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3. ENGINE TROUBLESHOOTING
Proper maintenance and troubleshooting of the Detroit Diesel Series 40E engine, along
with its Detroit Diesel Electronic Controls System, requires the engine manufacturer's
Series 40E Service Manual, and the DDEC IV Troubleshooting Guide. Engine trouble-
shooting is performed using the hand held external Diagnostic Data Reader (DDR). The
Electronic Control Module’s (ECM's) built-in-test (BIT) feature utilizes an electronically
erasable programmable read only memory (EEPROM) chip.The EEPROM chip controls
basic engine functions, such as rated speed and power, timing of fuel injection, engine
governing, torque shaping cold start logic, transient fuel delivery, diagnostics, and engine
protection. Refer to Detroit Diesel Electronic Controls System Diagnostics (7SE40E), for
specific information regarding troubleshooting the ECM. For the purpose of simplicity,
and to assist maintenance personnel in the understanding of the system, basic test pro-
cedures and operations have been included in the following pages. The information pro-
vided is not intended to replace the Detroit Diesel manuals, but to augment them for the
convenience of the user.
Figure 2. Fault Mode Indicators and Status Switch
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A. Engine Operation Description
Engines equipped with the DDEC IV are provided with a variety of options designed to
warn the operator of an engine malfunction. These options include CHECK ENGINE and
STOP ENGINE fault mode panel lights located on the genset control panel (see figure 1).
Fault lamp illumination is activated by low coolant level, low oil pressure, high engine oil
or coolant temperature, or overspeed.
When the unit control panel GEN ON switch is first placed to GEN ON, both the CHECK
ENGINE Light (CEL) and STOP ENGINE Light (SEL) illuminate for approximately 5 sec-
onds. This not only functions as a bulb test, but is the result of the ECM computer diag-
nosing the system to ensure everything is functional. If all systems test okay, both lights
will go out.
CAUTION
DO NOT START THE UNIT IF THE CEL OR SEL FAULT MODE LIGHTS STAY
ON, OR IF THEY DO NOT COME ON MOMENTARILY AFTER SETTING
ENGINE ON/OFF SWITCH TO ON. THE FAULT MUST BE CORRECTED
PRIOR TO OPERATION. FAILURE TO COMPLY MAY RESULT IN SEVERE
ENGINE DAMAGE.
(1)Fuel Injection System: The Series 40E engine is equipped with an electronically
controlled fuel injection system. There are no control racks or mechanical link-
age to adjust.
(2)Governor System: The Series 40E engine has no mechanical governor. Engine
horsepower, torque, idle and engine speed are contained in the internal elec-
tronics. Therefore there are no mechanical adjustments for idle and high speed
control.
(3)System 24 Volt Power Requirements: The Series 40E ECM operates at 24 volts.
Should voltage be too low for proper operation, the unit will start, but will operate
only at reduced rpm, and the CHECK ENGINE light will come on. When battery
voltage reaches a point where the ECM will no longer function, the engine will
shut down. The storage battery must be in a fully charged condition to provide
operating control voltage.
NOTE
Battery must be fully charged to provide control voltages. Do not
attempt to start engine if genset VOLTS battery voltmeter indicates
less than 20 volts.
B. Engine Diagnostic Functions
Whenever the fault mode CHECK ENGINE Light (CEL) or the fault mode STOP ENGINE
Light (SEL) come on, it indicates that the ECM computer has diagnosed a fault and will then
store this information as a diagnostic code in its memory. The SEL will flash "active diagnos-
tic codes" and the CEL will flash "inactive diagnostic codes. "A fault occurring at the control
panel at the time an operator is checking codes is an "active" fault. The active codes are
those which are currently keeping the SEL or CEL light on. Active codes are flashed via the
SEL light. Active codes are all codes logged in the ECM (whether or not they are currently
turning on the SEL or CEL light). Inactive codes can be cleared by using the external Pro-
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Link® 9000 Engine Diagnostic Computer, also referred to as the Diagnostic Data Reader
(DDR). Inactive codes are flashed via the CEL light. Inactive codes are logged into the ECM
and time stamped with the following information: first occurrence of the code in engine
hours, last occurrence of the code in engine hours, and total time in seconds that the diag-
nostic code was received. The CEL lights if a minor fault occurs. This indicates the problem
should be addressed as soon as possible.
Once a malfunction has been corrected, the malfunction code recorded in the computer
memory will remain until it is erased by a technician using the DDR.
(1)Obtaining and Understanding Malfunction Codes: Engine malfunction codes
stored in the computer memory may be recalled and displayed in either of two
ways: Panel fault lamps or Diagnostic Data Reader (DDR) (see below).
• Pro-Link® 9000 Engine Diagnostic Computer (see figure 4) hereafter referred
to as the Diagnostic Data Reader (DDR).
• The DDR is a microprocessor-based test instrument designed to tap into the
ECM computer. It is programmed to interpret the computer signals and provide
readouts the technician can use for diagnosis. The technician has instant
access to any of the engine’s operating data.
• A six pin electrical connector, mounted on the genset control panel (see figure
2), permits the connection of the DDR to the ECM.
• ENGINE STATUS switch (see figure 2) with coded CHECK ENGINE light
flashes.
• A series of coded light flashes on the CHECK ENGINE light which correspond
to individual "inactive" error codes which indicate the system error. Active error
codes are flashed on the STOP ENGINE light.
• To read stored engine malfunction codes, the air conditioner unit is shut-down,
then the engine control circuitry turned on by holding the genset control panel
ON/OFF switch to ON without starting the engine. The ENGINE STATUS
switch (see figure 2) is pressed ON. The CHECK or STOP ENGINE lights will
flash any stored codes.
CAUTION
DO NOT PRESS ENGINE STATUS SWITCH (FIGURE 1) WHILE THE UNIT IS
OPERATING. IF THIS IS DONE, THE DIAGNOSTIC MODE LINE WILL BE
GROUNDED, AND THE THROTTLE WILL BE FORCED TO IDLE.
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navcm01.pcx
Figure 3. Electronic Control Module (ECM)
C. Electronic Control System Components and Configuration:
The Electronic Control Module (ECM) (see figure 3) is mounted at left rear the engine. Wir-
ing harnesses from the ECM provide sensor signals from various engine components; injec-
tors; oil temperature and pressure; fuel temperature and pressure; timing and sync
reference sensors; and turbo boost pressure Before repairing or replacing any system
component as indicated by the diagnostic charts, you should:
• Disconnect the appropriate connector(s) associated with the suspected defec-
tive component and check for bent, broken, or dirty terminals or mating tabs.
Clean, straighten, or replace as required.
• If a problem was found, reconnect all connectors previously disconnected.
Then recheck the system to see if the problem has been corrected.
NOTE
Do not probe the back of a connector or pierce the DDEC wiring for
purposes of taking measurements. This can cause intermittent faults
or system failures and may affect the DDEC warranty.
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Figure 4. Pro-Link® Engine Diagnostic Data Reader (DDR) (J38500H)
D. Check Engine Light (CEL) Diagnostic Codes (refer to table 2)
Whenever the ECM system detects an engine fault, the CHECK ENGINE or STOP ENGINE
light will illuminate. The ECM computer will determine where the problem is, and will then
store this information in its memory.
If the malfunction is intermittent, the "lights" will come on and go off as the computer senses
the changing engine condition.
The malfunction code can be obtained by the operator by causing the CEL light to flash a
code number which will identify the malfunction. It will, for example, flash
twice....pause....flash five times....pause. This is code 25.
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E. Retrieving Fault Codes
(1)Output Circuit Check Test. Prior to retrieving codes, perform an output circuit
check test with the engine OFF as follows:
(a)With the unit control GEN ON switch set to OFF, at genset control panel hold
ON/OFF switch to ON and depress the ENGINE STATUS push-button
switch.
(b)Release the ENGINE STATUS push-button switch.
(2)Code Retrieval. The following steps should be executed to retrieve the active and
inactive codes:
(a)Press the ENGINE STATUS push-button switch. The red Stop Engine Light
(SEL) will flash once.
(b)Count the amber Check Engine Light (CEL) flashes until a short pause
occurs.
NOTE
The number of CEL flashes before the first pause represents the
first digit in the three-digit code.
(c)Record the first digit.
(d)Continue counting the CEL flashes until another pause occurs.
NOTE
The number of flashes between the first and second pause repre-
sents the second digit in the three-digit code.
(e)Record the second digit.
(f)Continue counting the CEL flashes until the SEL flashes once indicating the
third digit of code has been displayed.
(g)Record the third digit.
NOTE
The SEL will flash once, when more than one code is active. If code
111 is flashed, no faults have been detected.
(h)Repeat steps b through g to obtain the remaining codes.
NOTE
All of the active codes will be displayed first. Once all of the active
codes have been displayed, the SEL will flash twice, indicating the
start of the inactive code transmission.
(i)Repeat steps b through h to obtain the inactive codes.
NOTE
Upon completion of the inactive code transmission, the SEL will
flash three times.
NOTE
If it is necessary to repeat the transmission of codes, press the
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ENGINE STATUS push-button switch and repeat the retrieval pro-
cess.
F. Clearing the Fault Codes
NOTE
Fault codes cannot be retrieved after clearing them. Codes should
only be cleared after reading and recording them.
(1)Active and inactive codes can be cleared by performing the following steps:
(a)With engine not running, hold genset control panel ON/OFF switch to ON.
(b)Press and hold the ENGINE STATUS push-button switch.
(c)Start engine by setting unit control panel GEN ON switch to ON.
(d)Release the ENGINE STATUS push-button switch.
G. Re-initializing the S11 Timers
Upon completion of scheduled maintenance, perform the following steps to re-initialize the S11
timers so the next interval can be identified:
NOTE
Codes cannot be retrieved after clearing them. Codes should only
be cleared after reading and recording them.
(1)Retrieve and record all inactive codes. Refer to paragraph I.
NOTE
Steps 2 through 5 must be completed within 10 seconds for the S11
timers to be sucessfully reset.
(2)Do not start engine. Hold genset control panel ON/OFF switch to ON, but do not
start the engine.
(3)Depress and release ENGINE STATUS push-button switch two (2) times.
(4)Depress and hold the ENGINE STATUS push-button switch for three (3) seconds.
(5)Release the ENGINE STATUS push-button switch.
The SEL light may flash out active codes which are high priority faults and require imme-
diate operator attention to avoid engine damage. A SEL fault will be indicated when any
or all of the following conditions occur:
• Low coolant level
• High coolant temperature
• High oil temperature
• Low oil pressure
• Engine overspeed
The CEL light may flash out inactive codes if a low priority fault is present (happening
now) or past fault(s) remain stored in the ECM memory. The inactive codes are low prior-
ity faults and only affect engine performance. Eventual operator attention is required.
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H. Diagnostic Procedure
When diagnosing the cause for engine performance, fuel economy or exhaust system
complaints, perform normal check on the engine and systems prior to considering ECM
as the possible source of the problem.
The codes and procedures listed in this manual (refer to table 2) are also found in the
Detroit Diesel Electronic Controls System Diagnostics, and are provided as a first refer-
ence. Refer to the Detroit Diesel Troubleshooting Manual for further information and for
procedures not covered in this manual.
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Table 2: Fault Codes
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Table 2: Fault Codes (Continued)
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Table 2: Fault Codes (Continued)
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Table 2: Fault Codes (Continued)
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Table 2: Fault Codes (Continued)
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Table 2: Fault Codes (Continued)
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Table 2: Fault Codes (Continued)
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Table 2: Fault Codes (Continued)
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Table 2: Fault Codes (Continued)
I. Using The Pro-Link® 9000 Diagnostic Data Reader (DDR)
Proper use of this reader is described in the instruction manual supplied with the unit.
This device is infinitely more useful in reading fault codes and diagnosing engine elec-
tronic faults than the Check Engine Light code process.
(1)Clearing Codes: This can only be done using the DDR. Note that removing the bat-
tery cables on the GPU will not clear codes.
(2)EEPROM Reprogramming: The DDR is equipped with capabilities to reprogram
part of the engine calibration in the ECM. Specifically, the following calibration
changes can be made using the DDR:
• Change DDR, EEPROM password.
• Set idle shutdown timer to any whole number between 3 and 100 minutes.
• Enable/Disable shutdown override feature.
• Change engine run speeds.
• Add/Delete engine shutdown feature.
4. TROUBLESHOOTING CHART
This troubleshooting chart (See table 3) lists information under three headings as fol-
lows:
• Problem
• Cause
• Remedy.
A. Use of the Troubleshooting Chart
If the cause of a trouble is uncommon and cannot be located using the chart, a good
place to start your checks is at the last known source of power. Then proceed by check-
ing each component in the circuit/system thoroughly. Use the schematics and diagrams.
Electrical components in the troubleshooting chart (such as S1, T1, etc.), are identified
by a noun name and a corresponding symbol to identify the item on schematic diagrams.
It is assumed that wiring and connections in defective circuits have been thoroughly
checked before condemning any component(s).
B. Support Test Equipment Required
• Multimeter (FLUKE Model No. 8060 or equivalent)
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• At least two jumper leads with alligator clips and test prods
are required.
• Pro-Link® 9000 Engine Diagnostic Computer (J38500H - Detroit Diesel®).
• See engine shop manual tool requirements.
5. GENERAL ENGINE TROUBLESHOOTING INFORMATION
Stop the engine immediately should any component fail. Practically all engine failures
give some warning to the operator before the component fails and ruins the engine.
Many engines have been saved because alert operators heed warning signs such as a
sudden drop in oil pressure, unusual noises, etc. and immediately shutdown the engine.
For the purpose of simplicity, and to assist maintenance personnel in the understanding
of the system, basic test procedures and operations have been included in the following
pages. The information provided is not intended to replace the Detroit Diesel Service
Manuals, but to augment them for the convenience of the user.
A. Locating a Misfiring Cylinder.
The engine's ability to start and operate properly depends on an adequate supply of air,
compressed to sufficiently high pressure, and the injection of the proper amount of fuel at
the right time. Lack of power, uneven running, excessive vibration, can be caused by low
compression, faulty injectors in one or more cylinders or lack of sufficient air. For a pro-
cedure to locate a defective cylinder refer to Detroit Diesel Troubleshooting Guide-DDEC
IV, Section V-D.1 Cylinder Cutout Test.
B. Built in Test (BIT)
The Detroit Diesel Electronic Controls System provides a variety of options designed to
warn the operator of an engine malfunction. These options include CHECK ENGINE fault
light (CEL) and STOP ENGINE fault lights (SEL) located on the genset Control Panel
(see figure 2). The lighting of either/or the SEL or the CEL fault light(s) indicates an
engine problem. A SEL fault is an active of "real time" fault that results in automatic
engine power reduction, followed by automatic engine shutdown is activated by any of
the following conditions: low coolant level, high coolant temperature, high oil tempera-
ture, low oil pressure, or engine overspeed. A SEL fault is a high priority fault requiring
immediate operator attention to avoid engine damage. A CEL fault is an inactive fault. An
inactive fault may be presently occurring, but is a low priority fault indicating that an
engine subsystem is providing substandard performance.
With an active CEL indication the engine can still be operated until the fault is remedied.
When the ENGINE ON/OFF switch is first turned on, the CEL and SEL lights illuminate
for 5 seconds. This not only functions as a bulb test, but is the result of the ECM com-
puter diagnosing the system to ensure everything is functional. If all systems test okay,
both lights will go out.
Whenever the CEL or the SEL stays on, the Electronic Control Module (ECM) computer
has detected and stored engine fault information in its memory. If the malfunction is inter-
mittent, the lights will come on and go off as the computer senses changing engine con-
ditions. Once a fault has been corrected, the ECM system will return the engine to
normal operation. Engine malfunction codes stored in the ECM computer memory may
be recalled and displayed by the Diagnostic Data Reader (DDR). The fault code (s)
recorded in the ECM computer memory will remain until erased by a technician using the
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DDR.
C. Reading Stored Flash Codes
Flash Codes and procedures listed in this manual are an abbreviated adaptation of the
Detroit Diesel Troubleshooting Guide, and are provided as a first reference. Refer to
Detroit Diesel Operator's Guide Series 40E for further information and for procedures not
covered in this manual.
NOTE
If no CEL codes were recorded by the DDEC IV, but an operational
symptom remains, Refer to the START chart in the Detroit Diesel
Troubleshooting Guide-DDEC IV which can identify fault trees to
use based on the observed malfunction.
(1)Ensure that unit is shut-down with the unit control GEN ON switch set to OFF.
Note
Do not press ENGINE STATUS switch to read while the generator
set is operating. If this is done, the diagnostic mode line will be
grounded, and the throttle will be forced to idle.
(2)On genset control panel, hold ON/OFF switch to ON and press and hold down
ENGINE FAULT STATUS switch to read codes.
(3)The CEL will flash out stored Flash Codes, and will continue to flash and repeat as
long as the ENGINE STATUS switch is pressed to read codes. Record the
codes flashed, and refer to table 2 for their description.
D. Clearing Stored Flash Codes
Flash Code (s) recorded in the ECM computer memory will remain until erased by a
technician using the Diagnostic Data Reader (DDR). The clearing of stored Flash Codes
can only be done using the DDR. Disconnecting the genset battery cables will not clear
codes. The DDR is more useful in reading Flash Codes and diagnosing engine electronic
faults than the CEL code process.
E. Reprogramming Engine Calibration
The DDR can be used to reprogram certain engine calibration parameters.
F. ECM Connector Checkout
The Electronic Control Module (ECM) (see figure 3) is mounted at the left rear end of the
engine, with the connector side to the right side of the unit. All system connections are
environmentally protected. Wiring harnesses of the ECM provide sensor signals from
various engine components; injectors; oil temperature and pressure; fuel temperature
and pressure; timing and sync reference sensors; and turbo boost pressure. Before
repairing or replacing any system component, as indicated by the diagnostic charts, you
must disconnect the connector(s) associated with the suspected defective component.
Check connector for defects. Clean, straighten, or replace as required. If a problem was
found, connect all connectors previously disconnected. Then check the system to see if
the problem has been corrected.
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