1-50G60GTS-01A.PDF - PIDS - Freightliner Trucks · PDF file · 2013-04-025.12 pid...

5 PIDS

Section Page

5.1 DIAGNOSTIC CODES ............................................................................. 5-5

5.2 PID 51, FMI 0, FLASH CODE 65, THROTTLE PLATE POSITION ABOVE

NORMAL RANGE .................................................................................... 5-6

5.3 PID 51, FMI 1, FLASH CODE 65, THROTTLE PLATE POSITION BELOW

NORMAL RANGE .................................................................................... 5-12

5.4 PID 51, FMI 2, FLASH CODE 65, THROTTLE PLATE POSITION

ERRATIC .................................................................................................. 5-18


SENSOR INPUT VOLTAGE HIGH ........................................................... 5-25


SENSOR INPUT VOLTAGE LOW ............................................................ 5-31

5.7 PID 51, FMI 7, FLASH CODE 65, THROTTLE PLATE IS NOT

RESPONDING ......................................................................................... 5-37

5.8 PID 91, FMI 3, FLASH CODE 21, THROTTLE POSITION SENSOR

INPUT VOLTAGE HIGH ............................................................................ 5-42

5.9 PID 91, FMI 4, FLASH CODE 22, THROTTLE POSITION SENSOR

INPUT VOLTAGE LOW ............................................................................ 5-44

5.10 PID 94, FMI 0, FLASH CODE 47, FUEL PRESSURE HIGH ................... 5-48

5.11 PID 94, FMI 1, FLASH CODE 48, FUEL PRESSURE LOW .................... 5-51

5.12 PID 94, FMI 3, FLASH CODE 37, FUEL PRESSURE SENSOR INPUT

VOLTAGE HIGH ....................................................................................... 5-56

5.13 PID 94, FMI 4, FLASH CODE 38, FUEL PRESSURE SENSOR INPUT

VOLTAGE LOW ........................................................................................ 5-58

5.14 PID 100, FMI 1, FLASH CODE 45, OIL PRESSURE LOW ..................... 5-60

5.15 PID 100, FMI 3, FLASH CODE 35, OIL PRESSURE SENSOR INPUT

VOLTAGE HIGH ....................................................................................... 5-63

5.16 PID 100, FMI 4, FLASH CODE 36, OIL PRESSURE SENSOR INPUT

VOLTAGE LOW ........................................................................................ 5-65

5.17 PID 105, FMI 0, FLASH CODE 44, INTAKE MANIFOLD TEMPERATURE

HIGH ........................................................................................................ 5-67

5.18 PID 105, FMI 3, FLASH CODE 27, AIR TEMPERATURE SENSOR


5.19 PID 105, FMI 4, FLASH CODE 28, AIR TEMPERATURE SENSOR


5.20 PID 106, FMI 0, FLASH CODE 47, INTAKE MANIFOLD PRESSURE

HIGH ........................................................................................................ 5-74

5.21 PID 106, FMI 1, FLASH CODE 48, INTAKE MANIFOLD PRESSURE

LOW ......................................................................................................... 5-81

5.22 PID 106, FMI 3, FLASH CODE 67, MANIFOLD ABSOLUTE PRESSURE

SENSOR INPUT VOLTAGE HIGH ........................................................... 5-84

5.23 PID 106, FMI 4, FLASH CODE 67, MANIFOLD ABSOLUTE PRESSURE

SENSOR INPUT VOLTAGE LOW ............................................................ 5-86

5.24 PID 108, FMI 3, FLASH CODE 86, BAROMETRIC PRESSURE SENSOR


5.25 PID 108, FMI 4, FLASH CODE 87, BAROMETRIC PRESSURE SENSOR


5.26 PID 110, FMI 0, FLASH CODE 44, COOLANT TEMPERATURE HIGH .. 5-92

5.27 PID 110, FMI 3, FLASH CODE 14, THE COOLANT TEMPERATURE

SENSOR INPUT VOLTAGE IS LOW ........................................................ 5-96

5.28 PID 110, FMI 4, FLASH CODE 15, THE COOLANT TEMPERATURE

SENSOR INPUT VOLTAGE IS LOW ........................................................ 5-98

5.29 PID 111, FMI 1, FLASH CODE 43, COOLANT LEVEL LOW .................. 5-100

5.30 PID 111, FMI 3, FLASH CODE 16, COOLANT LEVEL SENSOR INPUT

VOLTAGE HIGH ....................................................................................... 5-103

All information subject to change without notice.

5-2 From Bulletin 1-50G/60GTS-01 6SE482 0109 Copyright © 2001 DETROIT DIESEL CORPORATION

SERIES 50G/60G TROUBLESHOOTING MANUAL

5.31 PID 111, FMI 4, FLASH CODE 13, COOLANT LEVEL SENSOR INPUT

VOLTAGE LOW ........................................................................................ 5-105

5.32 PID 173, FMI 3, FLASH CODE 81, EXHAUST TEMPERATURE SENSOR


5.33 PID 173, FMI 4, FLASH CODE 82, EXHAUST TEMPERATURE SENSOR


5.34 PID 174, FMI 3, FLASH CODE 23, FUEL TEMPERATURE SENSOR


5.35 PID 174, FMI 4, FLASH CODE 24, FUEL TEMPERATURE SENSOR



6SE482 0109 Copyright © 2001 DETROIT DIESEL CORPORATION From Bulletin 1-50G/60GTS-01 5-3


5.1 DIAGNOSTIC CODES

The Society of Automotive Engineers (SAE) and the Maintenance Council of the AmericanTrucking Association (TMC) have developed a standard data interchange format referred to asJ1587. This format defines a standard data list, controller names and numbers, parameter namesand numbers and diagnostic fault code formats and numbers.

Parameter IDentifiers (PID) are numbers and names used to identify the data in the message(i.e. engine RPM, coolant temperature).

Failure Mode Identifiers (FMI) describes the type of failure detected in the subsystem or partidentified by the PID.

Flash Code provides a two digit number to advise the operator of the general severity of the fault.



5.2 PID 51, FMI 0, FLASH CODE 65, THROTTLE PLATE POSITION ABOVE NORMAL RANGE

5.2 PID 51, FMI 0, FLASH CODE 65, THROTTLE PLATE POSITION ABOVENORMAL RANGE

The throttle plate position is above normal range due to an open or short or a faulty throttle.

5.2.1 Troubleshooting PID 51, FMI 0, Flash Code 65

Troubleshoot as follows:

NOTICE:

To avoid damage to the harness and connectors whendisconnecting harness connectors, ensure the pulling force isapplied to the connectors and not to the wires extending fromthe connectors.

1. Check wire 907 (dark green, throttle plate position) for short to the 12V/24V power supply.Check cavity R-1 in the Engine Sensor Harness (ESH) 30–pin connector (see Figure 5-1).If there is a short, repair or replace the wire(s), pins, and sockets.

Figure 5-1 Engine Sensor Harness 30–pin Connector




Also check pin F (throttle plate position) in the throttle actuator connector (see Figure 5-2).If there is a short, repair or replace the wire(s), pins, and sockets.

Figure 5-2 Throttle Actuator Connector

[a] If PID 51, FMI 0, Flash Code 65 is still active, go to step 2.

[b] If PID 51, FMI 0, Flash Code 65 is no longer active, refer to section 5.2.3.

2. Check wire 909 (light green, PWM #2 out) for short to the 12V/24V power supply.Check cavity Y-1 in the Engine Sensor Harness 30–pin connector (see Figure 5-1). Alsocheck pin E (PWM #2 out) in the throttle actuator connector. If there is a short, repairor replace the wire(s), pins, and sockets.



3. Check wire 452 (black, engine sensor return) to see if the wire is open. Check cavityY-2 in the Engine Sensor Harness 30–pin connector (see Figure 5-1). Also check pin D(engine sensor return) in the throttle actuator connector. Repair or replace any openwires, pins, and sockets.

[a] If PID 51, FMI 0, Flash Code 65 is still active, replace the throttle,refer to section 5.2.2.


5.2.2 Replacing the Throttle

Use the bolt tightening sequence and the throttle assembly procedure in the following sectionswhen replacing the throttle. Refer to section 5.2.2.1 for the bolt tightening sequence andrefer to section 5.2.2.2 for the throttle assembly procedure.

5.2.2.1 Bolt Tightening Sequence

Loosen the bolts using the following sequence

1. Loosen the four bolts that attach the intake elbow to the rear of the throttle.

2. Loosen the four bolts that attach the Mixer/PSV assembly to the front of the throttle.

3. Loosen the two bolts that attach the low pressure regulator to the intake elbow.

4. Loosen the four bolts that attach the throttle to the throttle bracket.




Tighten all the bolts using the following sequence:

NOTE:Torque for all bolts is 34 N·m (25 ft·lb).

1. Tighten the two bolts from the throttle bracket to the gear case.

2. Tighten the one bolt from the throttle bracket to the cylinder head.

3. Tighten the four bolts from the Mixer/PSV assembly to the throttle.

4. Tighten the four bolts from the throttle to the inlet elbow.

5. Tighten the two bolts from the IMPCO regulator.

6. Tighten the two bolts from the throttle bracket to the inlet elbow.

7. Tighten the four bolts from the bottom of the throttle bracket to the throttle.

5.2.2.2 Throttle Assembly Procedure

Replace the throttle assembly as follows:

1. Install the inlet elbow to the throttle body flange with the flow arrow on the throttle bodypointing towards the inlet elbow. Attach with four bolts but do not tighten.

2. Install mixer assembly and gasket to opposite flange with four bolts but do not tighten.

3. Attach the PSV and O-ring to the mixer with four Allen head screws but do not tighten.

4. Lubricate O-rings used with fuel transfer tube with Lubriplate® prior to assembly.

5. Install O-rings to fuel transfer tube. Apply Teflon® liquid pipe sealant to threads(see Figure 5-3).

6. Thread fuel transfer tube into regulator and tighten.

NOTE:The fuel transfer tube must thread into the regulator just far enough so the O-ringseal doesn’t bottom in the PSV valve and cut the seal when the regulator is bolted tothe inlet elbow.

Lubriplate® is a registered trademark of Fiske Brothers Refining Company.

Teflon® is a registered trademark of E. I. DuPont de Nemours and Company, Inc.




7. Install the low pressure regulator and fuel transfer into the PSV. Bolt regulator to inletelbow with two bolts but do not tighten (see Figure 5-3).

1. Fuel Pressure Sensor 9. Washer

2. IMPCO Regulator 10. PSV O-ring

3. Elbow 11. Bolt

4. Balance Line 12. Mixer Assembly

5. Fuel Transfer Tube 13. Gasket

6. O-rings 14. Throttle Body

7. PSV 15. Elbow

8. Bolt 16. Air Temperature Sensor

Figure 5-3 Assembling the Throttle — Series 50G




8. Install throttle, PSV, mixer and inlet elbow to engine positioning inlet hose over inletelbow and inlet manifold. Rest the throttle on the throttle bracket (see Figure 5-4).


2. Throttle Bracket 8. Elbow

3. Gear Case Cover-to-Bracket Bolts 9. Clamp

4. Throttle Actuator 10. Hose

5. Bushing 11. Inlet Manifold

6. Gasket

Figure 5-4 Throttle, Bracket, and Inlet Elbow Assembly — Series 50G

9. Install four bolts through the throttle bracket into the bottom of the throttle and two boltsthrough the side of the throttle bracket into the inlet elbow but do not tighten.

10. Tighten the four mixer to throttle bolts at 34 N·m (25 ft·lb) torque.




11. Tighten the four throttle to inlet elbow bolts at 34 N·m (25 ft·lb) torque.

12. Tighten the two bolts that hold the regulator to the inlet elbow and tighten the four screwsthat hold the PSV to the mixer.

13. Adjust the two bolts through the throttle bracket to the inlet elbow and the four boltsthrough the bottom of the throttle bracket to the throttle alternatively to insure that there isno bind in the throttle. Torque the two brackets to the inlet elbow bolts at 34 Nm (25 ft·lb)and the four throttle mounting bolts at 34 N·m (25 ft·lb).

5.2.3 Verification

Verify that troubleshooting was successful:

1. Check the DDR to see if PID 51, FMI 0, Flash Code 65 is still active.

[a] If the code is still active, go to step 2.

[b] If the code is not active, troubleshooting is complete.

2. Call Detroit Diesel Technical Service.



5.3 PID 51, FMI 1, FLASH CODE 65, THROTTLE PLATE POSITION BELOW NORMAL RANGE

5.3 PID 51, FMI 1, FLASH CODE 65, THROTTLE PLATE POSITION BELOWNORMAL RANGE

The throttle plate position is below normal range due to an open or short or a faulty throttle.



NOTICE:


1. Check wire 909 (light green, PWM #2 out) cavity Y-1 in the Engine Sensor Harness(ESH) 30–pin connector (see Figure 5-5) for a short to wire 956 (black, throttle actuatorground) pin B in the throttle actuator connector (see Figure 5-6). If there is a short, repairor replace the wire(s), pins, and sockets.





Also check pin E (PWM #2 out) in the throttle actuator connector (see Figure 5-6). Ifthere is a short, repair or replace the wire(s), pins, and sockets.



[b] If PID 51, FMI 1, Flash Code 65 is not active, refer to section 5.3.3.

2. Check wire 445 (throttle body power) to see if the wire is open at pin A (throttle bodypower) in the throttle actuator connector or pin D (throttle body power) in the OEMPower Harness (male/female connection).



3. Check wire 956 (black, throttle actuator ground) to see if the wire is open at pin B (throttleactuator ground) in the throttle actuator connector or pin B (throttle actuator ground) inthe OEM Ground Harness (male/female connection). Repair or replace any open wires,pins, and sockets.

[a] If PID 51, FMI 1, Flash Code 65 is still active, replace the throttle,refer to section 5.3.2.





Loosen the bolts using the following sequence:


2. Loosen the four bolts that attach the Mixer/PSV assembly to the front of the throttle

















1. Install the inlet elbow to the throttle flange with the flow arrow on the throttle pointingtowards the inlet elbow. Attach with four bolts but do not tighten.

2. Install mixer assemble to opposite flange using the same gasket with four bolts but do nottighten.


4. Lubricate O-rings used with fuel transfer tube with Lubriplate prior to assembly.

5. Install O-rings to fuel transfer tube. Apply Teflon liquid pipe sealant to threads .






7. Install the low pressure regulator and fuel transfer into the PSV. Bolt regulator to inletelbow with two bolts but do not tighten (See Figure 5-7) .



3. Elbow 11. Bolt


5. Fuel transfer Tube 113. Gasket


7. PSV 15. Elbow












6. Gasket









13. Adjust the two bolts through the throttle bracket to the inlet elbow and the four boltsthrough the bottom of the throttle bracket to the throttle alternatively to insure that there isno bind in the throttle. Torque the two brackets to the inlet elbow bolts at 34 N·m (25 ft·lb)and the four throttle mounting bolts at 34 Nm (25 ft·lb).

[a] If the code is still active, call Detroit Diesel Technical Service.

[b] If the code is no longer active, refer to section 5.3.3.

5.3.3 Verification

Verify that troubleshooting was successful :







5.4 PID 51, FMI 2, FLASH CODE 65, THROTTLE PLATE POSITION ERRATIC


The throttle plate position is erratic due to an open or short or a faulty throttle.



NOTICE:


1. Check wire 907 (dark green, throttle plate position) in cavity R-1 in the Engine SensorHarness (ESH) 30–pin connector to see if the wire is open (see Figure 5-9).





Also check pin F (throttle plate position) in the throttle actuator connector(see Figure 5-10). Repair or replace any open wires, pins, and sockets.



[b] If PID 51, FMI 2, Flash Code 65 is no longer active, refer to section 5.4.3

2. Check wire 907 (dark green, throttle plate position) cavity R-1 in the Engine SensorHarness (ESH) 30–pin connector for a short to wire 956 (black, throttle actuator ground) inthe throttle actuator connector (see Figure 5-9). Also check pin F (throttle plate position)in the throttle actuator connector, and pin B (throttle actuator ground) in the throttleactuator connector. If there is a short, repair or replace the wire(s), pins, and sockets.



3. Check wire 909 (light green, PWM #2 out) in cavity Y-1 in the Engine Sensor Harness(ESH) 30–pin connector to see if the wire is open (see Figure 5-9). Also check pin E(PWM #2 out) in the throttle actuator connector. Repair or replace any open wires, pins,and sockets.



4. Check wire 909 (light green, PWM #2 out) in cavity Y-1 in the Engine Sensor Harness(ESH) 30–pin connector for a short to wire 416 (gray, sensor supply 5 VDC) in cavityW-1 in the ESH 30–pin connector to see if the wire is open (see Figure 5-9). Also checkpin C (sensor supply +5 VDC) and pin E (PWM #2 out) in the throttle actuator connector.Repair or replace any open wires, pins, and sockets.



5. Check wire 910 (orange, PWM #3 out) in cavity W-2 in the Engine Sensor Harness (ESH)30–pin connector for a short to wire 416 (gray, sensor supply 5 VDC) in cavity W-1 in theESH 30–pin connector (see Figure 5-9). Also check pin C (sensor supply +5 VDC) and




pin H (PWM #3 out) in the PSV connector (see Figure 5-11). If there is a short, repairor replace the wire(s), pins, and sockets.

Figure 5-11 PSV Connector

[a] If PID 51, FMI 2, Flash Code 65 is still active, replace the throttle(refer to section 5.4.2).
























1. Install the inlet elbow to the throttle flange with the flow arrow on the throttle pointingtowards the inlet elbow. Attach with four bolts but do not tighten.




5. Install O-rings to fuel transfer tube. Apply Teflon liquid pipe sealant to threads(see Figure 5-12).









3. Elbow 11. Bolt



6. Bolt 14. Throttle Body

7. PSV 15. Elbow


Figure 5-12 Assembling the Throttle









5. Bushing 11. Inlet Assembly

6. Gasket









13. Adjust the two bolts through the throttle bracket to the inlet elbow and the four boltsthrough the bottom of the throttle bracket to the throttle alternatively to insure that there isno bind in the throttle. Torque the two brackets to the inlet elbow bolts at 34 N·m (25 ft·lb)and the four throttle mounting bolts at 34 N·m (25 ft·lb).



5.4.3 Verification









5.5 PID 51, FMI 3, FLASH CODE 17, THROTTLE PLATE POSITION SENSORINPUT VOLTAGE HIGH

The throttle plate position sensor input voltage is high due to a short or a faulty throttle.

5.5.1 Troubleshooting PID 51, FMI 3, FLASH CODE 17


NOTICE:


1. Check wire 907 (dark green, throttle plate position) cavity R-1 in the Engine SensorHarness (ESH) 30–pin connector for a short to wire 416 (gray, sensor supply, 5 VDC)cavity W-1 in the ESH (see Figure 5-14). If there is a short, repair or replace the wire(s),pins, and sockets.




5.5 PID 51, FMI 3, FLASH CODE 17, THROTTLE PLATE POSITION SENSOR INPUT VOLTAGE HIGH

Also check pin F (throttle plate position) and pin C (sensor supply +5 VDC) in the throttleactuator connector (see Figure 5-15). If there is a short, repair or replace the wire(s),pins, and sockets.




2. Check wire 907 for a short to the +12V/+24V power supply. Check cavity R-1 in the ESH30–pin connector and pin F (throttle plate position) in the throttle actuator connector. Ifthere is a short, repair or replace the wire(s), pins, and sockets.

[a] If PID 51, FMI 3, Flash Code 17 is still active, replace the throttle(refer to section 5.5.2).


5.5.2 Throttle Assembly Procedure






















1. Install the inlet elbow to the throttle flange with the flow arrow on the throttle pointingtowards the inlet elbow.




5. Install O-rings to fuel transfer tube. Apply Teflon liquid pipe sealant to threads(see Figure 5-16).









3. Elbow 11. Bolt




7. PSV 15. Elbow


Figure 5-16 Assembling the Throttle










6. Gasket












5.5.3 Verification









5.6 PID 51, FMI 4, FLASH CODE 18, THROTTLE PLATE POSITION SENSORINPUT VOLTAGE LOW

The throttle plate position sensor input voltage is below normal range due to an open or short or afaulty throttle.



NOTICE:


1. Check wire 907 (dark green, throttle plate position) in cavity R-1 in the Engine SensorHarness (ESH) 30–pin connector to see if the wire is open (see Figure 5-18). Repair orreplace any open wires, pins, and sockets.





5.6 PID 51, FMI 4, FLASH CODE 18, THROTTLE PLATE POSITION SENSOR INPUT VOLTAGE LOW


2. Check wire 907 (dark green, throttle plate position) cavity R-1 in the ESH 30–pinconnector (see Figure 5-18) for a short to wire 956 (black, throttle actuator ground) in thethrottle actuator connector (see Figure 5-19). Also check pin F (throttle plate position)in the throttle actuator connector, and pin B (throttle actuator ground) in the throttleactuator connector (see Figure 5-19). If there is a short, repair or replace the wire(s),pins, and sockets.




3. Check wire 416 (gray, sensor supply, 5 VDC) cavity W-1 in the ESH 30–pin connector tosee if the wire is open. ( see Figure 5-18) and check pin C (sensor supply +5 VDC) in thethrottle actuator connector. Repair or replace any open wires, pins, and sockets.



4. Check wire 416 (gray, sensor supply, 5 VDC) cavity W-1 in the ESH 30–pin connector tosee if there is a short to wire 956 (black, throttle actuator ground) in the throttle actuatorconnector . Also check pin C (sensor supply +5 VDC) and pin B (throttle actuator ground)both in the throttle actuator connector. If there is a short, repair or replace the wire(s),pins, and sockets.

[a] If the code is still active, replace the throttle (refer to section 5.6.2).


5.6.2 Throttle Assembly Procedure

Use the bolt tightening sequence and the throttle assembly procedure in the following sectionswhen replacing the throttle.





















1. Install the inlet elbow to the throttle flange with the flow arrow on the throttle pointingtowards the inlet elbow.




5. Install O-rings to fuel transfer tube. Apply liquid pipe sealant to threads (see Figure 5-20).









3. Elbow 11. Bolt




7. PSV 15. Elbow












6. Gasket












5.6.3 Verification









5.7 PID 51, FMI 7, FLASH CODE 65, THROTTLE PLATE IS NOTRESPONDING

The throttle plate is not responding due to an open wire, a short, throttle plate actuator alignment,or a faulty throttle plate actuator.



NOTICE:


1. Check wire 907 (dark green, throttle plate position) cavity R-1 in the Engine SensorHarness (ESH) 30–pin connector to see if the wire is open ( see Figure 5-22).




5.7 PID 51, FMI 7, FLASH CODE 65, THROTTLE PLATE IS NOT RESPONDING

Check pin F (throttle plate position ) in the throttle actuator connector (see Figure 5-23).Repair or replace any open wires, pins, and sockets.




2. Check wire 907 (dark green, throttle plate position) cavity R-1 in the ESH 30–pinconnector for a short to wire 956 (black, throttle actuator ground) in the throttle actuatorconnector (see Figure 5-22). Also check pin F (throttle plate position) in the throttleactuator connector, and pin B (throttle actuator ground) in the throttle actuator connector.If there is a short, repair or replace the wire(s), pins, and sockets.



3. Check wire 907 (dark green, throttle plate position) cavity R-1 in the ESH 30–pinconnector for a short to wire 416 (gray, sensor supply 5VDC) cavity W-1 in the ESH30–pin connector (see Figure 5-22). Also check pin F (throttle plate position) and pinC (sensor supply, +5VDC) in the throttle actuator connector. If there is a short, repairor replace the wire(s), pins, and sockets.



4. Check wire 416 (gray, sensor supply, 5VDC) cavity W-1 in the ESH 30–pin connector tosee if it is open (see Figure 5-22). Also check pin C (sensor supply, +5VDC) in the throttleactuator connector. Repair or replace any open wires, pins, and sockets.



5. Check wire 416 (gray, sensor supply, 5VDC) cavity W-1 in the ESH 30–pin connectorfor a short to wire 956 (black, throttle actuator ground) in the throttle actuator connector(see Figure 5-22). Also check pin C (sensor supply, +5VDC) in the throttle actuatorconnector, and pin B (throttle actuator ground) in the throttle actuator connector. If there isa short, repair or replace the wire(s), pins, and sockets.






6. Check wire 909 (light green, PWM #2 out) cavity Y-1 in the ESH 30–pin connector to seeif it is open (see Figure 5-22). Also check pin E (PWM #2 out) in the throttle actuatorconnector. Repair or replace any open wires, pins, and sockets.



7. Check wire 909 (light green, PWM #2 out) cavity Y-1 in the ESH 30–pin connector fora short to wire 956 (black, throttle actuator ground) in the throttle actuator connector(see Figure 5-22). Also check pin E (PWM #2 out) and pin B (throttle actuator ground)in the throttle actuator connector. If there is a short, repair or replace the wire(s), pins,and sockets.



8. Check wire 445 (red, throttle body power) pin A in the throttle actuator connector(see Figure 5-22). Also check pin D (throttle body power) in the OEM Power Harness(male/female connection).



9. Check wire 445 (red, throttle body power) pin A in the throttle actuator connector fora short to wire 956 (black, throttle actuator ground) and pin B in the throttle actuatorconnector (see Figure 5-22). Also check pin D (throttle body power) in the OEM PowerHarness (male/female connection) and pin B (throttle actuator ground) in the OEMGround Harness (male/female connection). If there is an open wire, repair or replace thewire(s), pins, and sockets.



10. Check wire 956 (black, throttle actuator ground) pin B in the throttle actuator connector tosee if it is open . (see Figure 5-22). Also check pin B (throttle actuator ground) in theOEM Ground Harness (male/female connection).



11. Check the throttle plate actuator alignment using the bolt tightening sequence(refer to section 5.7.2).

5.7.2 Bolt Tightening Sequence







5.7 PID 51, FMI 7, FLASH CODE 65, THROTTLE PLATE IS NOT RESPONDING











[a] If PID 51, FMI 7, Flash Code 65 is still active, replace the throttle plate actuator(refer to section 5.7.3).


5.7.3 Replacement of the Throttle Actualor

The throttle actuator (see Figure 5-24) is non-serviceable and should be replaced as a unit.

Figure 5-24 Throttle Actuator for the Series 60G Engine




5.7.3.1 Removal of Throttle Actuator

Remove the throttle actuator as follows:

1. Vent the fuel system.

2. Disconnect and remove the six-wire power harness connectors from the throttle actuator.

3. Remove the four bolts connecting the throttle actuator to the mounting bracket.

4. Remove the eight bolts attaching the throttle to the inlet and outlet tube assemblies.

5.7.3.2 Installation of Throttle Actuator

Install the throttle actuator as follows:

1. Secure the throttle actuator to the mounting bracket with the four bolts and torque to20 N·m (15 lb·ft).

2. Connect the six-wire power harness.

3. Install a new gasket and attach the outlet tube assembly using four bolts.

4. Install a new gasket and attach the inlet tube assembly using four bolts.

5. Run engine and check for air or air and fuel mixture leaks at the throttle and connectinghoses.


[b] If the code is no longer active, refer to section 5.7.4

5.7.4 Verification

Verify that troubleshooting was successful as follows:







5.8 PID 91, FMI 3, FLASH CODE 21, THROTTLE POSITION SENSOR INPUT VOLTAGE HIGH

5.8 PID 91, FMI 3, FLASH CODE 21, THROTTLE POSITION SENSOR INPUTVOLTAGE HIGH

The Throttle Position Sensor (TPS) in the Electronic Foot Pedal Assembly (EFPA),see Figure 5-25, has high input voltage due to a short.

Figure 5-25 Typical EFPA Device (Shown with 6–pin Connector)



NOTICE:


1. Check wire 417 (dark blue, Throttle Position Sensor) cavity D-2 in the Vehicle InterfaceHarness (VIH) 30–pin connector for a short to wire 916 (red/black) cavity A-3 in the VIH30–pin connector (see Figure 5-26). Also check pin B (TPS) and pin C (Sensor Supply,+5VDC) in the TPS connector within the EFPA. If there is a short, repair or replace thewire(s), pins, and sockets.




Figure 5-26 Vehicle Interface Harness 30-pin Connector



2. Check wire 417 (dark blue, Throttle Position Sensor) cavity D-2 in the VIH 30–pinconnector for a short to +12/24VDC (see Figure 5-26). Also check pin B (TPS) in theTPS connector within the EFPA. If there is a short, repair or replace the wire(s), pins,and sockets.

[a] If PID 91, FMI 3, Flash Code 21 is still active, call Detroit Diesel Technical Service.


5.8.2 Verification





2. If the code is still active, call Detroit Diesel Technical Service.



5.9 PID 91, FMI 4, FLASH CODE 22, THROTTLE POSITION SENSOR INPUT VOLTAGE LOW

5.9 PID 91, FMI 4, FLASH CODE 22, THROTTLE POSITION SENSOR INPUTVOLTAGE LOW

The Throttle Position Sensor (TPS) in the Electronic Foot Pedal Assembly (EFPA),see Figure 5-27, has low input voltage due to an open wire or a short.

Figure 5-27 Typical EFPA Device (Shown with 6–pin Connector)






NOTICE:


1. Check wire 910 (orange PWM #3 out) cavity W-2 in the Engine Sensor Harness (ESH)30–pin connector for a short to wire 416 (gray, sensor supply, 5VDC) cavity W-1 in theESH 30–pin connector (see Figure 5-28).




5.9 PID 91, FMI 4, FLASH CODE 22, THROTTLE POSITION SENSOR INPUT VOLTAGE LOW

Also check pin H (PWM #3 out) in the PSV connector (see Figure 5-29). If there is ashort, repair or replace the wire(s), pins, and sockets.




2. Check wire 909 (light green, PWM #2 out) cavity Y-1 in the ESH 30–pin connector for ashort to wire 416 (gray, sensor supply, 5VDC) cavity W-1 in the ESH 30–pin connector(see Figure 5-28). Also check pin E (PWM #2 out in the PSV connector (see Figure 5-29)and pin C (sensor supply, +5VDC) in the throttle actuator connector (see Figure 5-29). Ifthere is a short, repair or replace the wire(s), pins, and sockets.



3. Check to see if wire 417 (dark blue, Throttle Position Sensor) cavity D-2 in the VIH30–pin connector is open (see Figure 5-30). Also check pin B in the TBS connector in theEFPA. Repair or replace any open wires, pins, and sockets.




Figure 5-30 Vehicle Interface Harness 30–pin Connector



4. Check to see if wire 417 (dark blue, Throttle Position Sensor) cavity D-2 in the VIH30–pin connector is short to ground (see Figure 5-30). Also check pin B in the TBSconnector in the EFPA. If there is a short, repair or replace the wire(s), pins, and sockets.



5.9.2 Verification








5.10 PID 94, FMI 0, FLASH CODE 47, FUEL PRESSURE HIGH


The fuel pressure is high due to a faulty sensor connection, a faulty sensor or problem in thefuel system.



1. Check wire 905 (yellow, Fuel Pressure Sensor) in the Engine Sensor Harness (ESH)30–pin connector (see Figure 5-31). If there is a short or an open wire, repair or replacethe wire(s), pins, and sockets.







2. Check the Fuel Pressure Sensor (FPS) using the DDEC Sensor Tester J 37164(see Figure 5-32).

Figure 5-32 DDEC Sensor Tester J 37164

3. Disconnect the sensor. On Series 60G and 50G engines with a high pressure fuel system,the FPS is installed in a tee at the inlet to the low pressure regulator (see Figure 5-33).

Figure 5-33 Fuel Pressure Sensor Location




4. Disengage the locking tang on the three-wire connector. Grasp the body of the connectorand gently pull it free of the FPS.

5. Use the appropriate wrench on the hex end of the FPS to unscrew it from the inlet tee.

6. Connect the sensor to the tester at the correct connector.

7. Clip the power leads to the 12 volt power source.

8. Plug in a volt OHM meter. The tester will power up the sensor.

[a] If the sensor should be replaced, refer to section 5.10.1.1.

[b] If the sensor does not need to be replaced, refer to section 5.10.1.2.

5.10.1.1 Replacing the Fuel Pressure Sensor

The FPS is non-servicable and should be replaced as a unit. No adjustment is required.

Replace the FPS as follows:

NOTE:The FPS is an electrical device. Use care on installation.

1. On the replacement FPS, use Loctite® Pipe Sealant with Teflon, PT-7260, or equivalent onall but the first two threads of the FPS to prevent leaks.

2. Screw FPS into the regulator inlet tee.

3. Engage locking tang of the three wire connector to the FPS.

4. Turn the ignition to the ON position. Observe the DDR for any diagnostic code(s).


[b] If PID 94, FMI 0, Flash Code 47 is not active. Refer to section 5.10.2.

5.10.1.2 Checking the Fuel System

Check the fuel system and repair if necessary. When the check and/or repairs are finished:


2. If the code is no longer active, refer to section 5.10.2

5.10.2 Verification

Verify troubleshooting as follows:





Loctite® is a registered trademark of the Loctite Corporation.




5.11 PID 94, FMI 1, FLASH CODE 48, FUEL PRESSURE LOW

The fuel pressure is low due to a faulty sensor connection, a faulty sensor, problem in the fuelsystem, a short or an open wire.

5.11.1 Troubleshooting


1. Check wire 905 (yellow, Fuel Pressure Sensor) cavity M-1 in the Engine Sensor Harness(ESH) 30–pin connector (see Figure 5-34). If there is a short or an open wire, repairor replace the wire(s), pins, and sockets.







2. Check the Fuel Pressure Sensor (FPS) using the DDEC Sensor Tester J 37164(see Figure 5-35).


3. Disconnect the sensor. On Series 60G and 50G engines with a high pressure fuel system,the FPS is installed in a tee at the inlet to the low pressure regulator (see Figure 5-36).

Figure 5-36 Fuel Pressure Sensor Location




4. Disengage the locking tang on the three-wire connector. Grasp the body of the connectorand gently pull it free of the FPS.

5. Use the appropriate wrench on the hex end of the FPS to unscrew it from the inlet tee.




[a] If the FPS needs to be replaced, refer to section 5.11.1.1.

[b] If the FPS does not need to be replaced, go to Step 9.

9. Check the fuel system and fuel tanks and repair if necessary.



10. Check wire 909 (light green, PWM #2 out) cavity Y-1 to see if there is a short to wire 416(gray, sensor supply, 5VDC) cavity W-1 in the ESH 30–pin connector (see Figure 5-37).If there is a short, repair or replace the wire(s), pins, and sockets.

Figure 5-37 Engine Sensor Harness 30–pin connector






11. Check pin E (PWM #2 out) in the PSV connector (see Figure 5-38). If there is a short,repair or replace the wire(s), pins, and sockets.




12. Check wire 452 (black, engine sensor return) cavity Y-2 in the ESH 30–pin connector tosee if it is open (see Figure 5-37). Also check pin D (engine sensor return) in the throttleactuator connector (see Figure 5-39). Repair or replace any open wires, pins, and sockets.




5.11.1.1 Replacing the Fuel Pressure Sensor

The FPS is non-servicable and should be replaced as a unit. No adjustment is required.

Replace the FPS as follows:

NOTE:The FPS is an electrical device. Use care on installation.

1. On the replacement FPS, use Loctite® Pipe Sealant with Teflon, PT-7260, or equivalent onall but the first two threads of the FPS to prevent leaks.

2. Screw FPS into the regulator inlet tee.

3. Engage locking tang of the three wire connector to the FPS.






[b] If PID 94, FMI 1, Flash Code 48 is not active. Refer to section 5.11.2.

5.11.2 Verification








5.12 PID 94, FMI 3, FLASH CODE 37, FUEL PRESSURE SENSOR INPUT VOLTAGE HIGH

5.12 PID 94, FMI 3, FLASH CODE 37, FUEL PRESSURE SENSOR INPUTVOLTAGE HIGH

Input voltage from the Fuel Pressure Sensor is high due to a short.



NOTICE:


1. Check wire 905 (yellow, Fuel Pressure Sensor) cavity M-1 for a short to wire 416 (gray,sensor supply, 5VDC) cavity W-1 in the Engine Sensor Harness (ESH) 30–pin connector(see Figure 5-40). Also check pin C (fuel pressure) and pin B (sensor supple, +5VDC)in the Fuel Pressure Sensor connector. If there is a short, repair or replace the wire(s),pins, and sockets.






[b] If the code is on longer active, refer to section 5.12.2.

2. Check wire 905 (yellow, Fuel Pressure Sensor) cavity M-1 in the ESH 30–pin connectorfor a short to +12V/24V (see Figure 5-40). Also check pin C (fuel pressure) in the FuelPressure Sensor connector. If there is a short, repair or replace the wire(s), pins, andsockets.



5.12.2 Verification








5.13 PID 94, FMI 4, FLASH CODE 38, FUEL PRESSURE SENSOR INPUT VOLTAGE LOW

5.13 PID 94, FMI 4, FLASH CODE 38, FUEL PRESSURE SENSOR INPUTVOLTAGE LOW

Input voltage from the Fuel Pressure Sensor is low due to an open wire or a short.



NOTICE:


1. Check wire 905 (yellow, Fuel Pressure Sensor) cavity M-1 in the Engine Sensor Harness(ESH) 30–pin connector to see if it is open (see Figure 5-41). Also check pin C (fuelpressure) in the Fuel Pressure Sensor connector. Repair or replace any open wires, pins,and sockets.







2. Check wire 905 (yellow, Fuel Pressure Sensor) cavity M-1 in the ESH 30–pin connector fora short to ground (see Figure 5-41). Also check pin C (fuel pressure) in the Fuel PressureSensor connector. If there is a short, repair or replace the wire(s), pins, and sockets.



5.13.2 Verification








5.14 PID 100, FMI 1, FLASH CODE 45, OIL PRESSURE LOW


The oil pressure is low due to a faulty Oil Pressure Sensor or a low oil level.



1. Check the oil level.

[a] If the oil level is low, add oil and check to see if the codes are still active. If the codeis active, go to step 2.

[b] If the oil level is low, add oil and check to see if the code is still active. If the code isnot active, refer to section 5.14.2.

[c] If the oil level is not low, go to step 2.

2. Check the Oil Pressure Sensor (FPS) using the DDEC Sensor Tester J 37164(see Figure 5-42.





3. Disconnect the sensor. The Oil Pressure Sensor (OPS) is installed into the main engine oilgallery. A typical location is the left rear corner of the cylinder block (see Figure 5-43).

Figure 5-43 Oil Pressure Sensor Location

4. Disengage the locking tang on the three-wire connector. Grasp the body of the connectorand gently pull it free of the OPS.

5. Use the appropriate wrench on the hex end of the OPS to unscrew it from the engine.




[a] If the Oil Pressure Sensor needs to be replaced, refer to section 5.14.1.1.

[b] If the Oil Pressure Sensor does not need to be replaced, call Detroit Diesel TechnicalService.

5.14.1.1 Replacing the Oil Pressure Sensor

The OPS is non-serviceable and should be replaced as a unit. No adjustment is required.

Replace the OPS as follows:

1. Use Loctite® Pipe Sealer with Teflon, PT-7260, or equivalent on all but the first twothreads of the OPS to prevent leaks.

2. Install the sensor in the engine and using the appropriate wrench on the hex portionof the sensor tighten it.




3. Place the connector in the socket and engage the locking tang.




5.14.2 Verification









5.15 PID 100, FMI 3, FLASH CODE 35, OIL PRESSURE SENSOR INPUTVOLTAGE HIGH

The Oil Pressure Sensor input voltage is high due to a short.



NOTICE:


1. Check wire 530 (brown, oil pressure) cavity P–2 for a short to wire 416 (gray, sensorsupply, 5VDC) cavity W-1 in the Engine Sensor Harness (ESH) 30–pin connector(see Figure 5-44). Also check pin B (oil pressure) in the Oil Pressure Sensor connectorand pin C (sensor supply +5VDC) in the Fuel Pressure Sensor connector. If there isa short, repair or replace the wire(s), pins, and sockets.




5.15 PID 100, FMI 3, FLASH CODE 35, OIL PRESSURE SENSOR INPUT VOLTAGE HIGH


[b] If the code is on longer active, refer to section 5.15.2

2. Check wire 530 (brown, oil pressure) cavity P–2 in the ESH 30–pin connector for a shortto +12V/+24V (see Figure 5-44). Also check pin B (oil pressure) in the Oil PressureSensor connector. If there is a short, repair or replace the wire(s), pins, and sockets.


[b] If the code is on longer active, refer to section 5.15.2

5.15.2 Verification









5.16 PID 100, FMI 4, FLASH CODE 36, OIL PRESSURE SENSOR INPUTVOLTAGE LOW

The Oil Pressure Sensor Input Voltage is low due to a short or an open wire.



NOTICE:


1. Check wire 530 (brown, oil pressure) cavity P–2 in the Engine Sensor Harness (ESH)30–pin connector for a short to ground (see Figure 5-45). Also check pin B (oil pressure)in the Oil Pressure Sensor connector. If there is a short, repair or replace the wire(s),pins, and sockets.





5.16 PID 100, FMI 4, FLASH CODE 36, OIL PRESSURE SENSOR INPUT VOLTAGE LOW

[b] If the code is not active, refer to section 5.16.2.

2. Check wire 530 (brown, oil pressure) cavity P–2 in the ESH 30–pin connector to see ifit is open (see Figure 5-45). Also check pin B (oil pressure) in the Oil Pressure Sensorconnector. Repair or replace any open wire(s).



5.16.2 Verification









5.17 PID 105, FMI 0, FLASH CODE 44, INTAKE MANIFOLD TEMPERATUREHIGH

The intake manifold temperature is high due to a faulty Air Temperature Sensor.



1. Check the Air Temperature Sensor (ATS) to determine if it is faulty using the DDECSensor Tester J 37164 (see Figure 5-46).




5.17 PID 105, FMI 0, FLASH CODE 44, INTAKE MANIFOLD TEMPERATURE HIGH

2. Disconnect the sensor. The ATS is mounted to the bottom of the inlet elbow(see Figure 5-47).

Figure 5-47 Location of Air Temperature Sensor

3. Disengage locking tang on two-wire connector.

4. Grasp body of the connector and gently pull it from the socket.

5. Use the appropriate wrench on the hex portion of the sensor and unscrew it from inletelbow.


7. Connect the sensor to the tester at the correct connector

8. Plug in a volt OHM meter. The tester will power up the sensor. Check the values to see ifthe sensor is operating properly.

[a] If the ATS is faulty, refer to section 5.17.1.1 to replace the ATS.

[b] If the ATS is not faulty, go to step 9.





5.17.1.1 Replacing the Air Temperature Sensor

The ATS is installed into the air inlet tube. The ATS is non-serviceable, and is replaced as a unit.No adjustment is required. Remove the faulty sensor and replace as follows:

NOTICE:

Overtightening will distort and crack the sensor body, resultingin sensor malfunction. Damage may not be evident until sensorremoval, when body may break apart.

1. If installing a new ATS, there is no need to use sealer as it is applied during manufacturing.When reinstalling a serviceable ATS, apply Loctite pipe sealant with Teflon, PT-7260,or equivalent on all but first two threads.

2. Install ATS into the air inlet tube. Torque to 11-16 N·m (97-142 lb·in.).

NOTE:Because of its plastic body, the ATS must be hand started and carefully tightened.

3. Carefully fasten connector onto sensor and engage locking tang.

4. Turn the ignition to the ON position. Check the DDR for any diagnostic code(s).

[a] If the codes are no longer active, refer to section 5.17.2.

[b] If the codes are still active, call Detroit Diesel Technical Service.

5.17.2 Verification








5.18 PID 105, FMI 3, FLASH CODE 27, AIR TEMPERATURE SENSOR INPUT VOLTAGE HIGH

5.18 PID 105, FMI 3, FLASH CODE 27, AIR TEMPERATURE SENSOR INPUTVOLTAGE HIGH

The voltage is high for the Air Temperature Sensor due to a short or an open wire.



NOTICE:


1. Check wire 132 (white, air temperature) cavity N-2 in the Engine Sensor Harness (ESH)30–pin connector to see if it is open (see Figure 5-48). Also check pin B (air temperature)in the Air Temperature Sensor connector. Repair or replace any open wires, pins, andsockets.







2. Check wire 132 (white, air temperature) cavity N-2 in the ESH 30–pin connector for ashort to wire 416 (gray, sensor supply, 5VDC) cavity W-1 in the ESH 30–pin connector(see Figure 5-48). Also check pin B (air temperature) in the Air Temperature Sensorconnector. If there is a short, repair or replace the wire(s), pins, and sockets.



5.18.2 Verification








5.19 PID 105, FMI 4, FLASH CODE 28, AIR TEMPERATURE SENSOR INPUT VOLTAGE LOW

5.19 PID 105, FMI 4, FLASH CODE 28, AIR TEMPERATURE SENSOR INPUTVOLTAGE LOW

The input voltage is low for the Air Temperature Sensor due to a short.



NOTICE:


1. Check wire 132 (white, air temperature) cavity N-2 in the Engine Sensor Harness (ESH)30–pin connector for a short to ground (see Figure 5-49). If there is a short, repair orreplace the wire(s), pins, and sockets.







2. Check pin B (air temperature) in the Air Temperature Sensor connector for a short. Ifthere is a short, repair or replace the wire(s), pins, and sockets.



5.19.2 Verification








5.20 PID 106, FMI 0, FLASH CODE 47, INTAKE MANIFOLD PRESSURE HIGH


The intake manifold pressure is high due to a faulty Manifold Absolute Pressure (MAP) Sensoror incorrect turbocharger wastegate setting.



1. Check the MAP Sensor using the DDEC Sensor Tester J 37164 (see Figure 5-50).

Figure 5-50 DDEC Sensor Tester J37164




2. Disconnect the sensor. The MAP Sensor is threaded into the intake manifold(see Figure 5-51).

1. Intake Manifold 5. Bolt

2. Intake Manifold Inlet 6. Bolt

3. Intake Manifold Gasket 7. ATS (Low Pressure system only)

4. Cylinder Head 8. MAP Sensor

Figure 5-51 MAP Sensor Location — Series 60G

3. Disengage the locking tang on the MAP Sensor connector body. Grasp the terminalbody and gently pull it from the sensor.

4. Remove the MAP Sensor from the intake manifold.







[a] If sensor is faulty, replace the sensor, refer to section 5.20.1.1.

[b] If the sensor is not faulty, go to step 8.

8. Check the turbocharger wastegate setting, refer to section 5.20.1.2.

5.20.1.1 Replacing the MAP Sensor

The MAP Sensor is non-serviceable and must be replaced as an assembly. No adjustment isrequired. Replace as follows:

1. Install the MAP Sensor into intake sensor manifold. Torque to 2.4-3.0 N·m (21-26 lb·in.).

2. Engage the locking tang on the MAP Sensor connector body.


[a] If the code is still active, check the turbocharger wastegate setting(refer to section 5.20.1.2).


5.20.1.2 Turbocharger Wastegate Setting

This procedure provides a method for verifying proper wastegate calibration.

1. Remove hose from wastegate actuator (for gensets, remove line on top side of can).

2. Set-up an indicator at the end of the wastegate actuator adjusting rod to measure actuatorrod travel. The indicator should have a minimum travel of 2.54 mm (0.100 in).




3. Connect regulator and pressure gage set-up to wastegate actuator (see Figure 5-52).

1. Hose to Wastegate Actuator 4. Supply Air Shutoff Valve

2. Vent Valve 5. Pressure Regulator

3. Pressure Gage 6. Shop Air Supply

Figure 5-52 Wastegate Calibration Equipment Set Up




4. Apply specified calibration pressure (listed in Table 5-1) to the wastegate actuator.

Model Rating Set Pressure at 0.04 in. Rod Travel

S50G-Automotive 275 bhp18.5 psi ± 0.25 psi (short wastegate

canister 2 in. in length)

1997-2000 S50G-Automotive 275 bhp21.0 psi ± 0.25 psi (long wastegate


2001 S50G-Automotive 275 bhp22.0 psi ± 0.25 psi (long wastegate


S50G-150kW-Genset 260 bhp 23.0 psi ± 0.25 psi

S50G-180kW-Genset 300 bhp 31.0 psi ± 0.25 psi

S60G-Automotive 330 bhp 24.0 psi ± 0.25 psi

S60G Automotive 400 bhp 24.0 psi ± 0.25 psi

S60G-General Purpose Stationary 385 bhp 30.0 psi ± 0.25 psi

Table 5-1 Wastegate Calibration Pressure at 0.04 in. Rod Travel

NOTICE:

For genset turbochargers, NEVER apply pressure to bottom partof actuator can. Damage to actuator may result.

5. Close air supply shutoff valve. The pressure should hold at the specified pressure. If not,check air hose and fitting connections for leaks. If none are found, replace wastegateactuator assembly. Refer to section 5.20.1.3.

6. Open vent to relieve pressure. Check gage for zero pressure reading. Adjust regulator tozero pressure and close vent valve.

7. Adjust dial indicator so it just contacts the actuator rod end and adjust to zero reading.

8. Open air supply shutoff valve and slowly adjust regulator until dial indicator reads 0.040 in.Switch pressure on and off, opening and closing supply air and vent valves, to make certaindial indicator travel is from 0.00 in. to 0.040 in. and that the pressure reading is consistent.

9. For currently calibrated wastegate actuator, a pressure within ± 0.25 psi of the valuelisted in Table 5-1 will be required to obtain precisely 0.040 in. actuator travel.

[a] If the pressure required is outside this range, wastegate adjustment is necessary.Refer to section 5.20.1.3.

[b] If the pressure required is correct, refer to section 5.20.2.

5.20.1.3 Removal and Replacement of Wastegate Actuator

This procedure describes the removal of a actuator currently mounted on a turbocharger, thereplacement with a new service actuator and setting the pressure adjustment to achieve the correctpressure setting listed in Table 5-1.




1. Remove actuator hose from the top side of the actuator can. With the pressure gage set-up,apply enough pressure to the actuator can until the rod begins to move.

2. Remove the retaining clip that holds the actuator rod end on the wastegate lever pin. Liftrod off the wastegate lever pin (see Figure 5-53).

1. Wastegate Actuator Assembly 4. Adjusting Rod End

2. Locking Collar 5. Retainer Clip

3. Jam Nut 6. Wastegate Lever and Pin Assembly

Figure 5-53 Wastegate Adjustment




NOTICE:

Never remove the rod end from the wastegate lever pin unlesspressure is applied to the top side actuator port; otherwise,damage to the actuator diaphragm may result.

3. Remove the lock nuts that secure the actuator can to the base of the actuator bracket, andremove the can from the turbocharger assembly.

4. Install the replacement actuator can on bracket; tighten lock nuts.

5. Using pressure gage setup, apply enough pressure to the new service actuator can untilthe rod begins to move.

6. Adjust actuator rod end by turning either clockwise or counterclockwise on rod so thatthe rod end hole lines up with the wastegate lever arm. While the wastegate is held shut,slip the rod over pin.

7. Before installing the retaining clip again, the rod end will need to be adjusted to the correctsetting. Loosen the jam nut that secures the rod end on the actuator rod. If locking collar ispresent on the actuator rod, remove and discard collar (see Figure 5-53).

8. Remove the retaining clip that holds the actuator rod end on the wastegate lever arm pin.

NOTICE:

For a Genset actuator, NEVER apply pressure to the bottom sideof the actuator port. Damage to the actuator may result.

9. Using pressure gage setup, apply enough pressure to the top side actuator can port untilthe rod begins to move, lifting the wastegate valve off of its seal.

10. Slip rod end off the wastegate lever arm pin and adjust the rod as needed:� To INCREASE pressure setting at 0.04 in. turn rod end CLOCKWISE.� To DECREASE pressure setting at 0.04 in. turn rod end COUNTERCLOCKWISE.

11. With pressure still applied to actuator, replace rod end on wastegate lever arm and checkthe actuator set pressure again.� If the actuator is still out of adjustment, repeat this procedure.� If actuator is within specified set pressure, reinstall retaining clip on wastegate lever

arm pin.

12. Tighten jam nut to secure rod end. For verification, refer to section 5.20.2.

5.20.2 Verification









5.21 PID 106, FMI 1, FLASH CODE 48, INTAKE MANIFOLD PRESSURE LOW

The intake manifold pressure is low due to a faulty Manifold Absolute Pressure (MAP) Sensor.



1. Check the MAP Sensor using DDEC Sensor Tester J 37164 (see Figure 5-54).




5.21 PID 106, FMI 1, FLASH CODE 48, INTAKE MANIFOLD PRESSURE LOW

2. Disconnect the sensor. The MAP Sensor is threaded into the intake manifold(see Figure 5-55).

1. Intake Manifold 5. Bolt

2. Intake Manifold Inlet 6. Bolt

3. Intake Manifold Gasket 7. ATS (Low Pressure system only)

4. Cylinder head 8. MAP Sensor

Figure 5-55 MAP Sensor Location —Series 60G

3. Disengage the locking tang on the MAP Sensor connector body. Grasp the terminalbody and gently pull it from the sensor.

4. Remove the MAP Sensor from the intake manifold.







[a] If sensor is faulty, replace the sensor, go to step 8.

[b] If the sensor is not faulty, refer to section 5.21.2.

8. Install the MAP Sensor into intake sensor manifold. Torque to 2.4-3.0 N·m (21-26 lb·in.).

9. Engage the locking tang on the MAP Sensor connector body.

10. Turn the ignition to the ON position. check the DDR for any diagnostic code(s):



5.21.2 Verification








5.22 PID 106, FMI 3, FLASH CODE 67, MANIFOLD ABSOLUTE PRESSURE SENSOR INPUT VOLTAGE HIGH

5.22 PID 106, FMI 3, FLASH CODE 67, MANIFOLD ABSOLUTE PRESSURESENSOR INPUT VOLTAGE HIGH

The Manifold Absolute Pressure Sensor input voltage is high due to a short.



NOTICE:


1. Check wire 432 (light green, manifold air pressure) cavity P-1 in the Engine SensorHarness (ESH) 30–pin connector for a short to wire 416 (gray, sensor supply voltage,5VDC) cavity W-1 in the ESH 30–pin connector (see Figure 5-56). If there is a short,repair or replace the wire(s), pins, and sockets.






[b] If the code is not active, Refer to section 5.22.2.

2. Also check pin C (manifold air pressure ) and pin B (sensor supply, +5VDC) in the MAPSensor connector. If there is a short, repair or replace the wire(s), pins, and sockets.


[b] If the code is not active, Refer to section 5.22.2.

5.22.2 Verification








5.23 PID 106, FMI 4, FLASH CODE 67, MANIFOLD ABSOLUTE PRESSURE SENSOR INPUT VOLTAGE LOW

5.23 PID 106, FMI 4, FLASH CODE 67, MANIFOLD ABSOLUTE PRESSURESENSOR INPUT VOLTAGE LOW

The Manifold Absolute Pressure (MAP) Sensor input voltage is low due to an open wire or a short.



NOTICE:


1. Check wire 432 (light green, manifold air pressure) cavity P-1 in the Engine SensorHarness (ESH) 30–pin connector to see if it is open (see Figure 5-57). Also check pinC (manifold air pressure) in the MAP Sensor connector. Repair or replace any openwires, pins, and sockets.







2. Check wire 432 (light green, manifold air pressure) cavity P-1 in the ESH 30–pin connectorfor a short to ground (see Figure 5-57). Also check pin C (manifold air pressure) in theMAP Sensor connector. If there is a short, repair or replace the wire(s), pins, and sockets.



5.23.2 Verification








5.24 PID 108, FMI 3, FLASH CODE 86, BAROMETRIC PRESSURE SENSOR INPUT VOLTAGE HIGH

5.24 PID 108, FMI 3, FLASH CODE 86, BAROMETRIC PRESSURE SENSORINPUT VOLTAGE HIGH

The input voltage on the Barometric Pressure Sensor (BARO Sensor) is high due to a short.



NOTICE:


1. Check wire 904 (purple/white, barometric pressure) cavity L-1 in the Engine SensorHarness (ESH) 30–pin connector for a short to +12V/+24V (see Figure 5-58). Also checkpin B (barometric pressure) in the BARO Sensor connector. If there is a short, repairor replace the wire(s), pins, and sockets.







2. Check wire 904 (purple/white, barometric pressure) cavity L-1 for a short to wire416 (gray, sensor supply voltage, 5VDC) cavity W-1 in the ESH 30–pin connector(see Figure 5-58). Also check pin B (barometric pressure) in the BARO Sensor connectorand pin B (sensor supply, +5VDC) in the MAP Sensor connector. If there is a short, repairor replace the wire(s), pins, and sockets.



5.24.2 Verification








5.25 PID 108, FMI 4, FLASH CODE 87, BAROMETRIC PRESSURE SENSOR INPUT VOLTAGE LOW

5.25 PID 108, FMI 4, FLASH CODE 87, BAROMETRIC PRESSURE SENSORINPUT VOLTAGE LOW

The input voltage on the Barometric Pressure Sensor (BARO Sensor) is low due to an openwire or a short.



NOTICE:


1. Check wire 904 (purple/white, barometric pressure) cavity L-1 in the Engine SensorHarness (ESH) 30–pin connector to see if it is open (see Figure 5-59). Also check pin B(barometric pressure) in the BARO Sensor connector. Repair or replace any open wire(s).







2. Check wire 904 (purple/white, barometric pressure) cavity L-1 in the ESH 30–pinconnector for a short to ground (see Figure 5-59). Also check pin B (barometric pressure)in the BARO Sensor connector. If there is a short, repair or replace any open wire(s).



5.25.2 Verification


1. Check the DDR to see if PID 108, FMI 4 Flash Code 87 is still active.






5.26 PID 110, FMI 0, FLASH CODE 44, COOLANT TEMPERATURE HIGH


Coolant temperature is high due to a faulty Coolant Temperature Sensor or a short.



NOTICE:


1. Check wire 133 (yellow, coolant temperature) cavity P-3 in the Engine Sensor Harness(ESH) 30–pin connector for a short to +12V/+24V (see Figure 5-60). Also check pin B(coolant temperature) in the Coolant Temperature Sensor connector. If there is a short,repair or replace the wire(s), pins, and sockets.







2. Check wire 133 (yellow, coolant temperature) cavity P-3 for a short to wire 416 (gray,sensor supply voltage, 5VDC) cavity W-1 in the ESH 30–pin connector (see Figure 5-60).Also check pin B (coolant temperature) in the Coolant Temperature Sensor connector. Ifthere is a short, repair or replace the wire(s), pins, and sockets.



3. Check the CTS to see if it is faulty using DDEC Sensor Tester J 37164 (see Figure 5-61).





4. Disconnect the sensor. The CTS is mounted on the right rear corner of the cylinder head,behind the turbocharger (see Figure 5-62).

1. Coolant Temperature Sensor

Figure 5-62 Coolant Temperature Sensor Location

5. Remove the CTS by disengaging the locking tang on the two wire connector.

6. Grasp the body of the connector and gently pull it from the socket.

7. Use the appropriate wrench on the hex portion of the sensor and unscrew it from thecylinder head.

8. Clip the power leads to the 12 V power source.



[a] If the sensor is faulty, replace the sensor, refer to section 5.26.2.

[b] If the sensor is not faulty, refer to section 5.26.3.

5.26.2 Replacing the Coolant Temperature Sensor

The CTS is non-serviceable, and is replaced as a unit. No adjustment is required.

Replace the Coolant Temperature Sensor as follows:

1. Apply Loctite pipe sealant with Teflon, PT-7260, or equivalent on all but first two threadsof the replacement CTS.




2. Install CTS on the cylinder head. Torque to 102-127 N·m (75-94 lb·ft).

3. Carefully install the two-wire connector onto the sensor and engage the locking tang.



5.26.3 Verification








5.27 PID 110, FMI 3, FLASH CODE 14, THE COOLANT TEMPERATURE SENSOR INPUT VOLTAGE IS LOW

5.27 PID 110, FMI 3, FLASH CODE 14, THE COOLANT TEMPERATURESENSOR INPUT VOLTAGE IS LOW

The Coolant Temperature Sensor (CTS) input voltage is low due to an open wire or a short.



NOTICE:


1. Check wire 133 (yellow, coolant temperature) cavity P-3 in the Engine Sensor Harness(ESH) 30–pin connector to see if it is open (see Figure 5-63). Also check pin B (coolanttemperature) in the Coolant Temperature Sensor connector. Repair or replace any openwire(s).







2. Check wire 133 (yellow, coolant temperature) cavity P-3 in the ESH 30–pin connectorfor a short to +12V/+24V (see Figure 5-63). Also check pin B (coolant temperature)in the Coolant Temperature Sensor connector. If there is a short, repair or replace anyopen wire(s).



3. Check wire 133 (yellow, coolant temperature) cavity P-3 for a short to wire 416 (gray,sensor supply voltage, 5VDC) cavity W-1 in the ESH 30–pin connector (see Figure 5-63).Also check bin B (coolant temperature) in the Coolant Temperature Sensor connector. Ifthere is a short, repair or replace any open wire(s).



5.27.2 Verification








5.28 PID 110, FMI 4, FLASH CODE 15, THE COOLANT TEMPERATURE SENSOR INPUT VOLTAGE IS LOW

5.28 PID 110, FMI 4, FLASH CODE 15, THE COOLANT TEMPERATURESENSOR INPUT VOLTAGE IS LOW

The Coolant Temperature Sensor (CTS) input voltage is low due to a short.



NOTICE:


1. Check wire 133 (yellow, coolant temperature) cavity P-3 in the Engine Sensor Harness(ESH) 30–pin connector for a short to ground (see Figure 5-64). If there is a short, repairor replace any open wire(s).







2. Check pin B (coolant temperature) in the Coolant Temperature Sensor connector for ashort. If there is a short, repair or replace any open wire(s).

[a] If the code is still active, call Detroit Diesel Technical Support.


5.28.2 Verification








5.29 PID 111, FMI 1, FLASH CODE 43, COOLANT LEVEL LOW


The coolant level is low due to a faulty Coolant Level Sensor or a low engine coolant level.



1. Check the engine coolant level. If the coolant level is low, use the information found inthe Series 60 Service Manual, refer to section 5.4.9 or the Series 50 Service Manual,refer to section 5.4.9.



2. Check the Coolant Level Sensor to see if it is faulty using the DDEC Sensor Tester J37164 (see Figure 5-65).


3. Disconnect the sensor. The probe should be located in either the radiator top tank or aremote mounted surge tank. It should be mounted horizontally in the center of the tank tominimize tilt operation sensitivity and must be in a position to signal low coolant beforeaeration occurs. Typically, this is a height representing 98% of the drawdown quantity.The probe should be located so that it is not splashed by deaeration line, stand pipe or




coolant return line flows. The insulated portion of the probe should be inserted into thecoolant .5 in. or more past the inside wall of the tank. See Figure 5-66.

Figure 5-66 Coolant Level Sensor Location - Top of Radiator Tank

4. Open the drain cock at the bottom of the radiator and drain the coolant into an appropriatecontainer. Remove only as much coolant as is necessary to clear the CLS probe.

5. Remove ground wire screw and ground wire from side of probe.

6. Loosen and remove nut from sensor lead of probe.

7. Remove sensor lead, or unplug the two-pin connector.

8. Use the appropriate wrench on the hex portion of the sensor and unscrew it from theradiator.


10. Plug in a volt OHM meter. The tester will power up the sensor. The voltage should readabout 1.8 volts when the sensor is working and in water. If you power up the sensor out ofwater, the voltage should go to about 3 V.

[a] If the CLS is faulty, refer to section 5.29.2.

[b] If the CLS is not faulty, call Detroit Diesel Technical Service.




5.29.2 Replacing the Coolant level Sensor

Replace the CLS as follows:

NOTE:New sensors are pre-coated with a thread sealer. If sensor is new, no additional sealantis required. If sensor is reused, apply Loctite® 567 pipe sealant with Teflon® or equivalent.

1. Install and torque CLS to 11–14 N·m (97-142 lb·in.).

2. Connect the two-pin connector.

3. Fill the cooling system.

4. Turn the ignition to the ON position. Observe or read any diagnostic code(s).

5. Start the engine and check for leaks.

6. Shut down engine upon completion of installation.



5.29.3 Verification









5.30 PID 111, FMI 3, FLASH CODE 16, COOLANT LEVEL SENSOR INPUTVOLTAGE HIGH

The voltage input to the Coolant Level Sensor (CLS) is high due to an open wire or a short.



NOTICE:


1. Check wire 115 (orange, coolant level) cavity H-3 in the Vehicle Interface Harness (VIH)30–pin connector to see if it is open (see Figure 5-67). Also check cavity A in the CLSconnector. Repair or replace and open wire(s).


[a] If the code still active, go to step 2.



5.30 PID 111, FMI 3, FLASH CODE 16, COOLANT LEVEL SENSOR INPUT VOLTAGE HIGH


2. Check wire 115 (orange, coolant level) cavity H-3 in the VIH 30–pin connector for a shortto Sensor Supply Voltage (5VDC) (see Figure 5-67). Also check cavity A in the CLS. Ifthere is a short, replace or repair wire(s).



5.30.2 Verification









5.31 PID 111, FMI 4, FLASH CODE 13, COOLANT LEVEL SENSOR INPUTVOLTAGE LOW

The voltage input for the Coolant Level Sensor (CLS) is low due to a short to ground.

5.31.1 TROUBLESHOOTING PID 111, FMI 4, FLASH CODE 1


NOTICE:


1. Check wire 115 (orange, coolant level) cavity H-3 in the Vehicle Interface Harness (VIH)30–pin connector for a short to ground (see Figure 5-68). If there is a short, replace orrepair the wire(s).





5.31 PID 111, FMI 4, FLASH CODE 13, COOLANT LEVEL SENSOR INPUT VOLTAGE LOW


2. Check cavity A in the CLS connector for a short. If there is a short, replace or repair thewire(s).



5.31.2 Verification









5.32 PID 173, FMI 3, FLASH CODE 81, EXHAUST TEMPERATURE SENSORINPUT VOLTAGE HIGH

The Exhaust Temperature Sensor input voltage is high due to an open wire or a short.

5.32.1 TROUBLESHOOTING PID 173, FMI 3, FLASH CODE 81


NOTICE:


1. Check wire 120 (tan, exhaust temperature) cavity R-2 in the 30–pin Engine SensorHarness (ESH) connector to see if it is open (see Figure 5-69). Also check pin B (exhausttemperature) in the Exhaust Temperature Sensor connector. Repair or replace any openwire(s).





5.32 PID 173, FMI 3, FLASH CODE 81, EXHAUST TEMPERATURE SENSOR INPUT VOLTAGE HIGH


2. Check wire 120 (tan, exhaust temperature) cavity R-2 for a short to wire 416 (sensorsupply voltage, gray, +5VDC) cavity W-1 in the 30–pin ESH connector (see Figure 5-69).Also check pin B (exhaust temperature) in the Exhaust Temperature Sensor connector. Ifthere is a short, replace or repair the wire(s).



3. Check wire 120 (tan, exhaust temperature) cavity R-2 for a short to +12V/+24V cavity R–2in the 30–pin ESH connector (see Figure 5-69). Also check pin B (exhaust temperature) inthe Exhaust Temperature Sensor connector. If there is a short, replace or repair the wire(s).



5.32.2 Verification









5.33 PID 173, FMI 4, FLASH CODE 82, EXHAUST TEMPERATURE SENSORINPUT VOLTAGE LOW

The Exhaust Temperature Sensor input voltage is low due to a short.



NOTICE:


1. Check wire 120 (tan, exhaust temperature) cavity R-2 in the 30–pin Engine SensorHarness (ESH) connector for a short to ground (see Figure 5-70). If there is a short,replace or repair wire(s).






5.33 PID 173, FMI 4, FLASH CODE 82, EXHAUST TEMPERATURE SENSOR INPUT VOLTAGE LOW

2. Check pin B (exhaust temperature) in the Exhaust Temperature Sensor connector. Ifthere is a short, replace or repair the wire(s).



5.33.2 Verification









5.34 PID 174, FMI 3, FLASH CODE 23, FUEL TEMPERATURE SENSORINPUT VOLTAGE HIGH

The Fuel Temperature Sensor input voltage is high due to an open wire or a short.



NOTICE:


1. Check wire 472 (orange, fuel temperature) cavity R-3 in the Engine Sensor Harness(ESH) 30–pin connector for a short to ground (see Figure 5-71). Also check pin B (fueltemperature) in the Fuel Temperature Sensor connector. If there is a short, replace orrepair the wire(s).





5.34 PID 174, FMI 3, FLASH CODE 23, FUEL TEMPERATURE SENSOR INPUT VOLTAGE HIGH


2. Check wire 472 (orange, fuel temperature) cavity R-3 in the ESH 30–pin connectorto see if it is open (see Figure 5-71). Also check pin B (fuel temperature) in the FuelTemperature Sensor connector. Replace or repair any open wire(s).



3. Check wire 472 (orange, fuel temperature) cavity R-3 for a short to wire 416 (gray, sensorsupply voltage, +5VDC) cavity W-1 in the ESH 30–pin connector (see Figure 5-71). Alsocheck pin B (fuel temperature) in the Fuel Temperature Sensor connector. If there is ashort, replace or repair the wire(s).



4. Check wire 472 (orange, fuel temperature) cavity R-3 in the ESH 30–pin connector for ashort to +12V/+24V (see Figure 5-71). Also check pin B (fuel temperature) in the FuelTemperature Sensor connector. If there is a short, replace or repair the wire(s).



5.34.2 Verification









5.35 PID 174, FMI 4, FLASH CODE 24, FUEL TEMPERATURE SENSORINPUT VOLTAGE LOW

The Fuel Temperature Sensor input voltage is low due to a short to ground.



NOTICE:


1. Check wire 472 (orange, fuel temperature) cavity R-3 in the Engine Sensor Harness (ESH)30–pin connector for a short to ground (see Figure 5-72). If there is a short, replace orrepair the wire(s).






5.35 PID 174, FMI 4, FLASH CODE 24, FUEL TEMPERATURE SENSOR INPUT VOLTAGE LOW

2. Check pin B (fuel temperature) in the Fuel Temperature Sensor connector. If there is ashort, replace or repair the wire(s).

[a] If the code is still active, Call Detroit Diesel Technical Service.


5.35.2 Verification








1-50G60GTS-01A.PDF - PIDS - Freightliner Trucks · PDF file · 2013-04-025.12 pid...

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