Series 60 EGR – Section 10.3 Troubleshooting Tasks

Section 10.3
Troubleshooting Tasks

The following ordered tasks are recommendations to troubleshoot specific operational concerns.‪

Section 10.3.1
FLASH CODE 13 (SID 146/FMI 6) EGR VALVE CURRENT TOO HIGH

Troubleshooting steps are as follows.‪

1. Using DDDL, check for Flash Code 13 (SID 146/FMI 6).
   1. If Flash Code 13 (SID 146/FMI 6) was logged, perform "10.4.5 TEST E" .
   2. If Flash Code 13 (SID 111/FMI 4 or 6) was logged, refer to the proper code section of the DDEC V Single ECU Troubleshooting Guide , (6SE565) to troubleshoot that code.
2. Once troubleshooting is done, verify that troubleshooting step 1a or step 1b resolved the problem.
   1. If Flash Code 13 (SID 146/FMI 6) is still logged, contact the Detroit Diesel Customer Support Center at 313-592-5800.
   2. If Flash Code 13 (SID 146/FMI 6) is not logged, troubleshooting task is complete.

Section 10.3.2
Flash Code 16 (SID 146/FMI5) EGR VALVE CURRENT TOO LOW

Troubleshooting steps are as follows.‪

1. Using DDDL, check for Flash Code 16 (SID 146/FMI 5).
   1. If Flash Code 16 (SID 146/FMI 5) was logged, perform "10.4.5 TEST E" .
   2. If Flash Code 16 (SID 111/FMI 5) was logged, refer to the proper code section of the DDEC V Single ECU Troubleshooting Guide , (6SE565) to troubleshoot that code.
2. Once troubleshooting is done, verify that troubleshooting step 1a or step 1b resolved the problem.
   1. If Flash Code 16 (SID 146/FMI 5) is still logged, contact the Detroit Diesel Customer Support Center at 313-592-5800.
   2. If Flash Code 16 (SID 146/FMI 5) is not logged, troubleshooting task is complete.

Section 10.3.3
FLASH CODE 39

Troubleshooting steps are as follows.‪

1. Verify ECU program software version. Perform "10.4.5 TEST E" .
2. Inspect the VPOD air supply for leaks. Perform "10.4.7 TEST G" .
3. Perform "10.4.3 TEST C" .
4. Test drive the vehicle and perform a DDDL snapshot.
5. Perform "10.4.2 TEST B" .
6. Once service is done, verify that the problem has been resolved.
   1. If the problem has been resolved, no further testing is required.
   2. If the problem has not been resolved, contact the Detroit Diesel Customer Support Center at 313-592-5800.

Section 10.3.4
FLASH CODE 61

Troubleshooting steps are as follows.‪

1. Using DDDL, check for Flash Code 61.
   1. If Flash Code 61 was logged, perform step 2 .
   2. If Flash Code 61 was not logged, no further troubleshooting is required.
2. Verify that Modification Bulletin 05M-2, Series 60 EPA 04 Fuel System have been performed.
   1. If the procedures in Modification Bulletin 05M-2, Series 60 EPA 04 Fuel System have not been performed, do so now. To print a copy of 05M-2, please visit the Detroit Diesel Modification Letter Web Page at http://192.135.85.10/cust/mods/05mods/Index05.asp.
   2. If the procedures in Modification Bulletin 05M-2, Series 60 EPA 04 Fuel System have been performed, contact the Detroit Diesel Customer Support Center at 313-592-5800.
3. Once service is done, verify that the problem has been resolved.

Section 10.3.5
BLACK SMOKE

Troubleshooting steps are as follows.‪

1. Visually inspect the air filter element for excess dirt, blocked filter elements, and damage. Refer to the “Air Cleaner” section of the Series 60 Service Manual , (6SE483) for removal, inspection, and installation steps.
2. Visually inspect the air intake system for dirt and debris which is restricting proper fresh air flow. Refer to the “Cleaning of Intake Manifold“ section of the Series 60 Service Manual , (6SE483) for inspection steps.
3. Visuall inspect the exhaust system for dirt and debris which is restricting proper exhaust gas flow. Refer to OEM guidelines for inspection procedures.
4. Perform a turbocharger inspection. Refer to the “Inspection of Turbocharger” section of the Series 60 Service Manual , (6SE483) for inspection steps.
5. Perform the procedures in section "10.4.1 TEST A" .
6. Once service is done, verify that the problem has been resolved.

Section 10.3.6
BLACK FUEL

Troubleshooting steps are as follows.‪

1. Visually inspect the fuel tank for black fuel.
   1. If black fuel is present in the fuel tank, perform step 2 .
   2. If black fuel is not present in the fuel tank, no further troubleshooting is required.
2. Verify that Modification Bulletin 05M-2, Series 60 EPA 04 Fuel System have been performed.
   1. If the procedures in Modification Bulletin 05M-2, Series 60 EPA 04 Fuel System have not been performed, do so now. To print a copy of 05M-2, please visit the Detroit Diesel Modification Letter Web Page at http://192.135.85.10/cust/mods/05mods/Index05.asp.
   2. If the procedures in Modification Bulletin 05M-2, Series 60 EPA 04 Fuel System have been performed, contact the Detroit Diesel Customer Support Center at 313-592-5800.
3. Once service is done, verify that the problem has been resolved.

Section 10.3.7
ENGINE MISFIRE, ENGINE BACKFIRE, INTERMITTENT SMOKE ISSUES

Troubleshooting steps are as follows.‪

1. Start and run the engine to verify an engine misfire, engine backfire, and intermittent smoke issues are present.
   1. If the engine misfired, backfired, and had intermittent white, black or blue exhaust smoke from the tailpipe, perform step 2 .
   2. If the engine did not misfire, backfire, and had no intermittent white, black or blue exhaust smoke from the tailpipe, no further troubleshooting is required.
2. Verify that Modification Bulletin 05M-2, Series 60 EPA 04 Fuel System have been performed.
   1. If the procedures in Modification Bulletin 05M-2, Series 60 EPA 04 Fuel System have not been performed, do so now. To print a copy of 05M-2, please visit the Detroit Diesel Modification Letter Web Page at http://192.135.85.10/cust/mods/05mods/Index05.asp.
   2. If the procedures in Modification Bulletin 05M-2, Series 60 EPA 04 Fuel System have been performed, contact the Detroit Diesel Customer Support Center at 313-592-5800.
3. Once service is done, verify that the problem has been resolved.

Section 10.3.8
SLOBBERING FROM EXHAUST PIPE

Troubleshooting steps are as follows.‪

1. Using DDDL, perform a DDC Extraction of DDEC Reports. Review extraction data for excessive idle time.
   1. If the idle times were 35% and higher, which are considered to be excessive, reduce engine idle time. Proceed step 2 .
   2. If the idle times were less than 35%, proceed to step 2 .
2. Using DDDL, verify the engine coolant temperature.
   1. If the coolant temperature was below recommended operating parameters, refer to the “Coolant” section of the Series 60 Service Manual , (6SE483) coolant analysis program information.
   2. If the coolant temperature was at recommended operating parameters, proceed to step 3 .
3. Verify that none of the fuel injectors are leaking fuel. Refer to the “N3 Electronic Unit Injector” section of the Series 60 Service Manual , (6SE483) for removal, inspection, and replacement steps.
4. Verify valve lash clearances. Refer to section “Valve Clearance and Injector Timing” section of the Series 60 Service Manual , (6SE483) for inspection steps.
5. Check for worn cylinders.
   1. Perform a crankcase pressure test. Refer to the proper service section of the Series 60 Service Manual , (6SE483) for test procedures.
   2. Perform a compression test. Refer to the proper service section of the Series 60 Service Manual , (6SE483) for test procedures.
6. Verify that the VNT turbocharger is operating correctly. Refer to the “Turbocharger” section of the Series 60 Service Manual , (6SE483) for removal, inspection, and replacement steps.

Section 10.3.9
POOR ENGINE PERFORMANCE

Troubleshooting steps are as follows.‪

1. What version of software is the DDEC V ECU running?
   1. If the software version is lower than Level 2, reprogram the ECU. Perform "10.4.5 TEST E" . Once the ECU has been reprogrammed, proceed to step 2 .
   2. If the software is Level 2 or higher, proceed to step 2 .
2. Verify that the engine hardware has been campaigned or modified to the latest version.
   1. If you are uncertain or unable to determine if the engine has been campaigned or modified to the latest version, please contact the Detroit Diesel Customer Support Center at 313-592-5800.
   2. If you are able to determine that the engine has been campaigned or modified to the latest version, proceed to step 3 .
3. Verify that the fuel filters are not plugged. Refer to the “Preventive Maintenance” section of the Series 60 Service Manual , (6SE483) for inspection steps.
4. Visually inspect the air filter element for excess dirt, blocked filter elements, and damage. Refer to the “Air Cleaner” section of the Series 60 Service Manual , (6SE483) for removal, inspection, and installation steps.
5. Verify that the VPOD is connected to a dedicated air line.
   1. If the VPOD air line is not connected to a dedicated source, refer to OEM guidelines for a solution. Once the problem has been resolved, proceed to step 6 .
   2. If the VPOD air line is connected to a dedicated source, proceed to step 6 .
6. Perform "10.4.4 TEST D" to test the Barometric Pressure Sensor. Once the test has been completed, proceed to step 7 .
7. Perform "10.4.1 TEST A" to verify that the CAC system is not damaged.
   1. Once the test has been completed, verify that the reported poor engine performance problem has been resolved. If the problem has been resolved, the troubleshooting task has been completed.
   2. Once the test has been completed, verify that the reported poor engine performance problem has been resolved. If the problem has not been resolved, please contact the Detroit Diesel Customer Support Center at 313-592-5800.

Section 10.3.10
CAB ODORS

Troubleshooting steps are as follows.‪

1. Visually inspect the muffler, flex pipe to exhaust manifold, and exhaust system joints for excessive wear, holes, lose clamps, and for black soot indicating an exhaust gas leak.
   1. If any damage was found, refer to OEM guidelines for corrective service actions. Once these problems have been resolved, proceed to step 2 .
   2. If no damage was found, proceed to step 2 .
2. Inspect the exhaust manifold for damage and exhaust gas leaks. Refer to the “Exhaust Manifold” section of the Series 60 Service Manual , (6SE483) for inspection steps.
   1. If damage was found, resolve the problems and proceed to step 3 .
   2. If no damage was found, proceed to step 3 .
3. Verify repairs have resolved the cab odor problem.
   1. If cab odor problems have not been resolved, please contact the Detroit Diesel Customer Support Center at 313-592-5800.
   2. If the cab odor problems have been resolved, the troubleshooting task has been completed.

Section 10.3.11
LOSS OF ENGINE COOLANT

Troubleshooting steps are as follows.‪

1. Visually inspect the coolant for oil contamination.
   1. If the coolant has been contaminated, please contact the Detroit Diesel Customer Support Center at 313-592-5800 for instructions.
   2. If the coolant has not been contaminated, proceed to .
2. Visually inspect the coolant hose clamps to ensure that they are installed properly, securely fastened to the hose, and not damaged.
   1. If the coolant hose clamps are not installed or secured properly and are damaged. Refer to the proper service sections of the Series 60 Service Manual , (6SE483) for repair procedures. Once the problems have been resolved, proceed to step 3 .
   2. If the coolant hose clamps were installed and secured properly and were not damaged, proceed to step 3 .
3. Visually inspect the coolant hoses for excessive wear, cracks, and damage.
   1. If the coolant hoses are worn, broken, and damaged. Refer to the proper service sections of the Series 60 Service Manual , (6SE483) for repair procedures. Once the problems have been resolved, proceed to step 4 .
   2. If the coolant hoses are not worn, broken, and damaged, proceed to step 4 .
4. Visually inspect the cylinder head to cylinder block for coolant leaks.
   1. If cylinder head to cylinder block coolant leaks were detected. Refer to the proper service sections of the Series 60 Service Manual , (6SE483) for repair procedures. Once the problems have been resolved, proceed to step 5 .
   2. If cylinder head to cylinder block coolant leaks were not detected, proceed to step 5 .
5. Perform "10.4.6 TEST F" . Once the test has been perfromed, proceed to step 6 .
6. Verify that the troubleshooting task has resolved the problem.
   1. If the problem has not been resolved, please contact the Detroit Diesel Customer Support Center at 313-592-5800.
   2. If the problem has been resolved, the troubleshooting task is complete.