10 Intermittentfault10
10 Intermittentfault10
10 Intermittentfault10
Section Page
NOTE:
Do not use any other procedures (except for the suggestions listed in this guide) when
trying to solve an intermittent problem. Use of any other procedures for this type of
problem can result in the replacement of non-defective parts.
Many intermittent problems are caused by faulty electrical connectors or wiring. Diagnosis
must include a careful inspection of the indicated circuit wiring and connectors. For example,
an intermittent code 35 (Oil Pressure Sensor High Voltage) would indicate a problem in the
following areas associated with the Oil Pressure Sensor.
Wires #530 (signal line), #416 (+5 volt line), or #452 (ground line)
The Oil Pressure Sensor connector or ECM connector
An intermittent problem in the Oil Pressure Sensor (least likely)
Use the following checklist:
1. Check for poor mating of the connector halves or terminals not fully seated in the
connector body (backed out terminals).
2. Look for improperly formed or damaged terminals. All connector terminals in the problem
circuit should be carefully inspected to determine proper contact tension. Use a mating
terminal to test the contact tension.
3. Electrical system interference caused by a defective relay, ECM driven solenoid, or a
switch causing an electrical surge. Look for problems with the charging system (alternator,
etc.). In certain cases, the problem can be made to occur when the faulty component is
operated as in the case of a relay.
4. Verify alternator grounds are clean and making good contact. Disconnect the alternator
belt to test.
5. Wiggle wires and harnesses to try to make the problem active, or occur again.
The following procedures will diagnose engine cranks but will not start.
Perform the following steps to check the TRS status via a r/min readout:
1. Select engine speed and active codes on the DDR.
2. Crank the engine for ten seconds while observing DDR display. A battery voltage surge
while cranking with electric starters may blank or reset the DDR.
[a] If the display reads greater than or equal to 60 r/min, refer to section 10.2.9.
[b] If the display reads less than 60 r/min or constantly reads 60 r/min,
refer to section 10.2.5.
[c] If code 41 is displayed, refer to section 41.3.1.
[d] If code 42 is displayed, refer to section 42.3.1.
Perform the following steps to check the SRS/TRS mounting and the bracket:
1. Inspect SRS/TRS mounting.
[a] If the sensor and mount are secure, refer to section 10.2.7.
[b] If the sensor and mount are not secure, tighten the bolt or replace if necessary.
Refer to section 10.2.27.
Perform the following steps to check if the injector return wires are open:
1. Turn ignition OFF.
2. Disconnect the 5-way injector harness connector at the ECM.
3. Measure resistance between the injector return pin and all the power driver pins on both
harness connectors.
[a] If the resistance measurement is greater than 5 on any reading, an open exists in one
of the injector power driver or return wires. Repair the open. Refer to section 10.2.27.
[b] If the resistance measurement is less than or equal to 5 on any reading,
refer to section 10.2.12.
Perform the following steps to check if the injector lines are shorted to the ground:
1. Disconnect the 5-way injector harness connector at the ECM.
2. Measure resistance between socket D of the 5-way power harness connector to the
following sockets on the injector harness connector: A, B, C, D, E, G, H, J, K and L.
[a] If the resistance measurement is greater than or equal to 10,000 or open on all
readings, refer to section 10.2.13.
[b] If the resistance measurement is less than 10,000 on any reading, there is a short
to ground on the wire where resistance was less than 10,000 . Repair the short
and refer to section 10.2.27.
[c] If all tests do not pass and the test light is not flashing for one or more tests,
refer to section 10.2.8.
Perform the following steps to check for battery volts at the 5-way connector:
NOTE:
A high resistance in these wires may prevent engine starting but measure correct
voltage. Proper resistance based on wire length and size is listed in Table 46-2.
3. Measure voltage from socket A (red lead) of 5-way power harness connector to a good
ground.
4. Measure voltage from socket C (red lead) of 5-way power harness connector to a good
ground.
[a] If the voltage measurement is greater than 11.5 volts on all readings, refer to section
10.2.18.
[b] If the voltage measurement is less than 11.5 volts on any readings, refer to section
10.2.16.
Perform the following steps to check if the ECM power lines are open:
1. Measure voltage between battery side of one ECM fuse or circuit breaker (red lead)
and a good ground (black lead).
2. Measure voltage at other ECM fuse or circuit breaker. Note that battery side does not
contain #240 or #241 wires. See Figure 10-3.
[a] If the voltage measurement is less than 11.5 volts on any reading,
refer to section 10.2.17.
[b] If the voltage measurement is greater than 11.5 volts on all readings, an open exists in
either power wire (#240 or #241). Repair the open; refer to section 10.2.27.
Perform the following steps to check for +12 or +24 volts at the ignition wire:
1. Turn ignition OFF.
2. Disconnect the vehicle harness connector at the ECM. For vehicle harness schematic,
see Figure 10-4.
3. Turn ignition ON.
4. Measure voltage between socket B3 on the vehicle harness connector (red lead) and a
good ground (black lead).
[a] If the voltage measurement is greater than or equal to 11.5 volts,
refer to section 10.2.19.
[b] If the voltage measurement is less than 11.5 volts, refer to section 10.2.20.
[b] If the voltage measurement is less than 11.5 volts, the ECM ground wire (circuit
#150) is open or has a poor connection. Repair open; refer to section 10.2.27.
Perform the following steps to check if the ignition wire is shorted to ground:
1. Replace blown fuse or reset open circuit breaker.
2. Turn ignition ON for ten seconds.
3. Run engine for one minute.
4. Turn ignition OFF.
5. Check 5-amp ignition fuse or circuit breaker again.
[a] If both the fuse and circuit breaker are okay, refer to section 10.2.23.
[b] If the fuse and circuit breaker are not okay, the ignition line (circuit #439) is shorted
to ground. Repair the short; refer to section 10.2.27.
Perform the following steps to check if the ignition fuse or breaker is okay:
1. Reconnect all harness connectors at the ECM.
2. Start the engine.
3. Run engine for one minute.
4. Turn ignition OFF.
5. Check 5-amp ignition fuse or circuit breaker again. For 5-way ECM power harness
schematic, see Figure 10-6.
[a] If both the fuse and circuit breaker are okay, no short is currently present. Be warned
of an intermittent short that could shut down the engine or blow a fuse due to reverse
voltage at the battery. Refer to section 10.2.27.
[b] If the fuse or circuit breaker are not okay, refer to section 10.2.8.
NOTE:
For information concerning Fuel Filters, refer to section 29.4.11 in the appropriate service
manual. For information concerning Fuel Filter Replacement, refer to section 18 in
the appropriate service manual.
The following troubleshooting chart resolves erratic performance and no codes displayed. For
troubleshooting procedures, refer to the appropriate engine service manual.
Check the following symptoms to determine possible fault, listed in Table 10-1.
The following steps will troubleshoot a fault with the check engine or stop engine lights. These
lights are used to alert the operator of engine faults; flash any trouble codes stored in the ECM;
and illuminate for five seconds and then go out during a start sequence, as a bulb check.
Perform the following steps to determine the reason the ECM is requesting the light to be ON:
1. Verify the diagnostic request is not ON.
[a] If the diagnostic request is ON, refer to section 10.10.
[b] If the diagnostic request is not ON, refer to section 9.1, (troubleshoot code).
Perform the following steps to activate the light with the DDR:
1. Turn ignition ON.
2. Plug in DDR.
3. Select Activate Outputs.
4. Activate affected light; watch status.
[a] If the light stays off. Refer to section 10.4.6.
[b] If the light illuminates, the problem no longer exists. Refer to DDEC III Application
and Installation manual, 7SA800, to review the light operation.
Before using this procedure, all basic mechanical checks and physical inspections should have
been performed with no problem found. Also the diagnosis of the DDEC system in Section 9
referred you to this section.
Perform the following steps to read the codes on the CEL or SEL:
1. Unplug the DDR.
2. Ignition should be ON; engine not running.
3. Enable diagnostic request switch.
4. Read codes flashing on the CEL and SEL.
[a] If codes are flashing out, refer to section 10.5.4.
NOTE:
If you wish to bypass diagnosis of a potential data line of the DDR problem for now,
diagnose the active code by referring to the section that matches the code number.
[b] If CEL and SEL are not flashing out codes, refer to section 10.5.2.
Perform the following steps to check for a short to ignition and ground:
1. Remove all jumpers for the DDL connector.
2. Measure resistance between sockets A (#900) and C (ignition switch), A (#900) and E
(ground), B (#901) and E (ground), and B (#901) and C (ignition switch) of the DDL
connector.
[a] If the measured resistance is less than 5 on any reading, a short exists between the
data wires and ignition or ground. Repair the short and refer to section 10.5.8.
[b] If the measured resistance is greater than 5 , refer to section 10.5.7.
Before using this procedure, all basic mechanical checks and physical inspections should have
been performed with no problem found. Also the diagnosis of the DDEC system in Section 9
referred you to this section.
10.6.2 Check Stop Engine Light and Check Engine Light Bulbs
Perform the following steps to check the SEL and CEL bulbs:
1. Turn ignition OFF.
2. Remove CEL and SEL bulbs. Check to see if either is burned out or damaged.
[a] If the bulbs are okay, refer to section 10.6.3.
[b] If the bulbs are defective, replace the bulbs. Refer to section 10.6.4.
Before using this procedure, all basic mechanical checks and physical inspections should have
been performed with no problem found. Also the diagnosis of the DDEC system in Section 9
referred you to this section.
[b] If the functions are not assigned, reprogram the ECM. Refer to section 10.7.16.
To speed up the checking out of cruise control switches, quick check tables have been developed.
These tests are to be run with the ignition ON, and the engine not running. A DDR must be
plugged into the connector. All three quick check tables must be gone through to completely
check out the cruise control wiring and switches.
For Example: Listed in Table 10-3, step 2, you would do the following:
1. Ignition ON; engine not running; DDR plugged in.
2. Turn the cruise enable switch to ON.
3. Select switch/light status on the DDR.
4. Note the DDR display; if ON, check out brake and clutch switch as listed in Table 10-4.
Table 10-3 Cruise Control Quick Check Table I, Check Out Cruise Enable Switch
and Wiring (Ignition ON Not Running)
Table 10-4 Cruise Control Quick Check Table II, Check Out Brake and Clutch
Switch and Wiring (Ignition ON Not Running)
Table 10-5 Cruise Control Quick Check Table III, Check Out Set/Coast and
Resume/Accel Switches and Wiring (Ignition ON Not Running)
Perform the following steps to check for a short at the cruise enable circuit:
1. Turn ignition ON.
2. Turn cruise engage switch to off.
3. Disconnect the vehicle harness connector at the ECM.
4. Measure resistance between the cruise enable cavity (i.e. F2) on the vehicle harness
connector and a good ground.
[a] If the resistance measurement is less than or equal to 10,000 , reconnect the
vehicle harness. Turn the ignition on. Then run steps listed in Table 10-4; and
listed in Table 10-5. If any DDR display received is not okay, refer to the indicated
step. If all steps listed in Table 10-4 and listed in Table 10-5, pass, then the cruise
engage wire is shorted to the ground. Repair the short, or replace the switch.
Refer to section 10.7.16.
[b] If the resistance measurement is greater than 10,000 , refer to section 10.7.2.
Perform the following steps to check for an open at the cruise enable circuit:
1. Turn ignition ON.
2. Disconnect the vehicle harness connector at the ECM.
3. Turn cruise enable switch to ON.
4. Measure resistance between the cruise enable cavity (i.e. F2) on the vehicle harness
connector and a good ground.
[a] If the resistance measurement is greater than 5 , or open, the cruise engage switch is
bad, circuit #953 is open or the cruise enable wire is open. Repair the open or replace
the switch. Refer to section 10.7.16.
[b] If the resistance measurement is less than or equal to 5 , refer to section 10.7.2.
Perform the following steps to check for an open or miswired brake switch:
1. Turn ignition OFF.
2. Disconnect the vehicle harness connector at the ECM.
3. Ensure the service brake is not engaged.
4. Measure resistance between the service brake cavity (i.e. G2) on the vehicle harness
connector and a good ground.
[a] If the resistance measurement is greater than 5 , or open, the brake switch is
miswired or faulty, circuit #953 is open or the ground is bad. Repair the open, rewire
or replace the switch. Refer to section 10.7.16.
[b] If the resistance measurement is less than or equal to 5 , refer to section 10.7.2.
Perform the following steps to check for a short at the brake switch or circuit:
1. Turn ignition OFF.
2. Disconnect the vehicle harness connector at the ECM.
3. Engage the service brake.
4. Measure resistance between the service brake cavity (i.e. G2) on the vehicle harness
connector and a good ground.
[a] If the resistance measurement is less than or equal to 10,000 , the brake switch is
miswired or the service brake circuit is shorted to ground. Rewire, repair the short or
replace the switch. Refer to section 10.7.16.
[b] If the resistance measurement is greater than 10,000 , or open, refer to section
10.7.2.
Perform the following steps to check for an open or miswired clutch switch:
1. Turn ignition OFF.
2. Disconnect the vehicle harness connector at the ECM.
3. Ensure the clutch is not engaged.
4. Measure resistance between the clutch cavity (i.e. J2) on the vehicle harness connector
and a good ground.
[a] If the resistance measurement is greater than 5 , or open, the clutch switch is
miswired or faulty, circuit #953 is open, or there is a bad battery ground. Rewire,
repair the short or replace the switch. Refer to section 10.7.16.
[b] If the resistance measurement is less than or equal to 5 , refer to section 10.7.2.
This section covers only the DDEC controlled fan operation, (fan type single, dual or two-speed).
If the function is assigned, see description of DDEC fan control logic, listed in Table 10-6.
Fan Control Actual Fan Coolant Temp Oil Temp Air Temp
Status
Fan Control - 1 Fan ON 96 C / 204 F 110 C / 230 F 66 C / 150 F
Fan Control - 2 Fan ON 98 C / 208 F 113 C / 235 F N/A
Fan Control Fan OFF 92 C / 197 F 104 C / 219 F 49 C / 120 F
* Hot engine
The steps that led to this procedure do not indicate a problem with the fan control logic in the
ECM. The fan operation is normal if the steps that you checked led you to this section.
The fan status is correct according to what the ECM is requesting.
If you believe the fan state should be different, review the DDEC application and installation
manual for information on fan control configuration.
Read the status of the inputs used for fan operation listed in Table 10-9. (Note both together.)
Perform the following tests to check the auxiliary fan control switch:
1. Turn A/C OFF and ignition ON.
2. Is the auxiliary fan control status ON?
[a] If the auxiliary fan control is on, this should not request the fan on; this is normal.
The fan may remain on for up to three minutes after auxiliary fan control is turned on.
[b] If the auxiliary fan control is off, check that a normally open pressure switch is not
installed; then, refer to section 10.8.6.
The DDEC system via a PWM (Pulsewidth Modulation) signal will go to a high voltage (7-8
volts on a 12-volt system) on a cold engine for a low speed, and to a low voltage (0.8 - 1.0
volts on a 12-volt system) for a high speed.
Fan speed is ramped up as temperatures increase, as listed in Table 10-10. Calibrations can
vary. The table is provided only as a guide.
The following procedure will troubleshoot DDEC controlled Engine Brake Inoperative.
NOTE:
Set brake dash switch position on low.
[a] If Eng Brake Low is ON and Eng Brake Med is OFF, refer to section 10.10.3.
[b] If Eng Brake Low is ON and Eng Brake Med is ON, medium and low inputs are
shorted to each other. Repair. Refer to section 10.10.9.
[c] If Eng Brake Low is OFF and Eng Brake Med is ON, input wires are reversed.
Correct and refer to section 10.10.9.
[d] If Eng Brake Low is OFF and Eng Brake Med is OFF, refer to section 10.10.4.
5. Turn brake enable dash switch on.
NOTE:
Set brake dash switch position on medium.
[a] If Eng Brake Low is OFF and Eng Brake Med is ON, refer to section 10.10.5.
[b] If Eng Brake Low is ON and Eng Brake Med is ON, medium and low inputs are
shorted to each other. Repair. Refer to section 10.10.9. If this is a Series 55 engine,
refer to section 10.9.5.
[c] If Eng Brake Low is ON and Eng Brake Med is OFF, input wires are reversed.
Correct and refer to section 10.10.9.
[d] If Eng Brake Low is OFF and Eng Brake Med is OFF, refer to section 10.10.4.
NOTE:
These two functions may work separately or together.
[c] If the Eng Brk Svc Brk indicate No, and Eng Brk Min mph indicate 0, refer to section
10.10.6.
Perform the following steps listed in Table 10-11 to check out the brake and clutch switch, and
the wiring.
NOTE:
If table below leads to section 10.11, troubleshoot clutch and brake inputs. Then check
operation of engine brake. If engine brake is still inoperative, refer to section 10.10.7.
The following procedure will cover miscellaneous input switch faults. All faults function in the
same manner, allowing the same troubleshooting process to be used regardless of the function.
There are 12 digital input cavities, listed in Table 10-12, available on a DDEC ECM. Any
available function can be assigned (programmed with the Programming Station) to any of the
available cavities.
When a digital input wire is switched to battery ground (usually #953), it is a request to the
ECM to activate the function assigned to that wire. Additional conditions may need to be met
for the feature to activate. Refer to the appropriate Application and Installation manual for these
conditions.
[c] The feature always reads ON. This indicates the input wire is shorted to ground or the
switch is faulty. Repair wire or replace switch. Refer to section 10.11.4.
This section is designed to diagnose an output fault (feature not functioning). Since all outputs
operate in the same manner, this troubleshooting section can be used regardless of the function
assigned.
The DDEC ECM has six available digital output cavities. Three are located at the engine harness
connector and three at the vehicle harness connector. Output functions (features) are assigned
(programmed with the programming station) to any available cavity. The ECM switches the
cavity to battery (-) to allow the function to activate. Some output activation is dependent on other
parameters being met. (e.g. minimum, r/min, etc.) Perform the following steps to check the DDR
for codes. Available output cavities are listed in Table 10-14.
Additional outputs could be added at a later date. Available functions are listed in Table 10-15.
NOTE:
Service any other codes first.
[a] If the feature operates (e.g. light illuminates or solenoid activates, etc.) review the
Application and Installation manual for the operation of the designated feature.
Operation is dependent on other parameters. Refer to section 10.12.6.
[b] If the feature does not operate or cannot be activated, refer to section 10.12.3.
The following procedure will troubleshoot fire truck pressure governor fault.
The Pressure Sensor Governor (PSG) System is a DDEC feature, programmed to allow the engine
speed to change in order to maintain a steady water pump pressure (pressure mode) or hold a
steady engine speed (RPM Mode).
Perform the following steps to verify the PSG configuration. Refer to the Application and
Installation manual for the appropriate engine model to ensure correct inputs and outputs are
configured. Required In / Outs are listed in Table 10-16.
1. Turn ignition ON.
2. Plug in DDR.
3. View H2O governor enabled (engine configuration).
4. View In / Outs. Verify correct configuration.
[a] If the system is enabled and the in/outs are correctly configured,
refer to section 10.13.3.
[b] If the problem was found, correct the settings and retest. Refer to the DDEC III
Application And Installation manual, 7SA800 and refer to section 10.13.10.3.
Inputs Outputs
PSG Mode, (Press / RPM) PSG Active
PSG Enable Cruise Active
Res / Accel -
Set / Coast -
Use the following procedure to identify the problem with the PSG:
Does not operate; refer to section 10.13.4.
No pressure mode, refer to section 10.13.6.
No increase function refer to section 10.13.7.
No decrease function refer to section 10.13.8.
EFC Fault Information refer to section 10.13.9.
The Detroit Diesel Electronic Fire Command ™ (EFC) is designed to support Detroit Diesel
engines in the fire fighting market. It combines a Pressure Sensor Governor (PSG) controller, a
system monitor, and a display for vital engine operating parameters into one compact, durable
package. It also provides complete control and monitoring of the DDEC engine control system on
a fire truck when pumping.
The EFC commands the Detroit Diesel PSG system to operate in one of two modes. The RPM
Mode controls the engine speed to a constant number of revolutions per minute, and the Pressure
Mode varies the engine speed to maintain a constant pump discharge pressure. The operating
mode of the PSG can be changed from RPM Mode to Pressure Mode and back by pressing the
MODE button. When the unit is first turned on, the RPM Mode is active. Pressing MODE switch
engages the Pressure Mode and another press brings the system back to RPM Mode. The PSG
system utilizes the engine speed or pump pressure that is current at the time the button is pressed.
In the Pressure Mode, the PSG system operates like cruise control for the water pump pressure,
and maintains the pressure at a chosen setting. Engine speed is constantly adjusted to maintain the
desired pump discharge pressure. A pressure sensor in the output side of the fire pump is used to
measure and feed this pressure back to the DDEC Electronic Control Module (ECM).
The RPM Mode keeps the engine speed constant even when the load varies within the engine's
operating capability. The pump output pressure may vary in this mode, but the engine speed does
not. The driver/engineer uses the EFC to choose which of these two modes the PSG uses. The
EFC also allows the driver/engineer to finely adjust the pressure setting or the engine speed
setting to match prevailing conditions.
10.13.9.4 Cavitation
If the water pump discharge pressure falls below 30 psi and the engine r/min rises a minimum of
400 r/min above the current setpoint for more than five seconds, the system considers cavitation
to have occurred. It takes the following actions:
The engine will return to idle.
The current engine speed and discharge pressure setpoints will be cleared.
The check engine light will illuminate and a cavitation code will be logged.
Engine r/min, oil pressure, temperature, and system voltage are displayed continuously while
the EFC is in operation. In addition, any diagnostic code accompanying a Check Engine or Stop
Engine condition will be displayed on the Information Center message display. An audible alarm
will also be activated with the code.
As you scroll through the menu by repeatedly pressing the MENU button, the following items,
listed in Table 10-17, will appear sequentially in the Information Center display.
Item Explanation
RPM Preset Point preset engine speed
Pressure Set (PSI) preset PSI
Engine Hour meter information only
Pump Hour meter information only
Engine degrees oil or coolant
Pump Pressure (PSI) pressure reading, if active
DDEC Software Version ECM revision level
EFC Software Version EFC revision level
Fire Commander I/O Test test switches and outputs
Press Test Lights tests display panel
Set Time Clock set clock
Units of Measure English/Metric
Welcome Message enable/disable
Codes Currently Active information
Connector Data displays connection information
Save? [Idle Y] exit and save options
Engine r/mi
The Information Center displays DDEC ECM diagnostic codes and limited engine
information as well as PSG status.
The Information Center display can be used as an aid to troubleshooting the Pressure
Governor System and the Electronic Fire Commander.
The Fire Commander I/O Test checks the outputs as well as the switches. It automatically
runs through a test and displays the results for your information in troubleshooting.
The connector data displays the cavities of inputs and outputs necessary for correct
system operation.
The interlock lamps show which interlock circuits have been closed and if that part of
the system is ready for operation.
This section lists some of the common troubles encountered during the installation and check out
of the Electronic Fire Commander. These conditions are listed and the suggested actions follow
each one. The Electronic Fire Commander wiring is listed in Table 10-18, listed in Table 10-19,
listed in Table 10-20.
1. Condition: The EFC will not light up.
Check if the necessary switches are turned on.
Check if there is a 12 VDC between pins #1 and #2 at the EFC 4-pin connector.
2. Condition: The throttle will not increase in RPM Mode.
Check if the THROTTLE READY lamp is on. The EFC will not respond in RPM
mode unless the OEM safety interlock requirements that enable the throttle are met.
Press the PRESET and then the INC switches. Does the EFC indicate it is increasing
RPM on the data display?
Check the switch and outputs in the Menu I/O test.
Re-initialize the EFC. (Remove power to the EFC; wait ten seconds and then power
the unit and try again.)
NOTE:
The EFC performs a "self-test" when it is powered up. This is indicated on the EFC by a
momentary lighting of all the display segments.
6. Condition: The PUMP ENGAGED and OKAY TO PUMP lamps do not turn on.
Check that all OEM safety requirements for pump operation are fulfilled.
Is the parking brake on?
Is the transmission in the proper range for pump operation?
Is the hand throttle (PTO) engaged?
Is there an OK to PUMP indication in the cab?
Check for 12 VDC at pin #10 of the EFC 12-pin connector.
7. Condition: The mode will not change from RPM to Pressure.
Check: Are the PUMP ENGAGED and OKAY TO PUMP lamps on?
Does the MODE switch pass in the menu I/O test?
8. Condition: The PRESET switch does not work.
Check that the proper lamps are on for the mode you want to operate.
Is there a valid preset programmed into the menu? If not, refer to section 10.13.10 and
complete the steps given there.
Does the PRESET switch pass the menu I/O test?
Connector 2: DT06-12S
Cavity Circuit Description DDC# EFC Input/Output
1 DDEC PSG Mode Select 523 Output (ground) to DDEC
2 OEM Interlock from OEM - Input (+12 VDC)
3 Cavity plug - No connection
4 DDEC PSG Mode 499 Input (ground) from DDEC
5 DDEC PSG Enable - Output (ground) to DDEC
6 DDEC PSG Increase - Output (ground) to DDEC
7 DDEC PSG Decrease - Output (ground) to DDEC
8 DDEC PSG Active - Input (ground) from DDEC
9 Alarm - Output (ground) to DDEC
10 PTO Engaged - Input (+12 VDC) from OEM
11 Cavity Plug - No connection
12 Low fuel - Input (ground) from DDEC
NOTE:
If a replacement ECM is needed, replace the ECM with an ECM programmed with
Optimized Idle.
NOTE:
Service any code first.
[a] If an Optimized Idle code 62, 63, or 74 is logged, go to the appropriate flash code
section, based on Optimized Idle code logged.
[b] If an Optimized Idle code 62, 63 or 74 is not logged, refer to section 10.14.2.
Perform the following steps to troubleshoot the heater and A/C fans.
1. Check the heater and A/C blower fuse.
2. Turn ignition ON.
3. Plug in DDR.
4. Check the vehicle power down relay switch. Select switch light status (VEH PWR
DOWN).
[a] If the output status reads ON, check the relay and relay connections for proper
operation. Refer to section 10.14.3.
[b] If the output status does not read ON, install a test ECM. Refer to section 10.14.11.
The Optimized Idle active light should flash when all of the following occur:
1. Engine idling.
2. The transmission is in NEUTRAL and high-range, if equipped.
3. The hood is closed and the park brake is set.
4. The cruise switch is turned ON.
[a] If the active light is not flashing, refer to section 10.14.4.
[b] If the light is flashing, after the engine shuts down, turn the thermostat on. When the
light flashes, if the alarm turns ON and the engine starts, the system is OK.
[c] If the light is flashing, after the engine shuts down, turn the thermostat on. When
the light flashes, if the alarm does not turn ON and the engine does not start,
refer to section 10.14.10.
Perform the following steps to troubleshoot the park brake switch and other OEM interlock
devices.
1. Check the park brake switch and other OEM interlock devices (e.g. high-range switch).
2. Measure resistance across the park brake switch contacts with the park brake set.
[a] If the measured resistance is less than 100 , the 953 ground wire is open somewhere
between the ECM and the battery. Repair the open. Refer to section 10.14.11.
[b] If the measured resistance is more than 100 , replace the park brake switch or other
OEM interlock devices. Refer to section 10.14.11.
Numerous transmissions utilize the DDEC ECM to receive signals that are used to determine
shift points, and/or other information.
Perform the following steps to verify repairs. Start with the Menu Selection. An assistant is
needed for the following procedure.
1. Perform road test.
[a] If the problem is resolved, troubleshooting is complete.
[b] If the problem still exists, contact the OEM or transmission supplier. The steps
that led you here do not indicate a problem with the PWM #2 output or output
wire. Verify the correct configuration. Refer to the DDEC Application and
Installationmanual, 7SA800, for the appropriate engine.
The following procedures will troubleshoot the Exhaust Gas Recirculation (EGR) system:
NOTE:
EGR system related part numbers can be found in parts bulletin #2–PI-00.
1. Check ECM voltage via DDR. The system voltage must be 24V (not 12V).
2. Check bus air systems. Air pressure must be greater than 620 kPa (90 psi).
3. Check EGR solenoid assembly to ensure there is at least 90 psi air pressure to the solenoid.
If the bus has 620 kPa (90 psi), but not at solenoid, check the air lines to the solenoid.
4. Check hot, cold and cooler tubes and V-band clamps for leakage.
5. Disconnect the air hoses from the EGR valve and VGT (Variable Geometry Turbocharger)
actuator. See Figure 10-12.
[a] Install the pressure gauges at the outlet of these hoses. (Use two gauges or test
separately.)
[b] Use DDR/DDDL to activate output T3 and watch pressure at the EGR valve.
Pressure should be 503–545 kPa (73–79 psi). Low or high pressure indicates
PWM valve assembly fault.
[c] Use DDR/DDDL to cycle output S3 and watch the pressure gauge at the VGT
actuator. Pressure should be 427–448 kPa (62–65 psi). Low or high pressure
indicates PWM valve assembly fault.
NOTE:
The EGR solenoid and the PWM valve can be serviced separately.
6. Reconnect air hose and ensure bus air pressure is at least 620 kPa (90) psi.
[a] Activate output T3 and watch the EGR actuator rod for movement. If actuator rod
does not move, replace EGR valve assembly.
[b] Toggle output S3 and watch the VGT actuator rod for movement. If the rod does not
travel to set screw, adjust actuator rod length following the procedure outlined in
the Series 50 Service Manual. If adjustment cannot be obtained, replace actuator
assembly or inspect VGT vanes for damage.
NOTE:
Never adjust set screw.
7. Use the DDR/DDDL and check turbocharger speed at idle. The speed should be about
18,000 to 30,000 rpm. If speed is low, check inlet restriction. Also check the exhaust
back pressure.
8. Check the Delta-P orifice pressure at idle. Pressure at idle should be less than 1 kPa (0.15
psi). If pressure differs, shut the engine off. Turn the key on.
[a] If pressure is greater than 1 kPa (0.15 psi), viewed on the DDR/DDDL, replace the
EGR pressure sensor.
[b] If pressure is less than 1 kPa (0.15 psi), inspect the EGR valve, and replace if
necessary.
9. Check the Delta-P orifice pressure at idle. Pressure at idle should be less than 1 kPa (0.15
psi). If pressure differs, shut the engine off. Turn the key on.
[a] If pressure is greater than 1 kPa (0.15 psi), viewed on the DDR/DDDL, replace the
EGR pressure sensor.
[b] If pressure is less than 1 kPa (0.15 psi), inspect the EGR valve, and replace if
necessary.
10. If corrections have been made as a result of these checks, verify the repair by checking the
applicable flash code verification.
[a] If all tests pass, and no DDEC codes are present, contact DDC Technical Service.
[b] If all tests pass, but a problem still exists, view the DDEC codes for further
troubleshooting. For a list of EGR fault codes, refer to section 10.16.2.
DDEC Codes for Exhaust Gas Recirculation are listed in Table 10-21.
The DDEC Single ECM Troubleshooting Guide is organized by flash code. Refer to the corresponding section of the guide for
troubleshooting that code.
The following procedures will troubleshoot the Maintenance Alert System (MAS).
The following procedures will troubleshoot a Maintenance Alert System (MAS) display problem.
Listed in Table 10-22are typical faults.
5. Measure voltage between cavity A (#953) ground and cavity B, battery (+).
See Figure 10-13.
[a] If the measured voltage is less than 10.5 volts, charge the batteries or check for bad
12 volt wire. Refer to section 10.17.7.
[b] If the voltage is greater than 10.5 volts, replace the display; verify repair.
Refer to section 10.17.7.
Perform the following steps to check for open data link wires:
1. Unplug the MAS display harness connector at the display.
2. Insert a jumper wire between cavity E (#900) and cavity D (#901). See Figure 10-13.
3. Unplug the vehicle interface harness at the ECM.
4. Measure resistance between cavity C1 and C2 of the vehicle interface harness connector.
See Figure 10-14.
[a] If measured resistance is greater than 10 , one of the data link wires are open.
Locate the open and repair or replace the wire; then test. Refer to section 10.17.7.
[b] If measured resistance is less than 10 , proceed with the troubleshooting.
Refer to section 10.17.4.
Perform the following steps to check for shorted data link wires:
1. Remove jumper wire.
2. Measure resistance between cavity C1 and C2 of the vehicle interface harness connector.
See Figure 10-14.
[a] If the measured resistance is less than 10 , the data link wires are shorted to each
other. Replace wire or repair the short; test. Refer to section 10.17.7.
[b] If the measured resistance is greater than 10 , proceed with the troubleshooting.
Refer to section 10.17.5.
10.17.6 Information
A blank LED for an item indicates a fault in the sensor used for that display. If all lights (green
and red) illuminate during the bulb check sequence, refer to the affected sensor troubleshooting
section.
For all EGR related concerns (may include exhaust smoke complaints), perform the following
steps. If any corrections are made as a result of these checks, test the unit again before proceeding
further:
Basic checks for all Series 60 EGR engines require the following tools:
1,000 Ohm resistor (low watt)
DDR suite 8 or DDDL version 4.2 of higher
Volt Ohm Meter
Pressure gage 0–200 psi
Pressure gage 0–100 psi
10.18.2 Check Variable Output Pressure Device (VPOD) P/N and Supply
Voltage
The following checks should be performed for the VPOD P/N and supply voltage:
1. Check VPOD label to determine if it is + 12V or + 24V compatible.
2. Unplug VPODs mating connector. A 1,000 Ohm resistor is needed for the next step. Insert
the resistor between cavity 1 and 3 for ease of checking with the VOM.
[a] Turn ignition switch ON.
[b] Measure voltage from pin 3 to pin 1.
[c] Plug in DDR and check ECM voltage.
3. Is the VPOD P/N and voltage, and ECM voltage correct?
[a] If the VPOD P/N and voltage are correct, go to section 10.18.3.
NOTE:
VPOD power should have been verified under the P/N check. If not,
refer to section 10.18.2.
NOTE:
Both actuators operate their component with full travel of the linkage.
[a] If both of the PWM voltage measurements are correct, go to section 10.18.4.
[b] If the PWM voltage measurements are incorrect, and the wiring checks are okay, try
a test ECM programmed for EGR, or contact DDC Technical Service.
NOTE:
FMIs listed as 14 are diagnostic information codes and no troubleshooting is required.
For example, an engine derates due to high TCO temperature; a 404/14 code will be
stored. This would indicate that conditions warranted having the ECM derate the fueling
to the engine. If the customer complaint was a power loss, it could be explained that loss
of power was done by the ECM to protect other engine components.
5. If the issue is not related to the EGR system components, or assistance is needed, contact
Detroit Diesel Technical Service.
10.18.7 Test