Detroit Diesel MBE 4000 DDEC VI User manual

MBE 4000 DDEC VI TROUBLESHOOTING GUIDE
ENGINE EXHAUST
Consider the following before servicing engines:
PERSONAL INJURY
Diesel engine exhaust and some of its constituents are
known to the State of California to cause cancer, birth
defects, and other reproductive harm.
□Always start and operate an engine in a well ventilated
area.
□If operating an engine in an enclosed area, vent the
exhaust to the outside.
□Do not modify or tamper with the exhaust system or
emission control system.
TRADEMARK INFORMATION
DDC®, Detroit Diesel®, DDEC®, Diagnostic Link®, Optimized Idle®, Optimized Idle®,
Pro-Link®, and Series 60® are registered trademarks of Detroit Diesel Corporation. All other
trademarks used are the property of their respective owners.
MCM/CPC WARNING
Figure 1 MCM/CPC Replacement Warning
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MBE 4000 DDEC VI TROUBLESHOOTING GUIDE
SOFTWARE UPGRADES
NOTE:
These engines are equipped with DaimlerChrysler software. This software generally
assures optimal engine performance. The installation of software upgrades may cause
minor changes in features and engine performance.
ABSTRACT
This manual provides instruction for troubleshooting the 2007 Electronic Controls engines.
Specifically covered in this manual are troubleshooting and repair steps that apply to DDEC VI.
SAFETY INSTRUCTIONS
To reduce the chance of personal injury and/or property damage, the instructions contained in this
Troubleshooting Manual must be carefully observed. Proper service and repair are important to
the safety of the service technician and the safe, reliable operation of the engine.
If part replacement is necessary, the part must be replaced with one of the same part number or
with an equivalent part number. Do not use a replacement part of lesser quality. The service
procedures recommended and described in this manual are effective methods of performing
repair. Some of these procedures require the use of specially designed tools. Accordingly, anyone
who intends to use a replacement part, procedure or tool which is not recommended, must first
determine that neither personal safety nor the safe operation of the engine will be jeopardized by
the replacement part, procedure or tool selected.
It is important to note that this manual contains various "Cautions" and "Notices" that must be
carefully observed in order to reduce the risk of personal injury during repair, or the possibility
that improper repair may damage the engine or render it unsafe. It is also important to understand
that these "Cautions" and "Notices" are not exhaustive, because it is impossible to warn personnel
of the possible hazardous consequences that might result from failure to follow these instructions.
A LETTER TO THE TECHNICIANS
Technicians today are required to have computer skills, excellent comprehension of the written
word and possess an extensive diagnostic understanding of the various technological systems and
components. Technicians today must perform at a higher level of efficiency and competency than
their predecessors and at the same time furnish professional quality support.
As the leader in engine computer systems and technology, Detroit Diesel Corporation remains
focused on providing excellence in products, service support and training. As products become
more and more advanced, technicians must become specialized in multiple areas. This manual
is designed with that thought in mind. The DDEC VI MBE 4000 Troubleshooting Guide will
provide you with concentrated information that will allow you to excel in DDEC VI technology.
(Rev. ) All information subject to change without notice.
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MBE 4000 DDEC VI TROUBLESHOOTING GUIDE
REVISION NOTIFICATION
Modifications to this manual are announced in the form of Service Information Bulletins.
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MBE 4000 DDEC VI TROUBLESHOOTING GUIDE
TABLE OF CONTENTS
1 INTRODUCTION
1.1 OVERVIEW .............................................................................................. 1-3
1.2 SCOPE AND USE OF THIS GUIDE ........................................................ 1-4
1.3 SAFETY PRECAUTIONS ........................................................................ 1-6
2FUELINJECTION
2.1 PERFORMING TROUBLESHOOTING TESTS ....................................... 2-3
2.2 TEST #1: FUEL PRESSURE TEST ......................................................... 2-5
2.3 TEST #2: PERCENTAGE OF FUEL DELIVERY FOR A SMOOTH IDLE 2-9
2.4 TEST #4: FUEL PUMP DRIVEN GEAR BOLT TORQUE ........................ 2-10
2.5 TEST #5: LEAK TEST ............................................................................. 2-12
3 MISFIRING CYLINDER
3.1 POOR VEHICLE GROUND ..................................................................... 3-3
3.2 AERATED FUEL ...................................................................................... 3-5
3.3 IMPROPER VALVE CLEARANCE, WORN OR DAMAGED CAMSHAFT
LOBES AND ROLLERS ........................................................................... 3-7
3.4 FAULTY FUEL NOZZLE/UNIT PUMP ...................................................... 3-9
3.5 FAULTY MCM .......................................................................................... 3-10
3.6 WORN OR DAMAGED VALVE OR CYLINDER KIT ................................ 3-11
4 STARTING DIFFICULTY (ENGINE ROTATES)
4.1 TROUBLESHOOTING PROCEDURE FOR DDEC-CPC WIRING
HARNESS ................................................................................................ 4-3
4.2 VEHICLE CIRCUIT BREAKERS OR FUSES CHECK ............................. 4-4
4.3 DDEC-ECU POWER HARNESS VOLTAGE TEST .................................. 4-5
4.4 POWER HARNESS REPAIR ................................................................... 4-6
4.5 TROUBLESHOOTING PROCEDURE FOR AN EMPTY FUEL TANK ..... 4-7
4.6 LOW FUEL LEVEL RESOLUTION .......................................................... 4-8
4.7 TROUBLESHOOTING PROCEDURE FOR LOW BATTERY VOLTAGE . 4-9
4.8 BATTERY REPLACEMENT ..................................................................... 4-10
4.9 TEST ENGINE WITH REPLACED BATTERY ......................................... 4-11
4.10 TROUBLESHOOTING PROCEDURE FOR CORRODED OR DAMAGED
BATTERY TERMINALS ........................................................................... 4-12
4.11 CORRODED OR DAMAGED BATTERY TERMINAL REPAIR ................ 4-13
4.12 TROUBLESHOOTING PROCEDURE FOR DEFECTIVE MAGNETIC
SWITCH ................................................................................................... 4-14
4.13 MAGNETIC SWITCH REPLACEMENT ................................................... 4-15
4.14 TROUBLESHOOTING PROCEDURE FOR A DEFECTIVE STARTER .. 4-16
4.15 STARTER REPLACEMENT ..................................................................... 4-17
4.16 TROUBLESHOOTING PROCEDURE FOR LOW CRANKING SPEED .. 4-18
4.17 LOW CRANKING SPEED REPAIR .......................................................... 4-19
4.18 TROUBLESHOOTING PROCEDURE FOR THE FUEL SUPPLY VALVE 4-20
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4.19 FUEL SUPPLY VALVE REPAIR ............................................................... 4-21
4.20 PLUGGED FUEL FILTER(S) REPLACEMENT ........................................ 4-22
4.21 TROUBLESHOOTING PROCEDURE FOR FUEL PUMP ....................... 4-23
4.22 FUEL PUMP REPLACEMENT ................................................................. 4-24
4.23 TROUBLESHOOTING PROCEDURE FOR AERATED FUEL ................. 4-25
4.24 AERATED FUEL RESOLUTION .............................................................. 4-26
4.25 TROUBLESHOOTING PROCEDURE FOR RESTRICTIVE AIR FILTER 4-27
4.26 AIR FILTER REPLACEMENT .................................................................. 4-28
4.27 TROUBLESHOOTING PROCEDURE FOR LOW COMPRESSION ....... 4-29
4.28 LOW COMPRESSION REPAIR ............................................................... 4-30
5 NO START (ENGINE WILL NOT ROTATE)
5.1 ................................................................................................................. 5-3
6 EXCESSIVE OIL CONSUMPTION
6.1 MISCALIBRATED DIPSTICK ................................................................... 6-3
6.2 EXTERNAL OIL LEAKS ........................................................................... 6-4
6.3 ENGINE OIL LEAK REPAIR .................................................................... 6-5
6.4 LEAKING OIL HEAT EXCHANGER ......................................................... 6-6
6.5 TEST ENGINE WITH NEW OIL HEAT EXCHANGER ............................. 6-7
6.6 DEFECTIVE AIR COMPRESSOR ........................................................... 6-8
6.7 TEST ENGINE WITH REPAIRED AIR COMPRESSOR .......................... 6-10
6.8 DEFECTIVE TURBOCHARGER ............................................................. 6-11
6.9 WORNORDAMAGEDVALVEORCYLINDERKIT................................ 6-12
6.10 WORN OR DAMAGED VALVE(S) OR CYLINDER KIT(S) REPAIR ........ 6-17
7 EXCESSIVE CRANKCASE PRESSURE
7.1 OBSTRUCTION OR DAMAGE TO BREATHER SYSTEM ...................... 7-3
7.2 DEFECTIVE AIR COMPRESSOR ........................................................... 7-5
7.3 DEFECTIVE TURBOCHARGER ............................................................. 7-7
7.4 WORNORDAMAGEDVALVEORCYLINDERKIT ................................ 7-8
8 EXCESSIVE EXHAUST SMOKE (BLACK OR GRAY)
8.1 ................................................................................................................. 8-3
9 EXCESSIVE BLUE SMOKE
9.1 ................................................................................................................. 9-3
10 EXCESSIVE WHITE SMOKE
10.1 ................................................................................................................. 10-3
11 ROUGH RUNNING OR STALLING
11.1 ................................................................................................................. 11-3
12 LACK OF POWER
12.1 ................................................................................................................. 12-3
13 HIGH ENGINE COOLANT TEMPERATURE
13.1 ................................................................................................................. 13-3
14 LOW OIL PRESSURE
14.1 ................................................................................................................. 14-3
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15 LOW COOLANT TEMPERATURE
15.1 ................................................................................................................. 15-3
16 POOR FUEL ECONOMY
16.1 ................................................................................................................. 16-3
17 DDEC VI SYSTEM
17.1 DDEC VI SYSTEM--HOW IT WORKS ..................................................... 17-3
17.2 MOTOR CONTROL MODULE ................................................................ 17-4
17.3 COMMON POWERTRAIN CONTROLLER ............................................. 17-18
17.4 WIRES AND WIRING .............................................................................. 17-28
17.5 CONDUIT AND LOOM ............................................................................. 17-42
17.6 TAPE AND TAPING ................................................................................. 17-43
17.7 SENSORS ................................................................................................ 17-44
17.8 INSTRUMENT PANEL LAMPS ................................................................ 17-59
18 SPN 27 - EGR VALVE POSITION CIRCUIT FAULT
18.1 SPN 27/FMI 3 ........................................................................................... 18-3
18.2 SPN 27/FMI 4 ........................................................................................... 18-4
18.3 SPN 27/FMI 7 .......................................................................................... 18-7
19 SPN 51 - INTAKE THROTTLE VALVE ABOVE OR BELOW NORMAL
OPERATING RANGE
19.1 SPN 51/FMI 2, 3 OR 4 ............................................................................. 19-3
20 SPN 70 (CPC) - J1939 PARK BRAKE SWITCH SIGNAL ERRATIC
OR MISSING
20.1 SPN 70/FMI 13 ......................................................................................... 20-3
20.2 SPN 70/FMI 19 ......................................................................................... 20-3
21 SPN 84 (CPC) - J1939 WHEEL-BASED VEHICLE SPEED SIGNAL
ERRATICORMISSING
21.1 SPN 84/FMI 13 ......................................................................................... 21-3
21.2 SPN 84/FMI 19 ......................................................................................... 21-3
22 SPN 84 – VEHICLE SPEED SENSOR
22.1 SPN 84/FMI 2 ........................................................................................... 22-3
22.2 SPN 84/FMI 3 ........................................................................................... 22-3
22.3 SPN 84/FMI 4 ........................................................................................... 22-4
22.4 SPN 84/FMI 6 ........................................................................................... 22-4
22.5 SPN 84/FMI 8 ........................................................................................... 22-5
23 SPN 86 – ADAPTIVE CRUISE CONTROL FAULT
23.1 SPN 86/FMI 14 ......................................................................................... 23-3
24 SPN 91 – ACCELERATOR PEDAL SENSOR FAULT
24.1 SPN 91/FMI 2 ........................................................................................... 24-3
24.2 SPN 91/FMI 3 ........................................................................................... 24-4
24.3 SPN 91/FMI 4 ........................................................................................... 24-6
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25 SPN 94 – FUEL COMPENSATION PRESSURE SENSOR CIRCUIT
FAULT
25.1 SPN 94/FMI 3 OR 4 ................................................................................. 25-3
26 SPN 100 — ENGINE OIL PRESSURE OUTSIDE NORMAL OPERATING
RANGE
26.1 SPN 100/FMI 1 ......................................................................................... 26-3
26.2 SPN 100/FMI 2 ......................................................................................... 26-5
26.3 SPN 100/FMI 3 ......................................................................................... 26-6
26.4 SPN 100/FMI 4 ......................................................................................... 26-8
26.5 SPN 100/FMI 18 ....................................................................................... 26-9
27 SPN 103 – TURBO NO REVOLUTION
27.1 SPN 103/FMI 0 ......................................................................................... 27-3
27.2 SPN 103/FMI 1 ......................................................................................... 27-4
27.3 SPN 103/FMI 3 ......................................................................................... 27-5
27.4 SPN 103/FMI 4 ......................................................................................... 27-7
27.5 SPN 103/FMI 7 ......................................................................................... 27-9
28 SPN 110 — COOLANT TEMPERATURE ABOVE OR BELOW NORMAL
OPERATING RANGE
28.1 SPN 110/FMI 0 ......................................................................................... 28-3
28.2 SPN 110/FMI 2 ......................................................................................... 28-4
28.3 SPN 110/FMI 3 ........................................................................................ 28-5
28.4 SPN 110/FMI 4 ......................................................................................... 28-7
28.5 SPN 110/FMI 14 ....................................................................................... 28-9
29 SPN 111 – COOLANT LEVEL OUTSIDE NORMAL OPERATING
RANGE
29.1 SPN 111/FMI 1 ......................................................................................... 29-5
29.2 SPN 111/FMI 3 ......................................................................................... 29-7
29.3 SPN 111/FMI 4 ......................................................................................... 29-9
30 SPN 158 — BATTERY CHARGING FAULT
30.1 SPN 158/FMI 0 ......................................................................................... 30-3
30.2 SPN 158/FMI 1 ......................................................................................... 30-4
30.3 SPN 158/FMI 2 ......................................................................................... 30-6
31 SPN 168 – BATTERY VOLTAGE OUTSIDE NORMAL OPERATING
RANGE
31.1 SPN 168/FMI 0 ......................................................................................... 31-3
31.2 SPN 168/FMI 1 ......................................................................................... 31-4
32 SPN 174 – SUPPLY FUEL TEMPERATURE FAULT
32.1 SPN 174/FMI 3 ......................................................................................... 32-3
32.2 SPN 174/FMI 4 ......................................................................................... 32-5
33 SPN 175 – ENGINE OIL TEMPERATURE OUTSIDE NORMAL RANGE
33.1 SPN 175/FMI 2 ......................................................................................... 33-3
33.2 SPN 175/FMI 3 ......................................................................................... 33-5
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33.3 SPN 175/FMI 4 ......................................................................................... 33-7
34 SPN 190 - ENGINE SPEED HIGH
34.1 SPN 190/FMI 2 ......................................................................................... 34-3
35 SPN 191 (CPC) - J1939 ETC1 MESSAGE MISSING AND
TRANSMISSION OUTPUT SHAFT SPEED SIGNAL ERRATIC OR
MISSING
35.1 SPN 191/FMI 9 ......................................................................................... 35-3
35.2 SPN 191/FMI 13 ....................................................................................... 35-3
35.3 SPN 191/FMI 19 ....................................................................................... 35-4
36 SPN 274 (CPC) – MCM ENGINE HOURS DATA HIGHER OR LOWER
THAN EXPECTED
36.1 SPN 274/FMI 0 ......................................................................................... 36-3
36.2 SPN 274/FMI 1 ......................................................................................... 36-3
37 SPN 411 — EGR DIFFERENTIAL PRESSURE OR DELTA P SENSOR
CIRCUIT OUTSIDE OF NORMAL OPERATING RANGE
37.1 SPN 411/FMI 0 ......................................................................................... 37-3
37.2 SPN 411/FMI 1 ......................................................................................... 37-5
37.3 SPN 411/FMI 3 ......................................................................................... 37-6
37.4 SPN 411/FMI 4 ......................................................................................... 37-7
38 SPN 523 (CPC) - TRANSMISSION CURRENT GEAR SIGNAL
ERRATICORMISSING
38.1 SPN 523/FMI 19 ....................................................................................... 38-3
38.2 SPN 523/FMI 13 ....................................................................................... 38-3
39 SPN 524 (CPC) - J1939 ETC2 MESSAGE IS MISSING
39.1 SPN 523/FMI 9 ......................................................................................... 39-3
40 SPN 527 (CPC) - J1939 CCVS MESSAGE MISSING
40.1 SPN 527/FMI 9 ......................................................................................... 40-3
41 SPN 558 - IDLE VALIDATION SWITCH
41.1 SPN 558/FMI 1 ......................................................................................... 41-3
41.2 SPN 558/FMI 3 ......................................................................................... 41-3
41.3 SPN 558/FMI 4 ......................................................................................... 41-5
42 SPN 596 (CPC) - CRUISE CONTROL ENABLE SWITCH SIGNAL
ERRATICORMIS
SING
42.1 SPN 596/FMI 13 ....................................................................................... 42-3
42.2 SPN 596/FMI 19 ....................................................................................... 42-3
43 SPN 597 (CPC) - SERVICE BRAKE SWITCH SIGNAL ERRATIC OR
MISSING
43.1 SPN 597/FMI 13 ....................................................................................... 43-3
43.2 SPN 597/FMI 19 ....................................................................................... 43-3
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44 SPN 599 - CRUISE CONTROL SWITCHES NOT FUNCTIONING
PROPERLY
44.1 SPN 599/FMI 4 ......................................................................................... 44-3
45 SPN 600 (CPC) - CRUISE CONTROL COAST SWITCH SIGNAL
ERRATICORMISSING
45.1 SPN 600/FMI 13 ....................................................................................... 45-3
45.2 SPN 600/FMI 19 ....................................................................................... 45-3
46 SPN 602 (CPC) - CRUISE CONTROL ACCELERATE SWITCH SIGNAL
ERRATICORMISSING
46.1 SPN 602/FMI 13 ....................................................................................... 46-3
46.2 SPN 602/FMI 19 ....................................................................................... 46-3
47 SPN 609 - MCM FAULT (ERRONEOUS DATA)
47.1 SPN 609/FMI 12 ....................................................................................... 47-3
47.2 SPN 609/FMI 14 ....................................................................................... 47-4
48 SPN 615 - INTAKE AIR DELTA PRESSURE OUTSIDE OF NORMAL
OPERATING RANGE
48.1 SPN 615/FMI 3 ......................................................................................... 48-3
48.2 SPN 615/FMI 4 ......................................................................................... 48-5
49 SPN 615 (CPC) - J1939 DM1 MESSAGE FROM TRANSMISSION
MISSING
49.1 SPN 615/FMI 9 ......................................................................................... 49-3
50 SPN 625 - CAN FAULT
50.1 SPN 625/FMI 2 ......................................................................................... 50-3
50.2 SPN 625/FMI 4 ......................................................................................... 50-5
51 SPN 628 (CPC) - MULTIPLE FAULTS
51.1 SPN 628/FMI 13 (ALL FAULT DESCRIPTIONS) ..................................... 51-3
51.2 SPN 628/FMI 14 ....................................................................................... 51-3
52 SPN 629 (CPC) - MULTIPLE FAULTS
52.1 SPN 629/FMI 2 ......................................................................................... 52-3
52.2 SPN 629/FMI 12 ....................................................................................... 52-4
53 SPN 630 (CPC) - MULTIPLE FAULTS
53.1 SPN 630/FMI 14 ....................................................................................... 53-3
54 SPN 636 — CRANKSHAFT POSITION SENSOR OUTSIDE OF
NORMAL OPERATING CONDITIONS
54.1 SPN 636/FMI 1 ......................................................................................... 54-3
54.2 SPN 636/FMI 3 ......................................................................................... 54-5
54.3 SPN 636/FMI 4 ......................................................................................... 54-7
54.4 SPN 636/FMI 7 ......................................................................................... 54-9
54.5 SPN 636/FMI 8 ......................................................................................... 54-10
55 SPN651–INJECTOR#1NOTOPERATINGNORMALLY
55.1 SPN 651/FMI 5 ......................................................................................... 55-3
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55.2 SPN 651/FMI 10 ....................................................................................... 55-5
56 SPN 652 – INJECTOR #2 NOT OPERATING NORMALLY
56.1 SPN 652/FMI 5 ......................................................................................... 56-3
56.2 SPN 652/FMI 10 ....................................................................................... 56-5
57 SPN 653 – INJECTOR #3 NOT OPERATING NORMALLY
57.1 TROUBLESHOOTING SPN 653/FMI 5 ................................................... 57-3
57.2 TROUBLESHOOTING SPN 653/FMI 10 ................................................. 57-5
58 SPN 654 – INJECTOR #4 NOT OPERATING NORMALLY
58.1 TROUBLESHOOTING SPN 654/FMI 5 ................................................... 58-3
58.2 TROUBLESHOOTING SPN 654/FMI 10 ................................................. 58-5
59 SPN 655 – INJECTOR #5 NOT OPERATING NORMALLY
59.1 SPN 655/FMI 5 ......................................................................................... 59-3
59.2 SPN 655/FMI 10 ....................................................................................... 59-5
60 SPN 656 – INJECTOR #6 NOT OPERATING NORMALLY
60.1 SPN 656/FMI 5 ......................................................................................... 60-3
60.2 SPN 656/FMI 10 ....................................................................................... 60-5
61 SPN 701 - CONSTANT THROTTLE VALVE (AUX PWM #7) NOT
OPERATING NORMALLY
61.1 SPN 701/FMI 3 ......................................................................................... 61-3
61.2 SPN 701/FMI 4 ......................................................................................... 61-4
61.3 SPN 701/FMI 5 ......................................................................................... 61-6
62 SPN 703 (CPC) - ASG2 BACKUP LAMP
62.1 SPN 703/FMI 3 ......................................................................................... 62-3
62.2 SPN 703/FMI 4 ......................................................................................... 62-3
63 SPN 704 (CPC) - HIGH EXHAUST SYSTEM TEMPERATURE LAMP
63.1 SPN 704/FMI 3 ......................................................................................... 63-3
63.2 SPN 704/FMI 4 ......................................................................................... 63-3
64 SPN 705 (CPC) - MALFUNCTION INDICATOR LAMP
64.1 SPN 705/FMI 3 ......................................................................................... 64-3
64.2 SPN 705/FMI 4 ......................................................................................... 64-3
65 SPN 706 (CPC) - ASG2 CHECK TRANS TEMP LAMP
65.1 SPN 706/FMI 3 ......................................................................................... 65-3
65.2 SPN 706/FMI 4 ......................................................................................... 65-3
66 SPN 706 - ELECTRONIC PROPORTIONING VALVE CONTROL #2
NOT OPERATING NORMALLY
66.1 SPN 706/FMI 3 ......................................................................................... 66-3
66.2 SPN 706/FMI 4 ......................................................................................... 66-5
66.3 SPN 706/FMI 5 ......................................................................................... 66-7
67 SPN 707 (CPC) - AMBER WARNING LAMP
67.1 SPN 707/FMI 3 ......................................................................................... 67-3
67.2 SPN 707/FMI 4 ......................................................................................... 67-3
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68 SPN 708 (CPC) - ASG2 CHECK TRANS LAMP
68.1 SPN 708/FMI 3 ......................................................................................... 68-3
68.2 SPN 708/FMI 4 ......................................................................................... 68-3
69 SPN 709 - SINGLE-SPEED FAN (LOW-SIDE DIGITAL OUTPUT #3)
FAULT
69.1 SPN 709/FMI 3 ......................................................................................... 69-3
69.2 SPN 709/FMI 4 ......................................................................................... 69-5
69.3 SPN 709/FMI 5 ......................................................................................... 69-6
70 SPN 710 - ELECTRONIC PROPORTIONING VALVE 1 (ENTRY
SHUTOFF FLAP) NOT OPERATING NORMALLY
70.1 SPN 710/FMI 3 ......................................................................................... 70-3
70.2 SPN 710/FMI 4 ......................................................................................... 70-4
70.3 SPN 710/FMI 5 ......................................................................................... 70-6
71 SPN 711 (CPC) - DPF REGEN LAMP
71.1 SPN 711/FMI 3 ......................................................................................... 71-3
71.2 SPN 711/FMI 4 ......................................................................................... 71-3
72 SPN 713 (CPC) - TOP2 LOCKOUT SOLENOID
72.1 SPN 713/FMI 3 ......................................................................................... 72-3
72.2 SPN 713/FMI 4 ......................................................................................... 72-3
72.3 SPN 713/FMI 5 ......................................................................................... 72-3
72.4 SPN 713/FMI 7 ......................................................................................... 72-3
73 SPN 714 (CPC) - TOP2 SHIFT SOLENOID
73.1 SPN 714/FMI 3 ......................................................................................... 73-3
73.2 SPN 714/FMI 4 ......................................................................................... 73-3
73.3 SPN 714/FMI 5 ......................................................................................... 73-3
74 SPN 715 (CPC) - VEHICLE POWER SHUTDOWN
74.1 SPN 715/FMI 3 ......................................................................................... 74-3
74.2 SPN 715/FMI 4 ......................................................................................... 74-3
74.3 SPN 715/FMI 5 ......................................................................................... 74-3
75 SPN729-GRIDHEAT
ER NOT OPERATING NORMALLY
75.1 SPN 729/FMI 3 ......................................................................................... 75-3
75.2 SPN 729/FMI 4 ......................................................................................... 75-5
76 SPN 723 — CAMSHAFT POSITION SENSOR FAULT
76.1 SPN 723/FMI 3 ......................................................................................... 76-3
76.2 SPN 723/FMI 4 ......................................................................................... 76-5
76.3 SPN 723/FMI 8 ......................................................................................... 76-6
76.4 SPN 723/FMI 14 ....................................................................................... 76-7
77 SPN 904 (CPC) - J1939 EBC2 MESSAGE MISSING AND FRONT
AXLE SPEED SIGNAL ERRATIC OR MISSING
77.1 SPN 904/FMI 9 ......................................................................................... 77-3
77.2 SPN 904/FMI 13 ....................................................................................... 77-3
77.3 SPN 904/FMI 19 ....................................................................................... 77-4
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78 SPN 973 (CPC) - J1939 EBC1 MESSAGE MISSING AND ENGINE
RETARDER SELECTION SIGNAL IS ERRATIC OR MISSING
78.1 SPN 973/FMI 9 ......................................................................................... 78-3
78.2 SPN 973/FMI 13 ....................................................................................... 78-3
78.3 SPN 973/FMI 19 ....................................................................................... 78-4
79 SPN 975 - TWO-SPEED FAN (AUX PWM #6) FAULT
79.1 SPN 975/FMI 3 ......................................................................................... 79-3
79.2 SPN 975/FMI 4 ......................................................................................... 79-5
79.3 SPN 975/FMI 5 ......................................................................................... 79-6
80 SPN 986 (CPC) - J1939 CM1 MESSAGE IS MISSING
80.1 SPN 986/FMI 9 ......................................................................................... 80-3
81 SPN 1172 -TURBO COMPRESSOR IN TEMP HIGH OR LOW
81.1 SPN 1172/FMI 3 ....................................................................................... 81-3
81.2 SPN 1172/FMI 4 ....................................................................................... 81-5
82 SPN 1176 - TURBO COMPRESSOR INLET PRESSURE OUTSIDE
NORMAL RANGE
82.1 SPN 1176/FMI 3 ....................................................................................... 82-3
82.2 SPN 1176/FMI 4 ....................................................................................... 82-5
83 SPN 1188 - WASTEGATE VALVE CONTROL (AUX PWM #10)
83.1 SPN 1188/FMI 3 ....................................................................................... 83-3
83.2 SPN 1188/FMI 4 ....................................................................................... 83-4
83.3 SPN 1188/FMI 5 ....................................................................................... 83-5
84 SPN 1590 (CPC) - J1939 ACC1 MESSAGE FROM ADAPTIVE CRUISE
CONTROL IS MISSING
84.1 SPN 1590/FMI 9 ....................................................................................... 84-3
85 SPN 1624 (CPC) - J1939 TCO1 MESSAGE IS MISSING AND
TACHOGRAPHVEHICLESPEEDSIGNALISERRATICANDMISSING
85.1 SPN 1624/FMI 9 ....................................................................................... 85-3
85.2 SPN 1624/FMI 13 ..................................................................................... 85-3
85.3 SPN 1624/FMI 19 ..................................................................................... 85-4
86 SPN 1636 – INTAKE MANIFOLD TEMPERATURE OUTSIDE OF
NORMAL OPERATING RANGE
86.1 SPN 1636 /FMI 2 ...................................................................................... 86-3
86.2 SPN 1636/FMI 3 ....................................................................................... 86-4
86.3 SPN 1636/FMI 4 ....................................................................................... 86-6
86.4 SPN 1636/FMI 14 ..................................................................................... 86-7
87 SPN 1716 (CPC) - J1939 ERC1 MESSAGE IS MISSING
87.1 SPN 1716/FMI 9 ....................................................................................... 87-3
88 SPN 1845 (CPC) - J1939 TCFG2 MESSAGE IS MISSING
88.1 SPN 1845/FMI 9 ....................................................................................... 88-3
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89 SPN 2623 (CPC) - PWM ACCELERATOR PEDAL GAS1 AND GAS2
SIGNAL MISSING
89.1 SPN 2623/FMI 4 ....................................................................................... 89-3
89.2 SPN 2623/FMI 14 ..................................................................................... 89-3
90 SPN2791–EGRVALVE(AUXPWM#1)FAILEDOROPENCIRCUIT
90.1 SPN 2791/FMI 3 ....................................................................................... 90-3
90.2 SPN 2791/FMI 4 ....................................................................................... 90-5
90.3 SPN 2791/FMI 5 ....................................................................................... 90-6
91 SPN 2795 - CAN COMMUNICATION ERROR
91.1 SPN 2795/FMI 9 ....................................................................................... 91-3
92 SPN 2900 (CPC) - J1939 ETC7 MESSAGE IS MISSING
92.1 SPN 2900/FMI 9 ....................................................................................... 92-3
93 SPN 3242 - DOC INLET TEMPERATURE SENSOR ABOVE OR
BELOW NORMAL OPERATING RANGE
93.1 SPN 3242/FMI 2, 3, 4 OR 10 ................................................................... 93-3
94 SPN 3246 - DPF OUTLET TEMPERATURE SENSOR OPERATING
ABOVE OR BELOW NORMAL
94.1 SPN 3246/FMI 0, 2, 3, 4, 10, 14, 31 ......................................................... 94-3
95 SPN 3250 - DPF INLET TEMPERATURE SENSOR ABOVE OR BELOW
NORMAL OPERATING RANGE
95.1 SPN3250/FMI0,2,3,4,10,14,3
1 ......................................................... 95-3
96 SPN 3251 - DPF OUTLET PRESSURE ABOVE OR BELOW NORMAL
OPERATING RANGE
96.1 SPN 3251/FMI 0, 1 OR 16 ....................................................................... 96-3
97 SPN 3471 - ELECTRONIC DOSING VALVE SENSOR ABOVE OR
BELOW NORMAL OPERATINGRANGE
97.1 SPN 3471/FMI 1, 3, 4 OR 5 ..................................................................... 97-3
98 SPN 3480 - FUEL LINE PRESSURE SENSOR ABOVE OR BELOW
NORMAL OPERATING RANGE
98.1 SPN 3480/FMI 1, 2 OR 14 ....................................................................... 98-3
99 SPN 3482 - FUEL CUTOFF VALVE SENSOR ABOVE OR BELOW
NORMAL OPERATING RANGE
99.1 SPN 3482/FMI 3, 4, 5 OR 7 ..................................................................... 99-3
100 SPN 3509 - MULTIPLEXER 1 CHANNEL 1 OR 2 SHORT OR OPEN
CIRCUIT HIGH
100.1 SPN 3509/FMI 3 ....................................................................................... 100-3
101 SPN 3510 - MULTIPLEXER 2 CHANNEL 1 OR 2 SHORT OR OPEN
CIRCUIT HIGH
101.1 SPN 3510/FMI 3 ....................................................................................... 101-3
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102 SPN 3510 — ACCELERATOR PEDAL SUPPLY OUTSIDE OF
NORMAL OPERATING RANGE
102.1 SPN 3510/FMI 2 ....................................................................................... 102-3
102.2 SPN 3510/FMI 3 ....................................................................................... 102-5
102.3 SPN 3510/FMI 4 ....................................................................................... 102-6
103 SPN 3511 - MULTIPLEXER 3 CHANNEL 1 0R 2 SHORT OR OPEN
CIRCUIT HIGH
103.1 SPN 3511/FMI 3 ....................................................................................... 103-3
104 SPN 3556 - ELECTRONIC DOSING VALVE ABOVE OR BELOW
NORMAL OPERATING RANGE
104.1 SPN 3556/FMI 0 OR 1 ............................................................................. 104-3
105 SPN 3563 – INTAKE MANIFOLD PRESSURE OUTSIDE NORMAL
RANGE
105.1 SPN 3563/FMI 0/1/2 ................................................................................. 105-3
105.2 SPN 3563/FMI 3 ....................................................................................... 105-6
105.3 SPN 3563/FMI 4 ....................................................................................... 105-8
106 SPN 3603 (CPC) - J1939 ESS MESSAGE IS MISSING
106.1 SPN 3603/FMI 9 ....................................................................................... 106-3
107 SPN 3609 - DPF INLET PRESSURE SENSOR ABOVE OR BELOW
NORMAL OPERATING RANGE
107.1 SPN 3609FMI 2, 3, 4, 10, 20 OR 21 ........................................................ 107-3
108 SPN 3610 - DPF OUTLET PRESSURE SENSOR ABOVE OR BELOW
NORMAL OPERATING RANGE
108.1 SPN 3610/FMI 2, 3, 4, 14, 20 OR 21 ....................................................... 108-3
109 SPN 3659 — ELECTRONIC UNIT PUMP #1 NOT OPERATING
NORMALLY
109.1 SPN 3659/FMI 5 ....................................................................................... 109-3
109.2 SPN 3659/FMI 10 ..................................................................................... 109-5
110 SPN 3660 - ELECTRONIC UNIT PUMP #2 NOT OPERATING
NORMALLY
110.1 SPN 3660/FMI 5 ....................................................................................... 110-3
110.2 SPN 3660/FMI 10 ..................................................................................... 110-5
111 SPN 3661 - ELECTRONIC UNIT PUMP #3 NOT OPERATING
NORMALLY
111.1 SPN 3661/FMI 5 ....................................................................................... 111-3
111.2 SPN 3661/FMI 10 ..................................................................................... 111-5
112 SPN 3662 - ELECTRONIC UNIT PUMP #4 NOT OPERATING
NORMALLY
112.1 SPN 3662/FMI 5 ....................................................................................... 112-3
112.2 SPN 3662/FMI 10 ..................................................................................... 112-5
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113 SPN 3663 - ELECTRONIC UNIT PUMP #5 NOT OPERATING
NORMALLY
113.1 SPN 3663/FMI 5 ....................................................................................... 113-3
113.2 SPN 3663/FMI 10 ..................................................................................... 113-5
114 SPN 3664 - ELECTRONIC UNIT PUMP #6 NOT OPERATING
NORMALLY
114.1 SPN 3664/FMI 5 ....................................................................................... 114-3
114.2 SPN 3664/FMI 10 ..................................................................................... 114-5
115 SPN 3695 (CPC) - DPF REGEN MUX SWITCH MESSAGES NOT
OPERATING NORMALLY
115.1 SPN 3695/FMI 9 ....................................................................................... 115-3
115.2 SPN 3695/FMI 13 ..................................................................................... 115-4
115.3 SPN 3695/FMI 14 ..................................................................................... 115-4
115.4 SPN 3695/FMI 19 ..................................................................................... 115-5
116 SPN 3719 - SOOT LEVEL ABOVE NORMAL
116.1 SPN 3719/FMI 0, 15,16,OR 31 ................................................................ 116-3
117 SPN 3720 - ASH LEVEL ABOVE NORMAL
117.1 SPN 3720/FMI 15 OR 16 ......................................................................... 117-3
118 SPN 4077 FUEL LINE PRESSURE SENSOR CIRCUIT FAULT
118.1 SPN 4077/FMI 3, 4 OR 14 ....................................................................... 118-3
119 SPN 4227 - ELECTROSTATIC OIL SEPARATOR OUTSIDE OF
NORMAL OPERATING RANGE
119.1 SPN 4227/FMI 3 ....................................................................................... 119-3
119.2 SPN 4227/FMI 4 ....................................................................................... 119-4
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1INTRODUCTION
Section Page
1.1 OVERVIEW .............................................................................................. 1-3
1.2 SCOPE AND USE OF THIS GUIDE ........................................................ 1-4
1.3 SAFETY PRECAUTIONS ........................................................................ 1-6

(Rev. ) All information subject to change without notice.
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