIESEL CORPORATION 2 49 ...

Page 78: ...requirements The VSS see Figure 2 26 provides a vehicle speed signal for use in Cruise Control and Vehicle Speed Limiting The VSS signal type can be changed v NOTE DDC does not approve of the use of signal generator sensors Figure 2 26 Vehicle Speed Sensor All information subject to change without notice 2 50 PRELIMINARY 6SE567 0512 Copyright 2005 DETROIT DIESEL CORPORATION ...

Page 79: ...o 1 20 0 5 29 8 Anti Tamper 0 Disable 1 Enable VSS Anti Tamper Function via ABS 2 Enable Anti Tamper Function via Gear Ration 0 Disable 8 Gear Ratio Tolerance 0 60 2 Table 2 37 Vehicle Speed Sensor Parameters 2 7 5 1 Magnetic Pickup The magnetic pickup requirements are listed in Table 2 38 Magnetic Pickup size is determined by installation requirements Parameters Range Frequency Range 0 10 kHz Low...

Page 80: ...2 27 for the installation of the Magnetic VSS Figure 2 27 Magnetic Vehicle Speed Sensor Installation CPC All information subject to change without notice 2 52 PRELIMINARY 6SE567 0512 Copyright 2005 DETROIT DIESEL CORPORATION ...

Page 81: ... J1939 CCVS Source 3 4 Magnetic 8 Axle Ratio 1 20 0 5 29 8 Tire Revs per Unit Distance 160 1599 312 8 Top Gear Ratio 0 1 2 55 1 8 Second Highest Gear Ratio 0 5 75 2 54 8 Two Spd Axle Second Axle Ratio 1 20 0 5 29 8 Anti Tamper 0 Disable 1 Enable VSS ABS Anti Tampering Function 2 Enable VSS without ABS Anti Tampering Function 0 Disable 8 Gear Ratio Tolerance 0 60 2 Table 2 40 Vehicle Speed Sensor P...

Page 82: ...eeds limits Blinking yellow during stationary regeneration Truck may be driven to end of shift Call for service Blinking light indicates attention required now High Exhaust Temperature Lamp HET Lamp may be red or yellow Indicates exhaust temperature is above a preset limit Illuminates during regeneration process if speed below 30 mph and during stationary regeneration Truck may be driven If lamp r...

Page 83: ...3 SPN 27 EGR VALVE POSITION CIRCUIT FAULT Section Page 3 1 SPN 27 FMI 3 3 3 3 2 SPN 27 FMI 4 3 4 3 3 SPN 27 FMI 0 1 2 14 3 5 ...

Page 84: ...All information subject to change without notice 3 2 PRELIMINARY 6SE567 0512 Copyright 2005 DETROIT DIESEL CORPORATION ...

Page 85: ...tance again If you receive the same results contact the Detroit Diesel Customer Support Center 313 592 5800 3 1 1 1 Verify Repairs Verify repairs as follows 1 Turn ignition OFF Reconnect all connectors 2 Turn ignition ON Clear codes with DDDL 7 0 3 Start and run the engine for one minute Stop engine 4 Check DDDL 7 0 for codes a If no codes are displayed troubleshooting is complete b If SPN 27 3 is...

Page 86: ...etween pin 4 of the EGR valve connector and pin 60 of the 120 pin MCM connector Refer to section 3 2 1 1 3 2 1 1 Verify Repairs Verify repairs as follows 1 Turn vehicle ignition OFF Reconnect all connectors 2 Turn ignition ON Clear codes with DDDL 7 0 3 Start and run the engine for one minute Stop engine 4 Check DDDL 7 0 for codes a If no codes are displayed troubleshooting is complete b If SPN 27...

Page 87: ... the EGR valve actual position read less than 3 a If yes go to step 8 b If no go to step 12 8 Command the EGR pulse width to 50 9 Does the EGR valve actual position read between 46 and 54 a If yes go to step 10 b If no go to step 12 10 Command the EGR pulse width to 100 11 Does the EGR valve actual position read above 95 a If yes repeat steps 2 through 11 If the results are the same call the Detro...

Page 88: ...0 for codes a If no codes are displayed troubleshooting is complete b If SPN 27 0 1 2 14 is not logged and other codes are logged troubleshoot the logged codes c If SPN 27 0 1 2 14 and other codes are logged review this section to find the error If no error is found call the Detroit Diesel Customer Support Center 313 592 5800 All information subject to change without notice 3 6 PRELIMINARY 6SE567 ...

Page 89: ...4 SPN 84 VEHICLE SPEED SENSOR Section Page 4 1 SPN 84 FMI 3 4 3 4 2 SPN 84 FMI 4 4 4 ...

Page 90: ...All information subject to change without notice 4 2 PRELIMINARY 6SE567 0512 Copyright 2005 DETROIT DIESEL CORPORATION ...

Page 91: ... section 4 1 1 1 5 Turn OFF the ignition 6 Disconnect the CPC 3 connector 21 pin 7 Measure the resistance between a If the resistance measurement is less than 5 Ω repair the short in the harness between pin 13 and pin 14 of the CPC 3 connector 21 pin Refer to section 4 1 1 1 b If the resistance measurement is greater than 5 Ω replace the VSS Refer to section 4 1 1 1 4 1 1 1 Verify Repairs Verify r...

Page 92: ...p 5 5 Measure the resistance between pin 2 of the VSS harness connector and ground a If the resistance measurement is less than 5 Ω repair the short to ground between pin 14 of the CPC 3 connector 21 pin and pin 2 of the VSS harness connector Refer to section 4 2 1 1 b If the resistance measurement is greater than 5 Ω replace the VSS Refer to section 4 2 1 1 4 2 1 1 Verify Repairs Verify repairs a...

Page 93: ...5 SPN 86 ADAPTIVE CRUISE CONTROL FAULT Section Page 5 1 SPN 86 FMI 14 5 3 ...

Page 94: ...All information subject to change without notice 5 2 PRELIMINARY 6SE567 0512 Copyright 2005 DETROIT DIESEL CORPORATION ...

Page 95: ...e the parameter for Adaptive Cruise Control must be enabled This code appears if the parameter for Adaptive Cruise Control is enabled and the vehicle is not equipped with Eaton Smart Cruise All information subject to change without notice PRELIMINARY 6SE567 0512 Copyright 2005 DETROIT DIESEL CORPORATION 5 3 ...

Page 96: ...5 1 SPN 86 FMI 14 All information subject to change without notice 5 4 PRELIMINARY 6SE567 0512 Copyright 2005 DETROIT DIESEL CORPORATION ...

Page 97: ...6 SPN 91 ACCELERATOR PEDAL SENSOR FAULT Section Page 6 1 SPN 91 FMI 2 6 3 6 2 SPN 91 FMI 3 6 4 6 3 SPN 91 FMI 4 6 5 ...

Page 98: ...All information subject to change without notice 6 2 PRELIMINARY 6SE567 0512 Copyright 2005 DETROIT DIESEL CORPORATION ...

Page 99: ...b If the voltage is less than 4 5 go to step 4 4 Measure the voltage between pins 1 of the AP harness connector and ground a If the voltage is between 4 5 and 5 5 volts repair the open circuit between pin 3 of the AP harness connector and pin 4 of the CPC 1 connector Refer to section 6 1 1 1 b If the voltage is less than 4 5 repair the open circuit between pin 1 of the AP harness connector and pin...

Page 100: ... is found call the Detroit Diesel Customer Support Center 313 592 5800 6 2 SPN 91 FMI 3 The typical diagnosis for this fault is high voltage 6 2 1 High Voltage Check Check as follows 1 Disconnect the Accelerator Pedal AP 2 Turn ON the ignition key ON engine OFF 3 Measure the voltage between pins 1 and 3 of the AP harness connector a If the voltage is between 4 5 and 5 5 volts go to step 5 b If the...

Page 101: ...d the error If no error is found call the Detroit Diesel Customer Support Center 313 592 5800 6 3 SPN 91 FMI 4 The typical diagnosis for this fault is voltage low 6 3 1 Low Voltage Check Perform the following steps to troubleshoot low voltage 1 Disconnect the Accelerator Pedal AP connector 2 Disconnect the 1 connector of the CPC 3 Measure the resistance between pin 1 and pin 3 of the AP connector ...

Page 102: ... to section 6 3 1 1 6 3 1 1 Verify Repairs Verify repairs as follows 1 Turn the ignition OFF Reconnect all connectors 2 Turn ignition ON Clear codes with diagnostic tool 3 Start and run the engine for one minute Stop engine 4 Check diagnostic tool for codes a If no codes are displayed troubleshooting is complete b If code 91 4 is not logged and other codes are logged troubleshoot the logged codes ...

Page 103: ...7 SPN 100 ENGINE OIL PRESSURE OUTSIDE OF NORMAL OPERATING RANGE Section Page 7 1 SPN 100 FMI 1 7 3 7 2 SPN 100 FMI 2 7 4 7 3 SPN 100 FMI 3 7 5 7 4 SPN 100 FMI 4 7 7 7 5 SPN 100 FMI 14 7 9 ...

Page 104: ...All information subject to change without notice 7 2 PRELIMINARY 6SE567 0512 Copyright 2005 DETROIT DIESEL CORPORATION ...

Page 105: ...oil to proper level Refer to section 7 1 1 1 4 Check the operation of the oil gage a If the oil gage readings are erratic repair or replace the oil gage as required Refer to section 7 1 1 1 b If the oil gage readings are fine go to step 5 5 Check the condition of the oil pump suction pipe a If the pipe is loose or cracked replace a cracked pipe and reinstall a loose pipe Refer to section 7 1 1 1 b...

Page 106: ...owing steps to troubleshoot erratic data from the Engine Oil Pressure Sensor 7 2 1 Erratic Data From the Engine Oil Pressure Sensor Check Check for erratic data from the Engine Oil Pressure Sensor as follows 1 With the engine shut down all oil drained into the oil pan and the vehicle on a level surface check the oil level a If the oil level is not within the normal operating range on the dipstick ...

Page 107: ... no codes are displayed troubleshooting is complete b If code 100 2 is not logged and other codes are logged troubleshoot the logged codes c If code 100 2 and other codes are logged review this section to find the error If no error is found call the Detroit Diesel Customer Support Center 313 592 5800 7 3 SPN 100 FMI 3 A typical diagnosis is an Engine Oil Pressure Sensor short circuit 7 3 1 Short C...

Page 108: ...r the short to power on wire 54 of the 120 pin MCM connector see Figure 7 3 Refer to section 7 3 1 1 b If resistance is less than 5 Ω repair the short between pins 54 and 82 of the 120 pin MCM connector see Figure 7 3 Refer to section 7 3 1 1 Figure 7 3 120 pin MCM Connector All information subject to change without notice 7 6 PRELIMINARY 6SE567 0512 Copyright 2005 DETROIT DIESEL CORPORATION ...

Page 109: ...nd call the Detroit Diesel Customer Support Center 313 592 5800 7 4 SPN 100 FMI 4 This diagnosis is typically an Engine Oil Pressure Sensor open circuit fault 7 4 1 Open Circuit Check Check for an open circuit as follows 1 Disconnect the Engine Oil Pressure Sensor 2 Measure the resistance between pins 1 and 3 of the EOP Sensor See Figure 7 4 Figure 7 4 Engine Oil Pressure Sensor Wiring a If resist...

Page 110: ...er than 5 Ω go to step 10 b If the resistance is less than 5 Ω repair the short between pins 105 and 82 of the 120 pin MCM connector Refer to section 7 4 1 1 10 Measure the resistance between pins 1 and 2 of the EOP Sensor harness connector a If the resistance is greater than 5 Ω go to step 11 b If the resistance is less than 5 Ω repair the short between pins 105 and 54 of the 120 pin MCM connecto...

Page 111: ...e 100 3 is active in addition to code 100 4 refer to section 7 3 1 b If fault code 100 4 is active in addition to code 100 4 refer to section 7 4 1 c If only fault code 100 14 is active go to step 2 2 Start engine and check oil pressure a If pressure is fluctuating go to step 3 b If pressure is low but stable go to step 4 3 Stop the engine and allow sufficient time for the oil to drain into the oi...

Page 112: ...epairs as follows 1 Turn the ignition OFF Reconnect all connectors 2 Turn ignition ON Clear codes with diagnostic tool 3 Start and run the engine for one minute Stop engine 4 Check diagnostic tool for codes a If no codes are displayed troubleshooting is complete b If code 100 14 is not logged and other codes are logged troubleshoot the logged codes c If code 100 14 and other codes are logged revie...

Page 113: ...8 SPN 103 TURBO NO REVOLUTION Section Page 8 1 SPN 103 FMI 0 8 3 8 2 SPN 103 FMI 1 8 4 8 3 SPN 103 FMI 3 8 5 8 4 SPN 103 FMI 4 8 7 8 5 SPN 103 FMI 7 8 8 ...

Page 114: ...All information subject to change without notice 8 2 PRELIMINARY 6SE567 0512 Copyright 2005 DETROIT DIESEL CORPORATION ...

Page 115: ...he repairs are done refer to section 8 1 1 1 b If no visible damage is found go to step 4 4 Using Artisan perform the turbocharger self test a If the self test fails repair the turbo actuator as necessary When the repairs are done refer to section 8 1 1 1 b If the self test results are satisfactory go to step 5 5 Perform the fuel pressure test a If the fuel pressure is not within specifications re...

Page 116: ...rbo Speed Sensor a If the resistance is 0 or greater than 1k Ω replace the Turbo Speed Sensor Refer to section 8 2 1 1 b If the resistance is less than 1k Ω go to step 3 3 Visually inspect the turbocharger for damage a If damage is found repair as necessary When the repairs are done refer to section 8 2 1 1 b If no visible damage is found go to step 4 4 Using Artisan perform the turbocharger self ...

Page 117: ...o find the error If no error is found call the Detroit Diesel Customer Support Center 313 592 5800 8 3 SPN 103 FMI 3 This diagnosis is typically circuit failed high open circuit 8 3 1 Open Circuit Check Check as follows 1 Disconnect the Turbo Speed Sensor TSS 2 Measure the resistance across pins 1 and 2 of the sensor see Figure 8 1 Figure 8 1 Turbo Speed Sensor Terminal and Wire Locations a If the...

Page 118: ...ng a code The following is a recheck before requesting a new MCM 1 Turn the ignition OFF 2 Reconnect the TSS 3 Clear codes Run engine for one minute Stop engine 4 Recheck codes a If there are no codes troubleshooting is finished b If code 103 3 is logged go to step 5 5 Disconnect the Turbo Speed Sensor TSS 6 Measure the resistance across pins 1 and 2 of the sensor a If the resistance is greater th...

Page 119: ... connector a If the resistance is less than 5 Ω repair the short between the 120 pin MCM connector wires 50 and 51 Refer to section 8 4 2 1 b If the resistance is greater than 5 Ω go to step 4 4 Measure the resistance between pin 1 of the TSS harness connector and ground a If the resistance is less than 5 Ω repair the short between pin 1 of the TSS harness connector and ground Refer to section 8 4...

Page 120: ...en pin 2 of the TSS harness connector and ground a If the resistance is less than 5 Ω repair the short between pin 2 of the TSS harness connector and ground Refer to section 8 4 2 1 b If the resistance is greater than 5 Ω contact the Detroit Diesel Customer Support Center 313 592 5800 for authorization to replace the MCM 8 4 2 1 Verify Repairs Verify repairs as follows 1 Turn the ignition OFF Reco...

Page 121: ...Locations a If resistance is approximately 900 Ω refer to section 8 5 2 b If resistance is zero or higher than 950 Ω replace the sensor Refer to section 8 5 2 1 8 5 2 Adjust the Turbo Speed Sensor Air Gap Adjust the TSS air gap a follows 1 Remove the TSS from the turbo shaft housing 2 Adjust the air gap by adding a 0 020 in washer between the sensor body and the housing 3 Install the sensor into t...

Page 122: ... tool for codes a If no codes are displayed troubleshooting is complete b If code 103 7 is not logged and other codes are logged troubleshoot the logged codes c If code 103 7 and other codes are logged review this section to find the error If no error is found call the Detroit Diesel Customer Support Center 313 592 5800 All information subject to change without notice 8 10 PRELIMINARY 6SE567 0512 ...

Page 123: ...9 SPN 110 COOLANT TEMPERATURE ABOVE OR BELOW NORMAL OPERATING RANGE Section Page 9 1 SPN 110 FMI 0 9 3 9 2 SPN 110 FMI 2 9 3 9 3 SPN 110 FMI 3 9 4 9 4 SPN 110 FMI 4 9 7 9 5 SPN 110 FMI 14 9 9 ...

Page 124: ...All information subject to change without notice 9 2 PRELIMINARY 6SE567 0512 Copyright 2005 DETROIT DIESEL CORPORATION ...

Page 125: ...ollapsed hoses 7 Check for proper viscous fan operation 8 Once checks and repairs are finished refer to section 9 1 1 1 9 1 1 1 Verify Repairs Verify repairs as follows 1 Turn vehicle ignition OFF and reconnect all connectors 2 Turn vehicle ignition ON Clear the codes 3 Start and run the engine for eight minutes Stop the engine 4 Check for codes a If no codes are logged troubleshooting is complete...

Page 126: ...er 313 592 5800 b If no disconnect the ECT Sensor and the MCM connector Bridge pins X and X of the sensor and measure resistance at the MCM between pins X and X If the resistance is greater than 3 Ω repair the harness If the resistance is less than 3 Ω replace the sensor Refer to section 9 2 1 1 9 2 1 1 Verify Repairs Verify repairs as follows 1 Turn vehicle ignition OFF and reconnect all connecto...

Page 127: ...ure the resistance across pins 1 and 2 of the ECT Sesnor a If the resistance is greater than 4 kΩ replace the sensor Refer to section 9 3 2 1 b If the resistance is less than 4 kΩ go to step 3 3 Turn the ignition ON key On engine OFF 4 Measure the voltage between pins 1 and 2 of the ECT Sensor harness connector a If the voltage is between 2 75 and 3 25 volts go to step 6 b If the voltage is less t...

Page 128: ...igure 9 1 MCM Connector 6 Disconnect the 120 pin MCM connector Measure the resistance between pins 1 and 2 of the ECT Sensor harness connector See Figure 9 2 Figure 9 2 Engine Coolant Temperature Sensor Wiring a If the resistance is greater than 5 Ω replace the ECT Sensor Refer to section 9 3 2 1 All information subject to change without notice 9 6 PRELIMINARY 6SE567 0512 Copyright 2005 DETROIT DI...

Page 129: ...Disconnect the ECT Sensor 2 Disconnect the 120 pin MCM connector 3 Measure the resistance across pins 1 and 2 of the ECT Sensor connector See Figure 9 2 a If resistance is greater than 5 Ω go to step 4 b If resistance is less than 5 Ω repair short to ground between pins 55 and 110 of the 120 pin MCM connector Refer to section 9 4 1 1 4 Measure the resistance between pin 1 of the ECT Sensor harness...

Page 130: ... Check for codes a If no codes are logged troubleshooting is complete b If code 110 3 or 110 4 and any other codes are logged review this section to find the error If no error is found contact Detroit Diesel Customer Support Center 313 592 5800 for authorization to replace the MCM Set parameters on the new MCM All information subject to change without notice 9 8 PRELIMINARY 6SE567 0512 Copyright 2...

Page 131: ...e very high fault Repair or replace as required 1 Check for coolant loss 2 Check for blockage in radiator and charge air cooler 3 Check fan belt condition slippage 4 Check for proper location of fan shroud 5 Check for proper radiator hose condition no collapsed hoses 6 Check for proper viscous fan operation 7 Once checks and repairs are finished refer to section 9 5 2 1 9 5 2 1 Verify Repairs Veri...

Page 132: ...9 5 SPN 110 FMI 14 All information subject to change without notice 9 10 PRELIMINARY 6SE567 0512 Copyright 2005 DETROIT DIESEL CORPORATION ...

Page 133: ...10 SPN 111 COOLANT LEVEL OUTSIDE NORMAL OPERATING RANGE Section Page 10 1 SPN 111 FMI 1 10 3 10 2 SPN 111 FMI 3 10 5 10 3 SPN 111 FMI 4 10 7 ...

Page 134: ...All information subject to change without notice 10 2 PRELIMINARY 6SE567 0512 Copyright 2005 DETROIT DIESEL CORPORATION ...

Page 135: ...aults are active in addition to fault 111 1 troubleshoot the other faults first b If only fault 111 1 is active go to step 3 3 Check the coolant level in the reservoir See Figure 10 1 Figure 10 1 Engine Coolant Level Sensor Mounted in Radiator Top Tank a If the coolant level in the reservoir is not within limit refer to section 10 1 2 All information subject to change without notice PRELIMINARY 6S...

Page 136: ...k Check as follows 1 Check for coolant leak at cylinder head gasket 2 Check for coolant leak at air compressor head gasket 3 Check for external coolant leak at hose connections 4 Check for coolant in oil 5 Check for loose or faulty radiator cap 6 When these checks and subsequent repairs are finished Refer to section 10 1 2 1 All information subject to change without notice 10 4 PRELIMINARY 6SE567 ...

Page 137: ...omer Support Center 313 592 5800 c If any codes other than code 111 1 display troubleshoot those codes 10 2 SPN 111 FMI 3 This condition is typically an open circuit fault 10 2 1 Open Circuit Check Check as follows 1 Check for multiple codes a If other faults are active in addition to fault 111 3 troubleshoot the other faults first b If only fault 111 3 is active go to step 2 2 Disconnect the ECL ...

Page 138: ...ins 1 and 2 of the ECL Sensor harness connector a If the voltage is greater than 11 5 volts go to step 7 b If the voltage is less than 11 5 volts go to step 6 6 Measure the voltage between pin 1 of the ECL Sensor harness connector and ground a If the voltage is greater than 11 5 volts repair the open between pin 2 of the CPC 3 connector and the ECL Sensor harness Refer to section 10 2 1 1 All info...

Page 139: ... follows 1 Connect all the removed connectors 2 Start and run the engine for 5 minutes 3 Plug in the diagnostic tool 4 Read the active codes a If no codes display the repairs are complete b If code 111 3 displays review these steps to find the error If you cannot find the error call the Detroit Diesel Customer Support Center 313 592 5800 c If any codes other than code 111 3 display troubleshoot th...

Page 140: ...n 10 3 1 1 b If the resistance is greater than 5 Ω go to step 6 6 Measure the resistance between pin 1 of the ECL Sensor harness connector and ground a If the resistance is less than 5 Ω repair the short circuit between pin 1 of the ECL Sensor harness connector and ground Refer to section 10 3 1 1 b If the resistance is greater than 5 Ω go to step 7 7 Measure the resistance between pin 2 of the EC...

Page 141: ...Verify Repairs Verify repairs as follows 1 Connect all the removed connectors 2 Start and run the engine for 5 minutes 3 Plug in the diagnostic tool 4 Read the active codes a If no codes display the repairs are complete b If code 111 4 displays review these steps to find the error If you cannot find the error call the Detroit Diesel Customer Support Center 313 592 5800 c If any codes other than co...

Page 142: ...10 3 SPN 111 FMI 4 All information subject to change without notice 10 10 PRELIMINARY 6SE567 0512 Copyright 2005 DETROIT DIESEL CORPORATION ...

Page 143: ...11 SPN 158 BATTERY CHARGING FAULT Section Page 11 1 SPN 158 FMI 0 11 3 11 2 SPN 158 FMI 1 11 4 11 3 SPN 158 FMI 2 11 6 ...

Page 144: ...All information subject to change without notice 11 2 PRELIMINARY 6SE567 0512 Copyright 2005 DETROIT DIESEL CORPORATION ...

Page 145: ...fer to section 11 1 1 1 11 1 1 1 Verify Repairs Verify repairs as follows 1 Turn vehicle ignition OFF Reconnect all connectors 2 Turn ignition ON Clear codes with diagnostic tool 3 Start and run the engine for one minute Stop engine 4 Check diagnostic tool for codes a If no codes are displayed troubleshooting is complete b If code 158 0 is not logged and other codes are logged troubleshoot the log...

Page 146: ...he voltage across the battery terminals See Figure 11 1 Figure 11 1 Power Wiring a If the voltage is less than 11 0 V troubleshoot the battery starting and charging system for an under voltage condition Refer to the OEM Vehicle Manual b If the voltage is not less than 11 0 V go to step 3 All information subject to change without notice 11 4 PRELIMINARY 6SE567 0512 Copyright 2005 DETROIT DIESEL COR...

Page 147: ...erminal a If the voltage is less than 11 0 V and voltage drop between pin 2 3 of the CPC 2 connector and the negative battery terminal is greater than 0 5 V replace or repair the ground side wires and connectors between pin 2 3 of the CPC 2 connector and battery ground Refer to section 11 2 1 1 b If the voltage is less than 11 0 V and voltage drop between pin 2 3 of the CPC 2 connector and the neg...

Page 148: ... to section 12 1 b If fault codes 158 2 and 158 1 are both still active refer to section 11 2 1 c If fault codes 158 2 and 158 0 are both still active refer to section 11 1 1 d If fault code 158 1 only is active go to step 2 2 Measure the difference in voltage inputs between the CPC and the MCM See Figure 11 2 Figure 11 2 Power Wiring All information subject to change without notice 11 6 PRELIMINA...

Page 149: ...M21 7 power and pins M21 5 M21 6 M21 8 and M21 9 ground on the MCM 21 pin connector Refer to section 11 3 1 1 11 3 1 1 Verify Repairs Verify repairs as follows 1 Turn ignition OFF Reconnect all connectors 2 Turn ignition ON Clear codes with diagnostic tool 3 Start and run the engine for one minute Stop engine 4 Check diagnostic tool for codes a If no codes are displayed troubleshooting is complete...

Page 150: ...11 3 SPN 158 FMI 2 All information subject to change without notice 11 8 PRELIMINARY 6SE567 0512 Copyright 2005 DETROIT DIESEL CORPORATION ...

Page 151: ...12 SPN 168 BATTERY VOLTAGE OUTSIDE NORMAL OPERATING RANGE Section Page 12 1 SPN 168 FMI 0 12 3 12 2 SPN 168 FMI 1 12 4 ...

Page 152: ...All information subject to change without notice 12 2 PRELIMINARY 6SE567 0512 Copyright 2005 DETROIT DIESEL CORPORATION ...

Page 153: ...urn the vehicle ignition OFF and reconnect all connectors 2 Turn the vehicle ignition ON and clear codes 3 Start and run the engine for one minute Stop the engine 4 Check for codes a If no codes are present troubleshooting is complete b If code 168 0 is not logged but other codes are logged troubleshoot the other codes c If code 168 0 and other codes are logged repeat troubleshooting procedure If ...

Page 154: ...or replace as required a If fault is no longer active erase fault code memory b If fault is still active go to step 4 4 Check the condition of the battery does it hold the charge and replace if required a If fault is no longer active refer to section 12 2 2 1 b If fault is still active refer to section 12 2 2 12 2 2 Measure the Resistance Measure the resistance as follows 1 Measure the resistance ...

Page 155: ...ace the power circuit wires and connector Refer to section 12 2 2 1 b If resistance is less than 0 5 Ω in any wire go to step 3 3 Measure the current drop of the individual wires in the ground circuit MCM 21 5 21 6 21 8 21 9 and CPC 2 2 See Figure 12 1 a If the current drop is more than 0 2 volts in any wire repair or replace the ground circuit wires and connector Refer to section 12 2 2 1 b If th...

Page 156: ...follows 1 Turn the vehicle ignition OFF and reconnect all connectors 2 Turn the vehicle ignition ON and clear codes 3 Start and run the engine for one minute Stop the engine 4 Check for codes a If no codes are present troubleshooting is complete b If code 168 1 is not logged but other codes are logged troubleshoot the other codes c If code 168 1 and other codes are logged repeat troubleshooting pr...

Page 157: ...13 SPN 174 SUPPLY FUEL TEMPERATURE FAULT Section Page 13 1 SPN 174 FMI 3 13 3 13 2 SPN 174 FMI 4 13 5 ...

Page 158: ...All information subject to change without notice 13 2 PRELIMINARY 6SE567 0512 Copyright 2005 DETROIT DIESEL CORPORATION ...

Page 159: ...he Supply Fuel Temperature Sensor 3 Measure the resistance across pins 1 and 2 of the SFT Sensor See Figure 13 1 Figure 13 1 Supply Fuel Temperature Sensor a If the resistance is greater than 4k Ω replace SFT Sensor Refer to section 13 1 1 1 b If the resistance is less than 4k Ω go to step 4 4 Turn the ignition ON key ON engine OFF 5 Measure the voltage between pins 1 and 2 of the SFT Sensor harne...

Page 160: ...sure the resistance between pins 1 and 2 of the SFT Sensor harness connector a If the resistance is less than 5 Ω repair the short between pins 55 and 77 of the 120 pin MCM connector Refer to section 13 1 1 1 b If the resistance is greater than 5 Ω replace the sensor Refer to section 13 1 1 1 13 1 1 1 Verify Repairs Verify repairs as follows 1 Turn the ignition OFF and reconnect all connectors 2 T...

Page 161: ...ness connector and ground a If resistance is less than 5 Ω repair the short circuit between pin 1 of the SFT Sensor harness connector and ground Refer to section 13 2 1 1 b If resistance is greater than 5 Ω go to step 5 5 Measure the resistance between pin 2 of the SFT Sensor harness connector and ground a If resistance is less than 5 Ω repair the short circuit between pin 2 of the SFT Sensor harn...

Page 162: ... to find the error If not error is found call the Detroit Diesel Customer Support Center 313 592 5800 c If code 174 4 is not logged but other codes are logged troubleshoot the other codes All information subject to change without notice 13 6 PRELIMINARY 6SE567 0512 Copyright 2005 DETROIT DIESEL CORPORATION ...

Page 163: ...14 SPN 175 ENGINE OIL TEMPERATURE OUT OF NORMAL RANGE Section Page 14 1 SPN 175 FMI 2 14 3 14 2 SPN 175 FMI 3 14 4 14 3 SPN 175 FMI 4 14 6 ...

Page 164: ...All information subject to change without notice 14 2 PRELIMINARY 6SE567 0512 Copyright 2005 DETROIT DIESEL CORPORATION ...

Page 165: ...il temperature within X degrees of the coolant temperature a If yes go to step 4 b If no disconnect the EOT Sensor and the MCM connector Bridge pins 1 and 2 of the sensor harness Measure the resistance at the MCM between pins 55 and 108 If the resistance is greater than 3 Ω repair the harness If the resistance is less than 3 Ω replace the sensor Refer to section 14 1 1 1 Figure 14 1 Engine Oil Tem...

Page 166: ...his diagnosis is typically engine oil temperature open circuit 14 2 1 Open Circuit Check Check as follows 1 Check for multiple codes a If codes 110 3 174 3 and 175 3 are active at the same time repair the open circuit between pin 55 of the 120 pin MCM connector and pin 1 of the Engine Coolant Temperature ECT Sensor the Engine Oil Temperature Sensor EOT and the Supply Fuel Temperature SFT Sensor Re...

Page 167: ...Sensor harness connector a If the resistance is greater than 5 Ω replace the EOT Sensor Refer to section 14 2 1 1 b If the resistance is less than 5 Ω repair the short between pins 55 and 108 of the 120 pin MCM connector Refer to section 14 2 1 1 14 2 1 1 Verify Repairs Verify repairs as follows 1 Turn the ignition OFF and reconnect all connectors 2 Turn the ignition ON Clear the codes 3 Start and...

Page 168: ...nuity then repair the short to ground in the wire between pin 1 of the sensor connector at the sensor and pin 52 at the 120 pin connector refer to section 14 3 1 1 14 3 1 1 Verify Repairs Verify repairs as follows 1 Turn the ignition OFF and reconnect all connectors 2 Turn the ignition ON Clear the codes 3 Start and run the engine for eight minutes Stop the engine 4 Check for codes a If no codes a...

Page 169: ... SPN 411 EGR DIFFERENTIAL PRESSURE OR DELTA P SENSOR CIRCUIT OUTSIDE OF NORMAL OPERATING RANGE Section Page 15 1 SPN 411 FMI 0 15 3 15 2 SPN 411 FMI 1 15 4 15 3 SPN 411 FMI 3 15 5 15 4 SPN 411 FMI 4 15 7 ...

Page 170: ...All information subject to change without notice 15 2 PRELIMINARY 6SE567 0512 Copyright 2005 DETROIT DIESEL CORPORATION ...

Page 171: ...PW to 60 NOTE Do not exceed three minutes 6 Is the EGR Delta P count greater than 170 and the EGR temperature greater than 90 above coolant temperature a If yes repeat steps 1 through 6 in this section If the same results occur contact the Detroit Diesel Customer Support Center 313 592 5800 b If no go to step 7 7 Turn the engine OFF 8 Inspect the EGR delivery pipes for damage and proper assembly a...

Page 172: ... multiple codes a If codes other than 411 1 are present service them first b If only 411 1 is present go to step 2 2 Using DDDL 7 0 monitor the coolant temperature EGR Delta P EGR PW EGR valve position and EGR temperature 3 Idle the engine with the EGR PW less than 3 and the EGR position less than 5 NO EGR FLOW COMMANDED 4 Is the EGR Delta P greater than 130 counts and the EGR temperature greater ...

Page 173: ...e EGR Delta P Sensor 2 Measure the resistance across pins 1 and 3 of the EGR Delta P Sensor a If the resistance is greater than 130 kΩ replace the EGR Delta P Sensor Refer to section 15 3 1 1 b If the resistance is less than 130 kΩ go to step 3 3 Measure the resistance between pins 1 and 2 of the EGR Delta P Sensor a If the resistance is greater than 130 kΩ replace the EGR Delta P Sensor Refer to ...

Page 174: ...ctor and pins 117 and 109 of the 120 pin MCM connector Refer to section 15 4 1 1 b If the resistance is greater than 5 Ω go to step 10 10 Measure the resistance across pins 2 and 3 of the EGR Delta P Sensor harness connector a If the resistance is less than 5 Ω repair the short in wires between pins 109 and 103 of the 120 pin MCM connector Refer to section 15 4 1 1 b If the resistance is greater t...

Page 175: ...roubleshoot the other codes c If code 411 3 and other codes are logged repeat troubleshooting procedure If no error is found contact the Detroit Diesel Customer Support Center 313 592 5800 15 4 SPN 411 FMI 4 This diagnosis is typically EGR Delta P Sensor short to ground 15 4 1 Short to Ground Check Check as follows 1 Disconnect the EGR Delta P Sensor 2 Disconnect the 120 pin MCM connector 3 Measur...

Page 176: ...l the Detroit Diesel Customer Support Center 313 592 5800 b If the resistance is less than 3Ω repair the short circuit between pin 3 of the EGR Delta P Sensor harness connector and ground Refer to section 15 4 1 1 15 4 1 1 Verify Repairs Verify repairs as follows 1 Turn the ignition OFF Reconnect all connectors 2 Turn the vehicle ignition ON and clear codes 3 Start and run the engine for one minut...

Page 177: ...16 SPN 412 EGR TEMPERATURE IS OUTSIDE OF THE NORMAL RANGE Section Page 16 1 SPN 412 FMI 3 16 3 16 2 SPN 412 FMI 4 16 5 ...

Page 178: ...All information subject to change without notice 16 2 PRELIMINARY 6SE567 0512 Copyright 2005 DETROIT DIESEL CORPORATION ...

Page 179: ... greater than 4k Ω replace the EGR Temperature Sensor Refer to section 16 1 1 1 b If the resistance is less than 4k Ω go to step 4 4 Turn the ignition ON key ON engine OFF 5 Measure the voltage between pins 1 and 2 of the EGR Temperature Sensor harness connector a If the voltage is between 2 75 and 3 25 volts go to step 7 b If the voltage is less than 2 75 volts go to step 6 6 Measure the voltage ...

Page 180: ... 1 1 b If the resistance is greater than 5 Ω replace the EGR Out Temperature Sensor Refer to section 16 1 1 1 16 1 1 1 Verify Repairs Verify repairs as follows 1 Reconnect all connectors 2 Turn the ignition ON and clear codes 3 Start and run the engine for one minute Stop the engine 4 Check for codes a If no codes are present troubleshooting is complete b If code 412 3 is not logged but other code...

Page 181: ...tep 4 4 Measure the resistance between pin 1 of the EGR Temperature Sensor and ground a If the resistance is less than 5 Ω repair the short between pin 1 of the EGR Temperature Sensor and ground Refer to section 16 2 1 1 b If the resistance is greater than 5 Ω go to step 5 5 Measure the resistance between pin 2of the EGR Temperature Sensor harness connector and ground a If the resistance is less t...

Page 182: ... codes a If no codes are present troubleshooting is complete b If code 412 4 is not logged but other codes are logged troubleshoot the other codes c If code 412 4 and other codes are logged repeat troubleshooting procedure If no error is found contact the Detroit Diesel Customer Support Center 313 592 5800 All information subject to change without notice 16 6 PRELIMINARY 6SE567 0512 Copyright 2005...

Page 183: ...17 SPN 558 IDLE VALIDATION SWITCH Section Page 17 1 SPN 558 FMI 1 17 3 17 2 SPN 558 FMI 3 17 3 17 3 SPN 558 FMI 4 17 5 ...

Page 184: ...All information subject to change without notice 17 2 PRELIMINARY 6SE567 0512 Copyright 2005 DETROIT DIESEL CORPORATION ...

Page 185: ... the ignition ON key ON engine OFF 3 Measure the voltage between the Idle Validation Switch pins 4 and 6 a If the voltage is greater than 11 5 volts go to step 7 b If the voltage is less than 11 5 volts go to step 4 4 Measure the voltage between the Idle Validation Switch pin 4 and ground a If the voltage is greater than 11 5 volts go to step 5 b If the voltage is less than 11 5 volts repair the o...

Page 186: ...irs as follows 1 Turn the ignition OFF Reconnect all connectors 2 Turn the ignition ON and clear codes 3 Start and run the engine for one minute Stop the engine 4 Check for codes a If no codes are present troubleshooting is complete b If code 558 3 is not logged but other codes are logged troubleshoot the other codes c If code 558 3 and other codes are logged repeat troubleshooting procedure If no...

Page 187: ... than 5 Ω repair the short to ground between pin 6 of the CPC 1 connector and pin 4 of the Idle Validation Switch connector Refer to section 17 3 1 1 b If the resistance is greater than 5 Ω go to step 4 4 Measure the resistance between pin 5 of the Idle Validation Switch connector and ground a If the resistance is less than 5 Ω repair the short to ground between pin 3 of the CPC 1 connector and pi...

Page 188: ... codes a If no codes are present troubleshooting is complete b If code 558 4 is not logged but other codes are logged troubleshoot the other codes c If code 558 4 and other codes are logged repeat troubleshooting procedure If no error is found contact the Detroit Diesel Customer Support Center 313 592 5800 All information subject to change without notice 17 6 PRELIMINARY 6SE567 0512 Copyright 2005...

Page 189: ...18 SPN 599 CRUISE CONTROL SWITCHES NOT FUNCTIONING PROPERLY Section Page 18 1 SPN 599 FMI 12 18 3 ...

Page 190: ...All information subject to change without notice 18 2 PRELIMINARY 6SE567 0512 Copyright 2005 DETROIT DIESEL CORPORATION ...

Page 191: ... RES switch to pin 16 of the CPC 1 connector Refer to section 18 1 1 1 4 Unplug the SET Cruise Control Switch a If SET status is no longer displayed replace the Cruise Control SET Switch Refer to section 18 1 1 1 b If SET status is still displayed repair the short to ground in the wire from the SET switch to pin 12 of the CPC 1 connector Refer to section 18 1 1 1 18 1 1 1 Verify Repairs Verify rep...

Page 192: ...18 1 SPN 599 FMI 12 All information subject to change without notice 18 4 PRELIMINARY 6SE567 0512 Copyright 2005 DETROIT DIESEL CORPORATION ...

Page 193: ...19 SPN 601 CRUISE CONTROL SWITCHES NOT FUNCTIONING PROPERLY Section Page 19 1 SPN 601 FMI 12 19 3 ...

Page 194: ...All information subject to change without notice 19 2 PRELIMINARY 6SE567 0512 Copyright 2005 DETROIT DIESEL CORPORATION ...

Page 195: ... RES switch to pin 16 of the CPC 1 connector Refer to section 19 1 1 1 4 Unplug the SET Cruise Control Switch a If SET status is no longer displayed replace the Cruise Control SET Switch Refer to section 19 1 1 1 b If SET status is still displayed repair the short to ground in the wire from the SET switch to pin 12 of the CPC 1 connector Refer to section 19 1 1 1 19 1 1 1 Verify Repairs Verify rep...

Page 196: ...19 1 SPN 601 FMI 12 All information subject to change without notice 19 4 PRELIMINARY 6SE567 0512 Copyright 2005 DETROIT DIESEL CORPORATION ...

Page 197: ...20 SPN 609 MCM FAULT ERRONEOUS DATA Section Page 20 1 SPN 609 FMI 12 20 3 20 2 SPN 609 FMI 14 20 4 ...

Page 198: ...All information subject to change without notice 20 2 PRELIMINARY 6SE567 0512 Copyright 2005 DETROIT DIESEL CORPORATION ...

Page 199: ...ooting is finished b If fault code 233 12 is still active after resetting parameters go to step 2 2 Check the MCM parameters to ensure they are correct for the vehicle configuration a If parameters are not correct reset parameters on the MCM b If parameters are correct contact Detroit Diesel Customer Support Center 313 592 5800 for authorization to replace the MCM Set parameters on the new MCM All...

Page 200: ... MCM parameters a If fault code 233 14 is not active after the MCM parameters are reset troubleshooting is complete b If fault code 233 14 is still active after the MCM parameters are reset go to step 3 3 Check the MCM parameters to ensure they are correct for the vehicle configuration a If the MCM parameters are not correct reset the parameters b If the MCM parameters are correct contact Detroit ...

Page 201: ...21 SPN 625 CAN FAULT Section Page 21 1 SPN 625 FMI 2 9 10 13 14 21 3 21 2 SPN 625 FMI 4 21 5 ...

Page 202: ...All information subject to change without notice 21 2 PRELIMINARY 6SE567 0512 Copyright 2005 DETROIT DIESEL CORPORATION ...

Page 203: ...in connector NOTE Poor battery grounds can be a possible cause of low battery voltage b If the battery voltage is greater than 10 5 volts go to step 5 5 Turn ignition OFF leave the 21 pin MCM connector disconnected 6 Disconnect the CPC 4 connector 7 Measure the resistance between pins 1 and 3 of the CPC 4 connector a If the resistance is greater than 5 Ω go to step 8 b If the resistance is less th...

Page 204: ...ween pin 3 of the CPC 4 connector and pin 13 of the 21 pin MCM connector Refer to section 21 1 1 1 b If the resistance is less than 5 Ω call the DDC Customer Support Center 313 592 5800 21 1 1 1 Verify Repairs Verify repairs as follows 1 Turn the ignition OFF Reconnect all connectors 2 Turn the ignition ON and clear codes 3 Start and run the engine for one minute Stop the engine 4 Check for codes ...

Page 205: ...and ground Refer to section 21 2 1 1 5 Measure the resistance between pin 3 of the CPC 4 connector and ground a If the resistance is greater than 5 Ω go to step 6 b If the resistance is less than 5 Ω repair the short to ground between pin 3 of the CPC 4 connector and ground Refer to section 21 2 1 1 6 Measure the resistance between pin 1 of the CPC 4 connector and pin 19 of the 21 pin MCM connecto...

Page 206: ... codes a If no codes are present troubleshooting is complete b If code 625 4 is not logged but other codes are logged troubleshoot the other codes c If code 625 4 and other codes are logged repeat troubleshooting procedure If no error is found contact the Detroit Diesel Customer Support Center 313 592 5800 All information subject to change without notice 21 6 PRELIMINARY 6SE567 0512 Copyright 2005...

Page 207: ...PN 636 CRANKSHAFT POSITION SENSOR OUTSIDE OF NORMAL OPERATING CONDITIONS Section Page 22 1 SPN 636 FMI 1 22 3 22 2 SPN 636 FMI 3 22 4 22 3 SPN 636 FMI 4 22 6 22 4 SPN 636 FMI 7 22 7 22 5 SPN 636 FMI 8 22 9 ...

Page 208: ...All information subject to change without notice 22 2 PRELIMINARY 6SE567 0512 Copyright 2005 DETROIT DIESEL CORPORATION ...

Page 209: ...ult occurs at other times then when cranking the engine check that the CKP Sensor position is correct the sensor is seated in all the way a If fault is not active after checking CKP Sensor position repair the CKP Sensor clamping sleeve Refer to section 22 1 1 1 b If fault is still active after checking the CKP Sensor position go to step 3 3 Check the flywheel position through the inspection window...

Page 210: ...r codes are logged review this section to find the error If no error is found call the Detroit Diesel Customer Support Center 313 592 5800 22 2 SPN 636 FMI 3 The diagnostic condition is typically CKP Sensor has an open circuit 22 2 1 Open Circuit Check Check for a CKP Sensor open circuit as follows 1 Disconnect the CKP Sensor 2 Measure the resistance across pins 1 and 2 of the CKP Sensor See Figur...

Page 211: ...nce between pin 2 of the CKP Sensor harness connector and pin 43 of the 120 pin MCM connector a If the resistance is greater than 5 Ω repair the open between pin 2 of the CKP Sensor harness connector and pin 43 of the 120 pin MCM connector Refer to section 22 2 2 1 b If the resistance is less than 5 Ω refer to section 22 2 2 22 2 2 Crankshaft Position Sensor Gap Check Check as follows 1 Bar the en...

Page 212: ...d 22 3 1 Short to Ground Check Troubleshoot as follows 1 Disconnect the CKP Sensor 2 Measure the resistance between pin 1 of the CKP Sensor and ground a If the resistance is greater than 5 Ω go to step 3 b If the resistance is less than 5 Ω replace the sensor Refer to section 22 3 1 1 3 Measure the resistance between pin 2 of the CKP Sensor and ground a If the resistance is greater than 5 Ω go to ...

Page 213: ...l connectors 2 Turn ignition ON Clear codes with diagnostic tool 3 Start and run the engine for one minute Stop engine 4 Check diagnostic tool for codes a If no codes are displayed troubleshooting is complete b If code 636 4 is not logged and other codes are logged troubleshoot the logged codes c If code 636 4 and other codes are logged review this section to find the error If no error is found ca...

Page 214: ...or slots are missing or damaged replace the flywheel as needed refer to section 22 4 1 1 b If the flywheel holes or slots are all present go to step 8 8 Replace the MCM Refer to section 22 4 1 1 22 4 1 1 Verify Repairs Verify repairs as follows 1 Turn vehicle ignition OFF Reconnect all connectors 2 Turn ignition ON Clear codes with diagnostic tool 3 Start and run the engine for one minute Stop eng...

Page 215: ...r position a If fault 636 8 is not active after checking position replace CKP Sensor clamping sleeve Refer to section 22 5 1 1 b If fault 636 8 is active after checking position go to step 3 3 Replace the Vehicle Speed Sensor a If fault s 636 8 is not active refer to section 22 5 1 1 b If fault s 636 8 is still active go to step 4 4 Check the flywheel position in the timing case through the inspec...

Page 216: ...ition OFF Reconnect all connectors 2 Turn ignition ON Clear codes with diagnostic tool 3 Start and run the engine for one minute Stop engine 4 Check diagnostic tool for codes a If no codes are displayed troubleshooting is complete b If code 636 8 is not logged and other codes are logged troubleshoot the logged codes c If code 636 8 and other codes are logged review this section to find the error I...

Page 217: ...23 SPN 651 INJECTOR 1 NEEDLE VALVE NOT OPERATING NORMALLY Section Page 23 1 SPN 651 FMI 5 23 3 23 2 SPN 651 FMI 10 23 6 ...

Page 218: ...All information subject to change without notice 23 2 PRELIMINARY 6SE567 0512 Copyright 2005 DETROIT DIESEL CORPORATION ...

Page 219: ...of the connector a If the resistance is less than 3 Ω refer to section 23 1 2 b If the resistance is greater than 3 Ω go to step 5 5 Remove valve cover 6 Disconnect injector 1 connector 7 Measure the resistance between pin 1 of the injector connector and pin F of the injector harness 23 pin connector a If the resistance is greater than 3 Ω repair the open between pin 1 of the injector connector an...

Page 220: ...ector see Figure 23 1 Refer to section 23 1 3 1 Figure 23 1 120 pin MCM Connector b If the voltage is between 11 5 and 13 5 volts refer to section 23 1 3 3 Swap the injector a If fault code 651 5 is not active after swapping the injector replace the original injector Refer to section 23 1 3 1 b If fault code 651 5 is still active after swapping the injector call the Detroit Diesel Customer Service...

Page 221: ...troit Diesel Customer Support Center 313 592 5044 23 1 3 1 Verify Repairs Verify repairs as follows 1 Turn the ignition OFF and reconnect all connectors 2 Turn the ignition ON and clear codes 3 Start and run the engine for one minute Stop the engine 4 Check for codes a If no codes are present troubleshooting is complete b If code 651 5 is not logged but other codes are logged troubleshoot the othe...

Page 222: ... step 6 6 Recheck the resistance using steps 3 through 5 When you have just completed the recheck go to step 7 7 Clear the codes Check for active codes a If code 651 10 is still active call the Detroit Diesel Customer Support Center 313 592 5800 for authorization to replace the MCM b If there are no active codes troubleshooting is finished Refer to section 23 2 1 1 23 2 1 1 Verify Repairs Verify r...

Page 223: ...24 SPN 652 INJECTOR 2 NEEDLE VALVE NOT OPERATING NORMALLY Section Page 24 1 SPN 652 FMI 5 24 3 24 2 SPN 652 FMI 10 24 6 ...

Page 224: ...All information subject to change without notice 24 2 PRELIMINARY 6SE567 0512 Copyright 2005 DETROIT DIESEL CORPORATION ...

Page 225: ...ctor a If the resistance is less than 3 Ω refer to section 24 1 2 b If the resistance is greater than 3 Ω go to step 5 5 Remove valve cover 6 Disconnect injector 2 connector 7 Measure the resistance between pin 1 of the injector connector and pin F of the injector harness 23 pin connector a If the resistance is greater than 3 Ω repair the open between pin 1 of the injector connector and pin F of t...

Page 226: ...n connector see Figure 24 1 Refer to section 24 1 3 1 Figure 24 1 120 pin MCM Connector b If the voltage is between 11 5 and 13 5 volts go to step 3 3 Swap the injector a If fault code 652 5 is not active after swapping the injector replace the original injector Refer to section 24 1 3 1 b If fault code 652 5 is still active after swapping the injector call the Detroit Diesel Customer Service Cent...

Page 227: ...esel Customer Support Center 313 592 5044 24 1 3 1 Verify Repairs Verify repairs as follows 1 Turn the vehicle ignition OFF and reconnect all connectors 2 Turn the vehicle ignition ON and clear codes 3 Start and run the engine for one minute Stop the engine 4 Check for codes a If no codes are present troubleshooting is complete b If code 652 5 is not logged but other codes are logged troubleshoot ...

Page 228: ...han 5 Ω go to step 6 6 Recheck the resistance using steps 3 through 5 When you have completed the recheck go to step 7 7 Clear the codes Check for active codes a If code 653 10 is still active call the Detroit Diesel Customer Support Center 313 592 5800 for authorization to replace the MCM b If there are no active codes troubleshooting is finished Refer to section 24 2 1 1 24 2 1 1 Verify Repairs ...

Page 229: ...25 SPN 653 INJECTOR 3 NEEDLE VALVE NOT OPERATING NORMALLY Section Page 25 1 SPN 653 FMI 5 25 3 25 2 SPN 653 FMI 10 25 6 ...

Page 230: ...All information subject to change without notice 25 2 PRELIMINARY 6SE567 0512 Copyright 2005 DETROIT DIESEL CORPORATION ...

Page 231: ...tor a If the resistance is less than 3 Ω refer to section 25 1 2 b If the resistance is greater than 3 Ω go to step 5 5 Remove valve cover 6 Disconnect injector 3 connector 7 Measure the resistance between pin 1 of the injector connector and pin F of the injector harness 23 pin connector a If the resistance is greater than 3 Ω repair the open between pin 1 of the injector connector and pin F of th...

Page 232: ... pin connector see Figure 25 1 Refer to section 25 1 3 1 Figure 25 1 120 pin MCM Connector b If the voltage is between 11 5 and 13 5 volts go to step 3 3 Swap the injector a If fault code 653 5 is not active after swapping the injector replace the original injector Refer to section 25 1 3 1 b If fault code 653 5 is still active after swapping the injector call the Detroit Diesel Customer Service C...

Page 233: ...troit Diesel Customer Support Center 313 592 5044 25 1 3 1 Verify Repairs Verify repairs as follows 1 Turn the ignition OFF and reconnect all connectors 2 Turn the ignition ON and clear codes 3 Start and run the engine for one minute Stop the engine 4 Check for codes a If no codes are present troubleshooting is complete b If code 653 5 is not logged but other codes are logged troubleshoot the othe...

Page 234: ... go to step 6 6 Recheck the resistance using steps 3 through 5 When you have just completed the recheck go to step 7 7 Clear the codes Check for active codes a If code 653 10 is still active call the Detroit Diesel Customer Support Center 313 592 5800 for authorization to replace the MCM b If there are no active codes troubleshooting is finished Refer to section 25 2 1 1 25 2 1 1 Verify Repairs Ve...

Page 235: ...26 SPN 654 INJECTOR 4 NEEDLE VALVE NOT OPERATING NORMALLY Section Page 26 1 SPN 654 FMI 5 26 3 26 2 SPN 654 FMI 10 26 6 ...

Page 236: ...All information subject to change without notice 26 2 PRELIMINARY 6SE567 0512 Copyright 2005 DETROIT DIESEL CORPORATION ...

Page 237: ...f the resistance is less than 3 Ω refer to section 26 1 2 b If the resistance is greater than 3 Ω go to step 5 5 Remove valve cover 6 Disconnect injector 4 connector 7 Measure the resistance between pin 1 of the injector connector and pin K of the injector harness 23 pin connector a If the resistance is greater than 3 Ω repair the open between pin 1 of the injector connector and pin K of the injec...

Page 238: ... connector see Figure 26 1 Refer to section 26 1 3 1 Figure 26 1 120 pin MCM Connector b If the voltage is between 11 5 and 13 5 volts go to step 3 3 Swap the injector a If fault code 654 5 is not active after swapping the injector replace the original injector Refer to section 26 1 3 1 b If fault code 654 5 is still active after swapping the injector call the Detroit Diesel Customer Service Cente...

Page 239: ...troit Diesel Customer Support Center 313 592 5044 26 1 3 1 Verify Repairs Verify repairs as follows 1 Turn the ignition OFF and reconnect all connectors 2 Turn the ignition ON and clear codes 3 Start and run the engine for one minute Stop the engine 4 Check for codes a If no codes are present troubleshooting is complete b If code 654 5 is not logged but other codes are logged troubleshoot the othe...

Page 240: ...n 5 Ω go to step 6 6 Recheck the resistance using steps 3 through 5 When you have just completed the recheck go to step 7 7 Clear the codes Check for active codes a If code 654 10 is still active call the Detroit Diesel Customer Support Center 313 592 5800 for authorization to replace the MCM b If there are no active codes troubleshooting is finished Refer to section 26 2 1 1 26 2 1 1 Verify Repai...

Page 241: ...27 SPN 655 INJECTOR 5 NEEDLE VALVE NOT OPERATING NORMALLY Section Page 27 1 SPN 655 FMI 5 27 3 27 2 SPN 655 FMI 10 27 6 ...

Page 242: ...All information subject to change without notice 27 2 PRELIMINARY 6SE567 0512 Copyright 2005 DETROIT DIESEL CORPORATION ...

Page 243: ...er side of the connector a If the resistance is less than 3 Ω go to step 4 b If the resistance is greater than 3 Ω go to step 8 5 Remove valve cover 6 Disconnect injector 5 connector 7 Measure the resistance between pin 1 of the injector connector and pin K of the injector harness 23 pin connector a If the resistance is greater than 3 Ω repair the open between pin 1 of the injector connector and p...

Page 244: ...20 pin connector see Figure 27 1 Refer to section 27 1 3 1 Figure 27 1 120 pin MCM Connector b If the voltage is between 11 5 and 13 5 volts refer to section 27 1 3 3 Swap the injector a If fault code 655 5 is not active after swapping the injector replace the original injector Refer to section 27 1 3 1 b If fault code 655 5 is still active after swapping the injector call the Detroit Diesel Custo...

Page 245: ...troit Diesel Customer Support Center 313 592 5044 27 1 3 1 Verify Repairs Verify repairs as follows 1 Turn the ignition OFF and reconnect all connectors 2 Turn the ignition ON and clear codes 3 Start and run the engine for one minute Stop the engine 4 Check for codes a If no codes are present troubleshooting is complete b If code 655 5 is not logged but other codes are logged troubleshoot the othe...

Page 246: ...connector 6 Measure the resistance between pin H and ground on the engine side of the connector a If the resistance is less than 5 Ω repair the short to ground between Pin H and pin 20 of the MCM 120 pin connector Refer to section 27 2 1 1 b If the resistance is greater than 5 Ω go to step 7 7 Recheck the resistance using steps 3 through 6 When you have just completed the recheck go to step 8 8 Cl...

Page 247: ...leshoot the other codes c If code 655 10 and other codes are logged repeat troubleshooting procedure If no error is found contact the Detroit Diesel Customer Support Center 313 592 5800 All information subject to change without notice PRELIMINARY 6SE567 0512 Copyright 2005 DETROIT DIESEL CORPORATION 27 7 ...

Page 248: ...27 2 SPN 655 FMI 10 All information subject to change without notice 27 8 PRELIMINARY 6SE567 0512 Copyright 2005 DETROIT DIESEL CORPORATION ...

Page 249: ...28 SPN 656 INJECTOR 6 NEEDLE VALVE NOT OPERATING NORMALLY Section Page 28 1 SPN 656 FMI 5 28 3 28 2 SPN 656 FMI 10 28 6 ...

Page 250: ...All information subject to change without notice 28 2 PRELIMINARY 6SE567 0512 Copyright 2005 DETROIT DIESEL CORPORATION ...

Page 251: ...e connector a If the resistance is less than 3 Ω refer to section 28 1 2 b If the resistance is greater than 3 Ω go to step 5 5 Remove the valve cover 6 Disconnect injector 6 connector 7 Measure the resistance between pin 1 of the injector connector and pin K of the injector harness 23 pin connector a If the resistance is greater than 3 Ω repair the open between pin 1 of the injector connector and...

Page 252: ...in connector see Figure 28 1 Refer to section 28 1 3 1 Figure 28 1 120 pin Connector b If the voltage is between 11 5 and 13 5 volts go to step 3 3 Swap the injector a If fault code 656 5 is not active after swapping the injector replace the original injector Refer to section 28 1 3 1 b If fault code 656 5 is still active after swapping the injector call the Detroit Diesel Customer Service Center ...

Page 253: ...troit Diesel Customer Support Center 313 592 5044 28 1 3 1 Verify Repairs Verify repairs as follows 1 Turn the ignition OFF and reconnect all connectors 2 Turn the ignition ON and clear codes 3 Start and run the engine for one minute Stop the engine 4 Check for codes a If no codes are present troubleshooting is complete b If code 656 5 is not logged but other codes are logged troubleshoot the othe...

Page 254: ...s greater than 5 Ω go to step 6 6 Recheck the resistance using steps 3 through 5 When you have just completed the recheck go to step 7 7 Clear the codes Check for active codes a If code 656 10 is still active call the Detroit Diesel Customer Support Center 313 592 5800 for authorization to replace the MCM b If there are no active codes troubleshooting is finished 28 2 1 1 Verify Repairs Verify rep...

Page 255: ...29 SPN 701 JAKE BRAKES LOW AUX PWM 7 OPEN OR SHORT Section Page 29 1 SPN 701 FMI 3 29 3 29 2 SPN 701 FMI 4 29 5 29 3 SPN 701 FMI 5 29 6 ...

Page 256: ...All information subject to change without notice 29 2 PRELIMINARY 6SE567 0512 Copyright 2005 DETROIT DIESEL CORPORATION ...

Page 257: ...oltage Check The resistance and voltage check performed indicate that you should not be getting a code The following is a recheck before requesting a new MCM 1 Turn ignition OFF Reconnect all connectors 2 Turn ignition ON Clear codes with diagnostic tool 3 Start and run the engine for one minute Stop engine 4 Put the ignition switch in the OFF position 5 Disconnect the injector harness 23 pin conn...

Page 258: ...des 3 Start and run the engine for one minute Stop the engine 4 Check for codes a If no codes are present troubleshooting is complete b If code 701 3 is not logged but other codes are logged troubleshoot the other codes c If code 701 3 and other codes are logged repeat troubleshooting procedure If no error is found contact the Detroit Diesel Customer Support Center 313 592 5800 All information sub...

Page 259: ...9 2 2 Resistance Check The resistance check performed indicate that you should not be getting a code The following is a recheck before requesting a new MCM 1 Reconnect all connectors 2 Turn ignition ON Clear codes with diagnostic tool 3 Start and run the engine for one minute Stop engine 4 Put the ignition switch in the OFF position 5 Disconnect the injector harness 23 pin connector 6 Measure resi...

Page 260: ... Check as follows 1 Check for multiple codes a If SPN 701 5 and SPN 706 5 are active repair the open in between the pin 91 of the 120 pin MCM connector and the Jake Brake solenoids b If only SPN 701 5 is active go to step 2 2 Put the ignition switch in the OFF position 3 Disconnect the injector harness 23 pin connector 4 Measure the resistance between pin A and pin C on the valve cover side of the...

Page 261: ...an 11 5 volts repair the open between pin C of the injector connector and pin 32 of the 120 pin MCM connector b If the voltage is between 11 5 and 13 5 volts go to step 12 12 Check for codes If the code is still present contact Detroit Diesel Customer Support Center 313 592 5800 for MCM replacement authorization 29 3 1 1 Verify Repairs Verify repairs as follows 1 Turn the ignition OFF and reconnec...

Page 262: ...29 3 SPN 701 FMI 5 All information subject to change without notice 29 8 PRELIMINARY 6SE567 0512 Copyright 2005 DETROIT DIESEL CORPORATION ...

Page 263: ...30 SPN 704 TURBO ACTUATOR CONTROL AUX PWM 10 Section Page 30 1 SPN 704 FMI 3 30 3 30 2 SPN 704 FMI 4 30 4 30 3 SPN 704 FMI 5 30 5 ...

Page 264: ...All information subject to change without notice 30 2 PRELIMINARY 6SE567 0512 Copyright 2005 DETROIT DIESEL CORPORATION ...

Page 265: ...he resistance is less than 5 Ω repair the short between pins 1 and 3 of the turbo actuator connector and pins 35 and 93 of the 120 pin MCM connector Refer to section 30 1 1 1 b If the resistance is greater than 5 Ω refer to section 30 1 1 1 30 1 1 1 Verify Repairs Verify repairs as follows 1 Turn ignition OFF Reconnect all connectors 2 Turn ignition ON Clear codes with diagnostic tool 3 Start and ...

Page 266: ...nnector and ground a If the resistance is less than 5 Ω repair the short between pin 3 of the turbo actuator connector and ground Refer to section 30 2 1 1 b If the resistance is greater than 5 Ω go to step 6 6 Measure the resistance between pin 1 of the turbo actuator connector and ground a If the resistance is less than 5 Ω repair the short between pin 1 of the turbo actuator connector and groun...

Page 267: ...pin 1 of the turbo actuator connector and chassis ground a If the voltage is between 11 and 13 volts repair the open in the wire between pin 38 of the 120 pin MCM connector and pin 2 of the turbo actuator connector Refer to section 30 1 1 1 b If the voltage is less than 11 volts repair the open in the wire between pin 93 of the 120 pin MCM connector and pin 1 of the turbo actuator connector Refer ...

Page 268: ...ic tool for codes a If no codes are displayed troubleshooting is complete b If code SPN 704 5 is not logged and other codes are logged troubleshoot the logged codes c If SPN 704 5 and other codes are logged review this section to find the error If no error is found call the Detroit Diesel Customer Support Center 313 592 5800 All information subject to change without notice 30 6 PRELIMINARY 6SE567 ...

Page 269: ...31 SPN 706 JAKE BRAKE MEDIUM AUX PWM 13 OPEN OR SHORT Section Page 31 1 SPN 706 FMI 3 31 3 31 2 SPN 706 FMI 4 31 5 31 3 SPN 706 FMI 5 31 6 ...

Page 270: ...All information subject to change without notice 31 2 PRELIMINARY 6SE567 0512 Copyright 2005 DETROIT DIESEL CORPORATION ...

Page 271: ... 1 2 Resistance and Voltage Check The resistance and voltage check performed indicate that you should not be getting a code The following is a recheck before requesting a new MCM 1 Reconnect all connectors 2 Turn ignition ON Clear codes with diagnostic tool 3 Start and run the engine for one minute Stop engine 4 Turn the ignition OFF 5 Disconnect the injector harness 23 pin connector 6 Measure the...

Page 272: ...clear codes 3 Start and run the engine for one minute Stop the engine 4 Check for codes a If no codes are present troubleshooting is complete b If code 706 3 is not logged but other codes are logged troubleshoot the other codes c If code 706 3 and other codes are logged repeat troubleshooting procedure If no error is found contact the Detroit Diesel Customer Support Center 313 592 5800 All informa...

Page 273: ...1 2 2 Resistance Check The resistance check performed indicate that you should not be getting a code The following is a recheck before requesting a new MCM 1 Reconnect all connectors 2 Turn ignition ON Clear codes with diagnostic tool 3 Start and run the engine for one minute Stop engine 4 Put the ignition switch in the OFF position 5 Disconnect the injector harness 23 pin connector 6 Measure resi...

Page 274: ...n Circuit Check Check as follows 1 Check for multiple codes a If SPN 706 5 and SPN 704 5 are active repair the open in between the pin 91 of the 120 pin MCM connector and the Jake Brake solenoids b If only SPN 706 5 is active go to step 2 2 Turn the ignition OFF 3 Disconnect the injector harness 23 pin connector 4 Measure the resistance between pin A and pin B on the valve cover side of the connec...

Page 275: ...pair the open between pin B of the injector connector and pin 66 of the 120 pin MCM connector b If the voltage is between 11 5 and 13 5 volts go to step 12 12 Check for codes If the code is still present contact Detroit Diesel Customer Support Center 313 592 5800 for MCM replacement authorization 31 3 1 1 Verify Repairs Verify repairs as follows 1 Turn the ignition OFF and reconnect all connectors...

Page 276: ...31 3 SPN 706 FMI 5 All information subject to change without notice 31 8 PRELIMINARY 6SE567 0512 Copyright 2005 DETROIT DIESEL CORPORATION ...

Page 277: ...32 SPN 709 SINGLE SPEED FAN LOW SIDE DIGITAL OUTPUT 3 FAULT Section Page 32 1 SPN 709 FMI 3 32 3 32 2 SPN 709 FMI 4 32 5 32 3 SPN 709 FMI 5 32 6 ...

Page 278: ...All information subject to change without notice 32 2 PRELIMINARY 6SE567 0512 Copyright 2005 DETROIT DIESEL CORPORATION ...

Page 279: ...uld not be getting a code The following is a recheck before requesting a new MCM 1 Turn the ignition OFF Reconnect all connectors 2 Turn ignition ON Clear codes with diagnostic tool 3 Start and run the engine for one minute Stop engine 4 Turn the ignition OFF 5 Disconnect the fan control solenoid connector 6 Turn the ignition ON key On engine OFF 7 Measure the voltage between pin 1 of the fan cont...

Page 280: ...or codes a If no codes are present troubleshooting is complete b If code 711 3 is not logged but other codes are logged troubleshoot the other codes c If code 711 3 and other codes are logged repeat troubleshooting procedure If no error is found contact the Detroit Diesel Customer Support Center 313 592 5800 All information subject to change without notice 32 4 PRELIMINARY 6SE567 0512 Copyright 20...

Page 281: ... than 5 Ω repair the short to ground between pin 2 of the fan control solenoid connector and pin 91 of the 120 pin MCM connector Refer to section 32 2 1 1 32 2 1 1 Verify Repairs Verify repairs as follows 1 Reconnect all connectors 2 Turn the vehicle ignition ON and clear codes 3 Start and run the engine for one minute Stop the engine 4 Check for codes a If no codes are present troubleshooting is ...

Page 282: ... 120 pin MCM connector Refer to section 32 3 1 1 a If the voltage is less than 11 5 volts repair the open between pin 2 of the fan control solenoid connector and ground Refer to section 32 3 1 1 b If the voltage is greater than 11 5 repair the open between pin 1 of the fan control solenoid connector and pin 98 of the 120 pin MCM connector Refer to section 32 3 1 1 32 3 1 1 Verify Repairs Verify re...

Page 283: ...33 SPN 714 ETHER START LOW SIDE DIGITAL OUTPUT 8 FAULT Section Page 33 1 SPN 714 FMI 3 33 3 33 2 SPN 714 FMI 4 33 4 33 3 SPN 714 FMI 5 33 5 ...

Page 284: ...All information subject to change without notice 33 2 PRELIMINARY 6SE567 0512 Copyright 2005 DETROIT DIESEL CORPORATION ...

Page 285: ...an 4 5 volts go to step 5 5 Review steps 1 through 4 If the results are the same contact the Detroit Diesel Customer Support Center 313 592 5800 33 1 1 1 Verify Repairs Perform the following steps to verify repairs 1 Turn the ignition OFF and reconnect all connectors 2 Turn the ignition ON Clear the codes 3 Start and run the engine for eight minutes Stop the engine 4 Check for codes a If no codes ...

Page 286: ...ection 33 2 1 1 b If the resistance is greater than 5 Ω contact the Detroit Diesel Customer Support Center 313 592 5800 33 2 1 1 Verify Repairs Perform the following steps to verify repairs 1 Reconnect all connectors 2 Turn vehicle ignition ON Clear the codes 3 Start and run the engine for eight minutes Stop the engine 4 Check for codes a If no codes are logged troubleshooting is complete b If oth...

Page 287: ...0 of the 120 pin MCM connector Refer to section 33 3 1 1 b If the resistance is less than 5 Ω contact the Detroit Diesel Customer Support Center 313 592 5800 33 3 1 1 Verify Repairs Perform the following steps to verify repairs 1 Reconnect all connectors 2 Turn the ignition ON Clear the codes 3 Start and run the engine for eight minutes Stop the engine 4 Check for codes a If no codes are logged tr...

Page 288: ...33 3 SPN 714 FMI 5 All information subject to change without notice 33 6 PRELIMINARY 6SE567 0512 Copyright 2005 DETROIT DIESEL CORPORATION ...

Page 289: ...34 SPN 723 CAMSHAFT POSITION SENSOR FAULT Section Page 34 1 SPN 723 FMI 3 34 3 34 2 SPN 723 FMI 4 34 5 34 3 SPN 723 FMI 8 34 6 34 4 SPN 723 FMI 14 34 7 ...

Page 290: ...All information subject to change without notice 34 2 PRELIMINARY 6SE567 0512 Copyright 2005 DETROIT DIESEL CORPORATION ...

Page 291: ...sure the resistance across pins 1 and 2 of the CMP harness connector a If the resistance is less than 5 Ω repair short between pins 1 and 2 of the CMP harness connector and the pins 44 and 45 of the MCM 120 pin connector Refer to section 34 1 1 1 b If the resistance is greater than 5 Ω go to step 5 5 Measure the resistance between pin 1 of the CMP harness connector and pin 44 of the MCM 120 pin co...

Page 292: ...ition OFF and reconnect all connectors 2 Turn the ignition ON 3 Start and run the engine for one minute Stop engine 4 Check the diagnostic tool for codes a If no codes are logged troubleshooting is complete b If code 723 3 and any other codes are logged and the CMP was not replaced replace the sensor and retest c If code 723 3 and any other codes are logged and the CMP was replaced review this sec...

Page 293: ...nsor and ground a If the resistance is greater than 5 Ω go to step 4 b If the resistance is less than 5 Ω replace the CMP Sensor Refer to section 34 2 1 1 4 Disconnect 120 pin MCM connector 5 Measure the resistance across pins 1 and 2 of the CMP harness connector a If the resistance is greater than 5 Ω go to step 6 b If the resistance is less than 5 Ω repair the short between pins 1 and 2 of the C...

Page 294: ...3 Start and run the engine for one minute Stop engine 4 Check the diagnostic tool for codes a If no codes are logged troubleshooting is complete b If code 723 4 and any other codes are logged and the Engine Oil Pressure Sensor was not replaced replace the sensor and retest c If any codes except code 723 4 are logged troubleshoot those codes 34 3 SPN 723 FMI 8 A typical diagnosis is time out 34 3 1...

Page 295: ...al play is incorrect Refer to section 34 3 2 1 34 3 2 1 Verify Repairs Perform the following steps to verify repairs 1 Turn vehicle ignition OFF and reconnect all connectors 2 Turn vehicle ignition ON 3 Start and run the engine for one minute Stop engine 4 Check the diagnostic tool for codes a If no codes are logged troubleshooting is complete b If any codes except code 723 8 are logged troublesho...

Page 296: ...ps to verify repairs 1 Turn vehicle ignition OFF and reconnect all connectors 2 Turn vehicle ignition ON 3 Start and run the engine for one minute Stop engine 4 Check the diagnostic tool for codes a If no codes are logged troubleshooting is complete b If any codes except code 723 14 are logged troubleshoot those codes All information subject to change without notice 34 8 PRELIMINARY 6SE567 0512 Co...

Page 297: ...35 SPN 975 TWO SPEED FAN AUX PWM 6 FAULT Section Page 35 1 SPN 975 FMI 3 35 3 35 2 SPN 975 FMI 4 35 5 35 3 SPN 975 FMI 5 35 6 ...

Page 298: ...All information subject to change without notice 35 2 PRELIMINARY 6SE567 0512 Copyright 2005 DETROIT DIESEL CORPORATION ...

Page 299: ...a new MCM 1 Turn the ignition OFF Reconnect all connectors 2 Turn ignition ON Clear codes with diagnostic tool 3 Start and run the engine for one minute Stop engine 4 Turn the ignition OFF 5 Disconnect the fan control solenoid connector 6 Turn the ignition ON key On engine OFF 7 Measure the voltage between pin 1 of the fan control solenoid connector and ground a If the voltage is greater than 11 5...

Page 300: ...e 975 3 is not logged but other codes are logged troubleshoot the other codes c If code 975 3 and other codes are logged repeat troubleshooting procedure If no error is found contact the Detroit Diesel Customer Support Center 313 592 5800 All information subject to change without notice 35 4 PRELIMINARY 6SE567 0512 Copyright 2005 DETROIT DIESEL CORPORATION ...

Page 301: ...Ω repair the short to ground between pin 2 of the fan control solenoid and pin 91 of the 120 pin MCM connector Refer to section 35 2 1 1 35 2 1 1 Verify Repairs Verify repairs as follows 1 Reconnect all connectors 2 Turn the ignition ON and clear codes 3 Start and run the engine for one minute Stop the engine 4 Check for codes a If no codes are present troubleshooting is complete b If code 975 4 i...

Page 302: ...nector and ground a If the voltage is less than 11 5 volts repair the open between pin 2 of the fan control solenoid connector and pin 91 of the 120 pin MCM connector Refer to section 35 3 1 1 b If the voltage is greater than 11 5 repair the open between pin 1 of the fan control solenoid connector and pin 33 of the 120 pin MCM connector Refer to section 35 3 1 1 35 3 1 1 Verify Repairs Verify repa...

Page 303: ...36 SPN 1172 TURBO COMPRESSOR IN TEMP HIGH OR LOW Section Page 36 1 SPN 1172 FMI 3 36 3 36 2 SPN 1172 FMI 4 36 5 ...

Page 304: ...All information subject to change without notice 36 2 PRELIMINARY 6SE567 0512 Copyright 2005 DETROIT DIESEL CORPORATION ...

Page 305: ...en between pin 1 of the TCI Sensor connector and pin 27 of the 31 pin connector Refer to section 36 1 2 1 b If the resistance is less than 3 Ω repair the open between pin 2 of the TCI Sensor connector and pin 28 of the 31 pin connector Refer to section 36 1 2 1 7 Turn the ignition ON key On engine OFF 8 Measure the voltage between pin 27 and pin 28 of the 31 pin connector on the engine side a If t...

Page 306: ...t Diesel Customer Support Center 313 592 5800 for authorization to replace the MCM 36 1 2 1 Verify Repairs Verify repairs as follows 1 Turn the ignition OFF Reconnect all connectors 2 Turn ignition ON Clear codes with diagnostic tool 3 Start and run the engine for one minute Stop engine 4 Check diagnostic tool for codes a If no codes are displayed troubleshooting is complete b If code 1172 3 is no...

Page 307: ... Sensor Refer to section 36 2 1 1 b If the resistance is greater than 5 Ω go to step 7 7 Disconnect the 120 pin MCM connector 8 Measure resistance between pin 27 and pin 28 of the 31 pin connector on the engine side a If the resistance is less than 10 Ω repair the short between pin 27 and pin 28 between the 31 pin connector and the 120 pin MCM connector Refer to section 36 2 1 1 b If the resistanc...

Page 308: ...tic tool for codes a If no codes are displayed troubleshooting is complete b If code 1172 4 is not logged and other codes are logged troubleshoot the logged codes c If code 1172 4 and other codes are logged review this section to find the error If no error is found call the Detroit Diesel Customer Support Center 313 592 5800 All information subject to change without notice 36 6 PRELIMINARY 6SE567 ...

Page 309: ...37 SPN 1636 INTAKE AIR TEMPERATURE OUTSIDE OF NORMAL OPERATING RANGE Section Page 37 1 SPN 1636 FMI 2 37 3 37 2 SPN 1636 FMI 3 37 4 37 3 SPN 1636 FMI 4 37 6 37 4 SPN 1636 FMI 14 37 7 ...

Page 310: ...All information subject to change without notice 37 2 PRELIMINARY 6SE567 0512 Copyright 2005 DETROIT DIESEL CORPORATION ...

Page 311: ... the 120 pin MCM connector 6 Bridge pins 1 and 2 of the IAT Sensor measure the resistance at pins 52 and 106 of the 120 pin MCM connector a If the resistance is greater than 3 Ω repair the harness Refer to section 37 1 1 1 b If the resistance is less than 3 Ω replace the sensor Refer to section 37 1 1 1 7 With the engine running at 1500 rpm and coolant temperature above 160 command EGR PW to 50 EG...

Page 312: ...AT Sensor 2 Measure the resistance across pins 1 and 2 of the sensor see Figure 37 1 a If the resistance is greater than 4k Ω replace the sensor Refer to section 37 2 2 1 Figure 37 1 Intake Air Temperature Sensor Wiring b If the resistance is less than 4k Ω go to step 3 3 Turn the ignition switch to the ON position 4 Measure the voltage between pins 1 and 2 of the IAT Senor harness connector a If ...

Page 313: ...nsor Refer to section 37 2 2 1 b If the resistance is less than 4k Ω go to step 6 6 Turn the ignition ON key On engine OFF 7 Measure the voltage between pins 1 and 2 of the IAT Senor harness connector a If the voltage is between 2 75 and 3 25 volts contact the Detroit Diesel Customer Support Center 313 592 5800 for authorization to replace the MCM b If the voltage is less than 2 75 volts refer to ...

Page 314: ...s greater than 5 Ω go to step 5 5 Measure the resistance between pin 2 of the sensor harness connector and ground a If the resistance is less than 5 Ω repair the short circuit between pin 2 of the sensor harness connector and ground Refer to section 37 3 1 1 b If the resistance is greater than 5 Ω refer to section 37 3 1 1 37 3 1 1 Verify Repairs Verify repairs as follows 1 Turn the ignition OFF R...

Page 315: ...t 6 Start the engine idle for 30 seconds then TURN THE ENGINE OFF 7 Review the intake manifold engine oil engine coolant EGR and turbo outlet temperature parameters on snapshot 8 Are any of the temperature readings 20 F greater or less than that of the other sensors a If yes inspect the suspect temperature sensors electrical connector for corrosion bent or spread pins repair as necessary If there ...

Page 316: ... logged codes c If code 1636 14 and other codes are logged review this section to find the error If no error is found call the Detroit Diesel Customer Support Center 313 592 5800 All information subject to change without notice 37 8 PRELIMINARY 6SE567 0512 Copyright 2005 DETROIT DIESEL CORPORATION ...

Page 317: ...38 SPN 2629 TURBO COMPRESSOR OUT TEMP HIGH OR LOW Section Page 38 1 SPN 2629 FMI 3 38 3 38 2 SPN 2629 FMI 4 38 5 38 3 SPN 2629 FMI 20 38 7 38 4 SPN 2629 FMI 21 38 8 ...

Page 318: ...All information subject to change without notice 38 2 PRELIMINARY 6SE567 0512 Copyright 2005 DETROIT DIESEL CORPORATION ...

Page 319: ...nsor Refer to section 38 1 1 1 b If the resistance is less than 300k Ω go to step 4 4 Turn the ignition ON key On engine OFF 5 Measure the voltage between pins 1 and 2 of the TCO Sensor harness connector a If the voltage is between 2 75 and 3 25 volts go to step 7 b If the voltage is less than 2 75 volts go to step 6 6 Measure the voltage between pin 2 of the TCO Sensor harness connector and groun...

Page 320: ... connector Measure the resistance between pins 1 and 2 of the TCO Sensor harness connector a If the resistance is less than 5 Ω repair the short between pins 52 and 112 of the 120 pin MCM connector Refer to section 38 1 1 1 b If the resistance is greater than 5 Ω replace the TCO Sensor Refer to section 38 1 1 1 All information subject to change without notice 38 4 PRELIMINARY 6SE567 0512 Copyright...

Page 321: ...odes are logged review this section to find the error If no error is found call the Detroit Diesel Customer Support Center 313 592 5800 38 2 SPN 2629 FMI 4 This condition is typically a short circuit 38 2 1 Short Circuit Check Check as follows 1 Disconnect the TCO Sensor 2 Disconnect the 120 pin MCM connector 3 Measure the resistance a If the resistance is less than 5k Ω repair the short between t...

Page 322: ...greater than 5k Ω contact the Detroit Diesel Customer Support Center 313 592 5800 for authorization to replace the MCM 38 2 1 1 Verify Repairs Verify repairs as follows 1 Turn vehicle ignition OFF Reconnect all connectors and turn ignition ON 2 Clear codes with diagnostic tool 3 Start and run the engine for one minute Stop engine 4 Check diagnostic tool for codes a If no codes are displayed troubl...

Page 323: ...ecessary Refer to section 38 3 1 1 b If the connectors are OK replace the Turbo Out Temperature Sensor Refer to section 38 3 1 1 38 3 1 1 Verify Repairs Verify repairs as follows 1 Turn the ignition OFF Reconnect all connectors and turn ignition ON 2 Clear codes with diagnostic tool 3 Start and run the engine for one minute Stop engine 4 Check diagnostic tool for codes a If no codes are displayed ...

Page 324: ...Sensor harness connector and pin 52 of the 120 pin MCM connector Refer to section 38 4 1 1 b If the voltage is less than 2 75 volts repair the open circuit between pin 2 of the TCO Sensor harness connector and pin 112 of the 120 pin MCM connector Refer to section 38 4 1 1 6 Inspect the intake air and turbocharger outlet plumbing for leaks or cracks Repair if necessary 7 Perform the turbo hysterisi...

Page 325: ...bleshooting is complete b If code 2629 21 is not logged and other codes are logged troubleshoot the logged codes c If code 2629 21 and other codes are logged review this section to find the error If no error is found call the Detroit Diesel Customer Support Center 313 592 5800 All information subject to change without notice PRELIMINARY 6SE567 0512 Copyright 2005 DETROIT DIESEL CORPORATION 38 9 ...

Page 326: ...38 4 SPN 2629 FMI 21 All information subject to change without notice 38 10 PRELIMINARY 6SE567 0512 Copyright 2005 DETROIT DIESEL CORPORATION ...

Page 327: ...39 SPN 2791 EGR VALVE AUX PWM 1 FAILED OR OPEN CIRCUIT Section Page 39 1 SPN 2791 FMI 3 39 3 39 2 SPN 2791 FMI 4 39 5 39 3 SPN 2791 FMI 5 39 6 ...

Page 328: ...All information subject to change without notice 39 2 PRELIMINARY 6SE567 0512 Copyright 2005 DETROIT DIESEL CORPORATION ...

Page 329: ...pin MCM connector Refer to section 39 1 2 1 b If the resistance is less than 5 Ω refer to section 39 1 2 39 1 2 Resistance and Voltage Check The resistance and voltage check performed indicate that you should not be getting a code The following is a recheck before requesting a new MCM 1 Turn ignition ON key On engine OFF Reconnect all connectors 2 Clear codes with diagnostic tool 3 Start and run t...

Page 330: ... Turn the ignition OFF Reconnect all connectors 2 Turn the ignition ON and clear codes 3 Start and run the engine for one minute Stop the engine 4 Check for codes a If no codes are present troubleshooting is complete b If code 2791 3 is not logged but other codes are logged troubleshoot the other codes c If code 2791 3 and other codes are logged repeat troubleshooting procedure If no error is foun...

Page 331: ...age check performed indicate that you should not be getting a code The following is a recheck before requesting a new MCM 1 Reconnect all connectors 2 Turn the vehicle ignition ON key On engine OFF and clear codes 3 Disconnect EGR valve connector 4 Disconnect 120 pin MCM connector 5 Measure the resistance between pin 1 of the EGR valve connector and ground a If the resistance is less than 5 Ω repa...

Page 332: ...a If the voltage is between 11 and 13 volts go to step 6 b If the voltage is less than 11 volts go to step 4 4 Measure voltage between pin 2 of EGR valve connector and ground a If the voltage is between 11 and 13 volts repair the open in the wire between pin 95 of the 120 pin MCM connector and pin 3 of the EGR valve connector Refer to section 39 3 1 1 b If the voltage is less than 11 volts go to s...

Page 333: ...connect all connectors 2 Turn the vehicle ignition ON and clear codes 3 Start and run the engine for one minute Stop the engine 4 Check for codes a If no codes are present troubleshooting is complete b If code 2791 5 is not logged but other codes are logged troubleshoot the other codes c If code 2791 5 and other codes are logged repeat troubleshooting procedure If no error is found contact the Det...

Page 334: ...39 3 SPN 2791 FMI 5 All information subject to change without notice 39 8 PRELIMINARY 6SE567 0512 Copyright 2005 DETROIT DIESEL CORPORATION ...

Page 335: ...40 SPN 3510 ACCELERATOR PEDAL SUPPLY OUTSIDE OF NORMAL OPERATING RANGE Section Page 40 1 SPN 3510 FMI 2 40 3 40 2 SPN 3510 FMI 3 40 5 40 3 SPN 3510 FMI 4 40 6 ...

Page 336: ...All information subject to change without notice 40 2 PRELIMINARY 6SE567 0512 Copyright 2005 DETROIT DIESEL CORPORATION ...

Page 337: ...tep 5 b If the voltage is less than 4 5 go to step 4 4 Measure the voltage between pins 1 of the AP harness connector and ground a If the voltage is between 4 5 and 5 5 volts repair the open circuit between pin 3 of the AP harness connector and pin 4 of the CPC 1 connector Refer to section 40 1 1 1 b If the voltage is less than 4 5 repair the open circuit between pin 1 of the AP harness connector ...

Page 338: ... 1 Turn vehicle ignition OFF Reconnect all connectors 2 Turn ignition ON Clear codes with diagnostic tool 3 Start and run the engine for one minute Stop engine 4 Check diagnostic tool for codes a If no codes are displayed troubleshooting is complete b If code 3510 2 is not logged and other codes are logged troubleshoot the logged codes c If code 3510 2 and other codes are logged review this sectio...

Page 339: ...ignition OFF 6 Disconnect the CPC 1 connector 7 Measure the resistance between pin 2 of the AP harness connector and pin 7 of the CPC 1 connector a Measure the resistance between pin 2 of the AP harness connector and pin 7 of the CPC 1 connector Refer to section 40 2 1 1 b If the resistance is less than 3 Ω replace the Accelerator Pedal Refer to section 40 2 1 1 40 2 1 1 Verify Repairs Verify repa...

Page 340: ...een wires 7 and 14 of the CPC connector Refer to section 40 3 1 1 b If the resistance is greater than 5 Ω go to step 5 5 Measure the resistance between pin 1 of the AP connector and ground a If the resistance is less than 5 Ω repair the short circuit between pin 1 of the AP connector and ground Refer to section 40 3 1 1 b If the resistance is greater than 5 Ω go to step 6 6 Measure the resistance ...

Page 341: ... diagnostic tool for codes a If no codes are displayed troubleshooting is complete b If code 3510 4 is not logged and other codes are logged troubleshoot the logged codes c If code 3510 4 and other codes are logged review this section to find the error If no error is found call the Detroit Diesel Customer Support Center 313 592 5800 All information subject to change without notice PRELIMINARY 6SE5...

Page 342: ...40 3 SPN 3510 FMI 4 All information subject to change without notice 40 8 PRELIMINARY 6SE567 0512 Copyright 2005 DETROIT DIESEL CORPORATION ...

Page 343: ...41 SPN 3563 INTAKE MANIFOLD PRESSURE OUTSIDE NORMAL RANGE Section Page 41 1 SPN 3563 FMI 0 1 2 41 3 41 2 SPN 3563 FMI 3 41 6 41 3 SPN 3563 FMI 4 41 7 ...

Page 344: ...All information subject to change without notice 41 2 PRELIMINARY 6SE567 0512 Copyright 2005 DETROIT DIESEL CORPORATION ...

Page 345: ...CAC charge air cooler and the CAC hoses for leaks a If leaks are found repair or replace the CAC and or CAC hoses Refer to section 41 1 2 1 b If no leaks are found go to step 5 5 Check for a faulty turbocharger compressor wheel does not spin freely or is rubbing on side walls a If the turbocharger is faulty replace it Refer to section 41 1 2 1 b If the turbocharger is not faulty go to step 6 6 Ver...

Page 346: ...s within X kPa go to step 8 8 Using DDDL 7 0 read the value of the Barometric Pressure Sensor a If the value is not within X kPa replace the Barometric Pressure Sensor Due to its location in the MCM replacing the Barometric Pressure Sensor means replacing the MCM Refer to section 41 1 2 1 b If the value is within X kPa go to step 9 9 Run the engine to 1500 rpm 10 Using DDDL 7 0 read the value of t...

Page 347: ...d troubleshooting is complete b If code 3563 0 1 2 is not logged and other codes are logged troubleshoot the logged codes c If code 3563 0 21 and other codes are logged review this section to find the error If no error is found call the Detroit Diesel Customer Support Center 313 592 5800 All information subject to change without notice PRELIMINARY 6SE567 0512 Copyright 2005 DETROIT DIESEL CORPORAT...

Page 348: ... 2 1 1 Figure 41 1 Intake Manifold Pressure Sensor b If the resistance is greater than 5 Ω repair the short to power on pin 87 of the 120 pin MCM connector Refer to section 41 2 1 1 41 2 1 1 Verify Repairs Verify repairs as follows 1 Turn vehicle ignition OFF Reconnect all connectors 2 Turn ignition ON Clear codes with diagnostic tool 3 Start and run the engine for one minute Stop engine 4 Check d...

Page 349: ...n 41 3 1 1 b If resistance is less than 130 kΩ go to step 3 3 Measure the resistance between pins 1 and 2 of the sensor See Figure 41 2 Figure 41 2 Intake Manifold Pressure Sensor a If resistance is greater than 130 kΩ replace the IMP Sensor Refer to section 41 3 1 1 b If resistance is less than 130 kΩ go to step 4 4 Turn the ignition switch to the ON position 5 Measure the voltage between pins 1 ...

Page 350: ...the 120 pin MCM connector Refer to section 41 3 1 1 11 Measure the resistance between pin 3 of the IMP Sensor harness connector and ground a If the resistance is greater than 5 Ω go to step 12 b If the resistance is less than 5 Ω repair the short between pin 82 of the 120 pin MCM connector and ground Refer to section 41 3 1 1 12 Measure the resistance between pin 2 of the IMP Sensor harness connec...

Page 351: ...shoot the logged codes c If code 3563 4 and other codes are logged review this section to find the error If no error is found call the Detroit Diesel Customer Support Center 313 592 5800 All information subject to change without notice PRELIMINARY 6SE567 0512 Copyright 2005 DETROIT DIESEL CORPORATION 41 9 ...

Page 352: ...41 3 SPN 3563 FMI 4 All information subject to change without notice 41 10 PRELIMINARY 6SE567 0512 Copyright 2005 DETROIT DIESEL CORPORATION ...

Page 353: ...42 SPN 3659 INJECTOR 1 SPILL VALVE NOT OPERATING NORMALLY Section Page 42 1 SPN 3659 FMI 5 42 3 42 2 SPN 3659 FMI 10 42 6 ...

Page 354: ...All information subject to change without notice 42 2 PRELIMINARY 6SE567 0512 Copyright 2005 DETROIT DIESEL CORPORATION ...

Page 355: ...the connector a If the resistance is less than 3 Ω refer to section 42 1 2 b If the resistance is greater than 3 Ω go to step 5 5 Remove valve cover 6 Disconnect injector 1 connector 7 Measure the resistance between pin 3 of the injector connector and pin O of the injector harness 23 pin connector a If the resistance is greater than 3 Ω repair the open between pin 3 of the injector connector and p...

Page 356: ...in 14 of the MCM 120 pin connector see Figure 42 1 Refer to section 42 1 3 1 Figure 42 1 120 pin MCM Connector b If the voltage is between 11 5 and 13 5 volts go to step 3 3 Swap the injectors a If fault code 3659 5 is not active after swapping injectors replace the original injector Refer to section 42 1 3 1 b If fault code 3659 5 is still active after swapping injectors contact Detroit Diesel Cu...

Page 357: ...etroit Diesel Customer Support Center 313 592 5044 42 1 3 1 Verify Repairs Verify repairs as follows 1 Turn the vehicle ignition OFF and reconnect all connectors 2 Turn the vehicle ignition ON and clear codes 3 Start and run the engine for one minute Stop the engine 4 Check for codes a If no codes are present troubleshooting is complete b If code 3659 5 is not logged but other codes are logged tro...

Page 358: ...o step 6 6 Recheck the resistance using steps 3 through 5 When you have just completed the recheck go to step 7 7 Clear the codes Check for active codes a If code 3659 10 is still active call the Detroit Diesel Customer Support Center 313 592 5800 for authorization to replace the MCM b If there are no active codes troubleshooting is finished Refer to section 42 2 1 1 42 2 1 1 Verify Repairs Verify...

Page 359: ...43 SPN 3660 INJECTOR 2 SPILL VALVE NOT OPERATING NORMALLY Section Page 43 1 SPN 3660 FMI 5 43 3 43 2 SPN 3660 FMI 10 43 5 ...

Page 360: ...All information subject to change without notice 43 2 PRELIMINARY 6SE567 0512 Copyright 2005 DETROIT DIESEL CORPORATION ...

Page 361: ... the connector a If the resistance is less than 3 Ω refer to section 43 1 2 b If the resistance is greater than 3 Ω go to step 7 5 Remove the valve cover 6 Disconnect the 2 injector 7 Measure the resistance between pin 3 of the injector connector and pin O of the injector harness 23 pin connector a If the resistance is greater than 3 Ω repair the open between pin 3 of the injector connector and pi...

Page 362: ...n connector see Figure 43 1 Refer to section 43 1 3 1 b If the voltage is between 11 5 and 13 5 volts go to step 3 Figure 43 1 120 pin MCM Connector 3 Swap the injector a If fault code 3660 5 is not active after swapping the injector replace the original injector Refer to section 43 1 3 1 b If fault code 3660 5 is still active after swapping the injector call the Detroit Diesel Customer Service Ce...

Page 363: ...Check for codes a If no codes are present troubleshooting is complete b If code 3660 5 is not logged but other codes are logged troubleshoot the other codes c If code 3660 5 and other codes are logged repeat troubleshooting procedure If no error is found contact the Detroit Diesel Customer Support Center 313 592 5800 43 2 SPN 3660 FMI 10 This diagnostic condition is typically a short to ground 43 ...

Page 364: ... replace the MCM b If there are no active codes troubleshooting is finished Refer to section 43 2 1 1 43 2 1 1 Verify Repairs Verify repairs as follows 1 Turn the vehicle ignition OFF and reconnect all connectors 2 Turn the vehicle ignition ON and clear codes 3 Start and run the engine for one minute Stop the engine 4 Check for codes a If no codes are present troubleshooting is complete b If code ...

Page 365: ...44 SPN 3661 INJECTOR 3 SPILL VALVE NOT OPERATING NORMALLY Section Page 44 1 SPN 3661 FMI 5 44 3 44 2 SPN 3661 FMI 10 44 5 ...

Page 366: ...All information subject to change without notice 44 2 PRELIMINARY 6SE567 0512 Copyright 2005 DETROIT DIESEL CORPORATION ...

Page 367: ...the connector a If the resistance is less than 3 Ω refer to section 44 1 2 b If the resistance is greater than 3 Ω go to step 5 5 Remove valve cover 6 Disconnect injector 3 connector 7 Measure the resistance between pin 3 of the injector connector and pin O of the injector harness 23 pin connector a If the resistance is greater than 3 Ω repair the open between pin 3 of the injector connector and p...

Page 368: ... connector see Figure 44 1 Refer to section 44 1 3 1 b If the voltage is between 11 5 and 13 5 volts go to step 3 Figure 44 1 120 pin MCM Connector 3 Swap the injector a If fault code 3661 5 is not active after swapping the injector replace the original injector Refer to section 44 1 3 1 b If fault code 3661 5 is still active after swapping the injector call the Detroit Diesel Customer Service Cen...

Page 369: ... Check for codes a If no codes are present troubleshooting is complete b If code 3661 5 is not logged but other codes are logged troubleshoot the other codes c If code 3661 5 and other codes are logged repeat troubleshooting procedure If no error is found contact the Detroit Diesel Customer Support Center 313 592 5800 44 2 SPN 3661 FMI 10 This diagnostic condition is typically a short to ground 44...

Page 370: ...to replace the MCM b If there are no active codes troubleshooting is finished Refer to section 44 2 1 1 44 2 1 1 Verify Repairs Verify repairs as follows 1 Turn the vehicle ignition OFF and reconnect all connectors 2 Turn the vehicle ignition ON and clear codes 3 Start and run the engine for one minute Stop the engine 4 Check for codes a If no codes are present troubleshooting is complete b If cod...

Page 371: ...45 SPN 3662 INJECTOR 4 SPILL VALVE NOT OPERATING NORMALLY Section Page 45 1 SPN 3662 FMI 5 45 3 45 2 SPN 3662 FMI 10 45 5 ...

Page 372: ...All information subject to change without notice 45 2 PRELIMINARY 6SE567 0512 Copyright 2005 DETROIT DIESEL CORPORATION ...

Page 373: ... connector a If the resistance is less than 3 Ω refer to section 45 1 2 b If the resistance is greater than 3 Ω go to step 5 5 Remove valve cover 6 Disconnect injector 4 connector 7 Measure the resistance between pin 3 of the injector connector and pin S of the injector harness 23 pin connector a If the resistance is greater than 3 Ω repair the open between pin 3 of the injector connector and pin ...

Page 374: ... connector see Figure 45 1 Refer to section 45 1 3 1 Figure 45 1 120 pin MCM Connector b If the voltage is between 11 5 and 13 5 volts go to step 3 3 Swap the injector a If fault code 3662 5 is not active after swapping the injector replace the original injector Refer to section 45 1 3 1 b If fault code 3662 5 is still active after swapping the injector call the Detroit Diesel Customer Service Cen...

Page 375: ... codes are present troubleshooting is complete b If code 3662 5 is not logged but other codes are logged troubleshoot the other codes c If code 3662 5 and other codes are logged repeat troubleshooting procedure If no error is found contact the Detroit Diesel Customer Support Center 313 592 5800 45 2 SPN 3662 FMI 10 This diagnostic condition is typically a short to ground 45 2 1 Short to Ground Che...

Page 376: ... codes troubleshooting is finished Refer to section 45 2 1 1 45 2 1 1 Verify Repairs Verify repairs as follows 1 Turn the vehicle ignition OFF and reconnect all connectors 2 Turn the vehicle ignition ON and clear codes 3 Start and run the engine for one minute Stop the engine 4 Check for codes a If no codes are present troubleshooting is complete b If code 3662 10 is not logged but other codes are...

Page 377: ...46 SPN 3663 INJECTOR 5 SPILL VALVE NOT OPERATING NORMALLY Section Page 46 1 SPN 3663 FMI 5 46 3 46 2 SPN 3663 FMI 10 46 6 ...

Page 378: ...All information subject to change without notice 46 2 PRELIMINARY 6SE567 0512 Copyright 2005 DETROIT DIESEL CORPORATION ...

Page 379: ...e connector a If the resistance is less than 3 Ω refer to section 46 1 2 b If the resistance is greater than 3 Ω go to step 5 5 Remove valve cover 6 Disconnect injector 5 connector 7 Measure the resistance between pin 3 of the injector connector and pin S of the injector harness 23 pin connector a If the resistance is greater than 3 Ω repair the open between pin 3 of the injector connector and pin...

Page 380: ...8 of the MCM 120 pin connector see Figure 46 1 Refer to section 46 1 3 1 Figure 46 1 120 pin MCM Connector b If the voltage is between 11 5 and 13 5 volts go to step 3 3 Swap the injector a If fault code 3663 5 is not active after swapping the injector replace the original injector Refer to section 46 1 3 1 b If fault code 3663 5 is still active after swapping the injector call the Detroit Diesel ...

Page 381: ...oit Diesel Customer Support Center 313 592 5044 46 1 3 1 Verify Repairs Verify repairs as follows 1 Turn the vehicle ignition OFF and reconnect all connectors 2 Turn the vehicle ignition ON and clear codes 3 Start and run the engine for one minute Stop the engine 4 Check for codes a If no codes are present troubleshooting is complete b If code 3663 5 is not logged but other codes are logged troubl...

Page 382: ... Recheck the resistance using steps 3 through 5 When you have just completed the recheck go to step 7 7 Clear the codes Check for active codes a If code 3663 10 is still active call the Detroit Diesel Customer Support Center 313 592 5800 for authorization to replace the MCM b If there are no active codes troubleshooting is finished Refer to section 46 2 1 1 46 2 1 1 Verify Repairs Verify repairs a...

Page 383: ...47 SPN 3664 INJECTOR 6 SPILL VALVE NOT OPERATING NORMALLY Section Page 47 1 SPN 3664 FMI 5 47 3 47 2 SPN 3664 FMI 10 47 6 ...

Page 384: ...All information subject to change without notice 47 2 PRELIMINARY 6SE567 0512 Copyright 2005 DETROIT DIESEL CORPORATION ...

Page 385: ... 1 2 b If the resistance is greater than 3 Ω go to step 5 5 Measure the resistance between pin 3 of the injector connector and pin S of the injector harness 23 pin connector a If the resistance is greater than 3 Ω repair the open between pin 3 of the injector connector and pin S of the injector harness 23 pin connector Refer to section 47 1 3 1 b If the resistance is less than 3 Ω go to step 6 6 M...

Page 386: ...voltage is between 11 5 and 13 5 volts go to step 3 3 Swap the injector a If fault code 3664 5 is not active after swapping the injector replace the original injector Refer to section 47 1 3 1 b If fault code 3664 5 is still active after swapping the injector call the Detroit Diesel Customer Service Center 313 592 5800 All information subject to change without notice 47 4 PRELIMINARY 6SE567 0512 C...

Page 387: ...roit Diesel Customer Support Center 313 592 5044 47 1 3 1 Verify Repairs Verify repairs as follows 1 Turn the vehicle ignition OFF and reconnect all connectors 2 Turn the vehicle ignition ON and clear codes 3 Start and run the engine for one minute Stop the engine 4 Check for codes a If no codes are present troubleshooting is complete b If code 3664 5 is not logged but other codes are logged troub...

Page 388: ...o step 6 6 Recheck the resistance using steps 3 through 5 When you have just completed the recheck go to step 7 7 Clear the codes Check for active codes a If code 3664 10 is still active call the Detroit Diesel Customer Support Center 313 592 5800 for authorization to replace the MCM b If there are no active codes troubleshooting is finished Refer to section 47 2 1 1 47 2 1 1 Verify Repairs Verify...

Page 389: ...48 CPC DIGITAL OUTPUTS SPN FMI Section Page 48 1 CPC DIGITAL OUTPUT FAULT CODES 48 3 48 2 TROUBLESHOOTING THE CPC DIGITAL OUTPUTS 48 3 ...

Page 390: ...All information subject to change without notice 48 2 PRELIMINARY 6SE567 0512 Copyright 2005 DETROIT DIESEL CORPORATION ...

Page 391: ...C 705 4 MIL LAMP indicates a short to ground on the pin 13 circuit of the CPC 1 connector For wiring schematic information refer to OEM literature CPC 706 3 ASG2 CHECK TRANS TEMP LAMP indicates a short to power open circuit on pin 10 of the CPC 3 connector For wiring schematic information refer to OEM literature CPC 706 4 ASG2 CHECK TRANS TEMP LAMP indicates a short to ground on the pin 10 circuit...

Page 392: ... For wiring schematic information refer to OEM literature CPC 714 3 TOP2 SHIFT SOLENOID indicates a short to power on the pin 8 circuit CPC 3 connector For wiring schematic information refer to OEM literature CPC 714 4 TOP2 SHIFT SOLENOID indicates a short to ground circuit on pin 8 of the CPC 3 connector For wiring schematic information refer to OEM literature CPC 714 5 TOP2 SHIFT SOLENOID indica...

Page 393: ...ors 2 26 Deutsch Terminals Installation 2 26 Removal 2 28 G Guide Scope and Use 1 4 Electronic Troubleshooting 1 5 Mechanical Troubleshooting 1 4 M Motor Control Module MCM 2 4 120 pin connector Series 60 2 5 2 8 21 pin connector 2 10 31 pin connector 2 11 Connector Brackets 2 9 Engine Harness 2 4 S Safety Precautions 1 6 Batteries 1 12 Cleaning Agent 1 13 All information subject to change without...

Page 394: ...ck for Multiple Codes 7 9 SPN 100 FMI 2 7 4 Check for Erratic Data From the Engine Oil Pressure Sensor 7 4 SPN 100 FMI 3 7 5 Check 7 5 SPN 100 FMI 4 7 7 Check for Open 7 7 SPN 103 FMI 0 8 3 Check Equipment 8 3 SPN 103 FMI 1 8 4 Check Equipment 8 4 SPN 103 FMI 3 8 5 Check for Open 8 5 Resistance and Voltage Check 8 6 SPN 103 FMI 4 8 7 Check for Short 8 7 Resistance Check 8 7 SPN 103 FMI 7 8 8 Adjus...

Page 395: ...or 10 3 SPN 111 FMI 3 10 5 Check for Open Circuit 10 5 SPN 111 FMI 4 10 7 Check for Short to Ground 10 7 SPN 1172 FMI 3 36 3 Check for Open 36 3 Resistance and Voltage Check 36 4 SPN 1172 FMI 4 36 5 Check for Short 36 5 SPN 158 FMI 0 11 3 Check for Battery High Voltage 11 3 SPN 158 FMI 1 11 4 Check for Battery Voltage Switched Low 11 4 SPN 158 FMI 2 11 6 Check MCM and CPC Signals 11 6 SPN 1636 FMI...

Page 396: ...und 13 5 SPN 175 FMI 2 14 3 Rationality Check 14 3 SPN 175 FMI 3 14 4 Check for Open Circuit 14 4 SPN 175 FMI 4 14 6 Check for Short to Ground 14 6 SPN 2629 FMI 3 38 3 Check for Open 38 3 SPN 2629 FMI 4 38 5 Short Circuit Check 38 5 SPN 27 FMI 0 1 2 14 3 5 Check Valve Function 3 5 SPN 27 FMI 3 3 3 Check for a Short 3 3 SPN 27 FMI 4 3 4 Check for Short 3 4 SPN 2791 FMI 3 39 3 Check for Short 39 3 R...

Page 397: ...round 42 6 SPN 3659 FMI 5 42 3 Check for Open Circuit with the Ignition ON 42 4 Check for Open Circuits 42 3 Check the Injectors 42 5 SPN 3660 FMI 10 43 5 Check for Short to Ground 43 5 SPN 3660 FMI 5 43 3 Check for Open Circuits with the Ignition OFF 43 3 Check for Open Circuits with the Ignition ON 43 4 Check the Injectors 43 5 SPN 3661 FMI 10 44 5 Check for Short to Ground 44 5 SPN 3661 FMI 5 4...

Page 398: ...4 FMI 5 47 3 Check for Open Circuits with the Ignition OFF 47 3 Check for Open Circuits with the Ignition ON 47 3 Check the Injectors 47 5 SPN 411 FMI 0 15 3 Check EGR Components 15 3 SPN 411 FMI 1 15 4 Check EGR Components 15 4 SPN 411 FMI 3 15 5 Check for Open Circuit 15 5 SPN 411 FMI 4 15 7 Check for Short 15 7 SPN 412 FMI 3 16 3 Check for Open 16 3 SPN 412 FMI 4 16 5 Check for Short 16 5 SPN 5...

Page 399: ...for Short to Ground 22 6 SPN 636 FMI 7 22 7 Check for Camshaft and Crankshaft Signals Not Matching 22 7 SPN 636 FMI 8 22 9 Check Sensor Time Out 22 9 SPN 651 FMI 10 23 6 Check for Short to Ground 23 6 SPN 651 FMI 5 23 3 Check for Open Circuit with the Ignition ON 23 4 Check for Open Circuits with the Ignition OFF 23 3 Check the Injectors 23 5 SPN 652 FMI 10 24 6 Check for Short to Ground 24 6 SPN ...

Page 400: ...he Ignition ON 27 4 Check for Open Circuits with the Ignition OFF 27 3 Check the Injectors 27 5 SPN 656 FMI 10 28 6 Check for Short to Ground 28 6 SPN 656 FMI 5 28 3 Check for Open Circuit with the Ignition ON 28 4 Check for Open Circuits with the Ignition OFF 28 3 Check the Injectors 28 5 SPN 701 FMI 3 29 3 Check for Short to Power 29 3 Resistance and Voltage Check 29 3 SPN 701 FMI 4 29 5 Check f...

Page 401: ...to Ground 32 5 SPN 709 FMI 5 32 6 Check for Open 32 6 SPN 714 FMI 3 33 3 Check for Short to Power 33 3 SPN 714 FMI 4 33 4 Check for Short 33 4 SPN 714 FMI 5 33 5 Check for Open 33 5 SPN 723 FMI 14 34 7 Check for Pins Swapped 34 7 SPN 723 FMI 3 34 3 Check for Open Circuit 34 3 SPN 723 FMI 4 34 5 Check for Short to Ground 34 5 SPN 723 FMI 8 34 6 Check for Time Out 34 6 Check the Camshaft Position Se...

Page 402: ...oltage Check 35 3 SPN 975 FMI 4 35 5 Check for Short to Ground 35 5 SPN 975 FMI 5 35 6 Check for Open 35 6 T Tape and Taping 2 40 Tape Criteria 2 40 Taping Criteria 2 40 Terminal Installation Deutsch connectors 2 26 Terminal Removal Deutsch terminals 2 28 W Wires Recommendations 2 25 Requirements 2 25 All information subject to change without notice Index 10 PRELIMINARY 6SE567 0512 Copyright 2005 ...

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