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Andy
Andy, Technician
Category: Heavy Equipment
Satisfied Customers: 828
Experience:  310s and 310t technician licenses, 17 yrs experience, International Diamond Certified Tech 7 yrs
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A 06 Dt466 with intermitent ENGINE light on..master switch..resets

Resolved Question:

Have a 06 Dt466 with intermitent ENGINE light on. When the light is on the engine brake doesn't work. If I shut the master switch off sometimes it resets and is OK.
Submitted: 3 years ago.
Category: Heavy Equipment
Expert:  Andy replied 3 years ago.

Andy3221 :

Hi there! My name is XXXXX XXXXX I think I can help you resolve your problem!

Andy3221 :

Howabout we start with last 8 digitis of the vin please?

Andy3221 :

Also hav e you read fault codes

Customer:

6j3070059

Customer:

have 3 fault codes none have to do w/engine

Andy3221 :

Can you please verify again the last 8 digits of the vin - you have 9 digits there

Customer:

6j307059 sorry

Andy3221 :

ok

Andy3221 :

what code numbers did you end up with ?

Customer:

625 and 2023

Andy3221 :

what about the 3rd number?

Customer:

625

Andy3221 :

you said you had 3 faults in memory -correct?

Customer:

correct

Andy3221 :

625 , 2023 and -----

Customer:

there were 2 625's

Andy3221 :

I willlook them up for you

Andy3221 :

ok

Andy3221 :

Have you read theses

Andy3221 :

from a scan tool ?

Andy3221 :

or using the steering buttons

Customer:

steering buttons

Andy3221 :

ok

Andy3221 :

please wait a few minutes while i look up

Customer:

ok

Customer:

sometimes the engine quits after a few minutes on a cold start. it starts right away again.

Andy3221 :

Please follow this procedure to access engine codes ! All engine fault codes are 3 digits long on these engines . The fault codes you found were for body controller .





 



Accessing DTCs




NOTE: Read and be familiar with all steps and time limits in this procedure before starting.



 


1. Set parking brakefor the correct signal from the Electronic System Controller (ESC).


2. Turn the ignition switch to ON. (Do not crank the engine.)


 


 


3. Press and release the CRUISE ON and RESUME/ACCEL switches at the same time within 3 seconds of the ignition switch on.



NOTE: There could be as much as a 10 second delay from the time switches are pressed to the time DTCs are flashed.



 




 



Reading DTCs



1. The red ENGINE lamp will flash once to indicate the beginning of active DTCs.


2. The amber ENGINE lamp will flash repeatedly, signaling active DTCs.



NOTE: All DTCs are three digits. Code 111 indicates that no faults were detected.



 


3. Count the flashes of the amber ENGINE lamp in sequence. After each digit of the code a short pause will occur.


 



  • Two amber flashes, a pause; three amber flashes, a pause; and two amber flashes and a pause indicate code 232.


4. For more than one DTC, the red ENGINE lamp will flash once indicating the beginning of another active DTC.


5. After all active DTCs have flashed, the red ENGINE lamp will flash twice to indicate the start of inactive DTCs. Count the flashes from the amber ENGINE lamp. If there is more than one inactive code, the red ENGINE lamp will flash once between each DTC.


6. After all DTCs have been sent, the red ENGINE lamp will flash three times indicating end of DTC transmission.


7. To repeat DTC transmission, cycle the ignition switch and press and release the CRUISE ON and RESUME/ACCEL switches, at the same time, within 3 seconds of ignition switch on. The ECM will re-send stored DTCs.




 



Clearing DTCs




NOTE: Read and be familiar with all steps and time limits in this procedure before starting.



 


1. Set parking brakefor the correct signal from the Electronic System Controller (ESC).


2. Turn the ignition switch to ON. (Do not crank the engine.)


3. Press and hold the CRUISE ON and RESUME/ACCEL switches at the same time.


4. Press and release the accelerator pedal three times within 6 seconds of the ignition switch on.


5. Release the cruise control switches to clear the inactive DTCs.



NOTE: Completing this procedure within 3 seconds of the ignition switch on, without turning the ignition switch off, will restart DTC transmission to the instrument panel.



 







Customer:

ok i will do that and see what i get. the codes I got were by turning the ign on and pressing the cruise on and resume/accel at the same time. the codes showed up in the odometer display

Andy3221 :

need to follow the instructions and write down the active and inactive faults down to be able to help us .

Customer:

ok - thanks much - i'll have to talk back later the truck is out on a run right now

Andy3221 :

instructions I gave you also shows you how to clear faults but only after we figure out the problem and repair is complete!

Andy3221 :

ok no problem

Andy3221 :

will check in later

Andy, Technician
Category: Heavy Equipment
Satisfied Customers: 828
Experience: 310s and 310t technician licenses, 17 yrs experience, International Diamond Certified Tech 7 yrs
Andy and 4 other Heavy Equipment Specialists are ready to help you
Expert:  Andy replied 3 years ago.
Thank you for the accept ! I will be around to help you until we get through the problem !
Andy, Technician
Category: Heavy Equipment
Satisfied Customers: 828
Experience: 310s and 310t technician licenses, 17 yrs experience, International Diamond Certified Tech 7 yrs
Andy and 4 other Heavy Equipment Specialists are ready to help you
Customer: replied 3 years ago.
Followed the procedure for retrieving the codes. They are as follows: 547, 124, 354, 353. All are inactive, I also reset the DCT.
Expert:  Andy replied 3 years ago.

547-Engine Brake Control Pressure is above expected range

124-Injection Control Pressure signal out-of-range low

354-Variable Geometry Turbo control under duty cycle

353-Variable Geometry Turbo control over duty cycle

Those are the fault codes you had in memory !

Now that you have erased fault codes, try and duplicate the problem again to get the engine light to come on again and read faults again ! This way , we will know exactly which of the faults that were in memory is the one that comes back up again !

My guess is that fault 547 will come up ! Let me know what you find !

Andy, Technician
Category: Heavy Equipment
Satisfied Customers: 828
Experience: 310s and 310t technician licenses, 17 yrs experience, International Diamond Certified Tech 7 yrs
Andy and 4 other Heavy Equipment Specialists are ready to help you
Customer: replied 3 years ago.
I ran the truck myself today. Within an hour of start the light was back on. I checked the codes right away and 547 was the one it gave. I reset the DTC and turned the master switch off then back on. The light didn't come back on for the rest of the day. I think I see a pattern. One of my drivers had the same thing happen about a week ago. Light came on about an hour after start, switched the master off then back on, OK the rest of the day and if I remember right that is the way things have gone a time or two before.
Expert:  Andy replied 3 years ago.

Did the engine shut down when light came on at all or did the engine keep running?

Customer: replied 3 years ago.
the engine kept running although it seemed to smoke abit more under acceleration
Expert:  Andy replied 3 years ago.

ok then , i will try and find you the troubleshooting for code 547 but I am pretty sure you will find your trouble under the valve cover at the engine brake solenoid.

I have had a truck die on me just recently and when i connected to the ecm , i found that there was pressure building in the engine brake system even when the brake was not on causing the engine to get choked and die out . I think this will be your issue .

My suggestion is to follow the troubleshooter and i think you will your cause to be the engine brake solenoid is acting up

.

I will send you the troubleshooter now

Andy, Technician
Category: Heavy Equipment
Satisfied Customers: 828
Experience: 310s and 310t technician licenses, 17 yrs experience, International Diamond Certified Tech 7 yrs
Andy and 4 other Heavy Equipment Specialists are ready to help you
Expert:  Andy replied 3 years ago.

DTC 547
Engine brake control pressure above expected range


  • DTC 547 is set by the ECM when the brake control
    pressure is greater than desired brake control pressure of 4.5 MPa (653 psi) for
    more than three seconds.
  • DTC 547 can be set due to an open signal ground,
    V REF shorted to a voltage source higher than 5.5 V, or a faulty BCP
    sensor.
  • DTC 547 can be set due to a control circuit short
    to B+ or a brake shut-off valve stuck open. See "Brake Shut-off Valve - Section
    7.
  • When DTC 547 is active the amber ENGINE lamp is
    illuminated.


    Tools



  • EST with MasterDiagnostics® software
  • EZ-Tech® interface cable
  • Digital Multimeter (DMM)
  • 3-Banana Plug Harness
  • 500 Ohm Resistor Harness
  • VC Gasket Breakout Harness
  • UVC Pressure Breakout Harness
  • Breakout Box
  • Terminal Test Adapter Kit


BCP Operational Diagnostics





(Right click on graphic to bring up an option
list)


BCP circuit diagram


WARNING:


To avoid serious personal injury, possible death, or
damage to the engine or vehicle - comply with the following:


Be careful to avoid rotating
parts (belts and fan) and hot engine surfaces.



1. Using EST, open the D_ContinuousMonitor.ssn.




Continuous Monitor Test


2. To monitor signal voltage, run KOEO Continuous Monitor Test.


3. Monitor BCP signal voltage. Verify an active DTC for the BCP circuit.


4. If code is active, do step 6 and 7 to check circuit for the BCP sensor
using the following tables:



  • Circuit Checks for BCP Sensor - ECM to Valve
    Cover Gasket Connector
  • Circuit Checks for BCP Sensor - ECM to BCP Sensor

5. If code is inactive, wiggle connectors and wires at all suspected problem
locations. If circuit continuity is interrupted, the EST will display DTCs
related to the condition.


6. Disconnect engine harness from valve cover gasket connector.



NOTE: Inspect connectors for damaged pins,
corrosion, or loose pins. Repair if necessary.


7. Connect VC Gasket Breakout Harness to engine harness only.





(Right click on graphic to bring up an option
list)


BCP circuit diagram with
breakout harness































WARNING:


To avoid serious personal injury, possible death, or damage to the engine or
vehicle, always disconnect main negative battery cable first. Always connect the
main negative battery cable last.




Circuit Checks for BCP Sensor - ECM to Valve Cover Gasket Connector
(Use EST, DMM, 500 Ohm Resistor Harness, and VC Gasket Breakout Harness to
engine harness only.)


Test Condition


Spec


Checks


Harness disconnected from valve cover gasket connector using EST


0 V


If voltage > 0.039 V, check BCP signal for short to V REF or
B+.


Voltage from Pin B (Blue) of VC Gasket Breakout Harness to ground using DMM


5 V ±0.5 V


If voltage > 5.5 V, check V REF for short to B+. If voltage is
< 4.5 V, check V REF for open or short to ground.


500 Ohm Resistor Harness connected between Pin A (Green) and Pin B (Blue) of
VC Gasket Breakout Harness using EST.


5 V


If voltage < 4.9 V, check BCP signal for open or short to ground.



  • Disconnect connector 9260 Connector 9260 is a
    2-wire connector usually located in the battery box. Pin A is the chassis ground
    connection for the ECM and IDM. See truck Chassis Electrical Circuit Diagram
    Manualfor complete chassis side ECM and IDM ground circuit information. .
    Measure resistance from Pin A to Pin A of connector 9260 (spec > 1 kΩ) to
    check for short to ground within wiring harness.
  • Disconnect negative battery cable. Measure
    resistance from Pin A to ground cable to check for short to ground.
  • Use a breakout box to measure from Pin A to Pin
    X2-11 (spec < 5 Ω) to check for open in the harness.

Resistance from Pin C (Black) of VC Gasket Breakout Harness to ECM chassis
ground (Pin A of connector 9260) using DMM.


< 5 Ω


If resistance is > 5 Ω, check for open or high resistance between ECM and
UVC. Use a breakout box to measure resistance from X1-6 to Pin C (spec < 5
Ω).


Connect engine harness to UVC connector. Use the EST to clear DTCs. If test
results are to spec for all test conditions, but an active code remains, remove
valve cover and check between UVC gasket connection and BCP sensor. (See Circuit
Checks for BCP - ECM to BCP Sensor.)






(Right click on graphic to bring up an option
list)


BCP circuit diagram with































WARNING:


To avoid serious personal injury, possible death, or damage to the engine or
vehicle, always disconnect main negative battery cable first. Always connect the
main negative battery cable last.




Circuit Checks for BCP Sensor - ECM to BCP Sensor (If Circuit Checks
for BCP Sensor - ECM to Valve Cover Gasket Connector are complete and test
results are to specification for all test conditions, but an active code
remains, remove valve cover following procedure in the Engine Service Manual.
Use EST, DMM, 500 Ohm Resistor Harness, and UVC Pressure Sensor Breakout Harness
connected to UVC connector only.)


Test Condition


Spec


Checks


BCP sensor connector removed from UVC connector using EST


0 V


If voltage > 0.039 V, check BCP signal for short to V REF or
B+.


Voltage from Pin 2 (Blue) of UVC Pressure Sensor Breakout Harness to ground
using DMM.


5 V ±0.5 V


If voltage > 5.5 V, check V REF for short to B+. If voltage is
< 4.5 V, check V REF for open or short to ground.


500 Ohm Resistor Harness connected between Pin 3 (Green) and Pin 2 (Blue) of
VC Gasket Breakout Harness using EST


5 V


If voltage < 4.9 V, check BCP signal for open or short to ground.



  • Disconnect connector 9260 Connector 9260 is a
    2-wire connector usually located in the battery box. Pin A is the chassis ground
    connection for the ECM and IDM. See truck Chassis Electrical Circuit Diagram
    Manualfor complete chassis side ECM and IDM ground circuit information. .
    Measure resistance from Pin 3 to Pin A of connector 9260 (spec > 1 kΩ) to
    check for short to ground within wiring harness.
  • Disconnect negative battery cable. Measure
    resistance from Pin 3 to ground cable to check for short to ground.
  • Use a breakout box to measure from Pin 3 to Pin
    X2-11 (spec < 5 Ω) to check for open in the harness.

Resistance from Pin 1 (Black) of UVC Pressure Sensor Breakout Harness to ECM
chassis ground (Pin A of connector 9260) using DMM.


< 5 Ω


If resistance is > 5 Ω, check for open or high resistance between ECM and
UVC connector. Use a breakout box to measure resistance from X1-6 to Pin 1 (spec
< 5 Ω).


Connect BCP sensor to UVC connection. Use the EST to clear DTCs. If test
results are to spec for all test conditions, but an active code remains, replace
sensor.



NOTE:

If all tests are to specification, but DTCs return when the valve cover is
torqued down, replace the valve cover gasket.








































































Connector Voltage Checks (Disconnect engine harness from valve cover
gasket connector and connect VC Gasket Breakout Harness to engine harness only.
Turn the ignition switch to ON.)


Test Point


Spec


Comment


A to gnd


0 V to 0.25 V


If > 0.25 V, signal circuit is shorted to V REF or B+.


B to gnd


5 V ± 0.5 V


If voltage is not to spec, V REF shorted to ground, shorted to B+,
or open.


C to gnd


0 V to 0. 25 V


Signal ground (no voltage expected). If > 0.25 V, check ground circuit for
open or high resistance and check signal ground for short to V REF or
B+.


Connector Resistance Checks to ECM Chassis Ground (Turn the ignition
switch to OFF. Disconnect harness from valve cover gasket connector. Connect VC
Gasket Breakout Harness to engine harness only. Connector 9260 is a 2-wire
connector usually in the battery box. Pin A is the chassis ground connection for
the ECM and IDM. See truck Chassis Electrical Circuit Diagram Manual for
complete chassis side ECM and IDM ground circuit information. )


A to Pin A (9260)


> 1 kΩ


If < 1 kΩ, check for short to ground within wiring harness.


B to Pin A (9260)


> 500 Ω


If < 500 Ω, check for short to ground within wiring harness.


C to Pin A (9260)


< 5 kΩ


If > 5 kΩ, check for open circuit .




Connector Resistance Checks to Chassis Ground (Turn the ignition
switch to OFF. Disconnect chassis connector 9260 . Disconnect negative battery
cable. Disconnect harness from sensor. Use disconnected negative battery cable
for ground test point.)


A to gnd cable


> 1 kΩ


If < 1 kΩ, check for short to ground.


B to gnd cable


> 500 Ω


If< 500 Ω , check for short to ground.


C to gnd cable


> 500 Ω


If< 500 Ω , check for short to ground.


Harness Resistance Checks (Connect breakout box [X1] to engine harness
only. Connect VC Gasket Breakout Harness to engine harness only.)


X1-20 to A


< 5 Ω


If > 5 Ω, check for open BCP signal.


X1-14 to B


< 5 Ω


If > 5 Ω, check for open V REF .


X2-11 to C


< 5 Ω


If > 5 Ω, check for open ground.











































Operational Voltage Checks for BCP Sensor with VC Gasket Breakout Harness
(These checks are done if an EST is not available and the valve cover is not
removed. Check with VC Gasket Breakout Harness connected to valve cover gasket
connector and engine harness.)


Test Point


EST voltage readings: Signal to ground


Spec


Checks


A to C


0.15 V to 0.3 V


0 psi (0 kPa)


Atmospheric pressure with key-on engine-off


A to C


0.15 V to 0.3 V


0 psi (0 kPa)


Maximum at engine cranking speed


Operational Voltage Checks for BCP Sensor with breakout box (Check
with breakout box connected to ECM and engine harness.)


X2-11 to X1-6


0.15 V to 0.3 V


0 psi (0 kPa)


Atmospheric pressure with key-on engine-off


X2-11 to X1-6


0.15 V to 0.3 V


0 psi (0 kPa)


Maximum at engine cranking speed


BCP Diagnostic Trouble Codes


DTC 126 = Signal voltage was < 0.039 V for more than 0.1 second


DTC 127 = Signal voltage was > 4.9 V for more than 0.1 second


DTC 546 = Brake control pressure was < 4 MPa (580 psi) for more than 3.0
seconds


DTC 547 = Brake control pressure was > 4.5 MPa (653 psi) for more than 3.0
seconds


































































Connector Voltage Checks to Ground with Valve Cover Removed
(Disconnect sensor from UVC connector and connect UVC Pressure Sensor
Breakout Harness to UVC connector only. Turn the ignition switch to ON.)


Test Point


Spec


Comment


1 to gnd


0 V to 0.25 V


Signal ground (no voltage expected). If > 0.25 V, check ground circuit for
open or high resistance and check for short to V REF or B+.


2 to gnd


5 V ± 0.5 V


If voltage is not to spec, V REF is shorted to ground, shorted to
B+, or open.


3 to gnd


0 V to 0.25 V


If voltage > 0.25 V, signal circuit is shorted to V REF or B+.


Connector Resistance Checks to ECM Chassis Ground with Valve Cover Removed
(Turn the ignition switch to OFF. Disconnect sensor from UVC connector.
Disconnect chassis connector 9260 Connector 9260 is a 2-wire connector usually
located in the battery box. Pin A is the chassis ground connection for the ECM
and IDM. See truck Chassis Electrical Circuit Diagram Manual for complete
chassis side ECM and IDM ground circuit information. . Connect UVC Pressure
Sensor Breakout Harness to UVC connector only.)



1 to Pin A (9260)


< 5 Ω


If > 5 Ω, check for open circuit.


2 to Pin A (9260)


> 500 Ω


If < 500 Ω, check for short to ground within wiring harness.


3 to Pin A (9260)


> 1 kΩ


If < 1 kΩ, check for short to ground within wiring harness.



WARNING:


To avoid serious personal injury, possible death, or damage to the engine or
vehicle, always disconnect main negative battery cable first. Always connect the
main negative battery cable last.




Connector Resistance Checks to Chassis Ground with Valve Cover Removed
(Turn the ignition switch to OFF. Disconnect chassis connector 9260 .
Disconnect negative battery cable. Disconnect harness from sensor. Use
disconnected negative battery cable for ground test point.)


1 to gnd cable


> 500 Ω


If < 500 Ω, check for short to ground.


2 to gnd cable


> 500 Ω


If < 500 Ω, check for short to ground.


3 to gnd cable


> 1 kΩ


If < 1 kΩ, check for short to ground.


Harness Resistance Checks with valve cover removed (Connect breakout
box [X1 and X2] to engine harness only. Connect UVC Pressure Sensor Breakout
Harness to UVC connector only.)


X1-6 to 1


< 5 Ω


If > 5 Ω, check for open ground.


X1-14 to 2


< 5 Ω


If > 5 Ω, check for open V REF .


X2-11 to 3


< 5 Ω


If > 5 Ω, check for open BCP signal.


































Operational Voltage Checks for BCP Sensor with UVC Pressure Sensor
Breakout Harness
(Check with UVC Pressure Sensor Breakout Harness connected
to UVC connector and sensor.)



NOTE:

These checks are done only if an EST is not available. Do not use this method
to measure BCP when engine is running.




Test Point


EST voltage readings: Signal to ground


Spec


Checks


3 to 1


0.15 V to 0.3 V


0 kPa (0 psi)


Atmospheric pressure with key-on engine-off


3 to 1


0.15 V to 0.3 V


0 kPa (0 psi)


Maximum at engine cranking speed


BCP Diagnostic Trouble Codes


DTC 126 = Signal voltage was < 0.039 V for more than 0.1 second


DTC 127 = Signal voltage was > 4.9 V for more than 0.1 second


DTC 546 = Brake control pressure was < 4 MPa (580 psi) for more than 3.0
seconds


DTC 547 = Brake control pressure was > 4.5 MPa (653 psi) for more than 3.0
seconds

Andy, Technician
Category: Heavy Equipment
Satisfied Customers: 828
Experience: 310s and 310t technician licenses, 17 yrs experience, International Diamond Certified Tech 7 yrs
Andy and 4 other Heavy Equipment Specialists are ready to help you
Expert:  Andy replied 3 years ago.

personally, i work for an international dealership , and can tell you this from experience:

I would just go ahead and replace the engine brake solenoid under the valve IF the harness does not seem damaged anywhere . That is likely going to be your problem . If it gets any worse , it will eventually shut down your engine all the time .

Customer: replied 3 years ago.
Thanks for your help, I will replace the engine brake solenoid and see if that cures the problem. I'll have a look at the harness to make sure it is not damaged first. Is it a big job to get the valve cover off and replace the solenoid?
Expert:  Andy replied 3 years ago.
Not at all! The worst part is getting the valve cover off ! The valve cover gasket may be re-used if not damaged ! The engine brake solenoid will be mounted to the high pressure oil rail manifold around the center and will be in plain sight once you get valve cover off! Good Luck ! If you need anything else , I'll be in and out! Thanks for using JA!
Andy, Technician
Category: Heavy Equipment
Satisfied Customers: 828
Experience: 310s and 310t technician licenses, 17 yrs experience, International Diamond Certified Tech 7 yrs
Andy and 4 other Heavy Equipment Specialists are ready to help you
Customer: replied 3 years ago.
Thanks so much, I've appreciated having someone knowledgeable to discuss this with. Thanks again for your prompt service.
Expert:  Andy replied 3 years ago.

Not a problem ! Feedback on my answers is much appreciated ! Bonus is too but optional! Don't forget to tell all your friends about us here at JUST ANSWER! Thanks again!

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