7 20-14

7 20-14
1
7 20-14
SUBJECT
DATE
Symptom Diagnosis - ATD Checklist
August 2014
Additions, Revisions, or Updates
Publication Number / Title
DDC-SVC-MAN-0084
DDC-SVC-MAN-0009
Platform
Section Title
EPA10/
GHG14 DD
Platform
EPA07/EPA10/GHG14
ATD Checklist
EPA07
Series 60
EPA07 ATD Checklist
All information subject to change without notice.
7 20-14 Copyright © 2014 DETROIT DIESEL CORPORATION
Change
This is a new section.
3
2 ATD Checklist - EPA07/EPA10/GHG14
2
ATD Checklist - EPA07/EPA10/GHG14
Check as follows:
1. Reference FLB 09-35 (http://servicelit-dtna.app.corpintra.net/newbulletins/serviceBulletins.asp) and verify the air filter
is installed correctly. Measure the Air Inlet Restriction with a manual gauge under 100% load (do not use the gauge
on the air filter assembly). Is the Air Inlet Restriction greater than 18 H 2O"?
Table 1.
Yes
__________________ H2O"
No
__________________ H2O"
2. Pressurize the intake track, including the Charge Air Cooler (CAC) and associated piping, inspecting for leaks. Was a
leak found?
Table 2.
Yes
Repair(s) made:
No
3. With engine OFF, visually inspect the Exhaust Gas Recirculation (EGR) linkage for damage or limited travel.
Table 3.
Moves freely _________________________________________
Repair(s) made: _________________________________________
4. Inspect for excessive oil coming out of the turbocharger compressor wheel or turbine wheel. Was oil found?
Table 4.
Yes
Compressor or Turbine Wheel? _________________________________________
No
WARNING: PERSONAL INJURY
To avoid injury before starting and running the engine, ensure the vehicle is parked on a level
surface, parking brake is set, and the wheels are blocked.
WARNING: ENGINE EXHAUST
To avoid injury from inhaling engine exhaust, always operate the engine in a well-ventilated area.
Engine exhaust is toxic.
5. Using DiagnosticLink®, sweep the Intake Throttle Valve (ITV). Is the ITV stuck or is there limited travel?
Table 5.
Moves freely
Stuck/binding. Replace the ITV.
4
All information subject to change without notice.
Copyright © 2014 DETROIT DIESEL CORPORATION 7 20-14
7 20-14
WARNING: PERSONAL INJURY
To avoid injury before starting and running the engine, ensure the vehicle is parked on a level
surface, parking brake is set, and the wheels are blocked.
WARNING: ENGINE EXHAUST
To avoid injury from inhaling engine exhaust, always operate the engine in a well-ventilated area.
Engine exhaust is toxic.
6. Inspect for exhaust leaks before the Aftertreatment Device (ATD), are any exhaust leaks found?
Table 6.
Yes
Repair(s) made: _________________________________________
No
7. Inspect for plugged delta P ports. Are the delta P ports plugged?
Table 7.
Yes
Clean ports using procedure in 14 TS-2 (http://ddcsn-ddc.freightliner.com/cps/rde/xbcr/ddcsn/14TS2.pdf)
No
8. Using DiagnosticLink, with the ignition ON (key ON, engine OFF), is the Barometric Pressure (BP) sensor reading
above 69 kPa (10 psi) and below 110 kPa (16 psi)?
Table 8.
Yes
No
Try a test MCM
WARNING: PERSONAL INJURY
To avoid injury before starting and running the engine, ensure the vehicle is parked on a level
surface, parking brake is set, and the wheels are blocked.
WARNING: ENGINE EXHAUST
To avoid injury from inhaling engine exhaust, always operate the engine in a well-ventilated area.
Engine exhaust is toxic.
9. Compare Inlet Manifold Pressure (IMP) ______ kPa ______ (psi) and BP sensor ______ kPa ______ (psi). Are both
sensor readings within 10.3 kPa (1.5 psi) of each other?
Table 9.
Yes
No
Replace IMP sensor and verify it is now reading correctly
10. Get readings of ATD temperature sensors with the ignition ON (key ON, engine OFF). Note coolant temperature. The
best way to determine if a sensor has drifted out of range is to check the system with the ATD cool.
• Coolant ______ °C (______ °F)
• DOC in ______ °C (______ °F)
All information subject to change without notice.
7 20-14 Copyright © 2014 DETROIT DIESEL CORPORATION
5
2 ATD Checklist - EPA07/EPA10/GHG14
• DOC out _____ °C (______ °F)
• DPF out ______ °C (______ °F)
• SCR in _______ °C (______ °F)
• SCR out ______ °C (______ °F)
11. Inspect the CAC Outlet Temperature/Inlet Manifold Pressure (combination) sensor connector for corrosion. Was
corrosion found?
Table 10.
Yes
Replace the sensor and pigtail
No
12. Inspect the IMT sensor connector for corrosion. Was corrosion found?
Table 11.
Yes
Replace the sensor and pigtail
No
WARNING: PERSONAL INJURY
To avoid injury before starting and running the engine, ensure the vehicle is parked on a level
surface, parking brake is set, and the wheels are blocked.
WARNING: ENGINE EXHAUST
To avoid injury from inhaling engine exhaust, always operate the engine in a well-ventilated area.
Engine exhaust is toxic.
13. Perform Idle Speed Balance (ISB) test. Record results below.
Table 12.
Cyl 1
%
Cyl 2
%
Cyl 3
%
Cyl 4
%
Cyl 5
%
Cyl 6
%
WARNING: PERSONAL INJURY
To avoid injury before starting and running the engine, ensure the vehicle is parked on a level
surface, parking brake is set, and the wheels are blocked.
WARNING: ENGINE EXHAUST
To avoid injury from inhaling engine exhaust, always operate the engine in a well-ventilated area.
Engine exhaust is toxic.
14. Perform a Relative Cylinder Compression Test with DiagnosticLink.
Table 13.
6
Cyl 1
%
Cyl 2
%
Cyl 3
%
Cyl 4
%
Cyl 5
%
Cyl 6
%
All information subject to change without notice.
Copyright © 2014 DETROIT DIESEL CORPORATION 7 20-14
7 20-14
WARNING: PERSONAL INJURY
To avoid injury before starting and running the engine, ensure the vehicle is parked on a level
surface, parking brake is set, and the wheels are blocked.
WARNING: ENGINE EXHAUST
To avoid injury from inhaling engine exhaust, always operate the engine in a well-ventilated area.
Engine exhaust is toxic.
15. Remove DOC inlet pipe from ATD and perform 3 throttle snaps. There should be one puff of smoke (the size of a
basketball) that quickly clears. Is there excessive smoke?
Table 14.
Yes
Manually cut cylinders to try and identify an over fueling injector
No
All information subject to change without notice.
7 20-14 Copyright © 2014 DETROIT DIESEL CORPORATION
7
SERIES 60 DDEC VI TROUBLESHOOTING MANUAL
4.1
EPA07 ATD CHECKLIST
Check as follows:
1. Check fuel psi at idle and rated rpm at the pump fuel temperature sensor. Look for 427 to
448 kPa (62 to 65 psi) at idle and 565 to 592 kPa (82 to 86 psi) at rated rpm.
ENGINE EXHAUST
To avoid injury from inhaling engine exhaust, always
operate the engine in a well-ventilated area.
Engine
exhaust is toxic.
PERSONAL INJURY
To avoid injury before starting and running the engine,
ensure the vehicle is parked on a level surface, parking
brake is set, and the wheels are blocked.
□
□
_____ kPa (psi) @ idle
_____ kPa (psi) @ rated rpm
2. Check return fuel for aeration at idle and under load. Is there air present in the fuel?
ENGINE EXHAUST
To avoid injury from inhaling engine exhaust, always
operate the engine in a well-ventilated area.
Engine
exhaust is toxic.
PERSONAL INJURY
To avoid injury before starting and running the engine,
ensure the vehicle is parked on a level surface, parking
brake is set, and the wheels are blocked.
□
□
Yes
No
3. Check air system for leaks and restrictions (air lter to intake manifold).
□ Leaks. Repairs made: ________________________________
All information subject to change without notice.
DDC-SVC-MAN-0009
Copyright © 2012 DETROIT DIESEL CORPORATION
4-3
4.1
ATD CHECKLIST
□
None
4. Check exhaust system for leaks (Manifold to Aftertreatment Device [ATD] module).
ENGINE EXHAUST
To avoid injury from inhaling engine exhaust, always
operate the engine in a well-ventilated area.
Engine
exhaust is toxic.
PERSONAL INJURY
To avoid injury before starting and running the engine,
ensure the vehicle is parked on a level surface, parking
brake is set, and the wheels are blocked.
□
□
Leaks. Repairs made: ________________________________
None
5. Perform turbo hysteresis test. Refer to section 2.1
□ Pass
□ Fail
6. Check and visually inspect Exhaust Gas Recirculation (EGR) valve operation/condition.
ENGINE EXHAUST
To avoid injury from inhaling engine exhaust, always
operate the engine in a well-ventilated area.
Engine
exhaust is toxic.
PERSONAL INJURY
To avoid injury before starting and running the engine,
ensure the vehicle is parked on a level surface, parking
brake is set, and the wheels are blocked.
□
□
Moves freely, full range of travel
Stuck/binding; repairs made: ________________________________________
7. Check Intake Throttle Valve (ITV) valve operation visually.
4-4
DDC-SVC-MAN-0009
All information subject to change without notice.
Copyright © 2012 DETROIT DIESEL CORPORATION
SERIES 60 DDEC VI TROUBLESHOOTING MANUAL
ENGINE EXHAUST
To avoid injury from inhaling engine exhaust, always
operate the engine in a well-ventilated area.
Engine
exhaust is toxic.
PERSONAL INJURY
To avoid injury before starting and running the engine,
ensure the vehicle is parked on a level surface, parking
brake is set, and the wheels are blocked.
□
□
Moves freely, full range of travel
Stuck/binding; repairs made: ________________________________________
8. Get readings of ATD temperature sensors with the ignition ON (key ON, engine OFF).
Note coolant temperature. The best way to determine if a sensor has drifted out of range is
to check the system with the ATD cool.
□ Coolant ______ °C (______ °F)
□ DOC In ______ °C (______ °F)
□ DOC Out ______ °C (______ °F)
□ DPF Out ______ °C (______ °F)
9. Get readings of barometric pressure and inlet manifold pressure with the ignition ON (key
ON, engine OFF). Must be within 4.1 kPa (0.6 psi) of each other.
□ Baro ______ kPa (______ psi)
□ Inlet Manifold ______ kPa (______ psi)
10. Check the injector connectors at the rocker cover for oil saturation around the pins. Refer
to 11 TS 9.
□ If the injector connectors are saturated with oil, clean the connectors before performing
diagnostics.
11. Check for oil at the 120-pin MCM connector and check it for harness chafng.
□ If the 120-pin MCM connector is saturated with oil, clean the connector before
performing diagnostics.
12. Remove the ATD modules and separate them.
□ Inspect the DOC inlet for face plugging.
□ Send photos of ALL module faces to [email protected] for review.
13. Perform throttle snaps with unit in test pipe mode to check smoke output. Is there
excessive smoke?
All information subject to change without notice.
DDC-SVC-MAN-0009
Copyright © 2012 DETROIT DIESEL CORPORATION
4-5
4.1
ATD CHECKLIST
ENGINE EXHAUST
To avoid injury from inhaling engine exhaust, always
operate the engine in a well-ventilated area.
Engine
exhaust is toxic.
PERSONAL INJURY
To avoid injury before starting and running the engine,
ensure the vehicle is parked on a level surface, parking
brake is set, and the wheels are blocked.
□
□
Yes; manually cut cylinders to try and identify an over fueling injector.
No
14. Perform a parked regen and send log le for review.
HOT EXHAUST
During parked regeneration the exhaust gases will be
extremely HOT and could cause a re if directed at
combustible materials.
The vehicle must be parked
outside.
15. Get DDEC reports in XTR format.
4-6
DDC-SVC-MAN-0009
All information subject to change without notice.
Copyright © 2012 DETROIT DIESEL CORPORATION

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