Daimler Trucks

Conduct

• Detroit Diesel prohibits the use of jokes, cartoons or pictures that are directly or
indirectly derogatory toward race, religion, national origin, gender, age, disability,
height, weight or marital status. All employees, visitors, vendors or trainees must be
sensitive to the diversity of all employees within our workforce and treat each other
with dignity and mutual respect at all times.
• Undermining the dignity of others through inappropriate use of printed material,
comments or conduct and utilizing such available communication methods such as
email, facsimile, and copier will not be tolerated.

Daimler Trucks 2
 Class Agenda

• Introduction
- Class start
- Break
- Lunch
- Break
- End of day
• Review each engine system and know how they function
- Air, coolant, fuel, lube
• Review the internal components of the engine
- Liner, piston, connecting rods
• Technicians must be able to demonstrate that they understand and can perform the following:
- Identify fuel system flow, pressures and basic diagnostic
- Time the fuel pump
- Install and set up the gear train
- Set valve lash
- How the Turbocompound system operates

Daimler Trucks 3
 DD15 Curriculum (not in book)

Required Web Courses before taking DD15 Required Instructor Led Course for Expert
Instructor Led Classes: Certification:
• DD15 Specific Courses • DD15 Diagnostics
- DD15 Introduction (Base Engine)
- DD15 Systems Courses
- Air, Lube, Fuel, Cooling, Tune-Up and
DDEC VI for DD15
- DD15 Maintenance
• Other Required Web Courses
- 2007 Basic Diagnostics
- 2007 Aftertreatment Systems
- DDEC Reports

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Service Publications

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Service Publications

You can get to the DD15 engine service publications by just selecting “DD15” from the
side menu.

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Service Publications

When an ESN is used you can get to the related service information using the links at
the bottom of the page.

Daimler Trucks 7
Design And Manufacturing Of The DD15

Common Base Engine Design

• Developed as an EGR engine

- baseline NOx reduction strategy

• Ability to apply new technologies to a
common platform
• Capture best practices of all current
engines and manufacturing
processes
• First launch in NAFTA with Europe and
Asia following in 2010

Daimler Trucks 8
 Engine Configurations

All displacements similar design and construction

• In line 6-cylinder with wet liners, cast block, one piece (slab) cylinder head and dual overhead
camshafts (intake and exhaust)

Robust webbed cylinder block for noise and vibration reduction

• Capable of increased cylinder pressures up to 18.4:1

Rear gear train configuration

• Higher cylinder pressure capability with less torsional loading of crankshaft

• Advanced air system components

Bosch flexible common rail fuel system

• NOx reduction potential w/o fuel economy penalty

Integral Jake Brake

• Built into the rocker arm assembly

Cooled EGR system

New MCM specifically for DD15

CPC electronic controls common platform

• DD15/S60/900/4000

Daimler Trucks 9
DD15 TC Euro IV Differences to 2013 DD15 TC

Description Z Group Part Number Tracking Presentation

EGR Cold Pipe
Z53708097 A4721421940 Unique Featured
Support Bracket
Air Intake Adapter Z53708097 A4710982237 Unique Featured

Sealing Flange Z53706047 A4700781144 Unique Featured

Screw Plug Z53706047 N000908012009 Unique Featured

Cover Z53709339 A4721420091 Unique Featured

Gasket Z53709339 A4721420580 Unique Featured

Screw Plug Z53709339 N000000004678 Unique Featured

Wiring Harness Z53712979 A4721508033 Unique Not Featured

Cylinder Head Z53700121 A4730102520 Unique Not Featured

Turbo Z53702708 A4720962099 Running Change Not Featured

Daimler Trucks TP/PNC

10
Engine Horse Power Ratings

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Engine Serial Number Location

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 Engine Components Left Side
High Pressure Fuel Rail 1

11 Intake Manifold

Oil/ Coolant 2
Module

Coolant Pump 3

Thermostat 4
High Pressure
10
Fuel Pump

Low Pressure
9
Fuel Pump
8 Air Compressor

MCM 5 7 Power Steering Pump

6 KM 59 Fuel Filter Module

Daimler Trucks 14
 Engine Components Right Side

EGR Cooler 1
A/C Compressor
11
EGR Valve and Location
Actuator 2

Axial Power Turbine 3

S - Pipe 4

10 Alternator

APT Gear Box 5

6
Starter Location
7
Air Seal Pressure Supply Line
Crankcase Breather 8 9 Turbocharger

Daimler Trucks 15
Daimler Trucks
 Turbocompound System

Exhaust out to DPF

Conventional
1
Turbocharger

APT Drive
Gear

2
Interstage Duct

5
3 Axial Power Turbine (APT)
APT Gear Box
4 Air Seal Pressure Supply Line

Daimler Trucks 17
 Turbocharger

• The14.8L and 15.6L are able to use a

non wastegate turbocharger and meet
today’s stringent emission requirements
without reduced performance.
• Turbo speed sensor is not used on the
DD15.
Benefits
- Reduced weight
- Simplified operation
- Less parts to fail

Daimler Trucks 18
Axial Power Turbine

Oil to APT
HDEP_Mitec.ppt

Oil In

APT to Gear Box

Spacer

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EGR Valve/ Actuator

Coolant

Coolant
Actuator

Thermal Washer

EGR Delivery Elbow

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EGR Valve / Actuator / Push Rod / Hot Pipe

EGR Hot Pipe

EGR Valve

EGR Push Rod

EGR Actuator

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 Air Intake Manifold

Intake Manifold
Temperature Sensor

Delivery Pipe

Intake Elbow

Intake Elbow Intake Air Temperature Sensor

Intake Manifold Pressure
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 Delta P Sensor

• Delta P sensor values

- 0.50 V = -17.2 mbar or -6.9 “h2o
- 0.69 V = 0 mbar or 0 “h2o
- 4.50 V = 344.7 mbar or 138.4 “h2o

Cut away image of the Venturi showing passages

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 Exhaust Manifold

5 Piece Manifold

3 Piece Manifold

Bellows

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Exhaust Outlet

S - Pipe

Gasket

Cover Plate

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Daimler Trucks
Cooling System

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 Oil/Coolant Module
EGR Coolant Supply
(Water Pump Pressure
9
Supply)
Block Heater Port
6
Coolant Filter 1

8
Coolant Return
2 (Suction Side)
Fuel Cooler/ Air
Compressor
Coolant Return
(Water Pump
Suction Side)

3
Coolant Bypass
(Return Flow Of The
Crankcase To The
Thermostat Suction 7
Side) Coolant Return (Suction Side)
4 Coolant Inlet Of Bypass
Drain Plug for Bypass 5
Circuit Or Radiator Circuit
Circuit
Daimler Trucks 29
 Coolant Collector

Heat Exchanger Sleeper Bunk* 1

Heat Exchanger Automatic Trans* 2

Heat Exchanger Vehicle Heating* 3

Coolant Collector 4

Vent 5

* Port location descriptions may change based

on vehicle configuration and/or model year
Daimler Trucks 30
Coolant Collector

1 Into EGR Cooler

Out from EGR Cooler 2

Coolant Temperature Sensor

To Radiator or Bypass Circuit 3

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Thermostat Housing / Coolant Pump

• Aluminum Housing
- One built in Thermostat
- 88 degrees C (190 degrees F)
start to open
- 95 degrees C (203 Degrees F)
fully open
- Located on inlet side of system

Daimler Trucks 32
 Thermostat Differences (15mm to 12mm)

• Starting around August 2009 a new thermostat will be introduced in conjunction with a new oil coolant
module. The new thermostat has a stroke of 12mm compared to the current 15mm.

• These thermostats will physically fit on their respective modules but are not interchangeable between
each other and should not be swapped between oil coolant modules.
Old 15mm New 12mm

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EGR Cooler

1 Vent

3 Water Inlet

2 Water Outlet

Daimler Trucks 34
Daimler Trucks
 Poorly Maintained Coolant Systems

• Will lead to
- Poor combustion
- Overheated components
- Overheated lubricants
- Inability to meet emission standards
- Shortened engine and transmission life
- Impact sensors and computerized compartments
- Higher engine maintenance costs

Daimler Trucks 36
 Temperature

To meet these needs, today’s modern engines include

- Turbochargers with intercoolers
- Electronic timed fuel injection
- Computerized combustion controls
- Emission equipment
All are placing greater thermal loads (higher temperatures) on the coolant
• The result is that proper glycol control has become increasingly important for
boiling point control
• And increased system pressures must be monitored and maintained

Daimler Trucks 37
 Pressure

• As temperatures have risen, likewise cooling system pressures have climbed to

maintain control of the boil point
- Today a 15 lb, or higher, pressure cap is typical and necessary to reduce the
boiling point
- The pressure cap allows expansion and contraction of the coolant in the
system

Daimler Trucks 38
Engine Metal Expansion & Contraction

• With fluctuations in temperature, metals and fluids expand and

contract.
• The cast iron cylinders may expand and contract ¼” or more. While
particular aluminum alloys will expand twice that, to ½”.
• This expansion/contraction of dissimilar metals is especially critical in
piston to wall clearance in the combustion chamber.
• Also piston ring end gap will be affected

Daimler Trucks 39
Cavitation

Cylinder liner cavitation Pump blade damage

Flow and resulting damage Formation of cavities

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 Corrosion

• Corrosion is caused by the fluid becoming acid due to a number of possible

reasons, thermal degradation, poor source water leading to scale deposits,
improper additive chemistry

Cylinder liner cavitation/erosion Component corrosion Radiator metal corrosion

Daimler Trucks 41
 Erosion

• Increased coolant flow rates have caused an increase in the erosion of metal
surfaces.
• Erosion is the gradual wearing away metal surfaces caused by the accelerated
flow conditions generating shear forces sufficient to remove corrosion
passivating films or naturally protective oxides from the metal surfaces.
• Most prevalent with soft metals which have critical or limiting flow velocities,
above which the corrosion rapidly progresses.
• This can be accelerated by solid contaminants in the fluid, turbulence,
cavitation.
• Today’s trend toward use of softer metals in the cooling system make this
more common.

Daimler Trucks 42
Daimler Trucks
Amplified Pressure Common Rail System
(APCRS)
- Reduced NOx without fuel
economy penalty
- Improved performance throughout
torque range
- Ability to “fine tune” combustion event
reducing:
- Engine noise
- Vibration
- Fuel consumption

Daimler Trucks 44
 MAHLE
MAHLE Fuel
Fuel Updated
Updated Bosch
Bosch
Filter
Filter Module
Module
System
System

New
New ContiTech
ContiTech
Fuel
Fuel Lines
Lines

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Daimler Trucks
Daimler Trucks
Daimler Trucks
• Removes water from fuel
• Reduces the temperature of returned amplification
fuel
• Provides connections for several fuel returns at the
fuel gallery
• Notifies if the water level becomes critical with a
water in fuel (WIF) sensor
• Monitors fuel supply temperature with a temperature
sensor
• Provides a hand pump for fuel system priming
• Provides a COMPU check valve for external fuel
priming

Engine software is calibrated to monitor the WIF sensor output

and activate a fault code. Code 97/15 will set along with
illuminating the WIF Level Light and a 25% derate

Daimler Trucks 49
Daimler Trucks
Daimler Trucks
 1
11

2
10

9
4

Low
Fuel
Fuel Pressure
Quantity
Pressure
HP Outlet
Bypass
Fuel
Two
Fuel Inlet
InletControl
Relief
Outlet
Stage for
Valve
Inlet from
to Pump
Back
Emergency
Valve
from Valve
Valve
to (low
Filter
Filter
Module Module
for Low
Lubrication
(return
Pressure
pressure
(pre-filter) fuel) Pump
fuel)
Daimler Trucks 52
High Pressure Valve 7 High Pressure Outlet
6
Valve

Intake/Suction 8 High Pressure Pump

5
Valves Housing

4 High Pressure Pistons

3 Compression Spring

2 Roller Tappet

1 Camshaft
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Daimler Trucks 54
Daimler Trucks 55
Daimler Trucks 56
Fuel Rail Pressure Sensor / Pressure
Limiting Valve

Fuel Rail Pressure Sensor Pressure Limiting Valve

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Daimler Trucks
Daimler Trucks
Fuel Filter - Fuel rises up to the filter.
The patented EleMax®design allows
only a portion of the filter media to be
used maximizing filter life.
Water Separator -Water and large
contaminants fall to the bottom of the
body and can be drained away.
Fuel Heater (Optional) - Fuel flows
through the heated chamber and up
into the ”Seeing is Believing”®clear
cover filter area.
Seeing Is Believing® - The patented
clear cover allows the user to know
when not to change the filter.

Daimler Trucks 62
• Integrated Bracket

• Fuel In and Out Left Side

• Low Restriction Check Valve

• Internal System By-Pass Valve

• Current Production Fuel Pro Drain

• 7 Micron Filter Element

• 12V DC –250W Electric Heater Option

• 120V AC Overnight Heater Option

• ESOC Option

• Internal Volume = 2205 ml (.58 Gallons)

• Dry Weight = 10.5 lbs

Daimler Trucks 63
Daimler Trucks
 ESOC 350

Note: System must be primed before first time use

1. Connect air supply (nominal 120 PSIG)

2. Open ball valve and pour fuel into the fuel receptacle
until fuel reaches the top of the sight gauge.

3. Close the ball valve.

4. Connect the fuel dispenser (included) to the fill hose.

5. Press “START” (black) and dispense fuel into fuel

receptacle.

6. Press “STOP” (red) when all the air is eliminated.

7. Open the ball valve to drain the fuel receptacle and

close when completed.

Note: Keep valve closed unless draining the fuel

receptacle.

Daimler Trucks 68
Good KM 59 Fuel Filter Module Bad
Two Stage Valve 16 PSI

Main Filter Drain Broke 16 PSI

Low Pressure Relief stuck open

Pressure Normal during prime
Engine Will Start off Priming Source

By pass valve stuck open

Hand primer pump
unable to build pressure
No return fuel flow
During cranking
Daimler Trucks
KM 59 Fuel Filter Module Bad Priming Results

Daimler Trucks
All Three O – Rings Sealed
Daimler Trucks

1. Fuel Tank
2. Fuel Supply from Tank
3. Pre-filter
4. Hand Primer
5. Low Pressure Fuel Pump
6. Fuel Bypass Valve
7. Water Coalescer / Final Filter 17. Pressure Relief Valve
8. High Pressure Fuel Pump
9. Fuel Rail
10. Injector Feed Lines
21. High Pressure Fuel Flange 31. Fuel Return to Tank
11. Injectors 22. Fuel Cutoff Valve 32. Priming Port
12. Needle Return Line 23. Fuel Compensation Valve 33. Quantity Control Valve
13. Needle Return Pressure Control Valve 24. HC Doser Valve 34. Rail Pressure Sensor
14. Fuel Accumulator 25. Water Coalescer/Final Filter Drain 35. Water Drain
15. Fuel Return Bypass 26. Pressure Limiting Valve 36. Check Ball
16. Gallery Bypass Valve 27. Fuel Return from Pressure Limiting 37. Low Pressure Sensor
Valve
38. Fuel Temperature
28. HC Doser Fuel Supply Pressure Sensor
18. Fuel Return from Amplifiers Control Valve (KM59 Gen1 ONLY)
39. Pre-filter Drain
19. Fuel Cooler 29. Two-Stage Valve
40. Throttle Valve
20. HC Doser Feed Line 30. Two-Stage Valve Return Flow
41. Valve
Daimler Trucks
Daimler Trucks
 Lube System Flow

Front Jake Brake Rocker Arm Engine Brake Actuators

(Cyl 1 and 2) 17 16
Rear Engine Brake Rockers
Intake Rocker Arm / 14
15 (Cyl 3 thru 6)
Camshaft Feed
Crankcase Breather 10 Exhaust Rocker Arm /
13
Camshaft Feed
Turbo Feed 11

11
9 Oil Supply to Gear
10 12 Spindles
Oil Filter Element 7
9 APT Gearbox

Oil Cooler 6

Main Oil 8
Gallery/Mains/
Rods/Nozzles

Suction Pipe/ Strainer 1 Pressure Relief

4
Return Flow Check Valve 5 Valve/ in Pump

Pressure Regulator Valve 3 2 Oil Pump

Daimler Trucks 77
 System Specifications
Oil Capacity 45 Liters (47.5 Quarts) 1 Oil Fill
• Cartridge filter design
• 25K - 50K oil change interval (depending
on category) 2 Oil Filter
• Approximately 4.5 Liters remain in the
engine during oil change
• Higher oil capacity, improved filtration
combined with ULSD and CJ4 oil will result
in longer oil drain intervals without
compromising engine wear.
• Checking engine oil level must be performed
using the instructions outlined in the owners
manual. Failure to do so may result in over
filling the crankcase.

Oil Sampling
Valve/Pre- Lube
3

Daimler Trucks 79
Fully Blocking Thermostat for Oil Coolant Module

• The design below is intended to regulate main gallery oil temperature to improve fuel economy.
• In bypass mode the oil will not flow through the oil cooler.
• Operating temperatures: Begins to open: 115°C (239°F); fully open: 123°C (253°)
• A new tool will be developed to remove and install the thermostat.

Daimler Trucks 80
Thermatic Oil Coolant Module Oil Sample Valve

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Oil Pan with Oil Pump and Bridge

1 Oil Pump

2 Anti Drain Back Valve

3 Suction Tube

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Oil Pump

Safety Relief 1
2 Regulator

3 Oil Feed from

Block

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 Crankcase Breather

To Atmosphere
From Crankcase

Plastic Tray

Drive oil from Lube

System

Oil returned to
engine

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Oil Spray Nozzle

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Daimler Trucks
 Cylinder Liner

J-47407 Cylinder Liner

Installer

Top Liner Cooling

J-47415 Liner Protrusion

Measurement Plate

Daimler Trucks 87
 Piston

Oil Drain Hole

J-47386 Ring Compressor

W4705890031000 Piston
Protrusion Bridge

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Main Bearing
Sputter Bearing
Current Production

TriMetal Bearing

J-48884
Puller, Main
Bearing
Cap
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Connecting Rod

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Daimler Trucks
 Rear Geartrain

Camshaft Gear (Intake) 1

12 Camshaft Gear (Exhaust)

Fuel Pump Gear 2
11 Idler Gear 5

Idler Gear 1 3
10 Idler Gear 3

9 Idler Gear 2

Air Compressor 4
Gear

8 APT Gear
Oil Pump Gear 5
7 Idler Gear 4

6 Crankshaft Gear

Daimler Trucks 92
 Timing Tools

J-47487Idler
W470589054000 Camshaft Gear # 3
Timing/ Locking Tools Timing Tool

J-48630 Crankshaft
TDC Timing Tool

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Crankshaft Oil Seals

W470589004300 Rear Seal Installer/ W541589023300 Front Seal Installer/

Remover Remover
Daimler Trucks 95
Cup Plug Locations

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Daimler Trucks
 Overhead

J-48883 Puller, Cam Bearing Cap

J-47406 Valve Spring Compressor

W470589004000 Rocker Arm
Lifter/ Spacer
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Rocker Arm Shaft

30 mm groove towards the rear

Daimler Trucks 99
Exhaust Rocker Arm and Jake Brake
Exhaust Arm Engine Brake Assembly

Engine Brake Mode Exhaust Rocker

Engine Power Mode Exhaust Rocker

Click on engine brake picture to

the right to run animations.

Daimler Trucks 100

Daimler Trucks
 Diagnostics

• Rail pressure bleed off test using DDDL 7.9.SP2

• Normal low pressure fuel system readings.
• Diagnosing pressure limiting valve.
• No start condition.
• Hard starting (longer than normal crank times).
• Hard starting (engine will only start using an external priming source).

Daimler Trucks 102

Service Tools

J-48404

J-48706
J-48710

J-48707

J-48709 J-48876
J-48708
Daimler Trucks 103
 Rail Pressure Bleed Off (RPBO) Test using DDDL

• This procedure will allow a technician to identify a leak in the high pressure
system. A leak in one of the following locations will show a fast bleed down rate
over time.
• High pressure pump (pumping elements).
• Fuel lines from the high pressure pump to fuel rail.
• Fuel lines to each injector.
• Leak at the rail pressure sensor.
• Leaking pressure limiting valve. Click below to activate video
• Internal amplifier or needle leakage. Normal Leakage in Amplification
Circuit

Low or Small Leakage in

Amplification Circuit

High or Large Leakage in

Amplification Circuit

Daimler Trucks 104

Rail Pressure Bleed Off (RPBO) Test using DDDL

Note: If rail pressure is below 280 bar, increase rpm for a second and allow engine to
return back to idle.

Sealed High Pressure System Daimler Trucks 105

Rail Pressure Bleed Off (RPBO) Test using DDDL

Note: If rail pressure is below 280 bar, increase rpm for a second and allow engine to
return back to idle.

Leakage in High Pressure System Daimler Trucks 106

 PLV Leakage Temperature Test

• This procedure will allow a technician to identify a

leaky pressure limiting valve (PLV). A defective
PLV can cause the following conditions:
• Unstable rail pressure
• Long crank times
• Codes related to rail pressure deviation

Pressure Limiting Valve (PLV) Trend Data

Normal PLV Normal PLV Normal PLV Leaking PLV
(cold start) (after drive cycle) (after drive cycle)

Fuel Rail Surface Temperature 82-89 F 187 F 168 F 90-97 F

PLV Line Surface Temperature 76-77 F 160 F 155F 105-108 F
Daimler Trucks 107
NO Start Condition/Good Rail Pressure

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Rail Pressure Not Plausible 1077/7

Daimler Trucks 109

Rail Pressure Not Plausible 1077/7

Daimler Trucks 110

Daimler Trucks
Fuel Injector

12 Electrical Connection
11 Coil
Return Spring 1
10 Amplifier Control Valve

9 High Pressure Feed

Check Valve 2

8 Amplifier Piston

7 Amplifier

Injector Needle 3 6 Needle Solenoid Valve

5 Coil

4 Spring
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No Injection

Daimler Trucks 113

Non Amplified

Daimler Trucks 114

Amplified

Daimler Trucks 115

 Draining Fuel System Prior to Repairs

• This procedure will allow the fuel system to be drained prior to any repairs being
made.
- Remove the fuel feed line from the fuel filter module.
- Install J-48710 fuel pressure test kit onto the fuel feed line at the module.
- Do NOT remove the return line from the module.
- Use regulator and adjust the system pressure to 50 psi.
- After one to two minutes the system should be drained of fuel.
- Remove test equipment.
• Prior to making any repairs allow system to drain from 2 to 4 minutes

Daimler Trucks 116

 Injector Removal

J-47388 Injector Cup

Removal/ Installation

J-47391 Injector removal

Daimler Trucks 117
 Injector Removal

• Removal
- Disconnect the batteries.
- Remove the rocker cover.
- Disconnect the electrical contacts at the injector.
- Release the high pressure line and cam frame seal.
- Remove injector hold down bolt.
- Lift the clamp and injector from its seat in the cylinder head using the appropriate
injector removal tool.

• Note: The injector should not be disassembled. Only the seal rings and injector
washer are serviceable.

Daimler Trucks 118

 Injector Installation

• Note: The injector tube bore should be cleaned and inspected for damage before
installation of the injector. Use a new copper washer and injector bolt (screw).
- Blow or suction out any fuel remaining in the injector bore.
- Ensure the injector bore is thoroughly clean.
- Install a new copper washer on injector.
- Apply a thin coat of acid free grease or engine oil to the injector seal ring
and install them in the injector nut ring grooves. Make sure they are
properly seated.
- Install the injector and clamp as an assembly into the respective injector
tube bore
- Align the clamp over the retaining stud, install the bolt into injector clamp
and finger tighten hold down bolt.

J-48837 – Injector O-ring Installer

Daimler Trucks 119

 Injector Installation (Continued)

- Install high pressure lines finger tighten the cap nuts.

- Torque the injector clamp bolts to 20N·m and 90 degree torque
turn.
- Torque the high pressure lines to 40 N·m.
- Install the electrical contacts and tighten to 1.5 N·m.
- Tighten cam frame seal at the high pressure line.
• Torque all high pressure fuel lines
- 40 Nm
- Can be used more than once but needs to be
monitored
• All Injectors have a 5 digit code, the injector quantity compensation coding,
which is located on the upper side of the injector.

Daimler Trucks 120

 Diagnostics

• Diagnostics high amplified/ needle return flow.

• Cylinder cut out test.
• Idle speed balance values.

Daimler Trucks 121

Idle Speed Balance

Daimler Trucks 122

Daimler Trucks
 Left Side Sensor/Actuator Locations

Intake Manifold Temp 1

14 Fuel Rail Pressure

EGR Delta P 2
Cam
13
Inlet Air Temp 3 Position

12 LPPO

Inlet Manifold 4
Pressure
Coolant Inlet 5
Temp 11 Fuel Temp

Oil Temp 6 Quantity

10 Control
Valve
Crank
9
Position
Oil Pressure 7

8
Water In Fuel

Daimler Trucks 124

Right Side Sensor/Actuator Locations

2
Coolant Outlet
Temperature

1
EGR Actuator

Daimler Trucks 125

Engine Wiring Harness

Click on Diagram
Daimler Trucks 126
Parameter Tabs

Daimler Trucks 127

Action Tab Contains Service Routines

Daimler Trucks 128

Daimler Trucks
 Fuel System Integrity Check

FSIC / tools
Records
Runs
Diagnoses
FSIC
engine work
important
routine
true ininformation
through conjunction
original
is backward
several with
complaint J-48706
operational
compatible
savedcondition
in log
states
File
Aerated Fuel / leak test

FIS Low Pressure Leak Test

Displays
Pressure
Automatic
CreatesPass
adrop
Test
/ fail
< used
.5result
pressure psiWith
inevery
drop 10 system
inJ-48710
minutes
30 Sec
3 High Pressure Pump Inlet +

Fuel Temp Rise

4 High Pressure Pump Outlet OR
FCP or Return Flow

1 Low Pressure Pump Inlet Fuel Temp Rise +

2 Low Pressure Pump Outlet

Nominal Fuel System Pressures
MAHLE KM 59 / 63

600 RPM 1800 RPM

LPP Inlet
-4 -8 -11 -14
(In/Hg)
LPP Outlet
72 80 100 126
(PSI)
HPP Inlet
x x x x
(PSI)
HPP Outlet
(PSI) X x x x

Priming
Port (PSI) 72 80 100 120

Gen 1
Fuel Comp 72 85 80 95
Regulator
Gen 2 Fuel
85 100 100 130
Comp (PSI)
1 Low Pressure Circuit Test

2 High Pressure Circuit Test

3 Actual Fuel Mass

4 Air in Fuel Check

5 QCV Check
850 - 1800 RPM

6 Amplification Point Check

7 ΔP Check ( Filter Restriction)

8 ISB Update at idle

9 ΔT Check ( Chassis Restriction)

10 Rail Pressure Bleed Off
Engine in low idle or PTO mode, below 760 RPM
Engine in low idle or PTO mode, below 760 RPM
Torque below 20% load
Torque below 20% load
No active injector faults.
No active injector faults.
Engine Coolant between 158 and 230 F
Engine Coolant between 158 and 230 F
Fuel Temperature between 50 and 194 F
Fuel Temperature between 50 and 194 F
RPM variation less than 25 RPMs per second.
RPM variation less than 25 RPMs per second.
 RPM
Pressure Measurement Location Units
600 900 1100 1500 1800
Pre-filter
Pre-filterrestriction
restrictionisis
not
notdetected
detected
1 Prescreen in-Hg -4.48 -5.50 -5.50 -5.50 -5.50
“No
“NoBig
BigDeal”
Deal”
2 LPP Inlet Hose in-Hg n/a n/a n/a n/a n/a Pre-filter
Pre-filterInspected
Inspectedduring
during
tool
toolinstallation
installation

3 LPP Outlet Hose psi n/a n/a n/a n/a n/a

LPPO
LPPO // Priming
Priming Port
Port
4
LPPO Sensor psi 82 87 88 88 88 Pressure
Pressure are
are Lower
Lower
than
than Normal
Normal Baseline
Baseline
5 Priming Port psi 72 75 76 76 76 Readings
Readings

6 High Pressure Pump Inlet Hose psi n/a n/a n/a n/a n/a

7 Fuel Compensation Pressure psi 72 74 75 75 75

Fuel Temperature F 91-96

 RPM
Pressure Measurement Location Units
600 900 1100 1500 1800
Increased
Increased restriction
restriction
1 Prescreen in-Hg -10.99 -11.40 -11.40 -12.01 -11.40 seen
seen when
when issue
issue
exist
exist on
on chassis!
chassis!
2 LPP Inlet Hose in-Hg n/a n/a n/a n/a n/a

3 LPP Outlet Hose psi n/a n/a n/a n/a n/a

LPPO Sensor LPPO

LPPO // Priming
Priming Port
Port
4 psi 82 84 85 87 88 Pressure
Pressure are
are Lower
Lower
than
than Normal
Normal Baseline
Baseline
5 Priming Port psi 69 70 71 73 74 Readings
Readings

6 High Pressure Pump Inlet Hose psi n/a n/a n/a n/a n/a

7 Fuel Compensation Pressure psi n/a n/a n/a n/a n/a

Fuel Temperature F 80-84

Daimler Trucks
 The fault code SPN 2791 FMI 7 is

displayed in the MCM fault code list. Note

that this fault has an Advanced

Diagnostics troubleshooting procedure. To

proceed with the advanced procedure click

on the “Troubleshoot Fault” box.

NOTE: The actual screens in the most current version of
DDDL may vary somewhat from this sample case.
Daimler Trucks 140
The process will

always begin with

a description of

the condition that

you are about to

diagnose.

Daimler Trucks 141

The next screen

informs the user

that the ignition

is “ON”. To

proceed click on

the “Next box in

the lower right.

Daimler Trucks 142

On the next

screen the user

sees that the

application has

run the MCM

service routine to

activate PWM

outputs. The

values are pre-

set for the routine

and the results

will be analyzed

on the screens

thatDaimler
follow. To
Trucks 143
On the next 2

screens we

receive more

information on

what was just

done. The routine

requested that the

valve be opened

to a value of 50%.

For further

analysis the user

should move to

the next screen by

Daimler Trucks 144
The next screen tells

us that the valve

opened to a position

within the tolerance

of the requested

value.

Based on this

feedback from the

tool we are prepared

to proceed by

selecting the “Next”

box.

If the value
Daimler fell
Trucks 145
In the next screen

the user is

requested to turn

off the ignition.

The tool will

automatically

detect when the

ignition is shut off.

The control to

move to the next

screen will not

become active

until the ignition is

Daimler Trucks 146
Once the ignition

has been shut off

the user is directed

to perform specific

physical checks on

the EGR valve.

When the checks

have been

completed one of

the answers at the

bottom of the

screen should be

selected to
Daimler Trucks 147
proceed.
If the user answers “Yes”

he’ll be instructed to

repair the damage he’s

observed and clear the

fault.

If the answer is “No”

then the user should

replace the EGR valve.

Daimler Trucks 148

 In closing out the

Advanced

Diagnostics

procedure, the

user is asked to

fill in comments

on the

troubleshooting

process.

After this is

section is

completed the

user should click

Daimler Trucks 149
 A final

summary will

appear with

details of the

case. Click on

the “Finish” to

close out the

procedure.

Daimler Trucks 150