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1-MBE900-05A

1. 42907 1 Main Filter Housing 3 Test Hose 2 Check Valve 4 Fuel Feed Line Figure 15 9 Test Setup 4 Upstream Pressure Test 2 Install the pressure tester J 46380 Connect one end of the transparent test hose to the fuel pre filter using a union from the fuel adaptor parts kit J 46377 Connect the other end of the transparent test hose to the disconnected fuel feed line using a barbed adaptor to the proper sized fuel line fitting NOTE The opening arm of the union at the pre filter should press open the check valve All information subject to change without notice Rev 2005 6SE414 0404 Copyright 2005 DETROIT DIESEL CORPORATION From Bulletin 1 MBE900 05 15 39 15 3 FUEL INJECTION TROUBLESHOOTING Inspect the seals at the fitting on the fuel pre filter for damage and replace if necessary J 4 Prime the fuel system a If equipped with a hand pump on the fuel water separator work the hand pump until resistance is felt WARNING PERSONAL INJURY To avoid injury before starting and running the engine ensure the vehicle is parked on a level surface parking brake is set and the wheels are blocked b Crank the engine for 30 seconds at a time but no longer Before cranking the engine again wait at least two minutes The engine should start within four 30 second attempts The fuel system is bled automatically 5 Stand the pressure tester on a l
2. J 46377 NUT FROM FUEL ADAPTOR PARTS KIT J 46377 HOSE FROM FUEL ADAPTOR PARTS KIT 42906 1 Fuel Drain Line at filter 6 Banjo Bolt Union from kit J 46377 2 Drain Line Fitting 7 Banjo Fitting 3 Main Filter Housing secondary 8 Overflow Valve 4 Engine Trim Panel 9 Clean Container 5 Fuel Return Line at injector 10 Hose Figure 15 8 Test Setup 3 Flow Test at Fuel Filter 2 Disconnect the fuel return line at the overflow valve When loosening the banjo bolt hold a second wrench on the overflow valve to avoid loosening the valve 3 Using a banjo bolt nut and washer from the fuel adaptor parts kit J 46377 seal off the fuel return line Rev 2005 All information subject to change without notice 15 36 From Bulletin 1 MBE900 05 6SE414 0404 Copyright 2005 DETROIT DIESEL CORPORATION MBE900 SERVICE MANUAL 4 In place of the fuel return line attach the hose with a banjo fitting from the fuel adaptor parts kit J 46377 to the overflow valve When tightening the union hold a second wrench on the overflow valve to avoid over tightening the valve 5 At the main fuel filter detach the fuel drain line and its fitting from the main filter housing 6 In place of the fuel drain line attach a union from the fuel adaptor parts kit to the main filter housing 7 At the union attach a hose and run the other end of the hose into another clean container
3. 15 15 1 Troubleshooting Procedure for Improper Engine Coolant Level To determine if improper engine coolant level is causing high engine coolant temperature visually inspect the radiator coolant level refer to OEM guidelines 1 If the radiator coolant level is within approximately 50 mm 2 0 in of the radiator filler neck check for insufficient radiator air circulation refer to section 15 15 3 2 Ifthe radiator coolant level is not within approximately 50 mm 2 0 in of the radiator filler neck refer to section 15 15 2 15 15 2 Improper Coolant Level Resolution Perform the following steps to resolve improper coolant level 1 Fill coolant system to correct level refer to section 4 4 1 2 Verify coolant level resolution refer to section 15 15 2 1 15 15 2 1 Test Engine with Proper Coolant Level Perform the following to determine if proper coolant level resolved high engine coolant temperature WARNING PERSONAL INJURY To avoid injury before starting and running the engine ensure the vehicle is parked on a level surface parking brake is set and the wheels are blocked 1 Start and run the engine All information subject to change without notice Rev 2005 6SE414 0404 Copyright 2005 DETROIT DIESEL CORPORATION From Bulletin 1 MBE900 05 15 151 15 15 HIGH ENGINE COOLANT TEMPERATURE 2 Run the engine through its operating range with no load for approximately five minutes allowin
4. 1 Start and run the engine at rated speed if the oil pressure is 241 kPa 35 psi or more no further troubleshooting is required 2 Ifthe oil pressure at rated speed is less than 241 kPa 35 psi shut down the engine Check for faulty oil pressure gauge sensor refer to section 15 14 7 15 14 7 Troubleshooting Procedure for Faulty Oil Pressure Gauge Sensor To determine if a faulty oil pressure gauge sensor is causing low oil pressure perform the following steps 1 Install the Diagnostic Data Reader DDR WARNING PERSONAL INJURY To avoid injury before starting and running the engine ensure the vehicle is parked on a level surface parking brake is set and the wheels are blocked 2 Start and vary the engine speed between 1800 2100 rpm 3 Visually examine the DDR for oil pressure reading a Ifthe oil pressure is greater than or equal to 241 kPa 35 psi at rated speed shut down the engine No further troubleshooting is required b If the oil pressure is less than 241 kPa 35 psi at rated speed shut down the engine refer to section 15 14 8 15 14 8 Oil Pressure Gauge Sensor Replacement Perform the following steps to replace the oil pressure gauge sensor 1 Remove and replace the oil pressure gauge sensor refer to OEM guidelines 2 Verify oil pressure gauge sensor replacement refer to section 15 14 8 1 All information subject to change without notice Rev 2005 6SE414 0404 Copyright
5. The Fuel Inlet Pressure is Too High Rev 2005 All information subject to change without notice 15 22 From Bulletin 1 MBE900 05 6SE414 0404 Copyright O 2005 DETROIT DIESEL CORPORATION MBE900 SERVICE MANUAL Problem The Low Pressure Fuel System is Leaking Possible Cause The engine is leaking at external connections such as Replace seals and or gaskets as necessary Tighten the fuel temperature sensor the fittings at the base of all high pressure lines to 25 N m 18 lb ft and all banjo the fuel filter housing and or the overflow valve bolts to 40 50 N m 30 37 lb ft The O ring at one or more unit pumps is leaking worn Inspect the engine oil at the dipstick for the presence of or missing fuel Inspect the injector line fittings at the fuel pumps for leaks Remove the unit pump s and replace the O rings if necessary The O ring at one or more nozzle holders is leaking or Inspect the engine oil at the dipstick for the presence of the nozzle holders themselves are cracked or incorrectly fuel Inspect all the nozzle holders and especially their installed O rings for leaks Remove the nozzle holder s and replace the O rings if necessary Replace the nozzle holder s if cracked or otherwise broken and install correctly The cylinder head is cracked or there is cavitation in the Inspect the engine oil at the dipstick for the presence of oil chamber fuel Replace the cylinder head if necessary There are balls
6. The thermostat is damaged Replace the thermostat Check the fan hub Contact Detroit Diesel Customer Support Center at 313 592 5800 to have parameter settings reprogrammed in the DDEC ECU or DDEC VCU The fan is not operating properly Table 15 21 Problem The Coolant Temperature is Below Normal Problem The Cooling System Is Losing Coolant There is an external coolant leak Repair the leaking component The radiator cap is leaking Replace the radiator cap The air compressor head is damaged Replace the air compressor The cylinder head gasket is leaking Replace the head gasket Table 15 22 Problem The Cooling System is Losing Coolant All information subject to change without notice Rev 2005 6SE414 0404 Copyright 2005 DETROIT DIESEL CORPORATION From Bulletin 1 MBE900 05 15 15 15 2 GENERAL TROUBLESHOOTING Problem There Is Coolant in the Engine Oil The cylinder head gasket is damaged Replace the head gasket The oil water heat exchanger is leaking Replace the heat exchanger There is an internal coolant leak Check the cooling system for leak and repair Table 15 23 Problem There is Coolant in the Engine Oil Problem There Is Foam in the Engine Oil The oil level is too low or too high Correct the oil level The oil has not been changed within the recommended interval Change the oil The oil is not of the recommended quality Change the oil Table 15 24 Problem There i
7. 1 Perform a crankcase pressure test and record the test results Refer to section 15 4 10 1 Rev 2005 All information subject to change without notice 15 84 From Bulletin 1 MBE900 05 6SE414 0404 Copyright O 2005 DETROIT DIESEL CORPORATION MBE900 SERVICE MANUAL 2 Disconnect the air discharge line from the air compressor see Figure 15 19 Refer to section 10 1 1 A TO AIR GOVERNOR B FROM INTAKE SIDE OF TURBOCHARGER C TO WET TANK OR AIR DRYER IF INSTALLED 42477 1 Discharge Port 4 Unloader Port 2 Unloader Air Line 5 Discharge Air Line 3 Intake Air Line 6 Air Compressor Figure 15 19 Air Line Attachments Repeat step 1 and record the test results 4 Compare the results of test one with test two a If the engine crankcase pressure remained the same check the turbocharger refer to section 15 8 4 b If the engine crankcase pressure decreased repair or replace the air compressor refer to section10 1 15 8 3 1 Test Engine with Repaired Air Compressor Perform the following steps to determine if a repaired air compressor resolved the excessive crankcase pressure All information subject to change without notice Rev 2005 6SE414 0404 Copyright O 2005 DETROIT DIESEL CORPORATION From Bulletin 1 MBE900 05 15 85 15 8 EXCESSIVE CRANKCASE PRESSURE WARNING PERSONAL INJURY To avoid injury before starting and running the engine ensure the vehicle is parked on a level surface park
8. PERSONAL INJURY To avoid injury before starting and running the engine ensure the vehicle is parked on a level surface parking brake is set and the wheels are blocked 1 Attempt to start and run the engine if the engine starts and runs no further troubleshooting is required Shut down the engine 2 If the engine fails to start and run check the fuel filters refer to section 15 5 19 15 5 19 Troubleshooting Procedure for Plugged Fuel Filter s To determine if a plugged fuel filter s is causing starting difficulty perform the following steps 1 Disconnect the fuel line return hose from the fitting located at the fuel tank 2 Place the opened end of the fuel line into a five gallon container A WARNING PERSONAL INJURY To avoid injury before starting and running the engine ensure the vehicle is parked on a level surface parking brake is set and the wheels are blocked Start the engine Run the engine at 1000 rpm Clock fuel rate for one minute Dye E oa Measure the amount of fuel delivered into the container a Ifthe fuel flow is greater than 1 7 L min 0 5 gal min and aerated small bubbles check for air in fuel refer to section 15 5 23 b If the fuel flow is less than 1 7 L min 0 5 gal min replace the fuel filters refer to section 15 5 20 15 5 20 Plugged Fuel Filter s Replacement Perform the following steps to replace the fuel filter s 1 Replace the fuel filter refer to
9. 15 5 23 Troubleshooting Procedure for Aerated Fuel To determine if aerated fuel is causing starting difficulty perform the following steps 1 Disconnect the fuel line return hose from the fitting located at the fuel tank refer to OEM guidelines 2 Place the opened end of the fuel line into a suitable container Rev 2005 All information subject to change without notice 15 66 From Bulletin 1 MBE900 05 6SE414 0404 Copyright O 2005 DETROIT DIESEL CORPORATION MBE900 SERVICE MANUAL WARNING PERSONAL INJURY To avoid injury before starting and running the engine ensure the vehicle is parked on a level surface parking brake is set and the wheels are blocked Start the engine 4 Run the engine at 1000 rpm Visually check to see if air bubbles are rising to the surface of the fuel within the container a If air bubbles are present repair is necessary refer to section 15 5 24 b If air bubbles are not present check for a restrictive air filter Shut down the engine refer to section 15 5 25 15 5 24 Aerated Fuel Resolution Perform the following steps for aerated fuel resolution 1 Shut down the engine 2 Tighten all fuel line connections between fuel tank and fuel pump refer to OEM guidelines Visually inspect all fuel lines between fuel tank and fuel pump for leaks 4 Replace damaged components as required refer to OEM guidelines Verify aerated fuel resolution refer to section 15 5 24 1 15 5
10. 15 3 4 2 Test 3 1 Open the fuel fill cap to release pressure in the fuel tank WARNING PERSONAL INJURY To avoid injury before starting and running the engine ensure the vehicle is parked on a level surface parking brake is set and the wheels are blocked 2 Start the engine and run it at a slow idle 600 to 650 rpm until the fuel flows into the container with little or no bubbling 3 Check the fuel flow at the fuel filter NOTE When beginning the timed portion of this test take the transparent hose out of the clean container and insert it into a calibrated container or measuring cup a Measure the quantity of fuel that flows out of the hose in one minute 60 seconds If more than 300 mL 10 1 oz flow out fuel flow at the filter is too high at idle b Increase the engine speed to 2500 rpm c Measure the quantity of fuel that flows out of the hose in one minute If more than 300 mL 10 1 oz flow out fuel flow at the filter is too high at rated speed NOTE If fuel flow on either test is too high correct the problem Fuel flow is OK if the system passes both tests 4 Check the fuel flow at the overflow valve a Reduce engine speed back to slow idle 600 to 650 rpm NOTE When beginning the timed portion of this test take the transparent hose out of the clean container and insert it into a large calibrated container All information subject to change without notice Rev 2005 6SE414
11. 18 lb ft The fuel feed lines and connections are leaking drawing Replace the seals on the leaking lines Tighten the fittings on the fuel lines to 25 N m 18 lb ft and perform a fuel leak test The fuel pump is worn Replace the fuel pump The pressure limiting valve in the fuel pump is jammed Replace the fuel pump open or the drive lever is loose or broken The air admission valve in the fuel tank is blocked Remove air admission valve blockage The suction line and or strainer at the fuel level sensor Inspect the suction line and or strainer through the fuel is blocked or is touching the bottom of the fuel tank fill opening in the fuel tank Remove the fuel level sensor and repair or replace the line or strainer as necessary Table 15 35 Problem The Fuel Inlet Pressure is Too Low Problem The Fuel Inlet Pressure is Too High Possible Cause Remedy The fuel feed lines are kinked or blocked Inspect the lines and fittings for blockage Repair replace as necessary The suction line and or strainer at the fuel level sensor is Inspect the suction line and or strainer through the fuel blocked or is touching the bottom of the fuel tank fill opening in the fuel tank Remove the fuel level sensor and repair or replace the line or strainer as necessary The check valve in the fuel feed line is blocked or not Repair replace as necessary open wide the flange at the fitting connection is bent Table 15 36 Problem
12. 2 Verify battery replacement refer to section 15 12 2 1 15 12 2 1 Test Engine with Replaced Battery Perform the following steps to determine if the battery replacement resolved the concern Rev 2005 All information subject to change without notice 15 122 From Bulletin 1 MBE900 05 6SE414 0404 Copyright O 2005 DETROIT DIESEL CORPORATION MBE900 SERVICE MANUAL WARNING PERSONAL INJURY To avoid injury before starting and running the engine ensure the vehicle is parked on a level surface parking brake is set and the wheels are blocked 1 Start and run the engine 2 Run the engine at idle with a no load condition for approximately five minutes allowing the engine coolant to reach normal operating range 88 96 C 190 205 F a Ifthe engine is not running rough or stalling no further troubleshooting is required Shut down the engine b Ifthe engine is running rough or stalling shut down the engine Check for aerated fuel refer to section 15 12 3 15 12 3 Troubleshooting Procedure for Aerated Fuel To determine if aerated fuel is causing rough running or stalling perform the following steps 1 Disconnect the fuel line return hose from the fitting at the fuel tank refer to OEM guidelines 2 Place the open end of the fuel line into a suitable container WARNING PERSONAL INJURY To avoid injury before starting and running the engine ensure the vehicle is parked on a level surface parking
13. 42905 1 Engine Trim Panel 4 Banjo Fitting 2 Fuel Return Line 5 Seal Ring from kit J 46377 3 Washers 6 Adaptor from kit J 46377 Figure 15 7 Test Setup 2 Flow Test at Nozzle Holder 2 Using the injector line socket J 46371 remove the injection line at cylinder 4 on the 6 cylinder engine and at cylinder 2 on the 4 cylinder engine NOTE When removing the injection line the transfer tube thrust nut must be held inorder to keep the line from twisting Rev 2005 All information subject to change without notice 15 34 From Bulletin 1 MBE900 05 6SE414 0404 Copyright 2005 DETROIT DIESEL CORPORATION MBE900 SERVICE MANUAL 3 Remove the fuel return line banjo fitting and washers from the cylinder head at the same cylinder from which the injection line was removed 4 Using the adaptor and seal rings from the fuel adaptor parts kit J 46377 to install the fuel return line back onto the cylinder head Tighten adaptor securely 5 Install the injection line using the injector line socket J 46371 Torque injection line to 25 N m 18 lb ft 6 Place a clean cloth below the opening in the adaptor to catch any fuel which leaks out of the return line during the test 15 3 3 2 Test 2 i 1 Open the fuel fill cap to release pressure in the fuel tank WARNING PERSONAL INJURY To avoid injury before starting and running the engine ensure the vehicle is parked on a level surface parking brake is set and the
14. C 180 221 F and no leaks are found no further troubleshooting is required b Ifthe engine coolant temperature is 82 105 C 180 221 F and leaks are found repair the leaks refer to section 15 15 9 Shut down the engine c Ifthe engine coolant temperature is not 82 105 C 180 221 F and no leaks are found shut down the engine Check fan belt refer to section 15 15 10 15 15 10 Troubleshooting Procedure for Incorrectly Adjusted Fan Belt To determine is a misadjusted fan belt is causing high engine coolant temperature perform the following steps 1 Check the auto tensioner for spring loading 2 Compare tension to belt specifications a If the belt tension is normal check the thermo modulated fan refer to section 15 15 12 b Ifthe belt tension is not normal refer to section 15 15 11 15 15 11 Belt Tension Resolution Perform the following steps to resolve incorrect belt tension 1 Replace the auto tensioner as required 2 Verify belt tension resolution refer to section 15 15 11 1 15 15 11 1 Test Engine with Correct Belt Tension Perform the following to determine if belt tension resolved high engine coolant temperature All information subject to change without notice Rev 2005 6SE414 0404 Copyright 2005 DETROIT DIESEL CORPORATION From Bulletin 1 MBE900 05 15 155 15 15 HIGH ENGINE COOLANT TEMPERATURE WARNING PERSONAL INJURY To avoid injury before starting and running the engine ensure
15. Loop Fault 158 158 Switched Battery Voltage High Switched Battery Voltage Low Switched Battery Voltage Does Not match DDEC ECU and DDEC VCU Battery Voltage High 168 168 216 230 404 404 527 558 Battery Voltage Low Fuel Temperature Sensor Open Circuit Fuel Temperature Sensor Short to Ground Engine Oil Temperature Sensor Open Circuit Engine Oil Temperature Sensor Short to Ground Engine Speed High Other DDEC ECU Fault Missing Information Idle Variation Switch IVS Wired Backwards Turbo Compressor Out Temp High Turbo Compressor Out Temp Low Cruise Control DDEC VCU Internal Error Idle Validation Switch IVS Open Circuit Both Idle Validation Switches Closed Idle Validation Switch IVS not Idle and Accelerator Pedal Signal Idle Idle Validation Switch Idle IVS and Accelerator Pedal Signal not Idle Cruise Control Switch Contact Set Coast Both SET and RES Contacts Closed at the Same Time Table 15 5 DDEC VCU and DDEC ECU Fault Codes 3 of 7 _ a Rev 2005 All information subject to change without notice 15 6 From Bulletin 1 MBE900 05 6SE414 0404 Copyright 2005 DETROIT DIESEL CORPORATION MBE900 SERVICE MANUAL ale et SPN PID SID e contacts are closed at the same time Pee pa Saet Device Wrong Key soe 288 9 Saen No Transponder Code on Hare eos 293 1 Anite Catbraton ror soe ass 0 animen No Adional Key Can be Leama Pos 2 ovececuraie O
16. See Figure 15 17 3 Engage the starter switch All information subject to change without notice Rev 2005 6SE414 0404 Copyright 2005 DETROIT DIESEL CORPORATION From Bulletin 1 MBE900 05 15 73 15 6 NO START ENGINE WILL NOT ROTATE 4 View the voltage reading on the meter a Ifthe voltage is less than specification refer to OEM guidelines while cranking the engine replace starter refer to section 15 6 6 b If the voltage is to specification refer to OEM guidelines while attempting to crank the engine check for internal engine damage refer to section 15 6 7 15 6 6 Starter Replacement Perform the following steps for starter replacement 1 Replace the starter refer to section 8 1 2 Verify replacement of starter refer to section 15 6 6 1 15 6 6 1 Test Engine with New Starter To determine if the new starter resolved no start conditions perform the following steps WARNING PERSONAL INJURY To avoid injury before starting and running the engine ensure the vehicle is parked on a level surface parking brake is set and the wheels are blocked Attempt to start and run the engine if the engine starts and runs no further troubleshooting is required Shut down the engine If the engine fails to start or run check for internal engine damage Refer to section 15 6 7 15 6 7 Troubleshooting Procedure for Internal Engine Damage To determine if internal engine damage is causing
17. se engine oever sensorvotage Low se se 5 engine Outer Senso Open Great se se 2 eraine Oar ETE o o A ETT o o 2 Erone On reso Sensor operor o o 2 Enae o Pressure Sensor Daa Enare o 100 Erare On Pressure Sensor shore Gund ro o 4 gr On rea Toro sce toe 0 eoost Pressure ign id sce e eons Pression OO sce toe nostro Sensor Dato sce e 2 Boos Pressure Sensor Open Grout sce 100 Boos Pressure Sensor srono Gouna sce e 10 boos Pressure onone o ratas o rarezas ses hos 2 rake wanted Temperature Sensor Open Greut ras os Tra Wanted Temperature Sensor short Gaurd ras as 0 rake manto tempera Hgo ir sor a e en rigs Table 15 4 DDEC VCU and DDEC ECU Fault Codes 2 of 7 All information subject to change without notice Rev 2005 6SE414 0404 Copyright 2005 DETROIT DIESEL CORPORATION From Bulletin 1 MBE900 05 15 5 15 1 TROUBLESHOOTING THE ELECTRONIC ENGINE CONTROL SYSTEM Description TF az iI 107 Sl Air Filter Sensor Open Circuit sor 07 aries Sensor nono Ground Cm f A RL EI DE jo ono ee Engine Coolant Temperature Sensor Short to Ground Engine Coolant Temperature Sensor Open Circuit Coolant Level Low Coolant Level Sensor Open Circuit Coolant Level Sensor Short to Ground Coolant Level Very Low Optimized Idle Ol
18. 0404 Copyright 2005 DETROIT DIESEL CORPORATION From Bulletin 1 MBE900 05 15 37 15 3 FUEL INJECTION TROUBLESHOOTING b Measure the quantity of fuel that flows out of the hose in one minute 60 seconds If more than 1 7 Liter 1 8 qt flows out overflow valve fuel flow is too high If less than 0 9 Liter 0 95 qt flows out overflow valve fuel flow is too low If between 0 9 Liter 0 95 qt and 1 7 Liter 1 8 qt flows out overflow valve fuel flow is within range c Increase the engine speed to 2500 rpm d Measure the quantity of fuel that flows out of the hose in one minute If more than 7 5 Liter 7 9 qt flows out overflow fuel flow is too high If less than 2 7 Liter 2 9 qt flows out overflow fuel flow is too low If between 2 7 Liter 2 9 qt and 7 5 Liter 7 9 qt flows out overflow fuel flow is within range If overflow valve fuel flow is too low and filter fuel flow is too high see the causes listed in Table 15 33 Problem Fuel Flow Quantity is Too Low at the Overflow Valve and Too High at the Filter and correct the problem Make any necessary repairs and or replacements If overflow valve fuel flow is too low and fuel flow is OK at the filter see the causes listed in Table 15 34 Problem Fuel Flow Quantity is Too Low at the Overflow Valve and Within Range at the Filter and correct the problem Make any necessary repairs and or replacements If overflow valve fuel flow is too low and fuel
19. 10 1 1 A TO AIR GOVERNOR B FROM INTAKE SIDE OF TURBOCHARGER C TO WET TANK OR AIR DRYER IF INSTALLED 42477 1 Discharge Port 4 Unloader Port 2 Unloader Air Line 5 Discharge Air Line 3 Intake Air Line 6 Air Compressor Figure 15 18 Air Line Attachments Repeat step 1 and record the results 4 Compare the results of test one with test two a If the engine crankcase pressure remained the same check the turbocharger refer to section 15 7 6 b Ifthe engine crankcase pressure decreased replace the air compressor refer to section 10 1 1 Verify the replaced or new air compressor refer to section 15 7 5 1 15 7 5 1 Test Engine with Repaired Air Compressor Perform the following steps to determine if the replaced or new air compressor resolved the excessive crankcase pressure All information subject to change without notice Rev 2005 6SE414 0404 Copyright 2005 DETROIT DIESEL CORPORATION From Bulletin 1 MBE900 05 15 79 15 7 EXCESSIVE OIL CONSUMPTION WARNING PERSONAL INJURY To avoid injury before starting and running the engine ensure the vehicle is parked on a level surface parking brake is set and the wheels are blocked Start and run the engine Perform a crankcase pressure test Refer to section 15 4 10 1 a If the engine crankcase pressure exceeds 0 62 kPa 2 5 in H O shut down the engine Check for defective turbocharger refer to section 15 7 6 b If
20. 14 5 Troubleshooting Procedure for Lubricating Oil Diluted with Fuel or Engine Coolant To determine if lubricating oil diluted with fuel or engine coolant is causing low oil pressure perform the following steps 1 Ze Acquire a lubricating oil sample from the engine oil pan Visually examine lubricating oil sample for presence of engine coolant or fuel a If coolant or fuel are not present check for a faulty oil pressure gauge refer to section 15 14 7 b If coolant or fuel are present refer to section 15 14 6 15 14 6 Contaminated Lubricating Oil Resolution Perform the following steps to resolve contaminated lubricating oil 1 2 3 4 5 If coolant is present consider head gasket replacement and repair as required If fuel is present consider fuel nozzle replacement and repair as required Drain engine oil pan Refill engine crankcase with new oil Verify lubricating oil replacement refer to section 15 14 6 1 15 14 6 1 Test Replaced Lubricating Oil To determine if replaced lubricating oil resolved low oil pressure perform the following 15 142 Rev 2005 All information subject to change without notice From Bulletin 1 MBE900 05 6SE414 0404 Copyright O 2005 DETROIT DIESEL CORPORATION MBE900 SERVICE MANUAL WARNING PERSONAL INJURY To avoid injury before starting and running the engine ensure the vehicle is parked on a level surface parking brake is set and the wheels are blocked
21. 15 13 15 Troubleshooting Procedure for High Inlet Air Temperature To determine if high inlet air temperature is causing lack of power test check the radiator fan fan drive or fan shroud for proper operation or configuration Refer to OEM guidelines 1 If the radiator fan fan drive or fan shroud pass the OEM test check camshaft timing refer to section 15 13 17 2 If the radiator fan drive or shroud did not operate correctly refer to section 15 13 16 15 13 16 Radiator Fan Drive and Shroud Replacement Perform the following steps to replace the radiator fan drive and or shroud 1 Remove and replace the radiator fan drive and or shroud refer to OEM guidelines All information subject to change without notice Rev 2005 6SE414 0404 Copyright 2005 DETROIT DIESEL CORPORATION From Bulletin 1 MBE900 05 15 137 15 13 LACK OF POWER 2 Verify replacement refer to section 15 13 16 1 15 13 16 1 Test the Engine with Radiator Fan Fan Drive or Fan Shroud Replacement Perform the following steps to determine if replaced radiator fan fan drive or fan shroud resolved lack of power condition WARNING PERSONAL INJURY To avoid injury before starting and running the engine ensure the vehicle is parked on a level surface parking brake is set and the wheels are blocked 1 Start and run the engine 2 Test drive the vehicle to ensure lack of power has been resolved a If no lack of power occurred during the t
22. 2005 6SE414 0404 Copyright 2005 DETROIT DIESEL CORPORATION From Bulletin 1 MBE900 05 15 17 15 2 GENERAL TROUBLESHOOTING Problem The Engine Exhaust Is Black Cause MON Check the air restriction indicator Clean the intake air The air filter and or intake air system is clogged Bon ae system and replace the air filter if necessary The exhaust brake valve is malfunctioning Replace exhaust brake valve Check that the preheater is not staying on all of the time Replace preheater if necessary The valves are not adjusted properly Check the valve lash There is damage to the fuel system the fuel pump fuel Check the fuel system Replace defective fuel pump fuel nozzle s or unit pump s nozzle s or unit pump s The charge air temperature sensor is damaged Replace the charge air temperature sensor There is internal damage to the engine Repair internal damage in engine The intake air preheater is malfunctioning EGR valve not operating properly Replace EGR valve Turbocharger turbine wheel does not spin freely Replace the turbocharger Damaged cylinder components Perform cylinder Low cylinder compression compression test Repair replace damaged parts as necessary k for leak fuel filter fuel li fuel There are air bubbles in thefuei Chect or leaks at fuel filter fuel lines or fuel pump Repair replace as necessary The air filter is clogged Clean or replace the air filter Charge air cooler is
23. 2005 DETROIT DIESEL CORPORATION From Bulletin 1 MBE900 05 15 143 15 14 LOW OIL PRESSURE 15 14 8 1 Test Replaced Oil Pressure Gauge Sensor To determine if replaced oil pressure gauge sensor resolved the low oil pressure concern perform the following WARNING PERSONAL INJURY To avoid injury before starting and running the engine ensure the vehicle is parked on a level surface parking brake is set and the wheels are blocked Start and run the engine at rated speed if the oil pressure is 241 kPa 35 psi or more no further troubleshooting is required If the oil pressure at rated speed is less than is 241 kPa 35 psi shut down the engine Check for an obstructed oil pressure gauge line refer to section15 14 9 15 14 9 Troubleshooting Procedure for Oil Pressure Gauge Line Obstructed To determine if an oil pressure gauge line obstruction is causing low oil pressure perform the following steps lg Ze Disconnect oil gauge line from oil pressure gauge refer to OEM guidelines Visually inspect oil gauge line for obstructions a If no obstructions are found check to determine if rocker arm shaft plugs are missing new or rebuilt engines only b If obstructions are found refer to section 15 14 10 15 14 10 Obstructed Oil Pressure Gauge Line Repair Perform the following steps to resolve oil pressure gauge line obstructions 1 2 3 4 5 Remove oil pressure gauge line refer to OEM guideline
24. 3 1 Verify repair to cylinder valve s or cylinder kit components refer to section 15 8 7 1 15 8 7 1 Test Engine with Repairs Made to Correct Worn or Damaged Valve or Cylinder Kit Perform the following to determine if the repaired valve or cylinder kit resolved the excessive crankcase pressure 1 Ze 15 88 Move the vehicle requiring test to the chassis dynamometer refer to OEM guidelines Disconnect air compressor refer to section 10 1 1 A WARNING PERSONAL INJURY To avoid injury before starting and running the engine ensure the vehicle is parked on a level surface parking brake is set and the wheels are blocked Start the engine Run the engine and bring the engine coolant temperature to normal operating range approximately 88 96 C 190 205 F Run the vehicle to full load and rated speed Attach a manometer calibrated to read pressure in kPa or inches of H O to the oil dipstick opening Measure and record crankcase pressure Shut down the engine Remove the vehicle from the chassis dynamometer Compare the cylinder pressure test results to specifications listed in Table 1 10 a If cylinder pressure is within specifications no further troubleshooting is required Rev 2005 All information subject to change without notice From Bulletin 1 MBE900 05 6SE414 0404 Copyright O 2005 DETROIT DIESEL CORPORATION MBE900 SERVICE MANUAL b If cylinder pressure is not within specifications c
25. 4 b If external oil leaks are present refer to section 15 7 3 and repeat 15 7 4 Troubleshooting Procedure for a Leaking Oil Heat Exchanger Core To determine if a leaking oil heat exchanger core is causing excessive oil consumption perform the following 1 Check for oil in the engine coolant or radiator a If oil is present in either the engine coolant or radiator go to step 2 b If no oil is present in either the engine coolant or radiator check for a defective air compressor refer to section 15 7 5 2 Remove the oil heat exchanger core and housing Clean both the oil side and water side of the oil heat exchanger core 4 Visually inspect the core for cracks a If cracks are present replace oil heat exchanger core Refer to section 3 6 1 Verify the replacement of the oil heat exchanger core refer to section 15 7 4 1 All information subject to change without notice Rev 2005 6SE414 0404 Copyright O 2005 DETROIT DIESEL CORPORATION From Bulletin 1 MBE900 05 15 77 15 7 EXCESSIVE OIL CONSUMPTION b If no cracks are present complete a lube oil consumption report call the Detroit Diesel Customer Support Center at 313 592 5800 for a form 15 7 4 1 Test Engine with New Oil Heat Exchanger Core Perform the following steps to determine if the replaced oil heat exchanger core reduced the oil consumption WARNING PERSONAL INJURY To avoid injury before starting and running the engine ensu
26. If pressure at idle speed 600 650 rpm is greater than 0 09 to 0 12 bar 1 3 to 1 7 refer to Table 15 36 4 If ano pressure reading is observed replace the fuel pump refer to section2 15 1 Check fuel intake pressure upstream of fuel pump 15 5 22 Fuel Pump Replacement i Perform the following steps for fuel pump replacement 1 Replace the fuel pump refer to section 2 15 1 All information subject to change without notice Rev 2005 6SE414 0404 Copyright O 2005 DETROIT DIESEL CORPORATION From Bulletin 1 MBE900 05 15 65 15 5 STARTING DIFFICULTY ENGINE ROTATES A WARNING PERSONAL INJURY To avoid injury before starting and running the engine ensure the vehicle is parked on a level surface parking brake is set and the wheels are blocked 2 Test the engine to determine if starting has been improved refer to section 15 5 22 1 15 5 22 1 Engine Test with Replaced Fuel Pump To determine if the replaced fuel pump resolved starting difficulty perform the following steps WARNING PERSONAL INJURY To avoid injury before starting and running the engine ensure the vehicle is parked on a level surface parking brake is set and the wheels are blocked 1 Attempt to start and run the engine if the engine starts and runs no further troubleshooting is required Shut down the engine 2 If the engine fails to start and run check for aerated fuel refer to section 15 5 23
27. Individual Cylinders 400 58 Table 15 40 Compression Testing Specifications a If cylinder pressure is below specifications refer to section 15 5 28 b If cylinder pressure is within specifications call Detroit Diesel Customer Support Center at 313 592 5800 All information subject to change without notice Rev 2005 6SE414 0404 Copyright O 2005 DETROIT DIESEL CORPORATION From Bulletin 1 MBE900 05 15 121 15 12 ROUGH RUNNING OR STALLING 15 12 ROUGH RUNNING OR STALLING There are several causes for rough running or stalling These probable causes are Low Battery Voltage Aerated Fuel Insufficient Fuel Flow 15 121 Troubleshooting Procedure for Low Battery Voltage To determine if a weak battery is causing rough running or stalling perform the following steps WARNING PERSONAL INJURY To avoid injury before starting and running the engine ensure the vehicle is parked on a level surface parking brake is set and the wheels are blocked 1 Start and run the engine 2 Measure the battery voltage refer to OEM guidelines a Ifthe battery voltage is greater than or equal to 10 5 volts check for aerated fuel refer to section 15 12 3 b If the battery voltage is less than 10 5 volts replace the battery refer to section 15 122 15 12 2 Battery Replacement Perform the following steps for battery replacement 1 Remove and replace the battery refer to OEM guidelines
28. Shut down the engine Rev 2005 All information subject to change without notice 15 80 From Bulletin 1 MBE900 05 6SE414 0404 Copyright 2005 DETROIT DIESEL CORPORATION MBE900 SERVICE MANUAL 15 7 7 Troubleshooting Procedure for Worn or Damaged Valve or Cylinder Kit A loss of cylinder pressure can cause increased oil consumption The detection and elimination of cylinder pressure losses is vital to engine life and efficient operation To assist the mechanic in effectively measuring the loss of cylinder pressure and locating the source of abnormal leaks in individual cylinders the following test procedure has been developed 1 Move the vehicle requiring test to the chassis dynamometer refer to OEM guidelines 2 Disconnect the air compressor and remove refer to section 10 1 1 WARNING PERSONAL INJURY To avoid injury before starting and running the engine ensure the vehicle is parked on a level surface parking brake is set and the wheels are blocked Start the engine gt Run the engine and bring the engine coolant temperature to normal operating range approximately 88 96 C 190 205 F Run the vehicle to full load and rated speed Perform a crankcase pressure test Refer to section 15 4 10 1 Shut down the engine Remove the vehicle from the chassis dynamometer ANN Review the crankcase pressure test results a If the crankcase pressure exceeds 0 62 kPa 2 5 in H O repair worn or damage
29. Test Engine with New Thermostat Perform the following steps to determine if thermostat replacement resolved high engine coolant temperature All information subject to change without notice Rev 2005 6SE414 0404 Copyright 2005 DETROIT DIESEL CORPORATION From Bulletin 1 MBE900 05 15 157 15 15 HIGH ENGINE COOLANT TEMPERATURE WARNING PERSONAL INJURY To avoid injury before starting and running the engine ensure the vehicle is parked on a level surface parking brake is set and the wheels are blocked 1 Start and run the engine 2 Run the engine through its operating range with no load for approximately five minutes allowing the engine coolant to reach normal operating range a If the engine coolant temperature is 82 105 C 180 22 1 F no further troubleshooting is required Shut down the engine b Ifthe engine coolant temperature is not 82 105 C 180 221 F shut down the engine Check water pump refer to section 15 15 16 15 15 16 Troubleshooting Procedure for Faulty Water Pump To determine if a faulty water pump is causing high engine coolant temperature perform the following 1 Remove the water pump and inspect pump for failed shaft or rotor For Non EGR engines refer to section 4 2 1 for EGR engines refer to section 4 3 1 2 Replace water pump if damaged For Non EGR engines refer to section 4 2 2 for EGR engines refer to section4 3 2 15 15 16 1 Test Engine with Replaced Water Pump
30. UNIT PUMPS 1 Fuel Pump 9 Fuel Return Port 2 Main Fuel Filter secondary 10 Unit Pump 3 Fuel Delivery Port to unit pumps 11 Return Line 4 Fuel Leak Port 12 Fuel Pre filter 5 Nozzle Holder 13 Fuel Feed Line from pre filter to fuel pump 6 Transfer Tube 14 Assembly Valve in fuel feed line 7 Injector Line 15 Assembly Valve in fuel return line 8 Overflow Valve Figure 15 2 Fuel Circuit Flow Diagram Fuel is twice filtered once in a pre filter upstream of the fuel pump and for the second time in the main filter downstream of the fuel pump The main filter has a drain valve to return fuel caught in the filter to the fuel tank and constant ventilation to reduce and return any fuel vapor to the tank All information subject to change without notice Rev 2005 6SE414 0404 Copyright 2005 DETROIT DIESEL CORPORATION From Bulletin 1 MBE900 05 15 27 15 3 FUEL INJECTION TROUBLESHOOTING Unit pumps one for each cylinder boost minimum fuel pressure to 24 500 kPa 3 553 psi for purposes of injection The fuel passes through a high pressure line a high pressure connector inserted into the wall of the cylinder head and finally into the nozzle holder where it is injected into a specially designed swirl cup in the head of the piston Software maps in the DDEC ECU regulate the timing and amount of fuel injected Both fuel consumption and horsepower can be changed by downloading different software mapping Unused f
31. and runs no further troubleshooting is required Shut down the engine If the engine fails to start and run call the Detroit Diesel Customer Support Center at 313 592 5800 Rev 2005 All information subject to change without notice From Bulletin 1 MBE900 05 6SE414 0404 Copyright 2005 DETROIT DIESEL CORPORATION MBE900 SERVICE MANUAL 15 6 NO START ENGINE WILL NOT ROTATE There are several causes for the engine to not start These probable causes are Discharged Battery Defective Magnetic Switch Defective Starter Internal Engine Damage 15 6 1 Troubleshooting Procedure for Discharged Battery To determine if a discharged battery is causing the engine not to start measure and record the voltage at the battery terminals refer to OEM guidelines 1 If after charging the voltage recorded is below OEM specifications voltage is between 10 5 14 volts 21 26 volts for a 24 volt system and the engine failed to start replacement is necessary refer to section 15 6 2 2 If the voltage recorded is at recommended OEM specifications and the engine failed to start check the magnetic switch refer to section 15 6 3 15 6 2 Discharged Battery Resolution Perform the following steps for battery replacement 1 Replace the battery refer to OEM guidelines 2 Verify replacement of the battery refer to section 15 6 2 1 15 6 2 1 Test Engine with New Battery To determine if the new battery
32. assist the mechanic in effectively measuring the loss of cylinder pressure and locating the source of abnormal leaks in individual cylinders the following test procedure has been developed 1 Move the vehicle requiring test to the chassis dynamometer refer to OEM guidelines 2 Remove air compressor refer to section 10 1 1 3 Perform a crankcase pressure test Refer to section 15 4 10 1 4 Remove the vehicle from the chassis dynamometer 5 Review the crankcase pressure test results a If the crankcase pressure was greater than 0 62 kPa 2 5 in H O refer to section 15 4 11 b Ifthe crankcase pressure was less than 0 62 kPa 2 5 in H O perform a cylinder compression test Refer to section 1 2 2 2 6 Compare the cylinder compression test results to specifications refer to section 1 2 2 2 a If cylinder pressure is below specifications refer to section 15 4 11 b If cylinder pressure is within specifications call Detroit Diesel Customer Support Center at 313 592 5800 15 4 10 1 Crankcase Pressure Test Perform the following steps to check the engine crankcase pressure All information subject to change without notice Rev 2005 6SE414 0404 Copyright 2005 DETROIT DIESEL CORPORATION From Bulletin 1 MBE900 05 15 53 15 4 MISFIRING CYLINDER WARNING PERSONAL INJURY To avoid injury before starting and running the engine ensure the vehicle is parked on a level surface parking brake is set and the w
33. brake is set and the wheels are blocked Start and run the engine 4 Operate the engine at 1000 rpm Visually check to see if air bubbles are rising to the surface of the fuel within the container a If air bubbles are present shut down the engine refer to section 15 12 4 b If air bubbles are not present shut down the engine Check for high fuel temperature return which would be an indication of insufficient fuel flow 15 12 4 Aerated Fuel Resolution Perform the following steps to resolve aerated fuel All information subject to change without notice Rev 2005 6SE414 0404 Copyright 2005 DETROIT DIESEL CORPORATION From Bulletin 1 MBE900 05 15 123 15 12 4 ROUGH RUNNING OR STALLING Tighten all fuel line connections between fuel tank and fuel pump refer to OEM guidelines Visually inspect all fuel lines for leaks between fuel tank and fuel pump Repair damaged components as required refer to OEM guidelines Verify aerated fuel resolution refer to section 15 12 4 1 15 12 4 1 Test the Engine with Aerated Fuel Resolution Perform the following to determine if aerated fuel resolution has resolved rough running or stalling condition WARNING PERSONAL INJURY To avoid injury before starting and running the engine ensure the vehicle is parked on a level surface parking brake is set and the wheels are blocked Start and run the engine Run the engine at idle with a no load condition for ap
34. damaged Replace damaged charge air cooler The turbocharger is leaking oil Replace the turbocharger Take a fuel sample and have it tested Fuel must have a Fuel quality is not within DDC specifications cetane number greater than 45 and cetane index greater than 40 Drain fuel and replace with correct fuel Air intake manifold gasket leaking Faulty exhaust manifold gaskets Misadjusted exhaust brake valve Faulty exhaust brake valve Faulty constant throttle valve Table 15 27 Problem The Engine Exhaust is Black Rev 2005 All information subject to change without notice 15 18 From Bulletin 1 MBE900 05 6SE414 0404 Copyright O 2005 DETROIT DIESEL CORPORATION MBE900 SERVICE MANUAL Problem The Engine Exhaust Is Blue Tepon oil levatis Hee nigh endear Teaching Adjust the oil level and then recheck oil level the combustion chamber The turbocharger is leaking oil Replace the turbocharger The valve stem seals are loose or damaged Replace the valve stem seals The piston rings are worn Replace the piston rings Damaged cylinder components Perform cylinder Low cylinder compression compression test Repair replace damaged parts as necessary The oil is not of the recommended quality Change the oil Table 15 28 Problem The Engine Exhaust is Blue Problem Engine Brake Performance Is Poor The engine brake control switch is damaged Replace the brake control switch 3 E Check the operation of the v
35. engine ensure the vehicle is parked on a level surface parking brake is set and the wheels are blocked 1 Start the engine 2 Run the engine speed up to the occurrence of the misfiring 3 Listen for misfiring cylinder a Ifthe engine is not misfiring no further troubleshooting is required Shut down the engine b Ifthe engine is misfiring shut down the engine Call Detroit Diesel Customer Support Center at 313 592 5800 All information subject to change without notice Rev 2005 6SE414 0404 Copyright 2005 DETROIT DIESEL CORPORATION From Bulletin 1 MBE900 05 15 55 15 5 15 5 STARTING DIFFICULTY ENGINE ROTATES STARTING DIFFICULTY ENGINE ROTATES There are several causes for the engine to have starting difficulty These probable causes are DDEC ECU Wiring Harness Damage Empty Fuel Tank Low Battery Voltage Corroded or Damaged Battery Terminals Defective Magnetic Switch Defective Starter Low Cranking Speed Faulty Fuel Supply Valve Plugged Fuel Filter s Faulty Fuel Pump Aerated Fuel Restrictive Air Filter Low Compression 15 5 1 Troubleshooting Procedure for DDEC ECU Wiring Harness To determine if the DDEC ECU wire harness is causing starting difficulty perform the following Steps 1 2 15 56 Turn the ignition switch to the ON position Install the Diagnostic Data Link DDL adaptor to the d
36. is less than 12 kPa 3 5 in Hg check for high inlet air temperature refer to section 15 13 15 Rev 2005 All information subject to change without notice 15 136 From Bulletin 1 MBE900 05 6SE414 0404 Copyright O 2005 DETROIT DIESEL CORPORATION MBE900 SERVICE MANUAL b If the exhaust back pressure at full load is 12 kPa 3 5 in Hg or greater refer to section 15 13 14 15 13 14 Engine Exhaust System Resolution Perform the following steps to resolve the engine exhaust system concern 1 Visually inspect the engine exhaust system refer to OEM guidelines 2 Repair or replace defective exhaust system components refer to OEM guidelines 3 Verify exhaust system resolution refer to section 15 13 14 1 15 13 14 1 Test the Engine with Replaced Exhaust System Perform the following steps to determine if replaced engine exhaust system components have resolved the lack of power condition WARNING PERSONAL INJURY To avoid injury before starting and running the engine ensure the vehicle is parked on a level surface parking brake is set and the wheels are blocked 1 Start and run the engine 2 Test drive the vehicle to ensure lack of power has been resolved a If no lack of power occurred during the test drive no further troubleshooting is required Shut down the engine b If lack of power occurred during the test drive shut down the engine Check for high inlet air temperature refer to section 15 13 15
37. no start condition perform the following steps 1 Install a 3 4 in breaker bar or ratchet and attempt to bar the engine over by hand 2 Determine the severity of internal engine damage a If the engine rotates freely check the DDEC ECU wiring harness refer to section 15 5 1 b If the engine binds and will not rotate freely replace crankshaft bearings refer to section 1 6 and cylinder liners 15 6 8 Internal Engine Damage Replacement Perform the following steps for crankshaft bearings and cylinder liner replacement 1 Replace the crankshaft bearings refer to section 1 6 Rev 2005 All information subject to change without notice 15 74 From Bulletin 1 MBE900 05 6SE414 0404 Copyright O 2005 DETROIT DIESEL CORPORATION MBE900 SERVICE MANUAL 2 Replace the cylinder liners 3 Verify replacement of components refer to section 15 6 8 1 15 6 8 1 Test Engine with Replaced Components To determine if the new components resolved no start condition perform the following steps WARNING PERSONAL INJURY To avoid injury before starting and running the engine ensure the vehicle is parked on a level surface parking brake is set and the wheels are blocked 1 Attempt to start and run the engine if the engine starts and runs no further troubleshooting is required Shut down the engine 2 If the engine fails to start or run call Detroit Diesel Customer Support Center at 313 592 5800 All information su
38. of sealant in the fuel feed line or the Replace the cylinder block seals return port is leaking at the cylinder block Table 15 37 Problem The Low Pressure Fuel System is Leaking All information subject to change without notice Rev 2005 6SE414 0404 Copyright 2005 DETROIT DIESEL CORPORATION From Bulletin 1 MBE900 05 15 23 15 3 FUEL INJECTION TROUBLESHOOTING 15 3 FUEL INJECTION TROUBLESHOOTING There are five fuel injection system tests which measure fuel delivery performance of the MBE 900 engine Perform the following tests and make corrections or use the troubleshooting tables Test 1 Downstream Pressure Test Test 2 Flow Test At Nozzle Holder Test 3 Flow Test At Fuel Filter Test 4 Upstream Pressure Test Test 5 Leak Test 15 3 1 General Fuel System Information and Troubleshooting The fuel system contains five sub systems See Figure 15 1 The five sub systems are Fuel feed Fuel return Fuel delivery low pressure side Fuel delivery high pressure side Fuel drain Rev 2005 All information subject to change without notice 15 24 From Bulletin 1 MBE900 05 6SE414 0404 Copyright O 2005 DETROIT DIESEL CORPORATION MBE900 SERVICE MANUAL El E A es 21080 E muo Op A FUEL FEED SUB SYSTEM SUCTION SIDE B FUEL RETU
39. replace cylinder head gasket refer to section 1 2 2 2 Verify new cylinder head gasket replacement refer to section 15 15 18 1 15 15 18 1 Test Engine with Replaced Cylinder Head Gasket Perform the following to determine if cylinder head gasket replacement resolved high engine coolant temperature WARNING PERSONAL INJURY To avoid injury before starting and running the engine ensure the vehicle is parked on a level surface parking brake is set and the wheels are blocked 1 Start and run the engine 2 Run the engine through its operating range with no load for approximately five minutes allowing the engine coolant to reach normal operating range a If the engine coolant temperature is 82 105 C 180 221 F no further troubleshooting is required Shut down the engine b Ifthe engine coolant temperature is not 82 105 C 180 221 F shut down the engine Check radiator coolant flow refer to section 15 15 19 15 15 19 Troubleshooting Procedure for Abnormal Radiator Coolant Flow To determine if abnormal radiator coolant flow is causing high engine coolant temperature perform the following All information subject to change without notice Rev 2005 6SE414 0404 Copyright 2005 DETROIT DIESEL CORPORATION From Bulletin 1 MBE900 05 15 159 15 15 HIGH ENGINE COOLANT TEMPERATURE 1 Install a sight glass with string both ends to the radiator outlet hose near radiator and before fill and heater return line
40. resolved the no start condition perform the following steps WARNING PERSONAL INJURY To avoid injury before starting and running the engine ensure the vehicle is parked on a level surface parking brake is set and the wheels are blocked 1 Attempt to start and run the engine if the engine starts and runs no further troubleshooting is required Shut down the engine 2 If the engine fails to start or run check the magnetic switch refer to section 15 6 3 15 6 3 Troubleshooting Procedure for a Defective Magnetic Switch To determine if a defective magnetic switch is causing no start All information subject to change without notice Rev 2005 6SE414 0404 Copyright 2005 DETROIT DIESEL CORPORATION From Bulletin 1 MBE900 05 15 71 15 6 NO START ENGINE WILL NOT ROTATE WARNING PERSONAL INJURY To avoid injury before starting and running the engine ensure the vehicle is parked on a level surface parking brake is set and the wheels are blocked 1 Start engine 2 Clamp a heavy gage battery cable between the two large studs of the magnetic switch See Figure 15 16 MAGNETIC GROUND SWITCH RETURN START SWITCH BATTERY CRANKING MOTOR Figure 15 16 Basic Cranking Circuit a Ifthe engine cranked with the jumper cable in place the magnetic switch must be replaced refer to section 15 6 4 b Ifthe engine did not crank with the jumper cable in place check the starte
41. section 13 1 3 2 Test the engine to determine if starting has been improved refer to section 15 5 20 1 Rev 2005 All information subject to change without notice 15 64 From Bulletin 1 MBE900 05 6SE414 0404 Copyright 2005 DETROIT DIESEL CORPORATION MBE900 SERVICE MANUAL 15 5 20 1 Test Engine with Replaced Fuel Filters To determine if the replaced fuel filters resolved starting difficulty perform the following steps WARNING PERSONAL INJURY To avoid injury before starting and running the engine ensure the vehicle is parked on a level surface parking brake is set and the wheels are blocked 1 Attempt to start and run the engine if the engine starts and runs no further troubleshooting is required Shut down the engine 2 If the engine fails to start and run check the fuel pump refer to section 15 5 21 15 5 21 Troubleshooting Procedure for Fuel Pump To determine if the fuel pump is causing starting difficulty perform the following WARNING PERSONAL INJURY To avoid injury before starting and running the engine ensure the vehicle is parked on a level surface parking brake is set and the wheels are blocked 1 Start and run the engine If pressure at idle speed 600 650 rpm is 0 09 to 0 12 bar 1 3 to 1 7 check for aerated fuel Refer to section 15 5 23 2 If pressure at idle speed 600 650 rpm is less than 0 09 to 0 12 bar 1 3 to 1 7 refer to Table 15 35 3
42. specifications check for a faulty EGR valve refer to section 15 9 14 b Ifthe fuel did not meet specifications resolve improper grade of fuel refer to section 15 9 13 and DDC publication Lubricating Oil Fuel and Filters 7SE270 15 9 13 Improper Grade of Fuel Resolution Perform the following steps to resolve the improper grade of fuel 1 Drain the fuel tanks refer to OEM guidelines and dispose of fuel properly 2 Refill the fuel tanks with new fuel having a cetane number greater than 45 and cetane index greater than 40 3 Verify fuel resolution eliminated the excessive exhaust smoke condition refer to section 15 9 13 1 15 9 13 1 Test the Engine with New Fuel Perform the following steps to determine if the fuel refill resolved the excessive exhaust smoke condition WARNING PERSONAL INJURY To avoid injury before starting and running the engine ensure the vehicle is parked on a level surface parking brake is set and the wheels are blocked 1 Start and run the engine 2 Run the engine at idle under no load conditions for approximately five minutes allowing the engine coolant to reach normal operating range approximately 88 96 C 190 205 F 3 Visually inspect exhaust for excessive smoke a If the engine smoke emission appears normal no further troubleshooting is required Shut down the engine b If the engine exhaust smoke is excessively black or gray shut down the engine Check the EGR
43. subject to change without notice 15 10 From Bulletin 1 MBE900 05 6SE414 0404 Copyright O 2005 DETROIT DIESEL CORPORATION MBE900 SERVICE MANUAL 15 2 GENERAL TROUBLESHOOTING The tables that follow are designed to identify the causes of common problems and suggest further checks and appropriate remedies When technical support is necessary it is addressed in the table NOTE Resolve all electronic diagnostic codes prior to performing mechanical checks Problem The Engine Will Not Crank The batteries are damaged or weak Test the batteries Replace them if needed The ignition switch is damaged Replace the ignition switch f 1 i Table 15 10 Problem The Engine will Not Crank Problem The Engine Turns Over Slowly The batteries are damaged or weak Test the batteries Replace them if needed The ignition switch is damaged Replace the ignition switch The battery cables are damaged and or corroded Replace the battery cables The starter is damaged and or worn Replace the starter The engine oil does not meet the correct specifications Change the engine oil using the correct type of oil The transmission fluid does not meet the correct Change the transmission fluid using the correct type specifications of fluid Table 15 11 Problem The Engine Turns Over Slowly All information subject to change without notice Rev 2005 6SE414 0404 Copyright 2005 DETROIT DIESEL CORPORATION From Bulletin 1
44. the sensor is blocked or kinked line or strainer as necessary The overflow valve is faulty or the incorrect valve has Inspect the overflow valve Replace as necessary been installed The valve jams when closed as aresult NOTE Do not attempt to disassemble the overflow of wear or impurities in the fuel valve The overflow valve cannot be repaired Table 15 31 Problem Fuel Pressure is Too High Downstream of the Fuel Filter Problem Fuel Flows Out of the Fuel Return Line Possible Cause At one or more of the nozzle holders the transfer tube is Replace the damaged transfer tube s or install it leaking cracked or incorrectly installed correctly One or more nozzle holders are leaking cracked or Remove and inspect the nozzle holder s Replace if incorrectly installed necessary On one or more nozzle holders the O ring between the Remove the nozzle holder s and replace the O ring s nozzle holder and the heat isolator is leaking On one or more nozzle holders the O ring between the Inspect the engine oil at the dipstick for the presence of nozzle holder and the cylinder head is leaking fuel Inspect all the nozzle holders and especially their O rings for leaks Remove the nozzle holder s and replace the O rings if necessary Replace the nozzle holder s if cracked or otherwise broken and install correctly At one or more nozzle holders the heat isolator is Remove and inspect the heat isolator s Re
45. the engine fails to start and run check the starter refer to section 15 5 13 15 5 13 Troubleshooting Procedure for a Defective Starter To determine if a defective starter is causing starting difficulty perform the following steps 1 Place the red lead of a voltmeter to the solenoid BAT terminal see Figure 15 15 1 Black Voltmeter Lead 4 Harness Tube 2 Starter Ground Terminal Lug 5 Volt Ohm Meter 3 Red Voltmeter Lead Figure 15 15 Starting Motor Available Voltage Test All information subject to change without notice Rev 2005 6SE414 0404 Copyright 2005 DETROIT DIESEL CORPORATION From Bulletin 1 MBE900 05 15 61 15 5 STARTING DIFFICULTY ENGINE ROTATES 2 Place the black voltmeter lead to the starter ground terminal see Figure 15 15 Engage the starter switch 4 View the voltage reading on the meter a If the voltage is less than specification while cranking the engine replacement is necessary refer to section 15 5 14 b If the voltage is to specification while cranking the engine check the cranking speed refer to section 15 5 15 15 5 14 Starter Replacement Perform the following steps for starter replacement 1 Replace the starter Refer to section 8 1 2 Verify replacement of starter refer to section 15 5 14 1 15 5 14 1 Test Engine with Replaced Starter To determine if the replaced starter resolved starting difficulty perform the following steps WARNING
46. the vehicle is parked on a level surface parking brake is set and the wheels are blocked 1 Start and run the engine 2 Run the engine through its operating range with no load for approximately five minutes allowing the engine coolant to reach normal operating range a If the engine coolant temperature is 82 105 C 180 22 1 F no further troubleshooting is required Shut down the engine b Ifthe engine coolant temperature is not 82 105 C 180 221 F shut down the engine Check thermo modulated fan refer to section 15 15 12 15 15 12 Troubleshooting Procedure for Inoperative Thermo Modulated Fan To determine if an inoperative thermo modulated fan is causing high engine coolant temperature test the thermo modulated fan Refer to OEM guidelines 1 Ifthe thermo modulated fan is functioning correctly check thermostats refer to section 15 15 14 2 If the thermo modulated fan is not functioning correctly refer to section 15 15 13 15 15 13 Thermo Modulated Fan Replacement Perform the following steps to replace inoperative thermo modulated fan 1 Replace inoperative thermo modulated fan refer to OEM guidelines 2 Verify thermo modulated fan replacement refer to section 15 15 13 1 15 15 13 1 Test Engine with Replaced Thermo Modulated Fan Perform the following steps to determine if thermo modulated fan replacement resolved high engine coolant temperature Rev 2005 All information subject to change withou
47. to the engine Rev 2005 All information subject to change without notice 15 92 From Bulletin 1 MBE900 05 6SE414 0404 Copyright O 2005 DETROIT DIESEL CORPORATION MBE900 SERVICE MANUAL 3 Install the charge air cooler test gauge coupler into the inlet hose hot side of the charge air cooler coming from the turbocharger compressor Secure hose and coupler with clamp removed and torque the clamp to 5 6 6 78 N m 50 60 lb in See Figure 15 21 1 Gauge Regulator Assembly 6 Bleed off Coupler 2 Quick Disconnect Fitting 7 Charge Air Cooler Hose Cold Side 3 Gauge Coupler 8 Clamp 4 Charge Air Cooler Hose Hot Side 9 Charge Air Cooler 5 Safety Strap Figure 15 21 Charge Air Cooler and Tester J 41473 4 Attach the gauge regulator assembly to the quick disconnect fitting on the gauge coupler 5 Use the clamp removed to attach the bleed off coupler to the outlet hose cold side of the charge air cooler Torque the clamp to 5 6 6 78 N m 50 60 lb in All information subject to change without notice Rev 2005 6SE414 0404 Copyright O 2005 DETROIT DIESEL CORPORATION From Bulletin 1 MBE900 05 15 93 15 9 EXCESSIVE EXHAUST SMOKE BLACK OR GRAY 6 Connect the safety straps on the couplers to any convenient screw on the radiator mounting bracket WARNING PRESSURIZED AIR AND FLYING PARTICLES To avoid injury to eye or face wear a face shield or goggles when conducting a pressure test 7 Attach
48. unit pumps individual fuel injection pumps one for each cylinder On the way a fuel temperature sensor monitors the flow downstream from the filter This is the low pressure side of the fuel delivery sub system Each unit pump delivers fuel at high pressure to the fuel injectors This is the high pressure side of the fuel delivery sub system Excess fuel enters the return sub system through a leak line The leak line collects unused fuel and empties through an overflow valve The return lines bring the fuel back to the fuel tank This is the fuel return sub system Fuel caught in the fuel filter drains bank to the return line This is the fuel drain sub system 15 3 1 1 Principles of Operation The fuel pump controls the delivery of fuel from the fuel tank to the unit pumps Fuel pressure downstream of the fuel filter ranges from 400 to 650 kPa 58 to 94 psi The fuel pump has a pressure limiting valve to prevent fuel pressure from getting too high 920 kPa 133 psi and a check valve to prevent pressure from getting too low 20 kPa 3 psi See Figure 15 2 Rev 2005 All information subject to change without notice 15 26 From Bulletin 1 MBE900 05 6SE414 0404 Copyright O 2005 DETROIT DIESEL CORPORATION MBE900 SERVICE MANUAL A FUEL FEED SUCTION SIDE B FUEL RETURN FROM LEAK LINE C FUEL DELIVERY LOW PRESSURE SIDE DOWNSTREAM OF FUEL PUMP AND FUEL FILTER D FUEL DELIVERY HIGH PRESSURE SIDE DOWNSTREAM OF
49. valve refer to section 15 9 14 Rev 2005 All information subject to change without notice 15 100 From Bulletin 1 MBE900 05 6SE414 0404 Copyright O 2005 DETROIT DIESEL CORPORATION MBE900 SERVICE MANUAL 15 9 14 Troubleshooting Procedure for a Faulty EGR Valve To determine if a faulty EGR valve is causing excessive black or gray smoke perform the following 1 Remove the EGR valve refer to section 10 6 1 2 Inspect the EGR valve flap for freedom of movement a If freedom of movement is restricted remove soot and clean deposits as required b If movement of valve is still not free replace the EGR valve Refer to section 10 6 2 Verify the replacement of the EGR valve corrected the excessive exhaust smoke concern refer to section 15 9 14 1 3 Perform a PV2 activation test to verify flap valve functionality Call Detroit Diesel Customer Support Center at 313 592 5800 for instructions 15 9 14 1 Test the Engine with Replaced EGR Valve Perform the following steps to determine if the replaced EGR valve resolved the excessive exhaust smoke condition WARNING PERSONAL INJURY To avoid injury before starting and running the engine ensure the vehicle is parked on a level surface parking brake is set and the wheels are blocked 1 Start and run the engine 2 Run the engine at idle under no load conditions for approximately five minutes allowing the engine coolant to reach normal operating range approximat
50. 04 Copyright O 2005 DETROIT DIESEL CORPORATION MBE900 SERVICE MANUAL 15 11 16 1 Test Engine with Corrected Valve Clearance Worn or Damaged Camshaft Lobes and Rollers Perform the following steps to determine if the valve clearance worn or damaged camshaft lobes and rollers repair has resolved excessive white exhaust smoke condition WARNING PERSONAL INJURY To avoid injury before starting and running the engine ensure the vehicle is parked on a level surface parking brake is set and the wheels are blocked 1 Start and run the engine 2 Run the engine at idle with a no load condition for approximately five minutes allowing the engine coolant to reach normal operating range 3 Visually inspect exhaust for excessive white exhaust smoke a Ifthe engine exhaust smoke emission appears normal no further troubleshooting is required Shut down the engine b Ifthe engine exhaust smoke emission is excessive shut down the engine Check for low cylinder compression refer to section 15 11 17 To determine if low compression is causing excessive white smoke condition perform the following steps 1 Perform a cylinder compression test refer to section 1 2 2 2 I 15 11 17 Troubleshooting for Low Cylinder Compression A i 2 Compare cylinder compression test results to specifications as listed in Table 15 40 Pressure in kPa psi Compression Pressure at Starter Speed 2800 406 Permissible Difference between
51. 05 15 105 ee eee 15 9 EXCESSIVE EXHAUST SMOKE BLACK OR GRAY b If cylinder pressure is within specifications call Detroit Diesel Customer Support Center at 313 592 5800 15 9 21 Low Compression Repair Perform the following steps for low compression repair 1 Remove cylinder head refer to section 1 2 1 2 Inspect the cylinder head for worn or damaged valves refer to section 1 17 3 Replace damaged valves refer to section 1 17 5 4 Inspect the cylinder kit components for worn or damaged liners pistons or piston rings 5 Verify repairs made to cylinder head valve s or cylinder kit components have corrected the excessive exhaust smoke concern refer to section 15 9 21 1 15 9 21 1 Test Engine with Repaired Cylinder Head Valve s and Cylinder Kit To determine if the cylinder head valve and cylinder kit repair resolved excessive exhaust smoke perform the following steps A WARNING PERSONAL INJURY To avoid injury before starting and running the engine ensure the vehicle is parked on a level surface parking brake is set and the wheels are blocked 1 Attempt to start and run the engine if the engine starts and runs without excessive exhaust smoke no further troubleshooting is required Shut down the engine 2 Ifthe engine continues to have excessive exhaust smoke call the Detroit Diesel Customer Support Center at 313 592 5800 Rev 2005 All information subject to change without notice 15 106 From
52. 15 TROUBLESHOOTING Section 15 1 15 2 15 3 15 4 15 5 15 6 15 7 15 8 15 9 15 10 15 11 15 12 15 13 15 14 15 15 15 16 15 17 Page TROUBLESHOOTING THE ELECTRONIC ENGINE CONTROL A A A bode E 15 3 GENERAL TROUBLESHOOTING caciraas 15 11 FUEL INJECTION TROUBLESHOOTING c ccccccessesssteeeeeeseeseneeeees 15 24 MISFIRING GYIGINDER carte aora dro RIA 15 46 STARTING DIFFICULTY ENGINE ROTATES cocooococcccnononcccnnncnccncnnanononos 15 56 NO START ENGINE WILL NOT ROTATE c c ccccsssesesseeeeeeseseeseeeees 15 71 EXCESSIVE OIL CONSUMPTION c ccccccccsesseseeeeeseseeeeseeeeesesessetaaeeees 15 76 EXCESSIVE CRANKCASE PRESSURE c ccccccccseseseeeeeeeesesssnaeeeees 15 83 EXCESSIVE EXHAUST SMOKE BLACK OR GRAY ccccceseeseteeeees 15 90 EXCESSIVE BLUE SMOKE unid 15 107 EXCESSIVE WHITE SMOKE causalidad 15 112 ROUGH RUNNING OR STALLING co oocccccccnnccononnnonononononnnononcnononnncncncnnnonos 15 122 LACK OF POWER tana versed teens iii 15 126 LOW OIL PRESSURE aran mies tur ot ened alien dane N 15 140 HIGH ENGINE COOLANT TEMPERATURE cceceeeeseeeeeeeeeeeseneeeees 15 151 LOW COOLANT TEMPERATURE c cccccccccsesteeeeeececsesnteeeeeeeeeesssaeeeees 15 162 POOR FUEL EGONOMY anidaci n 15 165 From Bulletin 1 MBE900 05 Rev 2005 All information subject to change without notice 6SE414 0404 Copyright 2005 DETROIT DIESEL CORPORATION MBE900 SERVICE MANUAL 15 1 TROUBLESHOOTING
53. 2005 All information subject to change without notice 15 118 From Bulletin 1 MBE900 05 6SE414 0404 Copyright O 2005 DETROIT DIESEL CORPORATION MBE900 SERVICE MANUAL NOTICE To avoid engine damage follow the installation instructions provided with the air to air charge air cooler test kit 1 Visually inspect the core tanks and welds for cracks and holes If cooler fails visual inspection replace the charge air cooler refer to section15 11 14 2 Pressure test the charge air cooler Refer to section 15 9 3 1 3 Evaluate the results from pressure testing the charge air cooler a If the pressure drop is 34 kPa 5 psi or less in 15 seconds the cooler is good Check for faulty fuel injection nozzle refer to section 15 11 15 b Ifthe pressure drop is greater than 34 kPa 5 psi in 15 seconds replace the charge air cooler refer to section 15 11 14 Perform the following steps to replace the charge air cooler 1 Replace the charge air cooler refer to OEM guidelines 2 Verify that the replacement of the charge air cooler eliminated the excessive white exhaust smoke refer to section 15 11 14 1 15 11 14 1 Test the Engine with a Replaced Charge Air Cooler To determine if the replaced charge air cooler resolved the excessive white exhaust smoke condition perform the following I I 15 11 14 Charge Air Cooler Replacement I WARNING PERSONAL INJURY To avoid injury before starting and running the engine e
54. 2005 All information subject to change without notice From Bulletin 1 MBE900 05 6SE414 0404 Copyright O 2005 DETROIT DIESEL CORPORATION MBE900 SERVICE MANUAL 2 Visually inspect all fuel lines between fuel tank and fuel pump for leaks 3 Repair damaged components as required refer to OEM guidelines 4 Verify aerated fuel resolution refer to section 15 13 2 1 15 13 21 Test the Engine with Aerated Fuel Resolution Perform the following steps to determine if aerated fuel resolution has resolved lack of power condition WARNING PERSONAL INJURY To avoid injury before starting and running the engine ensure the vehicle is parked on a level surface parking brake is set and the wheels are blocked 1 Start and run the engine 2 Run the engine at idle with a no load condition for approximately five minutes allowing the engine coolant to reach normal operating range 3 Test drive the vehicle to ensure lack of power has been resolved a If no lack of power occurred during the test drive no further troubleshooting is required Shut down the engine b If lack of power occurred during the test drive shut down the engine Check for high fuel pressure refer to section 15 13 3 15 13 3 Troubleshooting Procedure for High Fuel Pressure To determine if high fuel pressure is causing a lack of power perform the following steps All information subject to change without notice Rev 2005 6SE414 0404 Copyright
55. 2005 DETROIT DIESEL CORPORATION From Bulletin 1 MBE900 05 15 127 15 13 LACK OF POWER 1 Remove the fuel temperature sensor See Figure 15 22 1 Fuel Temperature Sensor 2 Engine Wiring Harness Figure 15 22 Disconnecting the Sensor Rev 2005 All information subject to change without notice 15 128 From Bulletin 1 MBE900 05 6SE414 0404 Copyright O 2005 DETROIT DIESEL CORPORATION MBE900 SERVICE MANUAL 2 Install the adaptor and banjo fitting part of kit J 46377 and high pressure line J 46372 See Figure 15 23 1 Banjo Fitting 3 Adaptor from kit J 46377 2 Solenoid Unit Pump Figure 15 23 Connecting the Adaptor All information subject to change without notice Rev 2005 6SE414 0404 Copyright 2005 DETROIT DIESEL CORPORATION From Bulletin 1 MBE900 05 15 129 15 13 LACK OF POWER 3 Attach a calibrated gauge J 46378 capable of reading 0 100 psi to the high pressure fuel line J 46372 leading to the tee fitting See Figure 15 24 J 46378 J 46372 we y l 1 Engine Trim Panel 3 Fuel Temperature Sensor 2 Engine Wiring Harness Figure 15 24 Attaching the Calibrated Gauge WARNING PERSONAL INJURY To avoid injury before starting and running the engine ensure the vehicle is parked on a level surface parking brake is set and the wheels are blocked 4 Start and run the engine to the speeds lis
56. 24 1 Test Engine with Aerated Fuel Resolution To determine if aerated fuel resolution resolved starting difficulty perform the following steps WARNING PERSONAL INJURY To avoid injury before starting and running the engine ensure the vehicle is parked on a level surface parking brake is set and the wheels are blocked 1 Attempt to start and run the engine if the engine starts and runs no further troubleshooting is required Shut down the engine 2 Ifthe engine fails to start and run check for a restrictive air filter refer to section 15 5 25 All information subject to change without notice Rev 2005 6SE414 0404 Copyright 2005 DETROIT DIESEL CORPORATION From Bulletin 1 MBE900 05 15 67 15 5 STARTING DIFFICULTY ENGINE ROTATES 15 5 25 Troubleshooting Procedure for Restrictive Air Filter To determine if a restrictive air filter is causing starting difficulty perform the following steps 1 Remove the air filter element refer to OEM guidelines A WARNING PERSONAL INJURY To avoid injury before starting and running the engine ensure the vehicle is parked on a level surface parking brake is set and the wheels are blocked 2 Attempt to start and run the engine a If the engine starts and runs no further engine troubleshooting is required Shut down the engine b If the engine fails to start and run refer to section 15 5 26 15 5 26 Air Filter Replacement Perform the following ste
57. 4 0404 Copyright O 2005 DETROIT DIESEL CORPORATION
58. 9 11 1 b If the engine crankcase pressure is greater than 0 62 kPa 2 5 in H O shut down the engine Connect the oil drain outlet line to the turbocharger and call the Detroit Diesel Customer Support Center at 313 592 5800 15 9 11 1 Test Engine with a Replaced Turbocharger Perform the following steps to determine if a replaced turbocharger has resolved the excessive exhaust smoke condition WARNING PERSONAL INJURY To avoid injury before starting and running the engine ensure the vehicle is parked on a level surface parking brake is set and the wheels are blocked 1 Start the engine 2 Run the engine speed to full load Visually inspect the exhaust for excessive black or gray smoke a Ifthe engine exhaust emission appears normal no further troubleshooting is required Shut down the engine b Ifthe engine exhaust emission is excessive shut down the engine check for improper grade of fuel Refer to section 15 9 12 All information subject to change without notice Rev 2005 6SE414 0404 Copyright 2005 DETROIT DIESEL CORPORATION From Bulletin 1 MBE900 05 15 99 15 9 EXCESSIVE EXHAUST SMOKE BLACK OR GRAY 15 9 12 Troubleshooting Procedure for Improper Grade of Fuel To determine if an improper grade of fuel is causing excessive black or gray smoke perform the following 1 Acquire a fuel sample from the vehicle fuel tank s 2 Submit fuel sample for an ASTM test analysis a Ifthe fuel meets
59. Bulletin 1 MBE900 05 6SE414 0404 Copyright O 2005 DETROIT DIESEL CORPORATION MBE900 SERVICE MANUAL 15 10 EXCESSIVE BLUE SMOKE There are several causes for excessive blue exhaust smoke These probable causes are Miscalibrated Dipstick Improper Grade of Lubricating Oil Defective Turbocharger Worn or Damaged Intake Exhaust Valve or Cylinder Kit 15 10 1 Troubleshooting Procedure for Miscalibrated Dipstick To determine if an overfilled crankcase is causing the excessive blue smoke perform the following 1 Ensure the vehicle is parked on level ground 2 Drain the oil pan Refill oil pan to the proper capacity Refer to section 13 1 4 a Ifa calibration check indicates that the oil level is off by more than 2 mm 0 079 in contact Detroit Diesel Customer Support Center at 313 592 5800 b Verify that the correct oil level has eliminated the excessive blue smoke concern refer to section 15 10 2 15 10 2 Test the Engine with the Correct Oil Level Perform the following to determine if the correct oil level resolved the excessive blue smoke condition WARNING PERSONAL INJURY To avoid injury before starting and running the engine ensure the vehicle is parked on a level surface parking brake is set and the wheels are blocked 1 Start and run the engine 2 Run the engine at idle under no load conditions for approximately five minutes allowing the engine coolant to reach no
60. Current Below Normal or Open Circuit IC A A SEAN Table 15 7 DDEC VCU and DDEC ECU Fault Codes 5 of 7 NIN O al K o al A a 1D aja NTN o al 00 oO Y Y o EU AA ls Ll E MEE Earl ERAN e ai Rev 2005 All information subject to change without notice 15 8 From Bulletin 1 MBE900 05 6SE414 0404 Copyright 2005 DETROIT DIESEL CORPORATION MBE900 SERVICE MANUAL Description 5 Engine Starter Relay Engine Starter Relay Open Circuit Circuit y ogee Table 15 8 DDEC VCU and DDEC ECU Fault Codes 6 of 7 o XA J aw o al ral a a ayl yas ayn O1Tol lo ao laoy oaotlNIn al wo al wo 0 IE ae a a ME e ae eS ae ee ee Ee ee AE AA ES JS E E ae Als s E 2 5 ee ae ea e ae A EA Es 1371 CS 2 13 gt 20 18 ECON IRE E a rs 3 3 E IE E a EN A A A O EN RE EA ES l e 1 2 ee ee ee A IE E A e gt pro 5 fa Es AE ae a ae E TES EA E E s 2 j M eee o as e gt a ee ee orn N SI o N n o o W nm S walwlwln rwlalalalala O o olojaj K RI RATA All information subject to change without notice Rev 2005 6SE414 0404 Copyright 2005 DETROIT DIESEL CORPORATION From Bulletin 1 MBE900 05 15 9 15 1 TROUBLESHOOTING THE ELECTRONIC ENGINE CONTROL SYSTEM Pars ie ecm bas componen i Table 15 9 DDEC VCU and DDEC ECU Fault Codes 7 of 7 Rev 2005 All information
61. Guide 6SE422 and PID 45 a If heater operates correctly check for a defective fuel pump Refer to section 15 11 6 b If heater does not operate correctly replace air intake grid preheater refer to section 6 1 1 2 Verify replacing the air intake grid preheater resolved the excessive white smoke condition refer to section 15 11 5 1 15 11 5 1 Test the Engine with Replaced Air Intake Grid Preheater Perform the following to determine if replacing the air intake grid preheater corrected the excessive white smoke condition WARNING PERSONAL INJURY To avoid injury before starting and running the engine ensure the vehicle is parked on a level surface parking brake is set and the wheels are blocked 1 Start the engine 2 Run the engine speed to full load Visually inspect the exhaust for excessive white smoke a Ifthe engine exhaust emission appears normal no further troubleshooting is required Shut down the engine b Ifthe engine exhaust emission is excessive shut down the engine check for a defective fuel pump Refer to section 15 11 6 15 11 6 Troubleshooting Procedure for a Defective Fuel Pump To determine if the fuel pump is causing excessive white smoke perform the following to check fuel intake pressure upstream of fuel pump Refer to section 15 3 5 1 If the pressure at idle speed 600 650 rpm is in the normal range of 0 09 to 0 12 bar 1 3 to 1 7 psi 9 to 12 kPa che
62. In standard pan including oil filter Table 15 42 Lubricating Oil Capacity 15 14 2 Low Engine Oil Level Resolution Perform the following steps for low engine oil level 1 Fill engine oil pan to correct level listed in Table 15 42 2 Verify low engine oil resolution refer to section 15 14 2 1 15 14 21 Test for Proper Engine Oil Level Perform the following steps to determine if properly filled oil pan has resolved low oil pressure Rev 2005 All information subject to change without notice 15 140 From Bulletin 1 MBE900 05 6SE414 0404 Copyright O 2005 DETROIT DIESEL CORPORATION MBE900 SERVICE MANUAL WARNING PERSONAL INJURY To avoid injury before starting and running the engine ensure the vehicle is parked on a level surface parking brake is set and the wheels are blocked 1 Start and vary engine speed between 1800 2100 rpm 2 Measure engine oil pressure a If the oil pressure is 241 kPa 35 psi or more no further troubleshooting is required Shut down the engine b Ifthe oil pressure at rated speed is less than 241 kPa 35 psi shut down the engine Check lubricating oil viscosity refer to section 15 14 3 15 14 3 Troubleshooting Procedure for Improper Lubricating Oil Viscosity To determine if improper lubricating oil viscosity is causing low oil pressure perform the following steps 1 Acquire a lubricating oil sample from the engine oil pan 2 Submit oil sample for an ASTM test an
63. MBE900 05 15 11 15 2 GENERAL TROUBLESHOOTING Problem The Engine Cranks But Won t Start The batteries are damaged or weak Test the batteries Replace them if needed The cranking speed is slow Inspect the starter Replace if needed No intake air preheater is installed and it is too cold to F Install an intake air preheater start without one heck the intake ai h it if The intake air preheater is malfunctioning Check tie intake airpreheater aud teplace it necessary The camshaft TDC sensor and or the crank angle Push both sensors into their holes as far as they will go position sensor are out of adjustment If this does not solve the problem replace the sensor s The camshaft TDC sensor and or the crank angle Replace the camshaft TDC sensor and or the crank position sensor are damaged angle position sensor Check the fuel lines for leaks Bleed the fuel system There is air in the fuel system and start the engine according to the instructions in the service manual Table 15 12 Problem The Engine Cranks But Won t Start Problem The Engine Starts Only After Cranking for a Long Time Remedy The fuel tank is low or empty Add fuel and bleed the fuel system if necessary There are leaks inthe tuellines Check the fuel lines for leaks and repair them if necessary The fuel filter is clogged Replace the filter element The fuel line the fuel pre filter or the screen in the fuel Clean and ble
64. O O O O o o oo Poe Pes 4 OnececUCaibaionern OO Pon ist 4 01 Separator Diagnosis Storie rora on e Sosom ooo eo 2 Thott pesa Supp pata amare so a Trone Pedal Supply Above Noma eso 4 Trone Pedal Supay Below Normal Pos 28 18 ranita Data Link CAN Fale O O Proprietary Data Link No Communication Between C E ESTE Tao a erate Caltrain Parameters ata aso 2 amp 1 Crane Poston Sensor Str Vete Too Low Tass 2 amp 1 ro atn of Camsnat ana Ganka Seras Tas 21 Crananat Postion Sensortime Ow as 2 amp 1 14 oranan Postion Sensor Prs Suansed e 2 amp 1 _ orara Postion Sensor Short croua as 21 2 orenat Postion Sensor Open oron Teo os ero message mesg O Tesi 1 ita ose shores Great es Tori no Punger Injector Cylinder 1 Current Below Normal or Open oo l 3 Circuit Ta Soron sooo O O Tess corcyn srona Tes Tor Gyr te Smoamess Governora Lin Tes cor Gyr Sing GynderCooston at Lin ese 2 or er Shorea Grout ese 2 To aer se No Punger Table 15 6 DDEC VCU and DDEC ECU Fault Codes 4 of 7 All information subject to change without notice Rev 2005 6SE414 0404 Copyright 2005 DETROIT DIESEL CORPORATION From Bulletin 1 MBE900 05 15 7 15 1 TROUBLESHOOTING THE ELECTRONIC ENGINE CONTROL SYSTEM Description Ce A Injector ou 2
65. ORATION MBE900 SERVICE MANUAL 7 Install alternator belt Refer to section 8 2 1 NOTE Drive belts Vee and poly vee should be replaced every 2 000 hours or 100 000 miles 160 000 km 8 Verify negative lead repair refer to section 15 4 2 1 15 4 2 1 Verification of Repair for Negative Lead Perform the following steps to determine if negative lead repair resolved the misfiring cylinder condition WARNING PERSONAL INJURY To avoid injury before starting and running the engine ensure the vehicle is parked on a level surface parking brake is set and the wheels are blocked 1 Start the engine 2 Run engine speed up to the occurrence of the misfiring 3 Listen for misfiring cylinder a Ifthe engine is not misfiring no further troubleshooting is required Shut down the engine b Ifthe engine is misfiring check for aerated fuel Shut down the engine refer to section 15 4 3 15 4 3 Troubleshooting Procedure for Aerated Fuel To determine if aerated fuel is causing the cylinder to misfire perform the following steps 1 Disconnect the fuel line return hose from the fitting located at the fuel tank 2 Place the opened end of fuel line into a suitable container All information subject to change without notice Rev 2005 6SE414 0404 Copyright 2005 DETROIT DIESEL CORPORATION From Bulletin 1 MBE900 05 15 47 15 4 MISFIRING CYLINDER WARNING PERSONAL INJURY To avoid injury before starting
66. OTICE To avoid engine damage follow the installation instructions provided with the air to air charge air cooler test kit 1 Visually inspect the core tanks and welds for cracks and holes If charge air cooler fails visual inspection replace the charge air cooler Refer to section15 9 4 2 Pressure test the charge air cooler refer to section 15 9 3 1 Evaluate the results from pressure testing the charge air cooler a Ifthe pressure drop is 34 kPa 5 psi or less in 15 seconds the cooler is good Check for faulty air intake manifold Refer to section 15 9 5 b Ifthe pressure drop is greater than 34 kPa 5 psi in 15 seconds replace the charge air cooler Refer to section 15 9 4 All information subject to change without notice Rev 2005 6SE414 0404 Copyright 2005 DETROIT DIESEL CORPORATION From Bulletin 1 MBE900 05 15 91 15 9 EXCESSIVE EXHAUST SMOKE BLACK OR GRAY 15 9 3 1 Pressure Testing the Charge Air Cooler Perform the following to pressure test the charge air cooler 1 Use the charge air cooler tester J 41473 to test cooler for leaks See Figure15 20 for component parts 1 Gauge Coupler 6 Gauge 2 Bleed off Coupler 7 Pressure Relief Valve 3 Bleed Valve 8 Air Regulator Valve 4 Safety Straps 9 Air Shutoff Valve 5 Quick Disconnect 10 Quick Disconnect Fitting Figure 15 20 Charge Air Cooler Tester J 41473 2 Disconnect the air inlet and outlet piping connecting the charge air cooler
67. Oil Fuel and Filters 7SE270 15 11 11 Improper Grade of Fuel Resolution Perform the following steps to resolve the improper grade of fuel 1 Drain the fuel tanks refer to OEM guidelines and dispose of properly 2 Refill the fuel tanks with new fuel having a cetane number greater than 45 and cetane index greater than 40 3 Verify fuel resolution eliminated the excessive exhaust smoke condition refer to section 15 11 11 1 15 11 11 1 Test the Engine with New Fuel Perform the following steps to determine if the fuel refill resolved the excessive white smoke condition WARNING PERSONAL INJURY To avoid injury before starting and running the engine ensure the vehicle is parked on a level surface parking brake is set and the wheels are blocked 1 Start and run the engine 2 Run the engine at idle under no load conditions for approximately five minutes allowing the engine coolant to reach normal operating range approximately 88 96 C 190 205 F 3 Visually inspect exhaust for excessive smoke All information subject to change without notice Rev 2005 6SE414 0404 Copyright 2005 DETROIT DIESEL CORPORATION From Bulletin 1 MBE900 05 15 117 15 11 EXCESSIVE WHITE SMOKE a If the engine smoke emission appears normal no further troubleshooting is required Shut down the engine b If the engine exhaust smoke is excessively white shut down the engine Check the turbocharger control unit re
68. PERSONAL INJURY To avoid injury before starting and running the engine ensure the vehicle is parked on a level surface parking brake is set and the wheels are blocked 1 Attempt to start and run the engine if the engine starts and runs no further troubleshooting is required Shut down the engine 2 Ifthe engine fails to start and run check the cranking speed refer to section 15 5 15 15 5 15 Troubleshooting Procedure for Low Cranking Speed To determine if low cranking speed is causing starting difficulty install a tachometer to the engine and record engine revolution while cranking the engine Refer to OEM guidelines If the cranking speed is greater than 100 rpm check the OEM fuel supply valve refer to section 15 5 17 If the cranking speed is less than 100 rpm refer to section 15 5 16 15 5 16 Low Cranking Speed Repair Perform the following steps for low cranking speed repair 1 Drain the engine oil Refer to section 13 1 4 Rev 2005 All information subject to change without notice 15 62 From Bulletin 1 MBE900 05 6SE414 0404 Copyright 2005 DETROIT DIESEL CORPORATION MBE900 SERVICE MANUAL Remove the oil filter s Install new oil filter s Refer to section 13 1 4 Refill the lubrication system with new oil aie a ee Verify low cranking speed repair refer to section 15 5 16 1 15 5 16 1 Test Engine with Replaced Oil To determine if the replaced oil resolved starting difficult
69. PORATION From Bulletin 1 MBE900 05 15 97 15 9 EXCESSIVE EXHAUST SMOKE BLACK OR GRAY 15 9 9 1 Test Engine with Aerated Fuel Resolution To determine if aerated fuel resolution resolved the excessive exhaust smoke concern perform the following steps WARNING PERSONAL INJURY To avoid injury before starting and running the engine ensure the vehicle is parked on a level surface parking brake is set and the wheels are blocked 1 Attempt to start and run the engine if the engine starts and runs with no exhaust smoke no further troubleshooting is required Shut down the engine 2 Ifthe engine still has excessive exhaust smoke check for faulty fuel nozzle refer to section 15 9 10 15 9 10 Troubleshooting Procedure for a Faulty Fuel Nozzle To troubleshoot the fuel nozzle refer to section 15 3 on Fuel Injection Troubleshooting After completing fuel injection troubleshooting verify that repairs made corrected the excessive exhaust smoke Refer to section 15 9 10 1 15 9 10 1 Test the Engine with Replaced Fuel Nozzle Perform the following steps to determine if replaced fuel nozzle has resolved the excessive black or gray exhaust smoke condition WARNING PERSONAL INJURY To avoid injury before starting and running the engine ensure the vehicle is parked on a level surface parking brake is set and the wheels are blocked 1 Start and run the engine 2 Run the engine at idle with a no load condition fo
70. Perform the following steps to determine if thermo modulated fan replacement resolved high engine coolant temperature WARNING PERSONAL INJURY To avoid injury before starting and running the engine ensure the vehicle is parked on a level surface parking brake is set and the wheels are blocked 1 Start and run the engine 2 Run the engine through its operating range with no load for approximately five minutes allowing the engine coolant to reach normal operating range a If the engine coolant temperature is 82 105 C 180 22 1 F no further troubleshooting is required Shut down the engine Rev 2005 All information subject to change without notice 15 158 From Bulletin 1 MBE900 05 6SE414 0404 Copyright O 2005 DETROIT DIESEL CORPORATION MBE900 SERVICE MANUAL b Ifthe engine coolant temperature is not 82 105 C 180 221 F shut down the engine Check combustion gases in coolant refer to section 15 15 17 15 15 17 Troubleshooting Procedure for Combustion Gases in Coolant To determine if combustion gases in coolant is causing high engine coolant temperature perform a cylinder compression test Refer to section 1 2 2 2 1 If test results are to specifications check radiator coolant flow refer to section 15 15 19 2 If test results are not to specifications refer to section 15 15 18 15 15 18 Cylinder Head Gasket Replacement Perform the following steps to replace cylinder head gasket 1 Remove and
71. RN SUB SYSTEM FROM LEAK LINE C FUEL DELIVERY SUB SYSTEM LOW PRESSURE SIDE DOWNSTREAM OF FUEL PUMP AND FUEL FILTER D FUEL DELIVERY SUB SYSTEM HIGH PRESSURE SIDE DOWNSTREAM OF UNIT PUMPS E FUEL DRAIN SUB SYSTEM AT FUEL FILTER F LEAK TEST SYMBOL G PRESSURE TEST SYMBOL H FLOW TEST SYMBOL J TEST 1 DOWNSTREAM PRESSURE TEST AT FUEL FILTER K TEST 2 FLOW TEST AT NOZZLE HOLDER L TEST 3 FLOW TEST AT FUEL FILTER M TEST 4 UPSTREAM PRESSURE TEST AT FUEL FILTER N TEST 5 LEAK TEST AT FUEL FILTER 42900 1 Fuel Pump 10 Nozzle Holder 2 Check Valve in fuel pump 11 Overflow Valve 3 Pressure Limiting Valve 12 Constant Ventilation overflow 4 Main Fuel Filter 13 Air Admission Valve 5 Drain Valve 14 Fuel Tank 6 Constant Ventilation in fuel filter 15 Assembly Valve in return line 7 Fuel Temperature Sensor 16 Assembly Valve in feed line 8 Unit Pump fuel injection 17 Check Valve in pre filter 9 Bypass to fuel return port 18 Fuel Pre filter Figure 15 1 Fuel System Schematic The fuel pump feeds fuel from the tank through the fuel pre filter up to the fuel pump This is the fuel feed sub system All information subject to change without notice Rev 2005 6SE414 0404 Copyright O 2005 DETROIT DIESEL CORPORATION From Bulletin 1 MBE900 05 15 25 15 3 FUEL INJECTION TROUBLESHOOTING The fuel pump delivers fuel at low pressure to the main fuel filter and from there to the
72. Run the engine and bring the engine coolant temperature to normal operating range approximately 88 96 C 190 205 F Run the vehicle to full load and rated speed Attach a manometer calibrated to read pressure kPa or inches of H O to the oil dipstick opening Measure and record crankcase pressure Shut down the engine Remove the vehicle from the chassis dynamometer Review the crankcase pressure test a Ifthe crankcase pressure is greater than 0 62 kPa 2 5 in H O go to step 11 b If the crankcase pressure is less than 0 62 kPa 2 5 in H O no further troubleshooting is required Perform the cylinder compression test Refer to section 1 2 2 2 a If cylinder pressure is below specifications refer to Table and refer to section 15 8 7 All information subject to change without notice Rev 2005 6SE414 0404 Copyright O 2005 DETROIT DIESEL CORPORATION From Bulletin 1 MBE900 05 15 87 15 8 EXCESSIVE CRANKCASE PRESSURE b If cylinder pressure is within specifications call Detroit Diesel Customer Support Center at 313 592 5800 15 8 7 Worn or Damaged Valve or Cylinder Kit Repair Perform the following steps for a worn or damaged valve or cylinder kit 1 2 3 4 Remove the cylinder head refer to section 1 2 1 Inspect the cylinder head for worn or damaged valves refer to section 1 17 Inspect the cylinder kit components for worn or damaged liners piston or piston rings refer to section 1 15
73. THE ELECTRONIC ENGINE CONTROL SYSTEM Prior to performing troubleshooting tasks familiarize yourself with Safety Instructions and Precautions found in the General Information Section When the electronic engine control system detects a fault it broadcasts a message on the datalink The dash display will show the code 128 indicating there is an engine fault Troubleshooting problems and solutions for the MBE 900 engine are listed in Table 15 1 and 15 2 The Engine Performs Poorly Does Not Develop Full Listed in Table 15 18 Power The Engine is in Emergency Running Mode constant Listed in Table 15 19 speed 1300 rpm The Fuel Pressure is Too High Downstream of the Fuel Listed in Table 15 31 Filter Fuel Flows Out of the Fuel Return Line Listed in Table 15 32 Table 15 1 Engine Troubleshooting Problems and Recommended Solutions 1 of 2 All information subject to change without notice Rev 2005 6SE414 0404 Copyright 2005 DETROIT DIESEL CORPORATION From Bulletin 1 MBE900 05 15 3 15 1 TROUBLESHOOTING THE ELECTRONIC ENGINE CONTROL SYSTEM Fuel Flow Quantity is Too Low at the Overflow Valve and Listed in Table 15 33 Too High at the Filter Fuel Flow Quantity is Too Low at the Overflow Valve and Listed in Table 15 34 Within Range at the Filter The Fuel Inlet Pressure is Too Low Listed in Table 15 35 The Fuel Inlet Pressure is Too High Listed in Table 15 36 The Low Pressure Fuel System is Leaking Listed in Table 15 37 Ta
74. adiator Coolant Flow Perform the following to determine if abnormal radiator coolant flow repair resolved high engine coolant temperature WARNING PERSONAL INJURY To avoid injury before starting and running the engine ensure the vehicle is parked on a level surface parking brake is set and the wheels are blocked 1 Start and run the engine 2 Run the engine through its operating range with no load for approximately five minutes allowing the engine coolant to reach normal operating range a Ifthe engine coolant temperature is 82 105 C 180 221 F no further troubleshooting is required Shut down the engine b Ifthe engine coolant temperature is not 82 105 C 180 221 F shut down the engine Call the Detroit Diesel Customer Support Center at 313 592 5800 All information subject to change without notice Rev 2005 6SE414 0404 Copyright 2005 DETROIT DIESEL CORPORATION From Bulletin 1 MBE900 05 15 161 15 16 LOW COOLANT TEMPERATURE 15 16 LOW COOLANT TEMPERATURE There are several causes for low coolant temperature These probable causes are Faulty Thermostats Insufficient Radiator Air Circulation 15 16 1 Troubleshooting Procedure for Faulty Thermostats To determine if faulty thermostats are causing low engine coolant temperature perform the following steps 1 Remove thermostat from the thermostat housing refer to section 4 6 1 2 Inspect thermostat for correct operatio
75. ages of fuel economy reduction based on vehicle cruising speed Table 15 43 Fuel Economy Reduction based on Cruising Speed 15 17 2 Troubleshooting Guidelines for Excessive Engine Idling Another factor to consider is excessive engine idling Aside from the fact that the operator is getting 0 mpg during idling combustion is less than ideal Poor combustion can compromise the efficiency of the turbocharger Regarding the notion that idling maintains cab heat in the winter some tests have shown that during the first hour after full load operation the engine actually cools down at a faster rate when idling than when turned off Therefore to increase fuel economy minimize engine idling 15 17 3 Troubleshooting Guidelines for Fuel Economy in Cold Weather It is not uncommon to experience a loss in fuel economy during the winter Cold ambient conditions bring on more engine idling and increased resistance in moving parts such as engine transmission and axle due to fluid viscosity increase There is also the issue of winter blended fuel Blended fuel typically does not contain as much energy as summer fuel Therefore it takes more fuel to move the equipment Tests have shown that there can be as much as a 7 penalty in fuel economy due to blended fuels Therefore to save on fuel economy comparisons must be made for the same yearly time frame Rev 2005 All information subject to change without notice 15 166 From Bulletin 1 MBE900 05 6SE41
76. all Detroit Diesel Customer Support Center at 313 592 5800 All information subject to change without notice Rev 2005 6SE414 0404 Copyright 2005 DETROIT DIESEL CORPORATION From Bulletin 1 MBE900 05 15 89 15 9 EXCESSIVE EXHAUST SMOKE BLACK OR GRAY 15 9 EXCESSIVE EXHAUST SMOKE BLACK OR GRAY There are many causes for excessive black or gray exhaust smoke These probable causes are Restricted Air Cleaner Element Restricted or Cracked Charge Air Cooler Faulty Air Intake Manifold Gasket Faulty Exhaust Manifold Gasket Aerated Fuel Faulty Fuel Nozzle Defective Turbocharger Improper Grade of Fuel Faulty EGR valve Incorrectly Adjusted Exhaust Brake Faulty Exhaust Brake Valve Faulty Exhaust Brake Cylinder Faulty Constant Throttle Valve Incorrect Valve Clearance Low Compression 15 9 1 Troubleshooting Procedure for Restricted Air Cleaner Element To determine if a restrictive air cleaner element is causing excessive black or gray smoke perform the following 1 Remove the air filter element from the air cleaner container refer to OEM guidelines 2 Visually inspect the air cleaner element for damage or clogging a Ifno damage or clogging is found check the charge air cooler refer to section 15 9 3 b If damage or clogging is found refer to section 15 9 2 15 9 2 Air Filter Element Replacement Perform the followin
77. alve Replace valve if The exhaust brake is not operating properly necessary The constant throttle valves are malfunctioning Replace the malfunctioning constant throttle valve s r of the DDEC ECU and or DDEC VCU are Replace the damaged DDEC ECU and or DDEC VCU Table 15 29 Problem Engine Brake Performance is Poor Problem Cruise Control Is Not Working One or more of the cruise control switches are damaged Replace the damaged switch es Components at lis DES eer andlor D DEENEN ate Replace the damaged DDEC ECU and or DDEC VCU damaged or not working properly Table 15 30 Problem Cruise Control is Not Working All information subject to change without notice Rev 2005 6SE414 0404 Copyright 2005 DETROIT DIESEL CORPORATION From Bulletin 1 MBE900 05 15 19 15 2 GENERAL TROUBLESHOOTING Problem The Fuel Pressure is Too High Downstream of the Fuel Filter Possible Cause The continuous ventilation port in the cap of the main Inspect the continuous ventilation port for blockage fuel filter is blocked Clean the port and replace the cap if necessary The fuel drain lines downstream of the main filter housing Repair Replace as necessary are kinked or blocked The check valve in the fuel feed line is blocked or not Repair Replace as necessary open wide the flange at the fitting connection is bent The fuel return line and or strainer at the fuel level Remove the fuel level sensor and repair or replace
78. alysis a Ifengine oil sample meets ASTM specifications check to determine if lubricating oil 1s diluted with fuel or coolant refer to section 15 14 5 b If engine oil sample did not meet ASTM specifications refer to section 15 14 4 and DDC publication Lubricating Oil Fuel and Filters 7SE270 15 14 4 Lubricating Oil Replacement Perform the following steps to replace engine oil 1 Drain and refill engine with new lubricating oil Engine oil capacities are listed in Table 15 42 2 Verify lubricating oil replacement refer to section 15 14 4 1 15 14 4 1 Test Engine with Replaced Lubricating Oil Perform the following steps to determine if replaced lubricating oil resolved low oil pressure All information subject to change without notice Rev 2005 6SE414 0404 Copyright 2005 DETROIT DIESEL CORPORATION From Bulletin 1 MBE900 05 15 141 15 14 LOW OIL PRESSURE WARNING PERSONAL INJURY To avoid injury before starting and running the engine ensure the vehicle is parked on a level surface parking brake is set and the wheels are blocked Start and run engine at rated speed Measure engine oil pressure a If the oil pressure is 241 kPa 35 psi or more no further troubleshooting is required Shut down the engine b If the oil pressure at rated speed is less than 241 kPa 35 psi shut down the engine Check the lubricating oil for fuel and engine coolant dilution refer to section 15 14 5 15
79. amage Table 15 18 Problem The Engine Performs Poorly Does Not Develop Full Power Problem The Engine Is in Emergency Running Mode constant speed 1300 rpm The DDEC ECU or DDEC VCU is damaged Replace the DDEC ECU or DDEC VCU Table 15 19 Problem The Engine is in Emergency Running Mode constant speed 1300 rpm Rev 2005 All information subject to change without notice 15 14 From Bulletin 1 MBE900 05 6SE414 0404 Copyright 2005 DETROIT DIESEL CORPORATION MBE900 SERVICE MANUAL Problem The Coolant Temperature Is Above Normal The coolant level is too low Check for coolant leaks and repair as needed The poly vee belt is loose Tighten or replace the poly vee belt The coolant temperature gauge and or sensor is not Replace the coolant temperature gauge and or sensor reading correctly Clean the radiator Repair or replace the radiator if eee eee necessary The coolant pump is damaged Replace coolant pump The thermostat is damaged Replace the thermostat Check the fan hub Contact Detroit Diesel Customer Support Center at 313 592 5800 to have parameter settings reprogrammed in the DDEC ECU or DDEC VCU The fan is not operating properly Table 15 20 Problem The Coolant Temperature is Above Normal Problem The Coolant Temperature Is Below Normal Cause The coolant temperature gauge and or sensor is not Replace the coolant temperature gauge and or sensor reading correctly
80. an air pressure line with filtered air to the air shutoff valve and gradually pressurize the charge air cooler to a pressure of 205 kPa 30 psi If necessary perform the following steps to adjust the air regulator until the gauge reads 205 kPa 30 psi a Pull regulator knob outward to unlock b Turn knob to adjust pressure to 205 kPa 30 psi c Push the regulator knob back into locked position 8 Close the air shutoff valve and monitor the gauge with a stop watch for 15 seconds Note any decrease in air pressure 9 Repeat test at least three times to verify results a In pressure drop is 34 kPa 5 psi or less in 15 seconds the cooler is good b Ifthe pressure drop is greater than 34 kPa 5 psi in 15 seconds replace the charge air cooler Refer to section 15 9 4 Slowly release pressure with the charge air cooler by opening the valve in the bleed off coupler Remove all charge air cooler tester pieces and reconnect charge air cooler piping to the engine N Reconnect air inlet and outlet piping to engine Torque hose clamps to 5 6 6 78 N m 50 60 lb in 15 9 4 Charge Air Cooler Replacement Perform the following steps to replace the charge air cooler 1 Replace the charge air cooler refer to OEM guidelines 2 Verify that the replacement of the charge air cooler eliminated the excessive exhaust smoke refer to section 15 9 5 1 15 9 5 Troubleshooting Procedure for a Faulty Air Inta
81. and running the engine ensure the vehicle is parked on a level surface parking brake is set and the wheels are blocked Start the engine 4 Run the engine at 1000 rpm Visually check to see if air bubbles are rising to the surface of the fuel within the container a If air bubbles are present refer to section 15 4 4 b If air bubbles are not present shut down the engine Check for improper valve clearance and worn or damaged camshaft lobes and roller followers refer to section 15 4 5 15 4 4 Aerated Fuel Repair Perform the following steps to repair the air in the fuel 1 Shut down the engine 2 Tighten all fuel line connections between fuel tank and fuel pump refer to OEM guidelines Visually inspect all fuel lines between fuel tank and fuel pump for leaks 4 Replace any damaged components Verify repair of fuel lines a If no air in the fuel return refer to section 15 4 4 1 b If air in the fuel return locate and repair Then refer to section 15 4 4 1 15 4 4 1 Test the Engine with Repair for Aerated Fuel Perform the following steps to determine if the aerated fuel repair resolved the misfiring cylinder condition Rev 2005 All information subject to change without notice 15 48 From Bulletin 1 MBE900 05 6SE414 0404 Copyright 2005 DETROIT DIESEL CORPORATION MBE900 SERVICE MANUAL WARNING PERSONAL INJURY To avoid injury before starting and running the engine ensure the vehicle is
82. ata cable and plug the adaptor into the DDL connector in the vehicle Determine if DDEC ECU data is being received by the DDR If no data is being received by the DDR check for intermittent code or a fault and no codes by doing the following a Check for poor mating of the connector halves or terminals not fully seated in the connector body backed out terminals b Look for improperly formed or damaged terminals All connector terminals in the problem circuit should be carefully inspected to determine proper contact tension Use a mating terminal to test the contact tension c Electrical system interference may be caused by a defective relay or a switch causing an electrical surge Look for problems with the charging system alternator etc In certain cases the problem can be made to occur when the faulty component is operated as in the case of a relay d Verify alternator grounds are clean and making good contact Disconnect the alternator belt to test e Wiggle wires and harnesses to try to make the problem active or to occur again If data is being received by the DDR check the vehicle circuit breakers or fuses refer to section 15 5 2 Rev 2005 All information subject to change without notice From Bulletin 1 MBE900 05 6SE414 0404 Copyright 2005 DETROIT DIESEL CORPORATION MBE900 SERVICE MANUAL 15 5 2 Vehicle Circuit Breakers or Fuses Check To determine if the vehicle circuit breakers are causing startin
83. bable causes are Aerated Fuel High Fuel Pressure High Fuel Temperature Return Faulty Overflow Valve Restricted Air Cleaner Element Restricted or Cracked Charge Air Cooler or Leaking Intake Manifold Faulty Exhaust System High Inlet Air Temperature Incorrect Camshaft Timing 15 13 1 Troubleshooting Procedure for Aerated Fuel To determine if aerated fuel is causing lack of power perform the following steps 1 Za Test for aerated fuel Disconnect the fuel line return hose from the fitting located at the fuel tank refer to OEM guidelines Place the open end of the fuel line into a suitable container A WARNING PERSONAL INJURY To avoid injury before starting and running the engine ensure the vehicle is parked on a level surface parking brake is set and the wheels are blocked Start and run the engine Operate the engine at 1000 rpm Visually check to see if air bubbles are rising to the surface of the fuel that collects within the container a If air bubbles are not present shut down the engine check for high fuel pressure refer to section 15 13 3 b If air bubbles are present shut down the engine refer to section 15 13 2 15 13 2 Aerated Fuel Resolution Perform the following steps to resolve aerated fuel condition 1 15 126 Tighten all fuel line connections between fuel tank and fuel pump refer to OEM guidelines Rev
84. been resolved a If no lack of power occurred during the test drive no further troubleshooting is required Shut down the engine b If lack of power occurred during the test drive shut down the engine Call Detroit Diesel Customer Support Center at 313 592 5800 All information subject to change without notice Rev 2005 6SE414 0404 Copyright 2005 DETROIT DIESEL CORPORATION From Bulletin 1 MBE900 05 15 139 15 14 LOW OIL PRESSURE 15 14 LOW OIL PRESSURE There are several causes for low oil pressure These probable causes are Improper Engine Oil Level Improper Lubricating Oil Viscosity Lubricating Oil Diluted with Fuel or Engine Coolant Faulty Oil Pressure Gauge Sensor Obstructed Oil Pressure Gauge Line Restricted Oil Cooler Defective Bypass Valve Defective Pressure Relief Valve Defective Pickup Screen Tube and Screen Assembly Defective Crankshaft Main Bearing Shells Defective Oil Pump Assembly 15 14 1 Troubleshooting Procedure for Improper Engine Oil Level To determine if improper engine oil level is causing low oil pressure check the engine oil level listed in Table 15 42 1 If the engine oil level is correct check lubricating oil viscosity refer to section 15 14 3 2 If the engine oil level is incorrect refer to section 15 14 2 4 Cylinder Engines 6 Cylinder Engines Oil Fill Capacity 15 8 L 16 7 qt 29 0 L 30 6 at
85. bes and rollers repair has resolved excessive exhaust smoke condition WARNING PERSONAL INJURY To avoid injury before starting and running the engine ensure the vehicle is parked on a level surface parking brake is set and the wheels are blocked 1 Start and run the engine 2 Run the engine at idle with a no load condition for approximately five minutes allowing the engine coolant to reach normal operating range 3 Visually inspect exhaust for excessive exhaust smoke a Ifthe engine exhaust smoke emission appears normal no further troubleshooting is required Shut down the engine b Ifthe engine exhaust smoke emission is excessive shut down the engine Check for low compression refer to section 15 9 20 15 9 20 Troubleshooting Procedure for Low Compression To determine if low compression is causing excessive exhaust smoke perform the following steps 1 Perform a cylinder compression test refer to section 1 2 2 2 2 Compare cylinder compression test results to specifications as listed in Table 15 39 Pressure in kPa psi Compression Pressure at Starter Speed 2800 406 Permissible Difference between Individual Cylinders 400 58 Table 15 39 Compression Testing Specifications a If cylinder pressure is below specifications refer to section 15 9 21 All information subject to change without notice Rev 2005 6SE414 0404 Copyright 2005 DETROIT DIESEL CORPORATION From Bulletin 1 MBE900
86. bject to change without notice Rev 2005 6SE414 0404 Copyright 2005 DETROIT DIESEL CORPORATION From Bulletin 1 MBE900 05 15 75 15 7 EXCESSIVE OIL CONSUMPTION 15 7 EXCESSIVE OIL CONSUMPTION DDC recommends a vehicle accumulate at least 20 000 miles or 2nd oil change for oil consumption to stabilize Oil consumption rates above 700 miles quart are considered normal A high mileage engine will tend to be less There are several causes for excessive oil consumption These probable causes are Miscalibrated Dipstick External Oil Leaks Leaking Oil Heat Exchanger Core Defective Air Compressor Defective Turbocharger Worn or Damaged Valve or Cylinder Kit 15 7 1 Troubleshooting Procedure for Miscalibrated Dipstick To determine if an overfilled crankcase is causing excessive oil consumption perform the following 1 Ensure the vehicle is parked on level ground 2 Drain the oil pan Refill oil pan to the proper capacity Refer to section 13 1 4 a If a calibration check indicates that the oil level is off by more than 2 0 mm 0 079 in contact Detroit Diesel Customer Support Center at 313 592 5800 b Check for oil leaks refer to section 15 7 2 15 7 2 Troubleshooting Procedure for External Oil Leaks To determine if oil leaks are causing excessive oil consumption perform the following 1 Steam clean the engine WARNING PERSONAL INJURY To avoid injury before starti
87. ble 15 2 Engine Troubleshooting Problems and Recommended Solutions 2 of 2 NOTE I To read the complete fault code use a minidiag2 or Diagnostic Data Reader DDR 15 1 1 Engine Fault Codes The engine fault codes and their causes are listed in Table 15 3 ee J1587 J1587 ern PID SID p 45 e pe E A 5 TARARES a ee es eee PT vento speed Sensor Anta Faun Vehicle Speed Sensor Data Valid but Above Normal Range DOC CIO CIT Pe vento Speed Sensor Short Ground Ps Vehicle Speed Sensor Data Erratic Output shaft speed from J1939 ETCI not in normal range O OA O E S oa a 2 Accelerator Peal Vatage Above Normal or Shored Han ee A ee ee Accelerator Pedal Voltage Below Normal or Shorted Low Table 15 3 DDEC VCU and DDEC ECU Fault Codes 1 of 7 Rev 2005 All information subject to change without notice 15 4 From Bulletin 1 MBE900 05 6SE414 0404 Copyright O 2005 DETROIT DIESEL CORPORATION MBE900 SERVICE MANUAL Description 3 Fuel Pressure Sensor Fuel Pressure Sensor Open Circuit Circuit AI O O o oa o Ft Pressure High 3 3 oe A A Engine Fuel Pressure Sensor Data Not Correct Engine Fuel Pressure Sensor Measured Data Not Correct E A es o ra ese creat Fates ah Cs es Fee ese Grea restan se o 4 eoon Te o emmen o o o eonen o se se 2 engine oee sensorverase nian se
88. blocked 1 Start and run the engine 2 Run the engine through its operating range with no load condition for approximately five minutes allowing the engine coolant to reach normal operating range All information subject to change without notice Rev 2005 6SE414 0404 Copyright 2005 DETROIT DIESEL CORPORATION From Bulletin 1 MBE900 05 15 163 15 16 LOW COOLANT TEMPERATURE a Ifthe engine coolant temperature is 82 105 C 180 221 F no further troubleshooting is required Shut down the engine b If the engine coolant temperature is not 82 105 C 180 221 F shut down the engine Call Detroit Diesel Customer Support Center at 313 592 5800 Rev 2005 All information subject to change without notice 15 164 From Bulletin 1 MBE900 05 6SE414 0404 Copyright O 2005 DETROIT DIESEL CORPORATION MBE900 SERVICE MANUAL 15 17 POOR FUEL ECONOMY Customer expectations of fuel economy are usually based on past experiences recommendations from colleagues or sales staff and wishful thinking It is paramount that the end user attain reasonable expectations based on sound predictions Fuel economy management can be accomplished with the aid of Detroit Diesel s Spec Manager computer program The program takes into consideration a number of factors such as vehicle design duty cycle and route profile as it predicts real world fuel economy Contact the local Detroit Diesel distributor for Spec Manager support prior to contacting th
89. ck for aerated fuel Refer to section 15 11 8 2 If the pressure at idle speed 600 650 rpm is greater than 0 09 to 0 12 bar 1 3 to 1 7 psi 9 to 12 kPa refer to Table 15 36 Rev 2005 All information subject to change without notice 15 114 From Bulletin 1 MBE900 05 6SE414 0404 Copyright O 2005 DETROIT DIESEL CORPORATION MBE900 SERVICE MANUAL 3 If the pressure at idle speed 600 650 rpm is less than 0 09 to 0 12 bar 1 3 to 1 7 psi 9 to 12 kPa refer to Table 15 35 4 If ano pressure reading is observed replace the fuel pump refer to section 2 15 1 15 11 7 Replace Faulty Fuel Pump Perform the following steps for the replacement of the fuel pump 1 Replace the fuel pump refer to section 2 15 1 2 Test the engine to determine if the white smoke problem was resolved refer to section 15 11 7 1 15 11 7 1 Engine Test with Replaced Fuel Pump To determine if the replaced fuel pump resolved excessive white smoke difficulty perform the following steps WARNING PERSONAL INJURY To avoid injury before starting and running the engine ensure the vehicle is parked on a level surface parking brake is set and the wheels are blocked 1 Start and run the engine if no white smoke is visible no further troubleshooting is required Shut down the engine 2 If white smoke is visible check for aerated fuel refer to section 15 11 8 15 11 8 Troubleshooting Procedure for Aerated Fuel To determine
90. d valve s or cylinder kit refer to section 15 7 8 b If the crankcase pressure was less than or equal to 0 62 kPa 2 5 in H O perform a cylinder compression test Refer to section 1 2 2 2 10 Compare the cylinder compression test results to specifications as listed in Table 1 10 a Ifthe cylinder compression is below specifications repair worn or damaged valve s or cylinder kit refer to section 15 7 8 b If the cylinder compression is within specifications call Detroit Diesel Customer Support Center at 313 592 5800 15 7 8 Worn or Damaged Valve s or Cylinder Kit s Repair Perform the following steps to repair worn or damaged valve s and cylinder kit s 1 Remove the cylinder head refer to section 1 2 1 All information subject to change without notice Rev 2005 6SE414 0404 Copyright 2005 DETROIT DIESEL CORPORATION From Bulletin 1 MBE900 05 15 81 15 7 EXCESSIVE OIL CONSUMPTION Inspect the cylinder head for worn or damaged valves refer to section 1 17 Inspect the cylinder kit components for worn or damaged liners pistons or piston rings refer to section 1 15 3 1 Replace damaged cylinder kit components Verify repairs made to cylinder head valve s or cylinder kit components refer to section 15 7 8 1 15 7 8 1 Test Engine with Repaired Cylinder Head Valve s and Cylinder Kit To determine if the cylinder head valve and cylinder kit repair resolved starting difficulty perform the fol
91. e engine ensure the vehicle is parked on a level surface parking brake is set and the wheels are blocked 1 Start and run the engine at rated speed 2 Run the engine through its operating range with no load condition for approximately five minutes allowing the engine coolant to reach normal operating range 88 96 C 190 205 a If the DDR indicates 241 kPa 35 psi or more at rated speed shut down the engine and disconnect the DDR No further troubleshooting is required b If the DDR indicates less than 241 kPa 35 psi at rated speed shut down the engine and disconnect the DDR Check for defective oil filter bypass valve refer to section 15 14 13 f 15 14 13 Troubleshooting Procedure for Defective Oil Filter Bypass Valve To determine if a defective oil filter bypass valve is causing low oil pressure perform the following steps 1 Remove the oil filter cover and element refer to section 3 5 1 2 Inspect the oil filter bypass valve components a If no damage is found with the oil filter housing bypass valve components check for defective pressure relief valve refer to section 15 14 14 b If damage is found with the oil filter housing bypass valve bore replace housing Refer to section 3 4 1 f 15 14 14 Troubleshooting Procedure for Defective Oil Pump Pressure Relief Valve To determine if a defective oil pump pressure relief valve is causing low oil pressure perform the following steps 1 R
92. e factory Make sure that there is sound basis for the poor fuel economy complaint These precautions applies to both new and in service vehicles There are many variables which may affect fuel economy Included are Vehicle Frontal Area Vehicle Weight Rolling Resistance Static and rolling Air Resistance Excessive add ons increase air resistance trailer gap too large Engine Speed Tire Size Revs mile Axle Ratio Transmission Gear Ratios Road Surface Cement blacktop gravel Duty Schedule Highway stop and go excessive idling Vehicle Maintenance Plugged air filter low tire pressure poor wheel alignment brakes dragging Vehicle Cruise Speed Driver Habits Weather Conditions NOTE If any of these variables is not optimized a serious penalty in fuel economy will result Many of these items are out of the operator s control However there are factors that can be controlled and have a major impact on fuel economy 15 17 1 Troubleshooting Guidelines for Vehicle Cruise Speed One of the most common factors that reduces fuel economy is vehicle cruise speed All information subject to change without notice Rev 2005 6SE414 0404 Copyright 2005 DETROIT DIESEL CORPORATION From Bulletin 1 MBE900 05 15 165 15 17 POOR FUEL ECONOMY Maintain as slow a cruising speed as possible Listed in Table 15 43 are the approximate percent
93. e following steps to determine if a replaced pickup screen tube or screen assembly resolved low oil pressure WARNING PERSONAL INJURY To avoid injury before starting and running the engine ensure the vehicle is parked on a level surface parking brake is set and the wheels are blocked 1 Start and run the engine speed at rated speed 2 Visually examine oil pressure reading a If the oil pressure at rated speed is 241 kPa 35 psi or more no further troubleshooting is required b If the oil pressure at rated speed is less than 241 kPa 35 psi check for defective crankshaft main bearing shells refer to section 15 14 18 15 14 18 Troubleshooting Procedure for Defective Crankshaft Main Bearing Shells To determine if defective crankshaft main bearing shells are causing low oil pressure check main bearing to crankshaft journal clearances 1 If main bearing shell to journal clearance is within 0 051 0 127 mm 0 002 0 005 in check for defective oil pump assembly refer to section 15 14 20 2 If main bearing shell to journal clearance is not within 0 05 1 0 127 mm 0 002 0 005 in refer to section 15 14 19 Rev 2005 All information subject to change without notice 15 148 From Bulletin 1 MBE900 05 6SE414 0404 Copyright O 2005 DETROIT DIESEL CORPORATION MBE900 SERVICE MANUAL 15 14 19 Crankshaft Main Bearing Shell Repair Perform the following steps to repair crankshaft main bearing shells 1 R
94. e fuel in the fuel tank is no higher than 40 C 104 F Collect any fuel which flows out during the test The fuel should flow through free of bubbles 7 Perform the fuel system troubleshooting tests and correct any problems As indicated by the test results perform any follow up tests or check troubleshooting tables as required Make the necessary repairs and or replacements For troubleshooting tests and tables see the following subjects a Test 1 Downstream Pressure Test Refer to section 15 3 2 Rev 2005 All information subject to change without notice 15 28 From Bulletin 1 MBE900 05 6SE414 0404 Copyright 2005 DETROIT DIESEL CORPORATION MBE900 SERVICE MANUAL b Test 2 Flow Test At Nozzle Holder Refer to section 15 3 3 c Test 3 Flow Test At Fuel Filter Refer to section 15 3 4 d Test 4 Upstream Pressure Test Refer to section 15 3 5 e Test 5 Leak Test Refer to section 15 3 6 f Troubleshooting tables 8 When all the tests are completed the test equipment removed and all repairs replacements have been made prime the fuel system a If equipped with a hand pump on the fuel water separator work the hand pump until resistance is felt WARNING PERSONAL INJURY To avoid injury before starting and running the engine ensure the vehicle is parked on a level surface parking brake is set and the wheels are blocked b Crank the engine for 30 seconds at a time but no
95. e gauge reads 1 000 kPa 145 psi Turn the shut off lever to the OFF position and wait five minutes 4 At the end of five minutes read the pressure on the gauge again The gauge should read at least 975 kPa 141 psi If the gauge pressure is too low see the causes listed in Table 15 37 Problem The Low Pressure Fuel System is Leaking and correct the problem Make any necessary repairs and or replacements Rev 2005 All information subject to change without notice 15 44 From Bulletin 1 MBE900 05 6SE414 0404 Copyright O 2005 DETROIT DIESEL CORPORATION MBE900 SERVICE MANUAL 5 Check the engine oil for presence of fuel If there is fuel in the engine oil see the causes listed in Table 15 37 Problem The Low Pressure Fuel System is Leaking and correct the problem Make any necessary repairs and or replacements 6 Open the shut off valve and remove all the test equipment Connect the fuel feed and return lines as removed Reconnect the fuel temperature sensor 7 Make sure the fuel fill cap is tightly closed and the vehicle has been restored to operating condition All information subject to change without notice Rev 2005 6SE414 0404 Copyright 2005 DETROIT DIESEL CORPORATION From Bulletin 1 MBE900 05 15 45 15 4 15 4 MISFIRING CYLINDER MISFIRING CYLINDER There are several causes for the engine cylinder to be misfiring These probable causes are Po
96. e it up out of the way All information subject to change without notice Rev 2005 6SE414 0404 Copyright 2005 DETROIT DIESEL CORPORATION From Bulletin 1 MBE900 05 15 31 15 3 FUEL INJECTION TROUBLESHOOTING 5 Install the adaptor and seal from the fuel adaptor parts kit J 46377 in the fuel temperature sensor location and tighten adaptor securely See Figure 15 5 and Figure 15 6 42918 Figure 15 5 Fuel Adaptor Parts Kit J 46377 1 Banjo Fitting 3 Adaptor from kit J 46377 2 Unit Pump Figure 15 6 Connecting the Adaptor Rev 2005 All information subject to change without notice 15 32 From Bulletin 1 MBE900 05 6SE414 0404 Copyright O 2005 DETROIT DIESEL CORPORATION MBE900 SERVICE MANUAL 6 Attach the banjo fitting and banjo bolt union from the fuel adaptor kit J 46377 to the adaptor 7 Connect the high pressure fuel line J 46372 and gauge J 46378 to the adaptor 15 3 2 2 Test 1 i 1 Open the fuel fill cap to release pressure in the fuel tank WARNING PERSONAL INJURY To avoid injury before starting and running the engine ensure the vehicle is parked on a level surface parking brake is set and the wheels are blocked 2 Start the engine and run it at a slow idle 600 to 650 rpm Read off the fuel pressure on the high pressure gauge The gauge should read at least 430 kPa 62 psi If the
97. e manifold with two bolts Torque bolts to 11 N m 96 lb in Connect the harness connector to the boost sensor 4 Verify the turbocharger boost sensor resolution refer to section 15 11 4 1 15 11 4 1 Test Engine with Replace Turbocharger Boost Sensor Perform the following to determine if replacing the turbocharger boost sensor corrected the excessive white smoke condition WARNING PERSONAL INJURY To avoid injury before starting and running the engine ensure the vehicle is parked on a level surface parking brake is set and the wheels are blocked 1 Start the engine 2 Run the engine speed to full load Visually inspect the exhaust for excessive white smoke a Ifthe engine exhaust emission appears normal no further troubleshooting is required Shut down the engine b Ifthe engine exhaust emission is excessive shut down the engine check for a malfunctioning air intake grid preheater Refer to section 15 11 5 All information subject to change without notice Rev 2005 6SE414 0404 Copyright 2005 DETROIT DIESEL CORPORATION From Bulletin 1 MBE900 05 15 113 15 11 EXCESSIVE WHITE SMOKE 15 11 5 Troubleshooting Procedure for a Malfunctioning Air Intake Grid Preheater To determine if a malfunctioning air intake grid preheater is causing the excessive white smoke perform the following steps 1 Check the operation of the air intake grid preheater Refer to DDC publication MBE Troubleshooting
98. e smoke perform the following WARNING PERSONAL INJURY To avoid injury before starting and running the engine ensure the vehicle is parked on a level surface parking brake is set and the wheels are blocked Start and run the engine Run the engine at idle with a no load condition for approximately five minutes allowing the engine coolant to reach normal operating range approximately 88 96 C 190 205 F Visually inspect exhaust for excessive white smoke a Ifthe engine exhaust emission appears normal no further troubleshooting is required Shut down the engine b Ifthe engine exhaust emission is excessively white shut down the engine Check for improper valve clearance or damaged camshaft lobes and rollers refer to section 15 11 16 15 11 16 Troubleshooting Procedure for Improper Valve Clearance Worn or Damaged Camshaft Lobes and Rollers To determine if an improper valve clearance worn or damaged camshaft lobes or rollers are causing excessive white exhaust smoke perform the following 1 15 120 Check for improper valve clearance and worn or damaged camshaft lobes and rollers Repair as required Refer to section 1 17 2 and section 1 20 1 1 Verify valve clearance worn or damaged camshaft lobes and rollers repair corrected the excessive white exhaust smoke concern refer to section 15 11 16 1 Rev 2005 All information subject to change without notice From Bulletin 1 MBE900 05 6SE414 04
99. e wheels are blocked 1 Start and run the engine at rated speed 2 Run the engine at rated speed with a no load condition for approximately five minutes allowing the engine coolant to reach normal operating range 88 96 C 190 205 F a Ifthe oil temperature sensor is indicating a lubricating oil temperature less than or equal to 110 C 230 F shut down the engine and check for a defective oil filter bypass valve refer to section 15 14 13 b Ifthe oil temperature sensor is indicating a lubricating oil temperature greater than 110 C 230 F shut down the engine and repair heat exchanger refer to section 15 14 12 15 14 12 Heat Exchanger Repair Perform the following steps to repair the heat exchanger 1 Remove the heat exchanger refer to section 3 6 1 2 Clean the heat exchanger before sludge hardens Flush oil passages with clean hot water 3 Inspect the heat exchanger for damage All information subject to change without notice Rev 2005 6SE414 0404 Copyright 2005 DETROIT DIESEL CORPORATION From Bulletin 1 MBE900 05 15 145 15 14 LOW OIL PRESSURE 4 Install repaired heat exchanger refer to section 3 6 2 5 Verify repair of heat exchanger refer to section 15 14 12 1 15 14 12 1 Test Engine with Repaired Heat Exchanger Perform the following steps to determine if heat exchanger repair resolved low oil pressure WARNING PERSONAL INJURY To avoid injury before starting and running th
100. ed by cylinder cut out evaluation 15 4 7 Faulty Fuel Nozzle Unit Pump Repair Refer to the Injector Unit Pump section 2 1 for unit pump and nozzle replacement 15 4 7 1 Verification of Repair for Faulty Fuel Nozzle Unit Pump Perform the following steps to determine if the replaced fuel nozzle unit pump resolved the misfiring cylinder conditions All information subject to change without notice Rev 2005 6SE414 0404 Copyright 2005 DETROIT DIESEL CORPORATION From Bulletin 1 MBE900 05 15 51 15 4 MISFIRING CYLINDER WARNING PERSONAL INJURY To avoid injury before starting and running the engine ensure the vehicle is parked on a level surface parking brake is set and the wheels are blocked 1 Start the engine 2 Run the engine speed up to the occurrence of the misfiring 3 Listen for misfiring cylinder a If the engine is not misfiring shut down the engine No further troubleshooting is required b If the engine is misfiring shut down the engine and check for a faulty DDEC ECU refer to section 15 4 8 15 4 8 Troubleshooting Procedure for a Faulty DDEC ECU To determine if a faulty DDEC ECU is causing the cylinder to misfire install a test DDEC ECU NOTE Carefully disengage the lock tab on the vehicle wiring harness and engine wiring harness connectors when removing Follow instructions in the DDEC ECU section refer to section 2 5 1 15 4 9 Faulty DDEC ECU Repair There is no authorized
101. ed the system Check the fuel lines and tank is blocked filters Repair or replace as necessary Push both sensors into their holes as far as they will go If this does not solve the problem replace the camshaft TDC sensor and or crank angle sensor The camshaft TDC sensor and or the crank angle position sensor are out of adjustment The camshaft TDC sensor and or the crank angle Replace the camshaft TDC sensor and or the crank position sensor are damaged angle position sensor There are other problems in the fuel system Check the fuel system Table 15 13 Problem The Engine Starts Only After Cranking for a Long Time Rev 2005 All information subject to change without notice 15 12 From Bulletin 1 MBE900 05 6SE414 0404 Copyright O 2005 DETROIT DIESEL CORPORATION MBE900 SERVICE MANUAL Problem The Engine Starts But Dies Cause The fuel tank is low or empty Add fuel and bleed the fuel system if necessary The fuel filter is clogged Replace the filter element The fuel line the fuel pre filter or the screen in the fuel Clean and bleed the system Check the fuel lines and tank is blocked filters Push both sensors into their holes as far as they will go If this does not solve the problem replace the camshaft TDC sensor and or crank angle sensor The camshaft TDC sensor and or the crank angle Replace the camshaft TDC sensor and or crank angle position sensor are damaged position sensor The constant thrott
102. ely 88 96 C 190 205 F 3 Visually inspect exhaust for excessive smoke a If the engine smoke emission appears normal no further troubleshooting is required Shut down the engine b If the engine exhaust smoke is excessively black or gray shut down the engine Check the exhaust brake valve refer to section 15 9 16 Brake Valve To determine if a misadjusted exhaust brake valve is causing excessive black or gray smoke perform the following 1 Readjust the exhaust brake valve refer to section 7 2 3 for a 6 cylinder engine or refer to section 7 2 5 for a 4 cylinder engine i 15 9 15 Troubleshooting Procedure for a Incorrectly Adjusted Exhaust All information subject to change without notice Rev 2005 6SE414 0404 Copyright 2005 DETROIT DIESEL CORPORATION From Bulletin 1 MBE900 05 15 101 15 9 EXCESSIVE EXHAUST SMOKE BLACK OR GRAY 2 Verify the adjustment on the exhaust brake valve refer to section 15 9 15 1 15 9 15 1 Test Engine After Adjusting the Exhaust Brake Valve Perform the following steps to determine if the exhaust brake adjustment resolved the excessive exhaust smoke condition A WARNING PERSONAL INJURY To avoid injury before starting and running the engine ensure the vehicle is parked on a level surface parking brake is set and the wheels are blocked 1 Start and run the engine 2 Run the engine at idle under no load conditions for approximately five minutes allowing the engi
103. emove and replace defective crankshaft main bearing shells 2 Verify crankshaft main bearing shells repair refer to section 15 14 19 1 15 14 19 1 Test Engine with New Crankshaft Main Bearing Shells Perform the following steps to determine if new crankshaft main bearing shells have resolved low oil pressure WARNING PERSONAL INJURY To avoid injury before starting and running the engine ensure the vehicle is parked on a level surface parking brake is set and the wheels are blocked 1 Start and run engine at rated speed 2 Visually examine the oil pressure reading a If the oil pressure at rated speed is 241 kPa 35 psi or more no further troubleshooting is required Shut down the engine b Ifthe oil pressure at rated speed is less than 241 kPa 35 psi shut down the engine Check the oil pump assembly refer to section 15 14 20 15 14 20 Troubleshooting Procedure for Defective Oil Pump Assembly To determine if a defective oil pump is causing low oil pressure perform the following steps 1 Remove the oil pump assembly refer to section 3 3 1 2 Manually rotate the oil pump drive gear a If the drive gear rotates freely in the pump housing call Detroit Diesel Customer Support Center at 313 592 5800 b If the drive gear does not rotate freely replace the oil pump assembly and verify repair refer to section 15 14 20 1 15 14 20 1 Test Engine with Replaced Oil Pump Assembly Perform the followi
104. emove the oil pump pressure relief valve Rev 2005 All information subject to change without notice 15 146 From Bulletin 1 MBE900 05 6SE414 0404 Copyright O 2005 DETROIT DIESEL CORPORATION MBE900 SERVICE MANUAL 2 Inspect the oil pump pressure relief valve a If the relief valve moves freely in the valve body reinstall the oil pressure relief valve Check the pickup tube and screen assembly for defects b Ifthe relief valve will not move freely in the valve body refer to section 15 14 15 15 14 15 Oil Pump Pressure Relief Valve Repair i Perform the following steps to repair the oil pump pressure relief valve 1 Disassemble the pressure relief valve and replace damaged components 2 Assemble and install the pressure relief valve 3 Verify repair of the pressure relief valve refer to section 15 14 15 1 15 14 15 1 Test Engine with Repaired Oil Pump Pressure Relief Valve i Perform the following steps to determine if repaired oil pump pressure relief valve resolved low oil pressure 1 Install the DDR WARNING PERSONAL INJURY To avoid injury before starting and running the engine ensure the vehicle is parked on a level surface parking brake is set and the wheels are blocked 2 Start and run engine speed at rated speed 3 Visually examine the DDR for oil pressure reading a If the DDR indicates 241 kPa 35 psi or more at rated speed shut down the engine and disconnect the DDR No fur
105. er a If excessive engine lube oil is present replace the turbocharger refer to section 6 4 2 b Verify replacing the turbocharger corrected the excessive blue smoke concern refer to section 15 10 5 1 15 10 5 1 Test Engine with Replaced Turbocharger Perform the following steps to determine if a replaced turbocharger has resolved the excessive blue exhaust smoke condition WARNING PERSONAL INJURY To avoid injury before starting and running the engine ensure the vehicle is parked on a level surface parking brake is set and the wheels are blocked 1 Start and run the engine 2 Run the engine at idle speed with a no load condition for approximately five minutes allowing the engine coolant to reach normal operating range approximately 88 96 C 190 205 F 3 Visually inspect the exhaust for excessive blue smoke a Ifthe engine exhaust smoke emission appears normal no further troubleshooting is required Shut down the engine b Ifthe engine exhaust smoke is excessively blue shut down the engine Check for worn or damaged valves or cylinder kit refer to section 15 10 6 15 10 6 Troubleshooting Procedure for a Worn or Damaged Intake Exhaust Valve or Cylinder Kit To determine if a worn or damaged cylinder kit is causing excessive blue exhaust smoke perform the following 1 Move the vehicle requiring testing to the chassis dynamometer refer to OEM guidelines 2 Disconnect and remove the air compress
106. essary 2 Ifno damage was found to camshaft or roller followers continue with task Verify the proper lash setting following the procedure in the Valve Lash Checking and Adjustment section refer to section 1 17 2 15 4 5 1 Verification of Repair for Improper Valve Clearance or Injector Height Setting Perform the following steps to determine if valve clearance adjustment resolved the misfiring cylinder condition Rev 2005 All information subject to change without notice 15 50 From Bulletin 1 MBE900 05 6SE414 0404 Copyright 2005 DETROIT DIESEL CORPORATION MBE900 SERVICE MANUAL WARNING PERSONAL INJURY To avoid injury before starting and running the engine ensure the vehicle is parked on a level surface parking brake is set and the wheels are blocked 1 Start the engine 2 Run the engine at 1000 rpm 3 Listen for misfiring cylinder a If engine is not misfiring shut down the engine No further troubleshooting is required b If engine is misfiring shut down the engine and check for faulty fuel nozzle refer to section 15 4 6 15 4 6 Troubleshooting Procedure for Faulty Fuel Nozzle Unit Pump To determine if a faulty fuel nozzle or unit pump is causing the cylinder to misfire check for the following items 1 Use the minidiag2 to detect any fault codes 2 Make sure that the transfer tube is installed at the proper torque Refer to section 2 3 2 A leaking transfer tube may be identifi
107. est drive no further troubleshooting is required Shut down the engine b Iflack of power occurred during the test drive shut down the engine Check camshaft timing refer to section 15 13 17 15 13 17 Troubleshooting Procedure for Incorrect Camshaft Timing To determine if incorrect camshaft timing is causing lack of power check the camshaft timing refer to section 1 If the dial indicator reading on the unit pump lobe is 13 8 mm 0 54 in or above no further troubleshooting in required 2 If the dial indicator reading is not above 13 8 mm 0 54 in check engine timing refer to section 15 13 18 15 13 18 Engine Timing Resolution Perform the following steps to resolve incorrect engine timing 1 Perform an engine gear train timing check refer to section 1 7 2 2 Verify engine timing resolution refer to section 15 13 18 1 15 13 18 1 Test Engine with Correct Timing Perform the following steps to determine if corrected engine timing has resolved lack of power condition Rev 2005 All information subject to change without notice 15 138 From Bulletin 1 MBE900 05 6SE414 0404 Copyright O 2005 DETROIT DIESEL CORPORATION MBE900 SERVICE MANUAL WARNING PERSONAL INJURY To avoid injury before starting and running the engine ensure the vehicle is parked on a level surface parking brake is set and the wheels are blocked 1 Start and run the engine 2 Test drive the vehicle to ensure lack of power has
108. evel spot such as the frame rail NOTE The pressure tester must be level to indicate correctly f 15 35 2 Test 4 1 Open the fuel fill cap to release pressure in the fuel tank WARNING PERSONAL INJURY To avoid injury before starting and running the engine ensure the vehicle is parked on a level surface parking brake is set and the wheels are blocked 2 Start the engine and run it at a slow idle 600 to 650 rpm NOTE The pressure tester reads in bar 1 bar 14 5 psi or 100 kPa NOTE This test measures suction at the fuel inlet All pressure values are negative 3 Read off the fuel pressure on the pressure tester The gauge should read from 0 09 bar to 0 12 bar 1 3 to 1 7 psi 9 to 12 kPa If the fuel pressure is too low less suction see the causes listed in Table 15 35 Problem The Inlet Pressure is Too Low and correct the problem Make any necessary repairs and or replacements Rev 2005 All information subject to change without notice 15 40 From Bulletin 1 MBE900 05 6SE414 0404 Copyright 2005 DETROIT DIESEL CORPORATION MBE900 SERVICE MANUAL If the fuel pressure is too high more suction see the causes listed in Table 15 36 Problem The Inlet Pressure is Too High and correct the problem Make any necessary repairs and or replacements 4 Increase the engine speed to 2500 rpm Read off the fuel pressure on the pressure tester The gauge should read be
109. fer to section 15 11 12 15 11 12 Troubleshooting Procedure for Faulty Turbocharger Control Unit To determine if an improper turbocharger control unit is causing excessive white smoke inspect the turbocharger control unit for a leaking diaphragm Refer to section 6 4 1 1 If the control unit diaphragm is leaking replace the turbocharger refer to section 6 4 2 2 Verify the replacement of the turbocharger and unit control corrected the excessive white smoke condition refer to section 15 11 12 1 15 11 12 1 Test Engine with Replace Turbocharger and Control Unit Perform the following to determine if replacing the turbocharger and control unit corrected the excessive white smoke condition WARNING PERSONAL INJURY To avoid injury before starting and running the engine ensure the vehicle is parked on a level surface parking brake is set and the wheels are blocked 1 Start the engine 2 Run the engine speed to full load Visually inspect the exhaust for excessive white smoke a Ifthe engine exhaust emission appears normal no further troubleshooting is required Shut down the engine b Ifthe engine exhaust emission is excessive shut down the engine check for a restricted or cracked charge air cooler Refer to section 15 11 13 15 11 13 Troubleshooting Procedure for a Restricted or Cracked Charge Air Cooler To determine if a charge air cooler is causing excessive exhaust smoke perform the following Rev
110. flow is also too low at the filter perform test 4 Upstream Pressure Test Refer to section 15 3 5 If overflow valve fuel flow is OK and no fuel flows out at the filter the continuous ventilation port in the fuel filter is blocked by impurities Open the fuel filter and clean or replace the blocked port If overflow valve fuel flow is OK and fuel flow is also OK at the filter the overflow valve is faulty leaking jammed open worn or incorrectly installed Replace the overflow valve Refer to section 15 13 5 NOTE Do not attempt to disassemble the overflow valve The overflow valve cannot be repaired 6 Remove the union transparent hose banjo bolt and nut Restore the fuel return and drain lines to the original installation as removed Make sure the fuel fill cap is tightly closed and the vehicle has been restored to operating condition 15 3 5 Test 4 Upstream Pressure Test Perform the following test set up and test to determine the upstream pressure 15 38 Rev 2005 All information subject to change without notice From Bulletin 1 MBE900 05 6SE414 0404 Copyright 2005 DETROIT DIESEL CORPORATION MBE900 SERVICE MANUAL 15 3 5 1 Test Set Up 1 At the main filter housing disconnect the fuel feed line and feed line fitting This fitting is aft of the fuel return line and connects to the fuel pre filter See Figure 15 9 J 46377 UNION FROM FUEL ADAPTOR PARTS KIT J 46380
111. fuel pressure is too low perform test 3 Flow Test At Fuel Filter and correct the problem Refer to section 15 3 4 4 Increase the engine speed to 2500 rpm Read off the fuel pressure on the high pressure gauge The gauge should read from 400 to 650 kPa 58 to 94 psi a If the fuel pressure is within limits perform test 2 Flow Test At Nozzle Holder and correct the problem Refer to section 15 3 3 b Ifthe fuel pressure is too low perform test 3 Flow Test At Fuel Filter and correct the problem Refer to section 15 3 4 c Ifthe fuel pressure is too high see the causes listed in Table 15 31 Problem The Fuel Pressure is Too High Downstream of the Fuel Filter and correct the problem Make any necessary repairs and or replacements 6 Remove all test equipment Reconnect the fuel temperature sensor 7 Make sure the fuel fill cap is tightly closed and the vehicle has been restored to operating condition 15 3 3 Test 2 Flow Test At Nozzle Holder Perform the following test set up and test to determine the flow at the nozzle holder All information subject to change without notice Rev 2005 6SE414 0404 Copyright 2005 DETROIT DIESEL CORPORATION From Bulletin 1 MBE900 05 15 33 15 3 FUEL INJECTION TROUBLESHOOTING 15 3 3 1 Test Set Up 1 Remove the engine trim panel See Figure 15 7
112. g and running the engine ensure the vehicle is parked on a level surface parking brake is set and the wheels are blocked 1 Start and run the engine 2 Test drive the vehicle to ensure lack of power has been resolved a If no lack of power occurred during the test drive no further troubleshooting is required Shut down the engine b If lack of power occurred during the test drive shut down the engine Check the exhaust system refer to section 15 13 13 15 13 13 Troubleshooting Procedure for a Faulty Exhaust System To determine if a faulty exhaust system is causing lack of power perform the following steps 1 Drill an 11 32 in hole in the exhaust pipe 125 305 mm 5 12 in from the turbocharger exhaust outlet NOTE The tapped hole must be in a comparatively straight area of the turbocharger exhaust outlet 2 Tap the hole to accommodate a 1 8 in pipe plug 3 Connect a manometer calibrated to read pressure in kPa or inches of Hg WARNING PERSONAL INJURY To avoid injury before starting and running the engine ensure the vehicle is parked on a level surface parking brake is set and the wheels are blocked 4 Start and run the engine Run the engine at idle with a no load condition for approximately five minutes allowing the engine coolant to reach normal operating range approximately 88 96 C 190 205 F 6 Run the engine speed to full load a Ifthe exhaust back pressure at full load
113. g difficulty visually check DDEC ECU circuit breakers or fuses to determine if circuit breaker s or fuse s are tripped or blown 1 If circuit breakers are tripped determine cause and repair or replace as necessary refer to OEM guidelines Perform validation refer to section 15 5 4 1 2 If circuit breakers are not tripped measure the voltage at the DDEC ECU power harness An Electronic Control Troubleshooting Guide is currently under development for this procedure Contact DDC Customer Support Center at 313 592 5800 in the interim 15 5 3 DDEC ECU Power Harness Voltage Test An Electronic Control Troubleshooting Guide is currently under development Contact DDC Customer Support Center at 313 592 5800 in the interim 15 5 4 Power Harness Repair Perform the following steps to repair the power harness 1 Repair the damage to the power harness 2 Verify repair of the power harness refer to section 15 5 4 1 15 5 4 1 Test Engine with Repaired Power Harness To determine if the repair resolved the starter difficulty perform the following steps WARNING PERSONAL INJURY To avoid injury before starting and running the engine ensure the vehicle is parked on a level surface parking brake is set and the wheels are blocked 1 Attempt to start and run the engine if the engine starts and runs no further troubleshooting is required Shut down the engine 2 Ifthe engine fails to start and run check for an empty fue
114. g the engine coolant to reach normal operating range a If the engine coolant temperature is 82 105 C 180 221 F no further troubleshooting is required Shut down the engine b Ifthe engine coolant temperature is not 82 105 C 180 221 F shut down the engine Check for insufficient radiator air circulation refer to section 15 15 3 15 15 3 Troubleshooting Procedure for Insufficient Radiator Air Circulation To determine if insufficient radiator air circulation is causing high engine coolant temperature visually examine the radiator and radiator shrouding 1 If the radiator is absent of clogging debris and dirt check the pressure control cap refer to section 15 15 6 2 If the radiator has excessive clogging debris or dirt refer to section 15 15 4 3 If the radiator shrouding is not damaged incorrectly positioned or inadequate check the pressure control cap refer to section 15 15 6 4 Ifthe radiator shrouding is damaged incorrectly positioned or inadequate refer to section 15 15 5 15 15 4 Exterior Radiator Repair Perform the following for exterior radiator repair 1 Clean the exterior radiator of all clogging debris or excessive dirt refer to OEM guidelines 2 Verify exterior radiator repair refer to section 15 15 5 1 15 15 5 Radiator Shroud Repair Perform the following for radiator shroud repair 1 Repair or replace damaged radiator shrouding refer to OEM guidelines 2 Verify exterior
115. g to replace the air filter element 1 Remove and replace the damaged or clogged air filter element refer to OEM guidelines 2 Verify that replacing the air filter element eliminated the excessive exhaust smoke refer to section 15 9 2 1 15 9 2 1 Test the Engine with Replaced Air Filter Element Perform the following to determine if the new filter element resolved excessive exhaust smoke Rev 2005 All information subject to change without notice 15 90 From Bulletin 1 MBE900 05 6SE414 0404 Copyright O 2005 DETROIT DIESEL CORPORATION MBE900 SERVICE MANUAL WARNING PERSONAL INJURY To avoid injury before starting and running the engine ensure the vehicle is parked on a level surface parking brake is set and the wheels are blocked 1 Start and run the engine 2 Run the engine at idle with a no load condition for approximately five minutes allowing the engine coolant to reach normal operating range approximately 88 96 C 190 205 F 3 Visually inspect exhaust for excessive smoke a Ifthe engine exhaust emission appears normal no further troubleshooting is required Shut down the engine b Ifthe engine exhaust emission is excessively black or gray shut down the engine Check the charge air cooler refer to section 15 9 3 15 9 3 Troubleshooting Procedure for a Restricted or Cracked Charge Air Cooler To determine if a charge air cooler is causing excessive exhaust smoke perform the following N
116. gine Check the fuel nozzles refer to section 15 9 8 15 9 8 Troubleshooting Procedure for Aerated Fuel To determine if aerated fuel is causing excessive exhaust smoke perform the following steps 1 Disconnect the fuel line return hose from the fitting located at the fuel tank refer to OEM guidelines 2 Place the opened end of the fuel line into a suitable container WARNING PERSONAL INJURY To avoid injury before starting and running the engine ensure the vehicle is parked on a level surface parking brake is set and the wheels are blocked Start the engine 4 Run the engine at 1000 rpm Visually check to see if air bubbles are rising to the surface of the fuel within the container a If air bubbles are present repair is necessary refer to section 15 9 9 b If air bubbles are not present check for a low compression Shut down the engine refer to section 15 9 10 15 9 9 Aerated Fuel Resolution Perform the following steps for aerated fuel resolution 1 Shut down the engine 2 Tighten all fuel line connections between fuel tank and fuel pump refer to OEM guidelines Visually inspect all fuel lines between fuel tank and fuel pump for leaks 4 Replace damaged components as required Verify aerated fuel resolution corrected the excessive exhaust smoke condition refer to section 15 9 9 1 All information subject to change without notice Rev 2005 6SE414 0404 Copyright 2005 DETROIT DIESEL COR
117. gray shut down the engine Check for a faulty exhaust system refer to section 15 9 6 15 9 6 Troubleshooting Procedure for a Faulty Exhaust System i To determine if a faulty exhaust system is causing excessive black or gray exhaust smoke perform the following 1 Drill an 11 32 in hole in the exhaust pipe 125 305 mm 5 12 in from the turbocharger exhaust outlet NOTE The tapped hole must be in a comparatively straight section of the turbocharger exhaust outlet 2 Tap the hole to accommodate a 1 8 in pipe plug 3 Connect a manometer calibrated to read pressure in kPa or inches of Hg to the tapped hole All information subject to change without notice Rev 2005 6SE414 0404 Copyright 2005 DETROIT DIESEL CORPORATION From Bulletin 1 MBE900 05 15 95 15 9 EXCESSIVE EXHAUST SMOKE BLACK OR GRAY WARNING PERSONAL INJURY To avoid injury before starting and running the engine ensure the vehicle is parked on a level surface parking brake is set and the wheels are blocked 4 Start and run the engine Run the engine at idle with a no load condition for approximately five minutes allowing the engine coolant to reach normal operating range approximately 88 96 C 190 205 F 6 Run the engine speed to full load a Ifthe exhaust back pressure at full load is less than 12 kPa 3 5 in Hg check the fuel injectors and nozzles refer to section 15 9 10 Shut down the engine b If the exhaust bac
118. hand 2 Inspect the fuel lines for restrictions due to pinching kinking or other damage If damage is found repair as necessary refer to OEM guidelines Inspect the fuel return check valve for restrictive movement 4 Inspect the fuel pump drive assembly If damage is found repair as necessary refer to section 2 15 5 Verify repairs done to correct insufficient fuel flow refer to section 15 12 6 1 15 12 6 1 Test the Engine with Resolved Fuel Flow Perform the following steps to determine if the fuel flow resolution resolved rough running or stalling WARNING PERSONAL INJURY To avoid injury before starting and running the engine ensure the vehicle is parked on a level surface parking brake is set and the wheels are blocked 1 Start and run the engine 2 Run the engine at idle with a no load capacity for approximately five minutes allowing the engine coolant to reach normal operating range 88 96 C 190 205 F a Ifthe engine is not running rough or stalling no further troubleshooting is required Shut down the engine b If the engine is running rough or stalling shut down the engine Contact Detroit Diesel Customer Support Center at 313 592 5800 All information subject to change without notice Rev 2005 6SE414 0404 Copyright 2005 DETROIT DIESEL CORPORATION From Bulletin 1 MBE900 05 15 125 15 13 LACK OF POWER 15 13 LACK OF POWER There are several causes for lack of power These pro
119. he inside of the main fuel filter housing Replace contaminated the filter element The fuel feed lines are kinked or blocked Inspect the lines fittings and check valve for blockage Repair any kinks and replace the lines The suction pipe or the strainer at the fuel level is Open the fuel fill cap Inspect the suction pipe and blocked or touching the bottom of the fuel tank strainer Remove any blockages and reposition the suction pipe if necessary Remove the fuel level sensor and replace it if necessary The check valve in the fuel feed line is blocked or is not Repair replace as necessary sufficiently open the opening flange is bent at the fitting The overflow valve is faulty or the incorrect valve has Inspect the overflow valve Replace as necessary been installed The valve jams when closed as aresult NOTE Do not attempt to disassemble the overflow of wear or impurities in the fuel valve The overflow valve cannot be repaired Table 15 34 Problem Fuel Flow Quantity is Too Low at the Overflow Valve and Within Range at the Filter All information subject to change without notice Rev 2005 6SE414 0404 Copyright 2005 DETROIT DIESEL CORPORATION From Bulletin 1 MBE900 05 15 21 15 2 GENERAL TROUBLESHOOTING Problem The Fuel Inlet Pressure is Too Low Possible Cause The pre filter is leaking drawing air Replace the O ring Replace the filter element and tighten the cap on the filter housing 25 N m
120. heels are blocked 1 Start the engine 2 Run the engine and bring the engine coolant temperature to normal operating range approximately 88 96 C 190 205 F Return engine to idle and remove the oil dipstick gt Attach a manometer calibrated to read pressure in kPa or inches of H O to the oil dipstick opening Run the vehicle to full load and rated speed 5 6 Measure and record crankcase pressure 7 Shut down the engine 8 Remove the manometer from the oil dipstick opening and install the dipstick 15 4 11 Worn or Damaged Valve or Cylinder Kit Repair Perform the following steps to determine a worn or damaged valve or cylinder kit 1 Remove cylinder head refer to section 1 2 1 2 Inspect the cylinder head for worn or damaged valves refer to section 1 17 3 Inspect the cylinder head components for worn or damaged liners examine the pistons or piston rings 4 Verify repairs made to cylinder valve s or cylinder kit components refer to section 15 4 11 1 15 4 11 1 Verification of Repair for Worn or Damaged Valve or Cylinder Kit Perform the following steps to determine if the repaired valve or cylinder kit resolved the misfiring cylinder condition Rev 2005 All information subject to change without notice 15 54 From Bulletin 1 MBE900 05 6SE414 0404 Copyright O 2005 DETROIT DIESEL CORPORATION MBE900 SERVICE MANUAL WARNING PERSONAL INJURY To avoid injury before starting and running the
121. if aerated fuel is causing excessive white smoke perform the following steps 1 Disconnect the fuel line return hose from the fitting located at the fuel tank refer to OEM guidelines 2 Place the open end of the fuel line into a suitable container All information subject to change without notice Rev 2005 6SE414 0404 Copyright 2005 DETROIT DIESEL CORPORATION From Bulletin 1 MBE900 05 15 115 15 11 EXCESSIVE WHITE SMOKE WARNING PERSONAL INJURY To avoid injury before starting and running the engine ensure the vehicle is parked on a level surface parking brake is set and the wheels are blocked Start and run the engine 4 Operate the engine at 1000 rpm Visually check to see if air bubbles are rising to the surface of the fuel within the container a If air bubbles are present shut down the engine refer to section 15 11 9 b If air bubbles are not present shut down the engine check for improper grade of fuel refer to section 15 11 10 15 11 9 Aerated Fuel Resolution Perform the following steps to resolve aerated fuel 1 Tighten all fuel line connections between fuel tank and fuel pump refer to OEM guidelines 2 Visually inspect all fuel lines between fuel tank and fuel pump for leaks Repair damaged components as required refer to OEM guidelines 4 Verify aerated fuel resolution refer to section 15 11 9 1 15 11 9 1 Test the Engine with Aerated Fuel Resolution Perform the followi
122. ing brake is set and the wheels are blocked Start and run the engine Perform a crankcase pressure test refer to section 15 4 10 1 a If the engine crankcase pressure is within 0 62 kPa 2 5 in H O no further troubleshooting is required Shut down the engine b If the engine crankcase pressure is not within 0 62 kPa 2 5 in H O shut down the engine Check the turbocharger refer to section 15 8 4 15 8 4 Troubleshooting Procedure for a Defective Turbocharger To determine if a defective turbocharger is causing excessive crankcase pressure perform the following 1 2 NOTICE Ensure that the engine is not allowed to operate longer than necessary to perform the crankcase pressure test A complete loss of crankcase oil will severely damage the engine Remove the turbocharger drain line connected to the crankcase and place the drain line into a suitable container refer to section 6 4 2 Perform a crankcase pressure test refer to section 15 4 10 1 a If the engine crankcase pressure is less than 0 62 kPa 2 5 in H O replace the turbocharger refer to section 6 4 2 Shut down the engine b If the engine crankcase pressure indicates no change check for a worn or damaged valve or cylinder kit refer to section 15 8 6 Shut down the engine 15 8 5 Turbocharger Replacement Perform the following steps to replace a defective turbocharger 1 2 3 4 15 86 Remove the defective turbocharger f
123. ing range Rev 2005 All information subject to change without notice 15 132 From Bulletin 1 MBE900 05 6SE414 0404 Copyright O 2005 DETROIT DIESEL CORPORATION MBE900 SERVICE MANUAL 3 Test drive the vehicle to ensure lack of power has been resolved a If no lack of power occurred during the test drive no further troubleshooting is required Shut down the engine b If lack of power occurred during the test drive shut down the engine Check for high fuel temperature return refer to section 15 13 6 15 13 6 Troubleshooting Procedure for High Fuel Temperature Return To determine if high fuel temperature return is causing lack of power perform the following steps 1 Test for high fuel temperature return 2 Analyze the high fuel temperature test results a If the return fuel temperature is less than or equal to 60 C 140 F check for air cleaner restriction refer to section 15 13 8 b If the return fuel temperature is greater than 60 C 140 F resolve the high fuel temperature return condition refer to section 15 13 7 15 13 7 High Fuel Temperature Resolution Perform the following steps to resolve high fuel temperature return 1 Remove and replace fuel filter s refer to section 2 14 1 2 Verify high fuel temperature repair refer to section 15 13 7 1 15 13 7 1 Test the Engine with Resolved High Fuel Temperature Perform the following steps to determine if high fuel temperature repairs have resolved lac
124. ion subject to change without notice 15 42 From Bulletin 1 MBE900 05 6SE414 0404 Copyright O 2005 DETROIT DIESEL CORPORATION MBE900 SERVICE MANUAL 2 Disconnect the fuel temperature sensor See Figure 15 11 1 Fuel Temperature Sensor 2 Engine Wiring Harness Figure 15 11 Disconnecting the Sensor 3 Plug the disconnected fuel temperature sensor into the engine wiring harness and tie it up out of the way All information subject to change without notice Rev 2005 6SE414 0404 Copyright 2005 DETROIT DIESEL CORPORATION From Bulletin 1 MBE900 05 15 43 15 3 FUEL INJECTION TROUBLESHOOTING 4 Install the adaptor and seal from the fuel adaptor parts kit J 46377 See Figure 15 12 1 Banjo Fitting 3 Adaptor from kit J 46377 2 Unit Pump fuel Figure 15 12 Connecting the Adaptor 5 Attach a banjo fitting to the adaptor and use that to connect the high pressure fuel line J 46372 and gauge J 46378 6 Disconnect the fuel return line at the main filter housing Seal the opening with a cap 7 Disconnect the fuel feed line and feed line fitting at the main filter housing In their place attach the hose with a banjo fitting and the shut off lever from the fuel adaptor parts kit J 46377 15 3 6 2 Test 5 1 Open the fuel fill cap to release pressure in the fuel tank 2 Fill the low pressure fuel circuit with compressed air until the fuel pressure on the high pressur
125. is clogged Replace the filter element The exhaust brake valve is malfunctioning Check the operation of the valve Replace if necessary The engine performs poorly or does not develop The remedies are listed in Table 15 21 The Engine Performs full power Poorly Does Not Develop Full Power in this section Table 15 17 Problem Fuel Consumption is Too High Problem The Engine Performs Poorly Does Not Develop Full Power a A A Check the air restriction indicator Clean the intake air The air filter and or intake air system is clogged ee system and replace the air filter if necessary The exhaust brake valve is malfunctioning Repair or replace exhaust brake valve The fuel filter is clogged Replace the filter element There are other problems with the fuel system Check the fuel system The valves are not adjusted properly Check the valve lash The coolant temperature sensor is damaged or reading Replace the coolant temperature sensor incorrectly The fuel temperature sensor is damaged or reading Replace the fuel temperature sensor incorrectly The engine oil temperature sensor is damaged or Replace the oil temperature sensor reading incorrectly T cnarge ai temperature Sensor Ig damaged or Replace the charge air temperature sensor reading incorrectly Detroit Diesel There are problems with the DDEC ECU or DDEC VCU A lesel Customer support Center a There is internal damage to the engine Repair the internal d
126. k of power condition WARNING PERSONAL INJURY To avoid injury before starting and running the engine ensure the vehicle is parked on a level surface parking brake is set and the wheels are blocked 1 Start and run the engine 2 Test drive the vehicle to ensure lack of power has been resolved a If lack of power did not occur during the test drive no further troubleshooting is required Shut down the engine b If lack of occurred during the test drive shut down the engine Check for a restricted air cleaner element refer to section 15 13 8 All information subject to change without notice Rev 2005 6SE414 0404 Copyright 2005 DETROIT DIESEL CORPORATION From Bulletin 1 MBE900 05 15 133 15 13 LACK OF POWER 15 13 8 Troubleshooting Procedure for Restricted Air Cleaner Element To determine if a restricted air cleaner element is causing lack of power perform the following Steps 1 Remove the air filter element from the air cleaner container refer to OEM guidelines 2 Visually inspect the air cleaner element for damage or clogging a If no damage or clogging is found check the charge air cooler refer to section 15 13 10 b If damage or clogging is found refer to section 15 13 9 15 13 9 Air Filter Element Replacement Perform the following steps to replace the air filter element 1 Remove and replace the damaged or clogged air filter element refer to OEM guidelines 2 Verify air filter ele
127. k pressure at full load is 12 kPa 3 5 in Hg or greater refer to section 15 9 7 Shut down the engine 15 9 7 Engine Exhaust System Resolution Perform the following steps to resolve the engine exhaust system concern 1 Visually inspect the engine exhaust system refer to OEM guidelines 2 Repair and replace defective exhaust system components refer to OEM guidelines 3 Verify exhaust system resolutionrefer to section 15 9 7 1 15 9 7 1 Test the Engine with Replaced Exhaust System Perform the following steps to determine if replaced engine exhaust manifold has resolved the excessive black or gray exhaust smoke condition WARNING PERSONAL INJURY To avoid injury before starting and running the engine ensure the vehicle is parked on a level surface parking brake is set and the wheels are blocked 1 Start and run the engine 2 Run the engine at idle with a no load condition for approximately five minutes allowing the engine coolant to reach normal operating range approximately 88 96 C 190 205 F 3 Visually inspect exhaust for excessive smoke Rev 2005 All information subject to change without notice 15 96 From Bulletin 1 MBE900 05 6SE414 0404 Copyright O 2005 DETROIT DIESEL CORPORATION MBE900 SERVICE MANUAL a If the engine exhaust emission appears normal no further troubleshooting is required Shut down the engine b Ifthe engine exhaust emission is excessively black or gray shut down the en
128. ke Manifold Gasket A A eR ULL UDC UM UD UC gt Perform the following steps to troubleshoot the air intake manifold 1 Remove the air intake manifold refer to section 6 2 1 Rev 2005 All information subject to change without notice 15 94 From Bulletin 1 MBE900 05 6SE414 0404 Copyright 2005 DETROIT DIESEL CORPORATION MBE900 SERVICE MANUAL 2 Inspect the air intake manifold and gaskets 3 Install the air intake manifold with new gaskets refer to section 6 2 2 4 Verify repair of the air intake manifold refer to section 15 9 5 1 15 9 5 1 Test the Engine with a Replaced Charge Air Cooler or Air Intake Manifold Gasket Replacement i To determine if the replaced charge air cooler or air intake manifold gasket resolved the excessive exhaust smoke condition perform the following WARNING PERSONAL INJURY To avoid injury before starting and running the engine ensure the vehicle is parked on a level surface parking brake is set and the wheels are blocked 1 Start and run the engine 2 Run the engine at idle with a no load condition for approximately five minutes allowing the engine coolant to reach normal operating range approximately 88 96 C 190 205 F 3 Visually inspect exhaust for excessive black or gray smoke a Ifthe engine exhaust emission appears normal no further troubleshooting is required Shut down the engine b Ifthe engine exhaust emission is excessively black or
129. king brake is set and the wheels are blocked 1 Start and run the engine 2 Run the engine at idle under no load conditions for approximately five minutes allowing the engine coolant to reach normal operating range approximately 88 96 C 190 205 F 3 Visually inspect exhaust for excessive smoke a If the engine smoke emission appears normal no further troubleshooting is required Shut down the engine b If the engine exhaust smoke is excessively black or gray shut down the engine Refer to section 15 9 19 15 9 19 Troubleshooting Procedure for Improper Valve Clearance Worn or Damaged Camshaft Lobes and Rollers To determine if an improper valve clearance worn or damaged camshaft lobes or rollers are causing excessive exhaust smoke perform the following Rev 2005 All information subject to change without notice 15 104 From Bulletin 1 MBE900 05 6SE414 0404 Copyright O 2005 DETROIT DIESEL CORPORATION MBE900 SERVICE MANUAL 1 Check for improper valve clearance and worn or damaged camshaft lobes and rollers Repair as required Refer to section 1 17 2 and section 1 20 2 Verify valve clearance worn or damaged camshaft lobes and rollers repair corrected the excessive exhaust smoke concern refer to section 15 9 19 1 15 9 19 1 Test Engine with Corrected Valve Clearance Worn or Damaged Camshaft Lobes and Rollers Perform the following steps to determine if the valve clearance worn or damaged camshaft lo
130. l tank refer to section 15 5 5 15 5 5 Troubleshooting Procedure for an Empty Fuel Tank To determine if an empty fuel tank is causing starting difficulty check the amount of fuel in fuel tank refer to OEM guidelines 1 If fuel is at recommended level check for a weak battery refer to section 15 5 7 All information subject to change without notice Rev 2005 6SE414 0404 Copyright O 2005 DETROIT DIESEL CORPORATION From Bulletin 1 MBE900 05 15 57 15 5 STARTING DIFFICULTY ENGINE ROTATES 2 If fuel is below recommended level refer to section 15 5 6 15 5 6 Low Fuel Level Resolution Perform the following steps in order to resolve low fuel level 1 Fill fuel tank to full refer to OEM guidelines 2 Verify fuel tank refill refer to section 15 5 6 1 15 5 6 1 Test Engine with Filled Tank To determine if a filled fuel tank resolved starting difficulty perform the following steps WARNING PERSONAL INJURY To avoid injury before starting and running the engine ensure the vehicle is parked on a level surface parking brake is set and the wheels are blocked 1 Attempt to start and run the engine if the engine starts and runs no further troubleshooting is required Shut down the engine 2 Ifthe engine fails to start and run check the battery refer to section 15 5 7 15 5 7 Troubleshooting Procedure for Low Battery Voltage To determine if a weak battery is causing starting difficulty measure the battery vo
131. le valve s are malfunctioning Replace the constant throttle valve s There are other problems in the fuel system Check the fuel system Table 15 14 Problem The Engine Starts But Dies Problem The Engine Fan Doesn t Work The fan hub is damaged Replace the fan hub The fan wiring is damaged Repair the fan wiring he parameter settings in the DDEC ECU or DDEC VCU Contact Detroit Diesel Customer Support Center at are incorrect 313 592 5800 Table 15 15 Problem The Engine Fan Doesn t Work Problem The Engine Fan Is Constantly On Cause The fan override switch is on Check the operation of the fan override switch The camshaft TDC sensor and or the crank angle position sensor are out of adjustment The fan hub is damaged Replace the fan hub The parameter settings in the DDEC ECU or DDEC VCU Contact Detroit Diesel Customer Support Center at are incorrect 313 592 5800 Table 15 16 Problem The Engine Fan is Constantly On All information subject to change without notice Rev 2005 6SE414 0404 Copyright 2005 DETROIT DIESEL CORPORATION From Bulletin 1 MBE900 05 15 13 15 2 GENERAL TROUBLESHOOTING Problem Fuel Consumption Is Too High The tires are not properly inflated Check all tires for correct pressure Check the air restriction indicator Clean the intake air system The air filter and or intake air system is clogged are and replace the air filter if necessary The fuel filter
132. ling system hoses refer to OEM guidelines 1 If cooling system hoses are not soft deteriorated collapsed or have leaking connections check the fan belts refer to section 15 15 10 2 If cooling system hoses are soft deteriorated collapsed or have leaking connections refer to section 15 15 9 15 15 9 Coolant System Hoses Replacement Perform the following steps to resolve worn or damaged coolant system hoses 1 Remove and replace damaged or worn coolant hoses as necessary refer to OEM guidelines 2 Install new coolant hoses as necessary refer to OEM guidelines 3 Verify replaced coolant system hoses refer to section 15 15 9 1 15 15 9 1 Test Engine with Replaced Coolant Hoses Perform the following to determine if the new coolant hoses resolved high engine coolant temperature Rev 2005 All information subject to change without notice 15 154 From Bulletin 1 MBE900 05 6SE414 0404 Copyright O 2005 DETROIT DIESEL CORPORATION MBE900 SERVICE MANUAL WARNING PERSONAL INJURY To avoid injury before starting and running the engine ensure the vehicle is parked on a level surface parking brake is set and the wheels are blocked 1 Start and run the engine 2 Run the engine through its operating range with no load for approximately five minutes allowing the engine coolant to reach normal operating range and visually examine replaced hoses for any leaks a If the engine coolant temperature is 82 105
133. longer Before cranking the engine again wait at least two minutes The engine should start within four 30 second attempts The fuel system is bled automatically 9 Ifthe problem has still not been resolved test vehicle performance on a chassis dynamometer If there is no improvement in fuel consumption or performance connect a fuel consumption measuring system 15 3 2 Test 1 Downstream Pressure Test Perform the following test set up and test to determine the downstream pressure All information subject to change without notice Rev 2005 6SE414 0404 Copyright 2005 DETROIT DIESEL CORPORATION From Bulletin 1 MBE900 05 15 29 15 3 FUEL INJECTION TROUBLESHOOTING 15 3 2 1 Test Set Up 1 Remove the engine trim panel See Figure 15 3 J 46378 J 46372 1 Engine Trim Panel 3 Fuel Temperature Sensor 2 Engine Wiring Harness Figure 15 3 Test Setup 1 Downstream Pressure Test Rev 2005 All information subject to change without notice 15 30 From Bulletin 1 MBE900 05 6SE414 0404 Copyright O 2005 DETROIT DIESEL CORPORATION MBE900 SERVICE MANUAL 2 Disconnect the engine wiring harness from the fuel temperature sensor See Figure 15 4 1 Fuel Temperature Sensor 2 Engine Wiring Harness Figure 15 4 Disconnecting the Sensor 3 Remove the fuel temperature sensor 4 Install the disconnected fuel temperature sensor into the engine wiring harness and ti
134. lowing steps 15 82 WARNING PERSONAL INJURY To avoid injury before starting and running the engine ensure the vehicle is parked on a level surface parking brake is set and the wheels are blocked Attempt to start and run the engine if the engine starts and runs no further troubleshooting in required If the engine fails to start and run call the Detroit Diesel Customer Support Center at 313 592 5800 Rev 2005 All information subject to change without notice From Bulletin 1 MBE900 05 6SE414 0404 Copyright O 2005 DETROIT DIESEL CORPORATION MBE900 SERVICE MANUAL 15 8 EXCESSIVE CRANKCASE PRESSURE There are several causes for excessive crankcase pressure These probable causes are Obstruction or Damage to Cylinder Head Cover Breather Defective Air Compressor Defective Turbocharger Worn or Damaged Valve or Cylinder Kit 15 8 1 Troubleshooting Procedure for Obstruction or Damage to Cylinder Head Cover Breather To determine if an obstructed or damaged breather is causing excessive crankcase pressure perform a crankcase pressure test Refer to section 15 4 10 1 1 If the engine crankcase pressure is greater than 0 62 kPa 2 5 in H O replace wire mesh element refer to section 15 8 2 2 If the crankcase pressure remained the same check the air compressor refer to section 15 8 3 15 8 2 Cylinder Head Cover Breather Resolution Perform the following steps to replace
135. ltage refer to OEM guidelines 1 If voltage is between 10 5 14 volts 21 26 volts for a 24 volt system check the terminals for corrosion or damage refer to section 15 5 9 2 If voltage is less than 10 5 volts 21 volts for a 24 volt system battery replacement is necessary refer to section 15 5 8 15 5 8 Battery Replacement Perform the following steps for battery repair 1 Remove and replace the battery refer to OEM guidelines 2 Verify battery replacement refer to section 15 5 8 1 15 5 8 1 Test Engine with Replaced Battery To determine if the battery replacement resolved starting difficulty attempt to start and run the engine Rev 2005 All information subject to change without notice 15 58 From Bulletin 1 MBE900 05 6SE414 0404 Copyright 2005 DETROIT DIESEL CORPORATION MBE900 SERVICE MANUAL WARNING PERSONAL INJURY To avoid injury before starting and running the engine ensure the vehicle is parked on a level surface parking brake is set and the wheels are blocked 1 If the engine starts and runs no further troubleshooting is required Shut down the engine 2 If the engine fails to start and run check the terminals refer to section 15 5 9 15 5 9 Troubleshooting Procedure for Corroded or Damaged Battery Terminals To determine if corroded or damaged terminals are causing starting difficulty visually inspect terminals for corrosion or damage 1 If corrosion or damage are not f
136. mately five minutes allowing the engine coolant to reach normal operating range approximately 88 96 C 190 205 F All information subject to change without notice Rev 2005 6SE414 0404 Copyright 2005 DETROIT DIESEL CORPORATION From Bulletin 1 MBE900 05 15 103 15 9 EXCESSIVE EXHAUST SMOKE BLACK OR GRAY 3 Visually inspect exhaust for excessive smoke a If the engine smoke emission appears normal no further troubleshooting is required Shut down the engine b If the engine exhaust smoke is excessively black or gray shut down the engine Check the constant throttle valve refer to section 15 9 18 To determine if a faulty constant throttle valve is causing excessive black or gray smoke measure the resistance between wire 52 in the 55 pin connector and vehicle ground If the resistance is greater than 30 kQ replace the constant throttle valve refer to section 3 8 9 Verify the replacement of the constant throttle valve refer to section 15 9 18 1 2 If the resistance is less than 30 kQ refer to section 15 9 19 15 9 18 1 Test Engine for Replaced Constant Throttle Valve Perform the following steps to determine if the replaced constant throttle valve resolved the excessive exhaust smoke condition p 15 9 18 Troubleshooting Procedure for a Faulty Constant Throttle Valve I WARNING PERSONAL INJURY To avoid injury before starting and running the engine ensure the vehicle is parked on a level surface par
137. ment replacement refer to section 15 13 9 1 15 13 9 1 Test the Engine with Replaced Air Filter Element Perform the following steps to determine if the new air filter element has resolved lack of power WARNING PERSONAL INJURY To avoid injury before starting and running the engine ensure the vehicle is parked on a level surface parking brake is set and the wheels are blocked 1 Start and run the engine 2 Test drive the vehicle to ensure lack of power has been resolved a If lack of power did not occur during the test drive no further troubleshooting is required Shut down the engine b If lack of power occurred during the test drive shut down the engine Check the charge air cooler refer to section 15 13 10 15 13 10 Troubleshooting Procedure for Restricted or Cracked Charge Air Cooler To determine if a restricted or cracked charge air cooler is causing lack of power perform the following steps Rev 2005 All information subject to change without notice 15 134 From Bulletin 1 MBE900 05 6SE414 0404 Copyright O 2005 DETROIT DIESEL CORPORATION MBE900 SERVICE MANUAL NOTICE To avoid engine damage follow the installation instructions provided with the air to air charge air cooler test kit 1 Visually inspect the core tanks and welds for cracks and holes If cooler fails visual inspection replace the charge air cooler refer to section 15 13 11 2 Pressure test the charge air cooler refer
138. n refer to section 4 6 1 1 a If the thermostat is fully open at 95 C 203 F check insufficient radiator air circulation refer to section 15 16 3 b If the thermostat is not fully open at 95 C 203 F refer to section 15 16 2 15 16 2 Thermostat Replacement Perform the following steps to replace thermostats 1 Install new thermostat refer to section 4 6 2 2 Verify replaced thermostat refer to section 15 16 2 1 15 16 2 1 Test Engine with New Thermostat Perform the following steps to determine if thermostat replacement resolved low engine coolant temperature A WARNING PERSONAL INJURY To avoid injury before starting and running the engine ensure the vehicle is parked on a level surface parking brake is set and the wheels are blocked 1 Start and run the engine 2 Run the engine through its operating range with no load for approximately five minutes allowing the engine coolant to reach normal operating range a If the engine coolant temperature is 82 105 C 180 221 F no further troubleshooting is required Shut down the engine b Ifthe engine coolant temperature is not 82 105 C 180 221 F shut down the engine Check insufficient radiator air circulation refer to section 15 16 3 Rev 2005 All information subject to change without notice 15 162 From Bulletin 1 MBE900 05 6SE414 0404 Copyright O 2005 DETROIT DIESEL CORPORATION MBE900 SERVICE MANUAL 15 16 3 Troubleshooting Proced
139. ne coolant to reach normal operating range approximately 88 96 C 190 205 F 3 Visually inspect exhaust for excessive smoke a If the engine smoke emission appears normal no further troubleshooting is required Shut down the engine b If the engine exhaust smoke is excessively black or gray shut down the engine Check the exhaust brake valve refer to section 15 9 16 15 9 16 Troubleshooting Procedure for a Faulty Exhaust Brake Valve To determine if a faulty exhaust brake valve is causing excessive black or gray smoke check exhaust brake valve for freedom of movement 1 If movement is not free replace exhaust brake valve refer to section 7 2 Verify replacement of the exhaust brake valve refer to section 15 9 16 1 2 If movement is free check the exhaust brake cylinder refer to section 15 9 17 15 9 16 1 Test Engine for Replaced Exhaust Brake Valve Perform the following steps to determine if the replaced exhaust brake valve resolved the excessive exhaust smoke condition Rev 2005 All information subject to change without notice 15 102 From Bulletin 1 MBE900 05 6SE414 0404 Copyright O 2005 DETROIT DIESEL CORPORATION MBE900 SERVICE MANUAL WARNING PERSONAL INJURY To avoid injury before starting and running the engine ensure the vehicle is parked on a level surface parking brake is set and the wheels are blocked 1 Start and run the engine 2 Run the engine at idle under no load conditi
140. ng and running the engine ensure the vehicle is parked on a level surface parking brake is set and the wheels are blocked 2 Start and run the engine to operating temperature 88 C 190 F 3 Check for leaks at oil lines connections mating joints seals and gaskets a If no oil leaks are found shut down the engine and check for a leaking oil cooler core refer to section 15 7 4 b If oil leaks are found shut down the engine refer to section 15 7 3 Rev 2005 All information subject to change without notice 15 76 From Bulletin 1 MBE900 05 6SE414 0404 Copyright O 2005 DETROIT DIESEL CORPORATION MBE900 SERVICE MANUAL 15 7 3 Engine Oil Leak Repair Perform the following steps as necessary to resolve engine oil leaks 1 Repair or replace components leaking oil refer to chapter 3 2 Verify repairs made to correct oil leaks refer to section 15 7 3 1 15 7 3 1 Test Engine with Repairs Made to Correct Oil Leaks Perform the following steps to determine if the repairs resolved the oil leaks WARNING PERSONAL INJURY To avoid injury before starting and running the engine ensure the vehicle is parked on a level surface parking brake is set and the wheels are blocked 1 Start and run the engine to operating temperature 88 C 190 F 2 Shut down the engine 3 Check the engine for oil leaks a If no oil leaks are observed check for a leaking oil heat exchanger core refer to section 15 7
141. ng steps to determine if oil pump replacement resolved low oil pressure All information subject to change without notice Rev 2005 6SE414 0404 Copyright 2005 DETROIT DIESEL CORPORATION From Bulletin 1 MBE900 05 15 149 15 14 LOW OIL PRESSURE WARNING PERSONAL INJURY To avoid injury before starting and running the engine ensure the vehicle is parked on a level surface parking brake is set and the wheels are blocked 1 Start and run the engine speed at rated speed 2 Visually examine the oil pressure reading a Ifthe oil pressure at rated speed is 241 kPa 35 psi or more no further troubleshooting is required Shut down the engine b If the oil pressure at rated speed is less than 241 kPa 35 psi shut down the engine and call Detroit Diesel Customer Support Center at 313 592 5800 Rev 2005 All information subject to change without notice 15 150 From Bulletin 1 MBE900 05 6SE414 0404 Copyright O 2005 DETROIT DIESEL CORPORATION MBE900 SERVICE MANUAL 15 15 HIGH ENGINE COOLANT TEMPERATURE There are several causes for high engine coolant temperature These probable causes are Improper Engine Coolant Level Insufficient Radiator Air Circulation Faulty Pressure Control Cap Defective Coolant Hoses Incorrectly Adjusted Fan Belt Inoperative Thermo Modulated Fan Faulty Thermostats Faulty Water Pump Combustion Gases in Coolant Abnormal Radiator Coolant Flow
142. ng to determine if aerated fuel resolution resolved excessive white smoke condition WARNING PERSONAL INJURY To avoid injury before starting and running the engine ensure the vehicle is parked on a level surface parking brake is set and the wheels are blocked 1 Start and run the engine 2 Run the engine at idle with a no load condition for approximately five minutes allowing the engine coolant to reach normal operating range 3 Visually inspect exhaust for excessive white smoke Rev 2005 All information subject to change without notice 15 116 From Bulletin 1 MBE900 05 6SE414 0404 Copyright 2005 DETROIT DIESEL CORPORATION MBE900 SERVICE MANUAL a If the engine exhaust emission appears normal no further troubleshooting is required Shut down the engine b Ifthe engine exhaust emission is excessively white shut down the engine Check for improper grade of fuel refer to section 15 11 10 15 11 10 Troubleshooting Procedure for Improper Grade of Fuel To determine if an improper grade of fuel is causing the excessive white smoke perform the following 1 Acquire a fuel sample from the vehicle fuel tank s 2 Submit fuel sample for an ASTM test analysis a If the fuel meets specifications check for a faulty turbocharger control unit refer to section 15 11 12 b Ifthe fuel did not meet specifications resolve improper grade of fuel refer to section 15 11 11 and DDC publication Lubricating
143. nsure the vehicle is parked on a level surface parking brake is set and the wheels are blocked 1 Start and run the engine 2 Run the engine at idle with a no load condition for approximately five minutes allowing the engine coolant to reach normal operating range approximately 88 96 C 190 205 F 3 Visually inspect exhaust for excessive white smoke Shut down the engine b Ifthe engine exhaust emission is excessively white shut down the engine Check for a If the engine exhaust emission appears normal no further troubleshooting is required a faulty fuel injection nozzle holder refer to section 15 11 15 All information subject to change without notice Rev 2005 6SE414 0404 Copyright O 2005 DETROIT DIESEL CORPORATION From Bulletin 1 MBE900 05 15 119 15 11 15 11 EXCESSIVE WHITE SMOKE 15 Troubleshooting for a Faulty Fuel Injection Nozzle Holder To determine if a faulty fuel injection nozzle holder is causing excessive white smoke perform the following 1 15 11 Check for faulty fuel injection nozzle holder perform Flow Test at Nozzle Holder Refer to section 15 3 3 Repair or replace the faulty fuel injection nozzle holder refer to section 2 3 1 Verify fuel injection nozzle holder repair or replacement refer to section 15 11 15 1 15 1 Test the Engine with Repaired Fuel Injection Nozzle Holder To determine if a faulty fuel injector nozzle holder is causing excessive whit
144. o section 15 15 7 15 15 7 Pressure Control Cap Resolution Perform the following steps to resolve faulty pressure control cap 1 Remove and replace pressure control cap refer to OEM guidelines 2 Install a new pressure control cap refer to OEM guidelines 3 Verify pressure control cap repair refer to section 15 15 7 1 15 15 7 1 Test Engine with Replaced Pressure Control Cap Perform the following to determine if exterior radiator repair resolved high engine coolant temperature All information subject to change without notice Rev 2005 6SE414 0404 Copyright 2005 DETROIT DIESEL CORPORATION From Bulletin 1 MBE900 05 15 153 15 15 HIGH ENGINE COOLANT TEMPERATURE WARNING PERSONAL INJURY To avoid injury before starting and running the engine ensure the vehicle is parked on a level surface parking brake is set and the wheels are blocked 1 Start and run the engine 2 Run the engine through its operating range with no load for approximately five minutes allowing the engine coolant to reach normal operating range a Ifthe engine coolant temperature is normal no further troubleshooting is required Shut down the engine b Ifthe engine coolant temperature is not normal shut down the engine Check coolant hoses refer to section 15 15 8 15 15 8 Troubleshooting Procedure for Defective Coolant Hoses To determine if defective coolant hoses are causing high engine coolant temperature visually examine coo
145. oil specifications 3 Verify the oil resolution corrected the excessive blue smoke condition refer to section 15 10 4 1 15 10 4 1 Test Engine with New Lubricating Oil Perform the following to determine if the new oil level resolved the excessive blue smoke condition WARNING PERSONAL INJURY To avoid injury before starting and running the engine ensure the vehicle is parked on a level surface parking brake is set and the wheels are blocked 1 Start and run the engine 2 Run the engine at idle under no load conditions for approximately five minutes allowing the engine coolant to reach normal operating range approximately 88 96 C 190 205 F 3 Visually inspect exhaust for excessive blue smoke a Ifthe engine smoke emission appears normal no further troubleshooting is required Shut down the engine b If the engine exhaust smoke is excessively blue shut down the engine Refer to section 15 10 5 Rev 2005 All information subject to change without notice 15 108 From Bulletin 1 MBE900 05 6SE414 0404 Copyright O 2005 DETROIT DIESEL CORPORATION MBE900 SERVICE MANUAL 15 10 5 Troubleshooting Procedure for a Defective Turbocharger To determine if a defective turbocharger is causing excessive blue exhaust smoke perform the following 1 Remove the charge air cooler inlet duct connected between the turbocharger and charge air cooler 2 Visually inspect the compressor inlet side of the turbocharg
146. ons for approximately five minutes allowing the engine coolant to reach normal operating range approximately 88 96 C 190 205 F 3 Visually inspect exhaust for excessive smoke a Ifthe engine smoke emission appears normal no further troubleshooting is required Shut down the engine b If the engine exhaust smoke is excessively black or gray shut down the engine Check the exhaust brake cylinder refer to section 15 9 17 To determine if a faulty exhaust brake cylinder is causing excessive black or gray smoke check exhaust brake cylinder for full movement of travel by applying regulated air to cylinder 1 If movement of travel is not full replace the exhaust brake cylinder refer to section 7 2 1 Verify replacement of exhaust brake cylinder corrected the excessive exhaust smoke concern refer to section 15 9 17 1 I 15 9 17 Troubleshooting Procedure for a Faulty Exhaust Brake Cylinder 2 If full movement of travel is obtained refer to section 15 9 18 15 9 17 1 Test Engine for Replaced Engine Brake Cylinder i Perform the following steps to determine if the replaced engine brake cylinder resolved the excessive exhaust smoke condition WARNING PERSONAL INJURY To avoid injury before starting and running the engine ensure the vehicle is parked on a level surface parking brake is set and the wheels are blocked 1 Start and run the engine 2 Run the engine at idle under no load conditions for approxi
147. or refer to section 10 1 1 All information subject to change without notice Rev 2005 6SE414 0404 Copyright 2005 DETROIT DIESEL CORPORATION From Bulletin 1 MBE900 05 15 109 15 10 11 EXCESSIVE BLUE SMOKE WARNING PERSONAL INJURY To avoid injury before starting and running the engine ensure the vehicle is parked on a level surface parking brake is set and the wheels are blocked Start the engine Run the engine and bring the engine coolant temperature to normal operating range approximately 88 96 C 190 205 F Run the vehicle to full load and rated speed Attach a manometer calibrated to read pressure in kPa or inches of H O to the oil dipstick opening Measure and record crankcase pressure Shut down the engine Remove the vehicle from the chassis dynamometer Review the crankcase pressure test a Ifthe crankcase pressure was greater than 0 62 kPa 2 5 in H O refer to section 15 10 7 b If the crankcase pressure was less than 0 62 kPa 2 5 in H O perform a cylinder compression test refer to section 1 2 2 2 Compare the cylinder compression test results to specifications Refer to section 1 2 2 2 and specifications listed in Table 1 10 a If cylinder pressure is below specifications refer to section 15 10 7 b If cylinder pressure is within specifications call Detroit Diesel Customer Support Center at 313 592 5800 15 10 7 Worn or Damaged Intake Exhaust Valve or Cylinde
148. or Vehicle Ground Aerated Fuel Improper Valve Clearance Worn or Damaged Camshaft Lobes and Roller Followers Faulty Fuel Nozzle Faulty DDEC ECU Worn or Damaged Valve or Cylinder Kit 15 4 1 Troubleshooting Procedure for Poor Vehicle Ground To determine if poor vehicle ground is causing the cylinder to misfire perform the following steps 1 Remove the alternator belt Refer to section 8 2 1 WARNING PERSONAL INJURY To avoid injury before starting and running the engine ensure the vehicle is parked on a level surface parking brake is set and the wheels are blocked Start the engine Run the engine through operating range Listen for engine misfiring a Ifthe engine is not misfiring refer to section 15 4 2 Shut down the engine b Ifthe engine is still misfiring check for aerated fuel refer to section 15 4 3 15 4 2 Negative Lead Repair Perform the following steps for negative lead repair 1 Sy ae ents 15 46 Shut down the engine Remove negative lead s at frame ground stud near battery box Clean ground stud refer to OEM guidelines Clean negative lead s terminal lugs with low grit sandpaper Repair any loose or damaged lead s using the splice method or rosin core solder Install negative lead s to frame ground stud refer to OEM guidelines Rev 2005 All information subject to change without notice From Bulletin 1 MBE900 05 6SE414 0404 Copyright 2005 DETROIT DIESEL CORP
149. ound check the magnetic switch refer to section 15 5 11 2 If corrosion or damage are found repair is necessary refer to section 15 5 10 15 5 10 Corroded or Damaged Battery Terminal Repair Perform the following steps to repair corroded or damaged battery terminals 1 Repair or replace any corroded or damaged terminals refer to OEM guidelines 2 Verify repair of corroded or damaged terminals refer to section 15 5 10 1 15 5 10 1 Test with Repaired Battery Terminals To determine if the repair resolved starting difficulty perform the following steps WARNING PERSONAL INJURY To avoid injury before starting and running the engine ensure the vehicle is parked on a level surface parking brake is set and the wheels are blocked 1 Attempt to start and run the engine if the engine starts and runs no further troubleshooting is required Shut down the engine 2 If the engine fails to start and run check the magnetic switch refer to section 15 5 11 All information subject to change without notice Rev 2005 6SE414 0404 Copyright O 2005 DETROIT DIESEL CORPORATION From Bulletin 1 MBE900 05 15 59 15 5 STARTING DIFFICULTY ENGINE ROTATES 15 5 11 Troubleshooting Procedure for Defective Magnetic Switch To determine if a defective magnetic switch is causing starting difficulty WARNING PERSONAL INJURY To avoid injury before starting and running the engine ensure the vehicle is parked on a level su
150. parked on a level surface parking brake is set and the wheels are blocked 1 Start engine 2 Run the engine at 1000 rpm 3 Listen for misfiring cylinder a Ifthe engine is not misfiring no further troubleshooting is required Shut down the engine b Ifthe engine is misfiring check for improper valve clearance or worn or damaged camshaft lobes or rollers Shut down the engine refer to section 15 4 5 All information subject to change without notice Rev 2005 6SE414 0404 Copyright 2005 DETROIT DIESEL CORPORATION From Bulletin 1 MBE900 05 15 49 15 4 MISFIRING CYLINDER 15 4 5 Troubleshooting Procedure for Improper Valve Clearance Worn or Damaged Camshaft Lobes and Rollers Intake and exhaust valve clearance are adjusted by means of an adjusting set screw and locknut located at the push rod end of the rocker arm See Figure 15 13 for intake valves Exhaust valve is similar A VALVE LASH B VALVE LIFT 1 Rocker Arm 3 Intake Valves 2 Pushrod 4 Valve Bridge Figure 15 13 Intake Valves To determine if improper valve clearance is causing the cylinder to misfire check if a worn or damaged cam lobe or followers is causing the misfire Bar the engine over and inspect the camshaft and roller followers for wear or damage 1 If damage is found on the camshaft lobes or roller followers replace damaged components as nec
151. place if cracked faulty or not sealing properly necessary The cylinder head is cracked or there is cavitation in the Inspect the engine oil at the dipstick for the presence of oil chamber fuel Replace the cylinder head if necessary Table 15 32 Problem Fuel Flows Out of the Fuel Return Line Rev 2005 All information subject to change without notice 15 20 From Bulletin 1 MBE900 05 6SE414 0404 Copyright O 2005 DETROIT DIESEL CORPORATION MBE900 SERVICE MANUAL Problem Fuel Flow Quantity is Too Low at the Overflow Valve and Too High at the Filter Possible Cause The main fuel filter is leaking Repair or replace the leaking main fuel filter The O ring in the main fuel filter is worn missing or Replace the O ring or install it correctly incorrectly installed The main fuel filter cap is loose Tighten the to cap 25 N m 18 lb ft At one or more of the nozzle holders the transfer tube is Replace the transfer tube s or install it correctly leaking cracked or incorrectly installed One or more nozzle holders are leaking or cracked Replace the nozzle holder s Table 15 33 Problem Fuel Flow Quantity is Too Low at the Overflow Valve and Too High at the Filter Problem Fuel Flow Quantity is Too Low at the Overflow Valve and Within Range at the Filter The filter element in the fuel pre filter is blocked Replace the filter element The filter element in the main fuel filter is blocked or Clean t
152. proximately five minutes allowing the engine coolant to reach normal operating range Test for rough running condition a Ifthe engine appears normal no further troubleshooting is required Shut down the engine b Ifthe engine is still running rough shut down the engine Check for insufficient fuel flow Refer to section 15 12 5 15 12 5 Troubleshooting Procedure for Insufficient Fuel Flow To determine if insufficient fuel flow is causing rough running or stalling do the following steps b 15 124 Perform Fuel Flow Test 3 and measure the fuel return flow rate Refer to section 15 3 4 and see Figure 15 2 Analyze the fuel flow test results a Ifthe fuel rate is 0 9 L min 0 2 gal min or more no further troubleshooting is required Contact Detroit Diesel Customer Support Center at 313 592 5800 b If the fuel rate is less than 0 9 L min 0 2 gal min resolve the insufficient fuel flow refer to section 15 12 6 Rev 2005 All information subject to change without notice From Bulletin 1 MBE900 05 6SE414 0404 Copyright O 2005 DETROIT DIESEL CORPORATION MBE900 SERVICE MANUAL 15 12 6 Insufficient Fuel Flow Resolution Perform the following steps to resolve the insufficient fuel flow 1 Replace the fuel filter s refer to section 2 14 1 NOTE Always fill the filter s with clean fuel oil before installing Turn the filter s until they contact the gasket fully Then turn them an additional two thirds by
153. ps for air filter replacement 1 Visually inspect the air filter for clogging and replace as necessary refer to OEM guidelines 2 Visually inspect gaskets for deterioration and replace as necessary refer to OEM guidelines Visually inspect air inlets for restrictions and clean as necessary refer to OEM guidelines 4 Verify air filter replacement refer to section 15 5 26 1 15 5 26 1 Test Engine with Replaced Air Filter To determine if the replaced air filter resolved starting difficult perform the following steps WARNING PERSONAL INJURY To avoid injury before starting and running the engine ensure the vehicle is parked on a level surface parking brake is set and the wheels are blocked 1 Attempt to start the engine if the engine starts and runs no further troubleshooting is required Shut down the engine 2 Ifthe engine fails to start and run check compression refer to section 15 5 27 Rev 2005 All information subject to change without notice 15 68 From Bulletin 1 MBE900 05 6SE414 0404 Copyright O 2005 DETROIT DIESEL CORPORATION MBE900 SERVICE MANUAL 15 5 27 Troubleshooting Procedure for Low Compression To determine if low compression is causing starting difficulty perform the following steps 1 Perform a cylinder compression test Refer to section 1 2 2 2 2 Compare cylinder compression test results to specifications as listed in Table 15 38 Pressure in kPa psi Compression P
154. r refer to section 15 6 5 15 6 4 Magnetic Switch Replacement Perform the following steps for magnetic switch replacement 1 Replace the magnetic switch refer to OEM guidelines 2 Perform verification of magnetic switch replacement refer to section 15 6 4 1 Rev 2005 All information subject to change without notice 15 72 From Bulletin 1 MBE900 05 6SE414 0404 Copyright O 2005 DETROIT DIESEL CORPORATION MBE900 SERVICE MANUAL 15 6 4 1 Test Engine with New Magnetic Switch To determine if the magnetic switch replacement resolved the no start condition perform the following steps WARNING PERSONAL INJURY To avoid injury before starting and running the engine ensure the vehicle is parked on a level surface parking brake is set and the wheels are blocked 1 Attempt to start and run the engine if the engine starts and runs no further troubleshooting is required Shut down the engine 2 If the engine fails to start or run check the starter refer to section 15 6 5 15 6 5 Troubleshooting for a Defective Starter To determine if a defective starter is causing no start perform the following steps 1 Place the red lead of a voltmeter to the solenoid BAT terminal See Figure 15 17 1 Black Lead 4 Red Lead 2 Starter Ground 5 Voltmeter 3 Solenoid Terminal Figure 15 17 Cranking Motor Available Voltage Test 2 Place the black voltmeter lead to the starter ground terminal
155. r Kit Repair Perform the following steps for worn or damaged intake exhaust valves or a cylinder kit 1 2 15 110 Remove the cylinder head refer to section 1 2 1 Inspect the cylinder head for worn or damaged valves and worn or damaged valve stem seals refer to section 1 17 Inspect the cylinder kit components for worn or damaged liners pistons or piston rings refer to section 1 15 Verify repair to cylinder valve s or cylinder kit components refer to section 15 10 7 1 Rev 2005 All information subject to change without notice From Bulletin 1 MBE900 05 6SE414 0404 Copyright O 2005 DETROIT DIESEL CORPORATION MBE900 SERVICE MANUAL 15 10 7 1 Test Engine with Repairs Made to Correct Worn or Damaged Intake Exhaust Valve or Cylinder Kit Perform the following to determine if the repaired intake exhaust valve or cylinder kit has resolved the excessive crankcase pressure WARNING PERSONAL INJURY To avoid injury before starting and running the engine ensure the vehicle is parked on a level surface parking brake is set and the wheels are blocked 1 Start the engine 2 Run the engine and bring the engine coolant temperature to normal operating range approximately 88 96 C 190 205 F Run the vehicle to full load and rated speed 4 Visually inspect exhaust for excessive blue smoke a Ifthe engine exhaust smoke emission appears normal for a rebuilt engine no further troubleshooting is requi
156. r approximately five minutes allowing the engine coolant to reach normal operating range approximately 88 96 C 190 205 F 3 Visually inspect exhaust for excessive smoke a Ifthe engine exhaust emission appears normal no further troubleshooting is required Shut down the engine Rev 2005 All information subject to change without notice 15 98 From Bulletin 1 MBE900 05 6SE414 0404 Copyright 2005 DETROIT DIESEL CORPORATION MBE900 SERVICE MANUAL b Ifthe engine exhaust emission is excessively black or gray shut down the engine Check the turbocharger refer to section 15 9 11 15 9 11 Troubleshooting Procedure for a Defective Turbocharger To determine if a defective turbocharge is causing excessive exhaust smoke perform the following 1 Remove the turbocharger oil drain outlet line connected to the crankcase and place the drain line into a suitable container refer to section 6 4 2 2 Rotate turbine wheel to check for free movement If wheel does not move freely replace turbocharger refer to section 6 4 2 3 Verify that replacing the turbocharger corrected the excessive smoke problem refer to section 6 4 2 4 Perform a crankcase pressure test refer to section 15 4 10 1 a If the engine crankcase pressure is less than 0 62 kPa 2 5 in H O shut down the engine and replace the turbocharger refer to section 6 4 2 Verify replaced turbocharger corrected the excessive smoke problem refer to section 15
157. radiator repair refer to section 15 15 5 1 15 15 5 1 Test Engine with Repaired Exterior Radiator and Shrouding Perform the following to determine if exterior radiator and shrouding repair resolved high engine coolant temperature Rev 2005 All information subject to change without notice 15 152 From Bulletin 1 MBE900 05 6SE414 0404 Copyright O 2005 DETROIT DIESEL CORPORATION MBE900 SERVICE MANUAL WARNING PERSONAL INJURY To avoid injury before starting and running the engine ensure the vehicle is parked on a level surface parking brake is set and the wheels are blocked 1 Start and run the engine 2 Run the engine through its operating range with no load for approximately five minutes allowing the engine coolant to reach normal operating range a If the engine coolant temperature is 82 105 C 180 221 F no further troubleshooting is required Shut down the engine b Ifthe engine coolant temperature is not 82 105 C 180 221 F shut down the engine Check the pressure control cap refer to section 15 15 6 15 15 6 Troubleshooting Procedure for Faulty Pressure Control Cap To determine if a faulty pressure control cap is causing high engine coolant temperature perform coolant pressure control cap tests 1 Ifthe cooling system pressure is less than or equal to 62 kPa 9 psi check the coolant hoses refer to section 15 15 8 2 Ifthe cooling system pressure is greater than 62 kPa 9 psi refer t
158. re the vehicle is parked on a level surface parking brake is set and the wheels are blocked 1 Start and run the engine to operating temperature 88 C 190 F 2 Shut down the engine Check the engine coolant for the presence of oil a If no oil is present in the coolant perform a lube oil consumption test report refer to section 15 7 4 2 b If oil is present in the coolant check for a defective turbocharger Refer to section 15 7 6 15 7 4 2 Test Engine for Reduced Oil Consumption 313 592 5800 for a form Review the oil consumption report Perform a lube oil consumption report call the Detroit Diesel Customer Support Center at 1 If the oil consumption report data is within specifications check for defective air compressor refer to section 15 7 5 2 If the oil consumption report data is not within specifications call Detroit Diesel Customer Support Center at 313 592 5800 15 7 5 Troubleshooting Procedure for a Defective Air Compressor To determine if a defective air compressor is causing excessive oil consumption perform the following 1 Perform a crankcase pressure test and record the test results Refer to section 15 4 10 1 Rev 2005 All information subject to change without notice 15 78 From Bulletin 1 MBE900 05 6SE414 0404 Copyright O 2005 DETROIT DIESEL CORPORATION MBE900 SERVICE MANUAL 2 Disconnect the air discharge line from the air compressor See Figure 15 18 refer to section
159. red Shut down the engine b Ifthe engine exhaust smoke emission is excessively blue shut down the engine Call the Detroit Diesel Customer Support Center at 313 592 5800 All information subject to change without notice Rev 2005 6SE414 0404 Copyright 2005 DETROIT DIESEL CORPORATION From Bulletin 1 MBE900 05 15 111 15 11 EXCESSIVE WHITE SMOKE 15 11 EXCESSIVE WHITE SMOKE There are several causes for excessive white exhaust smoke These probable causes are Faulty DDEC ECU Faulty Turbocharger Boost Sensor Malfunctioning Air Intake Grid Preheater Defective Fuel Pump Aerated Fuel Improper Grade of Fuel Faulty Turbocharger Control Unit Restricted or Cracked Charge Air Cooler Faulty Fuel Nozzle Holder Improper Valve Clearance Worn or Damaged Camshaft Lobes and Rollers Low Cylinder Compression 15 11 1 Troubleshooting Procedure for Faulty DDEC ECU To determine if a faulty DDEC ECU is causing excessive white smoke perform the following 1 Check for faulty DDEC ECU Refer to DDC publication MBE Troubleshooting Guide 6SE422 and SID 233 2 Replace the faulty DDEC ECU refer to section 2 5 3 Verify DDEC ECU replacement refer to section 15 11 2 15 11 2 Test the Engine with Replaced DDEC ECU Perform the following to determine if the replaced DDEC ECU has resolved the excessive white smoke WARNING PERSONAL INJURY To avoid inju
160. repair for the DDEC ECU 15 4 9 1 Verification of Replacement for Faulty DDEC ECU Perform the following steps to determine if the test DDEC ECU has resolved the misfiring cylinder condition A WARNING PERSONAL INJURY To avoid injury before starting and running the engine ensure the vehicle is parked on a level surface parking brake is set and the wheels are blocked 1 Start the engine 2 Increase the engine speed up to the occurrence of the misfiring Rev 2005 All information subject to change without notice 15 52 From Bulletin 1 MBE900 05 6SE414 0404 Copyright 2005 DETROIT DIESEL CORPORATION MBE900 SERVICE MANUAL 3 Listen for misfiring cylinder a If the engine is not misfiring shut down the engine No further troubleshooting is required Replace the DDEC ECU with a new unit b If the engine is misfiring shut down the engine install original DDEC ECU and check for worn or damaged valves and cylinder kits refer to section 15 4 10 15 4 10 Troubleshooting Procedure for Worn or Damaged Valve or Cylinder Kit Loss of compression in MBE 900 engines may result from a variety of sources including worn or broken fire or compression rings holes in pistons leaky valves scored or worn cylinder walls leaky or broken gaskets and cracked cylinder heads or cylinder liners The detection and elimination of the cause or causes of cylinder pressure losses is vital to engine life and efficient operation To
161. ressure at Starter Speed 2800 406 Permissible Difference between Individual Cylinders 400 58 Table 15 38 Compression Testing Specifications a If cylinder pressure is below specifications refer to section 15 5 28 b If cylinder pressure is within specifications call Detroit Diesel Customer Support Center at 313 592 5800 15 5 28 Low Compression Repair Perform the following steps for low compression repair 1 Remove cylinder head refer to section 1 2 1 2 Inspect the cylinder head for worn or damaged valves refer to section 1 17 3 Replace damaged valves refer to section 1 17 4 Inspect the cylinder kit components for worn or damaged liners pistons or piston rings 5 Verify repairs made to cylinder head valve s or cylinder kit components refer to section 15 5 28 1 15 5 28 1 Test Engine with Repaired Cylinder Head Valve s and Cylinder Kit To determine if the cylinder head valve and cylinder kit repair resolved starting difficulty perform the following steps All information subject to change without notice Rev 2005 6SE414 0404 Copyright 2005 DETROIT DIESEL CORPORATION From Bulletin 1 MBE900 05 15 69 15 5 15 70 STARTING DIFFICULTY ENGINE ROTATES WARNING PERSONAL INJURY To avoid injury before starting and running the engine ensure the vehicle is parked on a level surface parking brake is set and the wheels are blocked Attempt to start and run the engine if the engine starts
162. rface parking brake is set and the wheels are blocked 1 Start the engine 2 Clamp a heavy gauge battery jumper cable between the two large studs of the magnetic switch See Figure 15 14 MAGNETIC GROUND SWITCH RETURN START SWITCH BATTERY CRANKING MOTOR Figure 15 14 Basic Cranking Circuit a Ifthe engine cranked with the jumper cable in place the magnetic switch must be replaced refer to section 15 5 12 b Ifthe engine did not crank with the jumper cable in place check the starter refer to section 15 5 13 15 5 12 Magnetic Switch Replacement Perform the following steps for magnetic switch replacement Rev 2005 All information subject to change without notice 15 60 From Bulletin 1 MBE900 05 6SE414 0404 Copyright O 2005 DETROIT DIESEL CORPORATION MBE900 SERVICE MANUAL 1 Replace the magnetic switch refer to OEM guidelines 2 Verify magnetic switch replacement refer to section 15 5 12 1 15 5 12 1 Test Engine with Replaced Magnetic Switch To determine if the magnetic switch replacement resolved the starting difficulty perform the following steps WARNING PERSONAL INJURY To avoid injury before starting and running the engine ensure the vehicle is parked on a level surface parking brake is set and the wheels are blocked 1 Attempt to start and run the engine if the engine starts and runs no further troubleshooting is required Shut down the engine 2 If
163. rmal operating range approximately 88 96 C 190 205 F 3 Visually inspect exhaust for excessive blue smoke Shut down the engine b If the engine exhaust smoke is excessively blue shut down the engine a If the engine smoke emission appears normal no further troubleshooting is required Refer to section15 10 3 All information subject to change without notice Rev 2005 6SE414 0404 Copyright O 2005 DETROIT DIESEL CORPORATION From Bulletin 1 MBE900 05 15 107 15 10 EXCESSIVE BLUE SMOKE 15 10 3 Troubleshooting Procedure for Improper Grade of Lubricating Oil To determine if an improper grade of lubricating oil is causing excessive blue smoke perform the following 1 Verify that the proper grade of lubricating oil is being used in the engine 2 See DDC publication Lubricating Oil Fuel and Filters 7SE270 for oil specifications 3 If the oil meets specifications check for defective turbocharger refer to section 15 10 5 4 If the oil did not meet specifications resolve improper grade of oil refer to section 15 10 4 See DDC publication Lubricating Oil Fuel and Filters TSE270 for oil specifications 15 10 4 Improper Grade of Lubricating Oil Resolution Perform the following steps to resolve the improper grade of lubricating oil 1 Drain the oil pan and filters Dispose of oil properly 2 Refill the engine oil pan with recommended oil See DDC publication Lubricating Oil Fuel and Filters 7SE270 for
164. rom the engine refer to section 6 4 2 Tag the removed turbocharger for remanufacture Install a replacement turbocharger to the engine refer to section 6 4 3 Verify replacement of new turbocharger refer to section 15 8 5 1 Rev 2005 All information subject to change without notice From Bulletin 1 MBE900 05 6SE414 0404 Copyright O 2005 DETROIT DIESEL CORPORATION MBE900 SERVICE MANUAL 15 8 5 1 Test Engine with New Turbocharger To determine if a new turbocharger resolved the excessive crankcase pressure perform a crankcase pressure test Refer to section 15 4 10 1 1 If the engine crankcase pressure is 0 62 kPa 2 5 in H O or less no further troubleshooting is required Shut down the engine If the engine crankcase pressure is greater than 0 62 kPa 2 5 in H O shut down the engine Check for a worn or damaged valve or cylinder kit refer to section 15 8 6 15 8 6 Troubleshooting Procedure for Worn or Damaged Valve or Cylinder Kit To determine if a worn or damaged cylinder kit is causing excessive crankcase pressure perform the following 1 2 10 11 Move the vehicle requiring test to the chassis dynamometer refer to OEM guidelines Remove air compressor refer to section 10 1 1 WARNING PERSONAL INJURY To avoid injury before starting and running the engine ensure the vehicle is parked on a level surface parking brake is set and the wheels are blocked Start the engine
165. ry before starting and running the engine ensure the vehicle is parked on a level surface parking brake is set and the wheels are blocked 1 Start and run the engine 2 Run the engine at idle with a no load condition for approximately five minutes allowing the engine coolant to reach normal operating range 3 Visually inspect the exhaust for excessive white smoke a If the engine exhaust emission appears normal no further troubleshooting is required Shut down the engine Rev 2005 All information subject to change without notice 15 112 From Bulletin 1 MBE900 05 6SE414 0404 Copyright 2005 DETROIT DIESEL CORPORATION MBE900 SERVICE MANUAL b If the engine exhaust emission is excessively white shut down the engine Refer to section 15 11 3 15 11 3 Faulty Turbocharger Boost Sensor To determine if a faulty turbocharger boost sensor is causing excessive white smoke perform the following 1 Check for faulty turbocharger boost sensor Refer to DDC publication MBE Troubleshooting Guide 6SE422 and PID 102 2 Resolve the faulty turbocharger boost sensor refer to section 15 11 4 15 11 4 Turbocharger Boost Sensor Resolution Perform the following steps to resolve a faulty turbocharger boost sensor 1 Disconnect harness connection from turbocharger boost sensor and remove two bolts securing the boost sensor to the air intake manifold Discard sensor 2 Secure the turbocharger boost sensor to the air intak
166. s Clean oil gauge line by soaking in cleaning solution for five minutes Blow out residue contamination in oil gauge line with compressed air Install cleaned oil gauge line refer to OEM guidelines Verify oil gauge line repair refer to section 15 14 10 1 15 14 10 1 Test the Engine with Repaired Oil Gauge Line To determine if repaired oil pressure gauge line resolved low oil pressure perform the following steps 15 144 Rev 2005 All information subject to change without notice From Bulletin 1 MBE900 05 6SE414 0404 Copyright O 2005 DETROIT DIESEL CORPORATION MBE900 SERVICE MANUAL WARNING PERSONAL INJURY To avoid injury before starting and running the engine ensure the vehicle is parked on a level surface parking brake is set and the wheels are blocked 1 Start and run the engine at rated speed If the oil pressure at rated speed is 241 kPa 35 psi or more no further troubleshooting in required Shut down the engine 2 If the oil pressure at rated speed is less than 241 kPa 35 psi shut down the engine Check for restricted heat exchanger refer to section 15 14 11 15 14 11 Troubleshooting Procedure for Restricted Heat Exchanger To determine if a restricted heat exchanger is causing low oil pressure perform the following steps WARNING PERSONAL INJURY To avoid injury before starting and running the engine ensure the vehicle is parked on a level surface parking brake is set and th
167. s see Figure 15 26 STRING SIGHT GLASS 24160 Figure 15 26 Radiator Flow Check A WARNING PERSONAL INJURY To avoid injury before starting and running the engine ensure the vehicle is parked on a level surface parking brake is set and the wheels are blocked 2 Start and run the engine at full load 3 Observe the string for flow and direction as well as the fill and bleed lines Continue observation while varying the engine speed between 1800 2400 rpm a Ifa balanced coolant flow is observed in the sight glass call Detroit Diesel Customer Support Center at 313 592 5800 Shut down the engine b Ifa balanced coolant flow is not observed in the sight glass refer to section 15 15 20 Shut down the engine 15 15 20 Abnormal Radiator Coolant Flow Resolution Perform the following steps as necessary to resolve abnormal radiator coolant flow 1 Correct bleed line size refer to OEM guidelines 2 Correct fill line size or connector fitting size refer to OEM guidelines 3 Correct restrictive top tank opening refer to OEM guidelines 4 Correct location of standpipe refer to OEM guidelines 5 Verify repairs made to correct abnormal radiator coolant flow refer to section 15 15 20 1 Rev 2005 All information subject to change without notice 15 160 From Bulletin 1 MBE900 05 6SE414 0404 Copyright O 2005 DETROIT DIESEL CORPORATION MBE900 SERVICE MANUAL 15 15 20 1 Test Engine with Resolved R
168. s Foam in the Engine Oil Problem The Engine Oil Pressure Is Low The oil pressur nd or sensor is not readin ay Bese dala ahd oreeyeckis A Replace the oil pressure gauge and or sensor i 1 Table 15 25 Problem The Engine Oil Pressure is Low Rev 2005 All information subject to change without notice 15 16 From Bulletin 1 MBE900 05 6SE414 0404 Copyright O 2005 DETROIT DIESEL CORPORATION MBE900 SERVICE MANUAL Problem The Engine Exhaust Is White Take a fuel sample and have it tested Fuel must have Fuel quality is not within DDC specifications a cetane number greater than 45 and a cetane index greater than 40 Drain fuel and replace with correct fuel The intake air preheater is malfunctioning Check the intake air preheater and replace if necessary The valves are not adjusted properly Check the valve lash There are air bubbles in the fuel Check for leaks at fuel filter fuel lines or fuel pump Repair replace as necessary Charge air cooler is damaged Replace damaged charge air cooler o tha cocant Check for leaking cylinder head gasket Replace if necessary Damaged cylinder components Perform cylinder Low cylinder compression compression test Repair replace damaged parts as necessary Turbocharger boost sensor is damaged or reading Replace the turbocharger boost sensor incorrectly Table 15 26 Problem The Engine Exhaust is White All information subject to change without notice Rev
169. t notice 15 156 From Bulletin 1 MBE900 05 6SE414 0404 Copyright O 2005 DETROIT DIESEL CORPORATION MBE900 SERVICE MANUAL WARNING PERSONAL INJURY To avoid injury before starting and running the engine ensure the vehicle is parked on a level surface parking brake is set and the wheels are blocked 1 Start and run the engine 2 Run the engine through its operating range with no load for approximately five minutes allowing the engine coolant to reach normal operating range a If the engine coolant temperature is 82 105 C 180 221 F no further troubleshooting is required Shut down the engine b Ifthe engine coolant temperature is not 82 105 C 180 221 F shut down the engine Check thermostats refer to section 15 15 14 15 15 14 Troubleshooting Procedures for Faulty Thermostats To determine if faulty thermostats are causing high engine coolant temperature perform the following 1 Remove thermostat from the thermostat housing refer to section 4 6 1 2 Inspect thermostat for correct operation refer to section 4 6 1 1 a If thermostat is fully open at 95 C 203 F check water pump refer to section 15 15 16 b If thermostat is not fully open at 95 C 203 F refer to section 15 15 15 15 15 15 Thermostat Replacement Perform the following steps to replace thermostats 1 Install new thermostat refer to section 4 6 2 2 Verify replaced thermostat refer to section 15 15 15 1 15 15 15 1
170. ted in Table 15 41 and record the fuel pressure Engine Speed rpm Fuel Pressure kPa psi 600 650 430 62 2500 400 650 58 94 Table 15 41 Fuel Pressure at Various Speeds 5 Shut down the engine 6 Remove the adaptor banjo fitting high pressure line and high pressure gauge Rev 2005 All information subject to change without notice 15 130 From Bulletin 1 MBE900 05 6SE414 0404 Copyright O 2005 DETROIT DIESEL CORPORATION MBE900 SERVICE MANUAL 7 Reinstall the fuel temperature sensor 8 Analyze the measure fuel pressure readings a If the fuel pressure is within specifications listed in Table 15 41 check for high fuel temperature return refer to section 15 13 6 b Ifthe fuel pressure is greater than specifications listed in Table 15 41 refer to section 15 13 5 15 13 4 Troubleshooting Procedure for Faulty Overflow Valve To determine if a faulty overflow valve is causing a lack of power perform the following steps 1 Run Fuel system Test 1 Downstream Pressure Test Refer to section 15 3 2 2 If Test 1 indicates faulty overflow valve proceed to step 3 3 Run fuel system Test 3 Flow Test At Fuel Filter Refer to section 15 3 4 4 If the overflow valve is found to be faulty replace the overflow valve Refer to section 15 13 5 15 13 5 Overflow Valve Replacement Perform the following steps to replace the overflow valve 1 Remove the overflow valve from the fuel return line All informa
171. the engine crankcase pressure is within 0 62 kPa 2 5 in H O shut down the engine no further troubleshooting is required 15 7 6 Troubleshooting Procedure for a Defective Turbocharger To determine if a defective turbocharger is causing excessive oil consumption perform the following l Remove the turbocharger drain line connected to the crankcase and place the drain line into a suitable container Perform a crankcase pressure test Refer to section 15 4 10 1 a If the engine crankcase pressure is less than 0 62 kPa 2 5 in H O shut down the engine Replace the turbocharger refer to section 6 4 2 Verify the replacement of the turbocharger refer to section 15 7 6 1 b If the engine crankcase pressure indicates no change shut down the engine Check for worn or damaged valve or cylinder kit Refer to section 15 7 7 15 7 6 1 Test Engine with New Turbocharger Perform the following steps to determine if a new turbocharger resolved the excessive crankcase pressure 1 Remove the turbocharger drain line connected to the crankcase and place the drain line into a suitable container 2 Perform a crankcase pressure test Refer to section 15 4 10 1 a If the engine crankcase pressure is greater than 0 62 kPa 2 5 in H O check for worn or damaged valve or cylinder kit shut down the engine Refer to section 15 7 7 b If the engine crankcase pressure is 0 62 kPa 2 5 in H O or less no further troubleshooting is required
172. ther troubleshooting is required b Ifthe DDR indicates less than 241 kPa 35 psi at rated speed shut down the engine and disconnect the DDR Check for defective pickup tube and screen assembly refer to section 15 14 16 15 14 16 Troubleshooting Procedure for Defective Pickup Screen Tube and Screen Assembly To determine if a defective pickup screen tube or screen assembly is causing low oil pressure perform the following steps 1 Remove pickup screen tube and screen assembly Refer to section 3 3 1 2 Visually inspect pickup screen tube and screen assembly All information subject to change without notice Rev 2005 6SE414 0404 Copyright O 2005 DETROIT DIESEL CORPORATION From Bulletin 1 MBE900 05 15 147 15 14 LOW OIL PRESSURE a If no tube stress cracks twisted screen tube or cracked flange are found check for defective crankshaft main bearing shells refer to section 15 14 18 b If stress cracks twisted screen tube or cracked flange are found refer to section 15 14 17 f 15 14 17 Pickup Screen Tube and Screen Assembly Replacement Perform the following steps to replace the pickup screen tube and screen assembly 1 Replace all damaged components identified during inspection and install Refer to section 3 3 2 2 Verify replacement to pickup screen tube and screen assembly refer to section 15 14 17 1 f 15 14 17 1 Test Engine with Replaced Pickup Screen Tube and Screen Assembly Perform th
173. tion subject to change without notice Rev 2005 6SE414 0404 Copyright 2005 DETROIT DIESEL CORPORATION From Bulletin 1 MBE900 05 15 131 15 13 LACK OF POWER 2 Install a new overflow valve Tighten the valve to 48 52 N m 35 38 lb ft See Figure 15 25 FLOW TEST AT FUEL FILTER FLOW TEST AT NOZZLE HOLDER FUEL DELIVERY SUB SYSTEM LOW PRESS SIDE DOWNSTREAM OF FUEL PUMP amp FILTER lt a B FUEL DELIVERY SUB SYSTEM HIGH PRESS SIDE DOWNSTREAM OF UNIT PUMPS lt a C FUEL RETURN SUB SYSTEM FROM LEAK LINE MO Unit Pump 4 Overflow Valve 2 Bypass to Fuel Return Port 5 Constant Ventilation overflow 3 Nozzle Holder Figure 15 25 Overflow Valve Location 3 Verify overflow valve replacement refer to section 15 13 5 1 15 13 5 1 Test the Engine with Replaced Overflow Valve Perform the following steps to determine if the replaced overflow valve has resolved lack of power condition WARNING PERSONAL INJURY To avoid injury before starting and running the engine ensure the vehicle is parked on a level surface parking brake is set and the wheels are blocked 1 Start and run the engine 2 Run the engine at idle with a no load condition for approximately five minutes allowing the engine coolant to reach normal operat
174. to section 15 9 3 1 3 Evaluate the results from pressure testing the charge air cooler a Ifthe pressure drop is 34 kPa 5 psi or less in 15 seconds the cooler is good Check for faulty air intake manifold refer to section 15 13 12 b Ifthe pressure drop is greater than 34 kPa 5 psi in 15 seconds replace the charge air cooler refer to section 15 13 11 15 13 11 Charge Air Cooler Replacement Perform the following steps to replace the charge air cooler 1 Remove and replace the charge air cooler refer to OEM guidelines 2 Verify replacement of the charge air cooler refer to section 15 13 12 1 15 13 12 Troubleshooting Procedure for a Faulty Air Intake Manifold Gasket Perform the following steps to troubleshoot a faulty air intake manifold gasket 1 Remove the air intake manifold refer to section 6 2 1 2 Inspect the air intake manifold and gaskets 3 Install the air intake manifold with new gaskets refer to section 6 6 2 4 Verify repair of the intake manifold refer to section 15 13 12 1 15 13 12 1 Test the Engine with Replaced Charge Air Cooler or Air Intake Manifold Gasket To determine if the repairs resolved the lack of power condition perform the following steps All information subject to change without notice Rev 2005 6SE414 0404 Copyright 2005 DETROIT DIESEL CORPORATION From Bulletin 1 MBE900 05 15 135 15 13 LACK OF POWER A WARNING PERSONAL INJURY To avoid injury before startin
175. tween 0 4 and 0 5 bar 5 8 to 7 3 psi 40 to 50 kPa If the fuel pressure is too low less suction see the causes listed in Table 15 35 Problem The Inlet Pressure is Too Low and correct the problem Make any necessary repairs and or replacements If the fuel pressure is too high more suction see the causes listed in Table 15 36 Problem The Inlet Pressure is Too High and correct the problem Make any necessary repairs and or replacements 6 Remove all test equipment Reconnect the fuel feed line 7 Make sure the fuel fill cap is tightly closed and the vehicle has been restored to operating condition 15 3 6 Test 5 Leak Test Perform the following test set up and test to determine if and where the fuel system is leaking All information subject to change without notice Rev 2005 6SE414 0404 Copyright 2005 DETROIT DIESEL CORPORATION From Bulletin 1 MBE900 05 15 41 15 3 FUEL INJECTION TROUBLESHOOTING 15 3 6 1 Test Set Up 1 Remove the engine trim panel See Figure 15 10 WY AX aw q amp HIGH PRESSURE FUEL GAUGE J 46372 HIGH PRESSURE FUEL LINE 6 3 46377 A LE SHUTOFF LEVER FROM CONNECTING LINE FROM FUEL ADAPTOR PARTS KIT FUEL ADAPTOR PARTS KIT 42908 1 Engine Trim Panel 4 Cap 2 Main Filter Housing 5 Fuel Return Line 3 Fitting 6 Fuel Feed Line Figure 15 10 Test Setup 5 Leak Test Rev 2005 All informat
176. uel is not wasted It runs off into a leak line which is controlled by a 450 kPa 65 psi overflow valve and returned to the fuel tank The overflow valve is also equipped with constant ventilation to reduce and return fuel vapor 15 3 1 2 Troubleshooting Tests Perform the following troubleshooting tests on the engine 1 Run the engine for two to three minutes at rated speed 2500 rpm NOTICE Correct torque on the high pressure lines is critical Incorrect torques could result in leaks or lack of power due to restricted fuel flow 2 Perform a visual inspection of all fuel lines pressure fittings and components including all the fittings that connect the fuel feed and drain hoses to the fuel filter housing Replace any components found to be damaged or leaking If necessary tighten all high pressure fittings to 25 N m 18 1b ft and all banjo bolts to 40 50 N m 30 37 Ib ft Inspect the filter element in the fuel pre filter Replace if necessary 4 Inspect the filter element in the main fuel filter Replace if necessary On engines with speed governors connect minidiag2 to the vehicle and increase the engine speed to 4000 rpm Note the governed engine speed given 6 Continue to run the engine until it reaches the operating temperature of approximately 82 C 180 F When the operating temperature has been reached shut the engine down and go to the next step NOTE When doing these tests be sure the temperature of th
177. ure for Insufficient Radiator Air Circulation To determine if insufficient radiator air circulation is causing low engine coolant temperature visually examine the radiator and radiator shrouding 1 If the radiator has excessive clogging debris or dirt refer to section 15 16 4 2 If the radiator shrouding is not damaged incorrectly positioned or inadequate and if the radiator is absent of clogging debris and dirt then call Detroit Diesel Customer Support Center at 313 592 5800 3 Ifthe radiator shrouding is damaged incorrectly positioned or inadequate refer to section 15 16 5 15 16 4 Exterior Radiator Repair Perform the following steps for exterior radiator repair 1 Clean the exterior radiator of all clogging debris or excessive dirt refer to OEM guidelines 2 Verify exterior radiator repair refer to section 15 16 5 1 15 16 5 Radiator Shroud Repair Perform the following steps for radiator shroud repair 1 Repair or replace damaged radiator shrouding refer to OEM guidelines 2 Verify exterior radiator repair refer to section 15 16 5 1 15 16 5 1 Test Engine with Repaired Exterior Radiator and Shrouding Perform the following steps to determine if exterior radiator or shrouding repair resolved the low engine coolant temperature WARNING PERSONAL INJURY To avoid injury before starting and running the engine ensure the vehicle is parked on a level surface parking brake is set and the wheels are
178. wheels are blocked 2 Start the engine and run it at a slow idle 600 to 650 rpm until the adaptor opening appears moist If fuel or coolant flows out of the return line see the causes listed in Table 15 32 Problem Fuel Flows Out of the Fuel Return Line and correct the problem Make any necessary repairs and or replacements 3 Increase the engine speed to 2500 rpm At most drops of fuel should appear at the adaptor opening If fuel or coolant flows out of the return line see the causes listed in Table 15 32 Problem Fuel Flows Out of the Fuel Return Line and correct the problem Make any necessary repairs and or replacements 4 Remove the adaptor and seal ring part of kit J 46377 Restore the fuel return line to the original installation as removed Tighten banjo bolt to 40 50 N m 30 37 lb ft 5 Make sure the fuel fill cap is tightly closed and the vehicle has been restored to operating condition 15 3 4 Test 3 Flow Test At Fuel Filter Perform the following test set up and test to determine the flow at the fuel filter All information subject to change without notice Rev 2005 6SE414 0404 Copyright 2005 DETROIT DIESEL CORPORATION From Bulletin 1 MBE900 05 15 35 15 3 FUEL INJECTION TROUBLESHOOTING 15 3 4 1 Test Set Up 1 Remove the engine trim panel See Figure 15 8 J 46377 4 UNION FROM FUEL ADAPTOR PARTS KIT al J 46377 WASHER FROM FUEL ae ADAPTOR PARTS KIT
179. wire mesh element 1 Remove the cylinder head cover refer to section 1 1 1 2 Remove the wire mesh element from the cylinder head cover 3 Install a new wire mesh element to the cylinder head cover 4 Install the cylinder head cover to the engine refer to section 1 1 2 5 Verify replacement of the wire mesh element refer to section 15 8 2 1 15 8 2 1 Test Engine with New Wire Mesh Element Perform the following steps to determine if the new wire mesh element resolved the excessive crankcase pressure All information subject to change without notice Rev 2005 6SE414 0404 Copyright 2005 DETROIT DIESEL CORPORATION From Bulletin 1 MBE900 05 15 83 15 8 EXCESSIVE CRANKCASE PRESSURE WARNING PERSONAL INJURY To avoid injury before starting and running the engine ensure the vehicle is parked on a level surface parking brake is set and the wheels are blocked 1 Start and run the engine 2 Perform a crankcase pressure test refer to section 15 4 10 1 a If the engine crankcase pressure is less than 0 62 kPa 2 5 in H O no further troubleshooting is required Shut down the engine b If the engine crankcase pressure is greater than 0 62 kPa 2 5 in H O check the air compressor refer to section 15 8 3 Shut down the engine 15 8 3 Troubleshooting Procedure for Defective Air Compressor To determine if a defective air compressor is causing excessive crankcase pressure perform the following
180. y perform the following steps WARNING PERSONAL INJURY To avoid injury before starting and running the engine ensure the vehicle is parked on a level surface parking brake is set and the wheels are blocked Attempt to start and run the engine if the engine starts and runs no further troubleshooting is required Shut down the engine If the engine fails to start and run check the fuel supply valve refer to section 15 5 17 15 5 17 Troubleshooting Procedure for the Fuel Supply Valve To determine if the fuel supply valve is causing starting difficulty check that the fuel supply valve is open refer to OEM guidelines 1 If the fuel supply valve is open check the fuel filters refer to section 15 5 19 2 Ifthe fuel supply valve is closed repair is necessary refer to section 15 5 18 15 5 18 Fuel Supply Valve Repair Perform the following steps for fuel supply valve repair 1 Correct valve operation or replace valve 2 Prime the fuel system refer to section 11 1 5 3 Verify fuel supply valve repair refer to section 15 5 18 1 15 5 18 1 Test Engine with Fuel Supply Valve Open To determine if opening the fuel supply valve resolved starting difficulty perform the following steps All information subject to change without notice Rev 2005 6SE414 0404 Copyright O 2005 DETROIT DIESEL CORPORATION From Bulletin 1 MBE900 05 15 63 15 5 STARTING DIFFICULTY ENGINE ROTATES A WARNING

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