NUMBER: 08 DDEC VI–20 S.M. REF.

: listed in Table 1 ENGINE: DD15 DATE: May 2008

SUBJECT: REVISED PROCEDURE AND A NEW PROCEDURE

PUBLICATION: DDC-SVC-MAN-0029
The changes to the mechanical troubleshooting are listed in the following table.
Change Section
Step 1 and step 5c are new procedures. Refer to section 2.1, “Discharged Battery”
Section 2.6 is a new procedure. Refer to section 2.6, “Seized Accessory Drive Component”

Table 1 Changes to DD15 Mechanical Troubleshooting

2.1 DISCHARGED BATTERY
Check as follows:
1. Bar the engine using the proper tool.
[a] If the engine rotates normally, go to the next step.
[b] If the engine does not rotate normally, refer to section 2.6, “Seized Accessory Drive
Components.”
2. Check all battery cables and connections. Reconnect or replace if necessary. If the engine
fails to rotate, go to the next step.
3. Measure and record the voltage at the battery terminals; refer to OEM guidelines.
[a] If the voltage recorded is at recommended OEM specifications and the engine failed to
rotate, check the magnetic switch; refer to section 2.2.
[b] If the voltage recorded is below OEM specifications and the engine failed to start, load test
the batteries. Refer to OEM guidelines. If a battery fails the load test, go to the next step.

Electrical Shock
To avoid injury from electrical shock, use care when
connecting battery cables. The magnetic switch studs are
at battery voltage.

ELECTRICAL SHOCK
To avoid injury from electrical shock, follow OEM furnished
operating instructions prior to usage.

4. Replace the battery according to OEM guidelines.

 ENGINE EXHAUST
To avoid injury from inhaling engine exhaust, always operate
the engine in a well-ventilated area. Engine exhaust is toxic.

5. To determine if the new battery resolved the no start condition, attempt to start and run the
engine.
[a] If the engine starts and runs, no further troubleshooting is required. Shut down the engine.
[b] If the engine fails to rotate, check the magnetic switch; refer to section 2.2.
[c] If the engine rotates but fails to start, refer to Chapter 3, “Starting Difficulty – Engine
Rotates.”

2.6 SEIZED ACCESSORY DRIVE COMPONENT

Check as follows:

PERSONAL INJURY
To avoid injury, never remove any engine component while
the engine is running.

PERSONAL INJURY
To avoid injury, use care when working around moving belts
and rotating parts on the engine.

PERSONAL INJURY
To avoid injury from accidental engine startup while servicing
the engine, disconnect/disable the starting system.

1. Remove the accessory drive belts.

2. Attempt to rotate the engine with the proper baring tool.
 [a] If the engine rotates normally, identify and replace the seized accessory components (i.e.
alternator, A/C compressor, water pump, cooling fan, etc.).
[b] If the engine does not rotate normally, check the gear driven components (i.e. turbo
compound, high pressure pump, air compressor, etc.) and repair or replace as necessary.
3. Attempt to rotate the engine with the proper baring tool. If the engine does not rotate normally,
refer to section 2.4, “Internal Engine Damage.”

ADDITIONAL SERVICE INFORMATION

Additional service information is available in the DD15 Troubleshooting Guide
(DDC-SVC-MAN-0029).

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