Detroit Diesel - Series 60 Ddec V Troubleshooting Guide Ch11

 

11   LOW POWER C CONC ONCERN ERN Sec t i o n

Pag e

11.1

FACTORS ACTORS THAT THAT AFFECT AFFECT WHEEL HORSEPOWER HORSEPOWER ......................... .............................. ..... 11-   3

11.2

LOW HORSEPOWER HORSEPOWER INTERVIEW INTERVIEW ............................. ........................................... ............................ .............. 11-   6

11.3

AERATED AERATED FUEL ................................. ............................................... ............................. ............................ ....................... .......... 11-13 1-13

11.4

HIGH FUEL PRESSURE PRESSURE .......................... ........................................ ............................ ............................ ................... ..... 11-15 1-15

11.5

HIGH FUEL TEMPERA TEMPERATURE RETURN RETURN ................................. ............................................... ................. ... 11-18 1-18

11.6

RESTRICTED RESTRICTED AIR CLEANER CLEANER ELEMENT ........................ ....................................... ....................... ........ 11-20 1-20

11.7

RESTRIC RESTRICTED TED OR CRAC CRACKED KED CHAR CHARGE GE AIR COOLER COOLER OR OR LEAKING LEAKING INTAKE INT AKE MANIFOLD MANIFOLD ............................... ............................................. ............................ ............................ ...................... ........ 11-21 1-21

11.8

FAULTY AULTY EXHAUST EXHAUST SYSTEM ................... ................................ ............................ ............................. ................... ..... 11-23 1-23

11.9

HIGH INLET AIR TEMPERA TEMPERATURE ...................... .................................... ............................ ...................... ........ 11-25 1-25

11.10 HIGH ALTITUDE ALTITUDE OPERATION OPERATION ............................ .......................................... ............................ ...................... ........ 11-27 1-27 11.11 1.11 INCORRECT INCORRECT CAMSHAFT CAMSHAFT TIMING ............................. ........................................... ............................ .............. 11-29 1-29 11.12 VERIFICA VERIFICATION OF POWER POWER WITH CHASSIS CHASSIS DYNAMOME DYNAMOMETER TER ........... 11-30 1-30

 

11-2

 

From Bulletin 3– DDEC V SECM-06

(Rev. 2006)   All information subject to change without notice.

 

6SE57 6SE570 0 0507   Copyright © 2005 DETROIT DIESEL CORPORATION CORPORATION

 

SERIES 60 DDEC V TROUBLESHOOTING GUIDE 

11.1 FACTORS THA THAT T AFFECT WHEE WHEEL L HORSEP HORSEPOWER OWER The factors affecting affecting wheel horsepower horsepower are listed listed in Table 11-1 able 11-1.. To begin low horsepower horsepower diagnosis, refer to section section 11.2  11.2 F ac t o r s

Co n s i d er at i o n s

DDE DD EC Power ower Ra Ratting ing

Is the the co corr rrec ectt powe powerr ra rattin ing g prog progra ram mme med d in into to the ECM? CM? Is th the e driv driver  er  aware of the effects that cruise power, or the lack of cruise power has on percei perceived ved power?

Ro Road ad Speed peed Sett etting ing

Is the road road spe speed se sett ttin ing g ca caus usin ing g a perc percei eive ved d la lack ck of powe power? r?

Crank Case Over filled lled

If the cran crank k ca case se lev evel el is to too o hi high gh,, the here re wi will ll be a lo loss ss of pow power due due to churning churni ng losses create created d by the crank shaft throws contacting contacting the oil.

Fuel Temperature

Make sure there is suffi  cient fuel supply (at least 1/3 of 1/3  of normal capacity) in the fuel tanks. Check fuel temperature. For every 10°F every  10°F increase in fuel inlet temperature above 100°F, the engine will experience a power loss of up to one percent.

Fuel Blend (specific gravity)

Check the specific gravity of the fuel/vehicle system. A good number 2 diesel fuel has a speci fic gravity of 0.840 or higher @ 60°F. It should be noted that No. 1 diesel fuel can reduce horsepower to 7% less than No. 2 fuel. Blends of No. 1 and No. 2 (common in winter) will produce less horsepower horsep ower,, depending on the percen percentt of the blend. This is a common common concern when dealing with low power complaints in cold climate locations.

Fuel Filter Restriction

Check for fuel  fl ow restrictions restrictions which can be caused by fuel heaters, heaters, water  separators, fuel  fl ow meters, undersize or improperly routed/damaged fuel lines, faulty check valves, contaminated fuel  fi lters or high fuel pressure resulting from a plugged restricted  fi tting or regulator valve. Repla Replacing cing the fuel  fi lter is often the best recommendation in lieu of testing for the filter condition.

Fu Fuel el Sh Shut ut-Of -Offf Val alve ve Po Posi siti tion on

Make Make sur sure e the the fuel fuel shu shutt-of offf va valv lve e is fu full lly y open open..

Fuel uel Sys yste tem m Leak Leak

Fu Fuel el sy syst stem em leak leaks s wh whic ich h re resu sult lt in aera erate ted d fuel uel are are norm normal ally ly caus caused ed by a leak at the connections and /or  fi  fi lters between the suction side of the fuel pump to the supply tank and not between the pressure side of the pump and engine.

Fu Fuel el Tank ank Vent ent Re Rest stri rict ctio ion n

A plugg plugged ed fuel fuel tank tank ve vent nt wi will ll cre creat ate e a va vacu cuum um in th the e ta tank nk and and resu result lt in a loss in fuel pressur pressure e at the injectors. injectors. This will reduce fuel delivery rate.

 Air in Fuel

Aerated fuel, caused by a fuel system leak, will result in reduced fuel  injection timing. delivery delive ry and late late injection

Plugged or Cracked Fuel Tank Stand Pipe

If the fuel tank stand pipe is plugged by a shop rag, fuel delivery will be restricted. restri cted. A cracked stand pipe will allow air to enter the fuel system and reduce fuel  fl ow and cause late injection timing timing..

Fa Fau ulty lty Inj Inject ector

A faul aulty in inje ject ctor or wi willl li lim mit fu fuel el de deli live very ry and and al alte terr th the e comb combu ust stio ion n proc proce ess such that power is compromised.

Injector Codes

Incorrect injector codes will limit fuel delivery.

Valve Lash

Incorrect valve lash will alter the combustion process such that power is compromised.

 All information subject to change without notice.   (Rev. 2006)

6SE570 6SE57 0 0507   Copyright © 2005 DETROIT DIESEL CORPORA CORPORATION TION

 

From Bulletin 3– DDEC V SECM-06

 

11-3

 

11.1

FACT ACTORS ORS THA THAT TA AFFEC FFECT T WHEEL WHEEL HORS HORSEPOW EPOWER ER

F ac t o r s

Co n s i d er at i o n s

Ca Cam msh shaf aftt Timin ing g

Inco Incorr rrec ectt ca cam m ti tim ming ing will ill al altter the com combu bust stio ion n proc proces ess s su such ch that hat po powe wer  r  is compromised.

 Air Flow Restriction

 fl ow must not be inhibited by plugged  fi lter, or inadequate inlet air  Air  fl duct shrouding.

Faul Faulty ty Tur urbo boch char arge gerr

A turb turboc ocha harg rger er that that ha has s whee wheell ru rubb bbin ing, g, oi oill le leak aks, s, bent bent bl blad ades es,, et etc. c. wi will ll no nott provide adequate air supply.

Tem empe pera ratu ture re Co Cont ntro roll lled ed Fa Fan n

A faul faulty ty ther thermo mo co cont ntro roll wi will ll cau cause se th the e fa fan n to be lo lock cked ed on and and dr drai ain n powe power  r  on a continuous basis.

 Air System Leaks (gaskets and seals seals))

Air sys system tem leaks will result in insuf ficient air for optimum optimum combustion.

Ch Char arge ge Air Coole oolerr Leak Leak

Air sy syst stem em leak leaks s wi will ll resu result lt in ins nsuf  uf ficient air for optimum combustion.

Cl Clim imat ate e (f (fre resh sh ai airr temp temp))

The The maxim maximum um allo allowa wabl ble e te temp mper erat atur ure e ri rise se from from ambi ambien entt ai airr to engi engine ne in inle lett is 30°F. Undersized or dirty air cleaner element, as well as damaged or  obstructed obstru cted air inlet piping can cause low power. Make sure under-hood hot air is not being taken in. Pressu Pressure re drop across the air to air charge cooler should be checked (3.0 in. Hg maximum from turbo discharge to intake intak e manif manifold). old). Check turbocha turbocharger rger boost pressure and compare compare to specification.

 Altitude Performance

Site altitude has an effect on engine horsepower. Expect approximately 2% loss in power when operati operating ng at an altitude of 1 mile, relative relative to sea level.

DDEC DD EC Pa Para rame mete terr Sett Settin ings gs

Make Make su sure re ve vehi hicl cle e se sett ttin ings gs su such ch as: as: axle axle rati ratio, o, ti tire re si size ze,, to top p gear gear rat ratio io,, et etc. c. are set correct correctly ly to avoid a false sense of engine performance. performance.

EGR Valve

A misadjusted or malfunct unctiioning EGR valve will alter the amoun untt of oxygen available for combustion as well as introduce inert gas that does not promote combustion.

Exh xhau aust st Re Rest stri rict ctiion

A dam damag aged ed,, unde unders rsiz ized ed,, or ot othe herw rwis ise e re rest stri rict cted ed muf fler or exhaust system can result in high exhaus exhaustt back pressure. Refer to the engine specification sheets for maximum allowable allowable pressure.

Delta lta P Sensor

The Delta P sensor, along with the exh xha aust temperat rature, det ete ermines EGR  fl ow rate. A faulty delta P sensor will cause the EGR system to malfunctio malf unction n and alter the amoun amountt of oxygen available available for combus combustion tion as well as introduce inert gas that will not promote combustion.

Ba Baro rome metr tric ic Pr Pres essu sure re Sens Sensor or

Th The e engi engine ne wi will ll tran transi siti tion on betw betwee een n EGR EGR and and boos boostt mo mode de at an al alti titu tude de of  6500 ft. Altitude is determined by the Barometric Pressure Sensor located on the engine engine.. A faul faulty ty Barometri Barometric c Pressu Pressure re Sensor Sensor will compromise compromise the availability of boost pressure.

VP VPOD OD and and Supp Supply ly Li Line nes s

Varia ariabl ble e press pressur ure e outp output ut devi device ces s co cont ntro roll th the e va vari riab able le geom geomet etry ry tu turb rbo o va vane nes s n. Impro Improper per turbo vane or EGR valve positio positions ns will and EGR valve positio position. alter the air  fl  fl ow system balance and subsequently the combustion process.

 Air Compressor Leak

An air compressor leak will cause the air compressor to work more and increase the parasitic load on the engine.

 Air Conditioner Leak

An air conditioner leak will cause the air conditioner to work more and increase the parasitic load on the engine.

Excessive Play in Power Steering System

Continuous movement of the steering wheel will call for continuous work by the power power steering unit. This will increase the parasitic load on the engine.

11-4

 

From Bulletin 3– DDEC V SECM-06

(Rev. 2006)   All information subject to change without notice.

 

6SE57 6SE570 0 0507   Copyright © 2005 DETROIT DIESEL CORPORATION CORPORATION

 

SERIES 60 DDEC V TROUBLESHOOTING GUIDE 

F ac t o r s

Co n s i d er at i o n s

 Alternator Load

Excessive use of vehicle electrical power will cause increased use of the alternator. This will increase the parasitic load on the engine.

Tire Pressure

Under inflated tires will significantly increase driveline resistance to rotation. rotation.

Tr Trail ailer er Aerodyn Aerodynami amics/ cs/Ali Alignm gnment ent

A traile trailerr tthat hat has poo poorr a aero erodyna dynamic mics so orr has misali misaligne gned da axle xles s ((cau causin sing g dog dog tailing) will significantly increase vehicle inertia and resistance to forward motion.

Vehi ehicl cle e Payl Payloa oad d

As vehi vehicl cle e load loadin ing g in incr crea ease ses, s, veh vehic icle le in iner erti tia a and and re resi sist sta anc nce e to forwa orward rd motion increases.

Wi Wint nter er-f -fro ront nt Inst Instal alla lati tion on

extremely high Impr Improp oper er inst instal alla lati tion on or us usag age e of a wi wint nter er-f -fro ront nt wi willl result in extremely intake air temperatures and reduced mass  fl ow of air into into the combustion chamber.

Veh ehic icle le Appl Applic icat atio ion n

Unus Unusua uall ap appl plic icat atio ions ns su such ch as trip triple le dr driv ive e ax axle les, s, PT PTO' O's, s, pump pumps, s, hi high gh ai air  r  compressor duty cycle, etc., will have higher parasitic loses resulting in less horsepower at the wheels.

Table 11-1 1-1

Factors Factors Affecting Wheel Wheel Horsepower  Horsepower 

 All information subject to change without notice.   (Rev. 2006)

6SE570 6SE57 0 0507   Copyright © 2005 DETROIT DIESEL CORPORA CORPORATION TION

 

From Bulletin 3– DDEC V SECM-06

 

11-5

 

11.2

LOW HORS HORSEPOW EPOWER ER INT INTERV ERVIEW  IEW 

11.2 LOW HO HORSEP RSEPOWER OWER INTER INTERVIEW VIEW To determine if low horsepower is causing a power concern, use the driver questionna ire, the troubleshoot troubl eshooting ing tree, and the low power troubleshooti troubleshooting ng chart.

11.2.1

Drive riverr Que uesti stionn onna aire

This section should serve as a guideline for the technician.

11-6

 

From Bulletin 3– DDEC V SECM-06

(Rev. 2006)   All information subject to change without notice.

 

6SE57 6SE570 0 0507   Copyright © 2005 DETROIT DIESEL CORPORATION CORPORATION

 

SERIES 60 DDEC V TROUBLESHOOTING GUIDE 

For an example of the driver questionnaire see Figure 11-1 Figure  11-1..

Fi gure gure 11-1

Dri rive verr Questi uestionn onna ai re

 All information subject to change without notice.   (Rev. 2006)

6SE570 6SE57 0 0507   Copyright © 2005 DETROIT DIESEL CORPORA CORPORATION TION

 

From Bulletin 3– DDEC V SECM-06

 

11-7

 

11.2

LOW HORS HORSEPOW EPOWER ER INT INTERV ERVIEW  IEW 

11.2.1.1

Drive riverr Que uestion stionna naire ire

Ask the driver to answer the following questions before attempting to repair an intermittent inte rmittent  problem, or a problem with symptoms but no diagnostic codes. Use this and the response as a guideline. Refer to section 11.2.1.2 section  11.2.1.2,, “Questionnaire Response Guideline.” 1. How often often does does the problem problem occur? occur? Can you and the driver driver take take the vehicle vehicle and demonstrate the problem in less than 30 minutes? 2. Has the vehicle vehicle been been to other shops for for the same same problem? problem? If so, what what was done done there? 3. Did the radio, radio, dash dash gages, or lights momentarily momentarily turn turn OFF when when tthe he problem occurred? 4. Does Does the prob problem lem occur occur only only at speci specific operating conditions? If so, at what load? Is it light, medium, or heavy? 5. Does the prob problem lem occur occur at a speci specific engine operating operating temperature? If so, at what engine temperature? 6. Does Does the the proble problem m occur occur at at a speci specific engine operating altitude? If so, at what altitude? 7. Does Does the probl problem em occur occur only only when above above or below below specific outside temperatures? If so, what temperature range? 8. Does the problem problem occur during during other other conditions conditions e.g. e.g. during or after rain, rain, spray spray washing, washing, snow? 9. Did the the probl problem em occur occur at at a speci specific vehicle speed? If so, at what vehicle speed? 10. Does Does the problem problem occur occur at speci specific engine RPM? If so, at what engine RPM?

11. 1.2. 2.1. 1.2 2

Que uestionna stionnaire ire Re Response sponse Gu Guide ideline line

questionnaire:: The following are typical responses typical  responses to the driver questionnaire

PERSONAL PER SONAL INJURY INJURY To avoid injury from loss of vehicle vehicle/v /ves esse sell control, the read operator of a DDEC equipped equ ipped engine must not use or read any diagnostic tool while the vehicle/ve vehicle/vessel ssel is moving.  repeatable, take the vehicle for a drive with Detroit Diesel Diagnostic 1. If the the pro probl blem em is is repeatable, Link (DDDL) connected connected and note the conditions when the problem occurs. occurs. Be prepared to take snapshot data using DDDL.  Ensure you operate the vehicle after correcting the problem and duplicate duplicate the operating conditions before releasing the unit, in order to verify the problem is corrected. 2. If the vehicle vehicle has been been to other shops shops for the the same problem, problem, call call the other shops and fi nd out what has been done. Avoid replacing the same components again unless absolutely sure they are the problem! It is unlikely a component will fail again following a recent replacement.

11-8

 

From Bulletin 3– DDEC V SECM-06

(Rev. 2006)   All information subject to change without notice.

 

6SE57 6SE570 0 0507   Copyright © 2005 DETROIT DIESEL CORPORATION CORPORATION

 

SERIES 60 DDEC V TROUBLESHOOTING GUIDE 

3. If other vehicle vehicle devices devices are affected, affected, this this indicates indicates there may be something something wrong wrong with the ignition wiring. 4. Operate the the engine under under similar similar load and and temperature temperature conditions conditions.. Check the fuel fuel system system for restrictions, primary   filter lter,, and fuel tanks for foreign objects blockin blocking g the fuel supply. supply. Also, check the air system. Utilize the DDDL snapshot feature. 5. Operate the the engine at this this temperature temperature while while attempting attempting to duplicate duplicate the problem. problem. Use the DDDL snapshot snapshot feature. feature. 6. It may not not be possible possible to duplicat duplicatee the fault fault or problem problem unless unless you  you can operate the unit in a similar simil ar environment. environment. You may want to talk to the Customer Customer Support Center, or a dealer in that area. They may have helpful experience. 7. If possible, possible, troubleshoot troubleshoot the problem problem in a simila similarr temperature range. 8. If the problem problem seems to occur occur during or aft after er the engine is subjecte subjected d to rain/spray rain/spray washing, washing, thoroughly thoroug hly inspect the connectors connectors for moisture entry. entry. 9. If the the proble problem m occurs occurs at a speci specific vehicle vehicle speed, check the parameters affecting vehicle speed to verify they are programmed close to the vehicle speed where the problem occurs. Check vehicle speed and watch DDDL (snapshot) for changes to see if the pulse wheel (VSS signal) is loose. 10. If the the probl problem em occur occurss at a speci specific engine rpm, unplug the oil, coolant, and air temperature sensors, sensor s, and note any changes to the problem. Gather this data and contact DDC Customer  Support Center at 313-592-5800. 313-592-5800.

 All information subject to change without notice.   (Rev. 2006)

6SE570 6SE57 0 0507   Copyright © 2005 DETROIT DIESEL CORPORA CORPORATION TION

 

From Bulletin 3– DDEC V SECM-06

 

11-9

 

11.2

LOW HORS HORSEPOW EPOWER ER INT INTERV ERVIEW  IEW 

11.2.2

Trouble roubleshooti shooting ng Tre ree e

Following is the troubleshooting tree for low horsepower:

Fi gure gure 11-2

11-10

 

Troubl rouble eshoot shootii n ng g Tre ree e

From Bulletin 3– DDEC V SECM-06

(Rev. 2006)   All information subject to change without notice.

 

6SE57 6SE570 0 0507   Copyright © 2005 DETROIT DIESEL CORPORATION CORPORATION

 

SERIES 60 DDEC V TROUBLESHOOTING GUIDE 

11.2.3

Low Powe owerr Trouble roubleshoot shooting ing Cha hart rt

There are three basic checks that should be performed: □

□

□

  Check for active/hist active/historic oric codes. Refer to DDC pocket card 7SE460 for select EGR engine engine codes. All causes need to be checked once the fault is identi fied. Record faults on the Application For Adjustment (AFA) claim, if there is to be a claim.   Check the DDEC parameters, progressive shift settings, settings, torque limiting values, and injector  codes. Are they correct? Is proper rating applied? If vehicle is new, is it spec'd correctly? Table  11-4   Check that the the dyno-measured dyno-measured power is within within DDC DDC specifications as Listed Listed in Table 11-4 and Table 11-5 Table  11-5 for  for minimum acceptable wheel HP data. Record data on AFA claim.

NOTE: Service information letter instructions published following following the date of this document take precedence. Possible causes of low power and symptoms are listed in Table 11-2 Table  11-2.. Symptoms Loss of  Possible Causes

Mis fi r es

Power 

Po o r    Ac cel erat io n

Erratic

Engine

Black

Excessive

Idle

Dies

Smoke

Oil Consumption

Fuel Filter Restriction refer to section 11.1 section  11.1

X

X

X

X

Fuel Shut-Off Valve not Open refer to section 11.1

X

X

X

X

 Air in the Fuel refer to section 11.3 section  11.3

X

X

X

X

Faulty Injector(s) refer to section 11.1 section  11.1

X

X

X

X

Faulty Turbocharger  refer to section 11.1 section  11.1

X

X

EGR Valve* refer to section 11.1 section  11.1

X

X

X

X

Delta P Sensor  or Plugged Lines* refer to section 11.1 section  11.1

X

X

X

X

VPOD or Air Supply Lines* refer to section 11.1

X

X

X

X

Charge Air Cooler  Leak refer to section

X

X

X

X

X

X

11.7

 All information subject to change without notice.   (Rev. 2006)

6SE570 6SE57 0 0507   Copyright © 2005 DETROIT DIESEL CORPORA CORPORATION TION

 

From Bulletin 3– DDEC V SECM-06

 

11-11

 

11.2

LOW HORS HORSEPOW EPOWER ER INT INTERV ERVIEW  IEW 

Symptoms Possible Causes

Loss of  Power 

Mis Mi s fi r es

Po o r    Ac cel erat io n

Erratic Idle

Engine Dies

Black Excessive Smoke Oil Consumption

Intake or Exhaust Manifold Manif old Leak

X

X

X

refer to section 11.7 section  11.7 and section 11.8 section  11.8 Quality/Grade Quality/Gr ade of  Fuel refer to section 11.1

X

High Fuel Temperature - Above 130°F refer to section 11.5 section  11.5

X

X

Restricted Air Intake refer to section 11.1 section  11.1

X

X

Crankcase Over filled Crankcase refer to section 11.1 section  11.1

X

X

Faulty Fan Operation,  Always On refer to section 11.1 section  11.1

X

X

Debris in Fuel Tank - Air Vent Plugged refer to section 11.1 section  11.1

X

Table able 11-2

X

X

X

X

X

X

X X

X

X

Low Power ower Troubleshootin roubleshooting g  Chart

* Refer to the  Series 60 EGR Technician's Manual  (7SE60) for test procedures.

11-12

 

From Bulletin 3– DDEC V SECM-06

(Rev. 2006)   All information subject to change without notice.

 

6SE57 6SE570 0 0507   Copyright © 2005 DETROIT DIESEL CORPORATION CORPORATION

 

SERIES 60 DDEC V TROUBLESHOOTING GUIDE 

11.3 AERA AERATE TED D FUE FUEL L To determine if aerated fuel is causing lack of power, perform the following steps: 1. Disconnect Disconnect the the fuel line return return hose hose from from the the  fi tting located at the fuel tank; refer to OEM guidelines. 2. Place the open open end of the fuel fuel line into into a suitable suitable container container..

To avoid injury before before starting starting and running the engine ngine,, ensure the vehicle is parked on a level surface, parkin g brake is set, and the wheels are blocked.

To avoid void injury injury from inha inhaling ling engine ngine exhaust, xhaust, always lways opera ope rate te the engine ngine in a wellwell-ve venti ntila late ted d area rea. Engine ngine exhaust is toxic. 3. Start Start and and run run the the en engine gine.. 4. Operate Operate the the engin enginee at 1000 1000 rpm. rpm. 5. Visuall isually y check to see if air bubbles are rising rising to the surface of the fuel wi within thin the container container.. [a]

If air bubbles bubbles are are not present, present, shut down down engine, engine, check for high fuel fuel pressure; pressure; refer to section 11.4 section  11.4..

[b]

If air air bubbles bubbles are present, present, shut down engine; engine; refer refer to to section section 11.3.1  11.3.1..

11.3.1

Ae Aera rate ted d Fue uell Resolut solution ion

Perform the following steps to resolve aerated fuel: 1. Ti Tight ghten en all all fuel fuel lin linee connections between the fuel tank and fuel pump; refer to OEM guidelines. 2. Visuall isually y inspect all fuel fuel lines between between the fuel tank tank and fuel pump for leaks. leaks. 3. Repai Repairr damage damaged d  components as required; refer to OEM guidelines. 4. Verify aerated aerated fuel resolut resolution; ion; refer refer to section section 11.3.1.1  11.3.1.1..

11. 1.3. 3.1 1.1

Test the Engine with Ae Aerate rated d Fue Fuell Re Resolution solution

Perform the following steps to determine if aerated fuel resolution resolved lack of power  condition:: condition 1. Start Start and and run run the the en engine gine..

 All information subject to change without notice.   (Rev. 2006)

6SE570 6SE57 0 0507   Copyright © 2005 DETROIT DIESEL CORPORA CORPORATION TION

 

From Bulletin 3– DDEC V SECM-06

 

11-13

 

11. 1.3 3

AE AERA RATE TED D FU FUEL EL

2. Run the engine engine at idle with a no-load no-load for approximat approximately ely 5 minutes, minutes, allowing allowing the engine coolant to reach normal operating range. 3. Test drive drive the vehicle vehicle to ensure ensure lack of power has been resolved. resolved. [a]

If no lack of power power occurred occurred during during the test drive, drive, no further further troubles troubleshootin hooting g is required. Shut down the engine.

[b]

If lack lack of power occurr occurred ed during during the test test drive, drive, shut down down the engine. engine. Check Check for  high fuel pressure; refer to section 11.4 section  11.4..

11-14

 

From Bulletin 3– DDEC V SECM-06

(Rev. 2006)   All information subject to change without notice.

 

6SE57 6SE570 0 0507   Copyright © 2005 DETROIT DIESEL CORPORATION CORPORATION

 

SERIES 60 DDEC V TROUBLESHOOTING GUIDE 

11.4 HIG HIGH HF FUEL UEL P PRES RESSU SURE RE To determine if high fuel pressure is causing lack of power, perform the following steps: steps: 1. Remove the the Supply Fuel Temperat Temperature ure Sensor Sensor (SFT (SFT Sensor) Sensor)   fitting from the fuel pump. see Figure 11-3 Figure  11-3 for  for SFT Sensor.

1. Fuel Pump

Figure igure 11-3

2. Fitting

Supply upply Fuel uel Tempera mperature ture Sensor 

2. Attach a calibrated calibrated gauge gauge capable of reading reading 0 - 345 kPa (0 - 50 psi) psi) to the fuel pump. pump.

 All information subject to change without notice.   (Rev. 2006)

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From Bulletin 3– DDEC V SECM-06

 

11-15

 

11.4

HIGH HIGH FUEL FUEL PRE PRESS SSURE  URE 

To avoid injury before starting starting and running running the engine, engine, ensure the vehicle is parked on a level surface, parking brake is set, and the wheels are blocked.

To avoid void injury injury from inha inhaling ling engine ngine exhaust, xhaust, always lways opera ope rate te the engine ngine in a wellwell-ve ventil ntila ated ted area rea. Engine ngine exhaust is toxic. 3. Start and and run the engine engine to the the speeds listed listed in Table Table 11-3  11-3 and  and record the fuel pressure:

NOTE: When checking fuel pressure, start the engine, run at the speeds listed in Table  11-3  11-3,, and record record fuel pressure pressure.. Shut down the engine.

Table 11-3 1-3

En g i n e Sp e e d , r p m

A v e r a g e F u e l Pr e s s u r e , k P a ( p s i )

600

124 (18)

1200

145 (21)

1800

165 (24)

2100

186 (27)

Fuel Fuel Pressure Pressure (D (DDE DEC C V with Regula Regulator) tor)

4. Shut down the engine. engine. 5. Remove Remove the calib calibrat rated ed gaug gaugee from the the fuel pump. pump. 6. Reinst Reinstall all the SFT Sensor, Sensor, refer to the  Series 60 Service manual (6SE483),  fuel system chapter. 7. Analyze the measured measured fuel pressur pressuree readings. readings. [a] [a]

Table  11-3,, check for high fuel If the the fuel fuel pres presssure is within specification listed in Table 11-3 temperature temper ature return; refer to section section  11.5.  11.5.

[b]

If the the fuel fuel pressu pressure re is greater greater than than speci specifications listed in Table 11-3 Table  11-3,, refer to section 11.4.1.. 11.4.1

11.4.1

Com ombi bina nati tio o n Check Valve/Regulator Replacement

Perform Perfor m the following steps to replace replace the combination check valve/regulato valve/regulator: r: 1. Remove the combinatio combination n check valve/regulat valve/regulator; or; refer to appropria appropriate te service service manual, fuel system chapter.

11-16

 

From Bulletin 3– DDEC V SECM-06

(Rev. 2006)   All information subject to change without notice.

 

6SE57 6SE570 0 0507   Copyright © 2005 DETROIT DIESEL CORPORATION CORPORATION

 

SERIES 60 DDEC V TROUBLESHOOTING GUIDE 

2. Install Install a new combination combination check valve/regulator valve/regulator;; refer to appropriate appropriate service service manual, fuel system chapter. 3. Verify new combination combination check valve/regul valve/regulator ator replacement; replacement; refer refer to section section  11.4.1.1.  11.4.1.1.

11. 1.4. 4.1 1.1

Test the Engine with R Rep eplace laced d C Combina ombination tion C Che heck ck Valve/Regulator 

Perform the following steps to determine if the replaced combination check valve/regulator  resolved lack of power condition: 1. Start Start and and run run the the en engine gine.. 2. Run the engine at idle idle with a no-load no-load for approximat approximately ely 5 minutes, minutes, allowing allowing the engine coolant to reach normal operating range. 3. Test dri drive ve the vehicle vehicle to ensure ensure lack of of power has been resolved. resolved. [a]

If no lack of of power occurred occurred during during the test test drive, no further further troubles troubleshooting hooting is is required. Shut down the engine.

[b]

If lack lack of power occurred occurred during the the test drive, drive, shut shut down the the engine. Check for high high fuel temperature return; refer to section 11.5 section  11.5..

 All information subject to change without notice.   (Rev. 2006)

6SE570 6SE57 0 0507   Copyright © 2005 DETROIT DIESEL CORPORA CORPORATION TION

 

From Bulletin 3– DDEC V SECM-06

 

11-17

 

11.5

HIG HIGH H FUEL TEMP TEMPERA ERATURE TURE RETURN  RETURN 

11.5 HIGH FUEL TEM TEMPERA PERATURE TURE RETU RETURN RN To determine if high fuel temperature return is causing lack of power, perform the following following steps: 1. Test for for high fuel temperat temperature ure return. return. 2. Analyze the high high fuel temperature temperature test test results. results. [a]

 check for air  If the return return fuel fuel temperature temperature is is less than or equal equal to 54°C 54°C (130°F), (130°F), check

[b]

cleaner restriction; restriction; refer to section section  11.6.  11.6. If the return return fuel fuel temperature temperature is is greater greater than 54°C 54°C (130°F), (130°F), resolve resolve the high high fuel temperature temper ature return condition; condition; refer to section section  11.5.1.  11.5.1.

11. 1.5. 5.1 1

High Fu Fuel el Tempe mperature rature Re Resolution solution

Perform the following steps to resolve high fuel temperature return: 1. Remove Remove and replace replace fuel fuel   filter( lter(s); s); refer to  Series 60 Service manual (6SE483),  fuel system chapter. 2. Inspect Inspect the combination combination check valve/regulat valve/regulator, or, replace replace if necessary; necessary; refer to Series 60 Service manual (6SE483), (6SE483),  fuel system chapter. 3. If equip equipped ped with with a fuel fuel cooler cooler,, refer refer to OEM OEM for inspection guidelines. 4. Verify high high fuel temperat temperature ure repair; repair; refer refer to section section 11.5.1.1  11.5.1.1..

11.5. 1.5.1. 1.1 1

Test the Engine with R Resolved esolved High Fue Fuell Tempe emperature rature

Perform the following steps to determine if high fuel temperature repairs resolved lack of power  condition:

To avoid injury before starting starting and running running the engine, engine, ensure the vehicle is parked p arked on a level surface, parking brake is set, and the wheels are blocked.

To avoid void injury injury from inha inhaling ling engine ngine exhaust, xhaust, always lways opera ope rate te the engine ngine in a wellwell-ve ventil ntila ated ted area rea. Engine ngine exhaust is toxic. toxi c. 1. Start Start and run the engine. engine. 2. Test est driv drivee  the vehicle to ensure lack of power has been resolved.

11-18

 

From Bulletin 3– DDEC V SECM-06

(Rev. 2006)   All information subject to change without notice.

 

6SE57 6SE570 0 0507   Copyright © 2005 DETROIT DIESEL CORPORATION CORPORATION

 

SERIES 60 DDEC V TROUBLESHOOTING GUIDE 

[a]

If lack of power did did not occur occur during during the test test drive, drive, no further further troubleshoo troubleshooting ting is required. Shut down the engine.

[b]

If lack lack of power power occurre occurred d during during the test test drive, drive, shut shut down the the engine. engine. Chec Check k for a restricted restr icted air cleaner element; refer to section section  11.6.  11.6.

 All information subject to change without notice.   (Rev. 2006)

6SE570 6SE57 0 0507   Copyright © 2005 DETROIT DIESEL CORPORA CORPORATION TION

 

From Bulletin 3– DDEC V SECM-06

 

11-19

 

11.6

RES RESTRI TRICTED CTED AIR CLEA CLEANER NER ELEM ELEMENT  ENT 

11.6 RE RESTR STRICT ICTED ED AIR CLEAN CLEANER ER E ELEME LEMENT NT To determine if a restricted air cleaner element is causing lack of power, perform th e following steps: 1. Remov Removee the the air  air   fi fi lter element from the air cleaner container; refer to OEM guidelines. guidelines. 2. Visual isually ly inspect inspect the air cleaner element element for damage or clogging. clogging. [a] [b]

If no damage damage or clogging clogging is found, found, check the charge charge air cooler; cooler; refer refer to section section 11.7  11.7.. If damag damagee or cloggi clogging ng is found found;; refer refer to sect section ion 11.6.1  11.6.1..

NOTE: Replace the air   filter, if close to a maintenance interval.

11. 1.6. 6.1 1

Air Fil Filter ter Ele leme ment nt Repla placem ceme ent

Perform the following steps to replace the air   filter element: guidelines. 1. Remove and replace replace the the damaged damaged or clogged air   fi fi lter element; refer to OEM guidelines. 2. Verify erify air   filter element replacement; refer to section section  11.6.1.1.  11.6.1.1.

11.6. 1.6.1. 1.1 1

Test the Engine with Re Replace placed d Air Filte Filterr Ele Element ment

Perform the following steps to determine if the new   filter element resolved lack of power:

To avoid injury before starting starting and running running the engine, engine, ensure the vehicle is parked on a level surface, parking brake is set, and the wheels are blocked. are  blocked.

ngine exhaust, xhaust, always lways To avoi voi d i n njj u ury ry from from i n nha hall ing engine opera ope rate te the engine ngine in a wellwell-ve ventil ntila ated ted area rea. Engine ngine exhaust is toxic. 1. Start Start and run the engine. engine. 2. Test drive drive the vehicle vehicle to ensure ensure lack of power has been resolved. resolved.

11-20

[a] [a]

If lack lack of of power power did not occur during the test drive, no further troubleshooting is required. Shut down the engine.

[b]

If lack lack of power occurr occurred ed during during the test test drive, drive, shut down down the engine. engine. Che Check ck the charge air cooler; cooler; refer to section 11.7 section  11.7..

 

From Bulletin 3– DDEC V SECM-06

(Rev. 2006)   All information subject to change without notice.

 

6SE57 6SE570 0 0507   Copyright © 2005 DETROIT DIESEL CORPORATION CORPORATION

 

SERIES 60 DDEC V TROUBLESHOOTING GUIDE 

11.7 RES RESTRI TRICTE CTED D OR CRACKE CRACKED D CHARG CHARGE E AIR COOLER O OR R LEAK LEAKING ING INTAKE MANIFOLD To determine if a restricted or cracked charge air cooler or leaking manifold is causing lack of   power, perform the following steps: 1. Attach air-to-a air-to-air ir charge charge air cooler test test kit, J-41473; J-41473; refer refer to OEM guidelines. guidelines. 2. Disconnect Disconnect the air air inlet hose hose from from the outlet outlet side of the turbochar  turbochar ger ger compressor housing; refer to appropriate appropriate service manual, air intake system system chapter. chapter. 3. Attach the air-to-ai air-to-airr cooler cooler test kit adaptor adaptor plug plug to   fit into the hose at the compressor  connector; refer to OEM guidelines. 4. Attach an air air pressure pressure hose to the the air chuck at the the regulator regulator and gradually gradually pressurize pressurize the the air inlet system to a pressure of 177 kPa (25 psi). tion, across the face of the charge 5. Apply Apply a water and and soap soluti solution on to each hose hose connec connection, air cooler. 6. Apply a water and and soap solution solution to the air intake intake manifold manifold and cylinder cylinder head mating surface surfa ce area. 7. Visuall isually y inspect all joints joints for air leaks leaks and all charge charge air cooler welded welded surfaces surfaces for  stress cracks. [a]

If charge charge air air coole coolerr leaks leaks are present present around the joints, replace the charge air cooler; refer to section 11.7.1 section  11.7.1..

[b]

If the the intake manifold manifold leaks, leaks, repair repair intake intake manifold; manifold; refer refer to section 11.7.2 section 11.7.2..

[c]

 nor intake manifold leaked, check the exhaust system; If neither neither charge charge air air cooler  cooler  nor refer to section 11.8 section  11.8..

8. Inspect charge air cooler cooler for leaks leaks (hoses, (hoses, clamps, clamps, etc.). etc.).

11.7.1

Cha harge rge Air Coole oolerr Repla place ceme ment nt

Perform the following Perform following steps to replace the charge air cooler: 1. Remove and replace replace the the charge air air cooler; cooler; refer refer to OEM guidelin guidelines. es. 2. If the intake intake manifold doesn't doesn't leak, verify verify replacement replacement of the charge charge air cooler; refer to section 11.7.2.1 section  11.7.2.1.. 3. If the intake intake manifold manifold leaks, leaks, repair intake intake manifold; manifold; refer refer to section section 11.7.2  11.7.2..

11.7.2

Air Inta ntake ke Manifol nifold d Repa pair  ir 

Perform the following steps to repair the air intake manifold: 1. Remov Removee the the  air intake manifold; refer to  Series 60 Service manual (6SE483),  Air system chapter.

 All information subject to change without notice.   (Rev. 2006)

6SE570 6SE57 0 0507   Copyright © 2005 DETROIT DIESEL CORPORA CORPORATION TION

 

From Bulletin 3– DDEC V SECM-06

 

11-21

 

11.7

RESTRI RESTRICTED CTED OR CRACKED CRACKED CHARGE AIR COOLER OR LEAKING INT INTAKE AKE MANIFOLD

2. Inspect Inspect the air intake intake manifol manifold; d; refer refer to Series 60 Service manual (6SE483),  Air system chapter. 3. Install Install the air intake intake manifol manifold; d; refer refer to Series 60 Service manual (6SE483),  Air system chapter. 4. Verify repair repair of the the intake manifol manifold; d; refer to to section section  11.7.2.1.  11.7.2.1.

11.7. 1.7.2. 2.1 1

Test the Engine with R Repla eplaced ced Cha Charge rge Air C Cooler ooler and Air IIntake ntake Manifold

To determine if the repairs resolved the lack of power condition, perform perform the following steps:

To avoid injury before starting starting and running the engine engine,, ensure the vehicle is parked on a level surface, parking brake is set, and the wheels are blocked.

To avoid void injury injury from inha inhaling ling engine ngine exhaust, xhaust, always lways ate ted d are area a. Engi ngi ne ne opera ope rate te the engine ngine in a wellwell-ve venti ntill a exhaust is toxic. 1. Start Start and run the engine. engine. 2. Test drive drive the vehicle vehicle to ensure ensure lack of power has been resolved. resolved.

11-22

[a]

If no lack of power power occurred occurred during during the test drive, drive, no further further troubles troubleshootin hooting g is required. Shut down the engine. the  engine.

[b]

If lack lack of power occurr occurred ed during during the test test drive, drive, shut down down the engine. engine. Che Check ck the exhaust system; refer to section 11.8 section  11.8..

 

From Bulletin 3– DDEC V SECM-06

(Rev. 2006)   All information subject to change without notice.

 

6SE57 6SE570 0 0507   Copyright © 2005 DETROIT DIESEL CORPORATION CORPORATION

 

SERIES 60 DDEC V TROUBLESHOOTING GUIDE 

11.8 FAULTY EXH EXHAUST AUST SYST SYSTEM EM To determine if a faulty exhaust system is causing lack of power, perform the followi ng steps: 1. Drill an 11/32 11/32 in. hole in the the exhaust pipe, 127 - 305 305 mm (5 - 12 in.) in.) from the turbochar turbocharger  ger  exhaust outlet.

NOTE:

The tapped hole must be in a comparatively straight area of the turbocharger exhaust outlet. 2. Tap the hol holee to accommodate accommodate a 1/8 1/8 in. pipe plug. Connect a manometer manometer to the the tapped hole.

To avoid injury before before starting starting and running the engine ngine,, ensure the vehicle is parked on a level surface, p arking brake is set, and the wheels are blocked.

To avoid void injury injury from inha inhaling ling engine ngine exhaust, xhaust, always lways opera ope rate te the engine ngine in a wellwell-ve venti ntila late ted d area rea. Engine ngine exhaust is toxic. 3. Start and run the engine engine at idle with with a no-load for approximate approximately ly 5 minutes, allowing allowing the engine coolant to reach normal norma l operating range. 4. Install Install the vehicle vehicle on a chassis dynamomete dynamometerr and run the engine engine speed to full full load. [a]

If the exhaust exhaust back back pressure pressure at full full load is is less than 10.1 kPa kPa (3.0 in.Hg), in.Hg), check check for  e; refer to section 11.9 section  11.9.. high inlet air temperatur e;

[b]

If the exhaust exhaust back back pressure pressure at full load load is 10.1 kPa (3.0 in.Hg) in.Hg) or greater greater,, refer to section 11.8.1 section  11.8.1..

11.8.1

Engin ngine e Exha xhaust ust Syste ystem m Resoluti solution on

Perform the following following steps to resolve the engine exhaust system: 1. Visuall isually y inspect the the engine exhaust exhaust system; system; refer refer to OEM guidelines guidelines.. 2. Repair or replace replace defective defective exhaust exhaust system system components; components; refer to to OEM guidelines. guidelines. system resolution; resolution; refer to section section  11.8.1.1.  11.8.1.1. 3. Verify erify exhaus exhaustt system

 All information subject to change without notice.   (Rev. 2006)

6SE570 6SE57 0 0507   Copyright © 2005 DETROIT DIESEL CORPORA CORPORATION TION

 

From Bulletin 3– DDEC V SECM-06

 

11-23

 

11.8

FAUL AULTY TY EXHAUST EXHAUST SYS SYSTEM  TEM 

11. 1.8. 8.1 1.1

Test the Engine with R Repl eplace aced d E Exhaust xhaust System

Perform the following steps to determine Perform determine if replaced engine exhaust system components components resolved lack of power condition: 1. Start Start and run the engine. engine. 2. Test drive drive the vehicle vehicle to ensure ensure lack of power has been resolved. resolved.

11-24

[a]

If no lack of power power occurred occurred during during the test drive, drive, no further further troubles troubleshootin hooting g is required. Shut down the engine.

[b]

If lack lack of power occurred occurred during during the test drive, shut down down the engine. Check for high inlet air temperature; refer to section 11.9 section  11.9..

 

From Bulletin 3– DDEC V SECM-06

(Rev. 2006)   All information subject to change without notice.

 

6SE57 6SE570 0 0507   Copyright © 2005 DETROIT DIESEL CORPORATION CORPORATION

 

SERIES 60 DDEC V TROUBLESHOOTING GUIDE 

11.9 HIG HIGH H INLET AIR T TEMP EMPERA ERATUR TURE E To determine if high inlet air temperature is causing lack of power, perform the following: following: 1. Test the ra radiator diator fan, fan, fan drive, drive, or fan shroud shroud for proper proper operation operation or configuration; refer  to OEM guidelines.

NOTE:

The engine will be torque limited to protect the turbocharger and charge air cooler; (you will receive derate codes 110 and 404, FMI 14). This is normal engine operation for component protection. 2. Examine Examine test test rresul esults. ts. [a]

If the radiat radiator or fan, fan drive drive,, or fan shroud shroud pass OEM OEM test, test, check high high altitude altitude operation; refer to section 11.10 section  11.10..

[b]

If the radiator radiator fan, drive drive or shroud shroud did not operate correct correctly; ly; refer refer to section section 11.9.1  11.9.1..

11. 1.9 9.1

Rad adiato iatorr Fa Fan, n, Drive and Shroud Rep epla laceme cement nt

Perform the following steps to replace the radiator fan, drive and or shroud: guidelines. 1. Remove Remove and repla replace ce the radia radiator tor fan, fan, drive drive and/or and/or shroud; refer to OEM guidelines. 2. Verify replacement; replacement; refer refer to to section section 11.9.1.1  11.9.1.1..

11. 1.9. 9.1. 1.1 1

Test the Engine with R Radia adiator tor F Fan, an, Fa Fan n D Drive, rive, or F Fan an Shroud Replacement

Perform the following steps to determine if replaced radiator fan, fan drive, or fan shroud resolved lack of power condition:

To avoid injury before before starting starting and running the engine ngine,, ensure the vehicle is par ked k ed on a level surface, parking brake is set, and the wheels are blocked.

To avoid void injury injury from inha inhaling ling engine ngine exhaust, xhaust, always lways opera ope rate te the engine ngine in a wellwell-ve venti ntila late ted d area rea. Engine ngine exhaust is toxic. 1. Start Start and and run run the the en engine gine.. 2. Test dri drive ve the vehicle vehicle to ensure ensure lack of power has been resolved. resolved.

 All information subject to change without notice.   (Rev. 2006)

6SE570 6SE57 0 0507   Copyright © 2005 DETROIT DIESEL CORPORA CORPORATION TION

 

From Bulletin 3– DDEC V SECM-06

 

11-25

 

11.9

11-26

HIG HIGH H INLE INLET T AIR TEMP TEMPERA ERATURE  TURE 

[a]

If no lack of power power occurred occurred during during the test drive, drive, no further further troubles troubleshootin hooting g is required. Shut down the engine.

[b]

If lack of power occurred occurred during the test test drive, drive, shut down down the engine. engine. Check high high altitude altitu de operati operation; on; refer to section section  11.10.  11.10.

 

From Bulletin 3– DDEC V SECM-06

(Rev. 2006)   All information subject to change without notice.

 

6SE57 6SE570 0 0507   Copyright © 2005 DETROIT DIESEL CORPORATION CORPORATION

 

SERIES 60 DDEC V TROUBLESHOOTING GUIDE 

11.10 HIGH ALTITUDE OPERATION To determine if high altitude operation is causing lack of power: 1. Examine the altitude altitude performance performance curve, curve, see see Figure Figure  11-4.  11-4. 2. Based on the altitude altitude curve curve data, , decide decide if high altitude altitude is causing causing the lack of power power.. [a]

If your your vehicle vehicle is opera operatin ting g above sea sea level, level, a loss of power power will will be encountered, encountered,

[b]

no further further troubleshoot troubleshooting ing is required. required. If your your vehicle vehicle is operati operating ng at or below sea sea level and there there is a lack of power, power, refer to section 11.11 section  11.11..

 All information subject to change without notice.   (Rev. 2006)

6SE570 6SE57 0 0507   Copyright © 2005 DETROIT DIESEL CORPORA CORPORATION TION

 

From Bulletin 3– DDEC V SECM-06

 

11-27

 

11.10

HIG HIGH H ALTITU ALTITUDE DE OPE OPERA RATIO TION  N 

Fi gure gure 11-4

11-28

 

Al Alti titud tude e Perform rforma ance nce Cur urve ve

From Bulletin 3– DDEC V SECM-06

(Rev. 2006)   All information subject to change without notice.

 

6SE57 6SE570 0 0507   Copyright © 2005 DETROIT DIESEL CORPORATION CORPORATION

 

SERIES 60 DDEC V TROUBLESHOOTING GUIDE 

11.11 INCORRECT CAMSHAFT TIMING To determine if incorrect camshaft timing is causing lack of power, perform the foll owing steps: Check the camshaft timing; if the dial indicator reading is within 0.262 - 0.284 in. (6.655 - 7.214 mm), no further troubleshooting is required. If the dial indicator reading is not within 0.262 0.284 in. (6.655 - 7.214 mm), check engine timing; refer to section  11.11.1.  11.11.1.

NOTE: The above camshaft timing settings apply to all 12.7L and 14L DDEC V engine models.

11. 1.1 11.1

Engine Timing Re Resolution solution

Perform Perfor m the following steps to resolve resolve incorrect incorrect engine timing: timing: 1. Perform Perform an engine gear train train timing timing check; refer to to appropriate appropriate service service manual, engine engine chapter. 2. Verify engine engine timing timing resolution; resolution; refer refer to section section 11.11.1.1  11.11.1.1..

11. 1.1 11. 1.1. 1.1 1

Test Engine with C Correct orrect Timing

Perform the following steps to determine if corrected engine timing resolved lack of power  condition:

To avoid injury before before starting starting and running the engine ngine,, ensure the vehicle is parked on a level surface, parking brake is set, and the wheels are blo cked.

To avoid void injury injury from inha inhaling ling engine ngine exhaust, xhaust, always lways opera ope rate te the engine ngine in a wellwell-ve venti ntila late ted d area rea. Engine ngine exhaust is toxic. 1. Start Start and and run run the the en engine gine.. 2. Test dri drive ve the vehicle vehicle to ensure ensure lack of of power has been resolved. resolved. [a]

If no lack lack of of pow power er occurred during the test drive, no further troubleshooting is required. Shut down the engine.

[b]

If lack of of power occurred occurred during the the test drive, shut shut down the the engine. Call the Detroit Detroit Diesel Customer Customer Support Center (313-592-5800). (313-592-5800).

 All information subject to change without notice.   (Rev. 2006)

6SE570 6SE57 0 0507   Copyright © 2005 DETROIT DIESEL CORPORA CORPORATION TION

 

From Bulletin 3– DDEC V SECM-06

 

11-29

 

11.12

VER VERIFI IFICA CATIO TION N OF POWE POWER R WI WITH TH CHASS CHASSIS IS DYNA DYNAMOME MOMETER TER

11.12 VERIFICATION OF POWER WITH CHASSIS DYNAMOMETER The chassis dynamometer is a device for applying specific loads to a vehicle to determine determ ine if the vehicle will perform to published specifications and to permit a physical inspection for leaks of  any kind. It is an excellent method for detecting improper tune-up, misfiring injectors, low compression, compres sion, and other malfunctions. malfunctions.

11.12 1.12.1 .1

Cha Chassis ssis Dyna Dynamomete mometerr Room Ventila entilation tion Re Recommendations commendations

For safe and accurate dynamometer readings, the chassis dynamometer room must be properly ventilated.

To avoid injury before starting starting and running running the engine, engine, ensure the vehicle is parked on a level surface, parking brake is set, and the wheels are blocked.

To avoid void injury injury from inha inhaling ling engine ngine exhaust, xhaust, always lways opera ope rate te the engine ngine in a wellwell-ve ventil ntila ated ted area rea. Engine ngine exhaust is toxic. If a vehicle is tested on a dynamometer located in an area without proper ventilation, the engine will be subject to high ambient air temperatures. temperatures. High air inlet temperatures can result in false low power readings on the dynamometer. dynamometer. To help ensure accurate horsepower readings, the dynamometer room should have a ceiling-moun ceili ng-mounted ted fan with a 850 to 1133 m3 /min (30,000 to 40,000 ft3 /min) capacity. capacity. This will  provide proper ventilation ventilation of exhaust gases and heat radiated by the operating engine. For direct engine cooling, Detroit Diesel recommends the use of a 368 m3 /min (13,000 ft3 /min) or greater capacity barrel-type ram air fan. This should be portable so that it can be conveniently  placed three to   five feet (approximately one to two meters) in front of the truck and aimed directly at the radiator/charge air cooler package.

11.12 1.12.2 .2

Cha Chassis ssis D Dynamomete ynamometerr Test and RunRun-in in Proce Procedure dure

The function of the dynamometer is to absorb and measure the engine output after it has been transmitted through through the vehicle transmission and driveline to the drive tires.

11-30

 

From Bulletin 3– DDEC V SECM-06

(Rev. 2006)   All information subject to change without notice.

 

6SE57 6SE570 0 0507   Copyright © 2005 DETROIT DIESEL CORPORATION CORPORATION

 

SERIES 60 DDEC V TROUBLESHOOTING GUIDE 

The vehicle is connected to dynamometer through the roller absorption unit. The load on the vehicle may be varied from zero to maximum by decreasing or increasing the resistan ce in the unit. The amount of power absorbed in a water brake type dynamometer, as an example, is governed by the volume of   fluid within the working system. The   fluid offers resistance to a rotating motion. By controlling the volume of water in the absorption unit, the th e load may be increased or decreased as required. The following are some tips to keep in mind in preparing the vehicle before the dynamometer  run and during the actual testing: □   Follow all applicable safety safety procedures from the chassis dynamometer manufacturer. □   Observe Observe the air intake duct and charge air fan shroud shrouding ing to identify mis misalignme alignments. nts. Correct Correct as necessary. □   Make sure sure the different differential ial lock is “on.” □   Make sure the radiator/ch radiator/charge arge air cooler cooler system fan(s) fan(s) are locked locked on. □   If the vehicle is equipped equipped with antianti-lock lock brakes (ABS), (ABS), disa ble the ABS controller by unplugging unpluggi ng it or removing removing its power fuse/breaker fuse/breaker.. □   Instrument Instrument the engine for fuel pressure, air inlet rest restricti riction, on, exhaust backpressure, backpressure, and dynamometer run. crankcase pressure, and note these readings during the t he dynamometer □   Make sure the vehicle vehicle hood is down and lock locked ed into its normal normal position. position. □   Make sure the engine is fully fully warmed up before placing the vehic vehicle le on the dynamometer. dynamometer. □

□

□

□

□

□ □

Both oil and coolant temperature should be at least 180° 180° F (82° C).   When loading loading the vehicle on the dynamometer dynamometer,, make sure the vehicle is pos positione itioned d onto the rollers as straight as possible.   For direct direct engine cooling, cooling, Detroit Detroit Diesel Diesel recommends recommends the use of a 368 m3 /min (13,000 ft3 /min) or greater capacity barrel-type ram air fan. This should be portable so that it can be conveniently placed three to   five feet (approximately one to two meters) in front of the truck and aimed directly at the charge air ai r cooler. This is especially important at high altitudes.   During high ambient ambient temperat temperature ure conditions conditions (90+° F, F, 32+° C), it may also be necessary to overheating. use a water spray mist fan in front of the ve hicle to prevent overheating.   Running the dynamometer dynamometer in “manual” “manual” mode instead instead of “automatic” “automatic” mode allows for  maximum control of the test process and may result in more consistent test results.   During the the horsepower horsepower test, test, make sure sure “percent “percent engine load” and “torque limiting factor” are 100% by monitoring them with a computer equipped with DDDL.   Select a transmissio transmission n gear with a 1:1 gear ratio during the horsepower horsepower test test..   Take horsepower horsepower reading reading at 1500 1500 rpm and and 1750 rpm. Stabilize at rated speed for at least one minute before taking a  fi nal horsepower reading. Compare the recorded horsepower to the appropriate appropriate minimum horsepower tables below for particular particular ratings.

 All information subject to change without notice.   (Rev. 2006)

6SE570 6SE57 0 0507   Copyright © 2005 DETROIT DIESEL CORPORA CORPORATION TION

 

From Bulletin 3– DDEC V SECM-06

 

11-31

 

11.12

□

VERIF VERIFICA ICATION TION OF POWER WITH CHASSI CHASSIS S DYNAMO DYNAMOMETER METER

  Note that the following following charts are for vehicles with manual transmissions. Vehicles Vehicles with automatic transmissions (i.e. equipped with torque converters) will have slightly lower  minimum horsepower values then listed in Table 11-4 Table  11-4 and  and Table 11-5 Table  11-5 Engine Model 60 6067 67MV_ MV_E E 12L 12L Minimum Acceptable Wheel HP @

Engine HP Rating (Peak (Peak Torque) 1500 r p m

1750 r p m

390 bhp @ 1800 (1350 lb-ft)

300

303

425 bhp @ 1800 (1450 lb-ft)

322

330

435 bhp @ 1800 (1450 lb-ft)

322

338

445 bhp @ 1800 (1450 lb-ft)

322

345

445 bhp @ 1800 (1550 lb-ft)

342

345

450 bhp @ 1800 (1550 lb-ft)

342

349

455 bhp @ 1800 (1550 lb-ft)

345

353

380 bhp @ 1800 (1350 lb-ft)

Table 11-4 1-4

295

295

Minimum Acceptable Acceptable Wheel Wheel HP 12L 12L Engine Model 60 6067H 67HV_ V_E E 14L 14L Minimum Acceptable Wheel HP @

Engine HP Rating (P (Pea eak k Torque) 1500 r p m

1750 r p m

515 bhp @ 1800 (1450 lb-ft)

320

392

455 bhp @ 1800 (1550 lb-ft)

344

353

490 bhp @ 1800 (1550 lb-ft)

344

380

515 bhp @ 1800 (1550 lb-ft)

344

400

470 bhp @ 1800 (1650 lb-ft)

365

365

490 bhp @ 1800 (1650 lb-ft)

366

380

515 bhp @ 1800 (1650 lb-ft)

366

400

Table 11-5 1-5

11-32

 

Minimum Acceptable Acceptable Wheel Wheel HP 14L 14L

From Bulletin 3– DDEC V SECM-06

(Rev. 2006)   All information subject to change without without notice.

 

6SE570 0507   Copyright © 2005 DETROIT DIESEL CORPORATION CORPORATION