Series 60 DDEC V Troubleshooting – Section 20.18 Exhaust Gas Recirculation System Basic Checks for Series 60 Engines

Section 20.18
Exhaust Gas Recirculation System Basic Checks for Series 60 Engines

For all EGR related concerns (may include exhaust smoke complaints) and Code 39 etc., 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 9 or DDDL version 6.0 or higher
• Volt Ohm Meter
• Pressure gage 0–200 psi (0-1378 kPa)
• Pressure gage 0–100 psi (0-689 kPa)
• Regulated shop air pressure (10 psi)

Section 20.18.1
Check EGR Controls

Perform the following steps to check the EGR system components.‪

1. Turn ignition ON.
2. Plug in DDR/DDDL.
3. Any EGR Related codes (except Flash Code 39)?
   1. If codes were logged, troubleshoot the codes as necessary.
   2. If no codes were logged (besides Code 39), proceed to step 4 .
4. Inspect system for any air leaks in the exhaust, EGR, or intake system (including charge-air-cooler).
   1. If leaks were detected, repair as necessary.
   2. If no leaks are present, go to step 5 .
5. Check Delta P Counts on DDR/DDDL (counts should be between 86 and 118).

   Note: The ignition is set to the ON position and the engine is not running.

   1. If the counts were between 86 and 118, refer to "20.18.2 Check VPOD Input Pressure" .
   2. If the counts were not between 86 and 118, replace the Delta P Sensor and refer to "20.18.7.1 Test" .

Section 20.18.2
Check VPOD Input Pressure

Follow these steps to check VPOD input pressure: ‪

1. Measure the vehicle air supply pressure to VPOD input pressure to port 1; ensure it is between 102 – 188 psi. (703 – 1296 kPa).
   1. If the supply pressure is not between 102 – 188 psi (703 – 1296 kPa), troubleshoot the vehicle air system until that result is obtained.
   2. If the supply pressure is between 102 – 188 psi (703 – 1296 kPa ), refer to "20.18.3 Check VPOD Output Pressure" .

Section 20.18.3
Check VPOD Output Pressure

Follow these steps to check VPOD output pressure: ‪

1. Disconnect the air hose from the VNT (Variable Nozzle Turbocharger) actuator.
2. Install a 100 psi pressure gauge (accurate to within 1.4 kPa [0.2 psi]) at the outlet of the VNT hose.
3. Using the DDR/DDDL, activate cavity E-4 (VNT) duty cycle and monitor the output pressure from the VPOD.
4. Test: Activate the cavity to 50 % duty cycle: Pressure = 310 ± 14 kPa (45 ± 2 psi).
   1. If the VPOD readings are as listed above, refer to "20.18.6 Check EGR Valve" .
   2. If the results in this step cannot be attained, or if the VPOD leaks when activated replace the VPOD.
   3. If the VPOD has been replaced, refer to "20.18.4 Check VPOD Supply Voltage" .

Section 20.18.4
Check VPOD Supply Voltage

The following checks should be performed for the VPOD supply voltage:‪

1. Check VPOD label to determine if it is + 12V or + 24V compatible.
2. Unplug VPOD 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.
   

   Figure 1. VNT/VPOD Schematic

   1. Turn ignition switch ON.
   2. Measure system voltage from pin 3 to pin 1. See Figure "VNT/VPOD Schematic" .
   3. Plug in DDR and check ECM/ECU voltage.
3. Is the VPOD supply voltage, and ECM/ECU voltage correct?
   1. If the VPOD and system voltage are correct, refer to "20.18.5 Check VPOD Wiring" .
   2. If the VPOD supply voltage and ECM/ECU voltage are not correct, contact the Detroit Diesel Customer Support Center (313–592–5800).

Section 20.18.5
Check VPOD Wiring

The following checks should be performed for the VPOD wiring. ‪

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 either a DDR or DDDL, activate the VPOD used for the VNT. Ensure activating 50% duty cycle: The reading should be = 50% of the VPOD supply voltage ± 1 volt, The acceptable range will depend on the supply system voltage (e.g. voltage to VPOD = 13.8V * 0.5 = 6.9V; therefore 5.9V to 7.9V at PWM is okay.)
6. Note any air leakage when PWMs are activated to 90% and correct the leaks as needed.
   1. If the voltage measurements is correct, replace the VPOD.
   2. If the voltage measurement are incorrect, and the wiring checks are okay, try a test ECM/ECU programmed for EGR, or contact the Detroit Diesel Customer Support Center (313–592–5800).

Section 20.18.6
Check EGR Valve

Perform the following steps to check the EGR Valve.‪

1. Disconnect the oil supply from the EGR valve actuator. Connect shop air to the actuator and regulate the pressure at 10 psi to the EGR actuator.
   

   1. EGR Valve and Actuator Assembly‪	3. Oil Outlet Hose and Fitting‪
   2. Oil Inlet Hose and Fitting‪	‪

   Figure 2. EGR Valve Assembly with Oil Lines

2. Plug in the DDDL.
3. Activate the EGR Valve output (E-1) and observe the EGR Valve travel (close 0% – open 100%).

   Note: Do not activate more than 3 cycles.

4. Visually inspect the EGR Valve for proper movement.
5. Did the EGR Valve close (0%) when activated?
   1. If the EGR Valve was fully closed at 0%, refer to "20.18.7 Check for Active Codes" .
   2. If the EGR Valve did not fully close at 0%, replace the EGR Valve. Refer to "20.18.7.1 Test" .
6. Did the EGR Valve open (100%) when activated?
   1. If the EGR Valve was fully opened at 100%, refer to "20.18.7 Check for Active Codes" .
   2. If the EGR Valve did not fully open to 100%, replace the EGR Valve. Refer to "20.18.7.1 Test" .

Section 20.18.7
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/ECU 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/ECU to protect other engine components.

5. If the issue is not related to the EGR system components, or assistance is needed, contact Detroit Diesel Customer Service Center (313-592-5800).

Section 20.18.7.1
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 Customer Service Center (313-592-5800).