NUMBER: 3 1–10 S.M. REF.

: Listed in Table ENGINE: EPA04 Series 60 DATE: March 2010

SUBJECT: EXHAUST GAS RECIRCULATION (EGR) DIAGNOSTICS

ADDITIONS, REVISIONS, OR UPDATES

Publication Number Platform Section Title Change Page Number(s)
DDC-SVC-MAN-0078 EPA04 SERIES 60 Exhaust Gas Sections added Input as section states
EGR TECHNICIANS Recirculation (EGR)
MANUAL DIAGNOSTICS
NOTE: Page numbers are based on the most recent version of the individual publication and may be adjusted throughout the annual print cycle.
EXHAUST GAS RECIRCULATION VALVE DIAGNOSTICS
Diagnose as follows:
1. Verify that DDDL is version 6.45 or higher.
2. Connect DDDL.
3. Verify that the calibration level is at DDEC V software R3.0 or higher.
4. Bring engine up to operating temperature. Are there codes in addition to the EGR codes? If
yes, repair them first.
5. Under Diagnostics Tab, click on Diagnostic Instrumentation. See Figure 1.

Figure 1 DDDL Diagnostics Tab

6. Click on the EGR *6 tab, the screen below will open. See Figure 2.

Figure 2 Diagnostic Information

7. Verify:
□ Torque limiting factor is 100%. If not, engine is de-rated and this concern needs to be
addressed first. See Figure 3.

Figure 3 Torque Limiting Factor Screen

□ Engine is not in smoke control mode. If in smoke control, check for concern affecting
the air fuel ratio. Examples would be: leak in the CAC, leak in intake manifold, low
fuel pressure, dirty air filter
□ Delta P sensor counts are 86 -118. If Delta P sensor counts are not within range, perform
Delta P sensor auto calibration. See Figure 4.

Figure 4 Recalibrate EGR DP Sensor

8. Allow engine to idle for at least 5 minutes.

 9. Check EGR temperature. If the temperature is within 20° F of the engine coolant temperature,
verify the EGR valve is not commanded open (EGR valve should be less than 20% and EGR
valve Current Signal less than 350mA). See Figure 5.

Figure 5 Diagnostic Instrumentation

10. Remove the cover from the EGR shaft and check the angle of the shaft. Verify the EGR valve is
not stuck open. See Figure 6.

Figure 6 EGR Valve

11. If the EGR valve is stuck open, replace the EGR Valve and retest.
12. Review and record the following parameters: see Figure 7
□ Turbocharger Shaft Spekrpm
□ EGR Delta Press H2O
□ EGR Delta P Counts
□ EGR Temperature

Figure 7 Parameters

13. With the engine at idle and operating temperature, press throttle pedal three times to put the
engine into EGR mode. Once in this mode it will stay there for three minutes. If the throttle
pedal is pressed while in EGR mode, the ECM will disable EGR mode until the throttle is
returned back to idle.
14. To determine if the engine is in EGR mode, check the EGR valve parameter. It should read
greater than 40% and the EGR valve Current signal should be greater than 1300 mA. See
Figure 8

Figure 8 Parameters
15. Once In EGR mode, monitor the following parameters and compare them with the readings
before: see Figure 9
□ Turbocharger Shaft Spekrpm
□ EGR Delta Press H2O
□ EGR Delta P Counts
□ EGR Temperature

Figure 9 Parameters
Use the readings above to determine the next steps in the following flow chart. See Figure 10

Figure 10 Flowchart
CHECKING EXHAUST GAS RECIRCULATION TEMPERATURE SENSOR
Check as follows:
1. Turn engine OFF (key OFF, engine OFF).
2. Disconnect the ECM connector.
3. Remove the EGR temperature sensor from the delivery pipe and allow the EGR temperature
sensor to reach room temperature (Approx. 5 minutes).
4. Without the temperature sensor touching any surface, measure the resistance between pins
E15 and E10. Is the resistance correct to the chart below for the temperature of the EGR
delivery pipe?
5. Using an infrared thermometer, check the temperature of the EGR delivery pipe close to the
EGR temperature sensor.
[a] No; go to step 6.
[b] Yes; go to next step in the flow chart, see Figure 10
6. Disconnect the EGR temperature sensor and measure the resistance between pins 1 at the EGR
temperature sensor connector and pin E15 at the ECM. Is the resistance below 5 ohms?
[a] No; repair wire as needed and retest.
[b] Yes; go to step 7.
 7. Measure Resistance between pins 2 at the EGR Temperature Sensor connector and pin E10 at
the ECM. Is the resistance less than 5 ohms?
[a] No; repair wire as needed and retest.
[b] Yes; replace the EGR temperature sensor and retest.
Temperature °F Temperature °C MAX resistance (K ohms) MIN resistance (K ohms)
32 0 1053.00 624.00
50 10 601.75 367.98
68 20 357.27 224.97
86 30 219.54 142.08
104 40 139.17 92.40
122 50 90.75 61.72
140 60 60.72 42.23
158 70 41.58 29.55
176 80 29.10 21.09
194 90 20.77 15.34
212 100 15.09 11.35
230 110 11.13 8.28
248 120 8.33 6.13
266 130 6.33 4.61
284 140 4.88 3.52
302 150 3.80 2.72
320 160 3.00 2.12
338 170 2.39 1.68
356 180 1.92 1.34
374 190 1.56 1.08
392 200 1.28 0.88

Table 1 Temperatures
CHECKING DELTA P SENSOR
Check as follows:
1. Visually inspect the sensor, sensor base plate, venturi, tubes and hoses for leaks. One sign to
look for would be soot which would indicate a leak at that area. Was a leak found?
[a] Yes; repair leak and retest EGR system.
[b] No; go to step 2.
2. Remove the sensor and check for moisture. Was moisture found?
[a] Yes; clean and dry sensor and retest EGR system.
[b] No; go to step 3.
3. Check tubes, hoses and sensor ports for signs of plugging; are the tubes plugged?
[a] Yes; clean tubes as needed, retest EGR system.
[b] No; go to step 4.
4. Verify that the correct venturi is on the engine, 12L – 23533548 and 14L 23533549. Refer to
Technical service letter 04 TS-51. Is the correct venturi on the engine?
[a] Yes; go to step 5.
[b] No; replace the venturi with the correct one and retest the EGR system.
5. Was a repair made?
[a] Yes; retest EGR system for correct operation.
[b] No; replace Delta P sensor and retest EGR system.
CHECKING WIRES BETWEEN EXHAUST GAS RECIRCULATION VALVE AND ECM
Check as follows:
1. Measure resistance between pin A of the EGR valve connector and Pin E-1 at the ECM. Is the
resistance less than 5 ohms?
[a] Yes; go to step 2.
[b] No; repair wire and retest.
2. Measure resistance between pin B of the EGR valve connector and Pin E-51 at the ECM.
Is the resistance less than 5 ohms?
[a] Yes; go to next step in flow chart. See Figure 10.
[b] No; repair wire and retest.
CHECKING EXHAUST GAS RECIRCULATION TURBOCHARGER SPEED SENSOR OPERATION
Check as follows:
1. Turn engine OFF (key OFF, engine OFF).
2. Measure resistance between pins E-34 and E-35 at ECM; is resistance between 635 – 1065
Ohms?
[a] No; go to step 3.
[b] Yes; Turbocharger Speed Sensor is working correctly, continue with flow chart.
3. Measure resistance between pin E-34 at ECM and pin 1 of Turbocharger Speed Sensor; is
resistance less than 5 ohms?
[a] Yes; go to step 4.
[b] No; repair wire and retest.
4. Measure resistance between pin E-35 at ECM and pin 2 of Turbocharger Speed Sensor; is
resistance less than 5 ohms?
[a] Yes; replace Turbocharger Speed Sensor and retest EGR system.
[b] No; repair wire and retest.
ADDITIONAL SERVICE INFORMATION
Additional service information is available in Power Service Literature.

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