Detroit Diesel 60 EGR Series Guía para resolver problemas

INTRODUCTIONBASICSThe following listed items should be checked prior to starting any troubleshooting:Ensure engine serial number on the ECM matches th

DDEC V COMPONENTS8-6 All information subject to change without notice. (Rev. April 2004)7SE60 0404 Copyright © 2004 DETROIT D IESEL CORPORATION

SERIES 60 EGR TECHNICIAN'S GUIDE9 DDEC V CODESDDEC V EGR DESCRIPTIONSTo read codes, use the Detroit Diesel Diagnostic Link (DDDL). The DDDL will

DDEC V CODESDDC C ode #(Flashed)PID SID FMI Descri p tio n27 105-3Intake Manifold Temperature Sensor Input VoltageHigh27 171-3 Ambient Air Temperature

SERIES 60 EGR TECHNICIAN'S GUIDEDDC C ode #(Flashed)PID SID FMI Description36 100-4 Oil Pressure Sensor Input Voltage Low37 94-3 Fuel Pressure Se

DDEC V CODESDDC C ode #(Flashed)PID SID FMI Descri p tio n49 351-0 TCI Temperature Above Range49 404-0 Turbo Compressor O ut Temperature High49 404 14

SERIES 60 EGR TECHNICIAN'S GUIDEDDC C ode #(Flashed)PID SID FMI Description62-26 7Aux. Output #1 Mechanical System Not RespondingProperly -V462-4

DDEC V CODESDDC C ode #(Flashed)PID SID FMI Descri p tio n63-59 1 PWM #3 (E01) Below Normal Range63-59 3 PWM #3 (E01) Short to Battery (+)63-59 4 PWM

SERIES 60 EGR TECHNICIAN'S GUIDEDDC C ode #(Flashed)PID SID FMI Description75-221 3 Injector Ipullin Voltage Failed High75-232 0 Sensor Supply Vo

DDEC V CODESDDC C ode #(Flashed)PID SID FMI Descri p tio n81 355-3 Engine Oil Life Sensor Circuit Failed High82 98-4 Oil Level Sensor Input Voltage Lo

SERIES 60 EGR TECHNICIAN'S GUIDELOGIC CODES (MECHANICAL FAILURES)Logic codes indicate the detection of mechanical failures by the DDEC V system.

SERIES 60 EGR TECHNICIAN'S GUIDEOPERATOR INFORMATIONThis section should serve as a guideline for the technician:Intermittent Problems - Talk to t

DDEC V CODESCoil Temperature C Coil Temperature FAllowed Ranges (ohms)22 71 3.4 - 4.250 122 3.7 - 4.6100 212 4.4 - 5.4Table 9-2 Ranges Allowed (Ohms)P

SERIES 60 EGR TECHNICIAN'S GUIDEEGR Valve CurrentFailure Mode: SID 146, FMI 5 & 6EGR Valve Current is too low (FMI 5) or EGR Valve Current is

DDEC V CODES9-12 All information subject to change without notice. (Rev. April 2004)7SE60 0404 Copyright © 2004 DETROIT D IESEL CORPORATION

SERIES 60 EGR TECHNICIAN'S GUIDE10 DDEC V TESTINGAsofApril1,2004allcurrentknown2004DDECVissuescanberesolvedbyreprogrammingthe ECU.Flash Code 13 a

DDEC V TESTING10-2 All information subject to change without notice. (Rev. April 2004)7SE60 0404 Copyright © 2004 DETROIT D IESEL CORPORATION

SERIES 60 EGR TECHNICIAN'S GUIDEAPPENDIX A: LIST OF ACRONYMSAKA Also Known AsCEL Check Engine LightCAC Charge Air CoolerDelta P Differential Pres

APPENDIX A: LIST OF AC RON YMSA-2 All information subject to change without notice. (Rev. April 2004)7SE60 0404 Copyright © 2004 DETROIT D IESEL CORPO

SERIES 60 EGR TECHNICIAN'S GUIDEAPPENDIX B: DDEC IV WIRING SCHEMATICSDDEC IV Vehicle Harness — see Figure B-1.DDEC IV Engine Wiring Diagram — See

APPENDIX B: DDEC I V WI RING SCHEM ATICSB-2 All information subject to change without notice. (Rev. April 2004)7SE60 0404 Copyright © 2004 DETROIT D I

INTRODUCTIONFigure 1-1 Drivers Questionnaire1-4 All information subject to change without notice. (Rev. April 2004)7SE60 0404 Copyright © 2004 DETROIT

SERIES 60 EGR TECHNICIAN'S GUIDEAPPENDIX C: ENGINE DIAGNOSTIC QUESTIONNAIREEngine Diagnostic QuestionnaireAll information subject to change witho

APPENDIX C: E NGINE DIAGNOS TIC QU ESTIONNAIR EC-2 All information subject to change without notice. (Rev. April 2004)7SE60 0404 Copyright © 2004 DETR

SERIES 60 EGR TECHNICIAN'S GUIDEAPPENDIX D: SERVICE INFORMATION LETTERSServiceInformationLetter03TS-23(ViewOneofTwo)—seeFigureD-2.Service Informa

APPENDIX D: SERVICE INFORMATION L ETT ERSD-2 All information subject to change without notice. (Rev. April 2004)7SE60 0404 Copyright © 2004 DETROIT D

SERIES 60 EGR TECHNICIAN'S GUIDEDriver QuestionnaireAsk the driver to answer the following questions before attempting to repair an intermittentp

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INTRODUCTIONQuestionnaire Response GuidelineThe following are typical responses to the Driver Questionnaire:PERSONAL INJURYTo avoid i njury from loss

SERIES 60 EGR TECHNICIAN'S GUIDE2 COMPONENTSThe purpose of the EGR system is to reduce engine exhaust gas emissions in accordance withEPA regulat

COMPONENTSEGR (exhaust gas recirculation) allows a percentage of the exhaust gases to remix with the aircoming into the intake manifold. The exhaust g

SERIES 60 EGR TECHNICIAN'S GUIDE1. EGR Gas Delivery Pipe 4. Intake Manifold Air Temperature Sensor2. EGR Mixer 5. Barometric Pressure Sensor3. In

COMPONENTSFUNCTIONALITY OF THE EGR COMPONENTSVariable Pressure Output Device (VPOD)12 V/24V power supply systemDDEC I V ECM: PWM2 (Y1) EGR and PWM4 (

SERIES 60 EGR TECHNICIAN'S GUIDEAll information subject to change without notice. (Rev. April 2004) 2-57SE60 0404 Copyright © 2004 DETROIT DIESEL

COMPONENTSVariable Nozzle Turbocharger (VNT)Figure 2-5 VNT TurbochargerFigure 2-6 Cut Away View of the VanesThe results of being able to adjust like t

SERIES 60 EGR TECHNICIAN'S GUIDEProvides EGR transport mechanism in EGR modeMore vane closure increases the EGR flow rate (PWM % is high).Less va

COMPONENTSEGR ValveThe valve position is controlled by DDEC. The ECM continuously monitors all engine operationmodes and performs self diagnostic chec

SERIES 60 EGR TECHNICIAN'S GUIDE1. Butterfly Valve 4. Actuator Bracket2. Splined Crank Arm 5. Adjustable Linkage3. Pneumatic ActuatorFigure 2-9EG

COMPONENTSThe primary purpose of the E GR cooler (see Figure 2-10), is to cool the exhaust gases by:Providing a coolant flow to remove heat from the g

SERIES 60 EGR TECHNICIAN'S GUIDEFigure 2-12 Delta Pressure SensorThe Delta Pressure Sensor measures the pressure difference across the venturi in

COMPONENTSEGR Gas D elivery Pipe/MixerThe delivery pipe provides the path for the EGR gases to flow from the EGR cooler to the intakemanifold.MixerFig

SERIES 60 EGR TECHNICIAN'S GUIDEHigh Flow Water PumpThe EGR engine uses a high flow water pump to improve the coolant flow for added heatdissipat

COMPONENTS2-14 All information subject to change without notice. (Rev. April 2004)7SE60 0404 Copyright © 2004 DETROIT D IESEL CORPORATION

SERIES 60 EGR TECHNICIAN'S GUIDE3 MODESOPERATIONAL MODESNew terminology has been introduced as a result of the Series 60 EGR engine.Boost ModeBoo

ATTENTIONThe information in this document is accurate as of April 2004 and is subject to changewithout notice. This manual is to be used in conjunctio

MODESAltitudeThe engine will transition between EGR and boost mode at an altitude of 6500 ft. Altitude isdetermined by the Barometric Pressure Sensor

SERIES 60 EGR TECHNICIAN'S GUIDEEGR SYSTEMIn this section, various colors are used to illustrate a particular engine mode for the Series 60engine

MODESBoost ModeDuring Boost Mode the following occurs:EGR valve closedNo EGR flowing through the EGR cooler or delivery pipeVNT vane position controll

SERIES 60 EGR TECHNICIAN'S GUIDEBoost Mode OperationA typical Boost Mode operation c onsists of:Accelerating a vehicle from stationary position a

MODESEGR Valve and Pneumatic ActuationAir pressure supplied by the EGR VPOD to the EGR actuator opens the butterfly valve.Once the EGR butterfly valve

SERIES 60 EGR TECHNICIAN'S GUIDEEGR CoolingEGR CoolingExhaust gas enters the EGR cooler at high temperatures and is cooled by the engine coolants

MODESEGR MeasurementEGR ModeOnce EGR begins flow through the EGR cooler and past the venturi, pressure levels are measuredfrom the two venturi taps or

SERIES 60 EGR TECHNICIAN'S GUIDEVNT ControlsEGR Mode (Flow)The VNT turbocharger is the mechanism used to change the EGR rate.The VNT is controlle

MODES3-10 All information subject to change without notice. (Rev. April 2004)7SE60 0404 Copyright © 2004 DETROIT D IESEL CORPORATION

SERIES 60 EGR TECHNICIAN'S GUIDE4 CODESDIAGNOSTIC TR OUBLESHOOTINGThis section supports the DDEC IV fault codes recorded during EGR engine operat

CODESLogic codes identify a condition NOT a component.Example: Code 39 DDEC uses the Differential Pressure sensor and EGR temperature sensor tomonitor

SERIES 60 EGR TECHNICIAN'S GUIDEDDEC IV EGR DESCRIPTIONSTo read codes, use the Detroit Diesel Diagnostic Link (DDDL). The DDDL will display activ

CODESDDC C ode #(Flashed)PID SID FMI Description32-239 3CEL Short to Battery (+)32-239 4CELOpenCircuit33 102-3Turbo Boost Pressure Se nsor I nput Volt

SERIES 60 EGR TECHNICIAN'S GUIDEDDC C ode #(Flashed)PID SID FMI Description54 84-12Ve hicle Speed Sensor Fault55-216 14Other ECM Fault55-231 12 J

CODESDDC C ode #(Flashed)PID SID FMI Description63-60 1PWM #4 Below Norma l Range63-60 3PWM#4ShorttoBattery(+)63-60 4PWM #4 Open Circuit64 103-0Turbo

SERIES 60 EGR TECHNICIAN'S GUIDEDDC C ode #(Flashed)PID SID FMI Description83 73-0 Pump Pressure High83 411-0EGR Delta Pressure High83 412-0EGR T

CODESFailure Mode: SID146,FMI2—EGRLeak(BoostMode)Indicates: No EGR flow requested by DDEC and EGR flow detected.SID 146, FMI 2 will be set by the ECM

SERIES 60 EGR TECHNICIAN'S GUIDEFailure Mode: SID 147, FMI 7 — VNT Vanes Not Responding (EGR Mode)Indicates: EGR flow requested by DDEC and exces

CODESFailure Mode: SID147, FMI 2 — VNT Vanes Not Responding (Boost Power)Indicates: Low boost or high boost.SID147, FMI 2 will be set by the ECM if, t

SERIES 60 EGR TECHNICIAN'S GUIDEFailure Mode: SID147, FMI 12 — VNT Vanes N ot Responding (Boost Jake)Indicates: Low boost or high boost while bra

SERIES 60 EGR TECHNICIAN'S GUIDEA LETTER TO TECHNICIANSThe Series 60 engine is entering its 14th year!Since its introduction in 1987, over 729,00

CODESSensor CodesSpecific sensor failures and the system response are listed below:Barometric Pressure SensorFailure Modes: PID 108, FMI 3 - Voltage H

SERIES 60 EGR TECHNICIAN'S GUIDETurbo Speed SensorFailure Modes: PID 103, FMI 8 - Abnormal PeriodResponse: The CEL will be illuminated and the sy

CODESCoolant Level LowPID 111 FMI 1When the coolant level has fallen below the Coolant Level Sensor for 30 seconds, the CEL andSEL will illuminate.Oil

SERIES 60 EGR TECHNICIAN'S GUIDE5 DDEC IV TESTINGThe following pages identify a logical troubleshooting flow for specific operational concerns.Th

DDEC IV TESTINGIntermittent Black SmokePerform the following steps for Intermittent Black Smoke.1. Check for diagnostic trouble codes.[a] If Fault Cod

SERIES 60 EGR TECHNICIAN'S GUIDEPower Loss Under Heavy PullIn e xtreme cold ambient conditions, the engine will operate in Condensation Protectio

DDEC IV TESTINGLow Boost Under Cold Ambient ConditionsIn extreme cold ambient conditions, the engine will operate in Condensation Protection.During th

SERIES 60 EGR TECHNICIAN'S GUIDEExhaust Smell/FumesPerform the following steps for Exhaust Smell/Fumes.1. Visually inspect the exhaust system for

DDEC IV TESTINGEngine Coolant LossPerform the following steps for Engine Coolant Loss.1. Verify the quantity of engine coolant loss per mile.NOTE:____

SERIES 60 EGR TECHNICIAN'S GUIDETESTING PROCEDURESNOTE:If further repair, removal, and DDDL procedures are required when performing the testingpr

ii All information subject to change without notice. (Rev. April 2004)7SE60 0404 Copyright © 2004 DETROIT D IESEL CORPORATION

DDEC IV TESTINGTest BPerform Test B as follows:PERSONAL INJURYDiesel engine exhaust and some of its constituents are knownto the State of California t

SERIES 60 EGR TECHNICIAN'S GUIDEExhaust Gas Recirculation System Basic ChecksPerform the following basic steps to check the exhaust gas recircula

DDEC IV TESTINGCheck VPOD Output PressureFollow these steps to check both VPOD (EGR valve a nd VNT) output pressure:NOTE:Listen for air leaks at the V

SERIES 60 EGR TECHNICIAN'S GUIDE[b] If the results in t his step cannot be a ttained, Check VPOD Input Pressure.NOTE:Both activations must operat

DDEC IV TESTINGCheck VPOD WiringThe following checks should be performed for the VPOD wiring.NOTE:VPOD power should have been verified under the P/N c

SERIES 60 EGR TECHNICIAN'S GUIDECheck for Active CodesCheck for active codes as follows:1. Turn ignition ON.2. Plug in DDR/DDDL.3. Read active co

DDEC IV TESTING5-14 All information subject to change without notice. (Rev. April 2004)7SE60 0404 Copyright © 2004 DETROIT D IESEL CORPORATION

SERIES 60 EGR TECHNICIAN'S GUIDE6 DDDL/SNAPSHOTSWORKING WITH DDDL SNAPSHOTSCreating A Snapshot1. Use the proper steps to open DDDL and connect to

DDDL/SNAPSHOTS5. Some im portant facts to remember about this feature:All parameters broadcast by DDEC IV are recorded.Any codes that occur during the

SERIES 60 EGR TECHNICIAN'S GUIDE8. If you choose the Ye s option the Save As dialog box will appear on your screen. Asuggestedfilenamewillappearo

SERIES 60 EGR TECHNICIAN'S GUIDETABLE OF CONTENTS1 INTRODUCTION ...

DDDL/SNAPSHOTS9. If you want to accept the suggested name for the file click once with the left mouse buttonon the Save option box. You may replace th

SERIES 60 EGR TECHNICIAN'S GUIDENOTE:The default folder that snapshot files are saved in is C:\Detroit Diesel\Diagnostic andhave a file extension

DDDL/SNAPSHOTS6. Start the replay of a snapshot by clicking on Play. The play button changes to Pause whena snapshot is replaying. While the snapshot

SERIES 60 EGR TECHNICIAN'S GUIDENOTE:Not all DDDL windows can be activated when replaying the snapshot f eature. Youcannot access the injector re

DDDL/SNAPSHOTSGraph WindowUser Window6-8 All information subject to change without notice. (Rev. April 2004)7SE60 0404 Copyright © 2004 DETROIT D IESE

SERIES 60 EGR TECHNICIAN'S GUIDEFault Codes WindowAll information subject to change without notice. (Rev. April 2004) 6-97SE60 0404 Copyright © 2

DDDL/SNAPSHOTS6-10 All information subject to change without notice. (Rev. April 2004)7SE60 0404 Copyright © 2004 DETROIT D IESEL CORPORATION

SERIES 60 EGR TECHNICIAN'S GUIDE7 SNAPSHOT EXAMPLESSNAPSHOT EXAMPLESThe following snapshots are intended to show you how to “interpret” the infor

SNAPSHO T EXAM PLESEGR Flow at IdleDetroit Diesel EGR Engines will flow EGR @ idle, as certain conditions are met. MY-2002 EGRengines will flow EGR fo

SERIES 60 EGR TECHNICIAN'S GUIDETurbocharger Speed Sensor FaultsTurbocharger speeds rarely exceed 100,000 rpm for any length of time. Speeds exce

TABLEOFCONTENTSiv All information subject to change without notice. (Rev. April 2004)7SE60 0404 Copyright © 2004 DETROIT D IESEL CORPORATION

SNAPSHO T EXAM PLESEGR Flow Troubleshooting Tips7-4 All information subject to change without notice. (Rev. April 2004)7SE60 0404 Copyright © 2004 DET

SERIES 60 EGR TECHNICIAN'S GUIDEExamplesFigure 7-1 Engine at Idle with EGR FlowingAll information subject to change without notice. (Rev. April 2

SNAPSHO T EXAM PLESFigure 7-2 Idle — Cold Engine — No EGR Demand — No EGR Flow7-6 All information subject to change without notice. (Rev. April 2004)7

SERIES 60 EGR TECHNICIAN'S GUIDEFigure 7 -3 Throttling Without Load — EGR is On and OfAll information subject to change without notice. (Rev. Apr

SNAPSHO T EXAM PLESFigure 7-4 1500 — No Load — EGR Off7-8 All information subject to change without notice. (Rev. April 2004)7SE60 0404 Copyright © 20

SERIES 60 EGR TECHNICIAN'S GUIDEFigure 7-5 Start Up — EGR Valve Stuck Op enAll information subject to change without notice. (Rev. April 2004) 7-

SNAPSHO T EXAM PLESFigure 7-6 Code 147 14 — EGR Flow Too Low7-10 All information subject to change without notice. (Rev. April 2004)7SE60 0404 Copyrig

SERIES 60 EGR TECHNICIAN'S GUIDEFigure 7-7 146 2 EGR Leak — Boost PowerAll information subject to change without notice. (Rev. April 2004) 7-117S

SNAPSHO T EXAM PLESFigure 7-8 Leaking Charge Air Cooler7-12 All information subject to change without notice. (Rev. April 2004)7SE60 0404 Copyright ©

SERIES 60 EGR TECHNICIAN'S GUIDEFigure 7-9 One of the Delta P Ports Plugged in the D elivery PipeAll information subject to change without notice

SERIES 60 EGR TECHNICIAN'S GUIDE1 INTRODUCTIONThe Series 60 EGR Technician's Guide is intended to be used by a qualified service technicianf

SNAPSHO T EXAM PLESFigure 7-10 Normal Operation — Eaton Autoshift Transmission7-14 All information subject to change without notice. (Rev. April 2004)

SERIES 60 EGR TECHNICIAN'S GUIDEFigure 7-11 Normal EGR Flow with RequestAll information subject to change without notice. (Rev. April 2004) 7-157

SNAPSHO T EXAM PLESFigure 7-12 Normal — EGR Off7-16 All information subject to change without notice. (Rev. April 2004)7SE60 0404 Copyright © 2004 DET

SERIES 60 EGR TECHNICIAN'S GUIDEFigure 7-13 Plugged Delta P PortAll information subject to change without notice. (Rev. April 2004) 7-177SE60 040

SNAPSHO T EXAM PLES7-18 All information subject to change without notice. (Rev. April 2004)7SE60 0404 Copyright © 2004 DETROIT D IESEL CORPORATION

SERIES 60 EGR TECHNICIAN'S GUIDE8 DDEC V COMP ONENTSThe next generation of the Series 60 EGR engine includes several new features including a mor

DDEC V COMPONENTSDDEC V COMPONENTSDDEC V Electronic Control UnitFigure 8-1 DDEC V ECUDDEC V offe rs these advantages over previous DDEC releases (see

SERIES 60 EGR TECHNICIAN'S GUIDEDDEC V offers end users significant operating advantages such as:State-of-the-art fuel management and economy, in

DDEC V COMPONENTSHydraulic Actuated EGR ValveFigure 8-2 Hydraulic Actuated EGR ValveThe EGR Valve equipped on a DDEC V e ngine is a hydra ulically act

SERIES 60 EGR TECHNICIAN'S GUIDETube and Shell EGR CoolerFigure 8-3 Tube and Shell EGR CoolerThe new EGR C ooler features a durable tube & sh