Detroit Diesel Series 60 EGR User 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:
ƑUnderstand the function of the Series 60 EGR engine components and their interdependence
ƑUnderstand Series 60 EGR operating modes
ƑRecognize the logic, component, and protection codes logged within the ECM/ECU
ƑLearn the acceptable pressure output values from a Variable Pressure Output Device
(VPOD)
ƑBe able to record, playback, save, and e-mail a DDDL snapshot
ƑApply your understanding of the EGR system logic to review DDDL diagnostic snapshots
All information subject to change without notice. (Rev. June 2005) i
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ii All information subject to change without notice. (Rev. June 2005)
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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
8DDECVCOMPONENTS.................................................................................................... 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
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TABLE OF CONTENTS
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SERIES 60 EGR TECHNICIAN'S MANUAL
1INTRODUCTION
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:
ƑKnowledge of both the engine and vehicle principles of operation.
ƑAbility to perform and to understand service manual and troubleshooting manual
procedures.
ƑAvailability and training to use gages and diagnostic test equipment.
ƑFamiliarization 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.
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INTRODUCTION
BASICS
The following listed items should be checked prior to starting any troubleshooting:
ƑEnsure that the engine serial number on the ECM/ECU matches the serial number on
the cylinder block.
ƑWalk around the vehicle. Look for obvious problems such as leaks (air or liquid).
ƑInspect the ECM/ECU for worn isolators, debris or bolts lodged between ECM/ECU and
cylinder block.
ƑEnsure the fuel supply shut-off valve is set to full on.
ƑCheck that the fuel filter is secure and tight.
ƑCheck for a restricted air filter.
ƑInspect truck frontal area for air flow restriction through the CAC and radiator.
ƑEnsure that the fuel tank level is correct and that the fuel tank is full.
ƑLook for any vehicle damage.
ƑInvestigate any prior repairs, if applicable.
ƑCheck for broken wiring connectors.
ƑCheck for poor mating of the connector halves or terminals not fully seated in the connector
body (backed out terminals).
ƑLook 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.
ƑCheck 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.
ƑVerify that alternator grounds are clean and making good contact. Disconnect the alternator
belt to test.
ƑWiggle 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)
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SERIES 60 EGR TECHNICIAN'S MANUAL
OPERATOR INFORMATION
This section should serve as a guideline for the technician.
ƑIntermittent Problems - Talk to the operator/driver. Be specific!
ƑDevelop your own Driver Questionnaire (see Figure 1-1).
NOTE:
A full page copy of the questionnaire can be found in Appendix C.
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INTRODUCTION
Figure 1-1 Drivers Questionnaire
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SERIES 60 EGR TECHNICIAN'S MANUAL
Driver Questionnaire
Ask the driver to answer the following questions before attempting to repair an intermittent
problem, or a problem with symptoms but no diagnostic codes. Use this and the response as a
guideline. Refer to Questionnaire Response Guideline found on page 1–6.
1. How often does the problem occur? Can you and the driver take the vehicle and
demonstrate the problem in less than 30 minutes?
2. Has the vehicle been to other shops for the same problem? If so, what was done there?
3. Did the radio, dash gages, or lights momentarily turn OFF when the problem occurred?
4. Does the problem occur only at specific operating conditions? If so, at what load? Is it
light, medium, or heavy?
5. Does the problem occur at a specific engine operating temperature? If so, at what engine
temperature?
6. Does the problem occur at a specific engine operating altitude? If so, at what altitude?
7. Does the problem occur only when above or below specific outside temperatures? In
what temperature range?
8. Does the problem occur during other conditions e.g. during or after rain, spray washing,
snow?
9. Did the problem occur at a specific vehicle speed? If so, at what vehicle speed?
10. Does the problem occur at specific engine RPM? If so, at what engine RPM?
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INTRODUCTION
Questionnaire Response Guideline
The following are typical responses to the Driver Questionnaire:
PERSONAL INJURY
To avoid injury from loss of vehicle/vessel control, the
operator of a DDEC equipped engine must not use or read
any diagnostic tool while the vehicle/vessel is moving.
1. If the problem is repeatable, take the vehicle for a drive with the DDDL connected and
note the conditions when the problem occurs. Be prepared to take snapshot data using the
DDDL. Ensure you operate the vehicle after correcting the problem and duplicate
the operating conditions before releasing the unit, to verify the problem is corrected.
2. If the vehicle has been to other shops for the same problem, call the other shops and find
out what has been done. Avoid replacing the same components again unless absolutely
sure they are the problem! It is unlikely a component will fail again following a recent
replacement.
3. If other vehicle devices are affected, this indicates there may be something wrong with
the ignition wiring.
4. Operate the engine under similar load conditions. Check the fuel system for restrictions,
primary filter, and fuel tanks for foreign objects blocking the fuel supply. Also, check the
air system. Utilize the DDDL snapshot feature.
5. Operate the engine at this temperature while attempting to duplicate the problem. Use the
snapshot feature on the DDDL.
6. If possible, troubleshoot the problem in this temperature range.
7. If the problem seems to occur during or after the engine is subjected to rain/spray washing,
thoroughly inspect the connectors for moisture entry.
8. If the problem occurs at a specific vehicle speed, check the parameters affecting vehicle
speed to verify they are programmed close to the vehicle speed where the problem occurs.
Check Vehicle Speed and watch the DDDL (snapshot) for changes to see if the pulse
wheel (VSS signal) is loose.
9. If the problem occurs at a specific engine rpm, unplug the oil, coolant, and air temperature
sensors, and note any changes to the problem. Gather this data and contact DDC Customer
Support Center at 313-592-5800.
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SERIES 60 EGR TECHNICIAN'S MANUAL
2DDEC IV COMPONENTS
The primary purpose of the EGR system is to reduce engine exhaust gas emissions in accordance
with EPA regulations by allowing a percentage of the exhaust gases to remix with the air coming
into the intake manifold. Engine exhaust gases will dilute the incoming air by displacing some of
the oxygen in the air being supplied through the intake manifold. Less oxygen results in a slower
fuel burn which reduces the peak cylinder temperature permitting reduced nitrogen oxides (NOx)
emissions. Figure 2-1 illustrates how the components of a EGR system function.
Figure 2-1 EGR System
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DDEC IV COMPONENTS
To familiarize yourself with the pre-2004 DDEC IV EGR components, review Figure 2-2 and
Figure 2-3 .
1. EGR Valve Actuator 5. EGR Gas Delivery Pipe 8. EGR Cooler
2. VNT Actuator 6. S Pipe 9. High Flow Water Pump
3. VNT Turbocharger 7. EGR Valve
4. Delta Pressure Sensor
Figure 2-2 Pre-2004 Right Side View
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SERIES 60 EGR TECHNICIAN'S MANUAL
1. EGR Gas Delivery Pipe 4. Intake Manifold Air Temperature Sensor
2. EGR Mixer 5. Barometric Pressure Sensor
3. Intake Manifold 6. Turbo Boost Pressure Sensor
Figure 2-3 Pre-2004 Left Side View
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DDEC IV COMPONENTS
An enhancement program has been launched to upgrade production 2004 DDEC IV EGR engines.
For detailed information, please visit the DetroitDieselTechnicalInformationWebPageat
http://192.135.85.10/public/sp/spnav.asp and browse for 18SP597. Figure 2-4 illustrates some
of the enhancements such as tube and shell EGR cooler, redesigned delivery pipe, EGR valve,
and venturi tube.
NOTE:
You may also access 18SP documents after logging into the DDC Extranet by clicking on
Support, On-Highway, Service Information, Special Publications (18SPs).
1. Tube and Shell EGR Cooler 3. Delivery Pipe
2. EGR Valve 4. Venturi Tube
Figure 2-4 Enhanced DDEC IV 2004 EGR Engine
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SERIES 60 EGR TECHNICIAN'S MANUAL
FUNCTIONALITY OF THE EGR COMPONENTS
This section will present and discuss specific EGR components which collectively as a system
allow the engine to meet emission standards.
DDEC IV Electronic Control Module
The Electronic Control Module (ECM) is the backbone for engine management. The ECM
receives electronic inputs during vehicle operation via engine and vehicle mounted sensors.
Refer to Appendix E for a view of the DDEC IV ECM and related harness connectors.
DDEC IV ECM engine management benifits are:
ƑExcellent engine performance
ƑOptimum fuel economy
ƑEmission levels that meet current laws without after treatment
ƑEngine diagnostics
ƑSimple programming
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DDEC IV COMPONENTS
Variable Pressure Output Device (VPOD)
There are two VPODs which control the VNT and EGR valve. See Figure 2-5. The location of
the VPODs are application dependent.
Two system components are required for proper operation of EGR valve and VNT control system.
Ƒ12V or 24V power supply
ƑDDEC IV ECM: PWM#2 (Y1) EGR and PWM#4 (X2) VNT
Figure 2-5 EGR Valve and VNT Control System
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SERIES 60 EGR TECHNICIAN'S MANUAL
During engine EGR operation, the VPODs provide modulated air pressure to the pneumatic
actuators which change the position of the VNT vanes and the position of the EGR valve. The
results of the VNT vanes being able to adjust are:
ƑEnhanced air/fuel ratio during engine acceleration
ƑA proper mix of exhaust gas with intake charge air
ƑMore vane closure increases the EGR flow rate (PWM % is high).
ƑLess vane closure decreases the EGR flow rate (PWM % is low).
ƑEnhanced engine brake capability.
The following conditions are present when vane positions are at 90% PWM. See Figure 2-6
ƑRegulated air pressure to the VNT actuator from the VPOD is at the maximum.
ƑRegulated exhaust restriction is at the maximum.
ƑEGR flow is at maximum while operating in EGR mode
Figure 2-6 Maximum Regulated Air Pressure to the VNT
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DDEC IV COMPONENTS
Thefollowingconditionsarepresentwhenthevanepositionsareat50%PWM.SeeFigure2-7
ƑRegulated air pressure is supplied to the VNT actuator from the VPOD
ƑExhaust gas restriction is moderate
ƑEGR flow is increased while operating in EGR Mode
Figure 2-7 Regulated Air Pressure to the VNT
2-8 All information subject to change without notice. (Rev. June 2005)
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