NUMBER: 1 SECM 03 S.M. REF.: Listed in Table 1 ENGINE: ALL DATE: February 2003

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1 NUMBER: 1 SECM 03 S.M. REF.: Listed in Table 1 ENGINE: ALL DATE: February 2003 SUBJECT: UPDATES FOR TROUBLESHOOTING SERIES 60 AND SERIES 50 EGR RELATED CODES AND FAULTS INTRODUCTION The Series 60 engine for 2002/2003 includes EGR (Exhaust Gas Recirculation) technology. The use of EGR was developed on the Series 50 engine two years ago, and with some enhancements is now released on Series 50 and Series 60 on-highway engines. DETAILS AND REASON This bulletin is intended to provide troubleshooting of the DDEC related components used in the EGR system. The attachments to this SIB are designed to fit properly within the current DDEC Single ECM manual, and in most instances are full sections to make insert of the material into the manual easy. For that reason, change bars are not on the new material, but a revision date is entered in the footer. Attachments include the following; listed in Table 1:

2 Section Number Title Reference 02 Operations Refer to section ECM and Sensor Locations Refer to section Basic Knowledge Required Refer to section Flash Codes vs SAE Codes Refer to section TOC Intermittent Fault Refer to section Intermittent Fault; 10.16; 10.17; Refer to section Flash Code 17 Throttle Valve High: Relative Humidity Sensor High 18 Flash Code 18 - Throttle Valve Low; Relative Humidity Sensor Low Refer to section 17. Refer to section Flash Code 29 TCI / TCO Temperature Low Refer to section Flash Code 33 - TBS High Refer to section Flash Code 34 - TBS Low Refer to section Flash Code 39 EGR Valve / VNT Vane Fault Refer to section Flash Code 48 - Air / Fuel / EGR Pressure Low or EGR / TCI / TCO Temperature Low Refer to section Flash Code 49 TCO or TCI Temperature High Refer to section FlashCode51 TCOorTCITemperature Circuit Failed High Refer to section Flash Code 55 - J1939 Data Link Fault Refer to section Flash Code 77 - Exhaust Back Pressure Fault and several Information Codes 78 Flash Code 78 Cruise Control / Adaptive Cruise control 81 Flash Code 81 Oil Level, Exhaust Temp, EGR Temp or EGR Delta-Pressure, Circuit Failed High 82 Flash Code 82 Oil Level, Exhaust Temp, EGR Temp or EGR Delta-Pressure, Circuit Failed Low 83 FlashCode83 EGRTemp,EGR Delta-Pressure, Exhaust Temp, or External Pump Pressure High Refer to section 77. Refer to section 78. Refer to section 81. Refer to section 82. Refer to section TOC Engine Wiring Schematics For TOC, refer to section 92.

3 Section Number Title Reference Table 1 92 Engine Wiring Schematics Refer to section 92 for 92.8 and TOC Vehicle Wiring Schematics For TOC, refer to section Vehicle Wiring Schematics Refer to section 93 for 93.8 and Sections Updated Troubleshooting all EGR related complaints will start with section for Series 50 engine and section for Series 60 engines. New engine models designate the Series 60 is built with EGR technology; these models are listed in Table 2. Table 2 Engine Models 6067MK2E 6067HK2E 6067MK4E 6067HK4E 6067MK6E 6067HK6E EGR Technology Description 12L Coach 14L Coach 12L Fire Truck 14L Fire Truck 12L Truck 14L Truck The components used in today s Series 60 engines will also be applied to the Series 50 engines for These enhancements include: EGR Cooler VPOD (Variable Output Pressure Device) Delta-P Sensor EGR Temperature Sensor Relative Humidity/Turbo Compressor Inlet (TCI) Temperature All new engine sensors using improved connectors Turbo Compressor Outlet (TCO) Temperature

4 SERVICE Expanded information can be found in the DDEC IV A & I manual that can now be downloaded from the DDC Extranet. Standard DDEC tools are still required. To properly diagnose an EGR engine, the following tools are needed: 1000 ohm resistor Pressure gages (0 200 psi) DDR with suite 8 minimum DDDL version 4.2 or higher Terminals and Connectors Connector kits are available individually or in a kit P/N

5 Listed in Table 3 is the breakdown of this kit. P/N Description SRS TRS Oil Pressure Turbo Boost Pressure Barometric Pressure Intake Air Temp Oil Temp Coolant Temp EGR Temp Fuel Temp Relative Humidity/TCI OEM (Harness side) Turbo Compressor Temp EGR Delta-Pressure OEM (Vehicle side) VPOD/12v FCI connector (DDEC IV 2002 only) VPOD/24v Ampconnector (DDEC IV 2002 only) Turbo Speed (DDEC IV 2002 only) Table 3 Connector Kits ADDITIONAL SERVICE INFORMATION Additional service information is available in the Detroit Diesel DDEC III/IV Single ECM Troubleshooting Guide, 6SE497. The next revision to this guide will include the revised information. As a convenience to holders of the DDEC III/IV Single ECM Troubleshooting Guide, information in troubleshooting guide format is attached. The page(s) may be inserted into the guide.

6 NOTE: Manual insert pages are numbered for insertion into the current DDEC III/IV Single ECM Troubleshooting Guide dated July Troubleshooting guides are available from authorized Detroit Diesel distributors. If this bulletin was obtained from the Internet, troubleshooting guide page(s) are available by returning to the screen SIB Index, selecting attachment pages, and printing the page(s). Detroit Diesel, DDC and the spinning arrows design are registered trademarks of Detroit Diesel Corporation. DDEC Copyright 2003 Detroit Diesel Corporation. All rights reserved. Printed in U.S.A.