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60 EGR Series
Detroit Diesel 60 EGR Series User Manual
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2
Table of Contents
A Letter to Technicians
5
Table of Contents
7
Introduction
9
Basics
10
Operator Information
11
Drivers Questionnaire
12
Questionnaire Response Guideline
14
Egr System
15
Components
15
Right Side View
16
Left Side View
17
Functionality of the Egr Components
18
Variable Pressure Output Device (Vpod)
18
Egr Valve and Vnt Control System
18
Cut Away View of the Vanes
20
VNT Turbocharger
20
Variable Nozzle Turbocharger (VNT)
20
VNT Vane Position
21
EGR Valve
22
EGR Valve Actuator
22
EGR Cooler
23
EGR Cooler (Bar and Fin Design)
23
Delta Pressure Sensor/Egr Temperature Sensor
24
Venturi
24
Delta Pressure Sensor
25
EGR Temperature Sensor
25
EGR Gas Delivery Pipe/Mixer
26
Mixer
26
High Flow Water Pump
27
Operational Modes
29
Boost Mode
29
Transition from Boost to Egr Mode
29
Egr Mode
29
Altitude
30
Condensation Protection
30
Boost Mode Operation
33
EGR Valve Activated by DDEC IV
33
EGR Valve and Pneumatic Actuation
34
EGR Cooling
35
EGR Measurement
36
VNT Controls
37
EGR Mode (Flow)
37
Diagnostic Troubleshooting
39
Diagnostic Trouble Codes (Dtc)
39
Codes
39
Ddec IV Egr Descriptions
41
Logic Codes (Mechanical Failures)
45
Diagnosing Flash Code 39
45
Flash Codes, Sae Codes, Descriptions
45
Failure Mode: SID 146, FMI 12 — EGR Leak (Boost Jake)
46
Failure Mode: SID 146, FMI 2 — EGR Leak (Boost Mode)
46
Failure Mode: SID 147, FMI 7 — VNT Vanes Not Responding (EGR Mode)
47
Failure Mode: SID 147, FMI 14 — EGR Flow too Low
47
Failure Mode: SID147, FMI 2 — VNT Vanes Not Responding (Boost Power)
48
Failure Mode: SID147, FMI 12 — VNT Vanes Not Responding (Boost Jake)
49
Sensor Codes
50
Failure Modes: PID 108, FMI 3 - Voltage High and FMI 4 - Voltage Low
50
Failure Modes: PID 102, FMI 3 - Voltage High and FMI 4 - Voltage Low
50
Failure Modes: PID 105, FMI 3 - Voltage High and FMI 4 - Voltage Low
50
Turbo Speed Sensor
51
Protection Codes
51
Oil Pressure Shutdown
51
Failure Modes: PID 103, FMI 8 - Abnormal Period
51
Coolant Level Low
52
Oil Temperature High
52
Temperature Limits
52
Troubleshooting Task
53
Ddec IV Testing
53
Intermittent Black Smoke
54
Power Loss under Heavy Pull
55
Low Boost under Cold Ambient Conditions
56
Derate Codes 110 and 404 FMI 14
56
Code 39
56
Exhaust Smell/Fumes
57
Slobbering
57
Engine Vibration
57
Engine Coolant Loss
58
Engine Backfire, Engine Misfire, Intermittent Exhaust Smoke
58
Testing Procedures
59
Test B
60
Exhaust Gas Recirculation System Basic Checks
61
Check Delta P Sensor
61
Check VPOD Output Pressure
62
Check Variable Output Pressure Device (VPOD) P/N and Supply Voltage
63
Check VPOD Input Pressure
63
Check VPOD Wiring
64
Check for Active Codes
65
Working with Dddl Snapshots
67
Dddl/Snapshots
67
Using Snapshot Replay Controls
70
Normal Instrumentation Window
73
Diagnostic Instrumentation Window
73
Graph Window
74
User Window
74
Fault Codes Window
75
Normal Engine Operation as Viewed with Dddl Snapshots
77
Snapshot Examples
77
EGR Flow at Idle
78
Delta P Sensor and Piping
78
Stuck or Sticking VNT or EGR Valve Actuator
78
Turbo Compressor Outlet Temperature
79
Vpod
79
Relative Humidity/Turbo Compressor Inlet Temperature Sensor
79
Turbocharger Speed Sensor Faults
79
EGR Flow Troubleshooting Tips
80
Engine at Idle with EGR Flowing
81
Idle — Cold Engine — no EGR Demand — no EGR Flow
82
Throttling Without Load — EGR Is on and of
83
1500 — no Load — EGR off
84
Start up — EGR Valve Stuck Open
85
Code 147 14 — EGR Flow too Low
86
146 2 EGR Leak — Boost Power
87
Leaking Charge Air Cooler
88
One of the Delta P Ports Plugged in the Delivery Pipe
89
Normal Operation — Eaton Autoshift Transmission
90
Normal EGR Flow with Request
91
Normal — EGR off
92
Plugged Delta P Port
93
DDEC V Components
95
DDEC V Electronic Control Unit
96
Hydraulic Actuated EGR Valve
98
Tube and Shell EGR Cooler
99
DDEC V EGR Descsriptions
101
DDEC V Codes
101
Diagnosing Flash Code 13
109
EGR Valve Coil Wiring
109
Ranges Allowed (Ohms)
110
EGR Valve Current
111
DDEC V Testing
113
Appendix A: List of Acronyms
115
Appendix B: Ddec IV Wiring Schematics
117
OEM Responsibility
119
Ddec V Wiring Diagram
121
Appendix C: Engine Diagnostic Questionnaire
123
Appendix D: Service Information Letters
127
4
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Detroit Diesel 60 EGR Series Specifications
General
Brand
Detroit Diesel
Model
60 EGR Series
Category
Engine
Language
English
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