User manual | 08 ATS-2

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 the
DD15 engine.
MANUAL REFERENCE
Section
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 MECHANICAL
TROUBLESHOOTING
Added DD15 engine symptoms to left column in Table 6.2 Mechanical Troubleshooting via
Dash Switch and Table 6.3 Mechanical Troubleshooting via DDDL 7.0.
B.5 DDEC VI ENGINE HARNESS
FOR 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 is
listed in Table 2.
NOTE:
The DDEC VI engine control system monitors and controls the Aftertreatment Device for collected
ash volume. In the event that maintenance is not performed or if maintenance is required due to
unforeseen issues, the Amber Warning Lamp (AWL)/Check Engine will be illuminated to notify the
user that service is needed. Refer to section 6.2.3.
Engine Model
Table 2
Duty cycle (Miles)
Severe
Short - Haul
Long - Haul
Series 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
Maintenance Requirements
5 REGENERATION STRATEGY
Regeneration of the Aftertreatment Device (ATD) is fundamental for the oxidation of soot. This process
happens during the normal operation cycle of the vehicle; it can occur both passively and actively. The
operator 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. See
Figure 1 for Series 60, Figure 2 for Series 60 idle timing, Figure 3 for MBE 4000, Figure 4 for MBE
900, 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 off
for the rest of the parked regeneration. The engine rpm will increase to the required level as listed in
Table 3.
Table 3
Engine
Speed (rpm)
Series 60
1600
MBE 4000
1300
MBE 900
1200
DD15
1600
Engine Speeds
6.1 MECHANICAL TROUBLESHOOTING
Listed in Table 4 are the common symptoms and possible causes to guide you through mechanical
troubleshooting if regeneration is not functioning properly when initiated via the dash switch.
Symptom
A parked regeneration initiates
and runs indefinitely. (Intake
throttle on Series 60, DD15, and
MBE 4000 or Exhaust Flap on
MBE 900 closes, and there is no
HEST Lamp after 25 minutes.)
A parked regeneration initiates
and runs indefinitely. (Intake
Throttle on Series 60, DD15, and
MBE 4000 or Exhaust Flap on
MBE 900 does NOT close, and
there is no HEST Lamp after 25
minutes.)
A parked regeneration initiates
but aborts. (Test ends after 10-15
minutes of activation of Intake
Throttle on Series 60, DD15, and
MBE 4000 or Exhaust Flap on
MBE 900.)
Table 4
Possible Causes
Suggestions
Low fuel supply pressure
Manual test fuel pressure. Check for plugged fuel filters
or aerated fuel.
Fuel Doser Valve partially plugged
Monitor Doser Injection Status and Doser Fuel Line
Pressure. A high Doser Injection Status during regen,
usually greater than 25% and doser fuel line pressure
close to engine fuel pressure indicate plugging.
Intake Manifold Pressure Sensor
inaccurate
Compare reading to BARO (key ON, engine OFF).
DOC Outlet Temperature Sensor
non-responsive
Compare temperatures before and after engine startup.
No temperature change indicates sensor problem.
Electronic Dosing Valve
inoperative
Monitor fuel line pressure. Pressure should change when
valve commanded to open (PWM > 0).
Fuel Cutoff Valve inoperative
Monitor fuel compensation pressure. Pressure should
change when valve commanded to 100%.
DOC not active
Monitor temperature rise across DOC during regen. Little
or no temperature rise indicates DOC not active.
Low coolant temperature
Monitor coolant temperature. Temperature should be
greater than 60°C (140°F).
High DOC Outlet temperature
Monitor DOC outlet temperature. Temperature should be
greater than 100°C (212°F) prior to regen.
Engine in smoke control mode
Monitor smoke control status during regen. Smoke control
status should be 0.
DOC Inlet Temperature Sensor
non-responsive
Monitor DOC inlet temperature. No temperature change
after engine startup indicates sensor problem.
Intake Throttle Valve not
functioning 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 functioning
properly (MBE 900)
Check solenoid supply voltage and air pressure.
Aerated fuel
Check fuel for aeration.
Mechanical Troubleshooting via Dash Switch
Listed in Table 5 are the common symptoms and possible causes to guide you through mechanical
troubleshooting if regeneration is not functioning properly when initiated via DDDL 7.0.
Symptom
A parked regeneration initiates
and runs indefinitely. (Intake
throttle on Series 60, DD15, and
MBE 4000 or Exhaust Flap on
MBE 900 closes, and there is no
HEST Lamp after 25 minutes.)
A parked regeneration initiates
and runs indefinitely. (Intake
Throttle on Series 60, DD15, and
MBE 4000 or Exhaust Flap on
MBE 900 does NOT close, and
there is no HEST Lamp after
25 minutes.)
Table 5
Possible Causes
Suggestions
Low fuel supply pressure
Manual test fuel pressure. Check for plugged fuel filters
or aerated fuel.
Fuel Doser Valve partially plugged
Monitor Doser Injection Status and Doser Fuel Line
Pressure. A high Doser Injection Status during regen,
usually greater than 25% and Doser Fuel Line Pressure
close to engine fuel pressure indicate plugging.
Intake Manifold Pressure Sensor
inaccurate
Compare reading to BARO (key ON, engine OFF).
DOC Outlet Temperature Sensor
non-responsive
Compare temperatures before and after engine startup.
No temperature change indicates sensor problem.
Electronic Dosing Valve
inoperative
Monitor fuel line pressure. Pressure should change when
valve commanded to open (PWM > 0).
Fuel Cutoff Valve inoperative
Monitor fuel compensation pressure. Pressure should
change when valve commanded to 100%.
DOC not active
Monitor temperature rise across DOC during regen. Little
or no temperature rise indicates DOC not active.
DOC Inlet Temperature Sensor
non-responsive
Monitor DOC inlet temperature. No temperature change
after engine startup indicates sensor problem.
Intake Throttle Valve not
functioning 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 functioning
properly (MBE 900)
Check solenoid supply voltage and air pressure.
Aerated fuel
Check fuel for aeration.
Low coolant temperature
Monitor coolant temperature. Temperature should be
greater than 60°C (140°F).
High DOC Outlet temperature
Monitor DOC outlet temperature. Temperature should be
greater than 100°C (212°F) prior to regen.
Engine in smoke control mode
Monitor smoke control status during regen. Smoke control
status should be 0.
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–pin
connector 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, and
Table 9.
Pin
Function
1
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)
Connector
Pin
Function
30
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)
Connector
Pin
Function
61
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)
Connector
Pin
Function
91
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)
Connector
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.

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