Series 60 DDEC V Troubleshooting – Section 28.2 Troubleshooting Flash Code 22, PID 91/FMI 4

Section 28.2
Troubleshooting Flash Code 22, PID 91/FMI 4

This diagnostic condition is typically:‪

• Open sensor signal circuit
• Open sensor +5 volt supply circuit
• Sensor signal is shorted to sensor return circuit or to ground

Refer to "28.2.1 General Throttle Information (Automotive Limiting Speed Governor)" for general throttle information, refer to "28.2.2 Multiple Code Check" to begin troubleshooting Flash Code 22. ‪

Section 28.2.1
General Throttle Information (Automotive Limiting Speed Governor)

The correct TPS/AP Sensor counts for DDEC engines at idle should be 64 - 205 counts.‪

• Typical DDEC V foot pedals today, at idle, provide 90–175 counts.
• The DDEC system will log a TPS/AP Sensor low volt code (PID 91, FMI 4, Flash Code 22) if the TPS/AP Sensor counts go below 48.
• The DDEC system will log a TPS/AP Sensor high volt code (PID 91, FMI 3, Flash Code 21) if the TPS/AP Sensor counts go above 968 counts.
• In order to go from 0% to 100% throttle, the counts have to increase 546 above the idle count, or 100 counts, whichever is greater.
• If an idle validation switch (IVS) is configured, to go from 0% to 100% throttle, the counts have to increase 546 above the counts at which the IVS opens or 100 counts, whichever is greater.
• If 0% throttle is attained with the foot off the pedal, and if 100% throttle is attained with the pedal to the floor, then the pedal should not be considered a factor for low power complaints.

Section 28.2.2
Multiple Code Check

Perform the following steps to check for multiple codes.‪

1. Turn ignition ON.
2. Plug in diagnostic tool.
3. Read active codes.
   1. If active code p 91/4 and no other active codes are logged, refer to "28.2.3 Check for Device" .
   2. If code p 91/4 and any or all of the following codes are logged, p 91/3, p 187/4, or p 100/4, refer to "80.1 Troubleshooting the Vehicle Interface Harness +5 Volt Supply" .
   3. If codes other than the above are logged, refer to "18.3 First Step for Diagnosing a Fault Within the DDEC System" .

Section 28.2.3
Check for Device

Perform the following steps to check for device.‪

1. If there is a throttle (Automotive Limiting Speed Governor [ALSG]) wired to use the V-13 (ALSG) circuit, refer to "28.2.4 Sensor Check" .
2. If there is no throttle (ALSG) wired to use the V-13 (ALSG) circuit, contact Detroit Diesel Customer Support Center (313-592-5800), for possible change to the calibration.
   1. If required, reprogram the ECM/ECU after the mainframe is changed and refer to "28.2.13.1 Verify Repairs" .

Section 28.2.4
Sensor Check

Perform the following steps to check the sensor:‪

1. Turn ignition OFF.
2. Disconnect the TPS/AP Sensor connector.
3. Install a jumper wire between sockets A and V-13, C and V-11. See Figure "Throttle Position Sensor" .
4. Turn ignition ON.
5. Read active codes.
   1. If code p 91/4 and any other codes are logged, refer to "28.2.7 Check for +5 Volts" .
   2. If code p 91/3 and any other codes are logged, refer to "28.2.5 Check Throttle Position Sensor Adjustment" .
   

   Figure 1. Throttle Position Sensor

Section 28.2.5
Check Throttle Position Sensor Adjustment

Perform the following steps to check the TPS/AP Sensor adjustment:‪

1. Remove jumper and reconnect TPS/AP Sensor.
2. Hook up diagnostic tool and select TPS/AP Sensor - Counts.
3. Read Throttle Counts at both no throttle and full throttle positions. Take several readings.
   1. If at any time counts go lower than 49 counts, refer to "28.2.6 Attempt Throttle Position Sensor Adjustment" .
   2. If counts never go lower than 49 counts, go to step 4 .
4. Check terminals at the TPS/AP Sensor connector (both sensor and harness side) for bent, corroded, and unseated pins or sockets.
   1. If the terminals or the connectors are damaged, repair them. Refer to "28.2.13.1 Verify Repairs" .
   2. If the terminals and connectors are not damaged, replace the TPS/AP Sensor and refer to "28.2.13.1 Verify Repairs" .

Section 28.2.6
Attempt Throttle Position Sensor Adjustment

Perform the following steps to attempt a TPS/AP Sensor adjustment:‪

1. Check for pedal or linkage interferences.
2. Loosen the TPS/AP Sensor screws and attempt to adjust for the correct throttle reading (normal range - 64-205 counts). Do not attempt to adjust by bending the pedal mechanism.
3. Recheck counts at idle and at full throttle.
   1. If the throttle count has been corrected, refer to "28.2.13.1 Verify Repairs" .
   2. If the problem could not be corrected, go to step 4 .
4. Check terminals at the TPS/AP Sensor connector (both sensor and harness side) for bent, corroded, and unseated pins or sockets.
   1. If the terminals or the connectors are damaged, repair them. Refer to "28.2.13.1 Verify Repairs" .
   2. If the terminals and connectors are not damaged, replace the TPS/AP Sensor and refer to "28.2.13.1 Verify Repairs" .

Section 28.2.7
Check for +5 Volts

Perform the following steps to check for +5 volts:‪

1. Remove jumper wire.
2. Turn ignition ON.
3. Measure voltage on TPS/AP Sensor harness connector, socket C and V-11 (red lead) to socket B and V-60.
   1. If measured voltage is greater than 6 volts, refer to "28.2.12 Check for Short to Battery +" .
   2. If measured voltage is less than 4 volts, refer to "28.2.10 Check for Short" .
   3. If measured voltage is between 4 and 6 volts, refer to "28.2.8 Check for Short" .

Section 28.2.8
Check for Short

Perform the following steps to check for a short:‪

1. Turn ignition OFF.
2. Disconnect the vehicle harness connector at the ECM/ECU.
3. Measure resistance between sockets B and V-60, A and V-13 at the TPS/AP Sensor harness connector. See Figure "Throttle Position Sensor" .
4. Measure resistance between socket A and V-13 and a good ground (battery ground and chassis ground).
   1. If resistance measurement is less than or equal to 100 Ω, the signal line V-13 is shorted to the return line V-60 or battery ground. Repair short. Refer to "28.2.13.1 Verify Repairs" .
   2. If resistance measurement on both readings is greater than 100 Ω or open, refer to "28.2.9 Check for Signal Open" .
   

   Figure 2. Throttle Position Sensor

Section 28.2.9
Check for Signal Open

Perform the following steps to check for signal open:‪

1. Install a jumper wire between sockets A and V-13, B and V-60 of the TPS/AP Sensor harness connector.
2. Measure resistance between sockets V-13 and V-60 on the vehicle connector.
   1. If the resistance is less than or equal to 5 Ω, go to step 3 .
   2. If the resistance is greater than 5 Ω or open, the signal line V-13 or return line V-60 are open, repair the open. Refer to "28.2.13.1 Verify Repairs" .
3. Check terminals at the ECM/ECU harness connector (both ECM/ECU and harness side) for bent, corroded, and unseated pins or sockets. See Figure "ECM/ECU Vehicle Harness Connector" .
   

   Figure 3. ECM/ECU Vehicle Harness Connector

   1. If terminals and connectors are damaged, repair them. Refer to "28.2.13.1 Verify Repairs" .
   2. If terminals and connectors are not damaged, call Detroit Diesel Customer Support Center (313–592–5800) for assistance.

Section 28.2.10
Check for Short

Perform the following steps to check for a short.‪

1. Turn ignition OFF and disconnect the vehicle harness connector at the ECM/ECU.
2. Measure resistance between sockets B and V-60, C and V-11 on the TPS/AP Sensor harness connector. See Figure "ECM/ECU Vehicle Harness Connector" .
   1. If resistance between sockets A and C is greater than 1,000 Ω or open, refer to "28.2.11 Check for Open +5 Volt Line" .
   2. If resistance between sockets A and C is less than or equal to 1,000 Ω, the 5V wire (V-11) is shorted to the return (V-60). Repair the short and refer to "28.2.13.1 Verify Repairs" .

Section 28.2.11
Check for Open +5 Volt Line

Perform the following steps to check for an open +5 volt line:‪

1. Install a jumper wire between sockets B and V-60 and C and V-11 on the TPS/AP Sensor harness connector.
2. Measure resistance between sockets V-11 and V-60 on the vehicle harness connector. See Figure "Throttle Position Sensor" .
   1. If resistance between sockets V-11 and V-60 is less than or equal to 5 Ω, go to step 3 .
   2. If resistance between sockets V-11 and V-60 is greater than or equal to 5 Ω or open, the vehicle +5 volt line (V-11) is open. Repair the open. Refer to "28.2.13.1 Verify Repairs" .
   

   Figure 4. Throttle Position Sensor

3. Check terminals at the ECM/ECU harness connector (both ECM/ECU and harness side) for bent, corroded, and unseated pins or sockets. See Figure "ECM/ECU Vehicle Harness Connector" .
   1. If terminals and connectors are damaged, repair them. Refer to "28.2.13.1 Verify Repairs" .
   2. If terminals and connectors are not damaged, call Detroit Diesel Customer Support Center (313–592–5800) for assistance.

Section 28.2.12
Check for Short to Battery +

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

1. Turn ignition OFF.
2. Remove both fuses to ECM/ECU.
3. Disconnect the vehicle connector at the ECM/ECU.
4. Measure resistance between socket V-13 on the vehicle harness connector and socket V-61 and V-65. See Figure "ECM/ECU Vehicle Harness Connector" .
   1. If measured resistance is greater than 100 Ω or open, refer to "28.2.13 Check for Outside DDEC Battery +" .
   2. If measured resistance is less than or equal to 100 Ω, a short exists between sockets where resistance was measured. Repair short and reinsert fuses; refer to "28.2.13.1 Verify Repairs" .
   

   Figure 5. ECM/ECU Vehicle Harness Connector

Section 28.2.13
Check for Outside DDEC Battery +

Perform the following steps to check for outside DDEC battery +:‪

1. Turn ignition OFF.
2. Remove ECM/ECU vehicle harness connector.
3. Turn ignition ON.
4. Measure voltage V-11 (red lead) to battery ground.
5. Measure voltage V-60 (red lead) to battery ground.
   1. If measured voltage is less than 0.2 volts, go to step 6 .
   2. If measured voltage is greater than 0.2 volts, outside power is spliced/shorted into either line V-60 or line V-11. Remove the splice/short. Refer to "28.2.13.1 Verify Repairs" .
6. Check terminals at the ECM/ECU harness connector (both ECM/ECU and harness side) for bent, corroded, and unseated pins or sockets. See Figure "ECM/ECU Vehicle Harness Connector" .
   1. If terminals and connectors are damaged, repair them. Refer to "28.2.13.1 Verify Repairs" .
   2. If terminals and connectors are not damaged, call Detroit Diesel Customer Support Center (313–592–5800) for assistance.

Section 28.2.13.1
Verify Repairs

Perform the following steps to verify repairs:‪

1. Turn ignition OFF.
2. Reconnect all connectors.
3. Turn ignition ON.
4. Clear codes with diagnostic tool.
5. Start and run the engine for one minute at all throttle positions.
6. Stop engine.
7. Read active codes.
   1. If no codes are logged, troubleshooting is complete.
   2. If code 91/4 and any other codes are logged, all system diagnostics are complete. Review this section from the first step to find the error. Refer to "28.2.2 Multiple Code Check" .
   3. If code 91/4 is not logged, but other codes are logged, refer to "18.3 First Step for Diagnosing a Fault Within the DDEC System" .