Detroit Diesel Engine 60, 60 EGR Service Manual

Name: Detroit Diesel Engine 60
Brand: Detroit Diesel Engine
SKU: 4537386
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ATTENTION

The information in this document is accurate as of April 2004 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 ECM 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 GUIDE

A LETTER TO TECHNICIANS

The Series 60 engine is entering its 14th 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 covers the October 2002 through current production Series 60 EGR engines.

After completing this guide you will:

Understand the function of the Series 60 EGR engine components and their interdependence

Understand Series 60 EGR operating modes

Recognize the logic, component, and protection codes logged within the ECM

Learn the acceptable pressure output values from a Variable Pressure Output Device (VPOD)

Be able to record, playback, save, and e-mail a DDDL snapshot

Apply your understanding of the EGR system logic to review DDDL diagnostic snapshots

All information subject to change without notice. (Rev. April 2004)

SERIES 60 EGR TECHNICIAN'S GUIDE

TABLE OF CONTENTS

1	INTRODUCTION .................................................................................................................	1-1
2	COMPONENTS ...................................................................................................................	2-1
3	MODES ...............................................................................................................................	3-1
4	CODES ................................................................................................................................	4-1
5	DDEC IV TESTING .............................................................................................................	5-1
6	DDDL/SNAPSHOTS ...........................................................................................................	6-1
7	SNAPSHOT EXAMPLES ....................................................................................................	7-1
8	DDEC V COMPONENTS ....................................................................................................	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

All information subject to change without notice. (Rev. April 2004)

iii

TABLE OF CONTENTS

All information subject to change without notice. (Rev. April 2004)

SERIES 60 EGR TECHNICIAN'S GUIDE

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.

NOTE:

The Series 60 EGR system will be supported in the near future.

Prerequisites for effective diagnosis include the following topics:

Knowledge of both the engine and vehicle principles of operation.

Ability to perform and to understand service manual and troubleshooting manual procedures.

Availability and training to use gages and diagnostic test equipment.

Familiarization 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 DDC Technical Assistance. Once you have discussed your options with a technical support person, you can perform the required tests and evaluations. Please keep in contact with your technical support person. This allows you to stay on track.

All information subject to change without notice. (Rev. April 2004)

1-1

INTRODUCTION

BASICS

The following listed items should be checked prior to starting any troubleshooting:

Ensure engine serial number on the ECM matches the serial number on the cylinder block.

Walk around the vehicle. Look for obvious problems such as leaks (air or liquid).

Inspect the ECM for worn isolators, debris or bolts lodged between ECM and cylinder block.

Ensure the fuel supply shut-off valve is set to full on.

Check that the fuel filter is secure and tight.

Check for a restricted air filter.

Inspect truck frontal area for air flow restriction through the CAC and radiator.

Ensure that the fuel tank level is correct and that the fuel tank is full.

Look for any vehicle damage.

Investigate any prior repairs, if applicable.

Check for broken wiring connectors.

Check for poor mating of the connector halves or terminals not fully seated in the connector body (backed out terminals).

Look 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.

Check for electrical system interference caused by a defective relay, ECM 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.

Verify that alternator grounds are clean and making good contact. Disconnect the alternator belt to test.

Wiggle wires and harnesses to try to make the problem active, or re-occur.

1-2	All information subject to change without notice. (Rev. April 2004)

SERIES 60 EGR TECHNICIAN'S GUIDE

OPERATOR INFORMATION

This section should serve as a guideline for the technician:

Intermittent Problems - Talk to the operator/driver. Be specific!

Develop your own Driver Questionnaire (see Figure 1-1).

NOTE:

A full page copy of the questionnaire can be found in Appendix C.

All information subject to change without notice. (Rev. April 2004)

1-3

Detroit Diesel Engine 60, 60 EGR Service Manual

INTRODUCTION

Figure 1-1 Drivers Questionnaire

1-4	All information subject to change without notice. (Rev. April 2004)

SERIES 60 EGR TECHNICIAN'S GUIDE

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?

All information subject to change without notice. (Rev. April 2004)

1-5

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 Detroit Diesel Technical Service.

1-6	All information subject to change without notice. (Rev. April 2004)

SERIES 60 EGR TECHNICIAN'S GUIDE

2COMPONENTS

The purpose of the EGR system is to reduce engine exhaust gas emissions in accordance with EPA regulations.

Figure 2-1

EGR System

All information subject to change without notice. (Rev. April 2004)

2-1

COMPONENTS

EGR (exhaust gas recirculation) allows a percentage of the exhaust gases to remix with the air coming into the intake manifold. The exhaust gas dilutes the incoming air, displacing some of the oxygen in the air. Less oxygen results in a slower burn and a reduced peak cylinder temperature which reduces NOx (nitrogen oxides).

Figure 2-1 illustrates how components of the EGR system function.

See Figure 2-2 and Figure 2-3 to familiarize yourself with the EGR components.

1.	VNT Turbocharger	6.	S Pipe
2.	Turbo Vane Actuator	7.	EGR Valve
3.	EGR Valve Actuator	8.	EGR Cooler
4.	Delta Pressure Sensor	9.	High Flow Water Pump
5.	EGR Gas Delivery Pipe

Figure 2-2 Right Side View

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SERIES 60 EGR TECHNICIAN'S GUIDE

1.	EGR Gas Delivery Pipe		4.	Intake Manifold Air Temperature Sensor
2.	EGR Mixer		5.	Barometric Pressure Sensor
3.	Intake Manifold		6.	Intake Manifold Boost Pressure Sensor
Figure 2-3		Left Side View

All information subject to change without notice. (Rev. April 2004)

2-3

COMPONENTS

FUNCTIONALITY OF THE EGR COMPONENTS

Variable Pressure Output Device (VPOD)

12 V/24V power supply system

DDEC IV ECM: PWM2 (Y1) EGR and PWM4 (X2) VNT

Figure 2-4 EGR Valve and VNT Control System

There are two Variable Pressure Output Devices (VPOD) that control the Variable Geometry Turbo (VNT) and the EGR system. The location of the VPODs is application dependent. During engine EGR operation, the VPOD provides modulated air pressure to the pneumatic actuators which change the VNT vanes and EGR valve positions. The VPOD interface with other systems may be viewed in see Figure 2-4.

2-4	All information subject to change without notice. (Rev. April 2004)

SERIES 60 EGR TECHNICIAN'S GUIDE

All information subject to change without notice. (Rev. April 2004)

2-5

COMPONENTS

Variable Nozzle Turbocharger (VNT)

Figure 2-5 VNT Turbocharger

Figure 2-6 Cut Away View of the Vanes

The results of being able to adjust like this are as follow. See Figure 2-5 and see Figure 2-6.

Enhanced air/fuel ratio during engine acceleration

2-6	All information subject to change without notice. (Rev. April 2004)

SERIES 60 EGR TECHNICIAN'S GUIDE

Provides EGR transport mechanism in EGR mode

More vane closure increases the EGR flow rate (PWM % is high).

Less vane closure decreases the EGR flow rate (PWM % is low).

Provides enhanced engine brake capability.

The VNT vanes adjust to control the exhaust gas velocity. See Figure 2-7.

Figure 2-7 VNT Vane Position

Vane Position During Engine Operation

PWM 7%

No air pressure to VNT actuator from the VPOD

Minimum exhaust restriction/Minimum EGR flow while operating in EGR Mode

PWM 50%

Regulated air pressure to the VNT actuator from the VPOD

Moderate exhaust restriction

Increased EGR flow while operating in EGR Mode

PWM 90%:

Maximum regulated air pressure to the VNT actuator from the VPOD

Maximum regulated exhaust restriction/Maximum EGR flow while operating in EGR Mode

All information subject to change without notice. (Rev. April 2004)

2-7

COMPONENTS

EGR Valve

The valve position is controlled by DDEC. The ECM continuously monitors all engine operation modes and performs self diagnostic checks of RPM, load, altitude, air temperature, etc. and uses this information to determine the valve position.

When the EGR valve is closed, exhaust flow from the exhaust manifold, past the turbine wheel in the turbocharger and out the exhaust system, in the traditional way.

When the valve is open, some of the exhaust gas is directed into the EGR cooler, through the delivery pipe and into the intake manifold.

EGR Valve Actuator

Figure 2-8 EGR Valve Actuator

The EGR valve regulates the EGR flow rate via air pressure input from the VPOD. The EGR valve has the following components (see Figure 2-9):

2-8	All information subject to change without notice. (Rev. April 2004)

SERIES 60 EGR TECHNICIAN'S GUIDE

1.	Butterfly Valve	4.	Actuator Bracket
2.	Splined Crank Arm	5.	Adjustable Linkage
3.	Pneumatic Actuator

Figure 2-9

EGR Cooler

Figure 2-10 EGR Cooler (Bar and Fin Design)

All information subject to change without notice. (Rev. April 2004)

2-9

COMPONENTS

The primary purpose of the EGR cooler (see Figure 2-10), is to cool the exhaust gases by:

Providing a coolant flow to remove heat from the gas side core.

Delta Pressure Sensor/EGR Temperature Sensor

Figure 2-11

Venturi

Monitoring the pressure differential across the venturi (adjacent to outlet of EGR cooler see Figure 2-11 and see Figure 2-12) and the temperature of the exhaust gases

(see Figure 2-13) determine precise Mass Flow Rate Measurement.

The ECM uses the delta pressure and exhaust temperature to determine the rate of EGR flow.

2-10	All information subject to change without notice. (Rev. April 2004)

SERIES 60 EGR TECHNICIAN'S GUIDE

Figure 2-12 Delta Pressure Sensor

The Delta Pressure Sensor measures the pressure difference across the venturi in the transfer pipe.

Figure 2-13 EGR Temperature Sensor

All information subject to change without notice. (Rev. April 2004)

2-11

COMPONENTS

EGR Gas Delivery Pipe/Mixer

The delivery pipe provides the path for the EGR gases to flow from the EGR cooler to the intake manifold.

Mixer

Figure 2-14

EGR Mixer

The mixer completes the EGR circuit. See Figure 2-14.

The mixer mixes exhaust gas into the fresh air supply flowing from the charge-air-cooler. Once the air has past the mixer, the intake manifold defuses EGR gas evenly to each cylinder. Sensors are mounted in the intake manifold to monitor the air temperature and the boost pressure.

2-12	All information subject to change without notice. (Rev. April 2004)

SERIES 60 EGR TECHNICIAN'S GUIDE

High Flow Water Pump

The EGR engine uses a high flow water pump to improve the coolant flow for added heat dissipation.

NOTE:

The high flow water pump is not interchangeable with a non-EGR engine.

All information subject to change without notice. (Rev. April 2004)

2-13

COMPONENTS

2-14	All information subject to change without notice. (Rev. April 2004)

SERIES 60 EGR TECHNICIAN'S GUIDE

3MODES

OPERATIONAL MODES

New terminology has been introduced as a result of the Series 60 EGR engine.

Boost Mode

Boost Mode is when the engine is generating power with NO EGR flowing. The EGR valve position is closed and the vanes in the turbocharger adjust to achieve a desired boost level. Boost levels are similiar to 'pre-EGR' engines.

Transition from Boost to EGR Mode

Transition from Boost to EGR Mode is when the engine is generating power using boost pressure and DDEC requests EGR to begin flow.

EGR Mode

EGR Mode occurs when DDEC is flowing EGR at a desired rate to maintain proper engine operation. The EGR valve position is open and vanes in the turbocharger adjust to achieve the desired EGR rate. Typically boost levels are higher under this operating mode when compared to 'pre-EGR' engines.

EGR Control Mode

EGR Control Mode occurs when the DDEC engine sensors are performing normally and all engine parameters are within calibration limits as determined by the sensor readings. These readings enable DDEC to accurately control exhaust gas flow.

Transition from EGR to Boost

Transition from EGR to Boost Mode occurs when the engine is generating power while flowing EGR and DDEC requests to close the EGR valve and generate power based upon boost pressure.

Braking Mode

Braking Mode occurs when the engine is absorbing energy (power) through an internal engine-braking device. The power for the engine brake is accomplished by activating the desired number of cylinders and adjusting the vanes in the turbocharger to achieve the desired boost level. The EGR valve position is closed during brake mode.

All information subject to change without notice. (Rev. April 2004)

3-1

MODES

Altitude

The engine will transition between EGR and boost mode at an altitude of 6500 ft. Altitude is determined by the Barometric Pressure Sensor located on the engine. See Figure 2-3.

Condensation Protection

In very cold ambient (i.e. < 30F) conditions the engine will operate in a "condensation protection" mode. EGR is disabled during this mode requiring a slower turbo speed. The engine will sound "different". During this mode of operation the operator will notice a lower "boost" reading compared to when EGR is active, however there is NO reduction of power.

3-2	All information subject to change without notice. (Rev. April 2004)

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