the aftertreatment system technician's guide (ddc · pdf filethe aftertreatment system...
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NUMBER: 08 ATS–2 S.M. REF.: Listed in Table 1. ENGINE: ATS DATE: February 2008
SUBJECT: ADDITIONAL ENGINE WAS ADDED
PUBLICATION: DDC-SVC-MAN-0036 (7SE63)
The Aftertreatment System Technician's Guide (DDC-SVC-MAN-0036) was revised to include theDD15 engine.
MANUAL REFERENCESection Change
4.1 REQUIREMENTS Added row to Table 4.1 Maintenance Requirements for the DD15 engine.
5 REGENERATION STRATEGY Updated Figures 5.1 through 5.4 for latest regeneration strategy of the Series 60, MBE 4000,and MBE 900 engines. Added Figures 5.6 and 5.6 for regeneration strategy of the DD15 engine.
5.3 PARKED REGENERATION Added row to Table 5.1 Engine Speeds for the DD15 engine.
6.1 MECHANICALTROUBLESHOOTING
Added DD15 engine symptoms to left column in Table 6.2 Mechanical Troubleshooting viaDash Switch and Table 6.3 Mechanical Troubleshooting via DDDL 7.0.
B.5 DDEC VI ENGINE HARNESSFOR DD15
Added section B.5 to Appendix B for DD15 engine harness.
Table 1 Manual Revisions
4.1 REQUIREMENTS
The interval of recommended maintenance related to ash removal from the Diesel Particulate Filter islisted in Table 2.
NOTE:The DDEC VI engine control system monitors and controls the Aftertreatment Device for collectedash volume. In the event that maintenance is not performed or if maintenance is required due tounforeseen issues, the Amber Warning Lamp (AWL)/Check Engine will be illuminated to notify theuser that service is needed. Refer to section 6.2.3.
Duty cycle (Miles)Engine Model
Severe Short - Haul Long - HaulSeries 60 550,000 550,000 550,000
MBE 900 150,000 150,000 150,000
MBE 4000 300,000 300,000 300,000
DD15 300,000 300,000 300,000
Table 2 Maintenance Requirements
5 REGENERATION STRATEGY
Regeneration of the Aftertreatment Device (ATD) is fundamental for the oxidation of soot. This processhappens during the normal operation cycle of the vehicle; it can occur both passively and actively. Theoperator will see no difference in vehicle performance or vehicle control.
There are three types of regeneration that can occur:
□ Passive Regeneration□ Active Regeneration□ Parked Regeneration
The following describes the regeneration strategy for the Detroit Diesel Aftertreatment System. SeeFigure 1 for Series 60, Figure 2 for Series 60 idle timing, Figure 3 for MBE 4000, Figure 4 for MBE900, Figure 5 for DD15, and Figure 6 for DD15 idle timing.
Figure 1 Regeneration Strategy – Series 60
Figure 2 Idle Timing – Series 60
Figure 3 Regeneration Strategy – MBE 4000
Figure 4 Regeneration Strategy – MBE 900
Figure 5 Regeneration Strategy – DD15
Figure 6 Idle Timing – DD15
5.3 PARKED REGENERATION
When the request is accepted, the DPF Regeneration Lamp will turn on for one second and then go offfor the rest of the parked regeneration. The engine rpm will increase to the required level as listed inTable 3.
Engine Speed (rpm)Series 60 1600
MBE 4000 1300
MBE 900 1200
DD15 1600
Table 3 Engine Speeds
6.1 MECHANICAL TROUBLESHOOTING
Listed in Table 4 are the common symptoms and possible causes to guide you through mechanicaltroubleshooting if regeneration is not functioning properly when initiated via the dash switch.
Symptom Possible Causes Suggestions
Low fuel supply pressureManual test fuel pressure. Check for plugged fuel filtersor aerated fuel.
Fuel Doser Valve partially plugged
Monitor Doser Injection Status and Doser Fuel LinePressure. A high Doser Injection Status during regen,usually greater than 25% and doser fuel line pressureclose to engine fuel pressure indicate plugging.
Intake Manifold Pressure Sensorinaccurate
Compare reading to BARO (key ON, engine OFF).
DOC Outlet Temperature Sensornon-responsive
Compare temperatures before and after engine startup.No temperature change indicates sensor problem.
Electronic Dosing Valveinoperative
Monitor fuel line pressure. Pressure should change whenvalve commanded to open (PWM > 0).
Fuel Cutoff Valve inoperativeMonitor fuel compensation pressure. Pressure shouldchange when valve commanded to 100%.
A parked regeneration initiatesand runs indefinitely. (Intakethrottle on Series 60, DD15, andMBE 4000 or Exhaust Flap onMBE 900 closes, and there is noHEST Lamp after 25 minutes.)
DOC not activeMonitor temperature rise across DOC during regen. Littleor no temperature rise indicates DOC not active.
Low coolant temperatureMonitor coolant temperature. Temperature should begreater than 60°C (140°F).
High DOC Outlet temperatureMonitor DOC outlet temperature. Temperature should begreater than 100°C (212°F) prior to regen.
A parked regeneration initiatesand runs indefinitely. (IntakeThrottle on Series 60, DD15, andMBE 4000 or Exhaust Flap onMBE 900 does NOT close, andthere is no HEST Lamp after 25minutes.)
Engine in smoke control modeMonitor smoke control status during regen. Smoke controlstatus should be 0.
DOC Inlet Temperature Sensornon-responsive
Monitor DOC inlet temperature. No temperature changeafter engine startup indicates sensor problem.
Intake Throttle Valve notfunctioning properly
Listen for the ITV to sweep at key up.
Turbo not functioning properly Perform a turbo hysteresis test.
Low output of Engine Fuel Injector Check for plugged tip. Perform cylinder cut out test.
Exhaust Flap not functioningproperly (MBE 900)
Check solenoid supply voltage and air pressure.
A parked regeneration initiatesbut aborts. (Test ends after 10-15minutes of activation of IntakeThrottle on Series 60, DD15, andMBE 4000 or Exhaust Flap onMBE 900.)
Aerated fuel Check fuel for aeration.
Table 4 Mechanical Troubleshooting via Dash Switch
Listed in Table 5 are the common symptoms and possible causes to guide you through mechanicaltroubleshooting if regeneration is not functioning properly when initiated via DDDL 7.0.
Symptom Possible Causes Suggestions
Low fuel supply pressureManual test fuel pressure. Check for plugged fuel filtersor aerated fuel.
Fuel Doser Valve partially plugged
Monitor Doser Injection Status and Doser Fuel LinePressure. A high Doser Injection Status during regen,usually greater than 25% and Doser Fuel Line Pressureclose to engine fuel pressure indicate plugging.
Intake Manifold Pressure Sensorinaccurate
Compare reading to BARO (key ON, engine OFF).
DOC Outlet Temperature Sensornon-responsive
Compare temperatures before and after engine startup.No temperature change indicates sensor problem.
Electronic Dosing Valveinoperative
Monitor fuel line pressure. Pressure should change whenvalve commanded to open (PWM > 0).
Fuel Cutoff Valve inoperativeMonitor fuel compensation pressure. Pressure shouldchange when valve commanded to 100%.
DOC not activeMonitor temperature rise across DOC during regen. Littleor no temperature rise indicates DOC not active.
DOC Inlet Temperature Sensornon-responsive
Monitor DOC inlet temperature. No temperature changeafter engine startup indicates sensor problem.
Intake Throttle Valve notfunctioning properly
Listen for the ITV to sweep at key up.
Turbo not functioning properly Perform a turbo hysteresis test.
Low output of Engine Fuel Injector Check for plugged tip. Perform cylinder cut out test.
Exhaust Flap not functioningproperly (MBE 900)
Check solenoid supply voltage and air pressure.
A parked regeneration initiatesand runs indefinitely. (Intakethrottle on Series 60, DD15, andMBE 4000 or Exhaust Flap onMBE 900 closes, and there is noHEST Lamp after 25 minutes.)
Aerated fuel Check fuel for aeration.
Low coolant temperatureMonitor coolant temperature. Temperature should begreater than 60°C (140°F).
High DOC Outlet temperatureMonitor DOC outlet temperature. Temperature should begreater than 100°C (212°F) prior to regen.
A parked regeneration initiatesand runs indefinitely. (IntakeThrottle on Series 60, DD15, andMBE 4000 or Exhaust Flap onMBE 900 does NOT close, andthere is no HEST Lamp after25 minutes.)
Engine in smoke control modeMonitor smoke control status during regen. Smoke controlstatus should be 0.
Table 5 Mechanical Troubleshooting via DDDL 7.0
B.5 DDEC VI ENGINE HARNESS FOR DD15
The MCM has a 120–pin connector Engine Harness which is factory installed. It also has a 21–pinconnector and 31–pin connector which are the responsibility of the OEM.
5.1 MCM 120–PIN CONNECTOR FOR DD15 ENGINES
The pinouts for the 120–pin connector for the DD15 engine are listed in Table 6, Table 7, Table 8, andTable 9.
Pin Function Connector1 Quality Control Valve
2 Quality Control Valve
3 NC
4 Spill Amplifier Control Valve (cyl 4) - pin 2
5 NC
6 Spill Amplifier Control Valve (cyl 6) - pin 2
7 Spill Amplifier Control Valve Common (cyl 4, 5, 6) - pin 1
8 Spill Amplifier Control Valve (cyl 5) - pin 2
9 NC
10 Spill Amplifier Control Valve (cyl 2) - pin 2
11 NC
12 Spill Amplifier Control Valve (cyl 3) - pin 2
13 Spill Amplifier Control Valve Common (cyl 1, 2, 3) pin 1
14 Spill Amplifier Control Valve (cyl 1) - pin 2
15 NC
16 Needle Control Valve (cyl 4) - pin 4
17 NC
18 Needle Control Valve (cyl 6) - pin 4
19 Needle Control Valve Common (cyl 4,5,6) - pin 3
20 Needle Control Valve (cyl 5) - pin 4
21 NC
22 Needle Control Valve (cyl 2) - pin 4
23 NC
24 Needle Control Valve (cyl 3) - pin 4
25 Needle Control Valve Common (cyl 1,2,3) - pin 3
26 Needle Control Valve (cyl 1) - pin4
27 NC
28 NC
29 DOC Outlet Temp Sensor
Table 6 MCM Connector – DD15 (1 of 4)
Pin Function Connector30 DPF Outlet Pressure Sensor
31 NC
32 Jake 1
33 Two-speed Fan or Variable Speed Fan
34 NC
35 NC
36 NC
37 NC
38 Ground
39 NC
40 NC
41 Grid Heater
42 NC
43 CKP/TRS (+)
44 NC
45 CMP/SRS (+)
46 NC
47 Fan Speed
48 CMP/SRS (-)
49 NC
50 Sensor Ground
51 Turbo Speed Sensor
52 Sensor Ground
53 NC
54 Sensor Ground
55 Sensor Ground
56 NC
57 Water-in-Fuel-Sensor
58 Sensor Power Supply
59 HDMS Fan Thermal Switch
60 EGR Valve Position
Table 7 MCM Connector – DD15 (2 of 4)
Pin Function Connector61 EGR Valve
62 Power Supply
63 NC
64 Power Supply
65 Doser
66 Jake 2
67 Sensor Ground
68 NC
69 Fuel Cutoff Valve
70 Ground
71 Sensor Supply
72 NC
73 CKP (-)
74 CAN (-)
75 CAN (+)
76 NC
77 Supply Fuel Temperature Sensor
78 Fuel Rail Pressure Sensor
79 Grid Heater
80 Coolant Inlet Temperature Sensor
81 NC
82 Sensor Supply
83 NC
84 Fuel Compensation Pressure Sensor
85 Sensor Supply
86 Turbo Compressor In Temp
87 Intake Manifold Pressure Sensor
88 Sensor Ground
89 DOC Inlet Temp Sensor
90 Intake Air Throttle Valve
Table 8 MCM Connector – DD15 (3 of 4)
Pin Function Connector91 Power Supply
92 Grid Heater
93 Air Seal Pressure Regulator Valve
94 NC
95 Ground
96 NC
97 NC
98 Single-speed Fan or Two-speed Fan
99 NC
100 Intake Air Throttle (+)
101 Intake Air Throttle (-)
102 Sensor Ground
103 Sensor Ground
104 Sensor Ground
105 Engine Oil Pressure Sensor
106 Intake Air Temperature Sensor
107 NC
108 Engine Oil Temperature Sensor
109 EGR Delta Pressure Sensor
110 Coolant Outlet Temp Sensor
111 Fuel Line Pressure Sensor
112 Turbo Compressor Out Temp
113 NC
114 Sensor Ground
115 DPF Outlet Temp Sensor
116 NC
117 Sensor Power Supply
118 DPF Inlet Pressure Sensor
119 Intake Manifold Pressure Sensor
120 NC
Table 9 MCM Connector – DD15 (4 of 4)
ADDITIONAL SERVICE INFORMATION
Additional service information is available in the Detroit Diesel ATS Technician's Guide,DDC-SVC-MAN-0036. The next revision to this manual will include the revised information.
Detroit Diesel®, DDC®, Series 60® and the spinning arrows design are registered trademarks of Detroit Diesel Corporation.© Copyright 2008 Detroit Diesel Corporation. All rights reserved. Printed in U.S.A.