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Series 60 EGR
Detroit Diesel Series 60 EGR User Manual
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Table of Contents
Table of Contents
5
Introduction
7
Checks Prior to Starting any Troubleshooting
8
All Information Subject to Change Without Notice. (Rev. June 2005) 7SE60 0506 Copyright © 2005 DETROIT DIESEL CORPORATION
11
EGR System Diagram
13
Ddec IV Components
13
Right Side View
14
Left Side View
15
EGR Engine View
16
Functionality of the EGR Components
17
Electronic Control Module
17
Variable Pressure Output Device (VPOD)
18
Maximum Regulated Air Pressure to the VNT
19
Regulated Air Pressure to the VNT
20
No Air Pressure to the VNT
21
Variable Nozzle Turbocharger
22
Turbocharger Boost Sensor
23
EGR Valve
24
EGR Valve Actuator
25
EGR Cooler
26
Delta P Sensor
28
Venturi Tube/Delivery Pipe
29
EGR Temperature Sensor
33
EGR Mixer
34
Charge Air Cooler
35
Turbocharger Compressor Inlet Temperature Sensor
35
High Flow Water Pump
36
Operational Modes
37
Boost Mode
38
Boost Mode Operation
40
Transition from Boost Mode to EGR Mode
40
EGR Mode
41
Coolant Flow through the EGR Cooler
41
EGR Measurement
42
VNT Control Flow
43
Ddec IV Diagnostic Codes
45
Logic Codes (Mechanical Failures)
50
Diagnosing Flash Code 39
50
EGR Valve Not Responding
50
EGR Leak (Boost Mode)
51
EGR Leak (Boost Jake)
51
Low or High Boost-Boost Mode/Vnt Vanes Not Responding-Boost Power
52
Excessive EGR Flow-EGR Mode/Vnt Vanes Not Responding-EGR Mode
52
Low/High Boost During Jake Operation/Vnt Vanes Not Respond-Boost Jake
53
EGR Flow too Low
54
FMI 0— Turbo Compressor out Temperature High
54
Diagnosing Flash Code 49
54
Sensor Codes
55
Barometric Pressure Sensor
55
Relative Humidity Sensor
55
Coolant Temperature Sensor
55
Turbo Speed Sensor
56
Ambient Air Temperature Sensor
56
Engine Protection Codes
56
Coolant Temperature High/Oil Pressure Low
56
Oil Temperature High
57
Coolant Level Low
57
Troubleshooting Task
59
Ddec IV Testing
59
Testing Procedures
60
Intermittent Black Smoke
61
Power Loss under Heavy Pull
62
Low Boost under Cold Ambient Conditions
63
Flash Codes 14 and 29
63
Flash Code 39
63
Engine Backfire, Engine Misfire, Intermittent Exhaust Smoke
64
Engine Vibration
64
Slobbering
64
Exhaust Fumes
64
Test a
65
Test B
66
Exhaust Gas Recirculation System Basic Checks
67
Check Delta P Sensor and Barometric Sensor
67
Check VPOD Output Pressure
68
Check Variable Output Pressure Device Input Pressure
69
Check Variable Output Pressure Device Part Number and Supply Voltage
69
Check VPOD Wiring
70
Check for Active Codes
71
Verification
71
Working with DDDL Snapshots
73
Creating a Snapshot
73
Using Snapshot Replay Controls
76
Normal Instrumentation Window
79
Diagnostic Instrumentation Window
79
Graph Window
80
User Window
80
Fault Codes Window
81
Normal Engine Operation as Viewed with DDDL Snapshots
83
Snapshot Examples
83
EGR Flow at Idle
84
Delta P Sensor and Piping
84
Stuck or Sticking VNT or EGR Valve Actuator
84
Turbocharger Speed Sensor Faults
85
Vpod
85
Relative Humidity/Turbo Compressor Inlet Temperature Sensor
85
Turbo Compressor Outlet Temperature
85
EGR Flow Troubleshooting Tips
86
Engine at Idle with EGR Flowing
87
Idle — Cold Engine — no EGR Demand — no EGR Flow
88
Throttling Without Load — EGR Is on and off
89
1500 — no Load — EGR off
90
Start up — EGR Valve Stuck Open
91
Code 147 14 — EGR Flow too Low
92
146 2 EGR Leak — Boost Power
93
Leaking Charge Air Cooler
94
One of the Delta P Ports Plugged in the Delivery Pipe
95
Normal Operation — Eaton Autoshift Transmission
96
Normal EGR Flow with Request
97
Normal — EGR off
98
Plugged Delta P Port
99
DDEC V Components
101
Overview of the DDEC V EGR System
102
EGR Valve and VNT Control System
103
Detailed Views of the DDEC V EGR Components
104
Delta P Sensor Location
108
VNT and Related Components Location
109
Fey Ring Exhaust Manifold
111
DDEC V Electronic Control Unit
112
EGR Valve and Related Components
112
DDEC V ECU View
112
Top Right Side View of EGR Components
113
Front Right Side View of EGR Components
114
EGR Cooler and Related Components
115
Functionality of EGR Components
116
EGR Valve View
116
Venturi Tube
118
Charge Air Mixer
120
VNT Actuator
122
Variable Pressure Output Device
123
Hydraulically Actuated EGR Valve
124
Hydraulic Actuator with Solenoid
124
Intake Manifold Pressure Sensor
127
DDEC V Codes
129
Diagnosing Flash Code 13
137
EGR Valve Electric Current Is too High
137
EGR Valve Coil Wiring
137
EGR Valve Electric Current
139
DDEC V Testing
141
FLASH CODE 13 (SID 146/FMI 6) EGR Valve Current too High
142
FLASH CODE 16 (SID 146/FMI5) EGR Valve Current too Low
142
Flash Code 61
143
Black Smoke - Troubleshooting
144
Black Fuel - Troubleshooting
144
Engine Misfire, Engine Backfire, Intermittent Smoke Issues
145
Slobbering from Exhaust Pipe
146
Poor Engine Performance
147
Cab Odors
148
Loss of Engine Coolant
149
Delta P Sensor Test
154
VPOD Output Pressure Test
155
VPOD Input Pressure Test
157
VPOD Part Number and Supply Voltage Test and Part Number Check
157
VPOD Wiring Test
158
Final Test
159
Active Codes Test
159
EGR Cooler Ports Setup
161
Filling the EGR Cooler with Tap Water
162
Observing the EGR Cooler for Bubbles
162
Appendix A: List of Acronyms
167
Appendix B: Ddec IV Wiring Schematics
169
Appendix C: Engine Diagnostic Questionnaire
175
Engine Diagnostics Questionnaire
177
Appendix D: Service Information Letters
178
S60 EGR De-Rating Due to Higher Temperatures - Air and Coolant
179
Series 60 EGR Turbocharger Service Parts and VNT Actuator Calibration
181
Series 60 VNT Actuator Removal and Replacement Procedure
182
VNT Actuator Installation and Calibration
182
Series 60 EGR VNT Actuator Seal Installation (Supercedes 03 TS-44)
186
VNT Actuator Removal
186
Appendix E: Ddec IV Ecm Overview and Vehicle Interface Harness
190
DDEC IV ECM Front Side View
191
ECM Engine Harness Connector View
192
Engine Harness Connector Pin Locations
193
Vehicle Interface Harness Connector
194
Vehicle Interface Harness Connector Pin Locations
195
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Detroit Diesel Series 60 EGR Specifications
General
Brand
Detroit Diesel
Model
Series 60 EGR
Category
Engine
Language
English
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