DDEC III/IV Single ECM Troubleshooting – Section 10.18 Exhaust Gas Recirculation System Basic Checks for Series 60 Engines

Section 10.18
Exhaust Gas Recirculation System Basic Checks for Series 60 Engines

For all EGR related concerns (may include exhaust smoke complaints), perform the following steps. If any corrections are made as a result of these checks, test the unit again before proceeding further:‪

Basic checks for all Series 60 EGR engines require the following tools:‪

• 1,000 Ohm resistor (low watt)
• DDR suite 8 or DDDL version 4.2 or higher
• Volt Ohm Meter
• Pressure gage 0–200 psi
• Pressure gage 0–100 psi

Section 10.18.1
Check Delta-P sensor

Follow these steps to check the Delta-P sensor:‪

1. Turn ignition ON.
2. Plug in DDR/DDDL.
3. Read Delta-P counts (EGR DPS)
   1. If Delta-P counts read 86–118, verify that the EGR pipes and hoses are correctly assembled from the EGR tube to the Delta-P sensor. Reversed hoses or pipes will create black smoke and surging. Go to step 3b .
   2. Also inspect carefully for split or leaking pipes or hoses in the EGR mixer tube from the EGR cooler to the intake manifold. If hoses/pipes are correct, Refer to "10.18.4 Check Variable Output Pressure Device (VPOD) P/N and Supply Voltage" .
   3. If counts do not fall within the 86–118 range, replace Delta-P sensor; then go to Test.

Section 10.18.2
Check VPOD Output Pressure

Follow these steps to check both VPOD (EGR valve and VNT) output pressure:‪

Note: Listen for air leaks at the VPOD during the test.

1. Disconnect the air hoses from the EGR and VNT (Variable Nozzle Turbine) actuators.
2. Install pressure gauges (accurate to within 1.4 kPa [0.2 psi]) at the outlet of the EGR and VNT hoses. (Use two gauges, or test separately.)
3. Using the DDR/DDDL, activate PWM #2 (EGR) and PWM #4 (VNT) duty cycles and monitor the output pressure from the VPOD.
4. Test: Activating 11 % duty cycle: Pressure = 120 ± 14 kPa (17.4 ± 2 psi). Go to steps 5a and 5b .
5. Test: Activating 90 % duty cycle: VDC = 500 ± 14 kPa (72.5 ± 2 psi).
   1. If the VPOD readings are as listed, go to section "10.18.6 Check for Active Codes" .
   2. If the results in this step cannot be attained, refer to "10.18.3 Check VPOD Input Pressure" .

   Note: Both activations must operate their component with full travel of the linkage to hit the stops.

Section 10.18.3
Check VPOD Input Pressure

Follow these steps to check VPOD input pressure: ‪

1. Measure VPOD input pressure to port 1; ensure it is between 703 – 1296 kPa (102 – 188 psi).
   1. If the supply pressure is not between 703 – 1296 kPa (102 – 188 psi), troubleshoot the vehicle air system until that result is obtained.
   2. If the supply pressure is between 703 – 1296 kPa (102 – 188 psi), go to section "10.18.4 Check Variable Output Pressure Device (VPOD) P/N and Supply Voltage" .

Section 10.18.4
Check Variable Output Pressure Device (VPOD) P/N and Supply Voltage

The following checks should be performed for the VPOD P/N and supply voltage:‪

1. Check VPOD label to determine if it is + 12V or + 24V compatible.
2. Unplug VPODs mating connector. A 1,000 Ohm resistor is needed for the next step. Insert the resistor between cavity 1 and 3 for ease of checking with the VOM.
   1. Turn ignition switch ON.
   2. Measure voltage from pin 3 to pin 1.
   3. Plug in DDR and check ECM voltage.
3. Is the VPOD P/N and voltage, and ECM voltage correct?
   1. If the VPOD P/N and voltage are correct, go to section "10.18.5 Check VPOD Wiring" .

Section 10.18.5
Check VPOD Wiring

The following checks should be performed for the VPOD wiring. ‪

Note: VPOD power should have been verified under the P/N check. If not, refer to "10.18.4 Check Variable Output Pressure Device (VPOD) P/N and Supply Voltage" .

1. Turn ignition switch ON.
2. Unplug the VPOD mating connector.
3. Insert a 1,000 ohm resistor between cavities #2 and #1 for the 12V version, or cavities #2 and #3 for the 24V version.
4. Connect a VOM to the VPOD connector between pin #2 and pin #3 for the 12V VPOD or pin #2 and pin #1 for the 24V VPOD.
5. Using a DDR/DDDL, activate the PWM #2 (EGR Valve) and PWM #4 (VNT), and ensure:
   1. Activating 11 % duty cycle: VDC = 90% of the VPOD supply voltage ± 1 volt (e.g. voltage to VPOD = 13.8V * 0.9 = 12.42V; therefore 11.42V to 13.42V at PWM is okay.)
   2. Activating 90 % duty cycle: VDC = 10% of the VPOD supply voltage ± 1 volt. (e.g. voltage to VPOD = 13.8V * 0.1 = 1.38V, therefore 0.38V to 2.38V at PWM is okay.)
6. Note any air leakage when PWMs are activated to 90% and correct the leaks as needed.
   1. If both of the PWM voltage measurements are correct, replace the VPOD that had the wrong pressure reading.
   2. 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.

Section 10.18.6
Check for Active Codes

Follow this procedure to check for active codes. ‪

1. Turn ignition ON.
2. Plug in DDR/DDDL.
3. Read active codes.
4. Record or print codes. Ensure that PID, SID, and FMI are recorded. Refer to the proper code section of this guide to troubleshoot that code.

   Note: FMIs listed as 14 are diagnostic information codes and no troubleshooting is required. For example, an engine derates due to high TCO temperature; a 404/14 code will be stored. This would indicate that conditions warranted having the ECM derate the fueling to the engine. If the customer complaint was a power loss, it could be explained that loss of power was done by the ECM to protect other engine components.

5. If the issue is not related to the EGR system components, or assistance is needed, contact Detroit Diesel Technical Service.

Section 10.18.7
Test

Follow these steps to test:‪

1. Reassemble connectors or components.
2. Start and run the engine.
3. Perform loaded road test if this is necessary to duplicate original complaint.
   1. If symptoms/codes are gone, repairs are complete.
   2. If any codes display, review this section again; contact Detroit Diesel Technical Service.