Series 60 EGR

Section 8.1 Overview of the DDEC V EGR System

Section 8.1
Overview of the DDEC V EGR System

The following subsections graphically illustrate the DDEC V EGR system.‪

EGR System

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 "EGR Component Overview" graphically illustrates how the EGR components function to accomplish reduced NOx emissions.‪

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Figure 1. EGR Component Overview

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 "EGR Valve and VNT Control System" .‪

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Figure 2. EGR Valve and VNT Control System

Detailed Views of the DDEC V EGR Components

See Figure "Right Side Component Engine View" for a right side engine view.‪

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 1. Turbocharger Oil Feed Line‪

 5. Venturi to Delta P Sensor Line‪

 9. VPOD Air Out to Turbocharger Actuator‪

 2. Variable Nozzle Turbocharger (VNT)‪

 6. High Flow Water Pump‪

 10. Variable Pressure Output Device (VPOD)‪

 3. Venturi to Delta P Sensor Line‪

 7. Tube and Shell EGR Cooler‪

 4. Delta P Sensor‪

 8. VNT Actuator‪

Figure 3. Right Side Component Engine View

See Figure "Left Side Component Engine View" for a left side engine view.‪

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 1. Camshaft Gear Cover‪

 3. Intake Air Temperature Sensor (IAT Sensor)‪

 5. Barometric Pressure Sensor (Baro)‪

 2. EGR Delivery Pipe‪

 4. Intake Manifold Pressure Sensor (IMP Sensor)‪

 6. Charge Air Mixer‪

Figure 4. Left Side Component Engine View

See Figure "Front Right Side Component Engine View" for a detailed front right side engine view.‪

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 1. Exhaust Manifold with Fey Seals‪

 5. EGR Delivery Pipe‪

 8. VNT Actuator‪

 2. Variable Nozzle Turbocharger (VNT)‪

 6. Venturi Tube‪

 9. EGR Valve Control Oil Supply Line‪

 3. Turbocharger Speed Sensor (TSS)‪

 7. EGR Tube and Shell Cooler‪

10. VPOD-to-VNT Actuator Air Line‪

 4. Delta P Sensor‪

Figure 5. Front Right Side Component Engine View

See Figure "Lower Rear Left Side Engine Components" for the lower rear right side engine components.‪

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 1. Barometric Pressure Sensor‪

 4. Engine Oil Pressure Sensor‪

 2. Check Valve and Regulator Fitting for Return Fuel‪

 5. Injector Harness Connector‪

 3. Breather Tube‪

Figure 6. Lower Rear Left Side Engine Components

See Figure "Delta P Sensor Location" a detailed view of the Delta P Sensor.‪

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 1.Thermostat Housing‪

 2. Delta P Sensor‪

Figure 7. Delta P Sensor Location

See Figure "VNT and Related Components Location" for a detailed view of the VNT, EGR valve, and related components location.‪

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 1. EGR Control Valve Oil Supply Line‪

 4. Delta P Sensor Lines‪

 2. VNT Actuator Air Line‪

 5. EGR Valve‪

 3. VNT Actuator‪

 6. EGR Valve Hydraulic Actuator‪

Figure 8. VNT and Related Components Location

See Figure "VNT and Related Components" for a detailed view of the VNT and related components.‪

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 1. Turbocharger Speed Sensor (TSS)‪

 3. Turbocharger Compressor Outlet Temperature Sensor (TCOT)‪

 2. Turbocharger Oil Inlet Line‪

 4. Variable Nozzle Turbocharger (VNT)‪

Figure 9. VNT and Related Components

See Figure "Fey Ring Exhaust Manifold" for an exploded view of the Fey ring exhaust manifold.‪

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 1. Fey Ring Grooves with Fey Rings‪

 3. Exhaust Manifold Assembly‪

 2. EGR Valve to Bellow Connector‪

Figure 10. Fey Ring Exhaust Manifold

DDEC V Electronic Control Unit

Figure "DDEC V ECU" illustrates the location of the DDEC V ECU.‪

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 1. Fuel Pump‪

 2. Fuel Pump Outlet Line‪

 3. DDEC V ECU‪

Figure 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 flow 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.‪

Top Right Side View of EGR Components

See Figure "Top Right Side View of EGR Components" for a detailed view of the EGR components.‪

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 1. Exhaust Manifold‪

 4. EGR  Control Valve Hydraulic Actuator‪

 7. Exhaust Manifold Center Housing to Bellow Pipe‪

 2. Bellows‪

 5. EGR Control Valve  Oil Return Connector‪

 3. EGR Control Valve Body‪

 6. EGR Control Valve Oil Supply Line‪

Figure 12. Top Right Side View of EGR Components

See Figure "Front Right Side View of EGR Components" for a detailed right side view of the EGR components.‪

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 1. EGR Control Valve Hydraulic Actuator‪

 2. Delivery Pipe Connection‪

Figure 13. Front Right Side View of EGR Components

See Figure "EGR Cooler and Related Components" for a detailed view of the EGR cooler and related components.‪

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 1. Bolt on EGR Valve‪

 4. Tube and Shell EGR Cooler‪

 2. Venturi Tube‪

 5. EGR Control Valve Oil Return Line‪

 3. High Volume Water Pump‪

Figure 14. EGR Cooler and Related Components

See Figure "EGR Valve" for a view of the EGR valve.‪

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 1. EGR Valve Assembly‪

 3. EGR Control Valve Oil Return Line Connection‪

 2. EGR Control Valve Oil Feed Connection‪

 4. EGR Control Valve Hydraulic Actuator‪

Figure 15. EGR Valve


Series 60 EGR Technician's Manual - 7SE60
Generated on 10-13-2008

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