Table Of Contents - Detroit Diesel Series 60 EGR Technician Manual

Table of Contents

Table Of Contents5
Introduction7
Checks Prior To Starting Any Troubleshooting8
All Information Subject To Change Without Notice. (Rev. June 2005) 7Se60 0506 Copyright © 2005 Detroit Diesel Corporation11
Egr System Diagram13
Ddec Iv Components13
Right Side View14
Left Side View15
Egr Engine View16
Functionality Of The Egr Components17
Electronic Control Module17
Variable Pressure Output Device (Vpod)18
Maximum Regulated Air Pressure To The Vnt19
Regulated Air Pressure To The Vnt20
No Air Pressure To The Vnt21
Variable Nozzle Turbocharger22
Turbocharger Boost Sensor23
Egr Valve24
Egr Valve Actuator25
Egr Cooler26
Delta P Sensor28
Venturi Tube/Delivery Pipe29
Egr Temperature Sensor33
Egr Mixer34
Charge Air Cooler35
Turbocharger Compressor Inlet Temperature Sensor35
High Flow Water Pump36
Operational Modes37
Boost Mode38
Boost Mode Operation40
Transition From Boost Mode To Egr Mode40
Egr Mode41
Coolant Flow Through The Egr Cooler41
Egr Measurement42
VNT Control Flow43
Ddec Iv Diagnostic Codes45
Logic Codes (Mechanical Failures)50
Diagnosing Flash Code 3950
Egr Valve Not Responding50
Egr Leak (Boost Mode)51
Egr Leak (Boost Jake)51
Low Or High Boost-Boost Mode/Vnt Vanes Not Responding-Boost Power52
Excessive Egr Flow-Egr Mode/Vnt Vanes Not Responding-Egr Mode52
Low/High Boost During Jake Operation/Vnt Vanes Not Respond-Boost Jake53
Diagnosing Flash Code 4954
Fmi 0— Turbo Compressor Out Temperature High54
Egr Flow Too Low54
Sensor Codes55
Barometric Pressure Sensor55
Relative Humidity Sensor55
Coolant Temperature Sensor55
Turbo Speed Sensor56
Ambient Air Temperature Sensor56
Engine Protection Codes56
Coolant Temperature High/Oil Pressure Low56
Coolant Level Low57
Oil Temperature High57
Troubleshooting Task59
Ddec Iv Testing59
Testing Procedures60
Intermittent Black Smoke61
Power Loss Under Heavy Pull62
Low Boost Under Cold Ambient Conditions63
Flash Codes 14 And 2963
Flash Code 3963
Exhaust Fumes64
Slobbering64
Engine Vibration64
Engine Backfire, Engine Misfire, Intermittent Exhaust Smoke64
Test A65
Test B66
Exhaust Gas Recirculation System Basic Checks67
Check Delta P Sensor And Barometric Sensor67
Check Vpod Output Pressure68
Check Variable Output Pressure Device Input Pressure69
Check Variable Output Pressure Device Part Number And Supply Voltage69
Check Vpod Wiring70
Check For Active Codes71
Verification71
Working With Dddl Snapshots73
Creating A Snapshot73
Using Snapshot Replay Controls76
Normal Instrumentation Window79
Diagnostic Instrumentation Window79
Graph Window80
User Window80
Fault Codes Window81
Snapshot Examples83
Normal Engine Operation As Viewed With Dddl Snapshots83
Egr Flow At Idle84
Delta P Sensor And Piping84
Stuck Or Sticking Vnt Or Egr Valve Actuator84
Turbocharger Speed Sensor Faults85
Vpod85
Relative Humidity/Turbo Compressor Inlet Temperature Sensor85
Turbo Compressor Outlet Temperature85
Egr Flow Troubleshooting Tips86
Engine At Idle With Egr Flowing87
Idle — Cold Engine — No Egr Demand — No Egr Flow88
Throttling Without Load — Egr Is On And Off89
1500 — No Load — Egr Off90
Start Up — Egr Valve Stuck Open91
Code 147 14 — Egr Flow Too Low92
146 2 Egr Leak — Boost Power93
Leaking Charge Air Cooler94
One Of The Delta P Ports Plugged In The Delivery Pipe95
Normal Operation — Eaton Autoshift Transmission96
Normal Egr Flow With Request97
Normal — Egr Off98
Plugged Delta P Port99
Ddec V Components101
Overview Of The Ddec V Egr System102
Egr Valve And Vnt Control System103
Detailed Views Of The Ddec V Egr Components104
Delta P Sensor Location108
Vnt And Related Components Location109
Fey Ring Exhaust Manifold111
Ddec V Electronic Control Unit112
Egr Valve And Related Components112
Ddec V Ecu View112
Top Right Side View Of Egr Components113
Front Right Side View Of Egr Components114
Egr Cooler And Related Components115
Functionality Of Egr Components116
Egr Valve View116
Venturi Tube118
Charge Air Mixer120
Vnt Actuator122
Variable Pressure Output Device123
Hydraulically Actuated Egr Valve124
Hydraulic Actuator With Solenoid124
Intake Manifold Pressure Sensor127
Ddec V Codes129
Diagnosing Flash Code 13137
Egr Valve Electric Current Is Too High137
Egr Valve Coil Wiring137
Egr Valve Electric Current139
Ddec V Testing141
Flash Code 13 (Sid 146/Fmi 6) Egr Valve Current Too High142
Flash Code 16 (Sid 146/Fmi5) Egr Valve Current Too Low142
Flash Code 61143
Black Smoke - Troubleshooting144
Black Fuel - Troubleshooting144
Engine Misfire, Engine Backfire, Intermittent Smoke Issues145
Slobbering From Exhaust Pipe146
Poor Engine Performance147
Cab Odors148
Loss Of Engine Coolant149
Delta P Sensor Test154
Vpod Output Pressure Test155
Vpod Input Pressure Test157
Vpod Part Number And Supply Voltage Test And Part Number Check157
Vpod Wiring Test158
Active Codes Test159
Final Test159
Egr Cooler Ports Setup161
Filling The Egr Cooler With Tap Water162
Observing The Egr Cooler For Bubbles162
Appendix A: List Of Acronyms167
Appendix B: Ddec Iv Wiring Schematics169
Appendix C: Engine Diagnostic Questionnaire175
Engine Diagnostics Questionnaire177
Appendix D: Service Information Letters178
S60 Egr De-Rating Due To Higher Temperatures - Air And Coolant179
Series 60 Egr Turbocharger Service Parts And Vnt Actuator Calibration181
Series 60 Vnt Actuator Removal And Replacement Procedure182
Vnt Actuator Installation And Calibration182
Series 60 Egr Vnt Actuator Seal Installation (Supercedes 03 Ts-44)186
Vnt Actuator Removal186
Appendix E: Ddec Iv Ecm Overview And Vehicle Interface Harness190
Ddec Iv Ecm Front Side View191
Ecm Engine Harness Connector View192
Engine Harness Connector Pin Locations193
Vehicle Interface Harness Connector194
Vehicle Interface Harness Connector Pin Locations195