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Detroit Diesel DD13, DD15, DD16 Exhaust EGR Aftertreatment Shop Manual CD-ROM

Product Specifics:

Product title: MechanicStar - Detroit DD Platform EPA07/10/GHG14 Exhaust, EGR, Aftertreatment Workshop Manual CD-ROM [2014]

Product description: This workshop manual on disc contains mechanical removal, inspection and installation workshop procedures for Detroit DD13, DD15, DD16 engines EGR, exhaust and aftertreatment components. Troubleshooting manual sold separately. 2014 publication.

Product code: MS-MAN-0083CD [340 pages]

Compatibility: Windows/Mac/Linux operating systems

This workshop manual on disc covers the following topics:

Description and Operation of the Exhaust Manifold and Related Parts
DD13 Exhaust Manifold
DD15 Exhaust Manifold
GHG14 DD15 AT Exhaust Manifold
EPA10 DD16 High-Horsepower Exhaust Manifold
2.2 Removal of the Exhaust Manifold
2.3 Removal of the GHG14 DD15 Asymmetrical Turbocharger Exhaust Manifold
2.4 Inspection of an Assembled Exhaust Manifold
2.6 Disassembly of the Exhaust Manifold
2.7 Assembly of the Exhaust Manifold
2.9 Installation of the Exhaust Manifold
2.10 Installation of the GHG14 DD15 Asymmetrical Turbocharger Exhaust Manifold
3.1 Description and Operation of the DD13 Exhaust Flanged Manifold
3.2 Removal of the DD13 Exhaust Flanged Manifold
3.3 Installation of the DD13 Exhaust Flanged Manifold
4.1 Description and Operation of the DD15 and DD16 Exhaust S-Pipe (Elbow) and Related Parts
4.2 Removal of the DD15 and DD16 Exhaust S-pipe
4.3 Installation of the DD15 and DD16 Exhaust S-pipe
5.1 Removal of the Exhaust Gas Recirculation Hot Pipe
5.2 Installation of the Exhaust Gas Recirculation Hot Pipe
6.1 Cleaning of the DD13 Exhaust Gas Recirculation System
6.2 Cleaning of the Turbo Compound DD15 and DD16 Exhaust Gas Recirculation Systems
6.3 Cleaning of the GHG14 DD15 Asymmetrical Turbocharger Exhaust Gas Recirculation System
7.1 Removal of the Exhaust Gas Recirculation Crossover Tube
7.2 Installation of the Exhaust Gas Recirculation Crossover Tube
8.1 Removal of the Exhaust Gas Recirculation Venturi
8.2 Installation of the Exhaust Gas Recirculation Venturi
10.1 Description and Operation of DD13 Exhaust Gas Recirculation Cooler Water Manifold Assembly
10.2 Removal of the DD13 Exhaust Gas Recirculation Cooler Water Manifold Assembly
10.3 Inspection of the DD13 EGR Cooler Water Manifold Assembly
10.4 Testing and Inspection of the DD13 Exhaust Gas Recirculation Cooler Water Manifold Assembly
10.5 Installation of the DD13 EGR Cooler Water Manifold Assembly
11.1 Description and Operation of the DD15 and DD16 Exhaust Gas Recirculation Cooler
11.2 Removal of the DD15 and DD16 Exhaust Gas Recirculation Cooler
11.3 Testing and Inspection of the DD15 and DD16 Exhaust Gas Recirculation Cooler
11.4 Installation of the DD15 and DD16 Exhaust Gas Recirculation Cooler
12.1 Removal of the Exhaust Gas Recirculation Valve Actuator Pull Rod
12.2 Inspection of DD13 Exhaust Gas Recirculation Valve Actuator Pull Rod
12.3 Installation of the DD13 Exhaust Gas Recirculation Valve Actuator Pull Rod
13.1 Removal of the Exhaust Gas Recirculation Valve Actuator Pull Rod
13.2 Installation of the DD15 and DD16 Exhaust Gas Recirculation Valve Actuator Pull Rod
14.1 Removal of the GHG14 DD15 AT Exhaust Gas Recirculation Valve Actuator Pull Rod
14.2 Inspection of the GHG14 DD15 AT Exhaust Gas Recirculation Valve Actuator Pull Rod
14.3 Installation of the GHG14 DD15 AT Exhaust Gas Recirculation Valve Actuator Pull Rod
15.1 Description and Operation of the DD13 Exhaust Gas Recirculation Valve Actuator
15.2 Removal of the DD13 Exhaust Gas Recirculation Valve Actuator
15.3 Installation of the DD13 Exhaust Gas Recirculation Valve Actuator
16.1 Description and Operation of the DD15 and DD16 Exhaust Gas Recirculation Valve Actuator
16.2 Removal of DD15 and DD16 Exhaust Gas Recirculation Valve Actuator
16.3 Installation of the DD15 and DD16 Exhaust Gas Recirculation Valve Actuator
16.4 Removal of the DD15 and DD16 Sonceboz® Exhaust Gas Recirculation Valve Actuator
16.5 Installation of the DD15 and DD16 Sonceboz® Exhaust Gas Recirculation Valve Actuator
17.1 Description and Operation of the GHG14 DD15 AT Exhaust Gas Recirculation Valve Actuator
17.2 Removal of the GHG14 DD15 AT Exhaust Gas Recirculation Valve Actuator
17.3 Installation of the GHG14 DD15 AT Exhaust Gas Recirculation Valve Actuator
18.1 Removal of the Exhaust Gas Recirculation Actuator Lever
18.2 Installation of the Exhaust Gas Recirculation Actuator Lever
19.1 Description and Operation of the GHG14 DD15 AT Exhaust Gas Recirculation Valve/Hot Pipe
19.2 Removal of the GHG14 DD15 AT Exhaust Gas Recirculation Valve/Hot Pipe
19.3 Installation of the GHG14 DD15 AT Exhaust Gas Recirculation Valve/Hot Pipe
20.1 Description and Operation of the GHG14 DD15 AT Flanged Exhaust Manifold and Related Parts
20.2 Removal of the GHG14 DD15 AT Flanged Exhaust Manifold
20.3 Installation of the GHG14 DD15 AT Flanged Exhaust Manifold
21.1 Description and Operation of the DD13 Exhaust Gas Recirculation Valve
22.1 Description and Operation of the DD15 and DD16 Exhaust Gas Recirculation Valve
22.2 Removal of the DD15 and DD16 Exhaust Gas Recirculation Valve
22.3 Installation of the DD15 and DD16 Exhaust Gas Recirculation Valve
23.1 Description and Operation of the Mixer Pipe
23.2 Removal of the Mixer Pipe
23.3 Inspection of the Mixer Pipe
23.4 Installation of the Mixer Pipe
24.1 Removal of the Hydrocarbon Doser Block Feed Line
24.2 Installation of the Hydrocarbon Doser Block Feed Line
25.1 Description and Operation of the Hydrocarbon Doser Block
25.2 Removal of the Hydrocarbon Doser Block
25.3 Installation of the Hydrocarbon Doser Block
26.1 Description and Operation of the Fuel Doser Injector Valve
26.3 Installation of the Hydrocarbon Doser Fuel Injector Valve
27.1 Removal of the Hydrocarbon Fuel Doser Housing
27.2 Installation of the Hydrocarbon Fuel Doser Housing
28.1 Removal of the Fuel Compensation Pressure Sensor
28.2 Installation of the Fuel Compensation Pressure Sensor
29.1 Description and Operation of Intake Throttle Valve and Adaptor
29.2 Removal of the Intake Throttle Valve and Adaptor
29.3 Installation of the Intake Throttle Valve and Adaptor
30.1 Overview of EPA07 Aftertreatment System
30.2 Description and Operation of the EPA07 Aftertreatment Device
30.3 Description and Operation of the Diesel Particulate Filter
30.4 EPA07 Aftertreatment Operating Requirements
30.5 EPA07 Aftertreatment System Component Overview
30.6 EPA07 Aftertreatment Regeneration Strategy
EPA07 DD15 Regeneration Strategy
EPA07 DD15 Idle Timing
30.6.1 Passive Regeneration
30.6.2 Active Regeneration
30.6.3 Parked Regeneration
30.7 Performing a Parked Regeneration - EPA07
30.8 Unable to Perform a Parked Regeneration - EPA07
30.9 Instrument Panel Lamps
Amber Warning Lamp
Red Stop Lamp
Diesel Particulate Filter Regeneration Lamp
High Exhaust System Temperature Lamp
Malfunction Indicator Lamp
31.1 Description and Operation of the EPA07 Aftertreatment Device Temperature Sensors
31.2 Removal of the EPA07 Temperature Sensors
31.3 Installation of the EPA07 Temperature Sensors
31.4 Removal of the EPA07 Pressure Sensors
31.5 Installation of the EPA07 Pressure Sensors
32.1 Accumulated Ash - EPA07
32.2 Requirements - EPA07
Service Record
33.1 Removal of the EPA07 Aftertreatment Device from the Vehicle
33.2 Installation of the EPA07 Aftertreatment Device
34.1 Disassembly of the EPA07 Aftertreatment Device
34.2 Preliminary Inspection of the Aftertreatment Device
34.3 Diesel Oxidation Catalyst (DOC) Inspection - All Years
34.4 Diesel Particulate Filter (DPF) Inspection - All Years
34.5 Outlet Flange Adapter Inspection - All Years
34.6 Assembly of the EPA07 Aftertreatment Device
35.1 Resetting the EPA07 Diesel Particulate Filter Ash Accumulators
35.2 Resetting the EPA10-GHG14 Diesel Particulate Filter Ash Accumulators
36.1 Description and Operation of the EPA10 Aftertreatment System
1-BOX™ Aftertreatment System Configuration
2-Box Aftertreatment Systems Configurations
Diesel Oxidation Catalyst, Diesel Particulate Filter, and Selective Catalytic Reduction Mounted
Diesel Oxidation Catalyst, Diesel Particulate Filter Mounted Horizontally, Selective Catalytic Reduction Mounted Vertically
Diesel Oxidation Catalyst (DOC), Diesel Particulate Filter (DPF), Selective Catalytic Reduction (SCR Catalyst) Mounted Horizont
36.2 Description and Operation of the Diesel Particulate Filter
36.3 Description and Operation of the Selective Catalytic Reduction (SCR Catalyst)
36.4 Description and Operation of the EPA10 Diesel Exhaust Fluid Heating
36.5 Description and Operation of the GHG14 Diesel Exhaust Fluid Heating
36.6 Description and Operation of the Diesel Exhaust Fluid Flow
36.7 Description and Operation of the Diesel Exhaust Fluid (Compressed Air Flow)
36.8 EPA10-GHG14 Aftertreatment Regeneration Strategy
EPA10/GHG14 Zone Trigger
EPA10/GHG14 Regeneration Strategy
36.8.1 Passive Regeneration
36.8.2 Active Regeneration
36.8.3 Parked Regeneration
36.9 Performing a Parked Regeneration - EPA10-GHG14
36.10 Performing a Parked Regeneration Using DDDL (Parked Regeneration Request Switch is not Available
36.11 EPA10-GHG14 Aftertreatment Diesel Exhaust Fluid Gauge-Lamps
36.12 Instrument Panel Lamps
Amber Warning Lamp
Red Stop Lamp
Diesel Particulate Filter Regeneration Lamp
High Exhaust System Temperature Lamp
Malfunction Indicator Lamp
Fuel Filter Restriction Sensor Lamp: Fuel Filter Failed
Water-In-Fuel Lamp (WIF)
37.1 Description and Operation of the Aftertreatment Control Module
37.1 Description and Operation of the Aftertreatment Control Module
37.2 EPA10-GHG14 Aftertreatment Device Sensor Locations
1-BOX™ Sensor Locations
Diesel Oxidation Catalyst, Diesel Particulate Filter, and Selective Catalytic Reduction (SCR Catalyst) Mounted Vertically
Diesel Oxidation Catalyst, Diesel Particulate Filter Mounted Horizontally, Selective Catalytic Reduction (SCR Catalyst) Mounted
37.4 Installation of the Aftertreatment Control Module
38.1 Description and Operation of the Diesel Exhaust Fluid Tank Header Unit
38.2 Removal of the EPA10 13 and 23 Gallon Diesel Exhaust Fluid Tank Header Unit
38.3 Installation of the EPA10 13 and 23 Gallon Diesel Exhaust Fluid Tank Header Unit
38.4 Removal of the GHG14 13 and 23 Gallon Diesel Exhaust Fluid Tank Header Unit
38.5 Installation of the GHG14 13 and 23 Gallon Diesel Exhaust Fluid Tank Header Unit
38.6 Removal of the GHG14 Six-Gallon Diesel Exhaust Fluid Tank Header
38.7 Installation of the GHG14 Six-Gallon Diesel Exhaust Fluid Tank Header
39.1 Description and Operation of the Diesel Exhaust Fluid Tank
39.2 Description and Operation of the EPA10 Diesel Exhaust Fluid Heating
39.3 Removal of the Six-Gallon Diesel Exhaust Fluid Tank
39.4 Installation of the Six-Gallon Diesel Exhaust Fluid Tank
39.5 Removal of the GHG14 Six-Gallon Diesel Exhaust Fluid Tank
39.6 Installation of the GHG14 Six-Gallon Diesel Exhaust Fluid Tank
39.7 Removal of the 13 and 23 Gallon Diesel Exhaust Fluid Tank
39.8 Installation of the 13 and 23 Gallon Diesel Exhaust Fluid Tank
39.9 Removal of the GHG14 13 and 23 Gallon Diesel Exhaust Fluid Tank
39.10 Installation of the GHG14 13 and 23 Gallon Diesel Exhaust Fluid Tank
40.1 Removal of the Diesel Exhaust Fluid Lines (Tank to Pump)
40.2 Installation of the Diesel Exhaust Fluid Lines (Tank to Pump)
40.3 Removal of the Diesel Exhaust Fluid Line Connections
40.4 Installation of the Diesel Exhaust Fluid Line Connections
40.5 Removal of DEF Supply Unit Coolant Line Fittings
40.6 Installation of the DEF Supply Unit Coolant Line Fittings
41.1 Description and Operation of the Diesel Exhaust Fluid Pump Assembly
41.2 Removal of the Diesel Exhaust Fluid Pump Module
41.3 Installation of the Diesel Exhaust Fluid Pump Module
41.4 Flushing of the Diesel Exhaust Fluid System
41.5 Removal of the Diesel Exhaust Fluid Pump Module Filter Screen
41.6 Installation of the Diesel Exhaust Fluid Pump Module Filter Screen
41.7 Removal of the Diesel Exhaust Fluid Pump Module Pneumatic Switching Valve
41.8 Installation of the Diesel Exhaust Fluid Pump Module Pneumatic Switching Valve
41.9 Removal of the Diesel Exhaust Fluid Pump Module Filter
41.10 Installation of the Diesel Exhaust Fluid Pump Module Filter
41.11 Removal of the Diesel Exhaust Fluid Pump Module Air Bladder
41.12 Installation of the Diesel Exhaust Fluid Pump Module Air Bladder
42.1 Removal of the GHG14 Diesel Exhaust Fluid Lines
42.2 Installation of the GHG14 Diesel Exhaust Fluid Lines
43.1 Description and Operation of the GHG14 Airless Dosing System Diesel Exhaust Fluid Pump
43.2 Removal of the GHG14 Diesel Exhaust Fluid Pump Module
43.3 Installation of the GHG14 Diesel Exhaust Fluid Pump Module
43.4 Flushing of the GHG14 Diesel Exhaust Fluid System
43.5 Removal of the Diesel Exhaust Fluid Pump Pressure Relief Valve
43.6 Installation of the Diesel Exhaust Fluid Pump Pressure Relief Valve
43.7 Removal of the GHG14 Diesel Exhaust Fluid Pump Module Inlet Screen
43.8 Installation of the GHG14 Diesel Exhaust Fluid Pump Module Inlet Screen
43.9 Removal of the GHG14 Diesel Exhaust Fluid Pump Module Coolant Line Connector Fitting
43.10 Installation of the GHG14 Diesel Exhaust Fluid Pump Module Coolant Connector Fitting
43.11 Removal of the GHG14 Diesel Exhaust Fluid Pump Module Filter
43.12 Installation of the GHG14 Diesel Exhaust Fluid Pump Module Filter
44.1 Description and Operation of the Diesel Exhaust Fluid Metering Unit
44.2 Compressed-Air Assisted Diesel Exhaust Fluid Supply Function
44.3 Removal of the Diesel Exhaust Fluid Metering Unit
44.4 Installation of the Diesel Exhaust Fluid Metering Unit
44.5 Removal of the Diesel Exhaust Fluid Screen
44.6 Installation of the Diesel Exhaust Fluid Screen
44.7 Removal of the Diesel Exhaust Fluid Metering Unit Compressed Air Supply Screen
44.8 Installation of the Diesel Exhaust Fluid Metering Unit Compressed Air Supply Screen
44.9 Removal of the Diesel Exhaust Fluid Pressure Sensor
44.10 Installation of the Diesel Exhaust Fluid Pressure Sensor
44.11 Removal of the Diesel Exhaust Fluid Temperature Sensor
44.12 Installation of the Diesel Exhaust Fluid Temperature Sensor
44.13 Removal of the Diesel Exhaust Fluid Metering Unit Air Pressure Sensor
44.14 Installation of the Diesel Exhaust Fluid Metering Unit Air Pressure Sensor
44.15 Removal of the Diesel Exhaust Fluid Metering Unit Doser Heater
44.16 Installation of the Diesel Exhaust Fluid Metering Unit Doser Heater
44.17 Removal of the Diesel Exhaust Fluid Metering Unit Diffuser Heater
44.18 Installation of the Diesel Exhaust Fluid Metering Unit Diffuser Heater
45.1 Description and Operation of the Diesel Exhaust Fluid Nozzle
45.2 Removal of the Diesel Exhaust Fluid Nozzle
45.3 Cleaning of the Diesel Exhaust Fluid Nozzle
45.4 Installation of the Diesel Exhaust Fluid Nozzle
46.1 Description and Operation of the GHG14 Diesel Exhaust Fluid Dosing Unit
46.2 Removal of the GHG14 Dosing System Doser
46.3 Installation of the GHG14 Dosing System Doser
46.4 Removal of the GHG14 Diesel Exhaust Fluid Dosing Unit Inlet Screen
46.5 Installation of the GHG14 Diesel Exhaust Fluid Dosing Unit Inlet Screen
47.1 Removal of the 1-BOX™ Sensor Box
47.2 Installation of the 1-BOX™ Sensor Box
48.1 Removal of the EPA10 Diesel Oxidation Catalyst Outlet Temperature Sensor
48.2 Installation of the EPA10 Diesel Oxidation Catalyst Outlet Temperature Sensor
48.3 Removal of the EPA10 Diesel Oxidation Catalyst Inlet Temperature Sensor
48.4 Installation of the EPA10 Diesel Oxidation Catalyst Inlet Temperature Sensor
48.5 Removal of the EPA10 Diesel Oxidation Catalyst Inlet Pressure Sensor
48.6 Installation of the EPA10 Diesel Oxidation Catalyst Inlet Pressure Sensor
48.7 Removal of the EPA10 Diesel Oxidation Catalyst Inlet Pressure Sensor Tube and Elbow
48.8 Installation of the EPA10 Diesel Oxidation Catalyst Inlet Pressure Sensor Tube and Elbow
48.9 Removal of the EPA10 Diesel Particulate Filter Outlet Temperature Sensor
48.10 Installation of the EPA10 Diesel Particulate Filter Outlet Temperature Sensor
48.11 Removal of the EPA10 Diesel Particulate Filter Outlet Pressure Sensor
48.12 Installation of the EPA10 Diesel Particulate Filter Outlet Pressure Sensor
48.13 Removal of the EPA10 Selective Catalyst Reduction Inlet NOx Sensor
48.14 Installation of the EPA10 Selective Catalyst Reduction Inlet NOx Sensor
48.15 Removal of the EPA10 Selective Catalyst Reduction Outlet NOx Sensor
48.16 Installation of the EPA10 Selective Catalyst Reduction Outlet NOx Sensor
49.1 Removal of the GHG14 Diesel Oxidation Catalyst Inlet Pressure Sensor
49.2 Installation of the GHG14 Diesel Oxidation Catalyst Inlet Pressure Sensor
49.3 Removal of the GHG14 Diesel Oxidation Catalyst Inlet Pressure Sensor Tube
49.4 Installation of the GHG14 Diesel Oxidation Catalyst Inlet Pressure Sensor Tube
49.5 Removal of the GHG14 Diesel Oxidation Catalyst Outlet Temperature Sensor
49.6 Installation of the GHG14 Diesel Oxidation Catalyst Outlet Temperature Sensor
49.7 Removal of the GHG14 Diesel Oxidation Catalyst Inlet Temperature Sensor
49.8 Installation of the GHG14 Diesel Oxidation Catalyst Inlet Temperature Sensor
49.9 Removal of the GHG14 Diesel Particulate Filter Outlet Pressure Sensor
49.10 Installation of the GHG14 Diesel Particulate Filter Outlet Pressure Sensor
49.11 Removal of the GHG14 Diesel Particulate Filter Outlet Pressure Sensor Tube
49.12 Installation of the GHG14 Diesel Particulate Filter Outlet Pressure Sensor Tube
49.13 Removal of the GHG14 Diesel Particulate Filter Outlet Temperature Sensor
49.14 Installation of the GHG14 Diesel Particulate Filter Outlet Temperature Sensor
49.15 Removal of the GHG14 Selective Catalyst Reduction Inlet Temperature Sensor
49.16 Installation of the GHG14 Selective Catalyst Reduction Inlet Temperature Sensor
49.17 Removal of the GHG14 Selective Catalyst Reduction Outlet Temperature Sensor
49.18 Installation of the GHG14 Selective Catalyst Reduction Outlet Temperature Sensor
49.19 Removal of the GHG14 Selective Catalytic Reduction Inlet NOx Sensor
49.20 Installation of the GHG14 Selective Catalytic Reduction Inlet NOx Sensor
49.20 Installation of the GHG14 Selective Catalytic Reduction Inlet NOx Sensor
49.21 Removal of the GHG14 Selective Catalytic Reduction Outlet NOx Sensor
49.21 Removal of the GHG14 Selective Catalytic Reduction Outlet NOx Sensor
49.22 Installation of the GHG14 Selective Catalytic Reduction Outlet NOx Sensor
49.22 Installation of the GHG14 Selective Catalytic Reduction Outlet NOx Sensor
50.1 Removal of the EPA10 Diesel Particulate Filter
50.2 Installation of the EPA10 Diesel Particulate Filter
51.1 Removal of the GHG14 Diesel Particulate Filter
51.2 Installation of the GHG14 Diesel Particulate Filter
52.1 Removal of the 1-BOX™ from the Vehicle
52.2 Installation of the 1-BOX™ to the Vehicle
53.1 Removal of the GHG14 1-BOX™ From the Vehicle
53.2 Installation of the GHG14 1-BOX™ to the Vehicle
55.1 Removal of the GHG14 Two-Box Diesel Particulate Filter
55.2 Installation of the GHG14 Two-Box Diesel Particulate Filter
55.3 Removal of the GHG14 2–Box Diesel Oxidation Catalyst/Diesel Particulate Filter
55.4 Installation of the GHG14 2–Box Diesel Oxidation Catalyst/Diesel Particulate Filter
55.5 Installation of the GHG14 Selective Catalytic Reduction (SCR Catalyst)
56.1 Removal of the GHG14 Two-Box Option (2V2) from the Vehicle
56.2 Installation of the GHG14 Two-Box Option (2V2) to the Vehicle
57.1 Diesel Oxidation Catalyst - Diesel Particulate Filter Additional Removal Information
57.2 Removal of the 2–Box Diesel Oxidation Catalyst / Diesel Particulate Filter
57.3 Installation of the 2–Box Diesel Oxidation Catalyst / Diesel Particulate Filter
57.4 Removal of the GHG14 Two-Box Diesel Oxidation Catalyst
57.5 Installation of the GHG14 Two-Box Diesel Oxidation Catalyst
57.6 Removal of the 2-Box Diesel Particulate Filter
57.7 Installation of the 2-Box Diesel Particulate Filter
58.1 Selective Catalytic Reduction (SCR Catalyst) Additional Removal Information
58.2 Removal of the Selective Catalytic Reduction (SCR Catalyst) from the Stanchion
58.3 Installation of the Selective Catalytic Reduction (SCR) Catalyst to the Stanchion
58.4 Removal of the Selective Catalytic Reduction (SCR Catalyst)
58.5 Installation of the Selective Catalytic Reduction (SCR Catalyst)

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