DDEC III/IV Single ECM Troubleshooting

Section 63.3 Troubleshooting Flash Code 63

Section 63.3
Troubleshooting Flash Code 63

For all EGR related codes, always perform the basic checks in EGR-1. Refer to "10.16 Exhaust Gas Recirculation System (EGR-1) – Fault, Series 50 Engine" . For EGR troubleshooting, Refer to "63.3.10 Check for Short in EGR System" . ‪

Section 63.3.1
Determine Assignment

Perform the following steps to determine assignment.‪

  1. Turn ignition ON. Plug in the DDR.
  2. Select INs/OUTs. To what is PWM assigned? Write down assignment vs cavity and code, listed in Table "PWM Assignments" .

    Code

    PWM

    Wire Location

    Wire #

    s 057‪

    PWM #1‪

    J3‪

    #908‪

    s 058‪

    PWM #2‪

    Y1‪

    #909‪

    s 059‪

    PWM #3‪

    W2‪

    #910‪

    s 060‪

    PWM #4‪

    X2‪

    #911‪

    Table 1. PWM Assignments
  3. Select code display. Determine Failure Mode Identifier (FMI).
    1. If FMI 3 displays, there is a short to the battery. Refer to "63.3.2 Verify Short to Battery" .
    2. If FMI 4 displays, refer to step 4 .
  4. Verify function.
    1. If there is a component wired to this position, refer to "63.3.3 Check Component Connections" .
    2. If there is no component wired to this position, reprogram to eliminate the assigned function. (A change may be required to the DDC mainframe.) Refer to "63.3.9 Verify Repairs" .

Section 63.3.2
Verify Short to Battery

Perform the following steps to verify a short to battery:‪

  1. Turn ignition OFF. Disconnect 30-pin connector: engine connector if PWM 2, 3 or 4; vehicle connector if PWM 1.
  2. Measure voltage between the cavity with the code and the good ground.
    1. If the voltage measurement is greater than 3 volts, the connector is shorted to the battery. Repair. Refer to "63.3.9 Verify Repairs" .
    2. If the voltage measurement is less than 3 volts, contact Detroit Diesel Technical Service.

Section 63.3.3
Check Component Connections

Perform the following steps to check component connections:‪

  1. Turn the vehicle ignition OFF.
  2. Inspect the connections of the PWM wire associated with the flash code logged at both harness connector and the item being driven.
    1. If the connectors are damaged or broken, repair or replace the damaged terminals. Verify repairs. Refer to "63.3.9 Verify Repairs" .
    2. If the connectors are not damaged or broken, ensure the item is connected to the pulse width modulation wire. If the item is not connected, repair or replace the connector. Verify repairs. Refer to "63.3.9 Verify Repairs" .
    3. If the item is connected, measure the resistance. Refer to "63.3.8 Measure Resistance Between Connector and the ECM Case" .
    4. If this is an Optimized Idle® vehicle, refer to "63.3.4 Check Installation of the Starter Harness Overlay Kit" .

Section 63.3.4
Check Installation of the Starter Harness Overlay Kit

Perform the following steps to check for proper installation of the starter harness overlay kit when a Code 63 is logged and the engine does not start; see Figure "Optimized Idle Schematic" .‪

  1. Turn off ignition (Optimized Idle Applications).
  2. Remove relay from relay block.
  3. Measure voltage between terminal 85 on the relay block and a good ground.
    1. If voltage measurement is less than 4 VDC, the power lead to the relay is open. Verify connection of wire #439 from the starter relay harness overlay to DDEC wire #439 in the cab.
    2. If voltage measurement is more than 4 VDC, measure voltage between terminal 86 on the relay block and a good ground. If voltage is less than 4 VDC, the resistor built into the harness is defective. Replace the harness and verify repairs. Refer to "63.3.5 Verify Installation of Starter Relay Harness Overlay Service Kit" .
    3. If voltage measurement is more than 4 VDC, measure voltage between terminal 86 on the relay block and a good ground. If voltage is more than 4 VDC, the circuit between terminal 86 on the new relay and power side of Optimized Idle starter relay is open. Repair the open circuit and verify repairs. Refer to "63.3.9 Verify Repairs" .
    4. Click to see this graphic in a separate window

      Figure 1. Optimized Idle Schematic

Section 63.3.5
Verify Installation of Starter Relay Harness Overlay Service Kit

Use the following procedure to verify installation of the starter relay harness overlay service kit on Optimized Idle equipped vehicles only.‪

  1. Turn ignition to ON position. Start engine.
  2. Toggle cruise ON/OFF switch from OFF to ON. The Optimized Idle light should flash.
  3. After the engine shuts down, turn the thermostat on by pressing any button.
  4. Press UP or DOWN arrow until the heat or cool symbol begins to flash.
    1. If the engine starts, the repairs are complete. Refer to "63.3.9 Verify Repairs" .
    2. If the engine does not start, refer to "63.3.6 Engine Does Not Start in Optimized Idle Mode" .

Section 63.3.6
Engine Does Not Start in Optimized Idle Mode

Perform the following steps to start the engine.‪

  1. Verify the hood is closed; the transmission is in neutral; the parking brake is set; and the vehicle wheels are blocked.
    caution

    UNEXPECTED ENGINE START

    To avoid injury from an unexpected startup of an engine equipped with the Optimized Idle system, remove the starter relay from the relay holder.‪

  2. Remove the overlay relay from the relay block.
  3. Measure voltage between terminal 85 and terminal 86 of the relay block.
    1. If voltage measurement is less than 4 VDC, the white wire in the overlay harness is open. Repair the open circuit between the overlay harness and the hood/cab switch. Refer to "63.3.5 Verify Installation of Starter Relay Harness Overlay Service Kit" .
    2. If voltage measurement is more than 4 VDC, the relay is inoperative. Replace the relay. Refer to section 8.6.5 of the proper engine Service Manual. Verify the repairs. Refer to "63.3.9 Verify Repairs" .
    3. If this is a Series 55 engine, refer to "63.3.7 Verify Harness" .

Section 63.3.7
Verify Harness

Perform the following steps to verify harness.‪

  1. If this is a Series 55 engine, verify the engine harness is correct, especially PWM 3 and 4.
    1. If the harness is not correct, replace it. Refer to "63.3.9 Verify Repairs" .
    2. If the harness is correct, refer to "63.3.8 Measure Resistance Between Connector and the ECM Case" .

Section 63.3.8
Measure Resistance Between Connector and the ECM Case

Perform the following steps to measure resistance between the connector and the ECM case:‪

  1. Turn the vehicle ignition to the OFF position.
  2. Ensure connector is installed on the engine harness side or vehicle harness side.
  3. Disconnect the PWM wire associated with the code logged at the component.
  4. Measure the resistance between the removed connector and the ECM case.
    1. If the resistance measurement is between 46,000 and 48,000 Ω, verify the pin assignment with wiring - view with DDR. Refer to "63.3.9 Verify Repairs" .
    2. If the resistance measurement is not between 46,000 and 48,000 Ω, the wire is open or shorted to battery. Repair or replace the wire. Verify repairs. Refer to "63.3.9 Verify Repairs" .

Section 63.3.9
Verify Repairs

Perform the following steps to verify repairs for Flash Code 63. To check Optimized Idle, refer to Optimized Idle Manual 6SE518.‪

  1. Reconnect all connectors.
  2. Clear all codes from the DDR.
  3. Plug in the DDR.
  4. Turn vehicle ignition switch to the ON position.
    1. If Flash Code 63 was not logged, no further troubleshooting is required.
    2. If Flash Code 63 was logged, please review this section from the first step to find the error. Refer to "63.3.1 Determine Assignment" .

Section 63.3.10
Check for Short in EGR System

Perform the following steps to troubleshoot the PWM valve of the EGR system: ‪

  1. Unplug the PWM valve.
  2. Measure resistance between circuits #1 and #2 of the PWM valve. See Figure "EGR Wiring System " .
    Click to see this graphic in a separate window

    Figure 2. EGR Wiring System

    1. If the resistance measurement is less than or equal to 5 Ω, wire #911 is shorted to the ground. Repair the short and verify the repair.
    2. If the resistance measurement is greater than 5 Ω, refer to "63.3.11 Check for Short to Battery" .

Section 63.3.11
Check for Short to Battery

Perform the following steps to check for short to the battery: ‪

  1. Turn ignition ON.
  2. Measure voltage between cavity 2 and 1 (battery ground).
    1. If the voltage reading is 10V or less, replace the PWM valve.
    2. If the voltage reading is greater than 10V. wire #911 is shorted to the battery. Repair and verify.

Section 63.3.12
Check for Open

Perform the following steps to check for an open: ‪

  1. Unplug the PWM valve.
  2. Install a jumper between cavity #2 and #3 of the PWM valve.
  3. Unplug the engine sensor harness 30–pin connector.
  4. Measure resistance between S3 and X2.
    1. If the measured resistance is less than or equal to 5 Ω, Refer to "63.3.13 Check for Open Battery Ground" .
    2. If the measured resistance is greater than 5 Ω, wire #911 is open. Repair and verify.

Section 63.3.13
Check for Open Battery Ground

Perform the following steps to test the battery ground‪

  1. Turn ignition OFF.
  2. Measure resistance between cavity 1 and battery ground.
    1. If the measured resistance is less than or equal to 5 Ω, replace the PWM valve.
    2. If the measured resistance is greater than 5 Ω, the ground is open.

Section 63.3.14
Verify Repair

Perform the following steps to verify the repair. ‪

  1. Connect all connectors.
  2. Start and run the engine.
  3. Road test the engine.
    1. If code 63 was not logged, no further troubleshooting is required.
    2. If code 63 was logged, please review this section from the first step to find the error. Refer to "63.3.1 Determine Assignment" . If this is the second time through the procedure, call Detroit Diesel Technical Service, or try a test ECM.


DDEC III/IV Single ECM Troubleshooting Guide - 6SE497
Generated on 10-13-2008

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