Detroit Diesel MBE 400 Technician Manual Download Page 26 | Manualshive

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COMPONENTS

PRELIMINARY

2.1.2

EXHAUST GAS RECIRCULATION SYSTEM

In general, the engine control system modulates the EGR rate of flow using parameters from the
various engine sensors to an optimize NOx and particulate levels in balance with the air fuel ratio.

The EGR system utilizes a combination of three EGR valves to control the exhaust gas
flow. See Figure 2-6. First there is an EGR shutoff valve on the hot side of the EGR cooler.
Secondly, there are reed valves mounted at the outlet of the EGR cooler. The third valve is an
electromagnetically actuated EGR control valve located downstream from the reed valves. The
system controls EGR flow during steady state and transient modes. EGR control is optimized for
maximum NOx control with consideration for particulate emission levels.

2-10

All information subject to change without notice.

(Rev. 5/05)

7SE940 0505

Copyright © 2005 DETROIT DIESEL CORPORATION

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Summary of Contents for MBE 400

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Page 3: ...out notice This manual is to be used in conjunction with the MBE Electronic Controls Troubleshooting Guide 6SE422 Detroit Diesel DDC DDEC and the spinning arrows design are registered trademarks of Detroit Diesel Corporation Diagnostic Link is a registered trademark of the Detroit Diesel Corporation ...

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Page 5: ...GNOSTIC TROUBLESHOOTING 4 1 4 1 1 SHUTDOWN ENGINE PROTECTION FAULT CODE RED 4 1 4 1 2 DERATE ENGINE PROTECTION FAULT CODE BLUE 4 1 4 1 3 PERFORMANCE FAULT CODES YELLOW 4 1 4 2 CODE DESCRIPTIONS 4 2 4 3 TROUBLESHOOTING OF PERFORMANCE CODES 4 8 4 3 1 DESCRIPTION OF SID 146 4 9 4 3 2 TROUBLESHOOTING SID 146 4 10 4 3 2 1 146 0 EGR TEMPERATURE ABOVE NORMAL 4 11 4 3 2 2 146 1 EGR TEMPERATURE BELOW NORMA...

Page 6: ...900 ENGINE AT VARIABLE SPEEDS AND LOADS 7 7 7 2 PROBLEM ENGINE OPERATION SNAPSHOTS 7 8 7 2 1 ENGINE WITH NO EGR TEMPERATURE READING 7 8 7 2 2 ENGINE WITH ABOVE NORMAL EGR TEMPERATURE READINGS 7 10 APPENDIX A LIST OF ACRONYMS A 1 APPENDIX B MBE DDEC WIRING SCHEMATICS B 1 APPENDIX C SERVICE INFORMATION LETTERS C 1 ii All information subject to change without notice Rev 5 05 7SE940 0505 Copyright 200...

Page 7: ...EGR engine is the Detroit Diesel Diagnostic Link DDDL This tool will provide all the help needed as it contains proper troubleshooting information for all products NOTE It is absolutely critical that you understand the EGR system to be qualified to offer any type of proper diagnostics Do not waste time trying to troubleshoot a DDC product you are not qualified to troubleshoot Your company may incu...

Page 8: ... prior repairs that could affect vehicle performance Check for damaged mating of the connector halves or terminals not fully seated in the connector body backed out terminals Look for improperly formed or damaged terminals Carefully inspect all connector terminals in the suspect circuit to determine proper contact tension Use a mating terminal to test the contact tension Check for electrical syste...

Page 9: ... If other vehicle devices are affected this indicates there may be something wrong with the ignition wiring 4 Does the concern occur only at specific operating conditions Operate the engine under similar load conditions 5 Does the concern occur at a specific engine operating temperature Operate the engine at this temperature while attempting to duplicate the concern Use the snapshot feature on the...

Page 10: ...ed Are the fuel filter and water separator clean A plugged filter will restrict fuel flow and result in low power How many miles are on the unit If mileage is high several hundred thousand miles valve lash may need adjusting or nozzles may need replacement Is the unit hard starting If there is a hard starting issue there may be a fuel system related concern or low compression Are the vehicle fuel ...

Page 11: ...See Service Information Letter No 03 TS 51 When the accelerator pedal is in the full throttle position does the DDDL or minidiag2 sense 100 throttle 1 3 2 FUEL SYSTEM The basic questions to ask for the Fuel System are Are the correct fuel filter and water separator installed and clean Is the Fuel System in proper working order Inspect the Fuel System Refer to MBE 4000 Service Manual 6SE412 and MBE...

Page 12: ...check it separately at 207 kPa 30 psi Pressure must not lose more than 35 kPa 5 psi in 15 seconds with shop air off Verify turbocharger is functioning properly 1 3 4 CHASSIS DYNAMOMETER TESTING Run the vehicle on a chassis dynamometer and look at the following EXHAUST FUMES To avoid injury or injury to bystanders from fumes engine or vehicle fuel system service operations should be performed in a ...

Page 13: ...ion and soot Is the CAC cracked Reduced air flow incomplete combustion and soot Are the intake air manifold gasket s leaking Reduced air flow incomplete combustion and soot NOTE The MBE 4000 uses multiple air manifold gaskets to cover individual cylinder heads The MBE 900 uses one gasket for every two adjacent cylinders on a single cylinder head Are there air bubbles in the coolant Head gasket fai...

Page 14: ...d fuel in the exhaust White Smoke can also be the result of a coolant leak that ends up as steam in the exhaust Is the fuel quality within DDC specification Cetane No minimum 45 Cetane Index minimum 40 Is the air preheater installed and functioning properly Cold air raw vaporized fuel in the exhaust Are there air bubbles in the coolant Suggests a head gasket failure vaporized water in exhaust Are ...

Page 15: ...nt is being used What type of inhibitor is being used 1 3 7 INTERMITTENT ISSUES The basic questions to ask with Intermittent Concerns are When was the last time the intermittent concern occurred Does the Amber Warning Lamp AWL come on Does the concern only occur in damp or rainy conditions Does the concern occur when the vehicle hits a bump or rough road Does the engine miss drop to idle quit runn...

Page 16: ...INTRODUCTION PRELIMINARY THIS PAGE INTENTIONALLY LEFT BLANK 1 10 All information subject to change without notice Rev 5 05 7SE940 0505 Copyright 2005 DETROIT DIESEL CORPORATION ...

Page 17: ... is to reduce engine emissions in accordance with Environmental Protection Agency EPA regulations The key components of an MBE EGR system consists of EGR Valves EGR Cooler Reed Valves EGR Mixer All information subject to change without notice Rev 5 05 2 1 7SE940 0505 Copyright 2005 DETROIT DIESEL CORPORATION ...

Page 18: ...GR control valve the reed valves all except the MBE 906 and the EGR mixer in the intake manifold where they are mixed with the charge air To view the arrangement of these components see Figure 2 1 for the MBE 4000 engine and Figure 2 2 for the MBE 900 engine Figure 2 1 Schematic of MBE 4000 EGR System 2 2 All information subject to change without notice Rev 5 05 7SE940 0505 Copyright 2005 DETROIT ...

Page 19: ...PRELIMINARY MBE EGR TECHNICIAN S GUIDE Figure 2 2 Schematic of MBE 900 EGR System All information subject to change without notice Rev 5 05 2 3 7SE940 0505 Copyright 2005 DETROIT DIESEL CORPORATION ...

Page 20: ...ough the reed valves during these pressure peaks The reed valves permit transport of exhaust only during the time when the exhaust pressure is greater than the charge air pressure The EGR systems for the MBE 900 and MBE 4000 engines are similar but differ in their specific components The EGR components are listed in Table 2 1 Component MBE 904 924 MBE 906 MBE 926 MBE 4000 Asymmetrical Turbocharger...

Page 21: ...inders after passing through an air to air intercooler mounted in the vehicle ahead of the cooling system radiator The intercooler cools the pressurized intake air charge coming from the turbocharger compressor before it is mixed with cooled recirculated exhaust gas and distributed to the intake ports by the intake manifold The MBE 4000 utilizes electronically controlled fuel injection and cooled ...

Page 22: ...ir Temperature Combination Sensor 6 Barometric Pressure Sensor located underneath the DDEC ECU 3 Camshaft Position Sensor 7 DDEC ECU 4 Crankshaft Position Sensor Figure 2 3 MBE 4000 EGR Sensor Locations Left Side 2 6 All information subject to change without notice Rev 5 05 7SE940 0505 Copyright 2005 DETROIT DIESEL CORPORATION ...

Page 23: ...erature Sensor 2 Engine Oil Pressure and Engine Oil Temperature Combination Sensor Figure 2 4 MBE 4000 EGR Sensor Locations Right Side All information subject to change without notice Rev 5 05 2 7 7SE940 0505 Copyright 2005 DETROIT DIESEL CORPORATION ...

Page 24: ...ystem IES that is used in commercial vehicles with the MBE 4000 engine The separation of functions of each controller is such that the DDEC Vehicle Control Unit DDEC VCU senses and controls the vehicle influencing parameters such as cruise control while the DDEC ECU covers engine operating parameters as described above The DDEC ECU is positioned on the left side of the engine and is cooled by mean...

Page 25: ...hrough separate inlets having different flow areas The smaller inlet causes higher exhaust back pressure providing the required level of pressure to drive EGR The turbocharger design must accommodate operations at elevated compressor wheel speeds because of the need to flow EGR See Figure 2 5 Figure 2 5 Cross Section of MBE 4000 Exhaust Manifold with EGR Due to the compressor characteristics it is...

Page 26: ...ee Figure 2 6 First there is an EGR shutoff valve on the hot side of the EGR cooler Secondly there are reed valves mounted at the outlet of the EGR cooler The third valve is an electromagnetically actuated EGR control valve located downstream from the reed valves The system controls EGR flow during steady state and transient modes EGR control is optimized for maximum NOx control with consideration...

Page 27: ...Hot Pipe 7 EGR Control Valve 3 EGR Shutoff Valve 8 Reed Valves 4 EGR Cooler 9 EGR Cooler Coolant Return 5 EGR Mixer 10 Exhaust Manifold Figure 2 6 MBE 4000 EGR System Components All information subject to change without notice Rev 5 05 2 11 7SE940 0505 Copyright 2005 DETROIT DIESEL CORPORATION ...

Page 28: ...loses the EGR system during the engine braking mode to prevent EGR cooler damage from high exhaust pressures See Figure 2 7 Figure 2 7 MBE 4000 EGR Shutoff Valve 2 12 All information subject to change without notice Rev 5 05 7SE940 0505 Copyright 2005 DETROIT DIESEL CORPORATION ...

Page 29: ... the intake manifold pressure flow occurs When the pressures are reversed the reed valves prevent flow Back flow could otherwise occur since the average intake manifold pressure is higher than the average exhaust manifold pressure See Figure 2 9 Figure 2 8 Reed Valves Figure 2 9 MBE EGR System Operating Pressure Characteristics All information subject to change without notice Rev 5 05 2 13 7SE940 ...

Page 30: ...to the EGR mixer The DDEC ECU controls the actuator position to determine the amount of valve opening See Figure 2 10 Figure 2 10 MBE 4000 EGR Control Valve 2 14 All information subject to change without notice Rev 5 05 7SE940 0505 Copyright 2005 DETROIT DIESEL CORPORATION ...

Page 31: ... valves to prevent reverse gas flow and a rotary valve that modulates EGR flow See Figure 2 11 NOTE The four cylinder engines MBE 904 and 924 do not have a divided turbine housing 1 Exhaust Manifold 6 EGR Delivery Pipe 2 EGR Rotary Valve 7 EGR Cooler Coolant Supply 3 EGR Cooler 8 EGR Exhaust Elbow 4 EGR Mixer 9 Asymmetrical Turbocharger 5 Reed Valves Figure 2 11 MBE 900 EGR System Components All i...

Page 32: ...nto the engine cylinders after passing through an air to air intercooler mounted in the vehicle ahead of the cooling system radiator The intercooler cools the pressurized intake air charge coming from the turbocharger compressor before it is mixed with cooled recirculated exhaust gas and distributed to the intake ports by the intake manifold 2 16 All information subject to change without notice Re...

Page 33: ... EGR systems See Figure 2 12 and Figure 2 13 for sensor locations 1 Barometric Pressure Sensor located underneath the DDEC ECU 5 Camshaft Position Sensor 2 Engine Fuel Supply Temperature Sensor 6 Crankshaft Position Sensor 3 Engine Coolant Temperature Sensor 7 DDEC ECU 4 Intake Manifold Pressure Air Temperature Combination Sensor Figure 2 12 MBE 900 EGR Sensor Locations Right Side All information ...

Page 34: ...ressure Sensor 3 Engine Oil Temperature Sensor 2 EGR Temperature Sensor Figure 2 13 MBE 900 EGR Sensor Locations Left Side 2 18 All information subject to change without notice Rev 5 05 7SE940 0505 Copyright 2005 DETROIT DIESEL CORPORATION ...

Page 35: ...nctions are as follows Fuel injection duration Fuel Injection Timing Beginning of Injection Modulated EGR Valve Position Idle Speed The DDEC ECU is one of two electronic controllers that make up the IES that is used in commercial vehicles with the MBE 900 engine The separation of functions of each controller is such that the DDEC VCU senses and controls the vehicle influencing parameters such as c...

Page 36: ... for cylinders 4 through 6 The flow from each set of cylinders enters the turbine housing through separate inlets having different flow areas The smaller inlet receiving flow from cylinders 1 to 3 causes higher exhaust back pressure increasing the pressure differential driving EGR flow into the intake manifold See Figure 2 14 1 EGR Outlet Figure 2 14 EGR Exhaust Manifold for MBE 906 and 926 Engine...

Page 37: ...haust manifold on these engines is designed with one chamber for cylinders 1 through 4 and the EGR outlet is located on the end See Figure 2 15 1 EGR Outlet Figure 2 15 EGR Exhaust Manifold for MBE 904 and 924 Engines All information subject to change without notice Rev 5 05 2 21 7SE940 0505 Copyright 2005 DETROIT DIESEL CORPORATION ...

Page 38: ... EGR system utilizes a combination of two EGR valves to control the exhaust gas flow The first valve is a rotary plate valve located in the end cover of the EGR cooler This valve is electro magnetically actuated to control EGR flow The actuator angle is determined by a DDEC ECU controlled PWM signal See Figure 2 16 Figure 2 16 MBE 900 EGR Control Valve 2 22 All information subject to change withou...

Page 39: ... into the exhaust manifold When the exhaust manifold pressure is higher than the intake manifold pressure flow occurs When the pressures are reversed the reed valves prevent flow Back flow could otherwise occur since the average intake manifold pressure is higher than the average exhaust manifold pressure See Figure 2 18 Figure 2 17 Reed Valves All information subject to change without notice Rev ...

Page 40: ...COMPONENTS PRELIMINARY Figure 2 18 MBE EGR System Operating Pressure Characteristics 2 24 All information subject to change without notice Rev 5 05 7SE940 0505 Copyright 2005 DETROIT DIESEL CORPORATION ...

Page 41: ...d position to 85 position of maximal flow area The EGR will operate until conditions are encountered that result in unacceptable operating characteristics If coolant temperature barometric pressure engine speed and percent torque are below certain limits the EGR will be disabled Excessively high charge air temperature will disable the EGR to prevent engine damage All information subject to change ...

Page 42: ... an IAT greater than or equal to 100 C 212 F as an indication of an EGR cooler failure At engine speeds lower than 1150 rpm the EGR is turned off During starting the EGR is turned off for better startability When the air mass flow is insufficient for the speed and load the EGR is turned off to control smoke At light loads the EGR is turned off The EGR is turned off at about 1740 m 5708 ft NOTE The...

Page 43: ...ontrol Unit DDEC VCU by the user If not enabled these codes act as derate engine protection fault codes 4 1 2 DERATE ENGINE PROTECTION FAULT CODE BLUE A derate engine protection DTC is activated when a engine operating condition exists that can cause engine damage if left unattended The engine slowly looses power so that the operator knows to correct the condition to prevent additional damage Howe...

Page 44: ... Grid Heater Defect 45 14 Grid Heater Special Instructions 84 0 Vehicle Speed Sensor Data Valid but Above Normal Range 84 1 Vehicle Speed Sensor Anti Tamper Fault 1 84 2 Vehicle Speed Sensor Data Erratic 84 3 Vehicle Speed Sensor Open Circuit 84 4 Vehicle Speed Sensor Short to Ground 84 5 Vehicle Speed Sensor Anti Tamper Fault 2 84 6 Vehicle Speed Sensor Grounded Circuit 84 14 Vehicle Speed Sensor...

Page 45: ...nsor Short to Ground 100 14 Engine Oil Pressure Too Low 102 0 Intake Manifold Pressure High 102 1 Intake Manifold Pressure Low 102 2 Intake Manifold Pressure Sensor Data Erratic 102 3 Intake Manifold Pressure Sensor Open Circuit 102 4 Intake Manifold Pressure Sensor Short to Ground 102 13 Intake Manifold Pressure Out of Range 103 7 Turbocharger 1 No Revolution 103 14 Turbocharger 2 No Revolution 1...

Page 46: ...essor Outlet Temperature Low 1 3 Injector Cylinder 1 Shorted High 1 4 Injector Cylinder 1 Short to Ground 1 5 Injector Cylinder 1 Current Below Normal or Open Circuit 1 6 Injector Cylinder 1 Shorted Circuit 1 7 Injector Cylinder 1 No Plunger 1 12 Injector Cylinder 1 Idle Smoothness Governor at Limit 1 14 Injector Cylinder 1 Single Cylinder Correction at Limit 2 3 Injector Cylinder 2 Shorted High 2...

Page 47: ...r 6 Short to Ground 6 5 Injector Cylinder 6 Current Below Normal or Open Circuit 6 6 Injector Cylinder 6 Shorted Circuit 6 7 Injector Cylinder 6 No Plunger 6 12 Injector Cylinder 6 Idle Smoothness Governor at Limit 6 14 Injector Cylinder 6 Single Cylinder Correction at Limit 7 3 Injector Cylinder 7 Shorted High 7 4 Injector Cylinder 7 Short to Ground 7 5 Injector Cylinder 7 Current Below Normal or...

Page 48: ...lay Starter Does Not Engage 39 14 Engine Starter Relay Relay Jammed 43 3 Gear Output 1 Open Circuit 43 4 Gear Output 1 Short to Ground 44 3 Gear Output 2 Open Circuit 44 4 Gear Output 2 Short to Ground 53 3 Aux PWM Driver 5 Shorted High 53 4 Aux PWM Driver 5 Short to Ground 53 11 Aux PWM Driver 5 Bank 2 Shorted 54 3 Aux PWM Driver 6 Open Circuit 56 3 Accessory Bus Shutdown Short to Battery 56 4 Ac...

Page 49: ... Switch Open Circuit 230 12 Idle Validation Switch Damaged or Signals Not Matching 231 2 J1939 Data Link Message Missing 232 2 Accelerator Pedal Supply Voltage Data Erratic 232 3 Accelerator Pedal Supply Voltage Above Normal 232 3 Accelerator Pedal Supply Voltage Below Normal 233 0 Anti Theft Failure or Incorrect Programming 233 2 Anti Theft No Additional Key Can Be Learned 233 9 Anti Theft No Tra...

Page 50: ...ngine 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 NOTE The EGR systems in the MBE 4000 and MBE 900 engines contain fewer components and use simpler control logic than the other series of Detroit Diesel engines Therefore using the DTCs should be the primary means of so...

Page 51: ... of the following fault codes EGR Temperature above Normal 146 0 refer to section 4 3 2 1 EGR Temperature below Normal 146 1 refer to section 4 3 2 2 Data Erratic 146 2 refer to section 4 3 2 3 EGR Valve not Responding 146 7 refer to section 4 3 2 4 Bad Component 146 12 refer to section 4 3 2 5 All information subject to change without notice Rev 5 05 4 9 7SE940 0505 Copyright 2005 DETROIT DIESEL ...

Page 52: ...ector Control of the EGR valve is routed through pins 11 42 and 50 of the 55 pin connector See Figure 4 1 1 55 Pin Connector Figure 4 1 Pin Locations on 55 Pin Connector The following procedures will troubleshoot SID 146 4 10 All information subject to change without notice Rev 5 05 7SE940 0505 Copyright 2005 DETROIT DIESEL CORPORATION ...

Page 53: ...ode s 146 1 is active code replace the EGR temperature sensor Erase the fault code memory and verify repairs Refer to section 4 3 2 6 c If fault code s 146 0 is still active code go to step 2 2 Bridge pin 1 of the EGR temperature sensor connector to ground and check for active fault codes See Figure 4 2 a If fault code s 146 0 is active repair open circuit in wire between pin 28 of the 55 pin conn...

Page 54: ...mal go to step 5 5 Check the following vehicle components for proper function Repair or replace as required Refer to the appropriate OEM Vehicle service manual as required a Check airflow through the CAC and radiator b Check fan belt condition for possible slippage c Check the fan shroud for proper position d Check the radiator hoses for collapsing e Check the viscous fan for proper operation f If...

Page 55: ...istance between pin 28 of the 55 pin connector and pin 1 of the EGR temperature sensor connector See Figure 4 3 a If resistance is less than 3 repair the short in the wire Erase the fault code memory and verify repairs Refer to section 4 3 2 6 b If resistance is greater than 3 go to step 3 3 Measure the resistance between pin 22 of the 55 pin connector and pin 3 of the EGR temperature sensor conne...

Page 56: ...ase the fault code memory and verify repairs Refer to section 4 3 2 6 b If the valve functions properly go to step 6 6 Check for damage to the reed valves as follows a Look for open valves damaged or stuck Replace valves as required b Look for heavy soot deposits on the valves If necessary clean valves Erase fault code memory and verify repairs Refer to section 4 3 2 6 c If the reed valve is undam...

Page 57: ...een pin 42 of the 55 pin connector and pin 2 of the EGR valve connector Erase fault code memory and verify repairs Refer to section 4 3 2 6 b If the resistance is less than 3 go to step 3 3 Bridge pin 3 of the EGR valve connector to ground and check for active fault codes See Figure 4 4 a If fault code s 146 2 is no longer active repair open circuit in wire between pin 11 of the 55 pin connector a...

Page 58: ... Check for active fault codes a If fault code s 146 2 is no longer active erase fault code memory and verify repairs Refer to section 4 3 2 6 b If fault code s 146 2 is still active go to step 6 6 Check coolant usage a If coolant usage indicates a leak perform an EGR Cooler Inspection Refer to appendix C Service Information Letter 04 TS 38 Clean and replace parts as indicated by inspection Erase f...

Page 59: ...Wiring Diagram a If the resistance less than 3 for wires from pins 50 to 1 pins 42 to 2 or pins 11 to 3 then there is a short in the wire Repair the short and verify repairs Refer to section 4 3 2 6 b If the resistance is greater than 10 k for wires from pins 50 to 1 pins 42 to 2 or pins 11 to 3 then there is a open circuit in the wire Repair the open circuit and verify repairs Refer to section 4 ...

Page 60: ... replace the EGR temperature sensor erase fault code memory and verify repairs Refer to section 4 3 2 6 c If fault code s 146 7 is still active go to step 4 4 Check coolant usage a If coolant usage indicates a leak perform an EGR Cooler Inspection Refer to appendix C Service Information Letter 04 TS 38 Clean and replace parts as indicated by inspection Erase fault code memory and verify repairs Re...

Page 61: ...epair the short and verify repairs Refer to section 4 3 2 6 b If the resistance is greater than 10 k for wires from pins 50 to 1 pins 42 to 2 or pins 11 to 3 then there is a open circuit in the wire Repair the open circuit and verify repairs Refer to section 4 3 2 6 c If fault code s 146 12 is still active replace EGR valve Erase fault code memory and verify repairs Refer to section 4 3 2 6 d If f...

Page 62: ...oting is complete b If a fault code other than SID 146 is logged refer to Detroit Diesel MBE Electronic Controls Troubleshooting Guide 6SE422 c If a fault code in SID 146 is logged refer to Section 4 3 2 1 for code s 146 0 Section 4 3 2 2 for code s 146 1 Section 4 3 2 3 for code s 146 2 Section 4 3 2 4 for code s 146 7 Section 4 3 2 5 for code s 146 12 4 20 All information subject to change witho...

Page 63: ...EGR Temperature reads too high or too low that the EGR Valve is not responding or there is a bad EGR System component The following conditions can limit the engine torque output to its current setting SID 21 indicates a problem with the Crankshaft Position Sensor data or a mismatch between the Crankshaft Position Sensor and Camshaft Position Sensor signals The DDEC ECU is reading the EGR Temperatu...

Page 64: ...CODES PRELIMINARY THIS PAGE INTENTIONALLY LEFT BLANK 4 22 All information subject to change without notice Rev 5 05 7SE940 0505 Copyright 2005 DETROIT DIESEL CORPORATION ...

Page 65: ...R Cooler Inspection Inspection of Thermostat Housing Refer to appendix C Service Information Letter 04 TS 57 MBE 900 Model Year 2004 EGR Overheat Condition Verifying DDEC ECU Parameter Settings Refer to appendix C Service Information Letter 04 TS 61 MBE 4000 PLD Parameters Inspection of Charge Air Cooler Refer to appendix C Service Information Letter 05 TS 01 Charge Air Cooler Leaks NOTE You may a...

Page 66: ...TESTING PRELIMINARY THIS PAGE INTENTIONALLY LEFT BLANK 5 2 All information subject to change without notice Rev 5 05 7SE940 0505 Copyright 2005 DETROIT DIESEL CORPORATION ...

Page 67: ...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 See Figure 6 1 Figure 6 1 Snapshot Drop Down Menu 3 Upon choosing the New option a Record Snapshot box will appear in the upper left section of the screen 4 The Record Time starts counting from the second the New option is clicked All...

Page 68: ...e to save the file 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 recording of the desired data is completed click once with the left mouse button on the Stop Recording ESC box See Figure 6 2 Figure 6...

Page 69: ...changes To save the recorded data to the hard drive click once with the left mouse button on the Yes option To discard the data recorded by the snapshot click on the NO option See Figure 6 3 Figure 6 3 Stop Recording ESC Options All information subject to change without notice Rev 5 05 6 3 7SE940 0505 Copyright 2005 DETROIT DIESEL CORPORATION ...

Page 70: ... with the left mouse button on the Save option box To replace the suggested name hit the space bar once to clear the line Type in the new file name before saving the file To change the location where the file is saved on the computer change the location designated in the Save In box For example the file may be saved to the A drive Once the file has been saved the process is complete 6 4 All inform...

Page 71: ...owing procedure 1 Go to the Snapshot drop down menu and select Open Do not have the computer connected to a vehicle when replaying a snapshot See Figure 6 5 Figure 6 5 Snapshot Drop Down Menu All information subject to change without notice Rev 5 05 6 5 7SE940 0505 Copyright 2005 DETROIT DIESEL CORPORATION ...

Page 72: ...ved in is C Detroit Diesel Diagnostic and the files have an extension of ddl 3 Highlight the desired the file with one click of the left mouse button The selected file 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 6 6 All information subject to change without notice Rev 5 05 7SE940 0505 Copyright 2005 DETROIT ...

Page 73: ...ves showing the progress of the replay and the time box next to it shows the time since the beginning of the recording When clicking 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 To stop the replay at a particular point of interest click on Pause The ins...

Page 74: ... Figure 6 8 Normal Instrumentation Window NOTE Not all DDDL windows can be activated when replaying the snapshot feature The response time window and the cylinder cutout window are not accessible in the injector in snapshot mode See Figure 6 9 Figure 6 10 Figure 6 11 and Figure 6 12 for samples of windows that may be activated 6 8 All information subject to change without notice Rev 5 05 7SE940 05...

Page 75: ... MBE EGR TECHNICIAN S GUIDE Figure 6 9 Diagnostic Instrumentation Window Figure 6 10 Graph Window All information subject to change without notice Rev 5 05 6 9 7SE940 0505 Copyright 2005 DETROIT DIESEL CORPORATION ...

Page 76: ...SEL DIAGNOSTIC LINK SNAPSHOTS PRELIMINARY Figure 6 11 User Window Figure 6 12 Fault Codes Window 6 10 All information subject to change without notice Rev 5 05 7SE940 0505 Copyright 2005 DETROIT DIESEL CORPORATION ...

Page 77: ...is folder was used to store snapshots view the snapshots available by going to Diagnostic Link opening up the Snapshot drop down menu and selecting Open See Figure 6 13 and Figure 6 14 Figure 6 13 Snapshot Drop Down Menu Figure 6 14 Available Snapshot Files from Diagnostic Link 2 Write down the names of the files to send and close Diagnostic Link All information subject to change without notice Re...

Page 78: ...t location when the files are created so this location is not always used The user can also do a search for file names using the snapshot file extension ddl to locate all the snapshots on their computer Figure 6 15 Location of the Detroit Diesel Folder on the C Drive 6 12 All information subject to change without notice Rev 5 05 7SE940 0505 Copyright 2005 DETROIT DIESEL CORPORATION ...

Page 79: ...iles to attach to the E mail If the files are not lined up as shown go up to the View drop down menu in the file manager and choose Details from the list This view makes it easier to work with them Click once with the left mouse button to select a file To select more files hold down the Control key and click once more for each additional file See Figure 6 17 Figure 6 17 Selecting the Snapshot File...

Page 80: ...e the menu will go away The operations in the file manager are finished Figure 6 18 Copying the Snapshot Files from the C Drive 7 Open up the E mail program and create a new E mail message Do a right mouse click on a blank area in the body of the E mail and select Paste from the menu See Figure 6 19 Figure 6 19 Pasting the Files in the E mail Message 6 14 All information subject to change without ...

Page 81: ...r of the files just reverses the process in order to read them with Diagnostic Link See Figure 6 21 Figure 6 21 Receiving the Snapshot Files from the E mail Message 10 Do a single right mouse click on each of the attached files and copy them from the E mail to the C Detroit Diesel Diagnostic folder 11 Open up Diagnostic Link and choose the Open selection from the File drop down menu The files rece...

Page 82: ...ETROIT DIESEL DIAGNOSTIC LINK SNAPSHOTS PRELIMINARY THIS PAGE INTENTIONALLY LEFT BLANK 6 16 All information subject to change without notice Rev 5 05 7SE940 0505 Copyright 2005 DETROIT DIESEL CORPORATION ...

Page 83: ...ermine good vs bad engine operation They are meant to give the user a good understanding of how the EGR system operates As more information becomes available the snapshot examples will be expanded to aid engine diagnosis Each snapshot in this chapter was generated under controlled vehicle operation Cold Engine at Idle Refer to section 7 1 1 Engine Warming Up With No Load Refer to section 7 1 2 MBE...

Page 84: ...f typical engine operation 7 1 1 COLD ENGINE AT IDLE For a cold engine at idle the EGR valve is closed and the EGR temperature after the EGR cooler is well below the engine coolant temperature See Figure 7 1 and Figure 7 2 for an MBE 900 engine operating at idle Figure 7 1 Cold MBE 900 Engine at Idle Diagnostic Instrumentation Window 7 2 All information subject to change without notice Rev 5 05 7S...

Page 85: ...ELIMINARY MBE EGR TECHNICIAN S GUIDE Figure 7 2 Cold MBE 900 Engine at Idle Graph Window All information subject to change without notice Rev 5 05 7 3 7SE940 0505 Copyright 2005 DETROIT DIESEL CORPORATION ...

Page 86: ... EGR cooler approaches the engine coolant temperature See Figure 7 3 and Figure 7 4 for an MBE 900 engine warming up with no load Figure 7 3 MBE 900 Engine Warming up at Intermediate Speeds Diagnostic Instrumentation Window 7 4 All information subject to change without notice Rev 5 05 7SE940 0505 Copyright 2005 DETROIT DIESEL CORPORATION ...

Page 87: ...BE EGR TECHNICIAN S GUIDE Figure 7 4 MBE 900 Engine Warming up at Intermediate Speeds Graph Window All information subject to change without notice Rev 5 05 7 5 7SE940 0505 Copyright 2005 DETROIT DIESEL CORPORATION ...

Page 88: ...riable engine speeds and loads In this snapshot the engine coolant is at operating temperature See Figure 7 5 NOTE The EGR temperature slowly builds while the coolant temperature remains steady Figure 7 5 MBE 4000 Engine at Low Vehicle Speed 7 6 All information subject to change without notice Rev 5 05 7SE940 0505 Copyright 2005 DETROIT DIESEL CORPORATION ...

Page 89: ...t variable engine speeds and loads In this snapshot the engine coolant is at operating temperature See Figure 7 6 NOTE The EGR temperature slowly builds while the coolant temperature remains steady Figure 7 6 MBE 900 Engine at Low Vehicle Speed All information subject to change without notice Rev 5 05 7 7 7SE940 0505 Copyright 2005 DETROIT DIESEL CORPORATION ...

Page 90: ...s 7 2 1 ENGINE WITH NO EGR TEMPERATURE READING If an engine runs with no EGR temperature reading such as a bad EGR temperature sensor or open EGR temperature circuit then there will be no value for EGR temperature after cooler See Figure 7 7 and Figure 7 8 for an MBE 900 engine with no EGR temperature reading Figure 7 7 MBE 900 Engine Running with No EGR Temperature Reading Diagnostic Instrumentat...

Page 91: ...EGR TECHNICIAN S GUIDE Figure 7 8 MBE 900 Engine Running with No EGR Temperature Reading Graph Window All information subject to change without notice Rev 5 05 7 9 7SE940 0505 Copyright 2005 DETROIT DIESEL CORPORATION ...

Page 92: ...R temperature sensor or open EGR temperature circuit then the fault description fault ID SID or PID and FMI will appear in the fault codes window See Figure 7 9 Figure 7 9 MBE 900 Engine Running with Above Normal EGR Temperature Fault Codes Window 7 10 All information subject to change without notice Rev 5 05 7SE940 0505 Copyright 2005 DETROIT DIESEL CORPORATION ...

Page 93: ...ation EPA Environmental Protection Agency ESC Abbreviation on a Computer Keyboard for Escape FMI Failure Mode Indentifier IAT Intake Air Temperature IES Integrated Electronic System IMAT Sensor Intake Manifold Air Temperature Sensor IMP Sensor Intake Manifold Pressure Sensor aka TBS kPa Kilopascals NAFTA North American Free Trade Agreement Area NOx Oxides of Nitrogen OEM Original Equipment Manufac...

Page 94: ...omotive Engineers SEL Stop Engine Light aka RSL SID System Identification TBS Turbocharger Boost Sensor aka IMP Sensor VSS Vehicle Speed Sensor A 2 All information subject to change without notice Rev 5 05 7SE940 0505 Copyright 2005 DETROIT DIESEL CORPORATION ...

Page 95: ...0 4000 DDEC Vehicle Interface Wiring Diagram See Figure B 1 MBE 4000 DDEC ECU Engine Wiring Diagram See Figure B 2 MBE 900 DDEC ECU Engine Wiring Diagram See Figure B 3 All information subject to change without notice Rev 5 05 B 1 7SE940 0505 Copyright 2005 DETROIT DIESEL CORPORATION ...

Page 96: ...APPENDIX B MBE DDEC WIRING SCHEMATICS PRELIMINARY B 2 All information subject to change without notice Rev 5 05 7SE940 0505 Copyright 2005 DETROIT DIESEL CORPORATION ...

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Page 101: ...ure C 6 Service Information Letter 04 TS 57 Subject MBE 900 Model Year 2004 EGR Overheat Condition See Figure C 7 and Figure C 8 Service Information Letter 04 TS 61 Subject MBE 4000 PLD Parameter Settings See Figure C 9 Figure C 10 Figure C 11 Figure C 12 Figure C 13 Figure C 14 and Figure C 15 Service Information Letter 05 TS 01 Subject Charge Air Cooler Leaks See Figure C 16 and Figure C 17 All ...

Page 102: ...APPENDIX C SERVICE INFORMATION LETTERS PRELIMINARY C 2 All information subject to change without notice Rev 5 05 7SE940 0505 Copyright 2005 DETROIT DIESEL CORPORATION ...

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Page 104: ...APPENDIX C SERVICE INFORMATION LETTERS PRELIMINARY C 4 All information subject to change without notice Rev 5 05 7SE940 0505 Copyright 2005 DETROIT DIESEL CORPORATION ...

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Page 106: ...APPENDIX C SERVICE INFORMATION LETTERS PRELIMINARY C 6 All information subject to change without notice Rev 5 05 7SE940 0505 Copyright 2005 DETROIT DIESEL CORPORATION ...

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Page 120: ...APPENDIX C SERVICE INFORMATION LETTERS PRELIMINARY C 20 All information subject to change without notice Rev 5 05 7SE940 0505 Copyright 2005 DETROIT DIESEL CORPORATION ...

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