Tag: Detroit Diesel Engine Repair

This instruction show you guide on how to perform mechanical cylinder compression test for Detroit Diesel GHG17 heavy duty.

 

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Note : This test should be performed only if directed here by a diagnostic procedure.

Perform the following steps for a mechanical compression test on a GHG17Heavy Duty DD Platform Engine:

Jake Brake ® /piston

Valve lash/valve train damage

Camshaft timing

Cylinder liner/ring damage

Fuel injector hold-downs

Blown cylinder head gasket

Cracked cylinder liner or cylinder head

Valve or seat damage

 

Note : First perform the Relative Cylinder Compression Test using DiagnosticLink.. If results indicate a weak cylinder, perform this mechanical compression test.

1 The valve lash needs to be checked before the mechanical compression test is performed.and adjust as necessary, if no adjustment is needed continue to step 2.

2 Run the engine and bring the engine coolant temperature to normal operating range, 88 to 96°C (190 to 205°F).

 

3 Disconnect the batteries and plug the batteries into a battery charger. Refer to OEM procedures.

4 Remove rocker cover.

5 Remove the fuel injector harness.

6 Disconnect electrical contacts at the fuel injectors.

7 Disconnect the two wiring terminals going to the Jake Brake ® solenoids.

8 Disconnect the 14-pin fuel injector harness connector.

9 Remove the spring clip holding the fuel injector harness connectors to camshaft frame.

10 Remove the fuel injector wiring harness(es).

11 Remove the high pressure fuel line from all cylinders.

12 Remove all fuel injectors.

13 Remove excess fuel from cylinders using a vacuum pump.

14 Install the compression test adapter (J-47411) into the fuel injector bore in the cylinder head.

15 Install the fuel injector hold-down clamp and bolt. Torque the bolt to 20 N·m (14 lb·ft) + 90 degrees.

16 Install the fuel rail plug (J-48704 or W470589129100).

17 Install a hold-down bolt onto the Jake-Brake ® solenoid and snug the bolt.

18 Reconnect the batteries; keep the battery charger plugged into the batteries.

Note : Verify that the battery voltage does not go low enough to affect engine cranking speed. If the cranking speed is affected, then the results will be inaccurate. A battery charger will help to maintain an acceptable battery voltage.

19 Using DiagnosticLink start the Mechanical Compression Test routine, this will disable fuel from the Quantity Control Valve.

20 With the batteries fully charged, crank the engine over five compression strokes at 150 rpm or greater using the starter motor. Record the compression reading on the gauge.

21 At normal operating temperature, the compression reading should be no less than 28 bar (400 psi). If compression readings are below specifications, repeat step 13 with a different gauge to be certain of the reading.

Note : Fuel injector hold-down bolts are a one-time use item.

22 Remove the fuel injector hold-down clamps. Discard the hold-down bolt and remove the compression test adaptors.

23 Repeat steps for all suspect cylinders.

24 Repair engine as necessary.

Here is the instruction show you guide on how to oxidation catalyst air clean for Detroit GHG17 engine.

 

Before performing this service routine, the cause of the DOC plugging should be found and corrected. Typical DOC plugging causes are vehicle duty cycles that are: stop-and-go, have excessive idle time, have stationary PTO operation, or have a hardware issue with the engine or vehicle. Perform the “ATD Checklist” to review these possible causes and correct them before running this service routine.

 

The Diesel Oxidation Catalyst (DOC) air cleaning will remove soot that has built up on the face of the DOC. Air cleaning the DOC will reduce the aftertreatment inlet pressure, allowing for a parked regeneration to safely run without damaging the engine.

 

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DOC air cleaning kit DSN0ATZ16002 is compatible for use on EPA10 1-Box, GHG14 1-Box, GHG17 1-Box, Gen 5 1-Box (with dual DOC) and 2016-2021 MDEG 1-Box aftertreatment systems. You will also need an air gun with a six-inch tip and shop vacuum equipped with a dust bag to capture soot removed from the aftertreatment. A shop vacuum with a 2 ½ inch diameter hose will provide the best sealing around the inlet reduction cone.

 

Check as follows:

WARNING

PERSONAL INJURY

Use caution when handling and cleaning the Diesel Oxidation Catalyst (DOC). Personal protective equipment and clothing in accordance with all applicable federal, state and local laws or regulations should be used. Contents of the ash and soot removed from the DOC may be classified as a hazardous waste under federal, state and/or local laws or regulations. Hazardous wastes must be handled and disposed of in accordance with all applicable federal, state and local laws or regulations.

 

 

1 Remove the 1-BOX™ aftertreatment from the vehicle. Refer to section “Removal of the 1-BOX™ from the Vehicle” .

2 Remove the outboard heat shield (1) from the 1-BOX™ configuration by disengaging the folded flange on the top of the outboard heat shield.

3 Remove the four mounting bolts (2) from the inboard heat shield (1). Slide the inboard heat shield down allowing better access to the inboard Diesel Particulate Filter (DPF), V-band and flat band clamp.

Note : Record the orientation of the bands and clamps. These components need to be installed in the same location.

4 Loosen the outboard V-band and flat band clamps on the outboard DPF.

5 Slide the outboard flat band clamp inward and the V-band clamp outward on the outboard DPF.

6 Remove the outboard DPF assembly (2) from the 1-BOX™ configuration and discard the flat band gasket (1).

7 Loosen the V-band and flat band clamps on the inboard DPF.

8 Slide the inboard flat band clamp inward and the V-band clamp outward on the inboard DPF.

Remove the inboard DPF (2) from the 1-BOX™ configuration and discard the flat band gasket (1).

10 Using DOC face cleaning kit W470589239100, slide the inlet reduction cone (3) over the aftertreatment inlet. See graphic below.

11 Install the DOC block-off plate (2) over the inboard DOC and hand-tighten clamp.

12 Attach the DOC cleaning cone (1) to the outboard DOC and hand-tighten clamp.

13 Attach the shop vacuum hose to the aftertreatment reduction cone (3).

 

CAUTION

EYE INJURY

To avoid injury from flying debris, wear a face shield or goggles.

14 Turn on the shop vacuum; you should be able to feel suction if you place your hand momentarily over the DOC cleaning cone opening.

 

NOTICE

Regulate air pressure to a maximum of 120 psi to prevent damage to the substrate.

15 Place the air gun nozzle inside the cleaning cone and keep the air gun tip 25 mm (1 in.) away from the DOC to prevent damage to the brick.

16 Start blowing compressed air into the DOC cleaning cone. Move the air nozzle in a circular pattern, starting from the outer edge and work your way inward to center of the DOC. Continue this motion for several minutes.

17 Remove the DOC cleaning cone.

18 Continue blowing air into the DOC using a slow sweeping motion, making sure to cover 100% of the DOC surface. Keep the air gun tip 25mm (1 in.) away from the DOC to prevent damage to the brick.

19 Move the block-off plate to the outboard DOC and install the cleaning cone onto the inboard DOC.

20 Place the air gun nozzle inside the cleaning cone, keep the air gun tip 25 mm (1 in.) away from the DOC to prevent damage to the brick. Start blowing compressed air into the DOC cleaning cone. Move the air nozzle in a circular pattern, starting from the outer edge and work your way inward to the center of the DOC. Continue this motion for several minutes.

21 Remove the inboard DOC cleaning cone.

22 Continue blowing air into the inboard DOC using a slow sweeping motion making sure to cover 100% of the DOC surface. Keep the air gun tip 25 mm (1 in.) away from the DOC to prevent damage to the brick.

 

23 Disconnect the vacuum and remove the inlet reduction cone and DOC block-off plate.

24 After each DOC has been air cleaned, reinstall both Diesel Particulate Filters (DPF) using new flat band clamps and V-band gaskets.

25 Reinstall the aftertreatment.

26 Run a Parked Regen to verify DOC inlet pressure and check for proper NOx conversion.

Detroit Diesel GHG17 Low Pressure Fuel System – Measuring Fuel Pressure Using Fuel System Integrity Check – Two-Filter Fuel System

 

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Note : KM59 GEN1 fuel filter module return lines are secured to the module with banjo bolts.

Note : KM63 GEN2 fuel filter module return lines are secured to the module with a mounting plate attached to the PLV return line.

This procedure is used to measure and record fuel pressures in the low pressure side of the fuel system at given locations and rpm. Once completed, it will provide electronic results that can be viewed in a DDDL log file.

Note : Step 1 only applies to the KM59 Gen 1 fuel system. For a KM63 Gen 2 fuel system, begin the test with step 2.

Check as follows:

1 For KM59 Gen 1 systems only , install tool number W470589099100 Fuel Pressure Test Plug into the high pressure flange. Refer to Tool Letter 11 TL-9 for installation instructions.

2 For KM59 Gen 1 fuel systems and KM63 Gen 2 fuel systems, install tool number W470589149100 Filter Cap w/Test Port. Refer to Tool Letter 12 TL-8 for installation instructions. Inspect the pre-filter at this time. If the filter is plugged, clean or replace only this filter as needed.

3 Connect the DDDL to the vehicle and turn the ignition on. From the “Service Routines,” open the Fuel System Integrity Check tab.

4 Start the Fuel System Integrity Check routine and follow the instructions in DDDL.

5 Monitor the low pressure pump outlet (LPPO) fuel pressure, the fuel compensation pressure and the low pressure pump inlet (LPPI) fuel pressure while the Fuel System Integrity Check routine is running.

6 Add the LPPI fuel pressure values as a user event into the log file. Press CTRL, SHIFT, and space bar at the same time, and add the pressure reading from the gauge.

7 Compare the recorded fuel pressure values with the normal fuel pressures.

8 Return to original troubleshooting. Remove the special tools from the engine after troubleshooting is completed

Detroit Diesel DEF Quantity Test provides the ability to troubleshoot the diesel exhaust fluid (DEF) dosing system by inspecting the nozzle spray pattern and measuring the amount of DEF dispensed. It may be used for diagnosing problems with DEF supply, pump pressure, metering unit, clogging, pressure limiting unit, vehicle air, and low NOx efficiency.This instruction show you guide on how to use JPRO Diagnostic software to do DEF quantity test for Detroit Diesel DD13,DD15 and DD16.

 

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The DEF Quantity Test is supported on:
✓ Detroit Diesel EPA 10 to EPA 13 for all DD13, DD15 and DD16 engines
✓ Detroit Diesel GHG17 and newer with Engine Software Version:

o App_040B	o App_040D	o App_040E	o App_0410
o App_0411	o App_2104	o App_2105	o App_2107
o App_2108	o App_2109

and ACM Software Version:

o acm_0x0232	o acm_0x0236	o acm_0x023E	o acm_0x0250
o acm_0x024E

 

1.Select the DEF Quantity Test and press Enter or the Start button.

2.The DEF Quantity Test dialog displays, providing important information about steps to take before running the test.

3.Select the Next button once all instructions have been read and followed.
4. Ensure all preconditions have been met.
5. Select the Start button to begin the test. The DEF Doser should start pumping out DEF fluid into the measuring container over a period of 4 minutes.

6.The dialog displays examples of correct and problem spray patterns that can be detected by observing the valve as it dispenses DEF into the collection container.

7.When the test is completed, results information is displayed, including steps to take depending on how much DEF was dispensed.
8. If desired, you may select the Rerun button to rerun the test.
9. Once the test has been completed, click the Exit button to return to the test selection dialog.

 

This instruction show you guide on how to solve/optimize idle will arm but will not restart the engine for Detroit EPA07 GHG14 DDEC VI 10.

 

Preparations:

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Procedures:

Check as follows:

1 Is MCM fault code SPN 1663 /FMI 7 present?

1aYes; troubleshoot this code first.

1b No; Go to step 2.

 

2 Was the CPC recently programmed?

2a Yes; check for proper CPC parameter settings. Refer to section “Optimized Idle” of the A&I Manual (See table below).

2b No; Go to step 3.

 

3 Using DiagnosticLink, verify the operation of the Optimized Idle Safety Loop and the Vehicle Speed Sensor (VSS). Under Instrumentation, go to the Chart tab and select the following on the chart:

 

• DSL: Parking Brake
• DSL: Hood Tilt Switch
• DSL: Neutral Switch
• ASL: Road Speed

Cycle each switch and monitor their functionality. Monitor the Road Speed; it should read zero when the vehicle is stationary.

Was a fault with either the Optimized Idle Safety Loop or VSS found?

3a Yes; repair as necessary.

3b No; Go to step 4.

 

4 Is the vehicle equipped with an Auxiliary Power Unit (APU) or ParkSmart?

4a Yes; vehicles with an APU or ParkSmart may not use Optimized Idle to control the cab temperatures. If this is the customer’s complaint, refer to the APU or ParkSmart operation instructions.

4b No; Go to step 5.

 

5 Check the Optimized Idle Thermostat settings; Refer to section “Thermostat Operation” of the Optimized Idle User Manual (DDC-SVC-MAN-0019) . Is the Optimized Idle Thermostat properly configured?

5a Yes; install a test CPC. Go to step 6.

5b No; Refer to section “Thermostat Operation” of the Optimized Idle User Manual (DDC-SVC-MAN-0019) . Verify repair.

 

6 Will Optimized Idle work correctly with the test CPC?

6a Yes; replace the CPC.

6b No; Go to step 7.

 

7 Set the Optimized Idle Thermostat mode to cool the cab and put the vehicle on Optimized Idle mode. Using a heat gun, apply heat to the Optimized Idle Thermostat Skin Temperature sensor; refer to OEM literature for sensor location. Did Optimized Idle start the engine to cool the cab?

7a Yes; Refer to section “Optimized Idle” of the A&I Manual (See table below) for proper Optimized Idle parameter configuration

7b No; Go to step 8.

 

8.Monitor the Optimized Idle Thermostat temperature reading while applying heat to the sensor. Is the reading on the Thermostat display accurate?

8a Yes; replace the Optimized Idle Thermostat.

8b No; Go to step 9.

 

9 Disconnect the Optimized Idle Thermostat electrical connector and measure the resistance between pin 3 of the Optimized Idle Thermostat connector, harness side and the sensor ground circuit of the Skin Temperature sensor harness side connector. Is the resistance less than five ohms?

9a Yes; Go to step 10.

9b No; repair the circuit.

 

10 Measure the resistance between pin 1 of the Optimized Idle Thermostat connector, harness side and the sensor signal circuit of the Skin Temperature sensor harness side connector. Is the resistance less than five ohms?

10a Yes; replace the Optimized Idle Thermostat.

10b No; repair the circuit.