2002 Onwards Detroit Diesel Series 60 EGR Service & Repair Manual

ATTENTION The information in this document is accurate as of June 2005 and is subject to change without notice. This manual is to be used in conjunction with the DDEC III/IV Single ECM Troubleshooting Guide and the DDEC V Single ECU Troubleshooting Guide. Series 60®, Detroit Diesel®, DDC®, DDEC® and the spinning arrows design are registered trademarks of Detroit Diesel Corporation. Diagnostic Link® is a registered trademarks of the Detroit Diesel Corporation.

SERIES 60 EGR TECHNICIAN'S MANUAL A LETTER TO TECHNICIANS The Series 60 engine is entering its 18th year! Since its introduction in 1987, over 729,000 Series 60 engines have been introduced in the market. The technological changes that have occurred during those 14 years have resulted in a different type of engine, requiring a different class of technicians. Today’s technician is required to have computer skills, excellent comprehension of the written word and possess an extensive diagnostic understanding of the various technological systems and components. Today’s technician must perform at a higher level of efﬁciency and competency than their predecessors and at the same time furnish professional quality support. As the leader in engine computer systems and technology, Detroit Diesel Corporation remains focused on providing excellence in products, service support and training. As products become more and more advanced, today’s technicians must become specialized in multiple areas. This manual is designed with that thought in mind. This Series 60 EGR Technician’s Guide will provide you with concentrated information that will allow you to excel in EGR technology. The Series 60 EGR Technician’s Guide supports the October 2002 through current production Series 60 EGR engines. Acronyms are used throughout this guide, acronyms which support both the DDEC IV and DDEC V system. To avoid any confusion, please refer to the acronym chart listed in Table A-1 to better understand the meaning and intended use of each acronym. After completing this guide you will: Understand the function of the Series 60 EGR engine components and their interdependence Understand Series 60 EGR operating modes Recognize the logic, component, and protection codes logged within the ECM/ECU Learn the acceptable pressure output values from a Variable Pressure Output Device (VPOD) Be able to record, playback, save, and e-mail a DDDL snapshot Apply your understanding of the EGR system logic to review DDDL diagnostic snapshots All information subject to change without notice. (Rev. June 2005) i 7SE60 0506 Copyright © 2005 DETROIT DIESEL CORPORATION

SERIES 60 EGR TECHNICIAN'S MANUAL TABLE OF CONTENTS 1 INTRODUCTION ................................................................................................................. 1-1 2 DDEC IV COMPONENTS ................................................................................................... 2-1 3 OPERATIONAL MODES .................................................................................................... 3-1 4 DDEC IV DIAGNOSTIC CODES ......................................................................................... 4-1 5 DDEC IV TESTING ............................................................................................................. 5-1 6 DDDL/SNAPSHOTS ........................................................................................................... 6-1 7 SNAPSHOT EXAMPLES .................................................................................................... 7-1 8 DDEC V COMPONENTS .................................................................................................... 8-1 9 DDEC V CODES ................................................................................................................. 9-1 10 DDEC V TESTING .............................................................................................................. 10-1 APPENDIX A: LIST OF ACRONYMS ........................................................................................... A-1 APPENDIX B: DDEC IV WIRING SCHEMATICS ......................................................................... B-1 APPENDIX C: ENGINE DIAGNOSTIC QUESTIONNAIRE .......................................................... C-1 APPENDIX D: SERVICE INFORMATION LETTERS ................................................................... D-1 APPENDIX E: DDEC IV ECM OVERVIEW AND VEHICLE INTERFACE HARNESS .................. E-1 All information subject to change without notice. (Rev. June 2005) iii 7SE60 0506 Copyright © 2005 DETROIT DIESEL CORPORATION

SERIES 60 EGR TECHNICIAN'S MANUAL 1 INTRODUCTION The Series 60 EGR Technician's Guide is intended to be used by a qualified service technician familiar with Detroit Diesel electronically controlled (DDEC) diesel engines and to provide a better understanding of the EGR system to improve the diagnosing of a Series 60® EGR system. Prerequisites for effective diagnosis include the following topics: Knowledge of both the engine and vehicle principles of operation. Ability to perform and to understand service manual and troubleshooting manual procedures. Availability and training to use gages and diagnostic test equipment. Familiarization of the computer software associated with DDC products. An essential tool to properly diagnose and troubleshoot a DDEC IV or DDEC V Series 60 EGR engine is the Detroit Diesel Diagnostic Link® (DDDL). This tool will provide you all the help you will need as it contains proper troubleshooting information for all products. NOTE: It is absolutely critical that you understand the EGR system to be qualified to offer any type of proper diagnostics. Do not waste time trying to troubleshoot a DDC product, you are not qualified to troubleshoot. Your company may incur wasted labor hours. If you are qualified to perform a troubleshooting task and have spent more than one hour on that task, STOP, and contact the Detroit Diesel Customer Support Center at 313-592-5800. Once you have discussed your options with a customer support center person, you can perform the required tests and evaluations. Please keep in contact with your customer support person. Doing so allows you to stay on track. All information subject to change without notice. (Rev. June 2005) 1-1 7SE60 0506 Copyright © 2005 DETROIT DIESEL CORPORATION

INTRODUCTION BASICS The following listed items should be checked prior to starting any troubleshooting: Ensure that the engine serial number on the ECM/ECU matches the serial number on the cylinder block. Walk around the vehicle. Look for obvious problems such as leaks (air or liquid). Inspect the ECM/ECU for worn isolators, debris or bolts lodged between ECM/ECU and cylinder block. Ensure the fuel supply shut-off valve is set to full on. Check that the fuel filter is secure and tight. Check for a restricted air filter. Inspect truck frontal area for air flow restriction through the CAC and radiator. Ensure that the fuel tank level is correct and that the fuel tank is full. Look for any vehicle damage. Investigate any prior repairs, if applicable. Check for broken wiring connectors. Check for poor mating of the connector halves or terminals not fully seated in the connector body (backed out terminals). Look for improperly formed or damaged terminals. All connector terminals in the problem circuit should be carefully inspected to determine proper contact tension. Use a mating terminal to test the contact tension. Check for electrical system interference caused by a defective relay, ECM/ECU driven solenoid, or a switch causing an electrical surge. Look for problems with the charging system (alternator, etc.). In certain cases, the problem can be made to occur when the faulty component is operated as in the case of a relay. Verify that alternator grounds are clean and making good contact. Disconnect the alternator belt to test. Wiggle wires and harnesses to try to make the problem active, or re-occur. 1-2 All information subject to change without notice. (Rev. June 2005) 7SE60 0506 Copyright © 2005 DETROIT DIESEL CORPORATION

SERIES 60 EGR TECHNICIAN'S MANUAL OPERATOR INFORMATION This section should serve as a guideline for the technician. Intermittent Problems - Talk to the operator/driver. Be speciﬁc! Develop your own Driver Questionnaire (see Figure 1-1). NOTE: A full page copy of the questionnaire can be found in Appendix C. All information subject to change without notice. (Rev. June 2005) 1-3 7SE60 0506 Copyright © 2005 DETROIT DIESEL CORPORATION

2002 Onwards Detroit Diesel Series 60 EGR Service & Repair Manual

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