DDEC III/IV Single ECM Troubleshooting – Section 10.16 Exhaust Gas Recirculation System (EGR-1) – Fault, Series 50 Engine

Section 10.16
Exhaust Gas Recirculation System (EGR-1) – Fault, Series 50 Engine

The following procedures will troubleshoot the Exhaust Gas Recirculation (EGR) system:‪

Section 10.16.1
Exhaust Gas Recirculation System Troubleshooting

Perform the following steps for all EGR related issues.‪

Note: EGR system related part numbers can be found in parts bulletin #2–PI-00.

1. Check ECM voltage via DDR. The system voltage must be 24V (not 12V).
2. Check bus air systems. Air pressure must be greater than 620 kPa (90 psi).
3. Check EGR solenoid assembly to ensure there is at least 90 psi air pressure to the solenoid. If the bus has 620 kPa (90 psi), but not at solenoid, check the air lines to the solenoid.
4. Check hot, cold and cooler tubes and V-band clamps for leakage.
5. Disconnect the air hoses from the EGR valve and VGT (Variable Geometry Turbocharger) actuator. See Figure "PWM Valve Assembly" .
   

   1. EGR Solenoid‪	5. Electrical Connectors‪
   2. PWM Valve air Line‪	6. Bolt‪
   3. EGR Solenoid Air Line‪	7. Bracket‪
   4. Air Supply air Line (hidden)‪	‪

   Figure 1. PWM Valve Assembly

   1. Install the pressure gauges at the outlet of these hoses. (Use two gauges or test separately.)
   2. Use DDR/DDDL to activate output T3 and watch pressure at the EGR valve. Pressure should be 503–545 kPa (73–79 psi). Low or high pressure indicates PWM valve assembly fault.
   3. Use DDR/DDDL to cycle output S3 and watch the pressure gauge at the VGT actuator. Pressure should be 427–448 kPa (62–65 psi). Low or high pressure indicates PWM valve assembly fault.

   Note: The EGR solenoid and the PWM valve can be serviced separately.

6. Reconnect air hose and ensure bus air pressure is at least 620 kPa (90) psi.
   1. Activate output T3 and watch the EGR actuator rod for movement. If actuator rod does not move, replace EGR valve assembly.
   2. Toggle output S3 and watch the VGT actuator rod for movement. If the rod does not travel to set screw, adjust actuator rod length following the procedure outlined in the Series 50 Service Manual. If adjustment cannot be obtained, replace actuator assembly or inspect VGT vanes for damage.

      Note: Never adjust set screw.

7. Use the DDR/DDDL and check turbocharger speed at idle. The speed should be about 18,000 to 30,000 rpm. If speed is low, check inlet restriction. Also check the exhaust back pressure.
8. Check the Delta-P orifice pressure at idle. Pressure at idle should be less than 1 kPa (0.15 psi). If pressure differs, shut the engine off. Turn the key on.
   1. If pressure is greater than 1 kPa (0.15 psi), viewed on the DDR/DDDL, replace the EGR pressure sensor.
   2. If pressure is less than 1 kPa (0.15 psi), inspect the EGR valve, and replace if necessary.
9. Check the Delta-P orifice pressure at idle. Pressure at idle should be less than 1 kPa (0.15 psi). If pressure differs, shut the engine off. Turn the key on.
   1. If pressure is greater than 1 kPa (0.15 psi), viewed on the DDR/DDDL, replace the EGR pressure sensor.
   2. If pressure is less than 1 kPa (0.15 psi), inspect the EGR valve, and replace if necessary.
10. If corrections have been made as a result of these checks, verify the repair by checking the applicable flash code verification.
    1. If all tests pass, and no DDEC codes are present, contact DDC Technical Service.
    2. If all tests pass, but a problem still exists, view the DDEC codes for further troubleshooting. For a list of EGR fault codes, refer to "10.16.2 DDEC Codes for Exhaust Gas Recirculation" .

Section 10.16.2
DDEC Codes for Exhaust Gas Recirculation

DDEC  Codes for Exhaust Gas Recirculation are listed in Table "DDEC Codes for Exhaust Gas Recirculation" . ‪

Flash‪ Code‪	Refer‪ To‪	J1587‪ Code‪	Description‪	Typical Reason‪
31‪	section "31 Flash Code 31 - Engine Brake Fault Code or EGR / PWM Fault" ‪	s 51 3 or 4‪	PWM valve power open or short to ground‪	Open or shorted wire‪
31‪	section "31 Flash Code 31 - Engine Brake Fault Code or EGR / PWM Fault" ‪	s 52 3 or 4‪	EGR Solenoid power open or short to ground‪	Open or shorted wire‪
39‪	section "39 Flash Code 39 – EGR Valve / VNT Vane Fault" ‪	s 146 2‪	EGR leak — boost power‪
39‪	section "39 Flash Code 39 – EGR Valve / VNT Vane Fault" ‪	s 146 12‪	EGR leak — boost Jake‪
39‪	section "39 Flash Code 39 – EGR Valve / VNT Vane Fault" ‪	s 152 7‪ or 146 7‪	EGR Valve mechanism not responding‪	EGR valve or air supply fault‪ EGR Delta-Pressure sensor fault‪
39‪	section "39 Flash Code 39 – EGR Valve / VNT Vane Fault" ‪	s 147 2‪	VNT vanes not responding — boost power‪
39‪	section "39 Flash Code 39 – EGR Valve / VNT Vane Fault" ‪	s 147 12‪	VNT vanes not responding — boost Jake‪
39‪	section "39 Flash Code 39 – EGR Valve / VNT Vane Fault" ‪	s 147 14‪	EGR flow too low‪
39‪	section "39 Flash Code 39 – EGR Valve / VNT Vane Fault" ‪	s 147 11‪	VNT vanes at max — Jake‪
39‪	section "39 Flash Code 39 – EGR Valve / VNT Vane Fault" ‪	s 153 7‪ or 147 7‪	VNT Vane Mechanism Not Responding‪	Failed Turbo or air supply fault‪ EGR Delta-Pressure sensor fault‪
48‪	section "48 Flash Code 48 - Air / Fuel / EGR Pressure Low or EGR / TCI / TCO Temperature Low" ‪	s 154 1‪ or 412 1‪	EGR Temperature Low‪	EGR valve not opening correctly‪
48‪	section "48 Flash Code 48 - Air / Fuel / EGR Pressure Low or EGR / TCI / TCO Temperature Low" ‪	s 155 1‪ or 411 1‪	EGR Delta-Pressure Low‪	EGR valve not opening correctly‪
63‪	section "63 Flash Code 63 - PWM Fault" ‪	s 60 3‪	PWM (#4) above or below normal range‪	Open or shorted wire‪
64‪	section "64 Flash Code 64 — Turbo Speed Sensor Fault" ‪	p 103 0‪	Turbo Overspeed Code‪	Turbo or turbo speed sensor‪
81‪	section "81 Flash Code 81 – Oil Level, Exhaust Temp, EGR Temp or EGR Delta-Pressure, Circuit Failed High" ‪	s 154 3‪ or 412 3‪	EGR Temperature Circuit Failed High‪	Wiring/sensor fault‪
81‪	section "81 Flash Code 81 – Oil Level, Exhaust Temp, EGR Temp or EGR Delta-Pressure, Circuit Failed High" ‪	s 155 3‪ or 411 3‪	EGR Delta-Pressure Circuit Failed High‪	Wiring/sensor fault‪
82‪	section "82 Flash Code 82 – Oil Level, Exhaust Temp, EGR Temp or EGR Delta-Pressure, Circuit Failed Low" ‪	s 154 4‪ or 412 4‪	EGR Temperature Circuit Failed Low‪	Wiring/sensor fault‪
82‪	section "82 Flash Code 82 – Oil Level, Exhaust Temp, EGR Temp or EGR Delta-Pressure, Circuit Failed Low" ‪	s 155 4‪ or 411 4‪	EGR Delta-Pressure Circuit Failed Low‪	Wiring/sensor fault or crossed Delta-P hoses‪
83‪	section "83 Flash Code 83 – EGR Temp, EGR Delta-Pressure, Exhaust Temp, or External Pump Pressure High" ‪	s 154 0‪ or 412 0‪	EGR Temperature High‪	EGR valve stuck/partly open‪
83‪	section "83 Flash Code 83 – EGR Temp, EGR Delta-Pressure, Exhaust Temp, or External Pump Pressure High" ‪	s 155 0‪ or 411 0‪	EGR Delta-Pressure High‪	EGR valve stuck open‪

The DDEC Single ECM Troubleshooting Guide is organized by flash code. Refer to the corresponding section of the guide for troubleshooting that code.