Detroit Diesel 60 EGR Series Technician Manual
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Detroit Diesel 60 EGR Series Technician Manual

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  • Page 3 Troubleshooting Guide and the DDEC V Single ECM Troubleshooting Guide. ® ® ® ® Series 60 , Detroit Diesel , DDC , DDEC and the spinning arrows design are registered ® trademarks of Detroit Diesel Corporation. Diagnostic Link is a registered trademarks of the Detroit Diesel Corporation.

  • Page 5: Introduction

    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.
  • Page 6 All information subject to change without notice. (Rev. April 2004) 7SE60 0404 Copyright © 2004 DETROIT DIESEL CORPORATION...

  • Page 7: Table Of Contents

    APPENDIX A: LIST OF ACRONYMS ................... APPENDIX B: DDEC IV WIRING SCHEMATICS ................. APPENDIX C: ENGINE DIAGNOSTIC QUESTIONNAIRE ............APPENDIX D: SERVICE INFORMATION LETTERS ..............All information subject to change without notice. (Rev. April 2004) 7SE60 0404 Copyright © 2004 DETROIT DIESEL CORPORATION...
  • Page 8 TABLE OF CONTENTS All information subject to change without notice. (Rev. April 2004) 7SE60 0404 Copyright © 2004 DETROIT DIESEL CORPORATION...
  • Page 9 INTRODUCTION The Series 60 EGR Technician's Guide is intended to be used by a qualified service technician familiar with Detroit Diesel electronically controlled (DDEC) diesel engines and to provide a ® better understanding of the EGR system to improve the diagnosing of a Series 60 EGR system.
  • Page 10 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. All information subject to change without notice. (Rev. April 2004) 7SE60 0404 Copyright © 2004 DETROIT DIESEL CORPORATION...
  • Page 11 Develop your own Driver Questionnaire (see Figure 1-1). NOTE: A full page copy of the questionnaire can be found in Appendix C. All information subject to change without notice. (Rev. April 2004) 7SE60 0404 Copyright © 2004 DETROIT DIESEL CORPORATION...
  • Page 12 INTRODUCTION Figure 1-1 Drivers Questionnaire All information subject to change without notice. (Rev. April 2004) 7SE60 0404 Copyright © 2004 DETROIT DIESEL CORPORATION...
  • Page 13 9. Did the problem occur at a specific vehicle speed? If so, at what vehicle speed? 10. Does the problem occur at specific engine RPM? If so, at what engine RPM? All information subject to change without notice. (Rev. April 2004) 7SE60 0404 Copyright © 2004 DETROIT DIESEL CORPORATION...
  • Page 14 (VSS signal) is loose. 9. If the problem occurs at a specific engine rpm, unplug the oil, coolant, and air temperature sensors, and note any changes to the problem. Gather this data and contact Detroit Diesel Technical Service.
  • Page 15 The purpose of the EGR system is to reduce engine exhaust gas emissions in accordance with EPA regulations. Figure 2-1 EGR System All information subject to change without notice. (Rev. April 2004) 7SE60 0404 Copyright © 2004 DETROIT DIESEL CORPORATION...
  • Page 16 8. EGR Cooler 4. Delta Pressure Sensor 9. High Flow Water Pump 5. EGR Gas Delivery Pipe Figure 2-2 Right Side View All information subject to change without notice. (Rev. April 2004) 7SE60 0404 Copyright © 2004 DETROIT DIESEL CORPORATION...
  • Page 17 4. Intake Manifold Air Temperature Sensor 2. EGR Mixer 5. Barometric Pressure Sensor 3. Intake Manifold 6. Intake Manifold Boost Pressure Sensor Figure 2-3 Left Side View All information subject to change without notice. (Rev. April 2004) 7SE60 0404 Copyright © 2004 DETROIT DIESEL CORPORATION...
  • Page 18 VNT vanes and EGR valve positions. The VPOD interface with other systems may be viewed in see Figure 2-4. All information subject to change without notice. (Rev. April 2004) 7SE60 0404 Copyright © 2004 DETROIT DIESEL CORPORATION...

  • Page 19: Series 60 Egr Technician's Guide

    SERIES 60 EGR TECHNICIAN'S GUIDE All information subject to change without notice. (Rev. April 2004) 7SE60 0404 Copyright © 2004 DETROIT DIESEL CORPORATION...
  • Page 20 The results of being able to adjust like this are as follow. See Figure 2-5 and see Figure 2-6. Enhanced air/fuel ratio during engine acceleration All information subject to change without notice. (Rev. April 2004) 7SE60 0404 Copyright © 2004 DETROIT DIESEL CORPORATION...
  • Page 21 Maximum regulated air pressure to the VNT actuator from the VPOD Maximum regulated exhaust restriction/Maximum EGR flow while operating in EGR Mode All information subject to change without notice. (Rev. April 2004) 7SE60 0404 Copyright © 2004 DETROIT DIESEL CORPORATION...

  • Page 22: Egr Valve

    The EGR valve regulates the EGR flow rate via air pressure input from the VPOD. The EGR valve has the following components (see Figure 2-9): All information subject to change without notice. (Rev. April 2004) 7SE60 0404 Copyright © 2004 DETROIT DIESEL CORPORATION...
  • Page 23 2. Splined Crank Arm 5. Adjustable Linkage 3. Pneumatic Actuator Figure 2-9 EGR Cooler Figure 2-10 EGR Cooler (Bar and Fin Design) All information subject to change without notice. (Rev. April 2004) 7SE60 0404 Copyright © 2004 DETROIT DIESEL CORPORATION...
  • Page 24 (see Figure 2-13) determine precise Mass Flow Rate Measurement. The ECM uses the delta pressure and exhaust temperature to determine the rate of EGR flow. 2-10 All information subject to change without notice. (Rev. April 2004) 7SE60 0404 Copyright © 2004 DETROIT DIESEL CORPORATION...
  • Page 25 Delta Pressure Sensor The Delta Pressure Sensor measures the pressure difference across the venturi in the transfer pipe. Figure 2-13 EGR Temperature Sensor 2-11 All information subject to change without notice. (Rev. April 2004) 7SE60 0404 Copyright © 2004 DETROIT DIESEL CORPORATION...
  • Page 26 EGR gas evenly to each cylinder. Sensors are mounted in the intake manifold to monitor the air temperature and the boost pressure. 2-12 All information subject to change without notice. (Rev. April 2004) 7SE60 0404 Copyright © 2004 DETROIT DIESEL CORPORATION...
  • Page 27 The EGR engine uses a high flow water pump to improve the coolant flow for added heat dissipation. NOTE: The high flow water pump is not interchangeable with a non-EGR engine. 2-13 All information subject to change without notice. (Rev. April 2004) 7SE60 0404 Copyright © 2004 DETROIT DIESEL CORPORATION...
  • Page 28 COMPONENTS 2-14 All information subject to change without notice. (Rev. April 2004) 7SE60 0404 Copyright © 2004 DETROIT DIESEL CORPORATION...
  • Page 29 The EGR valve position is closed during brake mode. All information subject to change without notice. (Rev. April 2004) 7SE60 0404 Copyright © 2004 DETROIT DIESEL CORPORATION...
  • Page 30 "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. All information subject to change without notice. (Rev. April 2004) 7SE60 0404 Copyright © 2004 DETROIT DIESEL CORPORATION...
  • Page 31 Red = Exhaust Gas Blue = No EGR Flow Green = Coolant Flow Yellow = Vehicle Air (VPODs) Orange = Cooled Exhaust Gas All information subject to change without notice. (Rev. April 2004) 7SE60 0404 Copyright © 2004 DETROIT DIESEL CORPORATION...
  • Page 32 No EGR flowing through the EGR cooler or delivery pipe VNT vane position controlled by intake manifold boost pressure and limited by the turbocharger speed All information subject to change without notice. (Rev. April 2004) 7SE60 0404 Copyright © 2004 DETROIT DIESEL CORPORATION...
  • Page 33 Once minimum RPM and boost levels are attained the ECM sends a signal via PWM#2 to initiate the valve opening event by providing air pressure to the EGR actuator. All information subject to change without notice. (Rev. April 2004) 7SE60 0404 Copyright © 2004 DETROIT DIESEL CORPORATION...
  • Page 34 Air pressure supplied by the EGR VPOD to the EGR actuator opens the butterfly valve. Once the EGR butterfly valve opens, the EGR flows through the EGR cooler and into the delivery pipe. All information subject to change without notice. (Rev. April 2004) 7SE60 0404 Copyright © 2004 DETROIT DIESEL CORPORATION...
  • Page 35 Exhaust gas enters the EGR cooler at high temperatures and is cooled by the engine coolant system to increase the density of the gas. This graphic illustrates coolant flow. All information subject to change without notice. (Rev. April 2004) 7SE60 0404 Copyright © 2004 DETROIT DIESEL CORPORATION...
  • Page 36 The delta pressure measurement, in conjunction with the EGR temperature, determines the EGR flow rate. All information subject to change without notice. (Rev. April 2004) 7SE60 0404 Copyright © 2004 DETROIT DIESEL CORPORATION...
  • Page 37 Changes to the vane position, either closing or opening, result in an increase or decrease to the EGR flow rate. All information subject to change without notice. (Rev. April 2004) 7SE60 0404 Copyright © 2004 DETROIT DIESEL CORPORATION...
  • Page 38 MODES 3-10 All information subject to change without notice. (Rev. April 2004) 7SE60 0404 Copyright © 2004 DETROIT DIESEL CORPORATION...
  • Page 39 “normal”. For example: If the ECM commands the EGR valve to open or close. The ECM monitors the EGR flow devices for confirmation that flow has begun or ended. All information subject to change without notice. (Rev. April 2004) 7SE60 0404 Copyright © 2004 DETROIT DIESEL CORPORATION...
  • Page 40 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. All information subject to change without notice. (Rev. April 2004) 7SE60 0404 Copyright © 2004 DETROIT DIESEL CORPORATION...
  • Page 41 SERIES 60 EGR TECHNICIAN'S GUIDE DDEC IV EGR DESCRIPTIONS To read codes, use the Detroit Diesel Diagnostic Link (DDDL). The DDDL will display active and inactive fault codes which are listed in Table 4-1. Yellow= Sensor Red = Protection Blue = Logic...
  • Page 42 TCO Temperature Derate Turbo Compressor Out Temperature Sensor Input Voltage High A/D Conversion Fail Nonvolatile Checksum Incorrect EEPROM Write Error Out of Calibration All information subject to change without notice. (Rev. April 2004) 7SE60 0404 Copyright © 2004 DETROIT DIESEL CORPORATION...
  • Page 43 PWM #3 Above Normal Range PWM #3 Below Normal Range PWM #3 Short to Battery (+) PWM #3 Open Circuit PWM #4 Above Normal Range All information subject to change without notice. (Rev. April 2004) 7SE60 0404 Copyright © 2004 DETROIT DIESEL CORPORATION...
  • Page 44 EGR Temperature Smart Sensor not Responding EGR Temperature Smart Sensor Failed — EGR Delta pressure circuit failed low — EGR Temperture circuit failed low All information subject to change without notice. (Rev. April 2004) 7SE60 0404 Copyright © 2004 DETROIT DIESEL CORPORATION...

  • Page 45: Mechanical Failures

    Leaking air lines from the VPOD to the actuators (insufficient air supply) Leaking or low vehicle air supply to the VPODs VPOD mechanical failure All information subject to change without notice. (Rev. April 2004) 7SE60 0404 Copyright © 2004 DETROIT DIESEL CORPORATION...
  • Page 46 Response: The CEL will illuminate and a fault message will be generated. Possible Causes: EGR valve mechanical failure (open) Defective Delta P sensor Plugged Delta P lines All information subject to change without notice. (Rev. April 2004) 7SE60 0404 Copyright © 2004 DETROIT DIESEL CORPORATION...
  • Page 47 Exhaust leaking at the S pipe Leaking air lines from the VPOD to the actuators (insufficient air supply) Leaking or low vehicle air supply to the VPODs All information subject to change without notice. (Rev. April 2004) 7SE60 0404 Copyright © 2004 DETROIT DIESEL CORPORATION...
  • Page 48 Low fuel pressure (e.g. restricted fuel supply) Exhaust manifold leakage Leaking delivery pipe Defective or leaking VPOD Leaking air system Charge air cooler Hoses Loose hose clamps 4-10 All information subject to change without notice. (Rev. April 2004) 7SE60 0404 Copyright © 2004 DETROIT DIESEL CORPORATION...
  • Page 49 Delivery pipe leakage Low vehicle air pressure supply Defective or leaking VPOD Leaking air system Charge air cooler Hoses Loose hose clamps 4-11 All information subject to change without notice. (Rev. April 2004) 7SE60 0404 Copyright © 2004 DETROIT DIESEL CORPORATION...
  • Page 50 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 fixed value. 4-12 All information subject to change without notice. (Rev. April 2004) 7SE60 0404 Copyright © 2004 DETROIT DIESEL CORPORATION...
  • Page 51 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 4-13 All information subject to change without notice. (Rev. April 2004) 7SE60 0404 Copyright © 2004 DETROIT DIESEL CORPORATION...
  • Page 52 250 F (121 C) 2004 — 243 F (117 C) 244 F (117 C) 253 F (122 C) Table 4-2 Temperature Limits 4-14 All information subject to change without notice. (Rev. April 2004) 7SE60 0404 Copyright © 2004 DETROIT DIESEL CORPORATION...

  • Page 53: Ddec Iv Testing

    Engine Backfire, Engine Misfire, Intermittent Exhaust Smoke . Page 5–6. Testing Procedures Test A . Page 5–7. Test B . Page 5–8. Exhaust Gas Recirculation System Basic Checks . Page 5–9. All information subject to change without notice. (Rev. April 2004) 7SE60 0404 Copyright © 2004 DETROIT DIESEL CORPORATION...
  • Page 54 6. Perform Exhaust Gas Recirculation System Basic Checks. . Page 5–9. 7. Test drive the vehicle with DDDL and perform a snapshot. Analyze the snapshot. 8. Perform Test B . Page 5–8. All information subject to change without notice. (Rev. April 2004) 7SE60 0404 Copyright © 2004 DETROIT DIESEL CORPORATION...
  • Page 55 [a] If seats are damaged, replace as necessary. NOTE: The injector may need to be replaced also. [b] If the seats are not damaged, testing is complete. All information subject to change without notice. (Rev. April 2004) 7SE60 0404 Copyright © 2004 DETROIT DIESEL CORPORATION...
  • Page 56 4. Inspect the VPOD air supply for leaks. [a] If the VPOD air supply has leaks, repair the leak. 5. Perform Test B . Page 5–8. All information subject to change without notice. (Rev. April 2004) 7SE60 0404 Copyright © 2004 DETROIT DIESEL CORPORATION...
  • Page 57 [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. All information subject to change without notice. (Rev. April 2004) 7SE60 0404 Copyright © 2004 DETROIT DIESEL CORPORATION...
  • Page 58 Engine Backfire, Engine Misfire, Intermittent Exhaust Smoke Perform the following steps for Engine Backfire, Engine Misfire, and Intermittent Exhaust Smoke. 1. Reprogram the ECM. All information subject to change without notice. (Rev. April 2004) 7SE60 0404 Copyright © 2004 DETROIT DIESEL CORPORATION...
  • Page 59 2. Visually inspect the EGR cooler for restrictions. If the EGR cooler is restricted, replace the EGR cooler. 3. Visually check the delivery pipe for restrictions. Clean as necessary to remove restrictions. All information subject to change without notice. (Rev. April 2004) 7SE60 0404 Copyright © 2004 DETROIT DIESEL CORPORATION...
  • Page 60 [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. All information subject to change without notice. (Rev. April 2004) 7SE60 0404 Copyright © 2004 DETROIT DIESEL CORPORATION...
  • Page 61 EGR cooler to the intake manifold. If hoses/pipes are correct, Check VPOD Output Pressure. [c] If counts do not fall within the 86–135 range, replace Delta-P sensor; then go to Test. All information subject to change without notice. (Rev. April 2004) 7SE60 0404 Copyright © 2004 DETROIT DIESEL CORPORATION...
  • Page 62 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. 5-10 All information subject to change without notice. (Rev. April 2004) 7SE60 0404 Copyright © 2004 DETROIT DIESEL CORPORATION...
  • Page 63 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.. 5-11 All information subject to change without notice. (Rev. April 2004) 7SE60 0404 Copyright © 2004 DETROIT DIESEL CORPORATION...
  • Page 64 [b] If the PWM voltage measurements are incorrect, and the wiring checks are okay, try a test ECM programmed for EGR, or contact DDC Technical Service. 5-12 All information subject to change without notice. (Rev. April 2004) 7SE60 0404 Copyright © 2004 DETROIT DIESEL CORPORATION...

  • Page 65: 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 Technical Service. 5-13 All information subject to change without notice.
  • Page 66 DDEC IV TESTING 5-14 All information subject to change without notice. (Rev. April 2004) 7SE60 0404 Copyright © 2004 DETROIT DIESEL CORPORATION...

  • Page 67: Dddl/Snapshots

    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. All information subject to change without notice. (Rev. April 2004) 7SE60 0404 Copyright © 2004 DETROIT DIESEL CORPORATION...
  • Page 68 Yes option. To discard the data recorded by the snapshot click on the NO option. All information subject to change without notice. (Rev. April 2004) 7SE60 0404 Copyright © 2004 DETROIT DIESEL CORPORATION...
  • Page 69 8. If you choose the Yes option the Save As dialog box will appear on your screen. A suggested file name will appear outlined in blue in the File Name box. All information subject to change without notice. (Rev. April 2004) 7SE60 0404 Copyright © 2004 DETROIT DIESEL CORPORATION...
  • Page 70 2. A dialog box will appear listing all the available snapshot files. All information subject to change without notice. (Rev. April 2004) 7SE60 0404 Copyright © 2004 DETROIT DIESEL CORPORATION...
  • Page 71 SERIES 60 EGR TECHNICIAN'S GUIDE NOTE: The default folder that snapshot files are saved in is C:\Detroit Diesel\Diagnostic and have a file extension of .ddl. 3. Highlight the file you wish to open with one click of the left mouse button. The selected file name will now appear in the File Name box.
  • Page 72 8. Move to a specific time in the replay by dragging the replay slider button. As you drag the slider, the time shown in the time box changes to reflect the position of the slider. All information subject to change without notice. (Rev. April 2004) 7SE60 0404 Copyright © 2004 DETROIT DIESEL CORPORATION...
  • Page 73 Samples of windows that may be activated include: Normal Instrumentation Window Diagnostic Instrumentation Window All information subject to change without notice. (Rev. April 2004) 7SE60 0404 Copyright © 2004 DETROIT DIESEL CORPORATION...
  • Page 74 DDDL/SNAPSHOTS Graph Window User Window All information subject to change without notice. (Rev. April 2004) 7SE60 0404 Copyright © 2004 DETROIT DIESEL CORPORATION...
  • Page 75 SERIES 60 EGR TECHNICIAN'S GUIDE Fault Codes Window All information subject to change without notice. (Rev. April 2004) 7SE60 0404 Copyright © 2004 DETROIT DIESEL CORPORATION...
  • Page 76 DDDL/SNAPSHOTS 6-10 All information subject to change without notice. (Rev. April 2004) 7SE60 0404 Copyright © 2004 DETROIT DIESEL CORPORATION...

  • Page 77: Snapshot Examples

    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. All information subject to change without notice. (Rev. April 2004) 7SE60 0404 Copyright © 2004 DETROIT DIESEL CORPORATION...
  • Page 78 SNAPSHOT EXAMPLES EGR Flow at Idle Detroit Diesel EGR Engines will flow EGR @ idle, as certain conditions are met. MY-2002 EGR engines will flow 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 flow.
  • Page 79 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. All information subject to change without notice. (Rev. April 2004) 7SE60 0404 Copyright © 2004 DETROIT DIESEL CORPORATION...
  • Page 80 SNAPSHOT EXAMPLES EGR Flow Troubleshooting Tips All information subject to change without notice. (Rev. April 2004) 7SE60 0404 Copyright © 2004 DETROIT DIESEL CORPORATION...
  • Page 81 SERIES 60 EGR TECHNICIAN'S GUIDE Examples Figure 7-1 Engine at Idle with EGR Flowing All information subject to change without notice. (Rev. April 2004) 7SE60 0404 Copyright © 2004 DETROIT DIESEL CORPORATION...
  • Page 82 SNAPSHOT EXAMPLES Figure 7-2 Idle — Cold Engine — No EGR Demand — No EGR Flow All information subject to change without notice. (Rev. April 2004) 7SE60 0404 Copyright © 2004 DETROIT DIESEL CORPORATION...
  • Page 83 SERIES 60 EGR TECHNICIAN'S GUIDE Figure 7-3 Throttling Without Load — EGR is On and Of All information subject to change without notice. (Rev. April 2004) 7SE60 0404 Copyright © 2004 DETROIT DIESEL CORPORATION...
  • Page 84 SNAPSHOT EXAMPLES Figure 7-4 1500 — No Load — EGR Off All information subject to change without notice. (Rev. April 2004) 7SE60 0404 Copyright © 2004 DETROIT DIESEL CORPORATION...
  • Page 85 SERIES 60 EGR TECHNICIAN'S GUIDE Figure 7-5 Start Up — EGR Valve Stuck Open All information subject to change without notice. (Rev. April 2004) 7SE60 0404 Copyright © 2004 DETROIT DIESEL CORPORATION...
  • Page 86 SNAPSHOT EXAMPLES Figure 7-6 Code 147 14 — EGR Flow Too Low 7-10 All information subject to change without notice. (Rev. April 2004) 7SE60 0404 Copyright © 2004 DETROIT DIESEL CORPORATION...
  • Page 87 SERIES 60 EGR TECHNICIAN'S GUIDE Figure 7-7 146 2 EGR Leak — Boost Power 7-11 All information subject to change without notice. (Rev. April 2004) 7SE60 0404 Copyright © 2004 DETROIT DIESEL CORPORATION...
  • Page 88 SNAPSHOT EXAMPLES Figure 7-8 Leaking Charge Air Cooler 7-12 All information subject to change without notice. (Rev. April 2004) 7SE60 0404 Copyright © 2004 DETROIT DIESEL CORPORATION...
  • Page 89 SERIES 60 EGR TECHNICIAN'S GUIDE Figure 7-9 One of the Delta P Ports Plugged in the Delivery Pipe 7-13 All information subject to change without notice. (Rev. April 2004) 7SE60 0404 Copyright © 2004 DETROIT DIESEL CORPORATION...
  • Page 90 SNAPSHOT EXAMPLES Figure 7-10 Normal Operation — Eaton Autoshift Transmission 7-14 All information subject to change without notice. (Rev. April 2004) 7SE60 0404 Copyright © 2004 DETROIT DIESEL CORPORATION...
  • Page 91 SERIES 60 EGR TECHNICIAN'S GUIDE Figure 7-11 Normal EGR Flow with Request 7-15 All information subject to change without notice. (Rev. April 2004) 7SE60 0404 Copyright © 2004 DETROIT DIESEL CORPORATION...
  • Page 92 SNAPSHOT EXAMPLES Figure 7-12 Normal — EGR Off 7-16 All information subject to change without notice. (Rev. April 2004) 7SE60 0404 Copyright © 2004 DETROIT DIESEL CORPORATION...
  • Page 93 SERIES 60 EGR TECHNICIAN'S GUIDE Figure 7-13 Plugged Delta P Port 7-17 All information subject to change without notice. (Rev. April 2004) 7SE60 0404 Copyright © 2004 DETROIT DIESEL CORPORATION...
  • Page 94 SNAPSHOT EXAMPLES 7-18 All information subject to change without notice. (Rev. April 2004) 7SE60 0404 Copyright © 2004 DETROIT DIESEL CORPORATION...

  • Page 95: Ddec V Components

    DDDL software Level 6.0 and higher will be the primary diagnostic tool. A diagnostic tool which is not PC supported will not have the ability to diagnose a DDEC V ECU. All information subject to change without notice. (Rev. April 2004) 7SE60 0404 Copyright © 2004 DETROIT DIESEL CORPORATION...
  • Page 96 Digital outputs: 19 (8 Hi, 11 Lo) vs 10 (2 Hi, 8 Lo) PWM outputs: 6 vs 4 (Lo side) Has full support for J1587 and J1939 Data Links All information subject to change without notice. (Rev. April 2004) 7SE60 0404 Copyright © 2004 DETROIT DIESEL CORPORATION...
  • Page 97 Easily retrievable historical fault codes for diagnostic capability Operating statistics are tracked, fuel consumed, miles traveled (hours used), ... for accurate unit and fleet management All information subject to change without notice. (Rev. April 2004) 7SE60 0404 Copyright © 2004 DETROIT DIESEL CORPORATION...
  • Page 98 This design feature eliminates the need for an EGR VPOD. The butterfly valve design is still used to control the exhaust gas flow. See Figure 8-2. All information subject to change without notice. (Rev. April 2004) 7SE60 0404 Copyright © 2004 DETROIT DIESEL CORPORATION...
  • Page 99 The new EGR Cooler features a durable tube & shell core and a cast housing that have less weld joints than the previous design. See Figure 8-3. All information subject to change without notice. (Rev. April 2004) 7SE60 0404 Copyright © 2004 DETROIT DIESEL CORPORATION...
  • Page 100 DDEC V COMPONENTS All information subject to change without notice. (Rev. April 2004) 7SE60 0404 Copyright © 2004 DETROIT DIESEL CORPORATION...
  • Page 101 SERIES 60 EGR TECHNICIAN'S GUIDE DDEC V CODES DDEC V EGR DESCRIPTIONS To read 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.
  • Page 102 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. April 2004) 7SE60 0404 Copyright © 2004 DETROIT DIESEL CORPORATION...
  • Page 103 Fuel Pressure Low Air Inlet Pressure Low TCI Temperature Below Range Turbo Compressor Temperature Out Low EGR Delta Pressure Low EGR Temperature Low All information subject to change without notice. (Rev. April 2004) 7SE60 0404 Copyright © 2004 DETROIT DIESEL CORPORATION...
  • Page 104 Injector #6 Circuit Short To Ground Aux. Output #1 Short to Battery (+) - V4 Aux. Output #1 Open Circuit - V4 All information subject to change without notice. (Rev. April 2004) 7SE60 0404 Copyright © 2004 DETROIT DIESEL CORPORATION...
  • Page 105 PWM #2 (V46) Short to Battery (+) PWM #2 (46) Open Circuit PWM #1 (V46) Mechanical System Failre PWM #3 (E01) Above Normal Range All information subject to change without notice. (Rev. April 2004) 7SE60 0404 Copyright © 2004 DETROIT DIESEL CORPORATION...
  • Page 106 Injector Vreg Voltage Failed High ECU Battery Voltage High Vehicle Sensor Supply Voltage High Injector Vslope Voltage Failed High RTC Backup Battery Voltage High All information subject to change without notice. (Rev. April 2004) 7SE60 0404 Copyright © 2004 DETROIT DIESEL CORPORATION...
  • Page 107 Exhaust Temperature Sensor Input Voltage High Engine Oil Life Sensor Circuit Failed High EGR Delta Pressure Circuit Failed High EGR Temperature Circuit Failed High All information subject to change without notice. (Rev. April 2004) 7SE60 0404 Copyright © 2004 DETROIT DIESEL CORPORATION...
  • Page 108 External RAM Failed Internal RAM Failed Module Forced To Boot Mode Boot Code Checksum INcorrect Table 9-1 Flash Codes, SAE Codes, Descriptions All information subject to change without notice. (Rev. April 2004) 7SE60 0404 Copyright © 2004 DETROIT DIESEL CORPORATION...
  • Page 109 [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 Technical Service. Figure 9-1 EGR Valve Coil Wiring All information subject to change without notice.
  • Page 110 There is an update program for the DDEC V troubleshooting in 6.0 DDDL. [a] 12L engine. [b] If the software level is below XX on a 14L engine. 9-10 All information subject to change without notice. (Rev. April 2004) 7SE60 0404 Copyright © 2004 DETROIT DIESEL CORPORATION...
  • Page 111 EGR Valve Current is too low (FMI 5) or EGR Valve Current is too high (FMI 6) The CEL (AWL) will be illuminated and the engine will operate in boost mode. 9-11 All information subject to change without notice. (Rev. April 2004) 7SE60 0404 Copyright © 2004 DETROIT DIESEL CORPORATION...
  • Page 112 DDEC V CODES 9-12 All information subject to change without notice. (Rev. April 2004) 7SE60 0404 Copyright © 2004 DETROIT DIESEL CORPORATION...

  • Page 113: Ddec V Testing

    As of April 1, 2004 all current known 2004 DDEC V issues can be resolved by reprogramming the ECU. Flash Code 13 and 16 — EGR Valve Current Cold engine/Idle Smoke Misfire — Shutter at Road Speed 10-1 All information subject to change without notice. (Rev. April 2004) 7SE60 0404 Copyright © 2004 DETROIT DIESEL CORPORATION...
  • Page 114 DDEC V TESTING 10-2 All information subject to change without notice. (Rev. April 2004) 7SE60 0404 Copyright © 2004 DETROIT DIESEL CORPORATION...

  • Page 115: Appendix A: List Of Acronyms

    Variable Geometry Turbocharger (aka VNT) Variable Nozzle Turbocharger (aka VGT) Volt Ohm Meter VPOD Variable Pressure Output (Orifice) Device < Less Than > Greater Than All information subject to change without notice. (Rev. April 2004) 7SE60 0404 Copyright © 2004 DETROIT DIESEL CORPORATION...
  • Page 116 APPENDIX A: LIST OF ACRONYMS All information subject to change without notice. (Rev. April 2004) 7SE60 0404 Copyright © 2004 DETROIT DIESEL CORPORATION...

  • Page 117: Appendix B: Ddec Iv Wiring Schematics

    DDEC IV Engine Wiring Diagram — See Figure B-2. DDEC V Engine Harness — see Figure B-3. DDEC V Vehicle Interface Harness — see Figure B-4. All information subject to change without notice. (Rev. April 2004) 7SE60 0404 Copyright © 2004 DETROIT DIESEL CORPORATION...
  • Page 118 APPENDIX B: DDEC IV WIRING SCHEMATICS All information subject to change without notice. (Rev. April 2004) 7SE60 0404 Copyright © 2004 DETROIT DIESEL CORPORATION...

  • Page 123: Appendix C: Engine Diagnostic Questionnaire

    SERIES 60 EGR TECHNICIAN'S GUIDE APPENDIX C: ENGINE DIAGNOSTIC QUESTIONNAIRE Engine Diagnostic Questionnaire All information subject to change without notice. (Rev. April 2004) 7SE60 0404 Copyright © 2004 DETROIT DIESEL CORPORATION...
  • Page 124 APPENDIX C: ENGINE DIAGNOSTIC QUESTIONNAIRE All information subject to change without notice. (Rev. April 2004) 7SE60 0404 Copyright © 2004 DETROIT DIESEL CORPORATION...

  • Page 127: Appendix D: Service Information Letters

    Service Information Letter (View Four of Four) — see Figure D-7. Service Information Letter (View One of One) — see Figure D-8. All information subject to change without notice. (Rev. April 2004) 7SE60 0404 Copyright © 2004 DETROIT DIESEL CORPORATION...
  • Page 128 APPENDIX D: SERVICE INFORMATION LETTERS All information subject to change without notice. (Rev. April 2004) 7SE60 0404 Copyright © 2004 DETROIT DIESEL CORPORATION...
  • Page 135 L tt 04 TS 17 (Vi...

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