Detroit Diesel Series 60 EGR Technician Manual

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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 ef fi ciency 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:

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/ECU

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

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SERIES 60 EGR TECHNICIAN'S MANUAL

INTRODUCTION

.................................................................................................................

DDEC IV COMPONENTS

...................................................................................................

OPERATIONAL MODES

....................................................................................................

DDEC IV DIAGNOSTIC CODES

.........................................................................................

DDEC IV TESTING

.............................................................................................................

DDDL/SNAPSHOTS

...........................................................................................................

SNAPSHOT EXAMPLES

....................................................................................................

DDEC V COMPONENTS

....................................................................................................

DDEC V CODES

.................................................................................................................

DDEC V TESTING

..............................................................................................................

APPENDIX A: LIST OF ACRONYMS

...........................................................................................

APPENDIX B: DDEC IV WIRING SCHEMATICS

.........................................................................

APPENDIX C: ENGINE DIAGNOSTIC QUESTIONNAIRE

..........................................................

APPENDIX D: SERVICE INFORMATION LETTERS

...................................................................

APPENDIX E: DDEC IV ECM OVERVIEW AND VEHICLE INTERFACE HARNESS

..................

9-1

10-1

A-1

B-1

C-1

D-1

E-1

5-1

6-1

7-1

8-1

1-1

2-1

3-1

4-1

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TABLE OF CONTENTS

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SERIES 60 EGR TECHNICIAN'S MANUAL

INTRODUCTION

The

Series 60 EGR Technician's Guide

is intended to be used by a quali fi ed 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:

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 quali fi ed to offer any type of proper diagnostics. Do not

waste time

trying to troubleshoot a DDC product, you are not quali fi ed to troubleshoot. Your company may incur wasted labor hours. If you are quali fi ed 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:

Ensure that the engine serial number on the ECM/ECU 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/ECU for worn isolators, debris or bolts lodged between ECM/ECU and cylinder block.

Ensure the fuel supply shut-off valve is set to

full on

Check that the fuel fi lter is secure and tight.

Check for a restricted air fi lter.

Inspect truck frontal area for air fl ow 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/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.

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.

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SERIES 60 EGR TECHNICIAN'S MANUAL

OPERATOR INFORMATION

This section should serve as a guideline for the technician.

Intermittent Problems - Talk to the operator/driver.

Be speci

Develop 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 speci fi c operating conditions? If so, at what load? Is it light, medium, or heavy?

5. Does the problem occur at a speci fi c engine operating temperature? If so, at what engine temperature?

6. Does the problem occur at a speci fi c engine operating altitude? If so, at what altitude?

7. Does the problem occur only when above or below speci fi c 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 speci fi c vehicle speed? If so, at what vehicle speed?

10. Does the problem occur at speci fi c 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 fi nd 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 fi lter, 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 speci fi c 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 speci fi c 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

DDEC 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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2-1

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

2. VNT Actuator

3. VNT Turbocharger

4. Delta Pressure Sensor

Figure 2-2

5. EGR Gas Delivery Pipe

6. S Pipe

7. EGR Valve

Pre-2004 Right Side View

8. EGR Cooler

9. High Flow Water Pump

2-2

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1. EGR Gas Delivery Pipe

2. EGR Mixer

3. Intake Manifold

Figure 2-3 Pre-2004 Left Side View

4. Intake Manifold Air Temperature Sensor

5. Barometric Pressure Sensor

6. Turbo Boost Pressure Sensor

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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

Detroit Diesel Technical Information Web Page

at 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

2. EGR Valve

Figure 2-4

3. Delivery Pipe

4. Venturi Tube

Enhanced DDEC IV 2004 EGR Engine

2-4

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FUNCTIONALITY OF THE EGR COMPONENTS

This section will present and discuss speci fi c 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 beni fi ts are:

Excellent engine performance

Optimum fuel economy

Emission levels that meet current laws without after treatment

Engine diagnostics

Simple 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.

12V or 24V power supply

DDEC IV ECM: PWM#2 (Y1) EGR and PWM#4 (X2) VNT

Figure 2-5 EGR Valve and VNT Control System

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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:

Enhanced air/fuel ratio during engine acceleration

A proper mix of exhaust gas with intake charge air

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

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

Enhanced engine brake capability.

The following conditions are present when vane positions are at 90% PWM. See Figure 2-6

Regulated air pressure to the VNT actuator from the VPOD is at the maximum.

Regulated exhaust restriction is at the maximum.

EGR fl ow 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

The following conditions are present when the vane positions are at 50% PWM. See Figure 2-7

Regulated air pressure is supplied to the VNT actuator from the VPOD

Exhaust gas restriction is moderate

EGR fl ow is increased while operating in EGR Mode

Figure 2-7 Regulated Air Pressure to the VNT

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The following conditions are present when the vane positions are at 7% PWM. See Figure 2-8

Air pressure is not supplied to the VNT actuator from the VPOD

Exhaust gas restriction is minimal

EGR fl ow is minimal while operating in EGR Mode

Figure 2-8 No Air Pressure to the VNT

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DDEC IV COMPONENTS

Variable Nozzle Turbocharger

Variable nozzle turbocharger (VNT), see Figure 2-9, uses a high pressure pneumatic actuator to regulate and control turbine vanes. There is no wastegate with this system. The VNT actuator is mounted on a bracket attached to the turbocharger and receives air pressure from engine-mounted

VPODs. VNT actuator connects via a rod to the pin joint of the turbine external arm. Rotation of external arm simultaneously rotates several pivoting nozzle vanes positioned inside turbine housing at the outer periphery of turbine wheel. This adjusts turbocharger speed, boost and EGR fl ow in accordance with DDEC engine management control.

NOTE:

VNT actuator is spring loaded. If air pressure is lost the actuator will open the VNT vanes resulting in low/no boost.

Figure 2-9 Variable Nozzle Turbocharger

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Turbocharger Boost Sensor

Turbocharger Boost Sensor (TBS), see Figure 2-10, is used to monitor air pressure in the intake manifold. DDEC IV uses this air pressure data for fuel management during engine acceleration.

The TBS sensor is supplied a 5-volt reference signal by ECM and returns a voltage signal to the

ECM relative to turbo boost pressure. Return voltage increases as boost pressure increases.

Operating values are 0.10-5.0 V during normal engine operation.

Figure 2-10 Turbocharger Boost Sensor

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DDEC IV COMPONENTS

EGR Valve

EGR valve position is controlled by the ECM. 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 EGR valve position. The ECM changes EGR valve position by regulating air pressure output from the VPOD to an actuator mounted to EGR valve.

The EGR valve outlet is connected to the EGR cooler and recirculates a fraction of the engine exhaust gases to the intake manifold for purposes of engine emission control. When the EGR valve is closed, exhaust fl ows from the exhaust manifold, past the turbine wheel into the VNT and out exhaust system in traditional way. See Figure 2-11 to view a pre-2004 EGR valve and see Figure 2-12 to view enhanced EGR valve.

NOTE:

The EGR actuator is spring loaded. If air pressure is lost the actuator will close the EGR valve resulting in no EGR fl ow.

Figure 2-11 Pre-2004 EGR Valve

2-12

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Figure 2-12 Enhanced EGR Valve

EGR Valve Actuator

The EGR valve actuator (see Figure 2-13) regulates EGR butter fl y valve.

Figure 2-13 EGR Valve Actuator

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DDEC IV COMPONENTS

EGR Cooler

The primary purpose of an EGR cooler is to cool exhaust gases. Coolant that fl ows through the cooler removes heat from exhaust gases that enter the EGR cooler. See Figure 2-14. See Figure

2-15 for a view of the current EGR cooler.

1. Pre-2004 EGR Cooler

Figure 2-14

2. Enhanced EGR Cooler

Pre-2004 EGR Cooler and Enhanced EGR Cooler

2-14

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Figure 2-15 View of Current EGR Cooler

Cooling is accomplished by directing exhaust gas past the cooling tubes in the EGR cooler. The

EGR cooler core transfers the heat from the exhaust gases to the engine cooling system as the gases are sent to the EGR/charge air mixer. The gases are then mixed with incoming air from the charge air cooler before being sent to the intake manifold.

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DDEC IV COMPONENTS

Delta P Sensor

ECM and returns a voltage signal to ECM relative to pressure difference across the Venturi tube. Return sensor voltage increases as pressure differential increases during engine operation

(operating values are 0.23-4.77 V).

1. Thermostat Housing

Figure 2-16 Delta P Sensor

2. Delta P Sensor

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Venturi Tube/Delivery Pipe

A Venturi tube with a port at each end is attached to the EGR delivery pipe at the EGR cooler outlet. The ports are connected to the Delta P Sensor to monitor the pressure differential across the venturi as EGR gases fl ow through EGR delivery pipe to the charge-air mixer. See Figure

2-17 to view pre-2004 delivery pipe and see Figure 2-18 to view enhanced delivery pipe. The

ECM uses this information along with temperature and density of exhaust gases to determine precise EGR mass fl ow rate. See Figure 2-19 for pre-2004 venturi tube and see Figure 2-20 for enhanced venturi tube.

Figure 2-17 Pre-2004 Delivery Pipe

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DDEC IV COMPONENTS

Figure 2-18 Enhanced Delivery Pipe

2-18

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Figure 2-19 Pre-2004 Venturi Tube

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DDEC IV COMPONENTS

Figure 2-20 Enhanced Venturi Tube

2-20

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EGR Temperature Sensor

ECM uses the EGR Temperature Sensor to monitor exhaust gas temperatures in the EGR delivery pipe and uses exhaust temperature and delta pressure across the Venturi tube to determine rate of

EGR fl ow. Temperature sensor is supplied a 5-volt reference signal from the ECM and returns a voltage signal to the ECM relative to exhaust gas temperatures in the EGR delivery pipe.

Sensor return voltage decreases as exhaust gas temperature increases (sensor operating values are

0.10-5.0 V). See Figure 2-21 to view the sensor with connector.

Figure 2-21 EGR Tempertaure Sensor

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DDEC IV COMPONENTS

EGR Mixer

The EGR air mixer combines exhaust gases with the fresh air supply fl owing from the charge air cooler. Once the air has passed through the EGR mixer, the intake manifold diffuses EGR gases evenly to each cylinder. Sensors are mounted within the intake manifold to monitor air temperature and boost pressure. See Figure 2-22 for a view of the pre-2004 EGR mixer and see Figure 2-23 for a view of the enhanced EGR mixer.

Figure 2-22 Pre-2004 EGR Mixer

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Figure 2-23 Enhanced EGR Air Mixer

Charge Air Cooler

The Charge air cooler (CAC) is mounted in front of the cooling system radiator which is connected to the turbocharger and the intake manifold. Compressed air leaving the turbocharger is directed through the CAC before it goes to the EGR air mixer to be mixed with EGR exhaust gases entering the intake manifold.

Cooling is accomplished by incoming fresh air fl owing past the tubes and fi ns of charge air cooler. Compressed intake charge air fl owing inside the CAC core transfers heat to the tubes and fi ns where it is transferred to the outside air.

The CAC is used to the reduce temperature of the compressed air leaving the turbocharger before entering the intake manifold allowing for a more dense charge of air to be delivered to engine.

Turbocharger Compressor Inlet Temperature Sensor

Turbocharger Compressor Inlet Temperature Senor (TCI) is a DDC part and is installed by the truck manufacturer within piping between the air fi lter and turbocharger inlet. The TCI sensor which is used to control EGR operation in high humidity and heat conditions that may cause damage to the engine is monitored by DDEC. The ECM will log a fault code for one or more functions of this sensor. Each sensor mode is supplied a 5 V reference signal by the ECM and returns a voltage signal to the ECM relative to temperature and humidity. Return voltage from the TCI sensor increases as atmospheric humidity increases and return voltage decreases as air inlet temperature increases.

The TCI operating values during normal engine operation are 0.23-4.93 V.

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DDEC IV COMPONENTS

High Flow Water Pump

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

NOTE:

The high fl ow water pump is not interchangeable between EGR and non-EGR engines.

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SERIES 60 EGR TECHNICIAN'S MANUAL

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

fl owing. 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 the EGR to begin fl ow.

EGR Mode

— EGR Mode occurs when DDEC is fl owing 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 fl ow.

Transition from EGR to Boost

— Transition from EGR to Boost Mode occurs when the engine is generating power while fl owing 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.

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.

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OPERATIONAL MODES

BOOST MODE

During boost mode the following occurs (see Figure 3-1):

EGR valve closed

No EGR fl owing through the EGR cooler or delivery pipe

VNT vane position controlled by intake manifold boost pressure and limited by the turbocharger speed

Red = Exhaust Gas

Blue= No EGR Flow

Figure 3-1

Yellow= Vehicle Air (VPODs)

Boost Mode EGR Valve Closed

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The VNT vane position is adjusted by the VNT actuator air pressure which is regulated by the

VPOD. The VPOD determines the correct air pressure via voltage signal from the DDEC V ECM.

Air pressure supplied by the EGR VPOD to the EGR actuator opens the butter fl y valve.

See Figure 3-2.

Once the EGR butter fl y valve opens, the EGR gases fl ow through the EGR cooler and into the delivery pipe.

Red = Exhaust Gas

Orange= Cooled Exhaust Gas

Figure 3-2 EGR Mode

Yellow= Vehicle Air (VPODs)

Green= Coolant Flow

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OPERATIONAL MODES

BOOST MODE OPERATION

A typical boost mode operation consists of:

Accelerating a vehicle from a stationary position and shifting up through the transmission gears

Performing engine brake operation

The vehicle must be at or above 6500 ft of altitude

High ambient humidity to prevent condensation of EGR gases in the intake manifold

TRANSITION FROM BOOST MODE TO EGR MODE

The EGR valve is actuated by the ECM. Initiation of EGR requires minimum engine speed and boost pressure (air fl ow) in order to transition into EGR mode without an abrupt drop in air/fuel ratio.

Once minimum RPM and boost levels are attained the ECM sends a signal via PWM #2, see Figure 3-3, to initiate the valve opening event by providing air pressure to the EGR actuator.

Figure 3-3 Transition from Boost Mode to EGR Mode

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EGR MODE

Figure 3-4 illustrates EGR coolant fl ow.

Exhaust gas enters the EGR cooler at high temperatures and is cooled by the engine coolant system to increase the density of the gas.

Figure 3-4 Coolant Flow through the EGR Cooler

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OPERATIONAL MODES

See Figure 3-5 for EGR measurement.

Once exhaust gases begin fl ow through the EGR cooler and past the venturi, pressure levels are measured from the two venturi taps or ports. The delta pressure measurement, in conjunction with the EGR temperature determines the EGR fl ow rate.

Figure 3-5 EGR Measurement

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See Figure 3-7 for VNT control fl ow.

The VNT turbocharger is the mechanism used to change the EGR rate

The VNT is controlled via the DDEC PWM #4, see Figure 3-6, which regulates the air pressure to change the VNT vane position.

Figure 3-6 EGR Valve and VNT Control System

All information subject to change without notice.

(Rev. June 2005)

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3-7

OPERATIONAL MODES

Changes to the vane position, either closing or opening, result in an increase or decrease to the EGR fl ow rate. See Figure 3-7.

Red = Exhaust Gas

Orange= Cooled Exhaust Gas

Figure 3-7 VNT Control Flow

Yellow= Vehicle Air (VPODs)

Green= Coolant Flow

3-8

All information subject to change without notice.

(Rev. June 2005)

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SERIES 60 EGR TECHNICIAN'S MANUAL

DDEC IV DIAGNOSTIC CODES

This section supports the DDEC IV fault codes/diagnostic trouble codes (DTC) recorded during

EGR engine operation.

The diagnostic trouble codes are generated in the ECM when a condition exists that prevents the engine from operating at peak ef fi ciency. The DTC will help guide the technician to the

condition

. The technician will require a knowledge of the system and proper tools to diagnose the components.

Three primary codes exist; they are Component, Logic, and Engine Protection.

Logic Codes

— This code is activated when speci fi c conditions occur within a given amount of time that the calibration determines is not “normal.” For example: If the ECM commands the

EGR valve to open or close, the ECM monitors the EGR fl ow devices for con fi rmation that fl ow has begun or ended.

Logic codes identify a condition NOT a component.

Component/Sensor Codes

— This code is activated when a speci fi c component failure exists.

This is most commonly seen as a high volt or low volt code for a speci fi c device. The failure can generally be found within the component or wiring for that component.

Engine Protection Codes

— This code is activated when a engine operating condition exists that can cause immediate damage to the engine and the engine should be shut down until the condition is corrected to prevent additional damage.

All information subject to change without notice.

(Rev. June 2005)

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4-1

DDEC IV DIAGNOSTIC CODES

DDEC IV CODE DESCRIPTIONS

To read codes, use the Detroit Diesel Diagnostic Link (DDDL). The DDDL will display active and inactive fault codes which are listed in the following color coded chart.

Blue = Logic Codes

Yellow= Component/Sensor Codes

Red= Engine Protection Codes

171

105

171

351

404

PID

354

174

175

110

175

111

187

111

110

105

SID

238

DDC Code #

(Flashed)

FMI

Description

Variable Speed Governor Sensor Voltage Low

Variable Speed Governor Sensor Voltage High

Coolant Level Sensor Input Voltage Low

Coolant Temperature Sensor Input Voltage High

Oil Temperature Sensor Input Voltage High

Coolant Temperature Sensor Input Voltage Low

Oil Temperature Sensor Input Voltage Low

Coolant Level Sensor Input Voltage High

Relative Humidity Sensor Circuit Failed High

Relative Humidity Sensor Circuit Failed Low

Throttle Position Sensor Input Voltage High

Throttle Position Sensor Input Voltage Low

Fuel Temperature Sensor Input Voltage High

Fuel Temperature Sensor Input Voltage Low

Reserved for “No Codes"

Aux. Shutdown #1 Active

Aux. Shutdown #2 Active

Intake Manifold Temperature Sensor Input

Voltage High

Ambient Air Temperature Sensor Input Voltage

High

Intake Manifold Temperature Sensor Input

Voltage Low

Ambient Air Temperature Sensor Input Voltage

Low

TCI Temperature Circuit Failed Low

TCO Out Sensor Input Voltage Low

Aux. Output #3 Open Circuit (High Side) - S3

Aux. Output #3 Short To Ground (High Side) - S3

Aux. Output #3 Mechanical System Fail - S3

Aux. Output #4 Open Circuit (High Side) - T3

Aux. Output #4 Short to Ground (High Side) - T3

Aux. Output #4 Mechanical System Failure - T3

SEL Short to Battery (+)

SEL Open Circuit

4-2

All information subject to change without notice.

(Rev. June 2005)

7SE60 0506

SERIES 60 EGR TECHNICIAN'S MANUAL

111

105

110

172

175

105

110

100

168

106

411

412

404

102

106

404

PID

102

100

DDC Code #

(Flashed)

SID

146

239

146

147

214

232

147

254

253

FMI

Description

CEL Short to Battery (+)

CEL Open Circuit

Turbo Boost Pressure Sensor Input Voltage High

Turbo Boost Pressure Sensor Input Voltage Low

Oil Pressure Sensor Input Voltage Low

Fuel Pressure Sensor Input Voltage High

Fuel Pressure Sensor Input Voltage Low

EGR Leak - Boost Power

EGR Leak - Boost Jake

EGR Valve Not Responding

Low or High Boost-Boost Mode

VNT Vanes not responding-Boost Mode

Excessive EGR Flow-EGR Mode

VNT Vanes not responding-EGR Mode

VNT Vanes at Max-Jake Mode

Low or High Boost during Jake Operation

VNT Vanes not repsonding-Jake Mode

EGR Flow too Low

Too Many SRS (missing TRS)

Too few SRS (missing SRS)

Coolant Level Low

Intake Manifold Temperature High

Coolant Temperature High

Air Inlet Temperature High

Oil Temperature High

Inlet Manifold Temperature Derate

Coolant Temperature Derate

Oil Pressure Low

ECM Battery Voltage Low

RTC Backup Battery Voltage Low

Sensor Supply Voltage Low

Turbo Boost Pressure High

Air Inlet Pressure High

Air Inlet Pressure Low

EGR OPD Low

EGR Temperature Low

Turbo Compressor Out Temperature High

TCO Temperature Derate

Turbo Compressor Out Temperature Sensor

Input Voltage High

A/D Conversion Fail

Nonvolatile Checksum Incorrect

All information subject to change without notice.

(Rev. June 2005)

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4-3

DDEC IV DIAGNOSTIC CODES

DDC Code #

(Flashed)

PID

SID

253

216

231

250

249

xxx

FMI

Description

EEPROM Write Error

Out of Calibration

Vehicle Speed Sensor Fault

Other ECM Fault

J1939 Data Link Fault

J1587 Data Link Fault

J1922 Data Link Fault

Torque Overload

Injector xxx Response Time Long

Aux. Output #1 Short to Battery (+) - F3

Aux. Output #1 Open Circuit - F3

Aux. Output #1 Mechanical System Not

Responding Properly - F3

Aux. Output #2 Short to Battery (+) - A2

Aux. Output #2 Open Circuit - A2

Aux. Output #2 Mechanical System Not

Responding Properly - A2

Aux. Output #5 Short to Battery (+) - W3

Aux. Output #5 Open Circuit - W3

Aux. Output #5 Mechanical System Not

Responding Properly - W3

Aux. Output #6 Short to Battery (+) - X3

Aux. Output #6 Open Circuit - X3

Aux. Output #6 Mechanical System Not

Responding Properly - X3

Aux. Output #7 Short to Battery (+) - Y3

Aux. Output #7 Open Circuit - Y3

Aux. Output #7 Mechanical System Not

Responding Properly - Y3

Aux. Output #8 Short to Battery (+) - A1

Aux. Output #8 Open Circuit - A1

Aux. Output #8 Mechanical System Not

Responding Properly - A1

PWM #1 Above Normal Range

PWM #1 Below Normal Range

PWM #1 Short to Battery (+)

PWM #1 Open Circuit

PWM #2 Above Normal Range

PWM #2 Below Normal Range

PWM #2 Short to Battery (+)

PWM #2 Open Circuit

PWM #3 Above Normal Range

PWM #3 Below Normal Range

PWM #3 Short to Battery (+)

4-4

All information subject to change without notice.

(Rev. June 2005)

7SE60 0506

SERIES 60 EGR TECHNICIAN'S MANUAL

102

108

174

354

411

412

168

121

100

106

PID

103

DDC Code #

(Flashed)

227

—

412

214

232

xxx

151

226

230

SID

FMI

Description

PWM #3 Open Circuit

PWM #4 Above Normal Range

PWM #4 Below Normal Range

PWM #4 Short to Battery (+)

PWM #4 Open Circuit

Turbo Overspeed

Turbo Speed Sensor Input Failure - Abnormal

Period

Air Inlet Pressure Sensor Input Voltage High

Air Inlet Pressure Sensor Input Voltage Low

TPS Idle Validation Circuit Fault (open circuit)

TPS Idle Validation Circuit Fault (short to ground)

Injector xxx Response Time Short

Vehicle Overspeed

Vehicle Overspeed (Absolute)

ESS Transmission Stuck in Gear

Transmission Neutral Switch Failure

(ESS Transmission)

Aux Analog Input Data Erratic, Intermittent, or

Incorrect (ESS Transmission)

Aux Analog Input #1 Voltage High (ESS

Transmission)

Aux Analog Input #1 Voltage Low (ESS

Transmission)

Optimized Idle Safety Loop Short to Ground

Oil Filter Restriction High

ECM Battery Voltage High

RTC Backup Battery Voltage High

Sensor Supply Voltage High

Engine Overspeed With Engine Brake

Engine Oil Pressure High

Turbo Boost Pressure Low

Barometric Pressure High

Barometric Pressure Low

Fuel Temperature High

Relative Humidity Above Range

Relative Humidity Below Range

Cruise Control/Adaptive Cruise Control Fault

EGR Delta pressure circuit failed high

EGR temperature circuit failed high

EGR temperature smart sensor not responding

EGR Temperature Smart Sensor not Responding

EGR Temperature Smart Sensor Failed

All information subject to change without notice.

(Rev. June 2005)

7SE60 0506

4-5

DDEC IV DIAGNOSTIC CODES

DDC Code #

(Flashed)

PID

411

412

411

412

190

108

SID

—

FMI

Description

EGR Delta pressure circuit failed low

EGR Temperture circuit failed low

Pump Pressure High

EGR Delta Pressure High

EGR Temperature High

Engine Overspeed

Engine Overspeed Signal

Pump Pressure Sensor Input Voltage High

Barometric Pressure Sensor Input Voltage High

Pump Pressure Sensor Input Voltage Low

Barometric Pressure Sensor Input Voltage Low

LOGIC CODES (MECHANICAL FAILURES)

Logic codes indicate the detection of mechanical failures by the DDEC system. The response will be a Flash Code.

Diagnosing Flash Code 39

Failure Mode

SID 146, FMI 7 — EGR Valve Not Responding

Indicates

EGR

ow requested by DDEC and no EGR

ow detected.

SID 146, FMI 7 will be set by the ECM if, the signal from the Delta P sensor and EGR temperature sensor indicate EGR fl ow is below a minimum allowable fl ow when the ECM is in

“EGR Mode” for a period greater than 50 seconds.

Response

: The CEL will be illuminated and the system will be forced into “Boost Mode” (EGR is

Disabled) for the remainder of the ignition cycle.

Possible Causes

Defective Delta P sensor

EGR valve mechanical failure (closed)

Exhaust leaking at the S Pipe

Exhaust leaking at the EGR valve

Leaking air lines from the VPOD to the actuators (insuf fi cient air supply)

Leaking or low vehicle air supply to the VPODs

Plugged Delta P ports

Plugged EGR cooler

VPOD mechanical failure

VNT vanes stuck in an open position

4-6

All information subject to change without notice.

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7SE60 0506

SERIES 60 EGR TECHNICIAN'S MANUAL

Failure Mode

SID 146, FMI 2 — EGR Leak (Boost Mode)

Indicates

No EGR

ow requested by DDEC and EGR

ow detected.

SID 146, FMI 2 will be set by the ECM if, the signal from the Delta P sensor and EGR temperature sensor indicate EGR fl ow is above a maximum allowable fl ow when the ECM is in

“Boost Mode” for a period greater than 50 seconds.

Response

: The CEL will illuminate and a fault message will be generated.

Possible Causes

Defective Delta P sensor

EGR valve mechanical failure (open)

Plugged Delta P lines

Failure Mode

SID 146, FMI 12 — EGR Leak (Boost Jake)

Indicates

No EGR

ow requested by DDEC and EGR

ow is detected while braking.

SID 146, FMI 12 will be set by the ECM if, the signal from the Delta P sensor and EGR temperature sensor indicate EGR fl ow is above a maximum allowable fl ow when the ECM is in

“Jake Mode” for a period greater than 50 seconds.

Response

: The CEL will illuminate and a fault message will be generated.

Possible Causes

Defective Delta P sensor

EGR valve mechanical failure (open)

Plugged Delta P lines

All information subject to change without notice.

(Rev. June 2005)

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4-7

DDEC IV DIAGNOSTIC CODES

Failure Mode

SID147, FMI 2 — Low or High Boost-Boost Mode/VNT Vanes Not

Responding-Boost Power

Indicates

Low boost or high boost.

SID147, FMI 2 will be set by the ECM if, the signal from the manifold pressure sensor indicates

“Actual Boost” is above “Desired Boost” OR “Actual Boost” is below “Minimum Boost” when the ECM is in “Boost Mode” for a period greater than 50 seconds.

Response

: The CEL will illuminate and a fault message will be generated.

Possible Causes

Defective VPOD

Delivery pipe leakage

Exhaust system (manifold) leakage

Leaks in charge cooler system (CAC, hoses, tubes, or clamps)

Leaking or low air supply to VPOD

Low fuel pressure

Mechanical failure, turbocharger actuator

Mechanical failure, VNT vane set

Restricted air intake including air fi lter

Failure Mode

SID 147, FMI 7 — Excessive EGR Flow-EGR Mode/VNT Vanes Not

Responding-EGR Mode

Indicates

EGR

ow requested by DDEC and excessive EGR

ow detected.

SID 147, FMI 7 will be set by the ECM if, the signal from the Delta P sensor and EGR temperature sensor indicate EGR fl ow is above a desired fl ow for a period greater than 50 seconds.

Response

: The CEL will be illuminated and the system will be forced into “Boost Mode” (EGR is

Disabled) for the remainder of the ignition cycle.

Possible Causes

Defective or leaking VPOD

Delta P sensor system measurement incorrect

Mechanical failure, EGR valve

Mechanical failure, turbocharger actuator

Mechanical failure, VNT vane set

4-8

All information subject to change without notice.

(Rev. June 2005)

7SE60 0506

SERIES 60 EGR TECHNICIAN'S MANUAL

Failure Mode

SID147, FMI 12 — Low or High Boost During Jake Operation/VNT Vanes

Not Responding-Boost Jake

Indicates

Low boost or high boost while braking.

SID147, FMI 12 will be set by the ECM if, the signal from the manifold pressure sensor indicates

“Actual Boost” is above “Desired Boost” OR “Actual Boost” is below “Minimum Boost” when the ECM is in “Jake Mode” for a period greater than 50 seconds.

Response

: The CEL will illuminate and a fault message will be generated.

Possible Causes

Defective VPOD

Exhaust leaks at “S” pipe or exhaust manifold

Leaks in charge air cooler system (CAC, hoses, tubes, or clamps)

Leaking or low air supply to VPOD

Mechanical failure, EGR valve

Mechanical failure, turbocharger actuator

Mechanical failure, turbocharger failure

Mechanical failure, VNT vane set

Restricted air intake including air fi lter

All information subject to change without notice.

(Rev. June 2005)

7SE60 0506

4-9

DDEC IV DIAGNOSTIC CODES

Failure Mode

SID 147, FMI 14 — EGR Flow Too Low

Indicates

EGR

ow requested by DDEC and insuf

cient EGR

ow detected.

SID 147, FMI 14 will be set by the ECM if, the signal from the Delta P sensor and EGR temperature sensor indicate EGR fl ow is below a desired fl ow for a period greater than 50 seconds.

Response

: The CEL will illuminate and a fault message will be generated.

Possible Causes

Defective Delta P sensor

EGR cooler restriction

EGR valve leaks

EGR valve mechanical failure

Exhaust leaking at the S pipe

Leaking air lines from the VPOD to the actuators (insuf fi cient air supply)

Leaking or low vehicle air supply to the VPODs

Plugged Delta P ports

VPOD mechanical failure

VNT vanes/actuator — mechanical failure

Diagnosing Flash Code 49

Failure Mode

FMI 0— Turbo Compressor Out Temperature High

Indicates

Turbocharger Compressor Inlet temperature or Turbocharger Compressor

Outlet temperature exceeds calibrated limits.

Response

: Red Stop Lamp (RSL) will illuminate and fault message will be generated.

Probable Causes

Restricted air fi lter

EGR valve stuck open

High exhaust back pressure

4-10

All information subject to change without notice.

(Rev. June 2005)

7SE60 0506

SERIES 60 EGR TECHNICIAN'S MANUAL

Sensor Codes

Speci fi c sensor failures and the system response are listed below:

Barometric Pressure Sensor

Failure Modes

: PID 108, FMI 3 - Voltage High and FMI 4 - Voltage Low

Response

: The CEL will be illuminated and the engine will be forced into boost mode. The turbocharger vane position will be forced open at idle to reduce turbocharger response.

Turbo Boost Pressure Sensor

Failure Modes

: PID 102, FMI 3 - Voltage High and FMI 4 - Voltage Low

Response

: The CEL will be illuminated and the system will be forced into boost mode. The turbocharger vane position will be set to a calibrated value to protect the engine and will be torque limited during this fault.

Intake Manifold Temperature Sensor

Failure Modes

: PID 105, FMI 3 - Voltage High and FMI 4 - Voltage Low

Response

: The CEL will be illuminated and the temperature will be set to a fi xed value.

Turbo Compressor Outlet Temperature Sensor

Failure Modes

: PID 404, FMI 3 - Voltage High and FMI 4 - Voltage Low

Response

: The CEL will be illuminated and the engine will be torque limited to protect the turbocharger and charge air cooler.

EGR Delta-Pressure Sensor

Failure Modes

: PID 411, FMI 3 - Voltage High and FMI 4 - Voltage Low

Response

: The CEL will be illuminated and the system will be forced into boost mode. The engine will be torque limited during this fault.

EGR Temperature Sensor

Failure Modes

: PID 412, FMI 3 - Voltage High and FMI 4 - Voltage Low

Response

: The CEL will be illuminated and the temperature will be set to a fi xed value.

Turbo Compressor Inlet Temperature Sensor

Failure Modes

: PID 351, FMI 3 - Voltage High and FMI 4 - Voltage Low

Response

: The CEL will be illuminated and the temperature will be set to a fi xed value.

Relative Humidity Sensor

Failure Modes

: PID 354, FMI 3 - Voltage High and FMI 4 - Voltage Low

Response

: The CEL will be illuminated and the sensor will be set to a fi xed value.

Coolant Temperature Sensor

Failure Modes

: PID 110, FMI 3 - Voltage High and FMI 4 - Voltage Low

Response

: The CEL will be illuminated and the temperature will be set to a fi xed value.

All information subject to change without notice.

(Rev. June 2005)

7SE60 0506

4-11

DDEC IV DIAGNOSTIC CODES

Turbo Speed Sensor

Failure Modes

: PID 103, FMI 8 - Abnormal Period

Response

: The CEL will be illuminated and the system will be forced into boost mode. The VNT vane position will be restricted so the vane will not close beyond a calibrated position. The engine will be torque limited during this fault.

Ambient Air Temperature Sensor

Failure Modes

: PID 171, FMI 3 - Voltage High and FMI 4 - Voltage Low

Response

: The CEL will be illuminated and the temperature will be set to a calibrated value.

Protection Codes

Engine Protection Codes

When these codes are logged and turn on both the check engine and stop engine lights. This alerts the operator that continued engine operation under those conditions will result in engine damage.

Coolant Temperature High

PID 110 FMI 0 indicates the coolant temperature has risen above the programmed value in the

ECM. The temperature limits are listed in Table 4-1.

Oil Pressure Low

PID 100 FMI 1 indicates that the oil pressure has dropped below a programmed value of 30 seconds. Both CEL and SEL will illuminate.

The Series 60 pressure limit parameters and listed below. See Figure 4-1.

Figure 4-1 Oil Pressure Shutdown

4-12

All information subject to change without notice.

(Rev. June 2005)

7SE60 0506

SERIES 60 EGR TECHNICIAN'S MANUAL

Coolant Level Low

PID 111 FMI 1

When the coolant level has fallen below the Coolant Level Sensor for 30 seconds, the CEL and

SEL will illuminate.

Oil Temperature High

PID 175 FMI 0 indicates that the oil temperature has risen above the programmed value in the

ECM. The CEL will illuminate at 239° F (115° C) and the SEL will illuminate at 250° F (121° C).

Listed in Table 4-1 are the vehicle performance temperature limits.

EGR Off CEL SEL Year

Coolant Temperature

2002

2004

Start Derate

214° F (101° C)

219° F (103° C)

221° F (105° C)

228° F (108° C)

223° F (106° C)

227° F 108(° C)

225° F (107° C)

229° F (109° C)

Compressor Discharge Temperatureat Sea Level

2002 453° F (223° C)

—

2004 445° F (229° C)

—

Intake Manifold Temperature

2002 201° F (93° C)

2004 203° F (95° C)

213° F (100° C)

216° F (102° C)

Oil Temperature

2002

2004

Table 4-1

239° F (115° C)

243° F (117° C)

Temperature Limits

—

554° F 290° C)

515° F (268° C)

218° F (103° C)

212° F (100° C)

239° F (115° C)

244° F (117° C)

—

250° F (121° C)

253° F (122° C)

All information subject to change without notice.

(Rev. June 2005)

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DDEC IV DIAGNOSTIC CODES

THIS PAGE INTENTIONALLY LEFT BLANK

4-14

All information subject to change without notice.

(Rev. June 2005)

7SE60 0506

SERIES 60 EGR TECHNICIAN'S MANUAL

DDEC IV TESTING

The following pages identify a logical troubleshooting fl ow for speci fi c operational concerns.

The complaints and diagnostics are based on conditions identi fi ed by the DDC Customer Support

Center at 313-592-5800. Information in this publication is accurate as of March 2004.

NOTE:

Prior to performing any DDEC IV troubleshooting or testing procedures, please ensure that the engine’s EGR system has been modi fi ed. Please refer to:

Service Information Letter 04 TS-32. For detailed information, please visit the

Detroit Diesel

Technical Service Letter Web Page

at http://192.135.85.10/cust/sletr/revised_2004.asp and browse for Technical Service Letter “04 TS-32”.

Service Information Letter 04 TS-62. For detailed information, please visit the

Detroit Diesel

Technical Service Letter Web Page

at http://192.135.85.10/cust/sletr/revised_2004.asp and browse for Technical Service Letter “04 TS-62”.

NOTE:

You may also access these TS letters after logging into the DDC Extranet by clicking on

Support, On-highway, Service Information, Service Information Letters,

2004–to-2006

Troubleshooting Task

Intermittent Black Smoke

Power Loss Under Heavy Pull

Low Boost Under Cold Ambient Conditions

Derate Codes 110 and 404 FMI 14

Flash Code 39

Exhaust Fumes

Slobbering

Engine Vibration

Engine Back fi re, Engine Mis fi re, Intermittent Exhaust Smoke

5-1

All information subject to change without notice.

(Rev. June 2005)

7SE60 0506

DDEC IV TESTING

Testing Procedures are:

Test A

Test B

Exhaust Gas Recirculation System Basic Checks

Poor performance, high exhaust temperatures, high soot levels, SID 147 codes, and black exhaust smoke checks. For detailed information, please visit the

Detroit Diesel Technical

Service Letter Web Page

at http://192.135.85.10/cust/sletr/revised_2004.asp and browse for Technical Service Letter 05 TS-01.

5-2

All information subject to change without notice.

(Rev. June 2005)

7SE60 0506

SERIES 60 EGR TECHNICIAN'S MANUAL

Intermittent Black Smoke

Perform the following steps for

Intermittent Black Smoke

1. Check for Flash Codes. If Flash Codes were logged, diagnose the logged codes fi rst.

2. Visually inspect the air fi lter for restrictions. If the air fi lter is clogged or dirty, replace the air fi lter.

3. Visually inspect the air inlet hoses for soft or collapsed areas. If the air inlet hoses are damaged, replace as necessary.

4. Visually inspect the air inlet for restrictions. If the air inlet has restrictions, clean as necessary.

5. Perform “Test A” in the “Testing Procedure” section.

6. Perform the checks in the “Exhaust Gas Recirculation System Basic Checks” section.

Refer to the “Exhaust Gas Recirculation System Basic Checks for Series 60 Engines” section of the

DDDEC III/IV Single ECM Troubleshooting Guide, (6SE497).

7. Test drive the vehicle with DDDL and perform a snapshot. Analyze the snapshot.

8. Perform “Test B” in the “Testing Procedure” section.

All information subject to change without notice.

(Rev. June 2005)

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5-3

DDEC IV TESTING

Power Loss Under Heavy Pull

With power loss under heavy pull and in extreme cold ambient conditions, the engine will operate in

Condensation Protection

. During this mode of operation, the engine

boost

will be reduced and there is no reduction of power. Operating in this mode is a normal operating condition and will not affect engine life or performance.

NOTE:

Trucks operating with winter fronts will experience this condition less often. DDC’s recommendations have not changed regarding winter front usage.

Perform the following steps for

Power Loss Under Heavy Pull

1. Check for diagnostic trouble codes. If Fault Codes are logged, diagnose the logged codes fi rst.

2. Visually inspect the air fi lter restrictions. If the air fi lter is clogged or dirty, replace the air fi lter.

3. Visually inspect the air inlet hoses for soft or collapsed areas. If the air inlet hoses are damaged, replace as necessary.

4. Visually inspect the air inlet for restrictions. If the air inlet has restrictions, clean as necessary.

5. Visually inspect the entire length of the breather tube for kinks. If the breather tube has kinks, repair as necessary.

6. Measure the fuel pressure under heavy loads.

[a] If the fuel pressure was spiking or decreasing, perform step 7.

[b] If the fuel pressure was not spiking or decreasing, testing is complete.

7. Remove the fuel pump.

[a] If the fuel pump is damaged, replace the fuel pump.

[b] If the fuel pump is not damaged, perform step 8.

8. Remove the fuel injectors and inspect for combustion passing the seat.

[a] If seats are damaged, replace as necessary.

NOTE:

The fuel injector may need to be replaced also.

[b] If the seats are not damaged, testing is complete.

5-4

All information subject to change without notice.

(Rev. June 2005)

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SERIES 60 EGR TECHNICIAN'S MANUAL

Low Boost Under Cold Ambient Conditions

In extreme cold ambient conditions, the engine will operate in

Condensation Protection

During this mode of operation, the engine

boost

will be reduced and there is no reduction of power. Operating in this mode is a normal operating condition and will not affect engine life or performance.

NOTE:

Trucks operating with winter fronts will experience this condition less often. DDC’s recommendations have not changed regarding winter front usage.

For low boost under cold ambient conditions, clear fault codes and return the engine to service

Flash Codes 14 and 29

Perform the following steps for codes indicating a derate condition, Flash Codes 14 (PID

110/FMI14 and Flash Code 29 (PID 404/FMI 14).

1. Determine if derate is typical operation (refer to Appendix D,

Service Information Letter

03 TS-23).

NOTE:

During

Typical

engine operating conditions, the engine will derate to prevent damage.

Higher ambient temperatures and loads will increase the frequency of DDEC applying this derate logic. If the derate is occurring only occasionally, this is

Typical

. If the derate occurs more than

Typical

for given operating conditions, continue investigation for possible defects.

[a] If considered

Typical

, clear Fault Codes and return the engine to service.

[b] If determined to be abnormal frequency, perform step 2.

2. Remove the water pump and inspect the pump impeller.

[a] If the impeller is damaged, replace the water pump.

[b] If the impeller is not damaged, reuse the water pump and replace the EGR cooler.

Flash Code 39

Perform the following steps for Flash Code 39 (SID 146/FMI 2, 7 or 12).

1. Perform the checks in the “Exhaust Gas Recirculation System Basic Checks” section.

2. Perform Test A in the “Testing Procedures” section.

3. Test drive the vehicle with DDDL and perform a snapshot. Analyze the snapshot.

4. Inspect the VPOD air supply for leaks. If the VPOD air supply has leaks, repair the leak.

5. Perform Test B in the “Testing Procedures” section.

All information subject to change without notice.

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5-5

DDEC IV TESTING

Exhaust Fumes

Perform the following steps for

Exhaust Fumes

1. Visually inspect the exhaust system for leaks (e.g. exhaust manifold, S-pipe, and turbocharger).

[a] If exhaust leaks were detected, repair as necessary.

[b] If no exhaust leaks were detected, perform step 2.

2. Tighten all S-pipe clamps to the proper torque speci fi cation.

3. Reprogram the ECM.

Slobbering

Perform the following steps for

Slobbering

1. Visually inspect the entire length of the breather tube for kinks.

[a] If the breather tube is damaged, repair as necessary.

[b] If the breather tube is not damaged, perform step 2.

2. Perform a DDC Extraction of DDEC Reports.

NOTE:

Review extraction for excessive idle time. Times of 35% and higher are considered excessive.

3. Drain the engine lubrication oil pan.

4. Re fi ll the lubrication oil pan with 32 quarts of approved engine oil and visually inspect the oil dipstick marking.

[a] If the oil dipstick marking is incorrect, replace the dipstick with a proper dipstick.

[b] If the oil dipstick marking was correct, testing is complete.

Engine Vibration

Perform the following steps for

Engine Vibration

1. Using a 0.060 in. feeler gage, measure the clearance between the bottom of the steel engine mount and the rubber biscuit at the rear engine chassis mounts.

[a] If the engine mount clearance is less than 0.060 in., replace the mount.

[b] If the engine mount clearance is greater than 0.060 in., testing is complete.

Engine Back

re, Engine Mis

re, Intermittent Exhaust Smoke

For engine back fi re, engine mis fi re, and intermittent exhaust smoke reprogram the ECM.

5-6

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SERIES 60 EGR TECHNICIAN'S MANUAL

TESTING PROCEDURES

NOTE:

If further repair, removal, and DDDL procedures are required when performing the testing procedures, please refer to the

Series 60 Service Manual, (6SE483)

or contact the EDS

Support Line for DDDL speci fi c questions.

Test A

Perform Test A as follows.

1. Remove the turbocharger to charge-air-cooler (CAC) pipe.

PRESSURIZED CHARGE COOLER SYSTEM

To avoid eye or face injury from fl ying debris, wear a face shield or goggles.

2. Pressurize the CAC inlet to 30 psi using special tool TLZ00100 or equivalent.

3. Monitor the boost psi using DDDL.

[a] If the pressure is below 27 psi, visually inspect the CAC, hoses, and the delivery tube for leaks.

[b] If the pressure is at 27 psi or higher, continue to step 4.

4. Activate EGR VPOD (PWM #2) to 90% using the DDDL.

5. Monitor the boost psi pressure for pressure drops when the EGR valve opens.

NOTE:

The pressure should have dropped signi fi cantly to approximately 9 psi.

[a] If the air pressure dropped to 9 psi, no further testing is required and Test A has been completed.

[b] If the pressure only dropped slightly, perform step 6 through step 8.

6. Physically inspect the EGR valve for a mechanical failure. If the EGR valve is not functioning correctly, replace the EGR valve.

7. Visually inspect the EGR cooler for restrictions. If the EGR cooler is restricted, replace the EGR cooler.

8. Visually check the delivery pipe for restrictions. Clean the pipe as necessary to remove restrictions.

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DDEC IV TESTING

Test B

Perform Test B as follows.

PERSONAL INJURY

Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.

Ƒ Always start and operate an engine in a well ventilated area.

Ƒ If operating an engine in an enclosed area, vent the exhaust to the outside.

Do not modify or tamper with the exhaust system or emission control system.

1. Run the engine on a dynamometer to get the engine hot. If a dynamometer is not available, run the engine until hot (>170° F [76° C] coolant temperature).

2. Activate the VPOD outputs to 90% and then back it down to 7% using the DDDL.

Visually inspect the VNT and EGR valve for proper rod travel (full travel to stops).

[a] If the VNT is not functioning properly, verify VNT vanes are moving freely. For detailed information, please visit the

Detroit Diesel Technical Service Letter Web

Page

at http://192.135.85.10/cust/sletr/revised_2004.asp and browse for Technical

Service Letter “04 TS-16”.

[b] If the EGR valve is not functioning properly, replace the EGR valve.

[c] If both the VNT and EGR valve have proper movement the test is complete.

NOTE:

Repeat this step three times.

5-8

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SERIES 60 EGR TECHNICIAN'S MANUAL

Exhaust Gas Recirculation System Basic Checks

Perform the following basic steps to check the exhaust gas recirculating system.

For all EGR related concerns (may include exhaust smoke complaints), perform the following steps. If any corrections are made as a result of these checks, test the unit again before proceeding further:

Basic checks for all Series 60 EGR engines require the following tools:

1,000 Ohm resistor (low watt)

DDR suite 8 or DDDL version 4.2 or higher

Volt Ohm Meter

Pressure gage 0-200 psi

Pressure gage 0-100 psi

Check Delta P Sensor and Barometric Sensor

Follow these steps to check the Delta P sensor:

1. Turn ignition ON.

2. Plug in DDDL or a DDR.

3. Read Delta P counts (EGR DPS)

[a] If Delta P counts read 86-135, verify that the EGR pipes and hoses are correctly assembled from the EGR tube to the Delta P sensor. Reversed hoses or pipes will create black smoke and surging. Go to step 3[b].

[b] Also inspect carefully for split or leaking pipes or hoses in the EGR mixer tube from the EGR cooler to the intake manifold. If hoses and pipes are correct, perform. check

VPOD output pressure (refer to the next section).

[c] If counts do not fall within the 86-135 range, replace Delta P sensor; then go to the

“Veri fi cation” section.

4. Measure and record barometric sensor pressure and compare recorded value to the intake pressure sensor value.

[a] If the sensor readings differ more than 4.14 kPa (0.6 psi), replace the barometric sensor.

[b] If the sensor readings do not differ more than 4.14 kPa (0.6 psi), task is complete.

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DDEC IV TESTING

Check VPOD Output Pressure

Follow these steps to check the VPOD input and output pressure:

NOTE:

Listen for air leaks at the VPOD during the test.

PERSONAL INJURY

To avoid injury from the sudden release of a high-pressure hose connection, wear a face shield or goggles.

1. Disconnect the air hoses from the EGR and VNT (Variable Nozzle Turbine) actuators.

2. Install pressure gauges (accurate to within 1.4 kPa [0.2 psi]) at the outlet of the EGR and

VNT hoses. (Use two gauges, or test separately.)

3. Using the DDDL/DDR, activate PWM #2 (EGR) and PWM #4 (VNT) duty cycles and monitor the output pressure from the VPOD.

4. Test: activating 11% duty cycle: Pressure = 106-134 kPa (15.4-19.4 psi). Go to steps

5[a] and 5[b].

5-10

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SERIES 60 EGR TECHNICIAN'S MANUAL

5. Test: activating 90% duty cycle: Pressure = 485 - 515 kPa (70-75 psi).

[a] If the VPOD readings are as listed, check for active codes. Refer to the “Check for

Active Codes” section.

[b] If the results in this step cannot be attained, check VPOD input pressure. Refer to the

“Check VPOD Input Pressure” section.

NOTE:

Both activations must operate their component with full travel of the linkage to hit the stops.

Check Variable Output Pressure Device Input Pressure

Testing steps are as follows.

1. Measure the VPOD input pressure to port 1; ensure it is between 703-1296 kPa (90 –

120 psi).

[a] If the supply pressure is greater than 703-1296 kPa (90-120 psi), troubleshoot the vehicle air system until that result is obtained.

[b] If the supply pressure is greater than 703-1296 kPa (90-120 psi), check the VPOD part number (P/N) and supply voltage. Refer to the “Check Variable Output Pressure

Device Part Number and Supply Voltage” section.

2. Perform a Check Variable Output Pressure Device Part Number and Supply Voltage .

Check Variable Output Pressure Device Part Number and Supply Voltage

The following checks should be performed for the VPOD part number and supply voltage:

1. Check the VPOD label to determine if it is +12V or +24V compatible.

2. Unplug VPOD's mating connector. A 1,000 Ohm resistor is needed for the next step. Insert the resistor between cavity 1 and 3 for ease of checking with the volt ohm meter (VOM)

[a] Turn ignition switch ON.

[b] Measure voltage from pin 3 to pin 1.

[c] Plug in either DDDL or DDR and check ECM voltage.

3. Is the VPOD P/N and voltage, and ECM voltage correct?

[a] If the VPOD P/N and voltage are correct, check VPOD wiring. Refer to the “Check

VPOD Wiring” section.

[b] If the VPOD P/N and voltage are not correct, contact the DDC Customer Support

Center at 313-592-5800.

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5-11

DDEC IV TESTING

Check VPOD Wiring

The following checks should be performed for the VPOD wiring.

NOTE:

VPOD power should have been veri fi ed under the part number check. If not, refer to the

“Check Variable Output Pressure Device part number and Supply Voltage” section.

1. Turn ignition switch ON.

2. Unplug the VPOD mating connector.

3. Insert a 1,000 ohm resistor between cavities #2 and #1 for the +12V version, or cavities

#2 and #3 for the +24V version.

4. Connect a VOM to the VPOD connector between pin #2 and pin #3 for the 12V VPOD or pin #2 and pin #1 for the 24V VPOD.

5. Using DDDL or a DDR, activate the PWM #2 (EGR Valve) and PWM #4 (VNT), and ensure:

[a] Activating 11% duty cycle: VDC = 90% of the VPOD supply voltage ± 1 volt (e.g., voltage to VPOD = 13.8V * 0.9 = 12.42V; therefore 11.42V to 13.42V at PWM is acceptable).

[b] Activating 90% duty cycle: VDC = 10% of the VPOD supply voltage ± 1 volt.

(e.g., voltage to VPOD = 13.8V * 0.1 = 1.38V, therefore 0.38V to 2.38V at PWM is acceptable.)

6. Note any air leakage when PWMs are activated to 90% and correct the leaks as needed.

[a] If both of the PWM voltage measurements are correct, replace the VPOD that had the wrong pressure reading.

[b] If the PWM voltage measurements are incorrect, and the wiring checks are okay, try a test ECM programmed for EGR, or contact the DDC Customer Support Center at 313-592-5800.

5-12

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SERIES 60 EGR TECHNICIAN'S MANUAL

Check for Active Codes

Check for active codes as follows:

1. Turn ignition ON.

2. Plug in DDDL or a DDR.

3. Read active codes.

4. Record or print codes. Ensure that PID, SID, and FMI are recorded. Refer to the proper code section of the

DDEC III/IV Single ECM Troubleshooting Guide

, (6SE497) to troubleshoot that code.

NOTE:

FMIs listed as 14 are diagnostic information codes and no troubleshooting is required.

For example, an engine derates due to high TCO temperature; a 404/14 code will be stored. This would indicate that conditions warranted having the ECM derate the fueling to the engine. If the customer complaint was a power loss, it could be explained that loss of power was done by the ECM to protect other engine components.

5. If the issue is not related to the EGR system components, or if assistance is needed, contact

Detroit Diesel Customer Support Center at 313-592-5800.

Veri

cation

Follow these steps to test:

1. Reassemble connectors or components.

2. Start and run the engine.

3. Perform a road test if this is necessary to duplicate original complaint.

[a] If symptoms/codes are gone, repairs are complete.

[b] If any codes display, review this section again; contact Detroit Diesel Customer

Support Center at 313-592-5800.

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5-13

DDEC IV TESTING

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5-14

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DDDL/SNAPSHOTS

WORKING WITH DDDL SNAPSHOTS

Creating A Snapshot

SERIES 60 EGR TECHNICIAN'S MANUAL

1. Use the proper steps to open DDDL and connect to the engine.

2. Go to the

Snapshot

drop-down menu and select the

New

option by clicking once with the left mouse button.

3. Upon choosing the

New

option a

Record Snapshot

box will appear in the upper left section of your screen.

4. The

Record Time

will be counting from the second you clicked on the

New

option.

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6-1

DDDL/SNAPSHOTS

5. Some important facts to remember about this feature:

All parameters broadcast by DDEC IV are recorded.

Any codes that occur during the snapshot are automatically marked.

There is no practical time limit for the snapshot, you just need enough room on your hard drive to save the fi le.

To mark an event other than a code, click once with the left mouse button on the

Mark User Event SPACE

box.

To insert additional comments about the snapshot click once with the left mouse button on the

Annotate

selection (version 4.1 or later).

6. When you have completed recording the data you wish to save, click once with the left mouse button on the

Stop Recording ESC box

6-2

7. Immediately upon selecting the

Stop Recording ESC

option a dialog box will appear asking if you wish to save your changes. If you want to save the recorded data to your hard drive, click once with the left mouse button on the

Yes

option. To discard the data recorded by the snapshot click on the

option.

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SERIES 60 EGR TECHNICIAN'S MANUAL

8. If you choose the

Yes

option the

Save As

dialog box will appear on your screen. A suggested fi le name will appear outlined in blue in the

File Name

box.

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6-3

DDDL/SNAPSHOTS

9. If you want to accept the suggested name for the fi le click once with the left mouse button on the

Save

option box. You may replace the suggested name by hitting the space bar once to clear the line. Type in the new fi le name before saving the fi le. You may also change the location of where the fi le is saved on your PC by changing the location designated in the

Save In

box. You may save the fi le to your

drive for example. Once the fi le has been saved the process is complete.

USING SNAPSHOT REPLAY CONTROLS

1. To replay a snapshot, go to the

Snapshot

drop-down menu and select

Open

. You should not be connected to a vehicle when replaying a snapshot.

2. A dialog box will appear listing all the available snapshot fi les.

6-4

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SERIES 60 EGR TECHNICIAN'S MANUAL

NOTE:

The default folder that snapshot fi les are saved in is C:\Detroit Diesel\Diagnostic and have a fi le extension of .ddl.

3. Highlight the fi le you wish to open with one click of the left mouse button. The selected fi le name will now appear in the

File Name

box.

4. Click once with the left mouse button on the

Open

box in the lower right of the dialog box.

5. When you have opened a snapshot, replay controls will appear at the bottom of the DDDL window you opened.

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6-5

DDDL/SNAPSHOTS

6. Start the replay of a snapshot by clicking on

Play

. The play button changes to

Pause

when a snapshot is replaying. While the snapshot is replaying, the replay slider next to the

Play/Pause button moves showing the progress of the replay, and the time box next to it shows the time since the beginning of the recording. When you click on

Play

the snapshot begins to play from its current position and the instruments show the appropriate readings.

The event window also changes during the replay to show the most recent event.

7. Stop the replay at a particular point of interest by clicking on

Pause

. The instruments will show the values at the time the replay was stopped.

8. Move to a speci fi c time in the replay by dragging the replay slider button. As you drag the slider, the time shown in the time box changes to re fl ect the position of the slider.

6-6

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SERIES 60 EGR TECHNICIAN'S MANUAL

NOTE:

Not all DDDL windows can be activated when replaying the snapshot feature. You cannot access the injector response time window or the cylinder cutout window in snapshot mode. Samples of windows that may be activated include:

Normal Instrumentation Window

Diagnostic Instrumentation Window

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6-7

DDDL/SNAPSHOTS

Graph Window

User Window

6-8

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Fault Codes Window

SERIES 60 EGR TECHNICIAN'S MANUAL

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6-9

DDDL/SNAPSHOTS

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6-10

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SERIES 60 EGR TECHNICIAN'S MANUAL

SNAPSHOT EXAMPLES

The following snapshots are intended to show you how to “interpret” the information recorded.

Use the examples to try to determine what area contains the fault.

Due to the variety of operating conditions that affect actual EGR fl ow and Turbo boost or speed readings, the following examples

SHOULD NOT

be used as a good vs. bad criteria.

Each snapshot that follows was controlled during running on a chassis dynamometer.

Some

failures

were induced to display the logic used to determine what is wrong with a particular area of the engine.

Idle operation with EGR. See Figure 7-1.

Cold Idle operation without EGR fl ow. See Figure 7-2.

Throttling without load, EGR is on and off. See Figure 7-3.

1500 rpm throttling no EGR. See Figure 7-4.

EGR Valve stuck open. See Figure 7-5.

147 14, EGR Flow too Low. See Figure 7-6.

146 2 EGR leak – boost. See Figure 7-7.

Leaking Charge Air Cooler. See Figure 7-8.

Delta P port plugged (graph). See Figure 7-9.

Normal Acceleration – Automatic Transmission. See Figure 7-10.

Typical EGR fl ow loaded. See Figure 7-11.

Normal Operation EGR off, Colder ambient. See Figure 7-12.

Plugged Delta P port (EGR tab). See Figure 7-13.

Normal Engine Operation as Viewed With DDDL Snapshots

It is important to understand what

Normal

looks like During normal engine operation, all parameters should have smooth transitions.

Review the snapshots in this section for examples of normal engine operation.

7-1

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SNAPSHOT EXAMPLES

EGR Flow at Idle

Detroit Diesel EGR Engines will fl ow EGR @ idle, as certain conditions are met. MY-2002 EGR engines will fl ow EGR for a short duration if DDEC determines a quick rise (snap-acceleration) in engine rpm’s over time. Engine parameters programmed determine the duration of EGR fl ow.

There is a time duration difference between MY-2002/03 - 2004.

Delta P Sensor and Piping

The Delta P sensor monitors the pressure differential across the venturi by readings from the two openings in the delivery pipe.

High Delta P with NO Flow Demand (PWM2 % = 7)

If the EGR valve is closed (7%) and the EGR temperature is between inlet manifold and engine temperature there should be little to no actual EGR fl ow. If the Delta P sensor is registering a high differential pressure in this condition:

Check for the pressure signal pipe of hose to one side of the sensor is plugged or leaking

(includes sensor mounting o rings).

The sensor being defective is the least likely.

Incorrectly wired (replacement sensor).

Low Delta P with Flow Demand (PWM2 % greater than 7 and less than 90)

If the EGR valve is open and the EGR temperature is elevated there should EGR fl ow.

If the Delta P sensor is registering a low differential pressure in this condition: it is likely that the pressure signal to both sides of the sensor are plugged or leaking Lastly, a defective sensor.

Stuck or Sticking VNT or EGR Valve Actuator

When the actuator is sticking, DDEC can’t control turbocharger speed or EGR fl ow smoothly.

Turbocharger speed and PWM 4- VNT % will fl uctuate greatly. If the EGR actuator is sticking you are able to see EGR fl ow with the PWM2 % staying at 7% (which is closed). The engine's temperature can be a factor in this operation.

DDEC is attempting to control turbocharger speed and is overcompensating with PWM4 in an attempt to control turbocharger speed.

7-2

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SERIES 60 EGR TECHNICIAN'S MANUAL

Turbocharger Speed Sensor Faults

Turbocharger speeds rarely exceed 100,000 rpm for any length of time. Speeds exceeding

100krpm and dropping rapidly is a warning sign. 30krpm changes in speed at 1 second intervals is almost impossible. Consider a false signal being sent to the ECM rather than this event actually occurring. The ECM is responding to the signals it is receiving from sensors.

Monitor the turbocharger speed and the engine boost, watch for normal, expected changes. Note in one of the next snap shot samples that the turbocharger speed reaches 108,000 rpm and boost is only 7.1psi. Turbo Speed Sensors (pn 23530252) that have a date code stamped on the sensor connector between 0703 to 3703 should be changed fi rst if suspect then contact DDC Customer

Support Center at 313-592-5800 for further assistance.

NOTE:

Remember that if a sensor fails and sends a signal to the ECM that is within a normal threshold for that sensor. No code will be generated however DDEC could try to respond to the false signal.

VPOD

The Variable Pressure Or fi ce (or Output) Device is used to control the pressure to the actuators used for the EGR valve and turbocharger vane position. The most common failure is external leakage of air. You can hear the leak when you activate the PWM for each VPOD.

Relative Humidity/Turbo Compressor Inlet Temperature Sensor

This sensor is a DDC part installed and wired by the OEM. Most faults here have been due to incorrectly wired 10 pin connector. The ECM will usually log a fault code for one or the other side this combination sensor.

Turbo Compressor Outlet Temperature

During heavy loaded operation the outlet of the turbo to the charge air cooler becomes very hot.

Logic built into DDEC allows for derating of torque to reduce these temperatures to prevent charge air cooler failures. The derate code ( fl ash code 49) of 404 14 logs without turning on the check engine light. This inactive code is stored to allow technicians the ability to assure the driver there is not any fault of failure and this operation is normal to the EGR system.

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7-3

SNAPSHOT EXAMPLES

EGR Flow Troubleshooting Tips

7-4

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Examples

SERIES 60 EGR TECHNICIAN'S MANUAL

Figure 7-1 Engine at Idle with EGR Flowing

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7-5

SNAPSHOT EXAMPLES

Figure 7-2 Idle — Cold Engine — No EGR Demand — No EGR Flow

7-6

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SERIES 60 EGR TECHNICIAN'S MANUAL

Figure 7-3 Throttling Without Load — EGR is On and Of

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7-7

SNAPSHOT EXAMPLES

Figure 7-4 1500 — No Load — EGR Off

7-8

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SERIES 60 EGR TECHNICIAN'S MANUAL

Figure 7-5 Start Up — EGR Valve Stuck Open

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7-9

SNAPSHOT EXAMPLES

Figure 7-6 Code 147 14 — EGR Flow Too Low

7-10

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SERIES 60 EGR TECHNICIAN'S MANUAL

Figure 7-7 146 2 EGR Leak — Boost Power

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7-11

SNAPSHOT EXAMPLES

Figure 7-8 Leaking Charge Air Cooler

7-12

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SERIES 60 EGR TECHNICIAN'S MANUAL

Figure 7-9 One of the Delta P Ports Plugged in the Delivery Pipe

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7-13

SNAPSHOT EXAMPLES

Figure 7-10 Normal Operation — Eaton Autoshift Transmission

7-14

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SERIES 60 EGR TECHNICIAN'S MANUAL

Figure 7-11 Normal EGR Flow with Request

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7-15

SNAPSHOT EXAMPLES

Figure 7-12 Normal — EGR Off

7-16

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SERIES 60 EGR TECHNICIAN'S MANUAL

Figure 7-13 Plugged Delta P Port

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7-17

SNAPSHOT EXAMPLES

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7-18

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SERIES 60 EGR TECHNICIAN'S MANUAL

DDEC V COMPONENTS

There have been numerous enhancements, component redesigns, and EGR system modi fi cations implemented to the 2004 Series 60 engine release. The following list highlights some of those improvements.

An enhanced DDEC V ECU

EGR Valve Hydraulic Actuator

Three Bolt Flange on Tube and Shell EGR Cooler

Improved Exhaust Manifold Sealing (Fey Rings)

Exhaust Gas Delivery Pipe

Flexible Bellow connecting the Upper Hot Pipe to the EGR Valve

Single VPOD

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8-1

DDEC V COMPONENTS

OVERVIEW OF THE DDEC V EGR SYSTEM

The following subsections graphically illustrate the DDEC V EGR system.

EGR System

Figure 8-1 graphically illustrates how the EGR components function to accomplish reduced

NOx emissions.

Figure 8-1 EGR Component Overview

8-2

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SERIES 60 EGR TECHNICIAN'S MANUAL

There is one Variable Pressure Output Device (VPOD) which regulates the Variable Nozzle Turbo

(VNT). Input values from the ECU regulates the VPOD air pressure which allows the VNT vanes to change position during engine operation. The VPOD also interfaces with other engine system components as illustrated in Figure 8-2.

Figure 8-2 EGR Valve and VNT Control System

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8-3

DDEC V COMPONENTS

Detailed Views of the DDEC V EGR Components

See Figure 8-3 for a right side engine view.

1. Turbocharger Oil Feed Line 5. Venturi to Delta P Sensor Line

2. Variable Nozzle Turbocharger

(VNT)

3. Venturi to Delta P Sensor Line

4. Delta P Sensor

Figure 8-3

6. High Flow Water Pump

7. Tube and Shell EGR Cooler

8. VNT Actuator

Right Side Component Engine View

9. VPOD Air Out to Turbocharger

Actuator

10. Variable Pressure Output

Device (VPOD)

8-4

All information subject to change without notice.

(Rev. June 2005)

7SE60 0506

See Figure 8-4 for a left side engine view.

SERIES 60 EGR TECHNICIAN'S MANUAL

1. Camshaft Gear Cover

2. EGR Delivery Pipe

Figure 8-4

3. Intake Air Temperature Sensor

(IAT Sensor)

4. Intake Manifold Pressure Sensor

(IMP Sensor)

5. Barometric Pressure Sensor

(Baro)

6. Charge Air Mixer

Left Side Component Engine View

All information subject to change without notice.

(Rev. June 2005)

7SE60 0506

8-5

DDEC V COMPONENTS

See Figure 8-5 for a detailed front right side engine view.

1. Exhaust Manifold with Fey Seals 5. EGR Delivery Pipe

2. Variable Nozzle Turbocharger

(VNT)

6. Venturi Tube

7. EGR Tube and Shell Cooler 3. Turbocharger Speed Sensor

(TSS)

4. Delta P Sensor

Figure 8-5 Front Right Side Component Engine View

8. VNT Actuator

9. EGR Valve Control Oil Supply

Line

10. VPOD-to-VNT Actuator Air Line

8-6

All information subject to change without notice.

(Rev. June 2005)

7SE60 0506

SERIES 60 EGR TECHNICIAN'S MANUAL

See Figure 8-6 for the lower rear right side engine components.

1. Barometric Pressure Sensor

2. Check Valve and Regulator Fitting for Return Fuel

3. Breather Tube

Figure 8-6

4. Engine Oil Pressure Sensor

5. Injector Harness Connector

Lower Rear Left Side Engine Components

All information subject to change without notice.

(Rev. June 2005)

7SE60 0506

8-7

DDEC V COMPONENTS

See Figure 8-7 a detailed view of the Delta P Sensor.

1.Thermostat Housing

Figure 8-7 Delta P Sensor Location

2. Delta P Sensor

8-8

All information subject to change without notice.

(Rev. June 2005)

7SE60 0506

SERIES 60 EGR TECHNICIAN'S MANUAL

See Figure 8-8 for a detailed view of the VNT, EGR valve, and related components location.

1. EGR Control Valve Oil Supply Line

2. VNT Actuator Air Line

3. VNT Actuator

Figure 8-8

4. Delta P Sensor Lines

5. EGR Valve

6. EGR Valve Hydraulic Actuator

VNT and Related Components Location

All information subject to change without notice.

(Rev. June 2005)

7SE60 0506

8-9

DDEC V COMPONENTS

See Figure 8-9 for a detailed view of the VNT and related components.

1. Turbocharger Speed Sensor (TSS) 3. Turbocharger Compressor Outlet Temperature

Sensor (TCOT)

4. Variable Nozzle Turbocharger (VNT) 2. Turbocharger Oil Inlet Line

Figure 8-9 VNT and Related Components

8-10

All information subject to change without notice.

(Rev. June 2005)

7SE60 0506

SERIES 60 EGR TECHNICIAN'S MANUAL

See Figure 8-10 for an exploded view of the Fey ring exhaust manifold.

1. Fey Ring Grooves with Fey Rings

2. EGR Valve to Bellow Connector

Figure 8-10 Fey Ring Exhaust Manifold

3. Exhaust Manifold Assembly

All information subject to change without notice.

(Rev. June 2005)

7SE60 0506

8-11

DDEC V COMPONENTS

DDEC V Electronic Control Unit

Figure 8-11 illustrates the location of the DDEC V ECU.

1. Fuel Pump 2. Fuel Pump Outlet Line 3. DDEC V ECU

Figure 8-11 DDEC V ECU

EGR Valve and Related Components

The EGR valve position is controlled by DDEC. The ECU 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 gas will fl ow from the exhaust manifold or through the turbine wheel in the turbocharger, and out the exhaust system.

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

8-12

All information subject to change without notice.

(Rev. June 2005)

7SE60 0506

Top Right Side View of EGR Components

See Figure 8-12 for a detailed view of the EGR components.

SERIES 60 EGR TECHNICIAN'S MANUAL

1. Exhaust Manifold

2. Bellows

3. EGR Control Valve Body

Figure 8-12

4. EGR Control Valve Hydraulic

Actuator

5. EGR Control Valve Oil Return

Connector

6. EGR Control Valve Oil Supply

Line

Top Right Side View of EGR Components

7. Exhaust Manifold Center

Housing to Bellow Pipe

All information subject to change without notice.

(Rev. June 2005)

7SE60 0506

8-13

DDEC V COMPONENTS

See Figure 8-13 for a detailed right side view of the EGR components.

1. EGR Control Valve Hydraulic Actuator

Figure 8-13

2. Delivery Pipe Connection

Front Right Side View of EGR Components

8-14

All information subject to change without notice.

(Rev. June 2005)

7SE60 0506

SERIES 60 EGR TECHNICIAN'S MANUAL

See Figure 8-14 for a detailed view of the EGR cooler and related components.

1. Bolt on EGR Valve

2. Venturi Tube

3. High Volume Water Pump

Figure 8-14

4. Tube and Shell EGR Cooler

5. EGR Control Valve Oil Return Line

EGR Cooler and Related Components

All information subject to change without notice.

(Rev. June 2005)

7SE60 0506

8-15

DDEC V COMPONENTS

See Figure 8-15 for a view of the EGR valve.

1. EGR Valve Assembly

2. EGR Control Valve Oil Feed Connection

Figure 8-15 EGR Valve

3. EGR Control Valve Oil Return Line Connection

4. EGR Control Valve Hydraulic Actuator

FUNCTIONALITY OF EGR COMPONENTS

The following subsections detail the functions of speci fi c EGR components.

DDEC V Electronic Control Unit

The Electronic Control Unit (ECU) provides overall engine management, self-diagnostic checks, and monitors other system components. System diagnostic checks are made at ignition-on and continue throughout all engine-operating modes.

A DDEC equipped engine is built with an electronically controlled fuel injection system which eliminates control racks or mechanical linkages requiring periodic adjust. Fuel economy and vehicle performance are also improved during cold starting and the increased initial idle speed allows for fast engine warm-up.

Horsepower, torque, idle, and engine speed are managed by the ECU. Such functionality eliminates the need for a mechanical governor. Mechanical governors are equipped with springs that require adjustments for idle and high-speed control.

The Accelerator Pedal Assembly (AP) eliminates the need for any throttle linkage eliminating throttle delay.

8-16

All information subject to change without notice.

(Rev. June 2005)

7SE60 0506

SERIES 60 EGR TECHNICIAN'S MANUAL

The DDEC V ECU has two 68-pin Tyco connectors; one for the engine and the other for the vehicle. There are two data links on the Vehicle Interface Harness (VIH). One link is based on SAE J1708 and the second is SAE J1939. The engine harness, is Controller Area Network

(CAN) based and will be used for proprietary communications such as multi-ECU applications and DDC factory programming. See Figure B-3 for the Engine Harness and see Figure B-4 for the Vehicle Interface Harness.

Turbocharger Compressor Inlet Temperature Sensor

The Turbocharger Compressor Inlet Temperature Sensor (TCI) sensor is installed by the OEM within piping between the air fi lter and the turbocharger inlet. The TCI sensor along with other

DDEC sensors are monitored by the ECU as a means of fuel management during normal operation.

The TCI sensor is supplied a 5-volt signal from the ECU and returns a voltage signal to the ECU relative to turbocharger compressor air inlet temperature. As return voltage decreases the air inlet temperature voltage increases. The TCI operating values during normal engine operation are 0.10-5.0 V.

All information subject to change without notice.

(Rev. June 2005)

7SE60 0506

8-17

DDEC V COMPONENTS

Venturi Tube

The venturi tube with a port at each end is located in the EGR delivery pipe which is connected to the EGR cooler outlet. The Venturi tube ports are connected to the Delta P Sensor to monitor the pressure differential across the venturi as EGR exhaust gases fl ow through the EGR delivery pipe to the charge air mixer. DDEC V uses this information along with temperature and density of the exhaust gases to determine precise EGR Mass Flow Rate.

Figure 8-16 Venturi Tube

8-18

All information subject to change without notice.

(Rev. June 2005)

7SE60 0506

SERIES 60 EGR TECHNICIAN'S MANUAL

EGR Cooler

The primary purpose of the EGR cooler, see Figure 8-17, is to cool the engine exhaust gases prior to entering the intake manifold. Exhaust gas cooling is accomplished by the fl ow of exhaust gases through the EGR cooler tubes. The EGR cooler core then transfers the heat removed from the exhaust gases to the engine coolant. The cooled exhaust gases are then mixed with incoming air from the charge air cooler before being sent to the intake manifold.

Figure 8-17 EGR Cooler

All information subject to change without notice.

(Rev. June 2005)

7SE60 0506

8-19

DDEC V COMPONENTS

Charge Air Mixer

The charge air mixer, see Figure 8-18, combines exhaust gases into the fresh air supply fl owing from the charge air cooler. Once the air has passed the charge air mixer, the intake manifold diffuses the EGR exhaust gases evenly to each cylinder. DDEC sensors are mounted in the intake manifold to monitor the air temperature and boost pressure.

Figure 8-18 Charge Air Mixer

Charge Air Cooler

The Charge Air Cooler (CAC), see Figure 8-19, is mounted in front of the cooling system radiator and is connected to the turbocharger and intake manifold which permits a more dense charge of air to be delivered to the engine. The compressed air leaving the turbocharger is directed through the CAC before it fl ows into the CAC to be mixed with EGR exhaust gases before entering the intake manifold. Cooling is accomplished by incoming air fl owing past the tubes and fi ns of the

CAC. The compressed intake charge air fl owing through the CAC core transfers the heat to the tubes and fi ns where it is dissipated to the outside air.

8-20

All information subject to change without notice.

(Rev. June 2005)

7SE60 0506

SERIES 60 EGR TECHNICIAN'S MANUAL

Figure 8-19 Charge Air Cooler

Variable Nozzle Turbocharger

Variable nozzle turbocharger (VNT), see Figure 8-20, uses an actuator to regulate and control turbine vanes. There is no wastegate with this system. The VNT actuator is mounted on a bracket attached to the turbocharger and receives air pressure from engine-mounted VPOD. The VNT actuator connects via a rod to the pin joint of the turbine external arm. Rotation of the external arm simultaneously rotates several pivoting nozzle vanes positioned inside the turbine housing at the outer periphery of the turbine wheel. This adjusts turbocharger speed, boost and EGR fl ow in accordance with DDEC engine management control.

NOTE:

VNT actuator is spring loaded. If air pressure is lost the actuator will open the VNT vanes resulting in low/no boost.

All information subject to change without notice.

(Rev. June 2005)

7SE60 0506

8-21

DDEC V COMPONENTS

Figure 8-20 VNT Actuator

8-22

All information subject to change without notice.

(Rev. June 2005)

7SE60 0506

SERIES 60 EGR TECHNICIAN'S MANUAL

Variable Pressure Output Device

There is one VPOD which controls the VNT. See Figure 8-21. The location of the VPOD is application dependent.

Two system components are required for proper operation of the EGR valve and the VNT control system.

12V or 24V Power Supply

DDEC V ECU: PWM#3 (E1) EGR and PWM#4 (E4) VNT

NOTE:

VNT is fully open at 7% and closed at 90%

Figure 8-21 EGR Valve and VNT Control System

All information subject to change without notice.

(Rev. June 2005)

7SE60 0506

8-23

DDEC V COMPONENTS

Hydraulically Actuated EGR Valve

The EGR valve is hydraulically actuated using engine oil and eliminates the need for an EGR

VPOD. The butter fl y valve design is still used to control the exhaust gas fl ow through the

EGR cooler. The ECU continuously monitors all engine operation modes and performs self diagnostic checks for engine RPM, engine load, altitude, incoming air temperature, and uses this information to determine the EGR valve position. The ECU changes the EGR valve position via a

PWM to the solenoid in the actuator. See Figure 8-22.

NOTE:

When installing a new hydraulic actuator or EGR valve, manually closing the valve during installation will make the fi rst start up easier. Once the engine has started and oil pressure through the actuator has equalized, operation will be normal.

The EGR valve operating values are 0-12 V or 0-24 V depending on vehicle electrical system.

Figure 8-22 Hydraulic Actuator with Solenoid

8-24

All information subject to change without notice.

(Rev. June 2005)

7SE60 0506

SERIES 60 EGR TECHNICIAN'S MANUAL

EGR Temperature Sensor

The ECU uses the EGR Temperature Sensor to monitor exhaust gas temperatures in the EGR delivery pipe and uses exhaust temperature and delta pressure across the venturi tube to determine rate of EGR fl ow. The temperature sensor is supplied a 5-volt reference signal from the ECU and returns a voltage signal to the ECU relative to exhaust gas temperatures in the EGR delivery pipe.

The sensor return voltage decreases as exhaust gas temperature increases (sensor operating values are 0.10-5.0 V). See Figure 8-23 to view the sensor with connector.

Figure 8-23 EGR Tempertaure Sensor

All information subject to change without notice.

(Rev. June 2005)

7SE60 0506

8-25

DDEC V COMPONENTS

Delta P Sensor

The Delta P Sensor monitors the pressure differential across the venturi (in the EGR delivery pipe at the EGR cooler outlet) and uses the delta pressure and exhaust temperature to determine the rate of EGR fl ow. See Figure 8-24. The sensor is supplied a 5-volt reference signal from the ECU and returns a voltage signal to ECU relative to pressure difference across the Venturi tube. Return sensor voltage increases as pressure differential increases during engine operation

(operating values are 0.23-4.77 V).

1. Thermostat Housing

Figure 8-24 Delta P Sensor

2. Delta P Sensor

8-26

All information subject to change without notice.

(Rev. June 2005)

7SE60 0506

SERIES 60 EGR TECHNICIAN'S MANUAL

Intake Manifold Pressure Sensor

The Intake Manifold Pressure Sensor (IMP Sensor), see Figure 8-25, is used to monitor air pressure in the intake manifold. The DDEC V ECU uses this air pressure data for fuel management during engine acceleration. The IMP Sensor sensor is supplied a 5-volt reference signal by ECU and returns a voltage signal to the ECU relative to turbo boost pressure. Return voltage increases as boost pressure increases. Operating values are 0.10-5.0 V during normal engine operation.

Figure 8-25 Turbocharger Boost Sensor

All information subject to change without notice.

(Rev. June 2005)

7SE60 0506

8-27

DDEC V COMPONENTS

THIS PAGE INTENTIONALLY LEFT BLANK

8-28

All information subject to change without notice.

(Rev. June 2005)

7SE60 0506

SERIES 60 EGR TECHNICIAN'S MANUAL

DDEC V CODES

To read DDEC V codes, use the Detroit Diesel Diagnostic Link (DDDL). The DDDL will display active and inactive fault codes which are listed in Table 9-1.

NOTE:

Some vehicle dashboard displays will show SAE faults.

Yellow= Sensor

Red= Protection

Blue = Logic

Green = MAS (Maintenance Alert System)

DDC Code #

(Flashed)

PID

187

174

187

111

110

175

110

175

111

FMI

SID

146

Description

Variable Speed Governor Sensor Voltage Low

Variable Speed Governor Switch System Not

Responding

Variable Speed Governor Sensor Voltage High

Coolant Level Sensor Input Voltage Low

Add Coolant Level Sensor Input Voltage Low

EGR Valve Current Too High

Coolant Temperature Sensor Input Voltage High

Oil Temperature Sensor Input Voltage High

Coolant Temperature Sensor Input Voltage Low

Oil Temperature Sensor Input Voltage Low

Coolant Level Sensor Input Voltage High

Add Coolant Level Sensor Input Voltage High

EGR Valve Current Too Low

Throttle Position Sensor Input Voltage High

Throttle Position Sensor Input Voltage Low

Fuel Temperature Sensor Input Voltage High

Fuel Temperature Sensor Input Voltage Low

Reserved for “No Codes"

Aux. Shutdown #1 Active

Aux. Shutdown #2 Active

All information subject to change without notice.

(Rev. June 2005)

7SE60 0506

9-1

DDEC V CODES

PID

171

172

351

404

105

171

172

105

102

100

DDC Code #

(Flashed)

9-2

SID

260

261

262

260

239

265

238

239

264

265

263

264

FMI

Description

Intake Manifold Temperature Sensor Input Voltage

High

Ambient Air Temperature Sensor Input Voltage High

Air Temperature Sensor Input Voltage High

Intake Manifold Temperature Sensor Input Voltage

Low

Ambient Air Temperature Sensor Input Voltage Low

Air Temperature Sensor Input Voltage Low

TCI Temperature Circuit Failed Low

Turbo Compressor Temperature Out Sensor Input

Voltage Low

Aux. Output #3 Open Circuit (High Side) - E49

Aux. Output #3 Short To Ground (High Side) - E49

Aux. Output #3 Mechanical System Fail - E49

Aux. Output #4 Open Circuit (High Side) - E48

Aux. Output #4 Short to Ground (High Side) - E48

Aux. Output #4 Mechanical System Failure - E48

Aux. Output #12 (E46) Open Circuit (High Side)

Aux. Output #12 (E46) Short To Ground (High Side)

Aux. Output #12 (E46) Mechanical System Failure

(High Side)

Aux. Output #13 (E47) Open Circuit (High Side)

Aux. Output #13 (E47) Short To Ground (High Side)

Aux. Output #13 (E47) Mechanical System Failure

Aux. Output #14 (E50) Open Circuit (High Side)

Aux. Output #14 (E50) Short To Ground (High Side)

Aux. Output #14 (E50) Mechanical System Failure

(High Side)

Aux. Output #15 (E51) Open Circuit (High Side)

Aux. Output #15 (E51) Short To Ground (High Side)

Aux. Output #15 (E51) Mechanical System Failure

Aux. Output #16 (E52) Open Circuit (High Side)

Aux. Output #16 (E52) Short To Ground (High Side)

Aux. Output #16 (E52) Mechanical System Failure

Aux. Output #17 (E53) Open Circuit (High Side)

Aux. Output #17 (E53) Short To Ground (High Side)

Aux. Output #17 (E53) Mechanical System Failure

RSL Short to Battery (+)

RSL Open Circuit

AWL Short to Battery (+)

AWL Open Circuit

Turbo Boost Pressure Sensor Input Voltage High

Turbo Boost Pressure Sensor Input Voltage Low

Oil Pressure Sensor Input Voltage Low

All information subject to change without notice.

(Rev. June 2005)

7SE60 0506

SERIES 60 EGR TECHNICIAN'S MANUAL

DDC Code #

(Flashed)

PID

100

111

105

102

106

351

404

110

172

175

100

168

147

211

212

214

221

232

—

155

SID

146

147

FMI

Description

Oil Pressure Sensor Input Voltage Low

Fuel Pressure Sensor Input Voltage High

Fuel Restriction Sensor Input Voltage High

Fuel Pressure Sensor Input Voltage Low

Fuel Restriction Sensor Input Voltage Low

EGR Leak - Boost Power

EGR Valve Not Responding

EGR Leak - Boost Jake

Low or High Boost-Boost Mode

VNT Vanes not responding-Boost Mode

Excessive EGR Flow-EGR Mode

VNT Vanes not responding-EGR Mode

VNT Vanes at Max - Jake

Low or High Boost during Jake Operation

VNT Vanes not responding-Jake Mode

EGR Flow too Low

Too Many SRS (missing TRS)

Too few SRS (missing SRS)

Coolant Level Low

Intake Manifold Temperature High

Engine Power Derate Due To Intake Manifold

Temperature

Coolant Temperature High

Engine Power Derate Due To Coolant Temperature

Air Inlet Temperature High

Oil Temperature High

Oil Temperature Derate

Oil Pressure Low

Injector Vreg Voltage Failed Low

ECU Battery Voltage Low

Vehicle Sensor Supply Voltage Low

Injector Vslope Voltage Failed Low

RTC Backup Battery Voltage Low

Injector ILpullin Voltage Failed Low

Sensor Supply Voltage Low

Fuel Pressure High

Engine Power Derate Due To Boost Pressure

Turbo Boost Pressure High

Air Inlet Pressure High

Fuel Pressure Low

Air Inlet Pressure Low

TCI Temperature Below Range

Turbo Compressor Temperature Out Low

All information subject to change without notice.

(Rev. June 2005)

7SE60 0506

9-3

DDEC V CODES

PID

411

412

351

404

351

404

DDC Code #

(Flashed)

9-4

216

231

216

242

246 xxx

244

245

246

242

243

244

254

253

SID

FMI

Description

EGR Delta Pressure Low

EGR Temperature Low

TCI Temperature Above Range

Turbo Compressor Out Temperature High

Engine Power Derate Due To TCO Temperature

TCI Temperature Circuit Failed High

Turbo Compressor Out Temperature Sensor Input

Voltage High

A/D Conversion Fail

Memory Check Failed On Startup

Memory Write Error - Single Location

Calibration Memory Error

Memory Write Error - All Locations

Vehicle Speed Sensor Fault

Other ECU Fault (This fault is logged in conjunction with another fault to indicate missing information from another ECU.)

J1939 Data Link Fault

Engine Retarder Switch Not Responding

Engine Retarder Switch Failed

Park Brake/Safety Loop Switch Not Responding

Park Brake/Safety Loop Switch Failed

Torque Overload

ECU Information Not Responding (Mux'd

Dashboard Devices)

Cruise Control Resume/Accel Switch Not

Responding

Cruise Control Resume/Accel Switch Failed

Cruise Control Set/Coast Switch Not Responding

Cruise Control Set/Coast Switch Failed

Cruise Control Enable Switch Not Responding

Cruise Control Enable Switch Failed

Clutch Pedal Switch Not Responding

Clutch Pedal Switch Failed

Service Brake Pedal Switch Not Responding

Service Brake Pedal Switch Failed

Injector xxx Response Time Long

Injector #1 Circuit Short To Ground

Injector #2 Circuit Short To Ground

Injector #3 Circuit Short To Ground

Injector #4 Circuit Short To Ground

Injector #5 Circuit Short To Ground

Injector #6 Circuit Short To Ground

Aux. Output #1 Short to Battery (+) - V4

All information subject to change without notice.

(Rev. June 2005)

7SE60 0506

SERIES 60 EGR TECHNICIAN'S MANUAL

DDC Code #

(Flashed)

PID

SID

250

257

258

259

FMI

Description

Aux. Output #1 Open Circuit - V4

Aux. Output #1 Mechanical System Not Responding

Properly -V4

Aux. Output #2 Short to Battery (+) - V5

Aux. Output #2 Open Circuit - V5

Aux. Output #2 Mechanical System Not Responding

Properly - V5

Aux. Output #5 Short to Battery (+) -V6

Aux. Output #5 Open Circuit - V6

Aux. Output #5 Mechanical System Not Responding

Properly - V6

Aux. Output #6 Short to Battery (+) - V7

Aux. Output #6 Open Circuit - V7

Aux. Output #6 Mechanical System Not Responding

Properly - V7

Aux. Output #7 Short to Battery (+) - V40

Aux. Output #7 Open Circuit - V40

Aux. Output #7 Mechanical System Not Responding

Properly - V40

Aux. Output #8 Short to Battery (+) - V53

Aux. Output #8 Open Circuit - V53

Aux. Output #8 Mechanical System Not Responding

Properly - V53

J1587 Data Link Fault

Aux.Output #9 (V54) Short To Battery

Aux.Output #9 (V54) Open Circuit

Aux.Output #9 (V54) Mechanical System Failure-Pin

Top 2

Aux.Output #10 (V55) Short To Battery

Aux.Output #10 (V55) Open Circuit)

Aux.Output #10 (V55) Mechanical System Failure

Top 2

Aux.Output #11 (E13) Short To Battery

Aux.Output #11 (E13) Open Circuit

Aux.Output #11 (E13) Mechanical System Failure

PWM #1 (V52) Above Normal Range

PWM #1 (V52) Below Normal Range

PWM #1 (V52) Short to Battery (+)

PWM #1 (V52) Open Circuit

PWM #1 (V52) Mechanical System Failre

PWM #2 (V46) Above Normal Range

PWM #2 (V46) Below Normal Range

PWM #2 (V46) Short to Battery (+)

PWM #2 (46) Open Circuit

PWM #1 (V46) Mechanical System Failre

All information subject to change without notice.

(Rev. June 2005)

7SE60 0506

9-5

DDEC V CODES

103

106

109

107

168

PID

103

DDC Code #

(Flashed)

SID

267

268

155

230

230 xxx

211

212

FMI

Description

PWM #3 (E01) Above Normal Range

PWM #3 (E01) Below Normal Range

PWM #3 (E01) Short to Battery (+)

PWM #3 (E01) Open Circuit

PWM #3 (E01) Mechanical System Failure

PWM #4 (E04) Above Normal Range

PWM #4 (E04) Below Normal Range

PWM #4 (E04) Short to Battery (+)

PWM #4 (E04) Open Circuit

PWM #4 (E04) Mechanical System Failure

PWM #5 (E08) Above Normal Range

PWM #5 (E08) Below Normal Range

PWM #5 (E08) Short To Battery

PWM #5 (E08) Open Circuit

PWM #5 (E08) Mechanical System Failure

PWM #6 (E11) Above Normal Range

PWM #6 (E11) Below Normal Range

PWM #6 (E11) Short To Battery

PWM #6 (E11) Open Circuit

PWM #6 (E11) Mechanical System Failure

Turbo Overspeed

Turbo Speed Sensor Input Failure - Abnormal

Period

Air Filter Restriction Sensor Voltage High

Air Filter Restriction Sensor Voltage Low

Oil Filter Restriction Sensor Voltage High

Oil Filter Restriction Sensor Voltage Low

Air Inlet Pressure Sensor Input Voltage High

Air Inlet Pressure Sensor Input Voltage Low

Coolant Pressure Circuit Failed High

Coolant Pressure Circuit Failed Low

TPS Idle Validation Circuit Fault (open circuit)

TPS Idle Validation Circuit Fault (short to ground)

Injector xxx Response Time Short

Vehicle Overspeed

Vehicle Overspeed (Absolute)

Optimized Idle Safety Loop Short to Ground

Oil Filter Restriction High

Injector Vreg Voltage Failed High

ECU Battery Voltage High

Vehicle Sensor Supply Voltage High

Injector Vslope Voltage Failed High

9-6

All information subject to change without notice.

(Rev. June 2005)

7SE60 0506

SERIES 60 EGR TECHNICIAN'S MANUAL

PID

175

177

171

172

174

109

110

111

171

105

107

108

177

173

355

411

100

102

121

DDC Code #

(Flashed)

SID

151

214

221

232

FMI

Description

RTC Backup Battery Voltage High

Injector Ipullin Voltage Failed High

Sensor Supply Voltage High

Engine Overspeed With Engine Brake

ECU Temperature Above Range

ECU Temperature Below Range

ECU Temperature Failed High

ECU Temperature Failed Low

Fire Pump Pressure Low

Exhaust Back Pressure High

Exhaust Back Pressure Low

Exhaust Back Pressure Sensor Voltage High

Exhaust Back Pressure Sensor Voltage Low

Exhaust Back Pressure at Rampdown Threshold

Fuel Filter Differential Pressure Low

Oil Filter Differential Pressure Low

Engine Oil Pressure High

Turbo Boost Pressure Low

Inlet Manifold Temperature Low

Air fi lter Restriction Pressure Low

Barometric Pressure High

Barometric Pressure Low

Coolant Pressure High

Coolant Temperature Low

Coolant Level High

Service Now Lamp Fault Expiration

Ambient Air Temperature High

Ambient Air Temperature Low

Air Inlet Temperature Low

Fuel Temperature High

Fuel Temperature Low

Engine Oil Temperature Low

Transmission Oil Temperature High

Transmission Oil Temperature Low

Transmission Oil Temperature Failed High

Transmission Oil Temperature Failed Low

Service Now Lamp Fault Expiration

Cruise Control/Adaptive Cruise Control Fault

Oil Level Sensor Input Voltage High

Exhaust Temperature Sensor Input Voltage High

Engine Oil Life Sensor Circuit Failed High

EGR Delta Pressure Circuit Failed High

All information subject to change without notice.

(Rev. June 2005)

7SE60 0506

9-7

DDEC V CODES

DDC Code #

(Flashed)

Table 9-1

SID

240

253

240

254

Flash Codes, SAE Codes, Descriptions

FMI

PID

108

355

190

111

101

153

173

355

411

412

355

411

412

355

101

153

173

355

Description

EGR Temperature Circuit Failed High

Engine Oil Life Sensor Circuit Failed High

Oil Level Sensor Input Voltage Low

Crankcase Pressure Sensor Input Voltage Low

Extended Crankcase Pressure Input Voltage Low

Exhaust Temperature Sensor Input Voltage Low

Engine Oil Life Sensor Circuit Failed Low

EGR Delta Pressure Circuit Failed low

EGR Temperature Circuit Failed Low

Aux. Pump Pressure High

Oil Level High

Crankcase Pressure High

Extended Crankcase Pressure High

Exhaust Temperature High

Coolant In Oil Detected

Change Oil Now

EGR Delta Pressure High

EGR Temperature High

Oil Level Low

Change Oil Soon

Engine Overspeed

Engine Overspeed Signal

Aux. Pump Pressure Sensor Input Voltage High

Barometric Pressure Sensor Input Voltage High

Pump Pressure Sensor Input Voltage Low

Barometric Pressure Sensor Input Voltage Low

Fuel Filter Restriction High

Maintenance Alert Coolant Level Fault

ECU Checksum Incorrect

Calibration Checksum Incorrect

Calibartion Checks Invalid

Calibration Versions Invalid

External RAM Failed

Internal RAM Failed

Module Forced To Boot Mode

Boot Code Checksum INcorrect

9-8

All information subject to change without notice.

(Rev. June 2005)

7SE60 0506

SERIES 60 EGR TECHNICIAN'S MANUAL

LOGIC CODES (MECHANICAL FAILURES)

Logic codes indicate the detection of mechanical failures by the DDEC V system. The response will be a Flash Code.

Diagnosing Flash Code 13

Failure Mode

SID 146, FMI 6

Indicates

EGR valve electric current is too high.

Response

: Perform the following steps if the EGR valve current is too high.

1. Check for a short circuit.

2. Disconnect the harness connector from the actuator control valve coil.

3. Measure the coil resistance between pins A and B. See Figure 9-1 for pin locations and compare the measured ohm values to the ohm values listed in Table 9-29–2.

[a] If the coil resistance is too low replace the actuator assembly.

[b] If the coil resistance is acceptable, go to step 4.

4. Disconnect engine harness at ECU and at coil and measure resistance across the two pin connector pins.

[a] If resistance is less than 100

, the two wires are shorted to each other.

[b] If the resistance is greater than 100

, try a test ECU or contact Detroit Diesel

Customer Support Center at 313-592–5800.

Figure 9-1 EGR Valve Coil Wiring

All information subject to change without notice.

(Rev. June 2005)

7SE60 0506

9-9

DDEC V CODES

Coil Temperature °C

100

Table 9-2

Coil Temperature °F

122

212

Ranges Allowed (Ohms)

Allowed Ranges (ohms)

3.4 - 4.2

3.7 - 4.6

4.4 - 5.4

Possible Causes

Wires shorted together.

Positive wire shorted to ground.

Low resistance in the solenoid.

NOTE:

This symptom may be improved with reprogramming.

Reprogram the ECU if the ECU has not been reprogrammed since the dates listed below.

12 L — 02–23–04

14 L — 03–08–04

NOTE:

There is an update program for the DDEC V troubleshooting in 6.0 DDDL.

9-10

All information subject to change without notice.

(Rev. June 2005)

7SE60 0506

SERIES 60 EGR TECHNICIAN'S MANUAL

EGR Valve Electric Current

Failure Mode

SID 146, FMI 5 & 6

EGR valve electric current is too low (FMI 5) or EGR valve electric current is too high

(FMI 6)

The CEL (AWL) will be illuminated and the engine will operate in boost mode.

All information subject to change without notice.

(Rev. June 2005)

7SE60 0506

9-11

DDEC V CODES

THIS PAGE INTENTIONALLY LEFT BLANK

9-12

All information subject to change without notice.

(Rev. June 2005)

7SE60 0506

SERIES 60 EGR TECHNICIAN'S MANUAL

DDEC V TESTING

PROBABLE COMPLAINTS

The following probable complaints are based on conditions identi fi ed by the Detroit Diesel

Customer Support Center.

Flash Code 13

Flash Code 16

Flash Code 39

Flash Code 61

Black Smoke

Black Fuel

Engine Mis fi re, Engine Back fi re, Intermittent Smoke Issues

Slobbering from Exhaust Pipe

Poor Engine Performance

Cab Odors

Loss of Engine Coolant

TESTING PROCEDURES

The following testing procedures are based on conditions identi fi ed by the Detroit Diesel

Customer Support Center.

Test A go to page 10-10

Test B go to page 10-12

Test C go to page 10-13

Test D go to page 10-20

Test E go to page 10-20

Test F go to page 10-21

Test G go to page 10-23

All information subject to change without notice.

(Rev. June 2005)

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10-1

DDEC V TESTING

TROUBLESHOOTING TASKS

The following ordered tasks are recommendations to troubleshoot speci fi c operational concerns.

FLASH CODE 13 (SID 146/FMI 6) EGR VALVE CURRENT TOO HIGH

Troubleshooting steps are as follows.

1. Using DDDL, check for Flash Code 13 (SID 146/FMI 6).

[a] If Flash Code 13 (SID 146/FMI 6) was logged, perform TEST E.

[b] If Flash Code 13 (SID 111/FMI 4 or 6) was logged, refer to the proper code section of the

DDEC V Single ECU Troubleshooting Guide

, (6SE565) to troubleshoot that code.

2. Once troubleshooting is done, verify that troubleshooting step 1[a] or step 1[b] resolved the problem.

[a] If Flash Code 13 (SID 146/FMI 6) is still logged, contact the Detroit Diesel Customer

Support Center at 313-592-5800.

[b] If Flash Code 13 (SID 146/FMI 6) is not logged, troubleshooting task is complete.

FLASH CODE 16 (SID 146/FMI5) EGR VALVE CURRENT TOO LOW

Troubleshooting steps are as follows.

1. Using DDDL, check for Flash Code 16 (SID 146/FMI 5).

[a] If Flash Code 16 (SID 146/FMI 5) was logged, perform TEST E.

[b] If Flash Code 16 (SID 111/FMI 5) was logged, refer to the proper code section of the

DDEC V Single ECU Troubleshooting Guide

, (6SE565) to troubleshoot that code.

2. Once troubleshooting is done, verify that troubleshooting step 1[a] or step 1[b] resolved the problem.

[a] If Flash Code 16 (SID 146/FMI 5) is still logged, contact the Detroit Diesel Customer

Support Center at 313-592-5800.

[b] If Flash Code 16 (SID 146/FMI 5) is not logged, troubleshooting task is complete.

10-2

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7SE60 0506

SERIES 60 EGR TECHNICIAN'S MANUAL

FLASH CODE 39

Troubleshooting steps are as follows.

1. Verify ECU program software version. Perform TEST E.

2. Inspect the VPOD air supply for leaks. Perform TEST G.

3. Perform TEST C.

4. Test drive the vehicle and perform a DDDL snapshot.

5. Perform TEST B.

6. Once service is done, verify that the problem has been resolved.

[a] If the problem has been resolved, no further testing is required.

[b] If the problem has not been resolved, contact the Detroit Diesel Customer Support

Center at 313-592-5800.

FLASH CODE 61

Troubleshooting steps are as follows.

1. Using DDDL, check for Flash Code 61.

[a] If Flash Code 61 was logged, perform step 2.

[b] If Flash Code 61 was not logged, no further troubleshooting is required.

2. Verify that Modi fi cation Bulletin 05M-2, Series 60 EPA 04 Fuel System have been performed.

[a] If the procedures in Modi fi cation Bulletin 05M-2, Series 60 EPA 04

Fuel System have not been performed, do so now. To print a copy of

05M-2, please visit the

Detroit Diesel Modi

cation Letter Web Page

at http://192.135.85.10/cust/mods/05mods/Index05.asp.

[b] If the procedures in Modi fi cation Bulletin 05M-2, Series 60 EPA 04 Fuel System have been performed, contact the Detroit Diesel Customer Support Center at

313-592-5800.

3. Once service is done, verify that the problem has been resolved.

All information subject to change without notice.

(Rev. June 2005)

7SE60 0506

10-3

DDEC V TESTING

BLACK SMOKE

Troubleshooting steps are as follows.

1. Visually inspect the air fi lter element for excess dirt, blocked fi lter elements, and damage.

Refer to the “Air Cleaner” section of the

Series 60 Service Manual

, (6SE483) for removal, inspection, and installation steps.

2. Visually inspect the air intake system for dirt and debris which is restricting proper fresh air fl ow. Refer to the “Cleaning of Intake Manifold“ section of the

Series 60 Service

Manual

, (6SE483) for inspection steps.

3. Visuall inspect the exhaust system for dirt and debris which is restricting proper exhaust gas fl ow. Refer to OEM guidelines for inspection procedures.

4. Perform a turbocharger inspection. Refer to the “Inspection of Turbocharger” section of the

Series 60 Service Manual

, (6SE483) for inspection steps.

5. Perform the procedures in section TEST A.

6. Once service is done, verify that the problem has been resolved.

BLACK FUEL

Troubleshooting steps are as follows.

1. Visually inspect the fuel tank for black fuel.

[a] If black fuel is present in the fuel tank, perform step 2.

[b] If black fuel is not present in the fuel tank, no further troubleshooting is required.

2. Verify that Modi fi cation Bulletin 05M-2, Series 60 EPA 04 Fuel System have been performed.

[a] If the procedures in Modi fi cation Bulletin 05M-2, Series 60 EPA 04

Fuel System have not been performed, do so now. To print a copy of

05M-2, please visit the

Detroit Diesel Modi

cation Letter Web Page

at http://192.135.85.10/cust/mods/05mods/Index05.asp.

[b] If the procedures in Modi fi cation Bulletin 05M-2, Series 60 EPA 04 Fuel System have been performed, contact the Detroit Diesel Customer Support Center at

313-592-5800.

3. Once service is done, verify that the problem has been resolved.

10-4

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7SE60 0506

SERIES 60 EGR TECHNICIAN'S MANUAL

ENGINE MISFIRE, ENGINE BACKFIRE, INTERMITTENT SMOKE ISSUES

Troubleshooting steps are as follows.

1. Start and run the engine to verify an engine mis fi re, engine back fi re, and intermittent smoke issues are present.

[a] If the engine mis fi red, back fi red, and had intermittent white, black or blue exhaust smoke from the tailpipe, perform step 2.

[b] If the engine did not mis fi re, back fi re, and had no intermittent white, black or blue exhaust smoke from the tailpipe, no further troubleshooting is required.

2. Verify that Modi fi cation Bulletin 05M-2, Series 60 EPA 04 Fuel System have been performed.

[a] If the procedures in Modi fi cation Bulletin 05M-2, Series 60 EPA 04

Fuel System have not been performed, do so now. To print a copy of

05M-2, please visit the

Detroit Diesel Modi

cation Letter Web Page

at http://192.135.85.10/cust/mods/05mods/Index05.asp.

[b] If the procedures in Modi fi cation Bulletin 05M-2, Series 60 EPA 04 Fuel System have been performed, contact the Detroit Diesel Customer Support Center at

313-592-5800.

3. Once service is done, verify that the problem has been resolved.

All information subject to change without notice.

(Rev. June 2005)

7SE60 0506

10-5

DDEC V TESTING

SLOBBERING FROM EXHAUST PIPE

Troubleshooting steps are as follows.

1. Using DDDL, perform a DDC Extraction of DDEC Reports. Review extraction data for excessive idle time.

[a] If the idle times were 35% and higher, which are considered to be excessive, reduce engine idle time. Proceed step 2.

[b] If the idle times were less than 35%, proceed to step 2.

2. Using DDDL, verify the engine coolant temperature.

[a] If the coolant temperature was below recommended operating parameters, refer to the “Coolant” section of the

Series 60 Service Manual

, (6SE483) coolant analysis program information.

[b] If the coolant temperature was at recommended operating parameters, proceed to step 3.

3. Verify that none of the fuel injectors are leaking fuel. Refer to the

“N3 Electronic Unit Injector” section of the

Series 60 Service Manual

, (6SE483) for removal, inspection, and replacement steps.

4. Verify valve lash clearances. Refer to section “Valve Clearance and Injector Timing” section of the

Series 60 Service Manual

, (6SE483) for inspection steps.

5. Check for worn cylinders.

[a] Perform a crankcase pressure test. Refer to the proper service section of the

Series 60

Service Manual

, (6SE483) for test procedures.

[b] Perform a compression test. Refer to the proper service section of the

Series 60

Service Manual

, (6SE483) for test procedures.

6. Verify that the VNT turbocharger is operating correctly. Refer to the “Turbocharger” section of the

Series 60 Service Manual

, (6SE483) for removal, inspection, and replacement steps.

10-6

All information subject to change without notice.

(Rev. June 2005)

7SE60 0506

SERIES 60 EGR TECHNICIAN'S MANUAL

POOR ENGINE PERFORMANCE

Troubleshooting steps are as follows.

1. What version of software is the DDEC V ECU running?

[a] If the software version is lower than Level 2, reprogram the ECU. Perform TEST E.

Once the ECU has been reprogrammed, proceed to step 2.

[b] If the software is Level 2 or higher, proceed to step 2.

2. Verify that the engine hardware has been campaigned or modi fi ed to the latest version.

[a] If you are uncertain or unable to determine if the engine has been campaigned or modi fi ed to the latest version, please contact the Detroit Diesel Customer Support

Center at 313-592-5800.

[b] If you are able to determine that the engine has been campaigned or modi fi ed to the latest version, proceed to step 3.

3. Verify that the fuel fi lters are not plugged. Refer to the “Preventive Maintenance” section of the

Series 60 Service Manual

, (6SE483) for inspection steps.

4. Visually inspect the air fi lter element for excess dirt, blocked fi lter elements, and damage.

Refer to the “Air Cleaner” section of the

Series 60 Service Manual

, (6SE483) for removal, inspection, and installation steps.

5. Verify that the VPOD is connected to a dedicated air line.

[a] If the VPOD air line is not connected to a dedicated source, refer to OEM guidelines for a solution. Once the problem has been resolved, proceed to step 6.

[b] If the VPOD air line is connected to a dedicated source, proceed to step 6.

6. Perform TEST D to test the Barometric Pressure Sensor. Once the test has been completed, proceed to step 7.

7. Perform TEST A to verify that the CAC system is not damaged.

[a] Once the test has been completed, verify that the reported poor engine performance problem has been resolved. If the problem has been resolved, the troubleshooting task has been completed.

[b] Once the test has been completed, verify that the reported poor engine performance problem has been resolved. If the problem has not been resolved, please contact the

Detroit Diesel Customer Support Center at 313-592-5800.

All information subject to change without notice.

(Rev. June 2005)

7SE60 0506

10-7

DDEC V TESTING

CAB ODORS

Troubleshooting steps are as follows.

1. Visually inspect the muf fl er, fl ex pipe to exhaust manifold, and exhaust system joints for excessive wear, holes, lose clamps, and for black soot indicating an exhaust gas leak.

[a] If any damage was found, refer to OEM guidelines for corrective service actions.

Once these problems have been resolved, proceed to step 2.

[b] If no damage was found, proceed to step 2.

2. Inspect the exhaust manifold for damage and exhaust gas leaks. Refer to the

“Exhaust Manifold” section of the

Series 60 Service Manual

, (6SE483) for inspection steps.

[a] If damage was found, resolve the problems and proceed to step 3.

[b] If no damage was found, proceed to step 3.

3. Verify repairs have resolved the cab odor problem.

[a] If cab odor problems have not been resolved, please contact the Detroit Diesel

Customer Support Center at 313-592-5800.

[b] If the cab odor problems have been resolved, the troubleshooting task has been completed.

10-8

All information subject to change without notice.

(Rev. June 2005)

7SE60 0506

SERIES 60 EGR TECHNICIAN'S MANUAL

LOSS OF ENGINE COOLANT

Troubleshooting steps are as follows.

1. Visually inspect the coolant for oil contamination.

[a] If the coolant has been contaminated, please contact the Detroit Diesel Customer

Support Center at 313-592-5800 for instructions.

[b] If the coolant has not been contaminated, proceed to 2.

2. Visually inspect the coolant hose clamps to ensure that they are installed properly, securely fastened to the hose, and not damaged.

[a] If the coolant hose clamps are not installed or secured properly and are damaged.

Refer to the proper service sections of the

Series 60 Service Manual

, (6SE483) for repair procedures. Once the problems have been resolved, proceed to step 3.

[b] If the coolant hose clamps were installed and secured properly and were not damaged, proceed to step 3.

3. Visually inspect the coolant hoses for excessive wear, cracks, and damage.

[a] If the coolant hoses are worn, broken, and damaged. Refer to the proper service sections of the

Series 60 Service Manual

, (6SE483) for repair procedures. Once the problems have been resolved, proceed to step 4.

[b] If the coolant hoses are not worn, broken, and damaged, proceed to step 4.

4. Visually inspect the cylinder head to cylinder block for coolant leaks.

[a] If cylinder head to cylinder block coolant leaks were detected. Refer to the proper service sections of the

Series 60 Service Manual

, (6SE483) for repair procedures.

Once the problems have been resolved, proceed to step 5.

[b] If cylinder head to cylinder block coolant leaks were not detected, proceed to step 5.

5. Perform TEST F. Once the test has been perfromed, proceed to step 6.

6. Verify that the troubleshooting task has resolved the problem.

[a] If the problem has not been resolved, please contact the Detroit Diesel Customer

Support Center at 313-592-5800.

[b] If the problem has been resolved, the troubleshooting task is complete.

All information subject to change without notice.

(Rev. June 2005)

7SE60 0506

10-9

DDEC V TESTING

TESTS

The following tests support the recommended troubleshooting fl ow for speci fi c operational concerns.

TEST A

Test A steps are as follows.

NOTE:

Two regulated air supply lines will be required to perform this test.

1. Remove the turbocharger to charge-air-cooler (CAC) pipe.

PRESSURIZED CHARGE COOLER SYSTEM

To avoid eye or face injury from fl ying debris, wear a face shield or goggles.

2. Pressurize the CAC inlet to 207 kPa (30 psi) using special tool TLZ00100 or equivalent.

3. Using DDDL, monitor the boost pressure (psi).

[a] If the pressure is below 187 kPa (27 psi), visually inspect the CAC, hoses, and the delivery tube for leaks. Repair as necessary.

[b] If the pressure is 187 kPa (27 psi) or higher, continue to step 4.

4. Disconnect the EGR actuator oil line.

NOTE:

The oil line fi tting is a 37 degree JIC #6 fi tting.

5. Connect a regulated air supply line to the EGR actuator regulated to 69 kPa (10 psi).

6. Using DDDL, activate the EGR Valve (PWM #2) to 90%.

7. Monitor the boost pressure for pressure drops when the EGR valve opens.

10-10

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(Rev. June 2005)

7SE60 0506

SERIES 60 EGR TECHNICIAN'S MANUAL

NOTE:

The pressure should have dropped signi fi cantly to approximately 62 kPa (9 psi).

[a] If the air pressure dropped to 62 kPa (9 psi), no further testing is required. Test

A has been completed.

[b] If the pressure dropped slightly, perform steps 8 through step 10.

8. Physically inspect the EGR valve for a mechanical failure. If the EGR valve is not functioning correctly, replace the EGR valve.

9. Visually inspect the EGR cooler for restrictions. If the EGR cooler is restricted, replace the EGR cooler.

10. Visually check the delivery pipe for restrictions. Clean the pipe as necessary to remove restrictions.

11. Verify repairs.

All information subject to change without notice.

(Rev. June 2005)

7SE60 0506

10-11

DDEC V TESTING

TEST B

Test B steps are as follows and should be performed in order as written.

Perform test as follows.

PERSONAL INJURY

Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.

Always start and operate an engine in a well ventilated area.

If operating an engine in an enclosed area, vent the exhaust to the outside.

Do not modify or tamper with the exhaust system or emission control system.

1. Run the engine on a dynamometer to get the engine hot. If a dynamometer is not available, run the engine until hot (> 170° F (76° C) coolant temperature).

2. Activate the VPOD outputs to 50% duty cycle using the DDDL. Visually inspect the

VNT and EGR valve for proper rod travel.

[a] If the VNT is not functioning properly, please visit the

Detroit Diesel Technical

Service Letter Web Page

at http://192.135.85.10/cust/sletr/revised_2004.asp and browse for Technical Service Letter 04 TS 16 or

Detroit Diesel Special Publications

Web Page

at http://192.135.85.10/public/sp/spnav.asp and browse for Special

Publication Number 18SP604.

[b] If the VNT is functioning properly, no further troubleshooting is required.

NOTE:

Repeat this step three times.

3. Verify repairs.

10-12

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(Rev. June 2005)

7SE60 0506

SERIES 60 EGR TECHNICIAN'S MANUAL

TEST C

Test C has eight basic tests and are as follows.

Delta P Sensor

VPOD Output Pressure

Barometric Sensor (Test D)

VPOD Input Pressure

VPOD Part Number and Supply Voltage

VPOD Wiring

Active Codes

Final Test

The following tools are required to perform the six basic tests.

Low wattage 1,000

resistor

DDDL version 4.2 or higher or DDR suite 8

Volt Ohm Meter (VOM)

Pressure gage 1379 kPa (0-200 psi)

Pressure gage 690 kPa (0-100 psi)

All information subject to change without notice.

(Rev. June 2005)

7SE60 0506

10-13

DDEC V TESTING

Delta P Sensor Test

Perform the following steps to check the Delta P Sensor.

1. Turn ignition On.

2. Connect either a Detroit Diesel Diagnostic Link® (DDDL) or a Diagnostic Data Reader

(DDR) to read the Delta P counts.

3. Record the Delta P counts.

[a] If the recorded Delta P counts are 86-135, verify that the Venturi ports are not plugged and that the Venturi Tube-to-Delta P sensor, see Figure 10-1, are correctly installed and are not damaged. Repair as necessary, verify repairs. If no problem was found, proceed to step 3[b].

NOTE:

Reversed and damaged tubes and Venturi ports will have an adverse effect on engine performance resulting in black exhaust smoke and engine surging.

[b] If the recorded Delta P counts are 86-135, visually inspect the delivery pipe for damage and proper assembly. If no damage or improper assembly were detected, perform a VPOD Output Pressure Test.

[c] If the recorded counts were not within a range of 86-135, replace the Delta-P Sensor and verify repairs. Proceed to TEST D.

10-14

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(Rev. June 2005)

7SE60 0506

SERIES 60 EGR TECHNICIAN'S MANUAL

VPOD Output Pressure Test

Test steps are as follows:

1. Disconnect the air hose from the VNT actuator. See Figure 10-1.

Figure 10-1 Location of Venturi Tube Hoses

2. Install gage at the outlet of the VNT air line. See Figure 10-2.

NOTE:

The gage should be accurate to within 1.4 kPa (0.2 psi).

All information subject to change without notice.

(Rev. June 2005)

7SE60 0506

10-15

DDEC V TESTING

Figure 10-2 Gage Setup

3. Using either DDDL or DDR, activate PWM #2 and PWM #4 duty cycles and monitor the output pressure from the VPOD. Activate the duty cycle to 50%. Pressure should equal 305-315 kPa (42-47 psi @ VPOD).

NOTE:

Both activations must have full linkage travel.

4. Repeat step 3 a total of 3 times.

NOTICE:

Ensure that the VPOD air supply line fi tting is not crossed-thread when connecting the VPOD air supply to the EGR actuator. If the air supply line fi tting is not properly seated, the EGR actuator will not function properly.

5. Connect VPOD air supply line to the EGR actuator. Perform a VPOD Input Pressure Test.

10-16

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(Rev. June 2005)

7SE60 0506

SERIES 60 EGR TECHNICIAN'S MANUAL

VPOD Input Pressure Test

Perform the following steps to test the VPOD input pressure.

1. Measure the VPOD input pressure to Port 1.

[a] If the supply pressure is not between 703-1296 kPa (90-120 psi), troubleshoot the vehicle air system until that result is obtained. Repair as necessary.

[b] If the supply pressure is between 703-1296 kPa (90-120 psi), perform a

VPOD Part Number and Supply Voltage Test.

2. Verify repairs.

VPOD Part Number and Supply Voltage Test and Part Number Check

Perform the follow steps to verify the VPOD part number and supply voltage.

1. Check VPOD label to determine if it is + 12 V or + 24 V system.

NOTE:

A 1,000

resistor or a volt Ohm meter is required to perform step 2.

2. Unplug the VPOD wire connectors and insert the 1,000

resistor between cavities 1 and 3.

[a] Turn ignition switch ON.

[b] Measure voltage from pin 3 to pin 1.

[c] Plug in DDDL or DDR to measure the ECU voltage.

3. Is the VPOD part number and voltage and the ECU voltage correct?

[a] If the VPOD part number and voltage and the ECU voltage are correct, perform a

VPOD Wiring Test.

[b] If the VPOD part number and voltage and the ECU voltage were not correct, match the VPOD component to the ECU voltage and perform a VPOD Wiring Test.

All information subject to change without notice.

(Rev. June 2005)

7SE60 0506

10-17

DDEC V TESTING

VPOD Wiring Test

Perform the following steps to test the VPOD wiring.

NOTE:

VPOD power should have been veri fi ed during the VPOD and Supply Voltage Test and

Part Number Check. If not, perform a VPOD Part Number and Supply Voltage Test.

1. Turn ignition switch ON.

2. Disconnect the VPOD sensor connectors.

3. Insert a 1,000

resistor between cavities Number 2 and Number 1 for a 12 V version, or cavities Number 2 and Number 3 for a 24 V version.

4. Connect a VOM to the VPOD connector between pin Number 2 and pin Number 3 for a

12 V VPOD or pin Number 2 and pin Number 1 for a 24 V VPOD.

5. Using either a DDDL or DDR, activate the PWM #4 (VNT) and ensure that activating 50

% duty cycle: VDC = 50% of the VPOD supply voltage ± 1 volt. (e.g. voltage to VPOD =

13.8 V * 0.5 = 6.8 V, therefore 5.8 V to 7.8 V at VPOD is okay).

6. Listen for air leaks from the VPOD when PWM are activated to 50%.

[a] If the PWM voltage measurement is correct, go to step 7.

[b] If the PWM voltage measurement is incorrect and the wiring checks were correct, try a test ECU programmed for EGR or contact the Detroit Diesel Customer Support

Center at 313-592-5800.

7. Verify repairs. Perform an Active Codes Test.

10-18

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7SE60 0506

SERIES 60 EGR TECHNICIAN'S MANUAL

Active Codes Test

Perform the following steps to test for active codes.

1. Turn ignition ON.

2. Connect either a DDDL or a DDR reader.

3. Read active codes.

4. Record or print codes. Ensure that PID, SID, and FMI are recorded. Refer to the proper code section of the

DDEC V Single ECU Troubleshooting Guide

, (6SE565) to troubleshoot that code.

NOTE:

FMIs listed as 14 are diagnostic information codes and no troubleshooting is required.

For example, an engine derates due to high TCO temperature; a 404/14 code will be stored. This would indicate that conditions warranted having the ECU derate the fueling to the engine. If the customer complaint was a power loss, it could be explained that loss of power was done by the ECU to protect other engine components.

5. If the issue is not related to the EGR system components, or if technical support is required, contact the Detroit Diesel Customer Support Center at 313-592-5800.

6. Perform a Final Test.

Final Test

Follow these steps for a fi nal test:

1. Reconnect all disconnected sensors and wiring harnesses and assemble all disassembled components.

2. Start and run the engine.

3. Perform a road test to try and duplicate the original complaint.

[a] If original symptoms and codes are not detected, repairs are complete.

[b] If any original codes are detected, review this section again and contact the Detroit

Diesel Customer Support Center at 313-592-5800.

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TEST D

Test D steps are as follows.

NOTE:

Engines built from February 2004 (Serial Number: 06R0761470) through the end of July

2004 (Serial Number: 06R0788688) may be affected.

1. Turn the ignition ON but leave the engine OFF.

2. Connect either a Detroit Diesel Diagnostic Link® (DDDL) or a Diagnostic Data Reader

(DDR) to measure the barometric pressure and the air inlet pressure. Compare the results of the measured values.

[a] If the difference is greater than 4.1 kPa (0.6 psi), replace the Barometric Pressure

Sensor.

[b] If the difference is less than 4.1 kPa (0.6 psi), contact the Detroit Diesel Customer

Support Center at 313-592-5800.

3. Verify repair.

[a] If Flash Code 39 (SID 147/FMI 2) is not logged, repair is complete.

[b] If Flash Code 39 (SID 147/FMI 2) is logged, contact the Detroit Diesel Customer

Support Center at 313-592-5800.

TEST E

Test E steps are as follows.

1. Verify ECU program software version.

[a] If the ECU software version is not Level 2.0, perform step 2 and 3.

[b] If the ECU software is Level 2.0 or higher, TEST E is complete.

2. Download the mainframe fi le for particular engine serial number (no mainframe changes required).

3. Program the ECU.

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TEST F

Engines equipped with a tube and shell bolted fl anged cooler that have a coolant-lost complaint need to be inspected for leaks from other sources. The spring wire hose clamps are a possible coolant leak path, and should be inspected. If the spring wire clamps are damaged, service kits are available to replace the damaged components.

A standard test to pressurize the coolant system and investigation of overall coolant system should have been performed prior to inspecting the cooler. There may be other components of the engine that are responsible for the loss of engine coolant.

NOTE:

Coolers with internal leaks usually show signs of a white coolant drop-out at the exhaust side of the cooler, the Delta P Sensor lines, or at the delivery pipe to intake manifold connector.

If the entire system has been tested, perform the following steps to inspect the cooler:

1. Use hoses, clamps, plugs, and a regulator to seal the cooler water inlet and water outlet ports. See Figure 10-3.

Figure 10-3 EGR Cooler Ports Setup

2. Fill the exhaust side of the cooler with hot tap water. Allow the water to over fl ow until the loose carbon has fl oated away allowing for a clear viewing of any bubbles. See Figure

10-4.

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DDEC V TESTING

Figure 10-4 Filling the EGR Cooler with Tap Water

3. Apply 207 kPa (30 psi) of regulated air to the regulator for three minutes. See Figure 10-3

4. Disconnect the regulated air supply from the regulator and watch for bubbles on the exhaust side of the cooler. See Figure 10-5.

[a] If bubbles were observed, replace the cooler.

[b] If no bubbles were observed, contact the Detroit Diesel Customer Support Center for further information (313-592-5800).

Figure 10-5 Observing the EGR Cooler for Bubbles

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TEST G

The air supply line which connects to the VPOD must be a dedicated air supply line. To ensure that the air supply line is a dedicated air supply line, please read Freightliner Service Information

Bulletin 01–81 (see Figure 10-6, see Figure 10-7, and see Figure 10-8).

Figure 10-6 Freightliner Service Bulletin 01–81 (Page One of Three)

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DDEC V TESTING

Figure 10-7 Freightliner Service Bulletin 01–81 (Page Two of Three)

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Figure 10-8 Freightliner Service Bulletin 01–81 (Page Three of Three)

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DDEC V TESTING

THIS PAGE INTENTIONALLY LEFT BLANK

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APPENDIX A: LIST OF ACRONYMS

Starting with DDEC V, DDC has begun using the nomenclature found in SAE J2403 which is industry standard. The previously used names and the SAE J2403 names are listed in Table A-1.

DDEC IV

Add Coolant Level Sensor (ACLS)

Air Filter Restriction Sensor

(Intake) Air Temperature Sensor (ATS)

Barometric Pressure Sensor

Check Engine Light (CEL)

Coolant Level Sensor (CLS)

Coolant Temperature Sensor (CTS)

EGR Delta Pressure Sensor (EGR Delta P)

EGR Temperature Sensor

Electronic Control Module (ECM)

Electronic Foot Pedal Assembly (EFPS)

Engine Sensor Harness (ESH)

Fire Truck Pump Pressure Sensor

Fuel Restriction Sensor (FRS)

Fuel Temperature Sensor (FTS)

Limiting Speed Governor (LSG)

Oil Level Sensor (OLS)

Oil Pressure Sensor (OPS)

Oil Temperature Sensor (OTS)

Relative Humidity/Turbo Compressor Inlet (TCI)

Temperature Sensor

Stop Engine Light (SEL)

Synchronous Reference Sensor (SRS)

Timing Reference Sensor (TRS)

Throttle Position Sensor (TPS)

Turbo Boost Sensor (TBS)

Turbo Compressor Out Temperature Sensor

Turbo Speed Sensor (TSS)

Vehicle Speed Sensor (VSS)

Table A-1 DDEC IV to DDEC V

DDEC V

Add Engine Coolant Level Sensor (AECL Sensor)

Air Filter Restriction Sensor (AFR Sensor)

Intake Air Temperature Sensor (IAT Sensor)

Barometric Pressure Sensor (Baro Sensor)

Amber Warning Lamp (AWL)

Engine Coolant Level Sensor (ECL Sensor)

Engine Coolant Temperature Sensor (ECT Sensor)

EGR Delta Pressure Sensor (EGR Delta P)

EGR Temperature Sensor (EGRT Sensor)

Electronic Control Unit (ECU)

Accelerator Pedal (AP)

Engine Harness (EH)

Fire Truck Pump Pressure Sensor

Fuel Restriction Sensor

Supply Fuel Temperature Sensor (SFT Sensor)

Automotive Limiting Speed Governor (ALSG)

Engine Oil Level (EOL Sensor)

Engine Oil Pressure Sensor (EOP Sensor)

Engine Oil Temperature Sensor (EOT Sensor)

Turbo Compressor Inlet Temperature Sensor (TCIT Sensor)

Red Stop Lamp (RSL)

Camshaft Position Sensor (CMP)

Crankshaft Position Sensor (CKP)

Accelerator Pedal Sensor (AP Sensor)

Intake Manifold Pressure Sensor(IMP Sensor)

Turbo Compressor Out Temperature Sensor (TCOT Sensor)

Turbo Speed Sensor (TSS)

Vehicle Speed Sensor (VSS)

A-1

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A-2

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APPENDIX B: DDEC IV WIRING SCHEMATICS

DDEC IV Vehicle Harness

DDEC IV Engine Wiring Diagram

DDEC V Engine Harness

DDEC V Vehicle Interface Harness

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B-1

APPENDIX B: DDEC IV WIRING SCHEMATICS

B-2

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APPENDIX C: ENGINE DIAGNOSTIC QUESTIONNAIRE

Engine Diagnostic Questionnaire

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C-1

APPENDIX C: ENGINE DIAGNOSTIC QUESTIONNAIRE

C-2

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APPENDIX D: SERVICE INFORMATION LETTERS

Technical Service Letter 03 TS-23

Technical Service Letter 03 TS-44

Technical Service Letter 04 TS-17

Technical Service Letter 04 TS-16

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APPENDIX E: DDEC IV ECM OVERVIEW AND

VEHICLE INTERFACE HARNESS

DDEC IV ECM Front Side View - see Figure E-1

ECM Engine Harness Connector View - see Figure E-2

Engine Harness Connector Pin Locations - see Figure E-3

Vehicle Interface Harness Connector - see Figure E-4

Vehicle Interface Harness Connector Pin Locations - see Figure E-5

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APPENDIX E: DDEC IV ECM OVERVIEW AND VEHICLE INTERFACE HARNESS

Figure E-1 DDEC IV ECM Front Side View

E-2

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Figure E-2 ECM Engine Harness Connector View

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E-3

APPENDIX E: DDEC IV ECM OVERVIEW AND VEHICLE INTERFACE HARNESS

Figure E-3 Engine Harness Connector Pin Locations

E-4

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Figure E-4 Vehicle Interface Harness Connector

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E-5

APPENDIX E: DDEC IV ECM OVERVIEW AND VEHICLE INTERFACE HARNESS

Figure E-5 Vehicle Interface Harness Connector Pin Locations

E-6

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