SPN 3480/FMI 0, 1, 3, 4, 14, 21, 31 October 2012 SPN 3480/FMI 0 SPN 3480/FMI 1 SPN 3480/FMI 3 SPN 3480/FMI 4 SPN 3480/FMI 14 SPN 3480/FMI 21

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1 SUBJECT DATE SPN 3480/FMI 0, 1, 3, 4, 14, 21, 31 October 2012 Additions, Revisions, or Updates Publication Number / Title Platform Section Title Change SPN 3480/FMI 0 SPN 3480/FMI 1 DDC-SVC-MAN-0084 EPA07/ EPA10/ GHG14 DD Platform SPN 3480/FMI 3 SPN 3480/FMI 4 SPN 3480/FMI 14 GHG14 qualifier added. SPN 3480/FMI 21 SPN 3480/FMI 31 All information subject to change without notice. 3

2 2 SPN 3480/FMI 0 - ALL YEARS 2 SPN 3480/FMI 0 - ALL YEARS This diagnostic is typically Fuel Compensation Pressure High. Table 1. SPN 3480/FMI 0 Fuel Compensation Pressure High Hydrocarbon (HC) Doser Fuel Line Pressure Dosing Enabled Continuous when enabling conditions met 1 minute Engine Reaction Derate 10% Parked Regeneration 1. Shut off the engine, apply the parking brake, chock the wheels and perform any other applicable safety steps. 2. Are any fuel system faults present? a. Yes; repair these faults first. b. No; Go to step 3. NOTE: One drop of fuel can cause a failure. 3. Visually inspect the (Hydrocarbon) HC doser block assembly and fuel doser injector valve fuel lines for external leaks. WARNING: FIRE To avoid injury from fire, contain and eliminate leaks of flammable fluids as they occur. Failure to eliminate leaks could result in fire. a. If external leaks are present, repair as necessary. Go to step 4. b. If no external leaks are present, Go to step Connect DDDL 7.08 SP2 or higher. WARNING: ENGINE EXHAUST To avoid injury from inhaling engine exhaust, always operate the engine in a well-ventilated area. Engine exhaust is toxic. 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. 5. Start the engine. NOTE: It may take up to three purge attempts to completely remove air from the system. Do not exceed three attempts. 6. Using DDDL SP2 or higher, perform a "Purge Hydrocarbon Doser" service routine. 4 All information subject to change without notice. Copyright 2012 DETROIT DIESEL CORPORATION

3 NOTE: The pressures listed in this procedure for fuel compensation pressure are absolute pressures, which is gauge pressure plus approximately 100 kpa (14.5 psi). 7. Once the fuel cutoff gets to 100%, begin monitoring the fuel compensation pressure and the HC doser fuel line pressure. a. If the fuel compensation pressure is between kpa (10-65 psi), perform a low fuel pressure test. Make repairs as needed; Go to step 8. Refer to section "Low Pressure Fuel System - Pressure Test". b. If the fuel compensation pressure is between kpa (65-95 psi), replace the FCP sensor (replace the Hydrocarbon Doser Block on DD15AT. Refer to section "Removal of the Hydrocarbon Doser Block "). Refer to section "Installation of the Fuel Compensation Pressure Sensor". Go to step 8. WARNING: HOT EXHAUST During parked regeneration the exhaust gases will be extremely HOT and could cause a fire if directed at combustible materials. The vehicle must be parked outside. 8. Perform a parked regeneration. Refer to section "Performing a Parked Regeneration Using DDDL". a. If SPN 3480/FMI 0 becomes active during regeneration, retain regeneration log file and contact the Detroit Customer Support Center at (800) b. If the parked regeneration successfully completes, clear active codes and release the vehicle. All information subject to change without notice. 5

4 3 SPN 3480/FMI 1 - ALL YEARS 3 SPN 3480/FMI 1 - ALL YEARS This diagnostic is typically Hydrocarbon (HC) Doser Fuel Supply Pressure Abnormal. Table 2. SPN 3480/FMI 1 Hydrocarbon (HC) Doser Fuel Supply Pressure Abnormal Hydrocarbon (HC) Doser Fuel Line Pressure Dosing Enabled Continuous when enabling conditions met 1 minute Engine Reaction Derate 10% Parked Regeneration 1. Shut off the engine, apply the parking brake, chock the wheels and perform any other applicable safety steps. 2. Is SPN 3480/FMI 14 also present (active or inactive)? a. Yes; repair SPN 3480/FMI 14 first. Refer to section "SPN 3480/FMI 14 - ALL YEARS". b. No; Go to step Visually inspect the HC doser block assembly for external leaks. a. If external leaks are present repair as necessary, Go to step 4. b. If no leaks are present, Go to step 4. WARNING: ENGINE EXHAUST To avoid injury from inhaling engine exhaust, always operate the engine in a well-ventilated area. Engine exhaust is toxic. 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. 4. Start the engine. NOTE: It may take three purge attempts to purge all air from the lines. Do not exceed three purge attempts. 5. Using DDDL/DDRS 7 08 SP2 or higher, perform Purge Hydrocarbon Doser service routine. Once the fuel cutoff valve reaches 100%, monitor fuel compensation pressure. a. If the fuel compensation pressure is between kpa (10-65 psi), perform a low fuel pressure test. After repairs are complete, Go to step 6. Refer to section "Low Pressure Fuel System - Pressure Test". b. If the fuel compensation pressure is less than 69 kpa (10 psi), replace the fuel compensation pressure sensor (replace the Doser Block on DD15AT. Refer to section "Removal of the Hydrocarbon Doser Block "). After repairs are complete, repeat this step. Refer to section "Installation of the Fuel Compensation Pressure Sensor". c. If the fuel compensation pressure is above 448 kpa (65 psi), Go to step Using J-48876, measure the priming port pressure at idle at 1800 rpm. Priming port specification is kpa (70-90 psi) at 600 rpm and kpa ( psi) at 1800 rpm. Are the priming port pressures within range? a. Yes; replace the fuel doser pressure control valve in the high pressure flange. Go to step 7. b. No; Refer to section "Low Pressure Fuel System Measuring Fuel Pressure Using Automatic Fuel System Integrity Check". Go to step 7. 6 All information subject to change without notice. Copyright 2012 DETROIT DIESEL CORPORATION

5 WARNING: HOT EXHAUST During parked regeneration the exhaust gases will be extremely HOT and could cause a fire if directed at combustible materials. The vehicle must be parked outside. 7. Using DDDL/DDRS 7.08 SP2 or higher, perform a Parked Regeneration. a. If SPN 3480/FMI 1 or 16 becomes active during the regeneration or the fault is still active, retain the regeneration log file and contact the Detroit Customer Support Center at (800) for further instruction. b. If regeneration successfully completes, clear faults and release the vehicle. All information subject to change without notice. 7

6 4 SPN 3480/FMI 3 - ALL YEARS 4 SPN 3480/FMI 3 - ALL YEARS This diagnostic is typically Fuel Compensation Pressure (FCP) sensor circuit failed high. Table 3. Engine Reaction SPN 3480/FMI 3 Fuel Compensation Pressure Sensor Circuit Failed High Fuel Compensation Pressure Sensor Always Enabled Always Enabled 2 Seconds Engine Idle (1 minute) 1. Check for multiple codes. a. If SPN 100/FMI 3, SPN 4077/FMI 3 and SPN 3480/FMI 3 are present, repair short to power between pin 82 of the MCM 120-pin connector and the engine oil pressure, fuel line and FCP sensors. b. If SPN 4077/FMI 3 and SPN 3480/FMI 3 are present, repair short to power between pin 104 of the MCM 120-pin connector and the fuel line and FCP sensors. c. If only SPN 3480/FMI 3 is present, Go to step Disconnect the FCP sensor connector. 3. Disconnect the MCM 120-pin connector. 4. Measure the resistance across pins 1 and 2 of the fuel line pressure sensor connector. a. If the resistance is less than 10K ohms, repair the short between pins 82 and 84 of the the MCM 120-pin connector. b. If the resistance is greater than 10K ohms, repair the short to power on circuit between pin 84 of the MCM 120- pin connector and pin 4 of the FCP sensor connector. 8 All information subject to change without notice. Copyright 2012 DETROIT DIESEL CORPORATION

7 5 SPN 3480/FMI 4 - ALL YEARS This diagnostic is typically Fuel Compensation Pressure (FCP) Sensor Circuit Failed Low. Table 4. Engine Reaction SPN 3480/FMI 4 Fuel Compensation Pressure Sensor Circuit Failed Low Fuel Compensation Pressure Sensor Always Enabled Always Enabled 2 Seconds Engine Idle (1 minute) 1. Check for multiple codes. a. If SPN 100/FMI 4, SPN 4077/FMI 4 and SPN 3480/FMI 4 are present, Go to step 2. b. If SPN 4077/FMI 4 and SPN 3480/FMI 4 are present, repair short to power between pin 104 of the MCM pin connector and the fuel line and FCP sensors. c. If only SPN 3480/FMI 4 is present, Go to step Disconnect the FCP sensor. 3. Disconnect the Motor Control Module (MCM) 120-pin connector. 4. Measure the resistance between pin 1 of the FCP sensor harness connector and ground (battery ground lug by starter). a. If resistance is less than 5 ohms, repair short to ground between pin 82 of the MCM 120-pin connector and the engine oil, fuel line and FCP sensors. b. If resistance is greater than 5 ohms, repair open circuit between pin 82 of the MCM 120-pin connector and the engine oil, fuel line and FCP sensors. 5. Disconnect the FCP sensor. 6. Disconnect the MCM 120-pin connector. 7. Measure the resistance between pin 1 of the FCP sensor harness connector and ground (battery ground lug by starter). a. If the resistance is less than 5 ohms, repair short to ground between pin 84 of the MCM 120-pin connector and pin 1 of the FCP sensor. b. If the resistance is greater than 5 ohms, repair open circuit between pin 84 of the MCM 120-pin connector and pin 1 of the FCP sensor. All information subject to change without notice. 9

8 6 SPN 3480/FMI 14 - ALL YEARS 6 SPN 3480/FMI 14 - ALL YEARS This diagnostic is typically Hydrocarbon (HC) Doser Fuel Line Pressure (FLP) Sensor - Failed Self-Test. Table 5. SPN 3480/FMI 14 Doser FLP Sensors-Failed Self Test Doser Fuel Line Pressure Dosing Enabled Continuous when enabling conditions met 1 Minute Engine Reaction Derate 10% Parked Regeneration 1. Shut off the engine, apply the parking brake, chock the wheels and perform any other applicable safety steps. 2. Replace the fuel compensation pressure sensor (replace metering unit on DD15AT Refer to section "Removal of the Hydrocarbon Doser Block "). Go to step 3. Refer to section "Installation of the Fuel Compensation Pressure Sensor" NOTE: It may take three purge attempts to purge all air from the lines. Do not exceed three purge attempts. 3. Using DDDL/DDRS 7.08 SP2 or newer, perform Purge Hydrocarbon Doser service routine. Go to step 4. WARNING: HOT EXHAUST During parked regeneration the exhaust gases will be extremely HOT and could cause a fire if directed at combustible materials. The vehicle must be parked outside. 4. Perform parked regeneration. Refer to section "Performing a Parked Regeneration Using DDDL" a. If regeneration successfully completes, clear faults and release vehicle. b. If SPN 3480/FMI 14 is still active, retain the regeneration log file and contact the Detroit Customer Support Center at (800) for further instruction. 10 All information subject to change without notice. Copyright 2012 DETROIT DIESEL CORPORATION

9 7 SPN 3480/FMI 21 - ALL YEARS This diagnostic is typically Fuel Cut-off Valve Pressure Not Plausible. Table 6. SPN 3480/FMI 21 Fuel Cut-off Valve Pressure Not Plausible Hydrocarbon (HC) Doser Fuel Compensation Pressure Dosing Enabled Continuous when enabling conditions met 1 Minute Engine Reaction Derate 10% Parked Regeneration 1. Shut off the engine, apply the parking brake, chock the wheels and perform any other applicable safety steps. 2. Are there any fuel system faults present? a. Yes, repair these faults first. b. No; Go to step 3. NOTE: One drop of fuel can cause a failure. 3. Visually inspect HC doser block assembly and fuel doser injector valve fuel lines for external leaks. WARNING: FIRE To avoid injury from fire, contain and eliminate leaks of flammable fluids as they occur. Failure to eliminate leaks could result in fire. a. If external leaks are present, repair as necessary. Go to step 4. b. If no external leaks are present, Go to step Replace the Fuel Compensation Pressure (FCP) sensor (replace the Doser Block on DD15AT. Refer to section "Removal of the Hydrocarbon Doser Block ") Refer to section "Installation of the Fuel Compensation Pressure Sensor". 5. Connect DDDL 7.08 SP2 or higher. WARNING: ENGINE EXHAUST To avoid injury from inhaling engine exhaust, always operate the engine in a well-ventilated area. Engine exhaust is toxic. 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. 6. Start the engine. NOTE: It may take up to three purge attempts to completely remove air from the system. Do not exceed three attempts. All information subject to change without notice. 11

10 7 SPN 3480/FMI 21 - ALL YEARS 7. Using DDDL 7.08 SP2 or higher, perform a "Purge Hydrocarbon Doser" service routine. WARNING: HOT EXHAUST During parked regeneration the exhaust gases will be extremely HOT and could cause a fire if directed at combustible materials. The vehicle must be parked outside. 8. Perform a parked regeneration. Refer to section "Performing a Parked Regeneration Using DDDL". a. If SPN 3480/FMI 21 becomes active during regeneration, retain regeneration log file and contact the Detroit Customer Support Center at (800) for further instruction. b. If the parked regeneration successfully completes, clear active codes and release vehicle. 12 All information subject to change without notice. Copyright 2012 DETROIT DIESEL CORPORATION

11 8 SPN 3480/FMI 31 - ALL YEARS This diagnostic is typically Fuel Cut-off Valve (FCV) Pressure Not Plausible. Table 7. SPN 3480/FMI 31 Fuel Cut Off Valve Pressure Not Plausible Fuel Compensation Pressure Sensor Dosing Enabled Continuous when enabling conditions met 1 Minute Engine Reaction Derate 25% Parked Regeneration 1. Shut off the engine, apply the parking brake, chock the wheels and perform any other applicable safety steps. 2. Is SPN 3480/FMI 14 also present (active or inactive)? a. Yes, repair SPN 3480/FMI 14 first. Refer to section "SPN 3480/FMI 14 - ALL YEARS". b. No, Go to step Replace the Fuel Compensation Pressure (FCP) sensor (replace the Doser Block on DD15AT. Refer to section "Removal of the Hydrocarbon Doser Block "). Refer to section "Installation of the Fuel Compensation Pressure Sensor". WARNING: ENGINE EXHAUST To avoid injury from inhaling engine exhaust, always operate the engine in a well-ventilated area. Engine exhaust is toxic. 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. 4. Start the engine. NOTE: It may take three purge attempts to purge all air from the lines. Do not exceed three purge attempts. 5. Using DDDL/DDRS 7.08 SP2 or higher, perform Purge Hydrocarbon Doser service routine. WARNING: HOT EXHAUST During parked regeneration the exhaust gases will be extremely HOT and could cause a fire if directed at combustible materials. The vehicle must be parked outside. 6. Using DDDL/DDRS 7.08 SP2 or higher, perform a Parked Regeneration. Refer to section "Performing a Parked Regeneration Using DDDL". a. If SPN 3480/FMI 31 becomes active during the regeneration, retain the log file and contact the Detroit Customer Support Center at (800) for further instruction. b. If regeneration successfully completes, clear faults and release vehicle. All information subject to change without notice. 13