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NUMBER: 5DDEC VI07 S.M. REF.

: 56 ENGINE: Series 60 DATE: March 2007

SUBJECT: SPN 641

PUBLICATION: 6SE567
Four FMIs and troubleshooting procedures have been added to SPN 641.

DETAILS AND REASON


SPN 641 typically concerns the Smart Remote Actuator 5/turbo actuator. The procedures for
troubleshooting FMIs 7, 8, 11, and 14 have been added and the procedures for FMI 9 have changed.

ADDITIONAL SERVICE INFORMATION


Additional service information is available in one of the DDEC VI troubleshooting guides. This
information is currently available in Power Service Literature. The next printed revision to these
manuals will be in July 2007.
56 SPN 641 - SMART REMOTE ACTUATOR 5 (VGT)
ABNORMAL OPERATION

Section Page

56.1 SPN 641/FMI 7 ......................................................................................... 56-3


56.2 SPN 641/FMI 8 ......................................................................................... 56-5
56.3 SPN 641/FMI 9 ......................................................................................... 56-6
56.4 SPN 641/FMI 11 ....................................................................................... 56-7
56.5 SPN 641/FMI 14 ....................................................................................... 56-9
SERIES 60 DDEC VI TROUBLESHOOTING GUIDE

56.1 SPN 641/FMI 7

This code typically means the Smart Remote Actuator 5 is in Failsafe Mode, Motor On.

56.1.1 Actuator Check

Check as follows:
1. Using DDDL 7.0, perform the Turbo Hysteresis test.
[a] If the test results pass, repeat the hysteresis test. If results are the same,
refer to section 56.1.1.1. If the test results fail, go to the next step.
[b] If the test results fail, go to the next step.
2. Turn the ignition OFF.
3. Inspect the turbocharger electrical connectors.
[a] If bent, corroded or damaged pins are found, repair as necessary. Refer to section
56.1.1.1.
[b] If electrical connections are OK, go to the next step.
4. Remove the turbo actuator.
5. Physically move the sector gear on the turbocharger from 1 to 2, see Figure 56-1.

1. Alignment Hole Alignment pin fits into housing 2. Reference Indentation Sector shaft covers one-half
of indentation

Figure 56-1 Moving the Sector Gear

All information subject to change without notice.


Copyright 2007 DETROIT DIESEL CORPORATION 56-3
56.1 SPN 641/FMI 7

6. Check the free movement from 1 to 2 (see Figure 56-1), return back to 1 and install the pin
to insure proper alignment. Once you have proper alignment, remove the pin.
[a] If there is free movement, replace the turbo actuator. Refer to section 56.1.1.1.
[b] If there is not free movement, go to the next step.
7. Remove the turbocharger and inspect for signs of foreign material contamination.
[a] If foreign material damage is found, repair the source of material entry and contact
the Detroit Diesel Customer Support Center at 3135925800 for turbocharger
replacement authorization.
[b] If no foreign material damage is found but there is no free movement, contact
the Detroit Diesel Customer Support Center at 3135925800 for turbocharger
replacement authorization.

56.1.1.1 Verify Repairs

Verify repairs as follows:


1. Turn ignition OFF.
2. Reconnect any electrical connections that were disconnected to perform the diagnosis.
3. Clear codes with DDDL 7.0 or latest version.
4. Start and bring engine up to operating temperature (over 140F/60C).
5. Verify operation is satisfactory and no warning lamps illuminate. If warning lamps
illuminate, troubleshoot the codes. If assistance is required, call the Detroit Diesel
Customer Support Center at 3135925800.

All information subject to change without notice.


56-4 Copyright 2007 DETROIT DIESEL CORPORATION
SERIES 60 DDEC VI TROUBLESHOOTING GUIDE

56.2 SPN 641/FMI 8

This code typically means the Smart Remote Actuator 5 has an internal test running.

56.2.1 Actuator Check

Check as follows:
1. Disconnect the turbo actuator.
2. Disconnect the MCM 120pin connector.
3. Measure the resistance between pin 3 of the turbo actuator harness connector and pin 74
of the MCM 120pin connector.
[a] If the resistance is less than 3 , go to step 4.
[b] If the resistance is greater than 3 , repair the open between pin 3 of the turbo actuator
harness connector and pin 74 of the MCM 120pin connector. Refer to section
56.2.1.1.
4. Measure the resistance between pin 4 of the turbo actuator harness connector and pin 75
of the MCM 120pin connector.
[a] If the resistance is less than 3 , replace the turbo actuator. Refer to section 56.2.1.1.
[b] If the resistance is greater than 3 , repair the open between pin 4 of the turbo actuator
harness connector and pin 75 of the MCM 120pin connector. Refer to section
56.2.1.1.

56.2.1.1 Verify Repairs

Verify repairs as follows:


1. Turn ignition OFF.
2. Reconnect any electrical connections that were disconnected to perform the diagnosis.
3. Clear codes with DDDL 7.0 or latest version.
4. Start and bring engine up to operating temperature (over 140F/60C).
5. Verify operation is satisfactory and no warning lamps illuminate. If warning lamps
illuminate, troubleshoot the codes. If assistance is required, call the Detroit Diesel
Customer Support Center at 3135925800.

All information subject to change without notice.


Copyright 2007 DETROIT DIESEL CORPORATION 56-5
56.3 SPN 641/FMI 9

56.3 SPN 641/FMI 9

This code typically means the Smart Remote Actuator 5 is in Failsafe Mode, Motor Off.

56.3.1 Actuator Check

Check as follows:
1. Disconnect the turbo actuator.
2. Inspect the turbo actuator connector and harness for damaged, bent or spread pins.
[a] If damage is found, repair as necessary. Refer to section 56.3.1.1.
[b] If no damage is found, go to the next step.
3. Disconnect the MCM 120pin connector.
4. Measure the resistance between pin 3 of the turbo actuator harness connector and pin 74
of the MCM 120pin connector.
[a] If the resistance is greater than 3 , repair the open circuit between pin 3 of the
turbo actuator harness connector and pin 74 of the MCM 120pin connector.
Refer to section 56.3.1.1.
[b] If the resistance is less than 3 , go to the next step.
5. Measure the resistance between pin 4 of the turbo actuator harness connector and pin 75
of the MCM 120pin connector.
[a] If the resistance is greater than 3 , repair the open circuit between pin 4 of the
turbo actuator harness connector and pin 75 of the MCM 120pin connector.
Refer to section 56.3.1.1.
[b] If the resistance is less than 3 , replace the turbo actuator. Refer to section 56.3.1.1.

56.3.1.1 Verify Repairs

Verify repairs as follows:


1. Turn ignition OFF.
2. Reconnect any electrical connections that were disconnected to perform the diagnosis.
3. Clear codes with DDDL 7.0 or latest version.
4. Start and bring engine up to operating temperature (over 140F/60C).
5. Verify operation is satisfactory and no warning lamps illuminate. If warning lamps
illuminate, troubleshoot the codes. If assistance is required, call the Detroit Diesel
Customer Support Center at 3135925800.

All information subject to change without notice.


56-6 Copyright 2007 DETROIT DIESEL CORPORATION
SERIES 60 DDEC VI TROUBLESHOOTING GUIDE

56.4 SPN 641/FMI 11

This code typically means the Smart Remote Actuator 5 has restricted operability.

56.4.1 Actuator Check

Check as follows:
1. Check for multiple codes.
[a] If 168/1 (low battery voltage) is present with 641/11 troubleshoot 168/1 first.
[b] If only 641/11 is present, go to the next step.
2. Using DDDL 7.0, perform the Turbo Hysteresis test.
[a] If you are unable to perform the Turbo Hysteresis test, go to step 10.
[b] If the Turbo Hysteresis test fails, go to step 6.
[c] If the Turbo Hysteresis test is a pass, repeat the test to see if the results are the same.
If the results are the same, refer to section 56.4.1.1. If the repeat test fails, go to
the next step.
3. Disconnect the turbo actuator.
4. Check the actuator supply voltage.
5. Measure the voltage between pins 1 and 2 of the turbo actuator harness connector.
[a] If the voltage is less than 11 volts, repair the cause of the low voltage. Refer to section
56.4.1.1.
[b] If the voltage is greater than 11 volts, go to the next step.
6. Turn the ignition OFF.
7. Disconnect the MCM 120pin connector.
8. Measure the resistance between pin 3 of the turbo actuator harness connector and pin 74
of the MCM 120pin connector.
[a] If the resistance is greater than 3 , repair the open circuit between pin 3 of the
turbo actuator harness connector and pin 74 of the MCM 120pin connector.
Refer to section 56.4.1.1.
[b] If the resistance is less than 3 , go to the next step.
9. Measure the resistance between pin 4 of the turbo actuator harness connector and pin 75
of the MCM 120pin connector.
[a] If the resistance is greater than 3 , repair the open circuit between pin 4 of the
turbo actuator harness connector and pin 75 of the MCM 120pin connector.
Refer to section 56.3.1.1.
[b] If the resistance is less than 3 , replace the turbo actuator. Refer to section 56.3.1.1.
10. Remove the turbo actuator.

All information subject to change without notice.


Copyright 2007 DETROIT DIESEL CORPORATION 56-7
56.4 SPN 641/FMI 11

11. Physically move the sector gear on the turbo from 1 to 2, see Figure 56-2.

1. Alignment Hole Alignment pin fits into housing 2. Reference Indentation Sector shaft covers one-half
of indentation

Figure 56-2 Moving the Sector Gear

12. Check the free movement from 1 to 2 (see Figure 56-1), return back to 1 and install the pin
to insure proper alignment. Once you have proper alignment, remove the pin.
[a] If there is free movement, replace the turbo actuator. Refer to section 56.4.1.1.
[b] If there is not free movement, go to the next step.
13. Remove the turbocharger and inspect for signs of foreign material contamination.
[a] If foreign material damage is found, repair the source of material entry and contact
the Detroit Diesel Customer Support Center at 3135925800 for turbocharger
replacement authorization.
[b] If no foreign material damage is found but there is no free movement, contact
the Detroit Diesel Customer Support Center at 3135925800 for turbocharger
replacement authorization.

All information subject to change without notice.


56-8 Copyright 2007 DETROIT DIESEL CORPORATION
SERIES 60 DDEC VI TROUBLESHOOTING GUIDE

56.4.1.1 Verify Repairs

Verify repairs as follows:


1. Turn ignition OFF.
2. Reconnect any electrical connections that were disconnected to perform the diagnosis.
3. Clear codes with DDDL 7.0 or latest version.
4. Start and bring engine up to operating temperature (over 140F/60C).
5. Verify operation is satisfactory and no warning lamps illuminate. If warning lamps
illuminate, troubleshoot the codes. If assistance is required, call the Detroit Diesel
Customer Support Center at 3135925800.

56.5 SPN 641/FMI 14

This code typically means the Smart Remote Actuator 5, no Failsafe Mode, Motor Off.

56.5.1 Actuator Check

Check as follows:
1. Using DDDL 7.0, perform the Turbo Hysteresis test.
[a] If the Turbo Hysteresis test fails, go to step 5.
[b] If you are unable to perform the Turbo Hysteresis test, go to the next step.
[c] If the Turbo Hysteresis test is a pass, repeat the test to see if the results are the
same. If the results are the same, refer to section 56.5.1.1.. If the repeat test fails,
go to the next step.
2. Disconnect the turbo actuator.
3. Check the actuator supply voltage.
4. Measure the voltage between pins 1 and 2 of the turbo actuator harness connector.
[a] If the voltage is less than 11 volts, repair the cause of the low voltage. Refer to section
56.5.1.1.
[b] If the voltage is greater than 11 volts, go to the next step.
5. Turn the ignition OFF.
6. Disconnect the MCM 120pin connector.
7. Measure the resistance between pin 3 of the turbo actuator harness connector and pin 74
of the MCM 120pin connector.
[a] If the resistance is greater than 3 , repair the open circuit between pin 3 of the
turbo actuator harness connector and pin 74 of the MCM 120pin connector.
Refer to section 56.5.1.1.
[b] If the resistance is less than 3 , go to the next step.

All information subject to change without notice.


Copyright 2007 DETROIT DIESEL CORPORATION 56-9
56.5 SPN 641/FMI 14

8. Measure the resistance between pin 4 of the turbo actuator harness connector and pin 75
of the MCM 120pin connector.
[a] If the resistance is greater than 3 , repair the open circuit between pin 4 of the
turbo actuator harness connector and pin 75 of the MCM 120pin connector.
Refer to section 56.5.1.1.
[b] If the resistance is less than 3 , replace the turbo actuator. Refer to section 56.5.1.1.
9. Remove the turbo actuator.
10. Physically move the sector gear on the turbo from 1 to 2, see Figure 56-3.

1. Alignment Hole Alignment pin fits into housing 2. Reference Indentation Sector shaft covers one-half
of indentation

Figure 56-3 Moving the Sector Gear

11. Check the free movement from 1 to 2 (see Figure 56-1), return back to 1 and install the pin
to insure proper alignment. Once you have proper alignment, remove the pin.
[a] If there is free movement, replace the turbo actuator. Refer to section 56.5.1.1.
[b] If there is not free movement, go to the next step.
12. Remove the turbocharger and inspect for signs of foreign material contamination.
[a] If foreign material damage is found, repair the source of material entry and contact
the Detroit Diesel Customer Support Center at 3135925800 for turbocharger
replacement authorization.

All information subject to change without notice.


56-10 Copyright 2007 DETROIT DIESEL CORPORATION
SERIES 60 DDEC VI TROUBLESHOOTING GUIDE

[b] If no foreign material damage is found but there is no free movement, contact
the Detroit Diesel Customer Support Center at 3135925800 for turbocharger
replacement authorization.

56.5.1.1 Verify Repairs

Verify repairs as follows:


1. Turn ignition OFF.
2. Reconnect any electrical connections that were disconnected to perform the diagnosis.
3. Clear codes with DDDL 7.0 or latest version.
4. Start and bring engine up to operating temperature (over 140F/60C).
5. Verify operation is satisfactory and no warning lamps illuminate. If warning lamps
illuminate, troubleshoot the codes. If assistance is required, call the Detroit Diesel
Customer Support Center at 3135925800.

All information subject to change without notice.


Copyright 2007 DETROIT DIESEL CORPORATION 56-11
56.5 SPN 641/FMI 14

All information subject to change without notice.


56-12 Copyright 2007 DETROIT DIESEL CORPORATION