NUMBER:10 02–10 S.M. REF.

: Listed in Table ENGINE: EPA07 Series 60 DATE: October 2010

SUBJECT: DOUBLE HYSTERESIS TEST

ADDITIONS, REVISIONS, OR UPDATES

Publication Number Platform Section Title Change Page Number(s)

DDC-SVC-MAN-0009 EPA07 Series 60 57.1 SPN 641/FMI 7 Service procedures Insert as stated.
have been revised.
57.4 SPN 641/FMI 11

57.5 SPN 641/FMI 14

93.3 SPN 2629/FMI 20

93.4 SPN 2629/FMI 21

NOTE: Page numbers are based on the most recent version of the individual publication and may be adjusted throughout the annual print cycle.
SPN 641/FMI 7
This code typically means the Smart Remote Actuator 5 is in Failsafe Mode, Motor On.

ACTUATOR CHECK
Check as follows:
1. Using DDDL 7.0, perform the Turbo Hysteresis test.
[a] If the Turbo Hysteresis test is a pass, repeat the Turbo Hysteresis test to see if the results
are the same. If the results are the same, refer to section . If the second Turbo Hysteresis
test fails, then go to the next step.
[b] If the test results fail, go to the next step.
2. Turn the ignition OFF (key OFF, engine OFF).
3. Inspect the turbocharger electrical connectors.
[a] If bent, corroded or damaged pins are found, repair as necessary. Refer to section .
[b] If electrical connections are OK, go to the next step.

NOTE:
Failure to follow these instructions will result in an inaccurate diagnosis of the actuator or the
turbocharger.

4. Perform Double Hysteresis test. Refer to section .

5. Did the Double Hysteresis test pass?
[a] Yes; go to next step.
[b] No; replace the turbo actuator. refer to section .
6. Remove the turbocharger and inspect for signs of foreign material contamination.
[a] If foreign material damage is found, repair the source of material entry. Replace the
turbocharger.
[b] If no foreign material damage is found, replace the turbocharger.
SPN 641/FMI 11
This code typically means the Smart Remote Actuator 5 has restricted operability.

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 12.
[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, verify repairs. 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. Verify repairs.
[b] If the voltage is greater than 11 volts, go to the next step.
6. Turn the ignition OFF (key OFF, engine OFF).
7. Disconnect the MCM 120–pin connector.
8. Measure the resistance between pin 3 of the turbo actuator harness connector and pin 74 of the
MCM 120–pin connector.
[a] If the resistance is greater than 3 Ω, repair the open circuit between pin 3 of the turbo
actuator harness connector and pin 74 of the MCM 120–pin connector. Verify repairs.
[b] If the resistance is less than 3 Ω, go to the next step.
9. Measure the resistance between pin 4 of the turbo actuator harness connector and pin 75 of the
MCM 120–pin connector.
[a] If the resistance is greater than 3 Ω, repair the open circuit between pin 4 of the turbo
actuator harness connector and pin 75 of the MCM 120–pin connector. Verify repairs.
[b] If the resistance is less than 3 Ω, replace the turbo actuator. Verify repairs.

NOTE:
Failure to follow these instructions will result in inaccurate diagnosis of the actuator or the
turbocharger.

10. Perform Double Hysteresis test. Refer to section .

11. Did the Double Hysteresis test pass?
[a] Yes; go to next step.
[b] No; replace the turbo actuator. Verify repairs.
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. Replace the
turbocharger.
[b] If no foreign material damage is found, replace the turbocharger.
SPN 641/FMI 14
This code typically means the Smart Remote Actuator 5, no Failsafe Mode, Motor Off.

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 7.
[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, verify repairs. If the repeat test fails, go to the next step.
2. Turn the ignition OFF (key OFF, engine OFF).
3. Disconnect the turbo actuator.
4. Turn key ON (key ON, engine OFF).
5. Check the actuator supply voltage.
6. 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. Verify repairs.
[b] If the voltage is greater than 11 volts, go to the next step.
7. Turn the ignition OFF (key OFF, engine OFF).
8. Disconnect the MCM 120–pin connector.
9. Measure the resistance between pin 3 of the turbo actuator harness connector and pin 74 of the
MCM 120–pin connector.
[a] If the resistance is greater than 3 Ω, repair the open circuit between pin 3 of the turbo
actuator harness connector and pin 74 of the MCM 120–pin connector. Verify repairs.
[b] If the resistance is less than 3 Ω, go to the next step.
10. Measure the resistance between pin 4 of the turbo actuator harness connector and pin 75 of the
MCM 120–pin connector.
[a] If the resistance is greater than 3 Ω, repair the open circuit between pin 4 of the turbo
actuator harness connector and pin 75 of the MCM 120–pin connector. Refer to section .
[b] If the resistance is less than 3 Ω, replace the turbo actuator. Refer to section .

NOTE:
Failure to follow these instructions will result in inaccurate diagnosis of the actuator or the
turbocharger.

11. Perform Double Hysteresis test. Refer to section .

12. Does the Double Hysteresis test pass?
 [a] Yes; go to next step.
[b] No; replace the turbo actuator. Verify repairs.
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. Replace the
turbocharger.
[b] If no foreign material damage is found, replace the turbocharger.
SPN 2629/FMI 20
This condition is typically temperature too high from the turbo outlet.

TURBOCHARGER CHECK
Check as follows:
1. Inspect the turbocharger outlet plumbing and charge air cleaner for blockage, leaks or cracks.
Repair as necessary.
2. Turn the ignition ON (key ON, engine OFF).
3. Perform the Turbo Hysteresis Test using DDDL 7.X.
[a] If the test fails, go to step 5.
[b] If the test is a pass, go to step 4.
4. Disconnect the Turbo Compressor Outlet Temperature Sensor.
[a] Inspect the connectors for damage, corrosion, spread or bent pins. Repair as necessary.
Verify repairs.
[b] If the connectors are OK, replace the Turbo Compressor Outlet Temperature Sensor.
Verify repairs.

NOTE:
Failure to follow these instructions will result in inaccurate diagnosis of the actuator or the
turbocharger.

5. Perform Double Hysteresis Test. Refer to section .

[a] If test fails, replace the turbocharger actuator.
[b] If test passes, check turbocharger sector shaft movement. Refer to section .
SPN 2629/FMI 21
This condition is typically temperature too low from the turbo outlet.

TURBOCHARGER CHECK
Check as follows:
1. Disconnect the Turbo Compressor Outlet (TCO) Sensor.
2. Measure the resistance across pins 1 and 2 of the Turbo Compressor Outlet Temperature Sensor.
[a] If the resistance is greater than 500k Ω, replace the Turbo Compressor Outlet Temperature
Sensor. Refer to section .
[b] If the resistance is less than 300k Ω, go to step 3.
3. Turn the ignition ON (key ON, engine OFF).
4. Measure the voltage between pins 1 and 2 of the Turbo Compressor Outlet Temperature
Sensor harness connector.
[a] If the voltage is between 2.75 and 3.25 volts, go to step 6.
[b] If the voltage is less than 2.75 volts, go to step 5.
5. Measure the voltage between pin 2 of the Turbo Compressor Outlet Temperature Sensor
harness connector and ground.
[a] If the voltage is between 2.75 and 3.25 volts, repair the open circuit between pin 1 of the
Turbo Compressor Outlet Temperature Sensor harness connector and pin 52 of the 120–pin
MCM connector. Verify repairs.
[b] If the voltage is less than 2.75 volts, repair the open circuit between pin 2 of the Turbo
Compressor Outlet Temperature Sensor harness connector and pin 112 of the 120–pin
MCM connector. Verify repairs.
6. Inspect the intake air and turbocharger outlet plumbing for leaks or cracks.
[a] Repair if necessary. Verify repairs.
[b] If no repairs are necessary, go to the next step.
7. Perform the Turbo Hysteresis Test using DDDL 7.X. Refer to section .
[a] If the test fails, go to step 9.
[b] If the test is a pass, go to step 8.
8. Disconnect the Turbo Compressor Outlet Temperature Sensor.
[a] Inspect the connectors for damage, corrosion, spread or bent pins. Repair as necessary.
Verify repairs.
[b] If the connectors are OK, replace the Turbo Compressor Outlet Temperature Sensor.
Verify repairs.

NOTE:
Failure to follow these instructions will result in inaccurate diagnosis of the actuator or the
turbocharger.
9. Perform Double Hysteresis Test. Refer to section.
[a] If test fails, replace the turbocharger actuator.
[b] Check turbocharger sector shaft movement. Refer to section .
ADDITIONAL SERVICE INFORMATION
Additional service information is available in Power Service Literature.

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