The Aftertreatment System Technician's Guide …

1 NUMBER:08 ATS REF.:Listed in Table :ATSDATE:February 2008 SUBJECT: ADDITIONAL ENGINE WAS ADDEDPUBLICATION: DDC-SVC-MAN-0036 (7SE63)The Aftertreatment System Technician's Guide (DDC-SVC-MAN-0036) wasrevised to include theDD15 REQUIREMENTSA dded row toTable Maintenance Requirementsfor the DD15 REGENERATION STRATEGY Updated Figures through for latest regeneration strategy of the Series 60, MBE 4000,and MBE 900 engines. Added Figures and for regeneration strategy of the DD15 PARKED REGENERATION Added row toTable Engine Speedsfor the DD15 MECHANICALTROUBLESHOOTINGA ddedDD15enginesymptomstoleftcolumninTabl e Mechanical Troubleshooting viaDash SwitchandTable Mechanical Troubleshooting via DDDL DDEC VI ENGINE HARNESSFOR DD15 Added section to Appendix B for DD15 engine 1 Manual REQUIREMENTSThe interval of recommended maintenance related to ash removal from the Diesel Particulate Filter islisted in Table :The DDEC VI engine control System monitors and controls the Aftertreatment Device for collectedash volume.

2 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 cycle (Miles)Engine ModelSevereShort - HaulLong - HaulSeries 60550,000550,000550,000 MBE 900150,000150,000150,000 MBE 4000300,000300,000300,000DD15300,000300, 000300,000 Table 2 Maintenance Requirements5 REGENERATION STRATEGYR egeneration 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 are three types of regeneration that can occur: Passive Regeneration Active Regeneration Parked RegenerationThe following describes the regeneration strategy for the Detroit Diesel Aftertreatment System .

3 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 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 PARKED REGENERATIONWhen 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 (rpm)Series 601600 MBE 40001300 MBE 9001200DD151600 Table 3 Engine MECHANICAL TROUBLESHOOTINGL isted in Table 4 are the common symptoms and possible causes to Guide you through mechanicaltroubleshooting if regeneration is not functioning properlywhen initiated via the dash CausesSuggestionsLow fuel supply pressureManual test fuel pressure.

4 Check for plugged fuelfiltersor aerated Doser Valve partially pluggedMonitor 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 Manifold Pressure SensorinaccurateCompare reading to BARO (key ON, engine OFF).DOC Outlet Temperature Sensornon-responsiveCompare temperatures before and after engine temperature change indicates sensor Dosing ValveinoperativeMonitor fuel line pressure. Pressure should change whenvalvecommandedtoopen(PWM>0).Fuel Cutoff Valve inoperativeMonitor fuel compensationpressure. 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.

5 Littleor no temperature rise indicates DOC not 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 parked regeneration initiatesand runs indefinitely. (IntakeThrottleonSeries60,DD15,andMBE 4000 or Exhaust Flap onMBE 900 does NOT close, andthereisnoHESTL ampafter25minutes.)Engine in smoke control modeMonitor smoke control status during regen. Smoke controlstatus should be Inlet Temperature Sensornon-responsiveMonitor DOC inlet temperature. No temperature changeafter engine startup indicates sensor Throttle Valve notfunctioning properlyListen for the ITV to sweep at key not functioning properlyPerform a turbo hysteresis output of Engine Fuel Injector Check for plugged tip. Perform cylinder cut out Flap not functioningproperly (MBE 900)Check solenoid supply voltage and air parked regeneration initiatesbut aborts.

6 (Test ends after 10-15minutes of activation of IntakeThrottleonSeries60,DD15,andMBE 4000 or Exhaust Flap onMBE 900.)Aerated fuelCheck fuel for 4 Mechanical Troubleshooting via Dash SwitchListed in Table 5 are the common symptoms and possible causes to guideyou through mechanicaltroubleshooting if regeneration is not functioning properly when initiated via DDDL CausesSuggestionsLow fuel supply pressureManual test fuel pressure. Check for plugged fuelfiltersor aerated Doser Valve partially pluggedMonitor 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 Manifold Pressure SensorinaccurateCompare reading to BARO (key ON, engine OFF).DOC Outlet Temperature Sensornon-responsiveCompare temperatures before and after engine temperature change indicates sensor Dosing ValveinoperativeMonitor fuel line pressure.

7 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 Inlet Temperature Sensornon-responsiveMonitor DOC inlet temperature. No temperature changeafter engine startup indicates sensor Throttle Valve notfunctioning properlyListen for the ITV to sweep at key not functioning properlyPerform a turbo hysteresis output of Engine Fuel Injector Check for plugged tip. Perform cylinder cut out Flap not functioningproperly (MBE 900)Check solenoid supply voltage and air 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.)

8 Aerated fuelCheck fuel for 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 parked regeneration initiatesand runs indefinitely. (IntakeThrottle on Series 60, DD15, andMBE 4000 or Exhaust Flap onMBE 900 does NOT close, andthereisnoHESTL ampafter25 minutes.)Engine in smoke control modeMonitor smoke control status during regen. Smoke controlstatus should be 5 Mechanical Troubleshooting via DDDL 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 MCM 120 PIN CONNECTOR FOR DD15 ENGINESThe pinouts for the 120 pin connector for the DD15 engine are listed in Table 6, Table 7, Table 8, andTable Control Valve2 Quality Control Valve3NC4 Spill Amplifier Control Valve (cyl 4) - pin 25NC6 Spill Amplifier Control Valve (cyl 6) - pin 27 Spill Amplifier Control Valve Common (cyl 4, 5, 6) - pin 18 Spill Amplifier Control Valve (cyl 5) - pin 29NC10 Spill Amplifier Control Valve (cyl 2) - pin 211NC12 Spill Amplifier Control Valve (cyl 3) - pin 213 Spill Amplifier Control Valve Common (cyl 1, 2, 3) pin 114 Spill Amplifier Control Valve (cyl 1) - pin 215NC16 Needle Control Valve (cyl 4) - pin 417NC18 NeedleControl Valve (cyl 6) - pin 419 Needle Control Valve Common (cyl 4,5,6) - pin 320 Needle Control Valve (cyl 5)

9 - pin 421NC22 Needle Control Valve (cyl 2) - pin 423NC24 Needle Control Valve (cyl 3) - pin 425 Needle Control Valve Common (cyl 1,2,3) - pin 326 Needle Control Valve (cyl 1) - pin427NC28NC29 DOC Outlet Temp SensorTable 6 MCM Connector DD15 (1 of 4)PinFunctionConnector30 DPF Outlet Pressure Sensor31NC32 Jake 133 Two-speed Fan or Variable Speed Fan34NC35NC36NC37NC38 Ground39NC40NC41 Grid Heater42NC43 CKP/TRS (+)44NC45 CMP/SRS (+)46NC47 Fan Speed48 CMP/SRS (-)49NC50 SensorGround51 Turbo Speed Sensor52 Sensor Ground53NC54 Sensor Ground55 Sensor Ground56NC57 Water-in-Fuel-Sensor58 Sensor Power Supply59 HDMSFanThermalSwitch60 EGR Valve PositionTable 7 MCM Connector DD15 (2 of 4)PinFunctionConnector61 EGR Valve62 Power Supply63NC64 Power Supply65 Doser66 Jake 267 Sensor Ground68NC69 Fuel CutoffValve70 Ground71 Sensor Supply72NC73 CKP (-)74 CAN (-)75 CAN (+)76NC77 Supply Fuel Temperature Sensor78 Fuel Rail Pressure Sensor79 Grid Heater80 Coolant Inlet Temperature Sensor81NC82 Sensor Supply83NC84 FuelCompensation Pressure Sensor85 Sensor Supply86 Turbo Compressor In Temp87 Intake Manifold Pressure Sensor88 Sensor Ground89 DOC Inlet Temp Sensor90 Intake Air Throttle ValveTable 8 MCM Connector DD15 (3 of 4)PinFunctionConnector91 Power Supply92 Grid Heater93 Air Seal Pressure Regulator Valve94NC95 Ground96NC97NC98 Single-speed Fan or Two-speed Fan99NC100 Intake Air Throttle (+)101 Intake Air Throttle (-)

10 102 Sensor Ground103 Sensor Ground104 Sensor Ground105 Engine Oil Pressure Sensor106 Intake Air Temperature Sensor107NC108 EngineOil Temperature Sensor109 EGR Delta Pressure Sensor110 Coolant Outlet Temp Sensor111 Fuel Line Pressure Sensor112 Turbo Compressor Out Temp113NC114 Sensor Ground115 DPF Outlet Temp Sensor116NC117 Sensor Power Supply118 DPF Inlet Pressure Sensor119 Intake Manifold Pressure Sensor120 NCTable 9 MCM Connector DD15 (4 of 4)ADDITIONAL SERVICE INFORMATIONA dditional service information is available in the Detroit DieselATS Technician's Guide ,DDC-SVC-MAN-0036. The next revision to this manual will include the revised 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