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SECTION 01: ENGINE
CONTENTS
1.
VOLVO D13 ENGINE ............................................................................................................................ 3
1.1
SYSTEM OVERVIEW..................................................................................................................... 3
1.2
ENGINE OVERVIEW...................................................................................................................... 6
1.3
ENGINE OIL ................................................................................................................................... 7
1.3.1
General.................................................................................................................................... 7
1.3.2
Oil Quality ................................................................................................................................ 7
1.3.3
Oil Change Intervals................................................................................................................ 8
1.3.4
Oil Filters ................................................................................................................................. 9
1.3.5
Synthetic Lubrication ............................................................................................................... 9
1.3.6
Oil Viscosity ............................................................................................................................. 9
1.3.7
Oil Additives............................................................................................................................. 9
1.3.8
Oil Consumption...................................................................................................................... 9
1.3.9
Oil Change............................................................................................................................. 10
1.3.10 Oil Filters Change.................................................................................................................. 10
1.3.11 Checking The Oil Level .........................................................................................................11
1.4
POWER PLANT ASSEMBLY REMOVAL..................................................................................... 11
1.5
POWER PLANT ASSY. INSTALLATION...................................................................................... 14
1.6
ENGINE MOUNTS ....................................................................................................................... 14
2.
DETROIT DIESEL SERIES 60 ENGINE ............................................................................................. 16
2.1
DDEC VI SYSTEM........................................................................................................................ 16
2.2
HARNESSES................................................................................................................................ 16
2.3
ENGINE OVERVIEW.................................................................................................................... 17
2.4
DDEC VI SENSORS..................................................................................................................... 18
2.5
PREVOST INSTALLED SENSORS ............................................................................................. 19
2.6
MOTOR CONTROL MODULE (MCM).......................................................................................... 19
2.7
COMMON POWERTRAIN CONTROLLER (CPC) ....................................................................... 19
2.8
DDEC VI DIAGNOSTICS.............................................................................................................. 19
2.8.1
Diagnostic system ................................................................................................................. 19
2.8.2
Check Engine Telltale Light (AWL) ....................................................................................... 20
2.8.3
Stop Engine Warning Light (RSL) ......................................................................................... 20
2.8.4
Stop Engine Override Switch (SEO) ..................................................................................... 20
2.8.5
Diagnostic Data Link (DDL) Connectors ............................................................................... 20
2.9
READING DIAGNOSTIC CODES – FLASHING LIGHT METHOD: ............................................. 20
2.10 DDEC VI CPC DIAGNOSTIC CODES LIST ................................................................................. 21
2.11 DDEC VI MCM DIAGNOSTIC CODES LIST ................................................................................ 28
2.12 ENGINE OIL LEVEL ..................................................................................................................... 39
2.13 ENGINE OIL AND FILTER CHANGE ........................................................................................... 40
2.14 RECOMMENDED ENGINE OIL TYPE ......................................................................................... 41
2.15 POWER PLANT ASSEMBLY REMOVAL..................................................................................... 41
2.16 POWER PLANT ASSY. INSTALLATION...................................................................................... 45
2.17 JAKE BRAKE................................................................................................................................ 45
2.18 ENGINE MOUNTS ....................................................................................................................... 45
3.
ELECTRONIC FOOT PEDAL ASSEMBLY (EFPA) & THROTTLE POSITION SENSOR ................ 46
4.
ENGINE TROUBLESHOOTING GUIDE............................................................................................. 47
5.
SPECIFICATIONS............................................................................................................................... 49
5.1
5.2
PA1561
SERIES 60 ENGINE ..................................................................................................................... 49
VOLVO D13 ENGINE ................................................................................................................... 50
1
Section 01: ENGINE
ILLUSTRATIONS
FIGURE 1: D13F ENGINE, ALTERNATOR SIDE (TYPICAL) ....................................................................................... 6
FIGURE 2: D13F ENGINE, TURBO SIDE (TYPICAL) ................................................................................................ 7
FIGURE 3: D13F OIL FILTERS ............................................................................................................................. 9
FIGURE 4: OIL FILTER WRENCH ........................................................................................................................ 10
FIGURE 5: OIL FITER REPLACEMENT................................................................................................................. 11
FIGURE 6: ENGINE OIL FILLING TUBE ................................................................................................................ 11
FIGURE 7: ENGINE OIL LEVEL DIPSTICK ............................................................................................................ 11
FIGURE 8: BELT TENSIONER VALVE .................................................................................................................. 12
FIGURE 9: ENGINE COMPARTMENT H3 COACHES (TYPICAL) ............................................................................... 14
FIGURE 10: VOLVO ENGINE POWER PLANT CRADLE INSTALLATION ..................................................................... 15
FIGURE 11: VEHICLE INTERFACE HARNESS (GENERAL APPLICATION SHOWN)...................................................... 16
FIGURE 12: DETROIT DIESEL 2007 SERIES 60 ENGINE (TYPICAL ........................................................................ 18
FIGURE 13: MOTOR CONTROL MODULE (MCM) .................................................................................................. 19
FIGURE 14: CPC ............................................................................................................................................. 19
FIGURE 15: THE CPC COMMUNICATES OVER THE J1587 AND J1939 DATA LINKS TO THE VEHICLE ........................ 19
FIGURE 16: FLASHING FAULTS CODES ............................................................................................................. 21
FIGURE 17: ENGINE OIL LEVEL DIPSTICK .......................................................................................................... 39
FIGURE 18: OIL RESERVE TANK ....................................................................................................................... 39
FIGURE 19: UNDER VEHICLE VIEW ................................................................................................................... 40
FIGURE 20: ENGINE COMPARTMENT ................................................................................................................ 42
FIGURE 21: ENGINE COMPARTMENT H3 COACHES (TYPICAL) ............................................................................. 44
FIGURE 22: ENGINE COMPARTMENT VIP (TYPICAL)............................................................................................ 44
FIGURE 23: POWER PLANT CRADLE INSTALLATION ............................................................................................ 45
FIGURE 24: ELECTRONIC FOOT PEDAL ASSEMBLY ............................................................................................. 46
PA1561
2
Section 01: ENGINE
provide input to the EMS:
1. VOLVO D13 ENGINE
1.1 SYSTEM OVERVIEW
NOTE
The “Premium Tech Tool” (PTT) is the
preferred tool for performing diagnostic work.
Contact your local dealer for more information.
The Engine Management System (EMS)
controls many engine functions such as: fuel
timing and delivery, engine protection functions,
engine brake operation, EGR valve function and
the turbocharger nozzle function. The Engine
Electronic Control Unit (EECU) along with other
supporting control units and sensors are
responsible for monitoring and controlling these
functions. These control units communicate
through the J1939 high speed serial data line to
share data.
In addition to their control functions, the modules
have on-board diagnostic capabilities. The onboard diagnostics are designed to detect faults
or abnormal conditions that are not within their
operating parameters. When the system detects
a fault or abnormal condition, the fault will be
logged in one or both of the modules’ memory.
The vehicle operator will be advised that a fault
has occurred by the illumination of a malfunction
indicator lamp and a message in the driver
information display, if equipped. The module
may initiate the engine shutdown procedure if
the system determines that the abnormal
condition could damage the engine. In some
situations, the system will enter the "limp home"
mode. Limp home mode allows continued
vehicle operation but, the system may substitute
a sensor or signal value that may result in
reduced engine performance.
Ambient Air Temperature Sensor
•
Ambient Pressure sensor
•
Boost Air Pressure (BAP) Sensor
•
Camshaft Position (Engine Position) Sensor
•
Crankshaft Position (Engine Speed) Sensor
•
Differential Pressure DPF Sensor
•
EGR Differential Pressure Sensor
•
EGR Temperature Sensor
•
Engine Coolant Level (ECL) Sensor
•
Engine Coolant Temperature (ECT) Sensor
•
Engine Oil Pressure (EOP) Sensor
•
Engine Oil Level (EOL) Sensor
•
Engine Oil Temperature (EOT) Sensor
•
Exhaust
Sensors)
•
Fuel Pressure Sensor
•
Intake Air Temperature And Humidity (IATH)
Sensor
•
Intake Manifold (Boost) Temperature Sensor
•
Throttle Position (TP) Sensor
•
Turbo Speed Sensor
•
Variable Geometry Turbocharger (VGT)
Position Sensor
Temperature
Sensor
(DPF
Sensors
Ambient Air Temperature Sensor
The Ambient Air Temperature Sensor is used to
detect the outside air temperature. The sensor
modifies a voltage signal from the ECM. The
modified signal returns to the ECM as the
ambient air temperature. The sensor uses a
thermistor that is sensitive to the change in
temperature. The electrical resistance of the
thermistor decreases as temperature increases.
Fault codes logged in the system memory, can
later be read to aid in diagnosing the fault.
These faults can be read via a diagnostic
computer or through the instrument cluster
display, if equipped. The “Premium Tech Tool”
(PTT) is the preferred tool for performing
diagnostic work. Using a diagnostic computer
(or
PTT)
connected
to
the
Serial
Communication Port, expands the technicians
diagnostic capabilities with additional data and
tests.
The Ambient Air Temperature Sensor is located
in the front of the vehicle.
Ambient (Atmospheric) Pressure Sensor
For diagnostic software, contact your local
dealer.
The Ambient (Atmospheric) Pressure Sensor
contains a pressure sensitive diaphragm and an
electrical amplifier. Mechanical pressure applied
The following is a list of engine sensors that
PA1561
•
3
Section 01: ENGINE
to the diaphragm causes the diaphragm to
deflect and the amplifier to produce an electrical
signal proportional to the deflection.
EGR Temperature Sensor
The EGR temperature sensor detects exhaust
gas temperature for EGR system. The sensor
modifies a voltage signal from the control unit.
The modified signal returns to the control unit as
the exhaust temperature of the EGR system to
confirm EGR operation. The sensor uses a
thermistor that is sensitive to the change in
temperature.
The Ambient (Atmospheric) Pressure Sensor is
built into the Engine Management System
(EMS) Module.
Camshaft Position Sensor
The Camshaft Position (Engine Position) Sensor
is located in the rear face of the timing gear
cover at the rear of the engine, near the bottom
of the valve cover. It uses magnetic induction to
generate a pulsed electrical signal. It senses the
passage of seven (7) timing bumps on the edge
of the camshaft dampener. Six of the holes
correspond to the phasing of the electronic unit
injectors, while the seventh hole indicates the
top dead center position.
The EGR Temperature Sensor is located near
the EGR valve.
Engine Coolant Level (ECL) Sensor
The Engine Coolant Level (ECL) Sensor is a
switch. If engine coolant level falls below a
calibrated point the contacts open and the driver
will be notified of the low coolant level.
The Engine Coolant Level (ECL) Sensor is
located in the cooling system reservoir tank.
Crankshaft Position (Engine Speed) Sensor
The Crankshaft Position (Engine Speed) Sensor
uses magnetic induction to generate a pulsed
electrical signal. Notches are machined into the
edge of the flywheel. When one of the notches
passes close to the sensor, electric pulses
result.
Engine Coolant Temperature (ECT) Sensor
The Crankshaft Position (Engine Speed) Sensor
also indicates when the crankshaft is at the top
dead center position.
The Engine Coolant Temperature Sensor is
located at the front of the engine. The sensor
will indicate a high coolant temperature caused
by problems like radiator blockage, thermostat
failure, heavy load, or high ambient
temperatures. This sensor is also used for cold
start enhancement and for fan clutch
engagement.
Differential Pressure DP Sensor
Engine Oil Pressure (EOP) Sensor
The differential pressure sensor is used for flow
measurement of the Diesel Particulate Filter
(DPF). This sensor has two pressure ports and
senses the difference in pressure between the
two ports. Measurement of the pressure before
and after the DPF is used to calculate diesel
filter regeneration.
The Engine Oil Pressure Sensor contains a
pressure sensitive diaphragm and a electrical
amplifier. Mechanical pressure applied to the
diaphragm causes the diaphragm to deflect and
the amplifier to produce an electrical signal
proportional to the deflection.
The Engine Oil Pressure Sensor is located on
the oil filter assembly. The sensor monitors
engine oil pressure to warn of lubrication system
failure.
The Differential Pressure DPF Sensor is located
on the side of the Diesel Particulate Filter (DPF).
EGR Differential Pressure Sensor
Engine Oil Level (EOL) Sensor
The EGR differential pressure sensor is used for
flow measurement of the Exhaust Gas
Recirculation (EGR) valve. This sensor has two
pressure ports and senses the difference in
pressure between the two ports. Measurement
of the pressure before and after the EGR valve
is used to calculate EGR flow.
The Engine Oil Level Sensor is located in the oil
pan.
Engine Oil Temperature (EOT) Sensor
The Engine Oil Temperature Sensor is a
thermistor whose resistance varies inversely to
temperature. The sensor has a negative
The EGR Differential Pressure Sensor is located
on the left or right side of the engine.
PA1561
4
Section 01: ENGINE
temperature coefficient, which means the sensor
resistance will decrease as the engine oil
temperature increases.
air temperature increases.
The Intake Manifold (Boost) Temperature
Sensor is located in the intake manifold.
The Engine Oil Temperature Sensor is located
in the oil pan.
Intake Manifold Pressure Sensor
The Intake Manifold Pressure Sensor contains a
pressure sensitive diaphragm and an electrical
amplifier. Mechanical pressure applied to the
diaphragm causes the diaphragm to deflect and
the amplifier to produce an electrical signal
proportional to the deflection.
Exhaust Temperature Sensor (DPF Sensors)
The exhaust gas temperature sensor detects
exhaust gas temperature for DPF protection as
well as DPF regeneration control. The sensor
modifies a voltage signal from the control unit.
The modified signal returns to the control unit as
the exhaust temperature at that specific location
of the exhaust. The sensor uses a thermistor
that is sensitive to the change in temperature.
The Intake Manifold Pressure Sensor is located
on the air inlet pipe before the intake manifold.
Throttle Position (TP) Sensor
The Exhaust Temperature Sensors are located in
the DPF assembly.
The Throttle Position Sensor is a potentiometer
that is mechanically linked to the accelerator
pedal. A potentiometer is a variable resistor
whose resistance will change as the pedal is
pressed. As the resistance changes, the signal
voltage of the sensor changes indicating the
accelerator pedal position.
Fuel Pressure Sensor
The fuel pressure sensor contains a diaphragm
that senses fuel pressure. A pressure change
causes the diaphragm to flex, inducing a stress
or strain in the diaphragm. The resistor values in
the sensor change in proportion to the stress
applied to the diaphragm and produces an
electrical output.
The Throttle Position Sensor is located above
the accelerator pedal. The sensor is designed to
improve the driver’s control by reducing
sensitivity to chassis motion. This sensor
provides the driver’s fuel request input to the
VECU.
The Fuel Pressure Sensor is located on top of
the fuel filter housing.
Intake Air Temperature and Humidity (IATH)
Sensor
Turbo Speed Sensor
The Turbo Speed Sensor informs the EMS of
the turbo shaft speed. The sensor does not read
from the vanes, but reads from the shaft. The
Engine Management System (EMS) Module
uses this signal in conjunction with the VGT
position sensor signal to control the speed of the
turbocharger and therefore optimize the intake
manifold pressure.
The Intake Air Temperature and Humidity (IATH)
Sensor contains a thermistor and a capacitive
sensor. The resistance of the thermistor varies
inversely to temperature. The output of the
capacitive sensor increases as the humidity of
the surrounding air increases. By monitoring the
signals from both portions of the sensor, the
Engine Management System (EMS) Module
calculates the temperature and humidity of the
air passing through the air filter housing.
The Turbo Speed Sensor is mounted in the
center of the turbocharger.
The Intake Air Temperature and Humidity (IATH)
Sensor is located in the air intake tube just
downstream from the air filter canister.
Variable Geometry Turbocharger
Remote Actuator (VGT SRA)
The Variable Geometry Turbocharger Smart
Remote Actuator (VGT SRA) takes the position
commands from the EMS, moves the nozzle of
the turbocharger to the desired position, and
performs all of the diagnostics and self checks
on the actuator.
Intake Manifold (Boost) Temperature Sensor
The Intake Manifold (Boost) Temperature
Sensor is a thermistor whose resistance varies
inversely to temperature. The sensor has a
negative temperature coefficient, which means
the sensor resistance will decrease as the inlet
PA1561
Smart
5
Section 01: ENGINE
1.2 ENGINE OVERVIEW
NOTE
For additional information concerning Volvo D13 engine components or engine-related components,
consult Volvo Trucks Canada or Volvo Trucks North America Web Site under: Parts & Service. On
Volvo web site, you will find detailed service procedures for parts replacement, repair and
maintenance.
FIGURE 1: D13F ENGINE, ALTERNATOR SIDE (TYPICAL)
1. Breather Tube
7. Fuel Filter
2. Intake Manifold
8. Fuel/Water Separator
3. Air Compressor
9. Fuel Filter
4. Power Steering Pump
10. Hand-Priming Pump
5. Fuel Pump
11. Crankcase Ventilator
6. Engine Electronic Control Unit (EECU)
12. EGR Mixing Chamber
PA1561
6
Section 01: ENGINE
FIGURE 2: D13F ENGINE, TURBO SIDE (TYPICAL)
13. Exhaust Manifold
20. Oil Filters
14. Valve Cover
21. Oil Pan
15. Engine Pre-Heater Element (Optional)
22. EGR Cooler
16. DRV Valve
23. Turbocharger
17. Coolant Pump
24. Starter Motor
18. Coolant Filter
25. EGR Valve
19. Venturi Pipe
1.3 ENGINE OIL
1.3.1 General
Keep the engine oil at the proper level and change it at the recommended intervals. Always replace the
oil filters at the same time as when the oil is changed.
1.3.2 Oil Quality
Volvo North America recognizes engine oils that meet or exceed the standards given by American
Petroleum Institute (API) for the oil classifications listed in this manual. Only oils licensed to carry the API
PA1561
7
Section 01: ENGINE
symbol should be used. Lubricants meeting API standards have provided maximum engine life when
used together with the recommended oil and oil filter change intervals.
EO-O Premium Plus (or VDS-4) diesel engine oil is mandatory for use in all 2007 emission compliant
Volvo engines. Chassis equipped with a 2007 emission compliant engine, which can be identified by the
presence of a Diesel Particulate Filter (DPF), also require the use of Ultra Low Sulfur Diesel (ULSD) fuel.
EO-O Premium Plus oils exceed the new API service category CJ-4.
CAUTION
DO NOT add extra oil additives. Additives such as break-in oils, top oils, graphitizers, and frictionreducing liquids are not necessary and can harm the engine.
1.3.3 Oil Change Intervals
The length of time an engine can operate before an oil change depends on the quality oil used, the type
of fuel used, fuel consumption, engine oil consumption, vehicle application, level of dust in the air, and
fuel consumption. The change intervals given in this manual are maximum intervals. If the vehicle is
operating in heavy-duty operation, dusty or off-road conditions, etc., reduce the intervals for more
frequent oil changes.
NOTE
Use the information in the table below to determine the operating condition and usage applicable to your
vehicle.
Engine Operating Condition
Medium
Heavy
Severe
Total Fuel Consumption (mpg)
More than 6
More than 4.7
More than 3.7
Total Fuel Consumption (L/100 KM)
Less than 39
Less than 50
Less than 64
Engine Oil and Filter Change
Interval, miles (km) – 41 U.S. quarts (39L)
Oil capacity
35,000 (55 000)
25,000 (40 000)
15,000 (24 000)
NOTE: If idle time is greater than 25%, use the next lower drain interval.
PA1561
8
Section 01: ENGINE
Choose the viscosity grade for the typical
ambient temperature for the application.
Multigrade oils have a broad range that suit
operation in changing temperature.
NOTE
Oil filters should always be changed when
changing the oil.
Volvo North America recommends the
viscosities shown in the viscosity/temperature
table for Volvo engines.
1.3.4 Oil Filters
There are three filters on the engine, one of
which is a bypass filter. This should be changed
at the same time as the full-flow filter(s).
CAUTION
Volvo branded oil filters are designed to
provide the proper level of filtration and
protection for Volvo engines. Filters that do
not meet the same stringent requirements
may void engine warranty.
1.3.7 Oil Additives
CAUTION
Extra oil additives must never be added to
any engine oil used. Additives such as breakin oils, top oils, graphitizers, and friction
reducing liquids are not necessary and may
even harm the engine.
Using
oils
to
the
quality
standards
recommended in this manual makes the use of
extra oil additives unnecessary, as these oils
already contain a balanced treatment of
additives.
FIGURE 3: D13F OIL FILTERS
1.3.5 Synthetic Lubrication
Synthetic oils are offered by some oil suppliers
as an alternative to the traditional, petroleum
based oils for engines. These oils may be used
in Volvo engines, provided they meet the quality
levels specified on the previous pages, that is:
both VDS-4 and EO-O Premium Plus.
1.3.8 Oil Consumption
Once the engine is stopped, check the oil level
daily. If the engine has just been stopped and it
is warm, wait approximately five minutes to allow
the oil to drain back to the oil pan before
checking. Add oil as necessary.
The use of synthetic oils does not permit the
extension of the recommended oil change
intervals.
CAUTION
1.3.6 Oil Viscosity
The viscosity grade defines the thickness of the
oil. The oil must be thin enough at low
temperatures for easy cold starts and thick
enough to protect at high temperatures. An oil is
not fully defined until both the API quality
classification and the viscosity grade are
specified.
PA1561
DO NOT overfill engine with oil.
All diesel engines are designed to consume
some oil, so it is normal to add oil periodically.
An engine used in heavy-duty operation will
consume more oil than one in normal operation.
9
Section 01: ENGINE
1.3.10 Oil Filters Change
1.3.9 Oil Change
WARNING
WARNING
A hot engine or engine oil can be dangerous.
Serious burns can result from contact with a
hot engine or oil. Take precautions when
draining the oil. Wear gloves or let the engine
cool down before draining.
Hot oil can cause severe burns. DO NOT
allow hot oil to contact the skin. When
changing oil, wear protective gloves.
CAUTION
WARNING
Volvo-branded oil filters are designed to
provide the proper level of filtration and
protection for Volvo engines. Filters that do
not meet the same stringent requirements
may cause unsatisfactory results.
When draining the oil, use the proper tools
and keep away as far as possible. Raise the
elbow so the forearm is parallel to the ground
to prevent oil running down the arm, causing
burns.
•
CAUTION
Clean around the oil filter housing and
remove the filters using the oil filter
wrench or the oil filter socket.
Always dispose of all lubricants (motor oil,
coolant, gear box oils, etc) and filters
according to Federal or local regulations.
Used oil disposed of in nature or waterways
contaminates our drinking water and kills
wildlife.
WARNING
Prolonged contact with used engine oil may
be harmful. Use rubber gloves when handling
used oil. Wash skin thoroughly if it comes in
contact with used oil.
FIGURE 4: OIL FILTER WRENCH
It is important to drain as much oil as possible.
Try to change oil immediately after driving, when
the oil is warm. Always replace the oil filters
when changing the oil.
Component
Capacity (L)
Oil pan
24 min - 32 max
Engine block
4.5
Filters (3)
6
Total oil fill (empty)
42.5
•
NOTE
Since about 1 liter of oil remains in the engine
after draining, approximately 38 liters will be
needed for a complete oil change.
PA1561
10
Prefill the new oil filters with approved
engine oil. Also, lubricate the filter gaskets
with engine oil (1). Hand tighten the oil
filters until they contact the sealing surface
of the oil filter housing (2). Manually
tighten the oil filters an additional ¾ to 1
full turn (3).
Section 01: ENGINE
FIGURE 6: ENGINE OIL FILLING TUBE
FIGURE 5: OIL FITER REPLACEMENT
•
Start the engine and check for leaks
around the oil filter housing and filters.
•
Check the oil level. Add approved engine
oil to the recommended level, if
necessary. Do not overfill.
FIGURE 7: ENGINE OIL LEVEL DIPSTICK
1.4 POWER PLANT ASSEMBLY REMOVAL
To access the engine or engine-related
components, the vehicle power plant assembly
must be removed as a whole unit by means of a
slide-out cradle. The power plant assembly
includes the engine, transmission (including
retarder if so equipped), air compressor,
alternator and transmission oil cooler.
1.3.11 Checking the Oil Level
Ensure that the vehicle is parked on level
ground before checking the oil level. Wait five
minutes after shutting off the engine and then
proceed with checking the oil.
Remove the power plant assembly as follows:
CAUTION
CAUTION
Tag hoses and cables for identification before
disconnecting in order to facilitate reinstallation.
Plug all openings to prevent dirt from entering
the system.
DO NOT let the oil level fall below the marking
on the dipstick. DO NOT overfill so the level is
above the upper marking on the dipstick. This
could lead to excessive oil temperature and/or
poor crankcase breather performance. Add oil
through the oil filler pipe as required in order
to maintain level within the safe range.
NOTE
No parts within the EECU are serviceable. If
found defective, replace the EECU as a unit.
• Preparation
1. Close the heater lines shut-off valves.
2. Disconnect the battery or batteries from the
starting system by removing one or both of
the battery cables from each battery system.
With the electrical circuit disrupted,
accidental contact with the starter button will
not produce an engine start.
PA1561
11
Section 01: ENGINE
9. Disconnect and remove the air intake duct
mounted between the turbocharger outlet
and the air cooler inlet.
WARNING
Due to the heavy load of the rear bumper
assembly, it must be adequately supported
before attempting to remove it.
10. Disconnect and remove section of coolant
pipe assembly mounted between the radiator
outlet and the water pump inlet.
3. Remove the rear bumper assembly from the
vehicle. Refer to Section 18 BODY, under
"Rear Bumper Removal".
11. Disconnect and remove a section of coolant
pipe assembly mounted between the
thermostat housing and the radiator inlet, if
applicable.
4. If applicable, disconnect the block heater
connector located near the EGR mixing
chamber.
12. Disconnect the electric fan-clutch connector
located near the cooling fan right angle
gearbox.
13. Disconnect the cooling fan drive shaft.
CAUTION
To avoid damage to cooling fan right angle
gearbox, make sure the power plant cradle
clears the gearbox when pulling the engine out.
14. Disconnect surge tank hoses connected to
the thermostat housing, the pump inlet and to
the transmission oil cooler.
FIGURE 8: BELT TENSIONER VALVE
15. Disconnect and remove the exhaust pipe
mounted between the flexible coupling and
the pipe going to the Aftertreatment Device
(ATD). If necessary, refer to Section 04
EXHAUST SYSTEM under “Muffler Removal
and Installation".
12200
5. Locate the A/C compressor belt tensioner
pressure releasing valve (Fig. 8). Turn
pressure
releasing
valve
handle
counterclockwise in order to release pressure
in belt-tensioner air bellows and loosen belt.
Remove the A/C compressor belt.
CAUTION
To avoid damage to turbocharger, cover the
turbocharger outlet opening to prevent foreign
material from entering.
6. To release all pressure from the air system.
Refer to Section 12, BRAKES & AIR
SYSTEM for instructions.
16. Remove the power steering pump.
17. Close engine fuel supply shutoff valve on
primary fuel filter or Fuel Pro. Disconnect the
fuel line located above fuel filters and
connected to inlet port. On vehicles equipped
with the optional fuel filter/water separator,
disconnect the connector and remove cable
ties from cradle.
7. Disconnect and remove the engine-air intake
duct mounted between air cleaner housing
and turbocharger inlet.
CAUTION
To avoid damage to turbocharger, cover the
turbocharger inlet opening to prevent foreign
material from entering.
• With Vehicle Raised
18. Using the quick-connect drain hose, drain
the engine cooling system. Refer to Section
05 COOLING under "Draining Cooling System".
8. Disconnect and remove the air intake duct
mounted between the air cooler outlet and
the engine intake.
PA1561
12
Section 01: ENGINE
19. From under the vehicle, disconnect the
propeller shaft as detailed in Section 09,
under heading "Propeller Shaft Removal".
34. On partition wall, disconnect connector C397
located between engine compartment and
main power compartment.
20. On vehicles equipped with an automatic
transmission provided with a hydraulic output
retarder, disconnect steel-braided airline from
pressure regulator output. The pressure
regulator is mounted in the upper section of
engine compartment backwall and is
accessible through the engine compartment
R.H. side door.
35. Inspect the power plant assembly to ensure
that nothing will interfere when sliding out the
cradle. Check for connections or hoses not
mentioned in this list as some vehicles are
equipped with special or aftermarket
components.
NOTE
Check if any spacer(s) have been installed
between power plant cradle and vehicle rear
subframe, and if so, note position of each
washer for reinstallation purposes.
21. Remove the retaining bolts, washers and
nuts securing the power plant cradle to the
vehicle rear subframe.
22. Disconnect transmission
transmission housing.
harness
from
36. Using a forklift, with a minimum capacity of
4,000 lbs (1 800 kg), slightly raise the power
plant cradle.
• With Vehicle Lowered
37. Pull engine out slowly from the engine
compartment. Make sure all lines, wiring and
accessories are disconnected and are not
tangled.
23. Disconnect the air compressor discharge,
governor steel-braided airlines and manual
filling airlines from compressor. Remove
retaining clips.
CAUTION
24. Disconnect the hose connecting the
compressor head to the sump tank, if
applicable.
Due to the minimum clearance between the
power plant equipment and the top of the
engine compartment, extreme care should be
used to raise the power plant cradle, just
enough to free the cradle. Clearance between
power plant cradle and mounting rail should
range between ¼" and ½" (6-12 mm).
25. Disconnect ground cables from rear
subframe ground-stud located close to the
starter motor.
26. Disconnect alternators cooling duct and put
aside.
27. Inside
rear
electrical
compartment,
disconnect starter, alternators and heater
cables. Also disconnect AFSS cable if
applicable.
28. Disconnect Aftertreatment
control cable.
Device
(ATD)
29. Disconnect VIH (vehicle interface harness)
connector.
30. Disconnect fuel return line from bulkhead
fixed on engine cylinder head end.
31. Unfasten and put aside engine compartment
lighting fixture and turbocharger fire
suppression nozzle if applicable.
32. Disconnect turbo boost pressure gauge
airline from engine air intake, if applicable.
33. Disconnect the engine coolant hose near the
starter.
PA1561
13
Section 01: ENGINE
FIGURE 9: ENGINE COMPARTMENT H3 COACHES (TYPICAL)
1.5 POWER PLANT ASSY. INSTALLATION
It is recommended that new rubber mounts be
installed at each major overhaul.
To install a power plant assembly, follow the
same procedure as in "Power Plant Assembly
Removal" except in reverse order, then proceed
with the following:
NOTE
Refer to the table on the following page for
engine cradle tightening torques.
1. Torque the power plant cradle mounting
bolts to 190 lbf-ft (255 Nm).
2. Refill cooling system with saved fluid (refer
to Section 05 COOLANT SYSTEM).
3. Once engine fuel system has been drained,
it will aid restarting if fuel filters are filled with
fuel oil (refer to Section 03 FUEL SYSTEM).
4. Start engine for a visual check. Check fuel,
oil, cooling, pneumatic and hydraulic system
connections for leakage. Test operation of
engine controls and accessories.
1.6 ENGINE MOUNTS
The power plant assembly is mounted to the
cradle by means of rubber mounts and supports.
Two engine support brackets are used at the
front of the engine while two rubber mounts are
mounted underneath the engine & radiator fan
drive mechanism support and the engine &
alternator support (Fig. 10).
PA1561
01193
14
Section 01: ENGINE
FIGURE 10: VOLVO ENGINE POWER PLANT CRADLE INSTALLATION
DRY TORQUES
REFERENCE
DESCRIPTION
Lbf-ft
Nm
A
SCREW, CAP HEXAGONAL HEAD M8 – 1.25 G8.8
16
22
B
SCREW, CAP HEXAGONAL HEAD M8 – 1.25 G10.9
22
30
C
SCREW, CAP HEXAGONAL HEAD M10 – 1.5 G10.9
43
58
D
SCREW, CAP HEXAGONAL HEAD M12 – 1.75 G8.8
60
81
E
SCREW, CAP HEXAGONAL HEAD M14 – 2.0 G8.8
90
122
F
SCREW, CAP HEXAGONAL HEAD M16 – 2.0 G8.8
140
190
G
SCREW, CAP HEXAGONAL HEAD M16 – 2.0 G10.9
190
258
H
SCREW, CAP HEXAGONAL HEAD M20 – 2.5 G10.9
450
610
PA1561
15
Section 01: ENGINE
system has a chassis-mounted control unit for
vehicle engine management, the Common
Powertrain Controller (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.).
DDEC VI controls the timing and amount of fuel
injected by the electronic unit injectors (EUI).
The system also monitors several engine
functions using electrical sensors, which send
electrical signals to the Motor Control Module
(MCM). The MCM computes the electrical
signals and determines the correct fuel output
and timing for optimum power, fuel economy
and emissions. The MCM also has the ability to
display warnings or shut down the engine
completely (depending on option selection) in
the event of damaging engine conditions, such
as low oil pressure or high engine temperature.
2. DETROIT DIESEL SERIES 60 ENGINE
The DDC series 60 engine is a 6-cylinder, fourcycle, 14.0 liters Detroit Diesel series 60 engine,
equipped with an electronic control system
(DDEC VI).
Complete maintenance and repair information
on the engine will be found in the current
DETROIT DIESEL SERIES 60 2007 ONHIGHWAY SERVICE MANUAL 6SE2007. This
essential manual contains complete instructions
on operation, adjustment (tune-up), preventive
maintenance and lubrication, parts verification,
repair or replacement. This manual’s sections
cover complete systems such as:
• Engine main assembly;
• Fuel system;
• Lubrication system;
• Cooling system;
• Fuel, lubricating oil and coolant;
2.2 HARNESSES
There are two major harnesses: the Engine
Harness (EH) and the Vehicle Interface Harness
(VIH). The Engine Harness is installed at the
Detroit Diesel factory and is delivered connected
to all engine sensors, the fuel injection system,
and the MCM.
The OEM supplied Vehicle Interface Harness
connects the CPC to other vehicle systems.
• Air intake system;
• Exhaust system;
• Exhaust gas recirculation components;
• Electrical equipment;
• Operation and verification;
• Engine tune-up;
• Preventive maintenance;
• Storage;
Refer to Series 60 DDEC VI Troubleshooting
Guide published by Detroit Diesel for more
complete
information
on
diagnosis
of
components and system problems.
Procedures for engine removal and installation
are given at the end of this section. The DDEC
system is self-diagnostic. It can identify faulty
components and other engine-related problems
by providing the technician with diagnostic
codes.
2.1 DDEC VI SYSTEM
DDEC VI (Detroit Diesel Electronic Control) is a
system that monitors and determines all values
required for the operation of the engine. A
diagnostic interface is provided to connect to an
external diagnosis tester. Besides the engine
related sensors and the engine-resident control
unit, the Motor Control Module (MCM), this
PA1561
FIGURE 11: VEHICLE INTERFACE HARNESS (GENERAL
APPLICATION SHOWN)
16
Section 01: ENGINE
2.3 ENGINE OVERVIEW
1- Starter motor
2- Oil pan drain plug
3- Primary fuel-filter/waterseparator
4- MCM (DDEC VI Electronics)
5- Secondary fuel filter shutoff
valve
6- Secondary fuel filter
7- Fuel pump
8- Air compressor
9- Engine oil filling tube
10- Bosch alternators (2)
11- Engine oil dipstick
12- EGR delta pressure sensor
13- EGR valve
14- Intake throttle
15- EGR mixer
16- Intake manifold
17- Engine Harness
18- Thermostat housing
19- Turbo compressor outlet
20- Actuator coolant return line
21- Electrically controlled actuator
22- HC doser
23- Closed-crankcase breather/oil separator
PA1561
17
Section 01: ENGINE
24- Water pump
25- EGR cooler
26- Oil filter (2)
27- Crankcase breather tube
28- EGR tube
FIGURE 12: DETROIT DIESEL 2007 SERIES 60 ENGINE (TYPICAL)
01179
• Engine Oil Pressure Sensor (EOP
Sensor): Senses gallery oil pressure for
functions such as engine protection.
2.4 DDEC VI SENSORS
• Camshaft Position Sensor (CMP Sensor):
Indicates a specific cylinder in the firing
order.
• Engine Oil Temperature Sensor (EOT
Sensor): Senses oil temperature for
functions such as reducing variation in fuel
injection and fan control.
• Crankshaft Position Sensor (CKP Sensor):
Senses crankshaft position and engine
speed for functions such as fuel control
strategy.
• Fuel Line Pressure Sensor: Senses fuel
line pressure.
• DPF Inlet Pressure Sensor Measures
pressure between the Diesel Oxidation
Catalyst (DOC) and the Diesel Particulate
Filter (DPF) in the aftertreatment assembly.
• Fuel Compensation Pressure Sensor:
Compensates fuel line pressure.
• Intake Manifold Pressure Sensor (IMP
Sensor): Senses turbo boost for functions
such as smoke control and engine protection.
• DPF Outlet Pressure Sensor: Measures
pressure on the outlet of the aftertreatment
device in the exhaust system of the vehicle.
• Intake Manifold Air Temperature Sensor
(IMT Sensor): Senses pressure. The MCM
uses this information to compute the amount
of air entering the engine.
• DPF
Outlet
Temperature
Sensor:
Temperature measured at the outlet of the
after-treatment system that is installed within
the exhaust system of the vehicle.
• Supply Fuel Temperature Sensor (SFT
Sensor): Senses fuel temperature for
functions such as engine fueling.
• DOC
Inlet
Temperature
Sensor:
Temperature measured at the outlet of the
after-treatment.
• Turbo Compressor Temperature Out
Sensor: Senses turbo out air temperature.
• DOC
Outlet
Temperature
Sensor:
Temperature measured between the DOC
and the DPF in the aftertreatment assembly.
• Turbo Speed Sensor (TSS): Monitors turbo
speed for overspeed conditions.
• EGR Delta Pressure Sensor: Senses EGR
pressure for EGR control.
• VGT Position Sensor/EGR Valve Position
Sensor.
• EGR Temperature Sensor: Senses EGR
exhaust temperature after EGR cooler. Used
for EGR system diagnosis.
• Intake Air Throttle Valve Sensor.
• Exhaust Valve Recirculation Valve (EGR)
Sensor.
• Engine Coolant Temperature Sensor (ECT
Sensor): Senses coolant temperature for
functions such as engine protection, fan
control and engine fueling.
PA1561
18
Section 01: ENGINE
2.7 COMMON POWERTRAIN CONTROLLER
(CPC)
2.5 PREVOST INSTALLED SENSORS
• Engine Coolant Level Sensor (ECL
Sensor): Senses coolant level for engine
protection (mounted on coolant surge tank).
The CPC is the interface between the MCM and
the vehicle/equipment for engine control and
manages other vehicle/equipment functions.
• Turbo Compressor In Temperature
Sensor: Senses the air temperature at the
turbo compressor inlet.
Within the CPC, sets of data for specific
applications are stored. These include idle
speed, maximum running speed, and speed
limitation. Customer programmable parameters
are also stored here. The CPC receives data
from the operator (accelerator pedal position,
switches and various sensors) and other
electronic control units. From this data,
instructions are computed for controlling the
engine and transmitted to the MCM via the
proprietary data link.
• Vehicle Speed Sensor (VSS): Provides a
vehicle speed signal (connected to
transmission).
2.6 MOTOR CONTROL MODULE (MCM)
The Motor Control Module is mounted, on the
starter side of the engine (Fig. 13). Considered
the "Brain" of the DDEC VI system, it provides
overall monitoring and control of the engine. It
does so by comparing input data from the
various sensors to a set of calibration data
stored in the EEPROM (Electrically Erasable,
Programmable, Read-Only Memory) within the
Motor Control Module. After comparing the
input data with the calibration data, the MCM
sends high-current command pulses to the
Electronic Unit Injectors (EUI) to initiate fuel
injection. The MCM also receives feedback
regarding the start and end of injection for a
given cylinder. The EEPROM within the Motor
Control Module is factory programmed by
Detroit Diesel. Reprogramming must be done at
a Detroit Diesel authorized service center.
However, some changes may be performed to
the cruise control and road speed limiter using a
diagnostic data reader (see paragraph "DDEC
VI Diagnostic Codes" in this section).
FIGURE 14: CPC
FIGURE 15: THE CPC COMMUNICATES OVER THE
J1587 AND J1939 DATA LINKS TO THE VEHICLE
2.8 DDEC VI DIAGNOSTICS
2.8.1 Diagnostic system
FIGURE 13: MOTOR CONTROL MODULE (MCM)
PA1561
Diagnostics is a standard feature of DDEC VI.
The purpose of this feature is to provide
information for problem identification and
01145
19
Section 01: ENGINE
problem solving in the form of a code. The MCM
and CPC continuously perform self diagnostic
checks and monitor the other system
components.
Information
for
problem
identification and problem solving is enhanced
by the detection of faults, retention of fault codes
and separation of active from inactive codes.
2.8.3 Stop Engine Warning Light (RSL)
The engine-mounted MCM includes control logic
to provide overall engine management. System
diagnostic checks are made at ignition on and
continue throughout all engine operating modes.
2.8.4 Stop Engine Override Switch (SEO)
This light, also mounted on the telltale light
panel, illuminates to indicate that a major engine
problem is occurring (with the exception of a 5second bulb check when the ignition is first
turned on).
This switch, mounted on the dashboard, may be
used to extend the 30-second delay period
before engine shutdown when the Stop engine
telltale light is illuminated. This switch can be
repeatedly depressed in order to move the
vehicle out of traffic.
Sensors provide information to the MCM and
CPC regarding various engine and vehicle
performance characteristics. The information is
used to regulate engine and vehicle
performance, provide diagnostic information,
and activate the engine protection system.
NOTE
The stop engine override switch will be
operative only if it has been depressed before
the end of the 30 second delay period.
The DDEC VI on-board diagnostic system
accessories include the following:
• Check Engine telltale light (AWL);
CAUTION
• Stop Engine telltale light (RSL);
The OVERRIDE switch must be used only in
emergency cases, such as to move the
vehicle out of traffic. Excessive use of this
switch can cause serious damage to the
engine.
• Stop Engine Override switch (SEO);
• Diagnostic Data Link (DDL) connectors.
The AWL is illuminated and a code is stored if
an electronic system fault occurs. This indicates
the problem should be diagnosed as soon as
possible. The CPC illuminates the AWL and
RSL and stores a malfunction code if a
potentially engine damaging fault is detected.
These codes can be accessed in one of four
ways:
This switch is also used for DDEC diagnostic
code requests. Press this switch with the engine
at idle or off but with the ignition in the "ON"
position and active codes will be flashed on the
CHECK ENGINE and STOP ENGINE telltale
lights alternately.
2.8.5 Diagnostic Data Link (DDL) Connectors
• Commercially
available
J1587/J1939
diagnostic tools.
• Detroit Diesel Diagnostic Link® (DDDL 7.0).
• Flashing the AWL and RSL with the
SEO/Diagnostic Request Switch.
• Dashboard’s Message Center Display
(MCD).
A connector is mounted on the L.H. footwell
wall. Another connector is located in the rear
electric compartment. They allow the connection
of the Diagnostic Data Reader (DDR) to read
the codes or to access pertinent data on the
condition of the engine. This enables a more
complete analysis of any defect found in the
DDEC system operation. For more information,
see Detroit Diesel Troubleshooting Guide
#6SE492.
2.8.2 Check Engine Telltale Light (AWL)
The CPC illuminates the Check Engine telltale,
mounted on the telltale light panel to indicate
that a problem has been detected and that a
code has been stored in the MCM memory.
This light also has a 5-second bulb check when
the ignition is first turned on.
PA1561
2.9 READING DIAGNOSTIC CODES –
FLASHING LIGHT METHOD:
DDEC VI makes use of two types of codes:
Active and inactive. The difference between the
two types of codes is as follows:
20
Section 01: ENGINE
Active Codes: Codes that are currently
keeping the Check Engine or Stop Engine
telltale light illuminated. Active codes are flashed
via the Stop Engine Light when checked with the
stop-engine-override switch.
Inactive Codes: These are all the codes
logged in the CPC, which have previously
occurred, (whether or not they are currently
turning on the Stop or Check Engine Light).
Inactive codes are flashed via the Check Engine
telltale light when checked with the stop-engineoverride switch.
FIGURE 16: FLASHING FAULTS CODES
Refer to DDEC Troubleshooting Manual 6SE567
for more information and SAE codes.
In most instances, only the DDR can provide the
information necessary for a quick diagnosis of
the problem. If you just need to read out codes,
however, and do not have a DDR available, the
following procedure will let you read out codes.
Make sure the rear-starting switch (located in
the engine compartment) is in the normal
position. With the ignition ON, the engine idling
or engine shut-off, momentarily depress the
Stop Engine Override (SEO) switch. Active
codes will be flashed on the stop engine telltale,
followed by the inactive codes being flashed on
the check-engine telltale panel.
The cycle
repeats itself until the operator depresses the
stop engine override switch again.
NOTE
Active codes are flashed in ascending
numerical flash code order. Inactive codes are
flashed in most recent to least recent order.
NOTE
Fault codes can only be cleared using the
DDR.
NOTE
The listed codes may not be used in all
applications. A default value in the normal
operating range is used by the MCM to
provide for engine operation if a sensor failure
is present.
Flashing codes provide a four digit number.
Each fault code is flashed twice in order to help
with counting the flashes. If there are no active
faults or if there are no inactive faults the
number “3” is flashed once followed by an ~3s
delay.
2.10 DDEC VI CPC DIAGNOSTIC CODES LIST
PID
PID/SID
ID
70
FLASH
CODES
2111
19
SID
234
2112
70
13
SID
234
2112
70
19
SID
234
2112
70
13
SID
234
2112
70
19
SID
234
2112
70
13
SID
234
2112
84
21
PID
84
2113
SPN
FMI
PID/SID
70
2
70
PA1561
FAULT DESCRIPTION
Park Brake Status Not Plausible (Vehicle Moving)
J1939 Park Brake Switch Signal from Source #1 is
erratic
J1939 Park Brake Switch Signal from Source #1 is
missing
J1939 Park Brake Switch Signal from Source #2 is
erratic
J1939 Park Brake Switch Signal from Source #2 is
missing
J1939 Park Brake Switch Signal from Source #3 is
erratic
J1939 Park Brake Switch Signal from Source #3 is
missing
Vehicle Speed Failure
21
Section 01: ENGINE
PID
PID/SID
ID
84
FLASH
CODES
2113
4
PID
84
2113
Vehicle Speed Sensor Circuit Failed Low
84
2
PID
84
2113
VSS Anti Tamper Detection via Virtual Gear Ratio
84
8
PID
84
2113
84
6
PID
84
2113
84
19
PID
84
2113
84
13
PID
84
2113
84
19
SID
84
2113
84
13
PID
84
2113
84
19
PID
84
2113
84
13
PID
84
2113
84
20
PID
84
2113
91
91
13
3
PID
PID
91
91
2114
2114
VSS Anti Tamper Detection via Fixed Frequency
Device
VSS Anti-Tamper Detection via ABS Vehicle Speed
Comparison
J1939 Wheel-Based Vehicle Speed Signal from
Source#1 is erratic
J1939 Wheel-Based Vehicle Speed Signal from
Source#1 is missing
J1939 Wheel-Based Vehicle Speed Signal from
Source#2 is erratic
J1939 Wheel-Based Vehicle Speed Signal from
Source#2 is missing
J1939 Wheel-Based Vehicle Speed Signal from
Source#3 is erratic
J1939 Wheel-Based Vehicle Speed Signal from
Source#3 is missing
Vehicle Speed Sensor Drifted High Error (VSS
signal not plausible)
Accelerator Pedal Learn Error
Accelerator Pedal Circuit Failed High
91
4
PID
91
2114
Accelerator Pedal Circuit Failed Low
91
8
PID
91
2114
91
14
PID
91
2114
Pwm Accelerator Pedal Signal 1 Frequency Out Of
Range
Pwm Accelerator Pedal Not Learned
91
7
PID
91
2114
Pwm Accelerator Pedal Idle Not Recognized
91
31
PID
91
2114
Pwm Accelerator Pedal Learned Range to Large
91
3
PID
91
2114
Accelerator Pedal Signal Circuit Failed High
91
9
SID
231
2615
J1939 EEC2 Message is missing
98
98
98
100
100
107
107
107
110
0
18
1
18
1
0
4
3
16
PID
PID
PID
PID
PID
PID
PID
PID
PID
98
98
98
100
100
107
107
107
110
2115
2115
2115
2121
2121
2122
2122
2122
2123
Oil Level High
Oil Level Low
Oil Level Very Low
Oil Pressure Low
Oil Pressure Very Low
Air Filter Restriction High
Air Filter Signal Circuit Failed Low
Air Filter Signal Circuit Failed High
Coolant Temperature High
SPN
FMI
PID/SID
84
3
84
PA1561
FAULT DESCRIPTION
Vehicle Speed Sensor Circuit Failed High
22
Section 01: ENGINE
PID
PID
PID
PID
PID
PID
PID
PID
PID
PID/SID
ID
110
111
111
111
111
168
168
168
168
FLASH
CODES
2123
2124
2124
2124
2124
2125
2125
2125
2125
14
PID
168
2125
171
2
PID
171
2131
171
14
PID
171
2131
171
9
PID
171
2131
191
9
SID
231
2615
191
19
SID
231
2132
191
13
SID
231
2132
247
9
PID
247
2615
247
10
PID
247
2615
247
0
PID
247
2615
J1939 Transmission Output Shaft Speed Signal is
erratic
J1939 Transmission Output Shaft Speed Signal is
missing
MCM Engine Hours Data not received or stopped
arriving
MCM Engine Hours Data increasing at an
implausible rate
MCM Engine Hours Data higher than expected
247
523
1
19
PID
PID
247
163
2615
2133
MCM Engine Hours Data lower than expected
J1939 Transmission Current Gear Signal is erratic
523
13
PID
163
2133
J1939 Transmission Current Gear Signal is missing
524
527
9
9
SID
SID
231
231
2615
2615
J1939 ETC2 Message is missing
J1939 CCVS Message from Source #1 is missing
527
9
SID
231
2615
J1939 CCVS Message from Source #2 is missing
527
9
SID
231
2615
J1939 CCVS Message from Source #3 is missing
558
558
558
558
558
2
5
6
4
3
SID
SID
SID
SID
SID
230
230
230
230
230
2134
2134
2134
2134
2134
Idle Validation Switch Inputs Reversed
Idle Validation Switch 2 Circuit Failed Low
Idle Validation Switch 2 Circuit Failed High
Idle Validation Switch 1 Circuit Failed Low
Idle Validation Switch 1 Circuit Failed High
SPN
FMI
PID/SID
110
111
111
111
111
168
168
168
168
0
18
3
4
1
0
0
18
14
168
PA1561
FAULT DESCRIPTION
Coolant Temperature Very High
Coolant Level Low
Coolant Level Circuit Failed High
Coolant Level Circuit Failed Low
Coolant Level Very Low
Battery Voltage Very Low
Battery Voltage High
Battery Voltage Low
Opt Idle Detected Charging System or Battery
Failure
ECU powerdown not completed (Main Battery
Terminal Possibly Floating)
Ambient Temperature Sensor Data Erratic
J1587 Ambient Air Temp Sensor Data Not
Received This Ign Cycle
J1587 Ambient Air Temp Sensor Data Message
Stopped Arriving
J1939 ETC1 Message is missing
23
Section 01: ENGINE
SID
PID/SID
ID
244
FLASH
CODES
2135
13
SID
244
2135
596
19
SID
244
2135
596
13
SID
244
2135
596
19
SID
244
2135
596
13
SID
244
2135
597
2
SID
246
2141
597
19
SID
246
2141
597
13
SID
246
2141
597
19
SID
246
2141
597
13
SID
246
2141
597
19
SID
246
2141
597
13
SID
246
2141
599
4
SID
243
2142
600
19
SID
243
2143
600
13
SID
243
2143
600
19
SID
243
2143
600
13
SID
243
2143
600
19
SID
243
2143
600
13
SID
243
2143
602
19
SID
242
2144
602
13
SID
242
2144
602
19
SID
242
2144
602
13
SID
242
2144
SPN
FMI
PID/SID
596
19
596
PA1561
FAULT DESCRIPTION
J1939 Cruise Control Enable Switch Signal from
Source #1 is erratic
J1939 Cruise Control Enable Switch Signal from
Source #1 is missing
J1939 Cruise Control Enable Switch Signal from
Source #2 is erratic
J1939 Cruise Control Enable Switch Signal from
Source #2 is missing
J1939 Cruise Control Enable Switch Signal from
Source #3 is erratic
J1939 Cruise Control Enable Switch Signal from
Source #3 is missing
Service Brake Status Not Plausible
J1939 Service Brake Switch Signal from Source #1
is erratic
J1939 Service Brake Switch Signal from Source #1
is missing
J1939 Service Brake Switch Signal from Source #2
is erratic
J1939 Service Brake Switch Signal from Source #2
is missing
J1939 Service Brake Switch Signal from Source #3
is erratic
J1939 Service Brake Switch Signal from Source #3
is missing
Cruise Control SET and RESUME Circuits Failed
Low
J1939 Cruise Control Coast Switch Signal from
Source #1 is erratic
J1939 Cruise Control Coast Switch Signal from
Source #1 is missing
J1939 Cruise Control Coast Switch Signal from
Source #2 is erratic
J1939 Cruise Control Coast Switch Signal from
Source #2 is missing
J1939 Cruise Control Coast Switch Signal from
Source #3 is erratic
J1939 Cruise Control Coast Switch Signal from
Source #3 is missing
J1939 Cruise Control Accelerate Switch Signal
from Source #1 is erratic
J1939 Cruise Control Accelerate Switch Signal
from Source #1 is missing
J1939 Cruise Control Accelerate Switch Signal
from Source #2 is erratic
J1939 Cruise Control Accelerate Switch Signal
from Source #2 is missing
24
Section 01: ENGINE
SID
PID/SID
ID
242
FLASH
CODES
2144
13
SID
242
2144
608
14
SID
250
2145
J1939 Cruise Control Accelerate Switch Signal
from Source #3 is erratic
J1939 Cruise Control Accelerate Switch Signal
from Source #3 is missing
J1708 Data Link Failure
609
12
SID
233
2145
CPC2 Hardware Failure
615
9
SID
231
2615
J1939 DM1 Message from Transmission is missing
625
13
SID
248
2151
625
9
SID
248
2151
625
10
SID
248
2151
625
2
SID
248
2151
625
14
SID
248
2151
625
625
9
9
SID
SID
248
248
2151
2151
ECAN ID_1629 Diagnostic Message Not Received
This Ignition Cycle
ECAN ID_1629 Diagnostic Message No Longer
Being Received
ECAN ID_1629 Reporting Inconsistent Number of
Frames
ECAN ID_1629 Diagnostic Message Reporting
Data Not Available
ECAN ID_1629 Diagnostic Message Reporting an
Unknown MUID
Incorrect MCM System ID Received
MCM System ID Not Received or Stopped Arriving
625
628
4
14
SID
SID
248
254
2151
2151
628
13
SID
155
2615
ECAN Link Circuit Failure
XFLASH Static Fault Code Memory Page Read
Write Failure
20ms ECU OS Task Locked in an Endless Loop
628
13
SID
155
2615
20ms ECU OS Task Timed out Prior to Completion
628
13
SID
155
2615
1000ms ECU OS Task Locked in an Endless Loop
628
13
SID
155
2615
629
2
SID
254
2151
1000ms ECU OS Task Timed out Prior to
Completion
CPC Hardware/Software Mismatch
629
12
SID
254
2151
DDEC Data Xflash Write Error. Replace CPC2.
630
2
SID
253
2152
EEPROM Checksum Failure
630
2
SID
253
2152
EEPROM Checksum Failure for the SCR Block
630
13
SID
253
2152
SCR Number Out of Range
630
14
SID
155
2615
630
14
SID
155
2615
630
14
SID
155
2615
MCM Fault Codes Unavailable via J1939 and
J1587
MCM Fault Code Table Inconsistant - Upgrade
MCM Software
Insufficient Static Fault Code Storrage Memory Upgrade CPC Software
SPN
FMI
PID/SID
602
19
602
PA1561
FAULT DESCRIPTION
25
Section 01: ENGINE
SID
PID/SID
ID
155
FLASH
CODES
2615
14
3
4
3
4
3
4
3
4
3
4
3
4
3
SID
SID
SID
SID
SID
SID
SID
SID
SID
SID
SID
SID
SID
SID
231
26
26
40
40
51
51
52
52
53
53
54
54
55
2153
2211
2211
2212
2212
2213
2213
2214
2214
2215
2215
2221
2221
2222
707
4
SID
55
2222
708
708
709
709
710
710
711
711
712
712
713
713
713
713
714
714
714
715
904
904
904
972
3
4
3
4
3
4
3
4
3
4
3
4
5
7
3
4
5
3
9
19
13
2
SID
SID
SID
SID
SID
SID
SID
SID
SID
SID
SID
SID
SID
SID
SID
SID
SID
SID
SID
SID
SID
SID
56
56
257
257
258
258
259
259
260
260
261
261
261
261
262
262
262
263
231
231
231
203
2223
2223
2224
2224
2225
2225
2231
2231
2232
2232
2234
2234
2234
2234
2235
2235
2235
2241
2615
2242
2242
2243
973
973
9
13
SID
SID
231
231
2615
2244
SPN
FMI
PID/SID
630
14
639
701
701
702
702
703
703
704
704
705
705
706
706
707
PA1561
FAULT DESCRIPTION
MCM Fault Code Table Inconsistant - Upgrade
MCM Software
J1939 Data Link Failure
Digital Output 4 09 Circuit Failed High
Digital Output 4 09 Circuit Failed Low
Digital Output 3 17 Circuit Failed High
Digital Output 3 17 Circuit Failed Low
Digital Output 3 09 Circuit Failed High
Digital Output 3 09 Circuit Failed Low
Digital Output 4 07 Circuit Failed High
Digital Output 4 07 Circuit Failed Low
Digital Output 1 13 Circuit Failed High
Digital Output 1 13 Circuit Failed Low
Digital Output 3 10 Circuit Failed High
Digital Output 3 10 Circuit Failed Low
Digital Output 2 10 Circuit Failed High (CEL / AWL
Lamp)
Digital Output 2 10 Circuit Failed Low (CEL / AWL
Lamp)
Digital Output 3 12 Circuit Failed High
Digital Output 3 12 Circuit Failed Low
Digital Output 3 16 Circuit Failed High
Digital Output 3 16 Circuit Failed Low
Digital Output 4 06 Circuit Failed High
Digital Output 4 06 Circuit Failed Low
Digital Output 1 05 Circuit Failed High
Digital Output 1 05 Circuit Failed Low
Digital Output 1 04 Circuit Failed High
Digital Output 1 04 Circuit Failed Low
Digital Output 3 07 Circuit Failed High
Digital Output 3 07 Circuit Failed Low
Digital Output 3 07 Open Circuit
TOP2 Shift Failure
Digital Output 3 08 Circuit Failed High
Digital Output 3 08 Circuit Failed Low
Digital Output 3 08 Open Circuit
Digital Output 4 10 Circuit Failed High
J1939 EBC2 Message from ABS is missing
J1939 Front Axle Speed Signal is erratic
J1939 Front Axle Speed Signal is missing
Throttle inhibit switch signal not plausible due to
excess vehicle speed
J1939 EBC1 Message is missing
J1939 Engine Retarder Selection Signal Missing
26
Section 01: ENGINE
SID
PID/SID
ID
231
FLASH
CODES
2244
2
PID
372
2245
974
974
981
3
4
0
PID
PID
SID
372
372
155
2245
2245
2311
986
1267
1267
1321
1321
1590
9
4
3
4
3
19
SID
SID
SID
SID
SID
SID
231
123
123
128
128
155
2615
2312
2312
2314
2314
2615
Remote Accelerator Pedal Supply Voltage Out of
Range
Remote Accelerator Pedal Circuit Failed High
Remote Accelerator Pedal Circuit Failed Low
PTO CC+ and CC- Switches Pressed
Simultaneously
J1939 CM1 Message is missing
Digital Output 4 10 Circuit Failed Low
Digital Output 4 10 Circuit Failed Open
Starter Lockout Output Shorted to Ground
Starter Lockout Output Open Circuit
Adaptive Cruise Control Message Not Received
1590
9
SID
231
2615
Adaptive Cruise Control Device Reporting Error
1624
1624
9
19
SID
SID
231
231
2615
2315
J1939 TCO1 Message is missing
J1939 Tachograph Vehicle Speed Signal is erratic
1624
13
SID
231
2315
J1939 Tachograph Vehicle Speed Signal is missing
1663
1716
1845
2623
7
9
9
14
SID
SID
SID
PID
123
231
231
91
2321
2615
2615
2322
2623
8
PID
91
2322
2900
3510
9
3
SID
SID
231
211
2615
2333
3510
4
SID
211
2333
3510
4
SID
211
2333
Optimized Idle Safety Loop Faulted
J1939 ERC1 Message is missing
J1939 TCFG2 Message is missing
Pwm Accelerator Pedal GAS1 and GAS2 Signal
Missing
Pwm Accelerator Pedal Signal 2 Frequency Out Of
Range
J1939 ETC7 Message is missing
Accelerator Pedal Supply Voltage Circuit Failed
High
Accelerator Pedal Supply Voltage Circuit Failed
Low
Pwm Accelerator Pedal Supply Voltage Missing
3510
3
SID
211
2333
3606
3695
9
2
SID
SID
231
155
2615
2334
3695
19
SID
155
2334
3695
13
SID
155
2334
3695
9
SID
155
2334
SPN
FMI
PID/SID
973
19
974
PA1561
FAULT DESCRIPTION
J1939 Engine Retarder Selection Signal Erratic
Accelerator Pedal Supply Voltage Circuit Failed
High
J1939 ESS Message is missing
Manual DPF Regen and DPF Inhibit Switch
Rationality Fault
DPF Regen Inhibit MUX Switch Message Contains
Data Error Indicator
DPF Regen Inhibit MUX Switch Message Contains
SNV Indicator
DPF Regen Inhibit MUX Switch Message Stopped
Arriving
27
Section 01: ENGINE
SID
PID/SID
ID
155
FLASH
CODES
2334
19
SID
155
2335
3696
13
SID
155
2335
3696
9
SID
155
2335
3696
14
SID
155
2335
SPN
FMI
PID/SID
3695
14
3696
FAULT DESCRIPTION
DPF Regen Inhibit MUX Switch Message Not
Received this Ign Cycle
DPF Regen Force MUX Switch Message Contains
Data Error Indicator
DPF Regen Force MUX Switch Message Contains
SNV Indicator
DPF Regen Force MUX Switch Message Stopped
Arriving
DPF Regen Force MUX Switch Message Not
Received this Ign Cycle
2.11 DDEC VI MCM DIAGNOSTIC CODES LIST
SPN
27
27
27
27
27
27
27
FMI
4
3
2
0
1
14
7
PID/SID
PID
PID
PID
PID
PID
PID
PID
PID/SID
ID
27
27
27
27
27
27
27
27
51
51
51
51
51
51
94
19
4
3
2
0
1
7
4
PID
SID
SID
PID
PID
PID
PID
PID
27
51
51
51
51
51
51
94
94
94
97
97
98
98
98
98
100
100
100
100
100
103
103
103
103
103
108
108
108
108
3
1
4
3
1
0
13
14
4
3
1
2
2
2
1
0
4
3
4
3
2
20
PID
PID
PID
PID
PID
PID
PID
PID
PID
PID
PID
PID
PID
PID
PID
PID
PID
PID
PID
PID
PID
PID
94
94
97
97
98
98
98
98
100
100
100
100
100
103
103
103
103
103
108
108
108
108
PA1561
FLASH
CODE
1111
1111
1111
1111
1111
1111
1111
1521
FAULT DESCRIPTION
EGR Valve Position Circuit Failed Low
EGR Valve Position Circuit Failed High
EGR Valve Position Feedback Failed
EGR Valve Position Feedback Failed (High Box)
EGR Valve Position Feedback Failed (Low Box)
EGR Valve Position Positive Torque Error
EGR Valve Stuck Open
1112
1112
1112
1112
1112
1112
1112
Smart Actuator Indicates EGR Position Error
Intake Air Throttle Circuit Failed Low
Intake Air Throttle Circuit Failed High
Intake Throttle Position Deviation Error
Intake Air Throttle Position High
Intake Air Throttle Position Low
Intake Throttle Auto Calibration Error
Fuel Compensation Pressure Sensor Circuit Failed Low
1112
1112
1615
1615
1114
1114
1634
1634
1114
1114
1114
1114
1114
1115
1115
1115
1115
1115
1211
1211
1211
1211
Fuel Compensation Pressure Sensor Circuit Failed High
Fuel Pressure Too High/Too Low
Water in Fuel Circuit Failed Low
Water in Fuel Circuit Failed High
Oil Level Circuit Failed Low
Oil Level Circuit Failed High
Oil Level Mesaurement, Configuration Error
Oil Level Mesaurement, Oil Level Too Low or Too High
Engine Oil Pressure Circuit Failed Low
Engine Oil Pressure Circuit Failed High
Engine Oil Pressure Low
Oil Pressure Plausibility - Engine Running
Oil Pressure Plausibility - Stop
Turbocharger Speed Not Plausible
Turbo Charger Speed Below Threshold (High Box)
Turbo Charger Speed Above Threshold (Low Box)
Turbo Charger Speed Sensor Circuit Failed Low
Turbo Charger Speed Sensor Circuit Failed High
Barometric Pressure Circuit Failed Low
Barometric Pressure Circuit Failed High
Ambient Pressure Plausibility Fault (Low Box)
Ambient Pressure Plausibility Fault (High Box)
28
Section 01: ENGINE
FLASH
CODE
1212
1212
1212
FMI
4
3
0
110
14
PID
110
1212
Coolant Temperature / Engine Oil Temperature Plausibility Fault
110
2
PID
110
1212
Engine Coolant Sensor (OUT), General Temp. Plausibility Error
132
7
PID
132
1213
Intake Air Throttle Valve Closure Detection- Positive Torque
132
132
132
14
14
1
PID
PID
PID
132
322
322
Intake Air Throttle Valve Closure Detection -Braking Condition
HC-Doser Fuel Pressure Not Plausible
Air Mass Flow Too Low
132
158
164
164
164
164
168
168
171
171
174
174
174
174
175
175
175
13
2
4
3
0
0
1
0
4
3
4
3
2
0
4
3
14
PID
PID
PID
PID
PID
PID
PID
PID
PID
PID
PID
PID
PID
PID
PID
PID
PID
132
43
164
164
164
164
168
168
171
171
174
174
174
174
175
175
175
1213
1635
1213
1213
1214
1215
1215
1215
1215
1221
1221
1222
1222
1223
1223
1223
1223
1224
1224
1224
Air Mass Auto Calibration Failed
Ignition Switch Not Plausible
Rail Pressure Governor Sensor Circuit Failed Low
Rail Pressure Governor Sensor Circuit Failed High
Rail Pressure Governor (High Side) Error
Rail Pressure Governor (Low Side) Error
Battery Voltage Low
Battery Voltage High
Ambient Temperature Circuit Failed Low
Ambient Temperature Circuit Failed High
Fuel Temperature Circuit Failed Low
Fuel Temperature Circuit Failed High
Fuel Temperature Sensor, General Temp. Plausibility
Fuel Temperature Too High
Engine Oil Temperature Circuit Failed Low
Engine Oil Temperature Circuit Failed High
Engine Oil Temperature Sensor Plausibility Fault
175
190
354
354
411
411
411
411
411
411
411
412
2
2
4
3
4
3
0
1
5
13
13
3
PID
PID
PID
PID
PID
PID
PID
PID
PID
PID
PID
PID
175
190
354
354
411
411
411
411
411
411
411
412
1224
1225
1231
1231
1232
1232
1232
1232
1232
1232
1232
1233
Engine Oil Temperature Sensor, General Temp. Plausibility
Engine Speed High
Relative Humidity Circuit Failed Low
Relative Humidity Circuit Failed High
EGR Delta Pressure Sensor Circuit Low
EGR Delta Pressure Sensor Circuit High
EGR Differential Pressure Failed (High Box)
EGR Differential Pressure Failed (Low Box)
EGR Sampling Range Failed
EGR Delta Pressure Sensor Out Of Calibration
EGR Delta Pressure Sensor Out Of Calibration
EGR Temperature Sensor Circuit Failed High
412
4
PID
412
1233
EGR Temperature Sensor Circuit Failed Low
412
20
PID
412
1233
EGR Temperature Drift (High Box)
412
21
PID
412
1233
EGR Temperature Drift (Low Box)
412
412
412
2
0
16
PID
PID
PID
412
412
412
1233
1512
1233
615
4
SID
155
1615
615
3
SID
155
1615
615
4
SID
155
1615
615
3
SID
155
1615
615
4
SID
155
1615
EGR Temperature Sensor, General Temp. Plausibility Error
EGR Temperature Very High
EGR Temperature Sensor / Temperature Too High
Reserved Monitoring Unit For Temperature Diagnostics, Circuit Failed Low
MU_ISP_T_TBD4_SRL
Reserved Monitoring Unit For Temperature Diagnostics, Circuit Failed High
MU_ISP_T_TBD4_SRH
Reserved Monitoring Unit For Temperature Diagnostics, Circuit Failed Low
MU_ISP_T_TBD1_SRL
Reserved Monitoring Unit For Temperature Diagnostics, Circuit Failed High
MU_ISP_T_TBD1_SRH
Reserved Monitoring Unit For Temperature Diagnostics, Circuit Failed Low
MU_ISP_T_TBD2_SRL
PA1561
PID/SID
PID
PID
PID
PID/SID
ID
110
110
110
SPN
110
110
110
FAULT DESCRIPTION
Engine Coolant Outlet Temperature Circuit Failed Low
Engine Coolant Outlet Temperature Circuit Failed High
Coolant Temperature High
29
Section 01: ENGINE
SPN
FMI
PID/SID
PID/SID
ID
FLASH
CODE
615
3
SID
155
1615
615
4
SID
155
1615
615
3
SID
155
1615
FAULT DESCRIPTION
Reserved Monitoring Unit For Temperature Diagnostics, Circuit Failed High
MU_ISP_T_TBD2_SRH
Reserved Monitoring Unit For Temperature Diagnostics, Circuit Failed Low
MU_ISP_T_TBD3_SRL
Reserved Monitoring Unit For Temperature Diagnostics, Circuit Failed High
MU_ISP_T_TBD3_SRH
615
4
SID
155
1615
Catalyst Temperature Sensor Circuit High Input (Bank 1 Sensor 1)
615
3
SID
155
1615
Catalyst Temperature Sensor Circuit Low Input (Bank 1 Sensor 1)
615
4
SID
155
1615
Catalyst Temperature Sensor Circuit High (Bank 1 Sensor 2)
615
615
615
615
615
615
615
615
3
4
3
5
4
3
5
4
SID
SID
SID
SID
SID
SID
SID
SID
155
51
51
51
55
55
55
259
1615
1322
1322
1322
1331
1331
1331
1335
Catalyst Temperature Sensor Circuit Low (Bank 1 Sensor 2)
Water Pump 1 Circuit Failed Low
Water Pump 1 Circuit Failed High
Water Pump 1 Circuit Failed Open
Turbo Compound Valve Circuit Failed Low
Turbo Compound Valve Circuit Failed High
Turbo Compound Valve Circuit Failed Open
Turbo Brake Sleeve Circuit Failed Low
615
3
SID
259
1335
Turbo Brake Sleeve Circuit Failed High
615
5
SID
259
1335
Turbo Brake Sleeve Circuit Failed Open
615
4
SID
261
1355
Function 20 Circuit Failed Low
615
3
SID
261
1355
Function 20 Circuit Failed High
615
5
SID
261
Function 20 Circuit Failed Open
615
3
SID
155
1355
1451
Service Push Button Circuit Failed High
615
14
SID
155
1615
Turbocharger/Supercharger Boost System Performance
615
14
SID
155
1615
Starter Electronic Fault / ECU internal (Res)
615
14
SID
155
1615
Starter Jammed (Tooth to Tooth Jam)
615
14
SID
155
1615
Rail Pressure Governor, Valve Stays Open
615
14
SID
155
1615
MU_RPG_INT_MON_SRH, I Term Value Too High
615
14
SID
155
1615
Rail Pressure Governor, Leakage in High Pressure Too High
615
14
SID
155
1615
Rail Pressure Governor Sensor, Signal Drift
615
14
SID
155
1615
Rail Pressure Governor Sensor, Sensor Supply Line Broken
615
4
SID
155
1615
Compressor Differential Pressure Outlet Failed Low
615
3
SID
155
1615
Compressor Differential Pressure Outlet Failed High
615
14
SID
155
1615
Doser Metering and Safety Unit Valve Seals Check
615
14
SID
155
1615
High Pressure Pump, Leakage or TDC Position Wrong
615
4
SID
155
1615
Flap In Front of EGR Cooler Circuit Failed Low
615
3
SID
155
1615
Flap In Front of EGR Cooler Circuit Failed High
615
5
SID
155
1615
Flap In Front of EGR Cooler Circuit Failed Open
615
4
SID
155
1615
Water Pump 2 Circuit Failed Low
615
615
615
615
615
615
615
615
615
615
615
615
3
5
4
3
5
4
3
5
4
3
5
4
SID
SID
SID
SID
SID
SID
SID
SID
SID
SID
SID
SID
155
156
157
158
159
160
161
162
163
164
165
166
1615
1615
1615
1615
1615
1615
1615
1615
1615
1615
1615
1615
Water Pump 2 Circuit Failed High
Water Pump 2 Circuit Failed Open
RCP Test Function 1 Circuit Failed Low
RCP Test Function 1 Circuit Failed High
RCP Test Function 1 Circuit Failed Open
RCP Test Function 2 Circuit Failed Low
RCP Test Function 2 Circuit Failed High
RCP Test Function 2 Circuit Failed Open
Volute Control Valve, Shorted to Ground
Volute Control Valve, Shorted to Battery
Volute Control Valve, Open Load
Volute Shut Off Valve, Shorted to Ground
PA1561
30
Section 01: ENGINE
SPN
615
615
615
FMI
3
5
4
PID/SID
SID
SID
SID
PID/SID
ID
167
168
169
FLASH
CODE
1615
1615
1615
615
3
SID
170
1615
Function 30 Circuit Failed High
615
5
SID
171
1615
Function 30 Circuit Failed Open
615
4
SID
172
1615
Function 31 Circuit Failed Low
615
3
SID
173
1615
Function 31 Circuit Failed High
615
5
SID
174
615
14
SID
155
1615
1453
Function 31 Circuit Failed Open
Smart Remote Actuator 2, No Failsafe Mode, Motor Off
615
9
SID
155
1453
Smart Remote Actuator 2, Failsafe Mode, Motor Off
615
16
SID
155
615
7
SID
155
615
11
SID
155
615
15
SID
155
FAULT DESCRIPTION
Volute Shut Off Valve, Shorted to Battery
Volute Shut Off Valve, Open Load
Function 30 Circuit Failed Low
1453
Smart Remote Actuator 2, Temperature Fault
1453
Smart Remote Actuator 2, Failsafe Mode, Motor On
1453
Smart Remote Actuator 2, Restricted Operability
1453
Smart Remote Actuator 2, Temperature Warning
1453
Smart Remote Actuator 2, Internal Test Running
1453
Smart Remote Actuator 2, Unknown Error Code
1454
Turbocharger Compressor Outlet Differential Pressure Sensor Out Of
Calibration
1454
Turbocharger Compressor Outlet Differential Pressure Sensor Out Of
Calibration
615
8
SID
155
615
31
SID
155
615
13
SID
155
615
13
SID
155
615
19
SID
155
1637
Smart Actuator Indicates Actuator Position Error
625
2
SID
248
1234
Invalid Data on Engine CAN Link
625
9
SID
248
1234
No Data Received from Engine CAN Link
625
9
SID
248
1234
Engine CAN Low Wire Defect - (wire 1)
1234
1452
Engine CAN High Wire Defect - (wire 2)
625
9
SID
248
630
12
SID
253
630
630
13
13
SID
SID
253
253
1455
1455
Calibration Data Not Plausible
Calibration Data Not Plausible (CPLD)
634
4
SID
40
1321
Constant Throttle Valve Circuit Failed Low
634
3
SID
40
1321
Constant Throttle Valve Circuit Failed High
634
5
SID
40
1321
Constant Throttle Valve Circuit Failed Open
EEPROM Read / Write Operation Failed
636
1
SID
21
1235
Crankshaft Position Sensor Signal Voltage Too Low
636
3
SID
21
1235
Crankshaft Position Sensor Open Circuit
636
4
SID
21
1235
Crankshaft Position Sensor Short to Ground
636
8
SID
21
1235
Crankshaft Position Sensor Time Out
636
14
SID
21
1235
Crankshaft Position Sensor Pins Swapped
636
2
SID
21
1235
No Match of Camshaft and Crankshaft Signals
641
4
SID
27
1542
Turbo Control Circuit Failed Low
641
3
SID
27
1542
Turbo Control Circuit Failed High
641
5
SID
27
641
14
SID
147
1542
1241
Turbo Control Circuit Open
Smart Remote Actuator 5 (VGT), No Failsafe Mode, Motor Off
641
9
SID
147
1241
Smart Remote Actuator 5 (VGT), Failsafe Mode, Motor Off
147
1241
Smart Remote Actuator 5 (VGT), Failsafe Mode, Motor On
Smart Remote Actuator 5 (VGT), Restricted Operability
641
7
SID
641
11
SID
147
1241
641
8
SID
147
1241
Smart Remote Actuator 5 (VGT), Internal Test Running
147
33
33
1241
Smart Remote Actuator 5 (VGT), Unknown Error Code
1334
1334
Fan Stage 1 Circuit Failed Low
Fan Stage 1 Circuit Failed High
641
647
647
PA1561
31
4
3
SID
SID
SID
31
Section 01: ENGINE
SPN
647
FMI
5
PID/SID
SID
PID/SID
ID
33
FLASH
CODE
1334
651
14
SID
1
1242
Injector Cylinder #1 Needle Control Valve Abnormal Operation
651
10
SID
1
1242
651
5
SID
1
1242
651
7
SID
1
1242
Injector Cylinder #1 Needle Control Valve Abnormal Rate of Change
Injector Cylinder 1, Nozzle Control Valve or Spill Control Valve, Jammed
Closed
Injector Cylinder 1, Nozzle Control Valve or Spill Control Valve, Jammed
Open or Leakage
651
6
SID
1
1242
Injector Cylinder #1 Needle Control Valve, Valve Shorted Circuit
651
31
SID
1
1242
Engine Smoothness Control / Cylinder #1 Value Out of Range
652
14
SID
2
1243
Injector Cylinder #2 Needle Control Valve Abnormal Operation
652
10
SID
2
1243
652
5
SID
2
1243
652
7
SID
2
1243
Injector Cylinder #2 Needle Control Valve Abnormal Rate of Change
Injector Cylinder 2, Nozzle Control Valve or Spill Control Valve, Jammed
Closed
Injector Cylinder 2, Nozzle Control Valve or Spill Control Valve, Jammed
Open or Leakage
652
6
SID
2
1243
Injector Cylinder #2 Needle Control Valve, Valve Shorted Circuit
652
31
SID
2
1243
Engine Smoothness Control / Cylinder #2 Value Out of Range
653
14
SID
3
1244
Injector Cylinder #3 Needle Control Valve Abnormal Operation
653
10
SID
3
1244
653
5
SID
3
1244
653
7
SID
3
1244
Injector Cylinder #3 Needle Control Valve Abnormal Rate of Change
Injector Cylinder 3, Nozzle Control Valve or Spill Control Valve, Jammed
Closed
Injector Cylinder 3, Nozzle Control Valve or Spill Control Valve, Jammed
Open or Leakage
653
6
SID
3
1244
Injector Cylinder #3 Needle Control Valve, Valve Shorted Circuit
653
31
SID
3
1244
Engine Smoothness Control / Cylinder #3 Value Out of Range
654
14
SID
4
1245
Injector Cylinder #4 Needle Control Valve Abnormal Operation
654
10
SID
4
1245
654
5
SID
4
1245
654
7
SID
4
1245
Injector Cylinder #4 Needle Control Valve Abnormal Rate of Change
Injector Cylinder 4, Nozzle Control Valve or Spill Control Valve, Jammed
Closed
Injector Cylinder 4, Nozzle Control Valve or Spill Control Valve, Jammed
Open or Leakage
654
6
SID
4
1245
Injector Cylinder #4 Needle Control Valve, Valve Shorted Circuit
654
31
SID
4
1245
Engine Smoothness Control / Cylinder #4 Value Out of Range
655
14
SID
5
1251
Injector Cylinder #5 Needle Control Valve Abnormal Operation
655
10
SID
5
1251
655
5
SID
5
1251
655
7
SID
5
1251
Injector Cylinder #5 Needle Control Valve Abnormal Rate of Change
Injector Cylinder 5, Nozzle Control Valve or Spill Control Valve, Jammed
Closed
Injector Cylinder 5, Nozzle Control Valve or Spill Control Valve, Jammed
Open or Leakage
655
6
SID
5
1251
Injector Cylinder #5 Needle Control Valve, Valve Shorted Circuit
655
31
SID
5
1251
Engine Smoothness Control / Cylinder #5 Value Out of Range
656
14
SID
6
1252
Injector Cylinder #6 Needle Control Valve Abnormal Operation
656
10
SID
6
1252
656
5
SID
6
1252
656
7
SID
6
1252
Injector Cylinder #6 Needle Control Valve Abnormal Rate of Change
Injector Cylinder 6, Nozzle Control Valve or Spill Control Valve, Jammed
Closed
Injector Cylinder 6, Nozzle Control Valve or Spill Control Valve, Jammed
Open or Leakage
656
6
SID
6
1252
Injector Cylinder #6 Needle Control Valve, Valve Shorted Circuit
656
31
SID
6
1252
Engine Smoothness Control / Cylinder #6 Value Out of Range
657
14
SID
7
1253
Injector Cylinder #7 Needle Control Valve Abnormal Operation
PA1561
FAULT DESCRIPTION
Fan Stage 1 Circuit Failed Open
32
Section 01: ENGINE
FLASH
CODE
FMI
657
10
SID
7
1253
Injector Cylinder #7 Needle Control Valve Abnormal Rate of Change
657
6
SID
7
1253
Injector Cylinder #7 Needle Control Valve, Valve Shorted Circuit
657
31
SID
7
1253
Engine Smoothness Control / Cylinder #7 Value Out of Range
658
14
SID
8
1254
Injector Cylinder #8 Needle Control Valve Abnormal Operation
658
10
SID
8
1254
Injector Cylinder #8 Needle Control Valve Abnormal Rate of Change
658
6
SID
8
1254
Injector Cylinder #8 Needle Control Valve, Valve Shorted Circuit
658
31
SID
8
1254
Engine Smoothness Control / Cylinder #8 Value Out of Range
677
2
SID
39
1255
Starter Switch Inconsistent
677
677
677
677
677
677
698
698
698
715
715
715
716
723
723
723
723
723
729
729
729
729
729
1071
1071
1071
1072
1072
1072
1073
1073
1073
1074
1074
1074
5
4
14
7
3
7
4
3
5
4
3
5
4
1
3
4
8
14
4
14
3
7
0
4
3
5
4
3
5
4
3
5
4
3
5
SID
SID
SID
SID
SID
SID
SID
SID
SID
SID
SID
SID
SID
SID
SID
SID
SID
SID
PID
PID
PID
PID
PID
SID
SID
SID
SID
SID
SID
SID
SID
SID
SID
SID
SID
39
39
39
39
39
39
58
58
58
263
263
263
264
64
64
64
64
64
45
45
45
45
45
60
60
60
79
79
79
80
80
80
81
81
81
Engine Starter Relay Circuit Failed Low
Engine Starter Relay Open Circuit
Starter Electronic Fault / ECU internal (Main)
Engine Starter Relay - Starter Does Not Engage
Engine Starter Relay Shorted to High Source
Engine Starter Relay Jammed
Gridheater Circuit Failed Low
Gridheater Circuit Failed High
Gridheater Circuit Failed Open
High Side Digital Output # 1 Circuit Failed Low
High Side Digital Output # 1 Circuit Failed High
High Side Digital Output # 2 Circuit Failed Open
High Side Digital Output # 2 Circuit Failed Low
Camshaft Position Sensor Signal Voltage Too Low
Camshaft Position Sensor Open Circuit
Camshaft Position Sensor Short to Ground
Camshaft Position Sensor Time Out
Camshaft Position Sensor Pins Swapped
Grid Heater Circuit Failed Low
Grid Heater Special Instructions
Grid Heater Circuit Failed High
Grid Heater Defect
Grid Heater Permanently On
Fan Stage 2 Circuit Failed Low
Fan Stage 2 Circuit Failed High
Fan Stage 2 Circuit Failed Open
Jake Brake Stage 1 Circuit Failed Low
Jake Brake Stage 1 Circuit Failed High
Jake Brake Stage 1 Circuit Failed Open
Jake Brake Stage 2 Circuit Failed Low
Jake Brake Stage 2 Circuit Failed High
Jake Brake Stage 2 Circuit Failed Open
Exhaust Brake Circuit Failed Low
Exhaust Brake Circuit Failed High
Exhaust Brake Circuit Failed Open
1077
14
PID
164
1255
1255
1255
1255
1255
1255
1312
1312
1312
1412
1412
1412
1413
1415
1415
1415
1415
1415
1421
1421
1421
1421
1421
1314
1314
1314
1422
1422
1422
1315
1315
1315
1345
1345
1345
1241
1077
5
PID
164
1423
Rail Pressure Governor Error, Current Governor, Current Too Low
1077
1077
7
6
PID
SID
164
155
1423
1423
Rail Pressure Governor Error, Pressure Governor, Pressure Not Plausible
Rail Pressure Governor Error, Current Too High
1127
4
SID
273
1424
Turbocharger Compressor Outlet Pressure Circuit Failed Low
1127
3
SID
273
1424
Turbocharger Compressor Outlet Pressure Circuit Failed High
1172
4
PID
351
1425
Turbocharger Compressor Inlet Temperature Circuit Failed Low
PA1561
PID/SID
PID/SID
ID
SPN
FAULT DESCRIPTION
Rail Pressure Governor Error, Open Loop Error
33
Section 01: ENGINE
SPN
FMI
PID/SID
PID/SID
ID
FLASH
CODE
1172
1172
3
2
PID
PID
351
351
1425
1425
1172
2
PID
351
1425
Turbocharger Compressor Inlet Temperature Circuit Failed High
Coolant Temp/Compressor Inlet Temp Plausibility Error
Turbocharger Compressor Inlet Temp. Sensor, General Temp. Plausibility
Error
1176
4
SID
314
1431
Turbocharger Compressor Inlet Pressure Circuit Failed Low
1176
1176
1176
3
2
5
SID
PID
PID
314
314
314
1431
1431
1431
Turbocharger Compressor Inlet Pressure Circuit Failed High
Compressor Pressure Plausibility Fault (High Box)
Compressor Inlet Pressure Plausibility Fault (Delta)
1176
1188
1188
1188
20
4
3
5
SID
SID
SID
SID
314
32
32
32
1188
14
SID
32
1431
1325
1325
1325
1432
Compressor Inlet Pressure Plausibility Error, Pressure Too High (High Box)
Waste Gate Circuit Failed Low
Waste Gate Circuit Failed High
Waste Gate Circuit Failed Open
Smart Remote Actuator 1 (Wastegate), No Failsafe Mode, Motor Off
1188
9
SID
32
1432
Smart Remote Actuator 1 (Wastegate), Failsafe Mode, Motor Off
1432
Smart Remote Actuator 1 (Wastegate), Temperature Fault
1432
Smart Remote Actuator 1 (Wastegate), Failsafe Mode, Motor On
1188
16
SID
32
1188
7
SID
32
1188
11
SID
32
1188
15
SID
32
1188
8
SID
32
1188
31
SID
32
FAULT DESCRIPTION
1432
Smart Remote Actuator 1 (Wastegate), Restricted Operability
1432
Smart Remote Actuator 1 (Wastegate), Temperature Warning
1432
Smart Remote Actuator 1 (Wastegate), Internal Test Running
1432
Smart Remote Actuator 1 (Wastegate), Unknown Error Code
1432
1188
1213
1213
1213
1323
1323
1324
1325
1326
1327
1328
1329
1330
1351
1351
1351
1636
1636
1636
19
4
3
5
31
14
31
31
31
31
31
31
31
4
3
5
4
3
2
SID
SID
SID
SID
SID
SID
SID
SID
SID
SID
SID
SID
SID
SID
SID
SID
PID
PID
PID
32
257
257
257
155
156
155
155
155
155
155
155
155
155
155
155
105
105
105
1636
21
PID
105
1511
1636
2
PID
105
1511
1636
1636
1636
2
20
21
PID
PID
PID
105
105
105
1511
1511
1511
Smart Actuator Indicates Turbocharger Wastegate Position Error
MIL Lamp Circuit Failed Low
MIL Lamp Circuit Failed High
MIL Lamp Circuit Failed Open
Cylinder 1 Misfire detected
Misfire Detected
Cylinder 2 Misfire detected
Cylinder 3 Misfire detected
Cylinder 4 Misfire detected
Cylinder 5 Misfire detected
Cylinder 6 Misfire Detected
Cylinder 7 Misfire Detected
Cylinder 8 Misfire Detected
Switchable Air Compressor Circuit Failed Low
Switchable Air Compressor Circuit Failed High
Switchable Air Compressor Circuit Failed Open
Intake Manifold Temperature Circuit Failed Low
Intake Manifold Temperature Circuit Failed High
Intake Manifold Temperature Plausibility Error
Difference Intake Manifold Temperature and EGR Temp. Less Than
Threshold (Low Box)
Difference Intake Manifold and I Cooler Temperature Out Less Than
Threshold (Low Box)
Difference Intake Manifold and I Cooler Temperature Out Less Than
Threshold (High Box)
Intake Manifold Temperature Drift (Low Box)
Intake Manifold Temperature Drift (High Box)
2629
4
PID
404
1513
Turbocharger Compressor Outlet Temperature Circuit Failed Low
2629
3
PID
404
1513
Turbocharger Compressor Outlet Temperature Circuit Failed High
2629
20
PID
404
1513
Turbocharger Out Temperature, Temperature Too High (Low Box)
PA1561
1333
1333
1333
1433
1434
1435
1441
1442
1443
1444
1445
1446
1615
1615
1615
1511
1511
1511
34
Section 01: ENGINE
SPN
FMI
PID/SID
PID/SID
ID
FLASH
CODE
2629
21
PID
404
1513
FAULT DESCRIPTION
2629
2
PID
404
1513
Turbocharger Out Temperature, Temperature Too Low (High Box)
Turbocharger Compressor Outlet Temp. Sensor, General Temp. Plausibility
Error
2630
4
SID
272
1514
Charge Air Cooler Outlet Temperature Circuit Failed Low
2630
3
SID
272
1514
Charge Air Cooler Outlet Temperature Circuit Failed High
2630
2630
2630
2631
2631
2659
2659
2791
2791
2791
2791
2
20
21
4
3
1
0
4
3
5
7
SID
SID
SID
SID
SID
SID
SID
PID
PID
PID
SID
272
272
272
273
273
277
277
146
146
146
146
1514
1514
1514
1515
1515
1515
1515
1521
1521
1521
1521
2791
14
SID
146
1521
Charge Air Cooler Outlet Temperature Sensor Plausibility Error
Charge Air Outlet Temperature Drift (Low box)
Charge Air Outlet Temperature Drift (High box)
Charge Air Cooler Outlet Pressure Circuit Failed Low
Charge Air Cooler Outlet Pressure Circuit Failed High
EGR Flow Target Error Diagnostic - Low Flow
EGR Flow Target Error Diagnostic - High Flow
EGR Valve Circuit Failed Low
EGR Valve Circuit Failed High
EGR Valve Circuit Failed Open
EGR Valve Position Incorrect
Smart Remote Actuator 3 (EGR), No Failsafe Mode, Motor Off
2791
9
SID
146
1521
2791
16
SID
146
1521
2791
7
SID
146
1521
2791
11
SID
146
1521
2791
15
SID
146
1521
2791
8
SID
146
1521
2791
31
SID
146
2795
2795
2795
2795
9
4
3
2
SID
SID
SID
SID
269
269
269
269
1521
1241
2795
0
SID
Smart Remote Actuator 3 (EGR), Failsafe Mode, Motor Off
Smart Remote Actuator 3 (EGR), Temperature Fault
Smart Remote Actuator 3 (EGR), Failsafe Mode, Motor On
Smart Remote Actuator 3 (EGR), Restricted Operability
Smart Remote Actuator 3 (EGR), Temperature Warning
Smart Remote Actuator 3 (EGR), Internal Test Running
Smart Remote Actuator 3 (EGR), Unknown Error Code
1522
1522
1522
CAN3 Communication Error
Position Waste Gate (VNT) Failed Low
Position Waste Gate (VNT) Failed High
VNT Valve Position Feedback Failed
269
1522
VNT Valve Position Feedback, Position Too Low (High Box)
1522
1522
2795
1
SID
269
2795
19
SID
147
VNT Valve Position Feedback, Position Too High (Low Box)
2797
4
SID
317
1523
Injector Needle Control Valve Cylinder 1, 2, 3 Shorted to Ground
2797
4
SID
317
1524
Injector Needle Control Valve Cylinder 4, 5, 6 Shorted to Ground
2797
4
SID
317
1615
Injector Needle Control Valve Bank 3, Shorted to Ground
2797
3
SID
317
1523
Injector Needle Control Valve Cylinder 1,2,3 Shorted to Battery
2797
3
SID
317
1524
Injector Needle Control Valve Cylinder 4,5,6, Shorted to Battery
2797
3
SID
317
1615
Injector Needle Control Valve Bank 3, Shorted to Battery
2798
4
SID
317
1615
Injector Spill Control Valve Cylinder 1, 2, 3 Shorted to Ground
2798
4
SID
317
1615
Injector Spill Control Valve Cylinder 4, 5, 6 Shorted to Ground
2798
4
SID
317
1615
Injector Spill Control Valve ("Amplifier") Bank 6, Shorted to Ground
2798
3
SID
317
1615
Injector Spill Control Valve Cylinder 1,2,3, Shorted to Battery
2798
3
SID
317
1615
Injector Spill Control Valve Cylinder 4,5,6, Shorted to Battery
Smart Actuator Indicates Turbocharger Vane Position Error
2798
3
SID
317
1615
Injector Spill Control Valve ("Amplifier") Bank 6, Shorted to Battery
2988
4
SID
262
1411
EGR Water Cooling Regulator Circuit Failed Low
988
3
SID
262
1411
EGR Water Cooling Regulator Circuit Failed High
2988
5
SID
262
1411
EGR Water Cooling Regulator Circuit Failed Open
PA1561
35
Section 01: ENGINE
SPN
FMI
PID/SID
PID/SID
ID
FLASH
CODE
FAULT DESCRIPTION
3050
0
SID
155
1525
Engine Air Flow Out of Range Low
3050
3058
1
13
SID
PID
324
146
1525
1615
Active Regen Temp Out of Range Low
EGR System Parametrization Failure
3064
13
SID
155
1615
DPF System Parametrization Failure
3242
4
PID
318
1531
DOC Inlet Temperature Circuit Failed Low
3242
3242
3242
3246
3246
3246
3246
3246
3246
3246
3250
3250
3250
3250
3250
3250
3250
3251
3251
3251
3251
3358
3358
3464
3
10
2
4
3
14
0
10
2
31
4
3
14
10
2
31
0
0
1
9
16
4
3
4
PID
SID
SID
SID
SID
SID
SID
SID
SID
SID
PID
PID
PID
SID
SID
PID
PID
SID
SID
SID
SID
SID
SID
SID
318
318
318
320
320
320
320
320
320
323
322
322
322
322
322
322
322
324
324
324
324
155
155
59
1531
1531
1531
1532
1532
1532
1532
1532
1532
1532
1533
1533
1533
1533
1533
1533
1533
1534
1534
1534
1534
1535
1535
1313
DOC Inlet Temperature Circuit Failed High
DOC Inlet Temperature Sensor Stuck
DOC Inlet Temperature Sensor - Plausibility Error
DPF Oulet Temperature Circuit Failed Low
DPF Oulet Temperature Circuit Failed High
Abnormal DPF Temperature Rise b)
DPF Outlet Temperature High
DPF Outlet Temperature Sensor Stuck
DPF Outlet Sensor, General Temp. Plausibility
Abnormal DPF Temperature Rise
DOC Outlet Temperature Circuit Failed Low
DOC Outlet Temperature Circuit Failed High
Abnormal DOC Temperature Rise
DOC Outlet Temperature Sensor Stuck
DOC Outlet Temperature Sensor - Plausibility Error
Abnormal DOC Temperature Rise
DOC Outlet Temperature High
DPF Pressure - Out of Range Very High
DPF Pressure - Out of Range Low
Abnormal Soot Rate
DPF Pressure - Out of Range High
EGR Pressure Failed Low
EGR Pressure Failed High
Intake Throttle Valve Circuit Failed Low
3464
3
SID
59
1313
Intake Throttle Valve Circuit Failed High
3464
5
SID
59
1313
Intake Throttle Valve Circuit Failed Open
3464
14
SID
59
1615
Intake Air Throttle Control Electrical Fault
3464
2
PID
51
1541
Intake Throttle Valve, Spring Response Time Not Plausible
3464
7
PID
51
1541
Intake Throttle Valve, Stuck
3464
14
PID
51
1541
Intake Throttle Valve, Integrated Absolute Error Plausibility
3464
8
PID
51
1541
Intake Throttle Valve, Current Deviation Too High
3470
4
SID
57
1311
Actuator Turbo Compound Bypass Circuit Failed Low
3470
3
SID
57
1311
Actuator Turbo Compound Bypass Circuit Failed High
3470
3471
3471
3471
3471
3480
3480
3480
3482
3482
3482
3482
3509
5
4
3
5
1
2
1
14
4
3
5
7
3
SID
SID
SID
SID
SID
SID
SID
SID
SID
SID
SID
SID
SID
57
334
334
334
155
332
332
332
56
56
56
155
212
1311
1323
1323
1323
1542
1543
1543
1543
1332
1332
1332
1544
1631
Actuator Turbo Compound Bypass Circuit Failed Open
HC Doser Circuit Failed Low
HC Doser Circuit Failed High
HC Doser Circuit Failed Open
EDV Failed Self Test
Doser Fuel Line Pressure Abnormal
Doser Fuel Supply Pressure Abnormal
Doser FLP Sensors Failed Self Test
Fuel Cut Off Valve Circuit Failed Low
Fuel Cut Off Valve Circuit Failed High
Fuel Cut Off Valve Circuit Failed Open
FCV Failed Self Test
Multiplexer 1 Channel 1, Shorted High
PA1561
36
Section 01: ENGINE
SPN
3509
3510
3510
3511
3511
3556
3556
3563
3563
FMI
3
3
3
3
3
1
0
4
3
PID/SID
SID
SID
SID
SID
SID
SID
SID
PID
PID
PID/SID
ID
212
211
211
211
211
155
155
106
106
FLASH
CODE
1631
1632
1632
1633
1633
1545
1551
1551
1551
3563
20
PID
106
1551
Ambient and Inlet Manifold Pressure Difference (Low Box)
3563
3563
3563
3563
3563
21
1
0
3
20
PID
PID
PID
PID
PID
106
106
106
106
106
1551
1551
1551
1551
1551
Ambient and Inlet Manifold Pressure Difference (High Box)
Inlet Manifold Pressure Failed Low
Inlet Manifold Pressure Failed High
Inlet Manifold Pressure Sampling Range Failed
Intake Manifold Pressure Plausibility (Low Box)
3563
3588
3588
3588
3597
3597
3597
3598
3598
3599
3599
3609
3609
3609
21
4
3
5
3
3
6
4
3
4
3
4
3
10
PID
SID
SID
SID
SID
SID
SID
SID
SID
SID
SID
PID
PID
SID
106
156
157
158
155
155
155
155
155
317
317
370
370
370
1551
1552
1552
1552
1553
1615
1325
1615
1615
1615
1615
1554
1554
1554
Intake Manifold Pressure Plausibility Error, Pressure Too Low (High Box)
Ether Start, Shorted to Ground
Ether Start, Shorted to Battery
Ether Start, Open Load
Proportional Valve Bank 1 Circuit Failed Low
Proportional Valve Bank 1 Circuit Failed High
Current Flow on HS1 IM1 Too High
Proportional Valve Bank 2 Circuit Failed Low
Proportional Valve Bank 2 Circuit Failed High
Switching Power Supply Voltage Failed Low
Switching Power Supply Voltage Failed High
DPF Inlet Pressure Circuit Failed Low
DPF Inlet Pressure Circuit Failed High
DPF Inlet Pressure Sensor Stuck
3609
20
SID
370
1554
DPF Inlet Pressure Sensor Drifted High In Range Fault (Low Box)
FAULT DESCRIPTION
Multiplexer 1 Channel 2, Shorted High
Multiplexer 2 Channel 1, Shorted High
Multiplexer 2 Channel 2, Shorted High
Multiplexer 3 Channel 1, Shorted High
Multiplexer 3 Channel 2, Shorted High
Regen Temperature - Out of Range Low
Regen Temperature - Out of Range High
Intake Manifold Pressure Circuit Failed Low
Intake Manifold Pressure Circuit Failed High
3609
2
SID
370
1554
DPF Inlet Pressure Sensor Drifted High In Range Fault (High Box)
3609
21
SID
370
1554
DPF Inlet Pressure Sensor Drifted Low In Range Fault (Low Box)
3609
3610
3610
3610
3610
3610
21
3
4
0
10
2
SID
SID
SID
SID
SID
SID
370
371
371
371
371
371
1554
1555
1555
1334
1555
1555
DPF Inlet Pressure Sensor Drifted Low In Range Fault (High Box)
DPF Outlet Pressure Circuit Failed High
DPF Outlet Pressure Circuit Failed Low
DPF System Back Pressure Too High
DPF Outlet Pressure Sensor Stuck
DPF Pressure Sensors - Plausibility Error
3610
20
SID
371
1555
DPF Outlet Pressure Sensor Drifted High In Range Fault (Low Box)
3610
14
SID
371
1555
DPF Outlet Pressure Sensor Drifted High In Range Fault (High Box)
3610
21
SID
371
1555
DPF Outlet Pressure Sensor Drifted Low In Range Fault (Low Box)
3610
31
SID
371
1555
DPF Outlet Pressure Sensor Drifted Low In Range Fault (High Box)
3659
14
SID
362
1611
3659
10
SID
362
1611
Injector Cylinder #1 Spill Control Valve Abnormal Operation
Injector Cylinder #1 Spill Control Valve ("Amplifier") Abnormal Rate of
Change
3659
6
SID
362
1611
Injector Cylinder #1 Spill Control Valve ("Amplifier"), Valve Shorted Circuit
3660
14
SID
363
1612
3660
10
SID
363
1612
Injector Cylinder #2 Spill Control Valve Abnormal Operation
Injector Cylinder #2 Spill Control Valve ("Amplifier") Abnormal Rate of
Change
3660
6
SID
363
1612
Injector Cylinder #2 Spill Control Valve ("Amplifier"), Valve Shorted Circuit
PA1561
37
Section 01: ENGINE
SPN
FMI
PID/SID
PID/SID
ID
FLASH
CODE
3661
14
SID
364
1613
3661
10
SID
364
1613
Injector Cylinder #3 Spill Control Valve Abnormal Operation
Injector Cylinder #3 Spill Control Valve ("Amplifier") Abnormal Rate of
Change
3661
6
SID
364
1613
Injector Cylinder #3 Spill Control Valve ("Amplifier"), Valve Shorted Circuit
3662
14
SID
365
1614
3662
10
SID
365
1614
Injector Cylinder #4 Spill Control Valve Abnormal Operation
Injector Cylinder #4 Spill Control Valve ("Amplifier") Abnormal Rate of
Change
3662
6
SID
365
1614
Injector Cylinder #4 Spill Control Valve ("Amplifier"), Valve Shorted Circuit
3663
14
SID
366
1615
3663
10
SID
366
1615
Injector Cylinder #5 Spill Control Valve Abnormal Operation
Injector Cylinder #5 Spill Control Valve ("Amplifier") Abnormal Rate of
Change
3663
6
SID
366
1615
Injector Cylinder #5 Spill Control Valve ("Amplifier"), Valve Shorted Circuit
3664
14
SID
367
1621
3664
10
SID
367
1621
Injector Cylinder #6 Spill Control Valve Abnormal Operation
Injector Cylinder #6 Spill Control Valve ("Amplifier") Abnormal Rate of
Change
3664
6
SID
367
1621
Injector Cylinder #6 Spill Control Valve ("Amplifier"), Valve Shorted Circuit
3665
14
SID
368
1622
3665
10
SID
368
1622
Injector Cylinder #7 Spill Control Valve Abnormal Operation
Injector Cylinder #7 Spill Control Valve ("Amplifier") Abnormal Rate of
Change
3665
6
SID
368
1622
Injector Cylinder #7 Spill Control Valve ("Amplifier"), Valve Shorted Circuit
3666
14
SID
369
1623
3666
10
SID
369
1623
Injector Cylinder #8 Spill Control Valve Abnormal Operation
Injector Cylinder #8 Spill Control Valve ("Amplifier") Abnormal Rate of
Change
3666
3719
3719
6
16
0
SID
SID
SID
369
155
155
3719
31
SID
155
1623
1624
1624
1635
Injector Cylinder #8 Spill Control Valve ("Amplifier"), Valve Shorted Circuit
Soot Level High
Soot Level Very High
DPF Zone 2 Condition
3719
3720
3720
4076
4076
15
15
16
4
3
SID
SID
SID
PID
PID
155
155
155
110
110
1625
1625
1212
1212
DPF Zone 3 Condition
DPF Ash Clean Request
DPF Ash Clean Request - Derate
Engine Coolant Inlet Temperature Circuit Failed Low
Engine Coolant Inlet Temperature Circuit Failed High
4076
4077
4077
4077
4226
4226
2
4
3
14
4
3
SID
SID
SID
SID
SID
SID
155
332
332
332
155
155
1615
1543
1543
1543
1615
1615
Engine Coolant Sensor (IN), General Temp. Plausibility Error
Doser Fuel Line Pressure Sensor Circuit Failed Low
Doser Fuel Line Pressure Sensor Circuit Failed High
Doser Fuel Line Pressure Failed Self Test
Compressor Differential Pressure Inlet Failed Low
Compressor Differential Pressure Inlet Failed High
4226
0
SID
155
1615
Turbocharger Compressor Inlet Differential Pressure Too High (Low Box)
4226
1
SID
155
1615
4226
5
SID
155
1615
1454
4226
13
SID
155
4226
4227
4227
13
4
3
SID
SID
SID
155
53
53
Turbocharger Compressor Inlet Differential Pressure Too Low (High Box)
Turbocharger Compressor Inlet Differential Pressure Sampling Range
Failure
Turbocharger Compressor Inlet Differential Pressure Sensor Out Of
Calibration
Turbocharger Compressor Inlet Differential Pressure Sensor Out Of
Calibration
Electrostatic Oil Separator Circuit Failed Low
Electrostatic Oil Separator Circuit Failed High
1636
1454
PA1561
1324
1324
FAULT DESCRIPTION
38
Section 01: ENGINE
SPN
4227
4227
4227
4227
FMI
5
4
3
7
PID/SID
SID
SID
SID
SID
PID/SID
ID
53
155
155
155
4228
16
SID
147
4228
15
SID
147
FLASH
CODE
1324
1615
1615
1615
1241
1241
FAULT DESCRIPTION
Electrostatic Oil Separator Circuit Failed Open
Oil Separator Circuit Failed Low
Oil Separator Circuit Failed High
Oil Separator, Max. Duration Time Reached
Smart Remote Actuator 5 (VGT), Temperature Fault
Smart Remote Actuator 5 (VGT), Temperature Warning
2.12 ENGINE OIL LEVEL
CAUTION
MAINTENANCE
If the oil level is constantly above normal and
excess lube oil has not been added to the
crankcase, consult with an authorized Detroit
Diesel service outlet for the cause. Fuel or
coolant dilution of lube oil can result in serious
engine damage.
Check the oil level daily with the engine
stopped. If the engine has just been stopped
and is warm, wait at least 10 minutes to allow
the oil to drain back to the oil pan before
checking. Wipe the dipstick clean then check
oil level. The level should always be within the
safe range on the dipstick (Fig. 17). Add the
proper grade of oil to maintain the correct level
on the dipstick.
All diesel engines are
designed to consume some oil, so a periodic
addition of oil is normal.
The vehicle is provided with an oil reserve tank
with a capacity of 2.2 US gallons (8,3 liters).
This reserve tank is connected to the crankcase
by a hose with a shutoff valve, allowing oil to be
added to crankcase. To adjust oil level, open the
oil reserve tank shutoff valve and allow oil to
discharge into the engine until the "Full" mark on
the dipstick is reached then close the valve.
Check oil reserve tank level and pour oil in the
reserve tank if necessary (Fig. 18). Comparison
of oil levels in sight gauge, before and after
adding oil to crankcase, shows approximately
how much oil has been added.
WARNING
Touching a hot engine can cause serious
burns.
CAUTION
Do not overfill. Oil may be blown out through
the crankcase breather if the crankcase is
overfilled.
CAUTION
Clean end of tube before removing the dipstick
to prevent oil contamination.
FIGURE 18: OIL RESERVE TANK
FIGURE 17: ENGINE OIL LEVEL DIPSTICK
PA1561
01027
39
01050
Section 01: ENGINE
2. Reinstall the drain plug.
2.13 ENGINE OIL AND FILTER CHANGE
3. Remove the spin-on filter cartridge using a
1/2" drive socket wrench and extension.
MAINTENANCE
4. Dispose of the used oil and filter in an
environmentally responsible manner in
accordance with state and/or federal (EPA)
recommendations.
Both the engine oil and filter should be
changed according to the following maximum
interval (based on an oil analysis program).
5. Clean the filter adapter with a clean rag.
Short Haul: 15,000 miles (24,000km) or once
a year, whichever comes first.
6. Lightly coat the filter gasket (seal) with clean
engine oil.
Long Haul: 30,000 miles (48,000km) or once
a year, whichever comes first.
7. Install the new filter on the adapter and
tighten manually until the gasket touches the
mounting adapter head. Tighten full-flow
filters an additional two-thirds of a turn
manually. Then, manually tighten bypass
filter one full turn.
Oil analysis program may be used to determine
whether this interval should be shorter, but
should not be used to lengthen the interval.
Short haul: 6,000 miles (10,000km) to 60,000
miles (100,000 km) annual.
Long haul: over 60,000 miles (100,000 km)
annual.
However, changes that are more frequent may
be required when the engine is subject to high
levels of contamination and/or overheating.
Change intervals may be decreased or gradually
increased with experience on specific lubricants
until the most practical service condition has
been established. Always refer to the lubricant
manufacturer's recommendations (analysis of
drained oil can be helpful).
FIGURE 19: UNDER VEHICLE VIEW
CAUTION
CAUTION
Do not use solvents to dilute the engine oil
when draining. Dilution of fresh oil can occur
which may be detrimental to the engine.
Overtightening may distort or crack the filter
adapter.
8. Remove the engine-oil filler cap and pour oil
in the engine until it reaches the "FULL" mark
on the dipstick (Fig. 17).
Change engine oil with the vehicle on a flat and
level surface and with the parking brake applied.
It is best to drain the oil when the engine is still
warm.
9. Start and run the engine for a short period
and check for leaks. After any leaks have
been corrected, stop the engine long enough
for oil from various parts of the engine to
drain back to the crankcase (approximately
20 minutes).
1. From under the vehicle, remove the engine
drain plug on the oil pan. Allow oil to drain
(Fig. 19).
WARNING
10. Add oil as required to bring the level within
Hot engine oil can cause serious burns. Wear
coveralls with sleeves pulled down and gloves
to protect hands.
PA1561
01029
the safe range on the dipstick.
40
Section 01: ENGINE
NOTE
MAINTENANCE
COLD WEATHER STARTING
The proper selection of the engine oil grade
will ease cold weather starting (refer to the
lubrication and servicing schedule for the
engine oil grade recommendation). Other
practical considerations, such as the use of
batteries, cables and connectors of adequate
size, proper setting of voltage regulator, ether
starting aid, oil and coolant heater systems,
and proper fuel selection will ease cold
weather starting.
Engine oil temperature should be checked
every 25,000 miles (40 000 km) to determine
oil cooler efficiency. This check should be
made by inserting a steel jacketed
thermometer
in
the dipstick opening,
immediately after stopping a hot, loaded
engine. If the oil temperature exceeds the
coolant temperature by more than 60 °F (33
°C), the oil cooler may be clogged.
For detailed oil specifications, refer to
DETROIT DIESEL SERIES 60 2007 ONHIGHWAY SERVICE MANUAL 6SE2007
under heading «Lubricating Oil for Detroit
Diesel Engines».
2.15 POWER PLANT ASSEMBLY REMOVAL
To access the engine or engine-related
components, the vehicle power plant assembly
must be removed as a whole unit by means of a
slide-out cradle. The power plant assembly
includes the engine, transmission (including
retarder if so equipped), air compressor,
alternator and transmission oil cooler.
2.14 RECOMMENDED ENGINE OIL TYPE
To provide maximum engine life, lubricants shall
meet the following specifications: SAE Viscosity
Grade: 15W-40 API Classification: CJ-4.
Remove the power plant assembly as follows:
CAUTION
CAUTION
Low ash oil formulation designated API CJ-4
is required in EPA-07 engines.
Tag hoses and cables for identification before
disconnecting
in
order
to
facilitate
reinstallation. Plug all openings to prevent dirt
from entering the system.
CJ-4 contains less than 1% ash which is the
key to achieving maximum diesel particulate
filter cleaning intervals. Use of high ash
engine oils will reduce the cleaning interval on
the Diesel Particulate Filter (DPF). DPF
regenerates the combustible soot, but the ash
(a product of the oil lubricant package) slowly
accumulates in the channels of the DPF.
NOTE
The MCM is non-serviceable.
defective, replace as a unit.
found
1. Disconnect the battery cables from the
batteries. With the electrical circuit disrupted,
accidental contact with the starter button will
not produce an engine start. In addition, the
Electronic Unit Injectors (EUI) will be
disabled, preventing any fuel delivery to the
injector tips.
NOTE
Monograde oils should not be used in these
engines
regardless
of
API
Service
Classification.
NOTE
WARNING
The use of supplemental oil additives is
discouraged from use in Detroit Diesel
Engines.
Due to the heavy load of the rear bumper
assembly, it must be adequately supported
before attempting to remove it.
Synthetic oils: Synthetic oils may be used in
Detroit Diesel engines provided they are APIlicensed and meet the performance and
chemical requirements of non-synthetic oils
outlined previously. Synthetic oils do not permit
extension of recommended oil drain intervals.
PA1561
If
2. Remove the rear bumper assembly from the
vehicle. Refer to Section 18 BODY, under
"Rear Bumper Removal And Installation".
41
Section 01: ENGINE
3. Drain the engine cooling system. Refer to
Section 05 COOLING under "Draining Cooling
System".
13. Disconnect
connector.
the
fan-clutch
electrical
14. Disconnect the radiator fan drive shaft.
15. Disconnect the small heater hose located on
the cylinder head at the back of the engine.
16. Disconnect and remove the exhaust pipe
mounted between the turbocharger outlet
and the exhaust bellows. If necessary, refer
to Section 04 EXHAUST SYSTEM under “AFT
Removal and Installation".
CAUTION
FIGURE 20: ENGINE COMPARTMENT
To avoid damage to turbocharger, cover the
turbocharger outlet opening to prevent foreign
material from entering.
01044
4. Locate the A/C compressor drive belt
tensioner control valve (Fig. 23). Turn handle
clockwise in order to release pressure in belttensioner air bellows and loosen belts.
Remove the belt.
17. Disconnect the block heater connector
above the power steering pump.
18. Disconnect the steel-braided airline from the
A/C compressor air bellows.
5. Release all pressure from the air system.
Refer to Section 12 BRAKES & AIR
SYSTEM for instructions.
19. Disconnect the oil delivery hose from the
valve located at the reserve tank drain.
6. Disconnect and remove the engine-air
intake duct mounted between air cleaner
housing and turbocharger inlet.
20. Remove the power steering pump, leaving
the supply and discharge hoses connected t
it.
CAUTION
21. Close engine fuel supply shutoff valve on
primary fuel filter. Disconnect the fuel line
connected to inlet port. On vehicles equipped
with the optional water-separator-fuel-filter,
disconnect the connector and remove cable
ties from cradle.
To avoid damage to turbocharger, cover the
turbocharger inlet opening to prevent foreign
material from entering.
7. Disconnect and remove the air intake duct
mounted between the turbocharger outlet
and the charge air cooler inlet.
22. Disconnect fuel return line from bulkhead
fixed on engine cylinder head end.
23. Disconnect the air compressor discharge
airline.
8. Disconnect and remove the air intake duct
mounted between the charge air cooler outlet
and the engine intake.
24. Disconnect the coolant hose to the sump
tank heater system.
9. Disconnect and remove section of coolant
pipe assembly mounted between the radiator
outlet and the water pump inlet.
25. Disconnect positive (+) cable (red terminal)
from starter motor solenoid.
10. Disconnect and remove a section of coolant
pipe assembly mounted between the
thermostat housing and the radiator inlet.
26. Disconnect starter motor ground cables from
rear subframe ground-stud located close to
the starter motor.
11. Disconnect the coolant delivery hose
mounted between the coolant surge tank and
the water pump.
27. Disconnect VIH (vehicle interface harness)
main connectors from MCM and VSS
(vehicle speed sensor).
12. Disconnect two vent hoses from the
thermostat housing and from the coolant pipe
assembly.
28. On vehicles equipped with an automatic
transmission provided with a hydraulic output
retarder, disconnect steel-braided airline from
PA1561
42
Section 01: ENGINE
pressure regulator output. The pressure
regulator is mounted in the upper section of
engine compartment backwall and is
accessible through the engine compartment
R.H. side door.
29. On vehicles equipped with an electrically
operated cold-starting aid, disconnect the
delivery hose from the starting-aid cylinder
solenoid valve. Remove cable ties securing
hoses.
30. Disconnect the transmission harness
(Allison: 2 main connectors, 1 connector to
the retarder accumulator solenoid) (ZF
transmission: 3 connectors).
31. From under the vehicle, disconnect the
propeller shaft as detailed in Section 09,
under heading "Propeller Shaft Removal".
32. Inspect the power plant assembly to ensure
that nothing will interfere when sliding out the
cradle. Check for connections or hoses not
mentioned in this list as some vehicles are
equipped with special or aftermarket
components.
33. Remove the six retaining bolts, washers and
nuts securing the power plant cradle to the
vehicle rear subframe (Fig. 23).
NOTE
Check if any spacer(s) have been installed
between power plant cradle and vehicle rear
subframe, and if so, note position of each
washer for reinstallation purposes.
34. Using a forklift, with a minimum capacity of
4,000 lbs (1 800 kg), slightly raise the power
plant cradle.
35. Pull engine out slowly from the engine
compartment. Make sure all lines, wiring and
accessories are disconnected and are not
tangled.
CAUTION
Due to the minimum clearance between the
power plant equipment and the top of the
engine compartment, extreme care should be
used to raise the power plant cradle, just
enough to free the cradle. Clearance between
power plant cradle and mounting rail should
range between 1/4" and 1/2" (6-12 mm).
PA1561
43
Section 01: ENGINE
FIGURE 21: ENGINE COMPARTMENT H3 COACHES (TYPICAL)
01177
FIGURE 22: ENGINE COMPARTMENT VIP (TYPICAL)
01178
PA1561
44
Section 01: ENGINE
2.17 JAKE BRAKE
2.16 POWER PLANT ASSY. INSTALLATION
Refer to both "The Jake Brake Troubleshooting
and Maintenance Manual" and "Installation
Manual for Model 797 Engine Brakes" for
troubleshooting and installation procedures.
They are annexed at the end of this section.
To install a power plant assembly, follow the
same procedure as in "Power Plant Assembly
Removal" except in reverse order, then proceed
with the following:
5. Torque the power plant cradle mounting
bolts to 190 lbf-ft (255 Nm).
2.18 ENGINE MOUNTS
6. If fan drive has been removed, reinstall and
align as per Section 05 COOLING SYSTEM,
under "Fan Drive Alignment".
The power plant assembly on a vehicle powered
with a series 60 engine is mounted to the cradle
by means of rubber mounts.
7. Refill cooling system with saved fluid (refer
to Section 05 COOLANT SYSTEM).
Two rubber mounts are used at the front of the
engine while two others are mounted on each
side of the flywheel housing (Fig. 23).
8. Once engine fuel system has been drained,
it will aid restarting if fuel filters are filled with
fuel oil (refer to Section 03 FUEL SYSTEM).
It is recommended that new rubber mounts be
installed at each major overhaul.
9. Start engine for a visual check. Check fuel,
oil, cooling, pneumatic and hydraulic system
connections for leakage. Test operation of
engine controls and accessories.
FIGURE 23: POWER PLANT CRADLE INSTALLATION
PA1561
01107
45
Section 01: ENGINE
the CPC will signal diagnostic codes of 21-12 for
idle error and 21-23 for wide-open throttle error.
3. ELECTRONIC FOOT PEDAL ASSEMBLY
(EFPA) & THROTTLE POSITION SENSOR
The Electronic Foot Pedal Assembly (EFPA)
connects the accelerator pedal to a Throttle
Position Sensor (TPS). The (TPS) is a device,
which sends an electrical signal to the Motor
Control Module (MCM). The TPS varies in
voltage depending on how far the pedal is
depressed. The system is installed in the space
normally occupied by a mechanical foot pedal.
The (EFPA) has maximum and minimum stops
that are built into the unit during manufacturing
(Fig. 24). The (TPS) converts the operator's foot
pedal input into a signal for the MCM.
When installed by the equipment manufacturer,
the TPS should not require adjustment. If the
TPS is suspected of being misadjusted, confirm
that the sensor is installed in accordance with
the
manufacturer's
specifications.
It
is
recommended that the idle count be at 50 or
higher with a full throttle count of up to 200.
The TPS is self-calibrating and therefore has no
optimum closed throttle or wide open throttle
count value. If the counts are within the 50 to
200 range, the sensor is properly set.
FIGURE 24: ELECTRONIC FOOT PEDAL ASSEMBLY 03035
Monitor the (TPS) at the controls as you move it
through its full stroke. Be sure there is no
misalignment or obstruction preventing the
smooth movement of the TPS through the full
stroke. Using a diagnostic data reader, check
that the idle and full throttle position counts do
not fall within the error zones. The error zones
occur when the idle position is less than 14
counts, or when the full throttle position is more
than 233 counts. Should these conditions occur,
PA1561
46
Section 01: ENGINE
4. ENGINE TROUBLESHOOTING GUIDE
START
does the
engine
rotate ?
go to
step 2
no
is the
engine
starting ?
no
yes
yes
see
note 1
plug the Diagnostics Data
Reader DDR into the receptacle
or momentarily depress the
stop engine "OVERRIDE"
switch to activate the DDEC
self-diagnostic system
does the red
"Stop Engine"
indicator
illuminate and
go off after 5
sec. ?
go to
step 3
yes
no
faulty 12-volt-system power supply,
probable causes :
- battery cables improperly connected
- fuse blown
- faulty battery equalizer
- activate the DDEC self-diagnostic system
and contact your Detroit Diesel service
center
with diagnostic code in
hand, contact your
Detroit Diesel service
center
step 2
there may be a problem
with the starter or starter
circuit. Contact Detroit
Diesel or Prévost Action
Service
engine does not rotate
yes
what is the
voltage reading
on 24-voltsystem
dashboard
indicator ?
higher than
24 volts
is the shift
selector to
neutral "N"
position ?
lower than
24 volts
faulty 24-volt-system power supply
or low battery voltage. Contact
Prévost Action Services
PA1561
no
place the shift selector to
neutral "N" position and start
the engine
47
yes
is the rear start
selector to
"NORMAL"
position?
no
Set the rear start
selector to "NORMAL"
Section 01: ENGINE
step 3
with diagnostic code in
hand, contact your
Detroit Diesel service
center
note 1
REFERENCES
-Operator's Manual chap. 3,4 & 8
-Detroit Diesel pamphlet "DDEC
III/IV diagnostic codes and MPSI
reader functions"
-8V92 series engine, switch is
located in service compartment
see
note 1
note 2
see the analog voltage indicator
on the dashboard or consult the
MCD "Message Center Display"
on the telltale panel. See the
Operator's Manual chap. 4 for
more details
is there motor
exhaust fumes
?
yes
plug the Diagnostics Data
Reader DDR into the
receptacle or momentarily
depress the stop engine
"OVERRIDE" switch to
activate the DDEC selfdiagnostic system
no
probable causes :
- 12-volt-system batteries low
- faulty battery equalizer
- 12-volt-system batteries
improperly connected
- 12-volt-system battery master
switch to "OFF" position (H3-40)
higher than
lower than
what is the
10 volts
10 volts
voltage
reading on the
12-volt-system
indicator ?
see
note 2
probable cause :
-no fuel
-check the 2 breakers on the injector
feeding system.
Contact Detroit Diesel
or Prévost Action Service
01089
PA1561
48
Section 01: ENGINE
5. SPECIFICATIONS
5.1 SERIES 60 ENGINE
Make ......................................................................................................................................... Detroit Diesel
Type ............................................................................................................... Diesel four cycle/in-line engine
Description ...................................................................................................... Turbo/Air to air charge cooled
No. of cylinders ............................................................................................................................................. 6
Operating range ....................................................................................................................1200-2100 RPM
Maximum RPM........................................................................................................................................ 2100
CAUTION
To avoid possible engine damage, do not use single grade (Monograde) lubricants in Detroit Diesel
four-cycle Series 60 engines, regardless of API classification.
Detroit Diesel Series 60 engine ratings
Series 60 engine ratings used in Prevost Car Models are listed in the following tables. The standard
engine ratings are written in bold, customer may easily switch from one rating to another within the same
table by having the DDEC VI system reprogrammed.
Coach Engine (14.0L)
425 HP
@1800 rpm; 1450 lb-ft @1200 rpm
445 HP
@1800 rpm; 1450 lb-ft @1200 rpm
Entertainer Engine (14.0L)
Motorhome (14.0L)
470 HP
@1800 rpm; 1650 lb-ft @1200 rpm
515 HP
@1800 rpm; 1650 lb-ft @1200 rpm
455 HP
@1800 rpm; 1550 lb-ft @1200 rpm
490 HP
@1800 rpm; 1550 lb-ft @1200 rpm
515 HP
@1800 rpm; 1550 lb-ft @1200 rpm
Capacity
Oil reserve tank ................................................................................................................. 8.4 US qts (8.0 L)
Engine oil level quantity
Oil Pan Capacity; Low Limit ..............................................................................................26 quarts/25 liters
Oil Pan Capacity; High Limit .............................................................................................32 quarts/30 liters
Total Engine Oil Capacity with Filters ...............................................................................38 quarts/36 liters
Lubricating oil filter elements
Make................................................................................................... AC Rochester Div. GMC # 25014505
Make............................................................................................................................. A/C Filter # PF-2100
Type ................................................................................................................................................ Full Flow
Prevost number................................................................................................................................. 510458
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Section 01: ENGINE
Torque specification
Engine oil filter.............................................................................. Tighten 2/3 of a turn after gasket contact
Filters
Engine Air Cleaner Filter
Make ............................................................................................................................. Nelson # 70337-N
Prevost number ............................................................................................................................. 530197
Engine Coolant Filter/Conditioner
Make .............................................................................................Nalco Chemical Company # DDF3000
Make .................................................................................................................Detroit Diesel # 23507545
Prevost number.............................................................................................................................. 550630
NOTE
For primary and secondary fuel filters, refer to Specifications in section 03.
5.2 VOLVO D13 ENGINE
Make ....................................................................................................................................Volvo Powertrain
Type ......................................................................................................................................Diesel four cycle
Description ...................................................................................................... Turbo/Air to air charge cooled
No. of cylinders .........................................................................................................................12.8 L inline 6
Recommended cruise speed range .....................................................................................1300-1500 RPM
Maximum RPM........................................................................................................................................ 2100
Engine oil level quantity
Oil Pan Capacity; Low Limit ..............................................................................................25 quarts/24 liters
Oil Pan Capacity; High Limit .............................................................................................34 quarts/32 liters
Total Engine Oil Capacity with Filters ............................................................................45 quarts/42.5 liters
Lubricating oil filter elements
Prevost number............................................................................................................... 478736 (Full Flow)
Prevost number.................................................................................................................510938 (By-pass)
Torque specification
Engine oil filter.............................................................................. Tighten 3/4 to 1 turn after gasket contact
Filters
Engine Air Cleaner Filter
Prevost number ............................................................................................................................. 530197
Engine Coolant Filter
Make ................................................................................................................................................. Volvo
Number ...................................................................................................................................... 20458771
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Section 01: ENGINE
NOTE
For primary and secondary fuel filters, refer to Specifications in section 03.
PA1561
51
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