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Detroit Diesel DD15 Operator`s Manual

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1. ese ese ee ee ee ee ee ee ee ee ee ee ee ee 16 ENGINE MODEL AND SERIAL NUMBER DESIGNATION 18 ENGINE MODEL AND SERIAL NUMBER oseere 18 ENGINE SERIAL NUMBER ese ee ee ee ee ee ee ee ee ee ee ee ee ee ee ee ee ee ee 18 ENGINE CERTIFICATION LABEL ees ese see ee ee ee dee ee ee ee ee ee ee ee ee 18 INSTRUCTIONS FOR STARTING THE ENGINE ese sees ee 21 FIRST TIME START RECOMMENDATIONS oseere 21 SYSTEM CHECKS SE at R e GEE Ee be Ge ee a ee Ee ee ed Gee ve de ed 21 CHECKING THE COOLING SYSTEM ese ee ee ee ee ee ee ee 21 LUBRICATION SYSTEM CHECKS ees ee ees ee se ees ee ee see ee ee ee 22 PRE LUBRICATING THE ENGINE ese ee se see ee ees ee ee ee 22 CHECKING THE OIL LEVEL ees se se ee ee se see ee ee ee ee ee ee ee ee ee 22 AFTER AN EXTENDED STORAGE leeis 23 FUEL SYSTEM CHECKS arnore aniran ee ee ee ees ee ee eed ee ee eke ee ee ee 24 All information subject to change without notice ili DDC SVC MAN 0075 Copyright 2010 DETROIT DIESEL CORPORATION TABLE OF CONTENTS ADDING FUEL eebe iii 24 PRIMING THE FUEL SYSTEM esse se see ee ee ee ee dee ee ee ee 25 CHECKING OTHER ENGINE AND ATS RELATED PARTS 26 FIRST TIME START OF THE ENGINE sesers 27 STARTING AN ENGINE WITH AN ELECTRIC STARTER 28 RUNNING THE ENGINE e esse ee ee ee ee ee ee ee ee ee ee dee ee ee ee dee ee ede 29 CHECKING THE OIL PRESSURE se ees ee ee ee ee ee ee ee ee dee 29 WARMING UP THE ENGINE ese ee
2. ll All information subject to change without notice 83 DDC SVC MAN 0075 Copyright 2010 DETROIT DIESEL CORPORATION MAINTENANCE Refer to section How to Select Coolant 3 Coolant for the listing of required intervals using the recommended coolants 4 Cooling systemriter Ri EE Fuel Filters Pree e TR TR TR RR RR Coalescer Water Separator Final Fiter pr r e e r e r r Adjust at 60 000 mi 100 000 km at 180 000 mi 300 000 km and then at every 180 000 mi 300 000 km or nearest maintenance interval DICO ER EE EE WE WEE RRE 8 Airsystem tT tT Pt Tt Pt tt Tt AirCleaner ITT 10 Exhaust system 1 tprfrprprjr Inspect external hardware and connections at 11 Aftertreatment Device every oil change Remove ash at 300 000 miles 480 000 km or 9 000 hours DEELER Whichever comes first All items are described in Routine Preventive Maintenance R Replace Inspect service correct or replace as necessary Initial Valve Lash Adjustment 84 All information subject to change without notice DDC SVC MAN 0075 Copyright 2010 DETROIT DIESEL CORPORATION EPAIO DD PLATFORM OPERATORS MANUAL Miles X 1000 35 70 105 140 175 210 245 280 Km X 1000 55 110 165 220 275 330 385 440 Hours 895 2690 3590 4485 5380 6280 7180 i tubricatrgor RT R R R R R RI R 2 Lubrcatngorrner R R R e R R RIR Refer to section H
3. These additives are not approved for use in Detroit Diesel engine cooling systems All information subject to change without notice A small amount of oil adversely affects heat transfer For example a 1 25 concentration of soluble oil increases fire deck temperature 6 A 2 50 concentration increases fire deck temperature 15 The use of soluble oil additives may result in engine overheating and or failure Chromate Additives These additives are not approved for use in Detroit Diesel engine cooling systems Chromate additives can form chromium hydroxide commonly called green slime This in turn can result in engine damage due to poor heat transfer Cooling systems operated with chromium inhibited coolant must be chemically cleaned with a recommended cooling system cleaner conditioner or equivalent sulfamic acid sodium carbonate cleaner and flushed Refer to section Detroit Diesel Genuine Cooling System Cleaners 123 DDC SVC MAN 0075 Copyright 2010 DETROIT DIESEL CORPORATION HOW TO PROCEDURES Testing for Supplemental Coolant Additives Detroit Diesel Genuine Fluid Analysis 3 Way Coolant Test Strips should be used to measure nitrite and glycol concentrations Refer to section Detroit Diesel Genuine Fluid Analysis Products for part numbers Cavitation corrosion is indicated on the strip by the level of nitrite concentration Freeze boil over protection is determined by glycol concentration
4. of chemicals follow the chemical manufacturer s usage handling and disposal instructions Observe all manufacturer s cautions 95 DDC SVC MAN 0075 Copyright 2010 DETROIT DIESEL CORPORATION MAINTENANCE NOTICE Never use galvanized steel fuel tanks fittings pipes or supply lines The fuel reacts chemically with the zinc coating to form powdery flakes that can quickly clog the fuel filters and damage the fuel pumps and injectors 6 Every 120 000 miles 200 000 kilometers or 12 months tighten all fuel tank mountings and brackets At the same time check the seal in the fuel tank cap the breather hole in the cap and the condition of the flexible fuel lines Repair or replace the parts as necessary Fuel Lines Flexible Hoses A pre start inspection of hoses and fuel lines is recommended Inspection for Fuel Leaks Make a visual check for fuel leaks at all engine mounted fuel lines and connections and at the fuel tank suction and return lines Since fuel tanks are susceptible to road hazards leaks in this area may best be detected by checking for an accumulation of fuel under the tank 96 AM WARNING HOT OIL To avoid injury from hot oil do not operate the engine with the rocker cover s removed NOTE Leaks are not only detrimental to machine operation but they can also result in added expense caused by the need to replace lost fluids Inspection of Hoses and Fittings
5. AA WARNING HOT COOLANT To avoid scalding from the expulsion of hot coolant never remove the cooling system pressure cap while the engine is at operating temperature Wear adequate protective clothing face shield rubber gloves apron and boots Remove the cap slowly to relieve pressure For best results take the test while the coolant is between 10 0 60 C 50 140 F Wait at least 60 but not longer than 75 seconds before reading the nitrite level Use the test strips as follows 124 1 Dip the strip into coolant for one second Remove and shake briskly to eliminate excess fluid 2 Immediately compare the pad end glycol to the color chart on the container 3 Sixty seconds one minute after dipping compare the nitrite pad to the color chart NOTE Color change of the additive indicator middle pad indicates the presence of inhibitor that is not approved by Detroit Diesel 4 Promptly replace and tighten the test strip container cap after each use Discard unused strips if they have turned light pink or tan NOTE A factory coolant analysis program is available through authorized Detroit Diesel service outlets Refer to Detroit Diesel Genuine Coolant Products for part numbers All information subject to change without notice DDC SVC MAN 0075 Copyright 2010 DETROIT DIESEL CORPORATION EPAIO DD PLATFORM OPERATORS MANUAL Removal of Dropout Excessive amounts of
6. Final Filter Filter ED EA at 60 000 mi EAKA km at 180 000 mi 300 000 km and then at every 180 000 mi 300 000 km or nearest maintenance interval a AA EECH ER 8 Airsystem tT tT tt io 9 AirCleaner fo tT tT tT tt 10 Exhaustsystem 1 t ot fot ot ft Inspect external hardware and connections at 11 Aftertreatment Device every oil change Remove ash at 300 000 miles 480 000 km or 9 000 hours DEE ip EL Whichever comes first All items are described in Routine Preventive Maintenance R Replace Inspect service correct or replace as necessary Initial Valve Lash Adjustment 86 All information subject to change without notice DDC SVC MAN 0075 Copyright O 2010 DETROIT DIESEL CORPORATION EPAIO DD PLATFORM OPERATORS MANUAL Routine Preventive Maintenance This section describes the items listed in the maintenance interval tables The Daily instructions apply to routine or daily starting of the engine They do not apply to a new engine or one that has been operated for a considerable period of time Monitoring the Lubricating Oil Perform the following maintenance on the lubricating oil 1 Check the oil level daily With the engine stopped use the oil dipstick and measure the oil level on crosshatch area on the dipstick If the oil reading is in the crosshatch area then the oil is at the proper level for engine operation SATISFACTORY OIL LEVEL RANGE
7. The engine will only operate at reduced rpm until the battery voltage reaches a point where the MCM will no longer function and the engine shuts down 46 Should the AWL Check Engine come on for any reason the vehicle can still be operated and the driver can proceed to the required destination This condition should be reported to an authorized Detroit Diesel distributor or dealer NOTICE When the RSL Stop Engine comes on the system has detected a major malfunction in the engine that requires immediate attention It is the operator s responsibility to shut down the engine to avoid serious damage The engine can be configured to give a warning only to ramp down reduce power or to shut down Ramp down will reduce engine rpm to a predetermined speed but will not shut down the engine With the 30 second shutdown option the engine will begin a 30 second stepped power down sequence until it shuts down completely The Stop Engine Override feature can be activated in the case where the vehicle is operating in a critical location Stop Engine Override Switch This feature allows the operator to override the automatic stop engine sequence All information subject to change without notice DDC SVC MAN 0075 Copyright 2010 DETROIT DIESEL CORPORATION EPAIO DD PLATFORM OPERATORS MANUAL This is done by pressing the Stop Engine Override Switch every 15 to 20 seconds to prevent engine shutdown
8. To avoid injury from accidental engine startup while servicing the engine disconnect disable the starting system 2 Keep the terminal surface clean 3 Inspect the cables clamps and hold down brackets regularly Clean and reapply a light coating of petroleum jelly when needed Have corroded or damaged parts replaced 98 4 If the engine is to be out of service for more than 30 days remove the batteries and store in a cool dry place a Keep batteries fully charged if possible b Replace any battery that fails to hold a charge Periodically check battery connections for corrosion and tightness a If necessary remove connections and wire brush any corrosion from terminals and cable ends b Replace damaged wiring Engine Steam Cleaning The engine and engine compartment should be steam cleaned every 60 000 miles 100 000 km or 2 000 hours whichever comes first All information subject to change without notice DDC SVC MAN 0075 Copyright 2010 DETROIT DIESEL CORPORATION EPAIO DD PLATFORM OPERATORS MANUAL NOTICE Do not apply steam or solvent directly to the battery charging alternator starting motor DDEC components sensors or other electrical components as damage may result Battery Charging Alternator Precautions must be taken when working on or around the alternator The diodes and transistors in the alternator circuit are very sensitive and can be easi
9. To avoid injury when using caustic cleaning agents follow the chemical manufacturers usage disposal and safety instructions DDC SVC MAN 0075 Copyright 2010 DETROIT DIESEL CORPORATION CAUTION SUMMARY AA WARNING PERSONAL INJURY To avoid injury from hot surfaces wear protective gloves or allow engine to cool before removing any component AA WARNING PERSONAL INJURY To avoid injury use care when working around moving belts and rotating parts on the engine AA WARNING FIRE To avoid injury from combustion of heated lubricating oil vapors stop the engine immediately if an oil leak is detected AA WARNING PERSONAL INJURY To avoid injury from contact with rotating parts when an engine is operating with the air inlet piping removed install an air inlet screen shield over the turbocharger air inlet The shield prevents contact with rotating parts AA WARNING HOT COOLANT To avoid scalding from the expulsion of hot coolant never remove the cooling system pressure cap while the engine is at operating temperature Wear adequate protective clothing face shield rubber gloves apron and boots Remove the cap slowly to relieve pressure AA WARNING FIRE To avoid injury from fire do not smoke or allow open flames when working on an operating engine All information subject to change without notice DDC SVC MAN 0075 Copyright 2010 DETROIT DIESEL CORPORATION EPAIO DD PLATFORM OP
10. 3 Inspect and clean the elements in accordance with the air cleaner manufacturer s recommendations if any All information subject to change without notice 129 DDC SVC MAN 0075 Copyright 2010 DETROIT DIESEL CORPORATION TROUBLESHOOTING TROUBLESHOOTING This section covers basic maintaining it properly make sure to troubleshooting of engine operation correct any malfunction promptly or performance malfunctions and their probable causes In addition to Abnormal Coolant operating the engine carefully and Temperature Abnormal Coolant Temperature Symptoms and Probable Causes Probable Causes AAR Restricted cooling system passages X Restricted radiator core passages Slipping fan drive belts Faulty temperature controlled fan Obstruction in front of radiator or intercooler Low coolant level Damaged hoses Faulty thermostat Faulty water pump Faulty radiator pressure cap Air in coolant Thermostat not fully closed PF x Leakage around thermostat seal EN x Faulty temperature controlled fan EN x 1 30 All information subject to change without notice DDC SVC MAN 0075 Copyright 2010 DETROIT DIESEL CORPORATION EPAIO DD PLATFORM OPERATORS MANUAL Hard Starting Hard Starting Symptoms and Probable Causes Engine Low Engine Probable Causes Will Not Cranking Cranks But Rotate Will Not Start connections intemal seizure x se Improper lubricating ol IL J E ee INC g X control m
11. AA WARNING BODILY INJURY To avoid injury from an explosion do not use ether or starting fluid on engines eduipped with a manifold grid heater The engine does not reguire starting aids down to 10 C 50 F Temperatures below 20 C 4 F will require a block heater and oil pan heater Winter Fronts A winter front may be used to improve cab heating while idling At least 25 of the grill opening should remain open in sectioned stripes that run perpendicular to the charge air cooler tube flow direction This assures even cooling across each tube and reduces header to tube stress and possible failure Winter fronts should only be used when the ambient temperature remains below 12 C 10 F 3 8 All information subject to change without notice DDC SVC MAN 0075 Copyright 2010 DETROIT DIESEL CORPORATION EPAIO DD PLATFORM OPERATORS MANUAL ELECTRONIC ENGINE CONTROL SYSTEM DDEC 10 All engines for 2010 are equipped with an electronic control system called Detroit Diesel Electronic Control DDEC 10 The electronic engine control system regulates the fuel injection quantity and timing using solenoid valves allowing extremely low emission operation Besides the engine and its related sensors the system has three other control modules Motor Control Module MCM Common Powertrain Controller CPC Aftertreatment Control Module ACM The three control units are co
12. Anti Lock Braking Systems Vehicles equipped with ABS have the ability to turn the engine brake OFF if a wheel slip condition is detected The engine brake will automatically turn itself ON once the wheel slip is no longer detected 55 DDC SVC MAN 0075 Copyright 2010 DETROIT DIESEL CORPORATION ENGINE BRAKE SYSTEM The DDEC 10 system will deactivate the engine brake system when the engine speed falls below a preset rpm or when the vehicle slows down to a preset speed depending on DDEC programming This prevents stalling the engine The engine brake can also be used with vehicle Cruise Control turned ON Operating on Flat Dry Pavement Use the following guidelines when driving on flat dry pavement 1 If driving on flat dry open stretches with a light load and greater slowing power is not required place the progressive braking switch in the LOW position 2 If you find you are still using the service brakes move the progressive braking switch to a higher position until you do not need to use the service brakes to slow the vehicle down 3 If you are carrying a heavier load and road traction is good move the progressive braking switch to the HIGH position 4 Check your progressive braking switch often for proper position since road conditions can change quickly Never skip a step when operating the progressive braking 56 switch Always go from OFF to LOW and then to a higher position Oper
13. If the fault is serious enough to impair normal operation the electronic control unit switches over to a limp home mode The limp home speed is dependent on engine control parameters and could be as low as 1000 rpm This allows you to safely move the vehicle to a service location or a safe stopping area Stop Engine Override Option The Stop Engine Override Option is used for a momentary override The electronic engine control system will record the number of times the override is activated after an engine fault occurs All information subject to change without notice Momentary Override A Stop Engine Override Switch is used to override the shutdown sequence This override resets the 60 second 30 second for oil pressure shutdown timer restoring power to the level when the RSL Stop Engine was illuminated The switch must be recycled after five seconds to obtain a subsequent override NOTE The operator has the responsibility to take action to avoid engine damage OBE E E DIAGNOSTIC AMBER ei REQUEST STOP WARNING STOP ENGINE LAMP LAMP OVERRIDE SWITCH 47471 Cold Weather Operation Special precautions must be taken during cold weather To protect your engine special cold weather handling is required for fuel engine oil coolant and batteries For EPA07 engines with a grid heater 37 DDC SVC MAN 0075 Copyright 2010 DETROIT DIESEL CORPORATION INSTRUCTIONS FOR STARTING THE ENGINE
14. Install and connect the battery Make sure the average specific gravity of the battery is 1 260 139 DDC SVC MAN 0075 Copyright 2010 DETROIT DIESEL CORPORATION ENGINE STORAGE or higher Charge the battery if necessary 10 Service the air cleaner if required 11 Transmission Follow the manufacturer s recommendations covering the return of the transmission to service 12 Power Take Off If equipped follow the manufacturer s recommendations covering the return of the power take off to service 13 Turbocharger Remove the covers from the turbocharger air inlet and turbine outlet connections Reconnect piping as required Prelube the turbocharger center bearing housing Refer to section Lubrication System Checks of this guide AA WARNING ENGINE EXHAUST To avoid injury from inhaling engine exhaust always operate the engine in a well ventilated area Engine exhaust is toxic 14 After all preparations are completed start the engine 140 DDC SVC MAN 0075 NOTE The small amount of rust preventive which remains in the fuel system will cause smoky exhaust for a few minutes NOTE Before subjecting the engine to a load or high speed allow it to reach normal operating temperature 15 Check for trouble codes a If there are no codes perform a parked regeneration b If there are codes repair what is necessary then perform a parked regeneration All information subject to cha
15. by an Aftertreatment Device ATD The ATD consists of a Diesel Oxidation Catalyst DOC a Diesel Particulate Filter DPF and a Selective Catalyst Reduction SCR system These components burn off collected particulate matter in a process called regeneration and reduce nitrous oxides NOx The key to successful regeneration is high exhaust temperature for an extended period of time Without adequate temperatures for regeneration the filter will continue to trap particulates and eventually plug In order to avoid DPF plugging Detroit Diesel uses an actively regenerated Aftertreatment System ATS The exhaust from an on highway diesel engine produces levels of nitrous oxide NOx that must be reduced To meet EPA10 emission standards a Selective Catalyst Reduction SCR system has been added to the current ATS The SCR system consists of an Aftertreatment Control Module ACM a tank for Diesel Exhaust Fluid DEF a DEF pump module an air control unit a DEF metering unit a DEF injector and an SCR module DEF is pumped through the metering unit to a DEF injector The DEF injector meters DEF into the SCR module to produce 64 a chemical reaction This chemical reaction converts nitrous oxides NOx present in the exhaust stream into water vapor and nitrogen There are two different configurations available for different types of applications Both configurations reduce the particulate matter more commonly kno
16. maintained for one minute 9 Check for leaks 10 Allow the engine to reach operating temperature of 60 C 140 F NOTICE Increasing engine speed above idle before oil pressure has stabilized may cause severe engine damage 11 Increase engine speed to 1800 rpm for three minutes 12 Return the engine to idle and allow to idle for approximately one minute then shut down the engine 13 Check for leaks Removal of the Prefilter Remove the prefilter as follows 1 Using a 36 mm socket unscrew the prefilter cap All information subject to change without notice NOTICE Do not tilt the prefilter when removing it from the housing Possible damage to the prefilter or stand pipe may occur 2 Pull the cap and prefilter straight up and out of the fuel filter housing 3 Remove the prefilter from the prefilter cap and discard 4 Discard the prefilter cap seal ring Installation of the Prefilter Install the prefilter as follows 1 Snap new prefilter 4 into the prefilter cap 1 NOTE The prefilter should snap into the cap in two positions The tabs 3 should align with the slot in the prefilter cap 5 4470023 111 DDC SVC MAN 0075 Copyright 2010 DETROIT DIESEL CORPORATION HOW TO PROCEDURES 2 Apply a thin coat of petroleum based lithium grease to the prefilter cap seal ring 2 3 Apply a thin coat of petroleum based lithium grease to the inside and
17. Check hoses daily as part of the pre start inspection 1 Examine hoses for leaks and check all fittings clamps and ties carefully 2 Make sure hoses are not resting on or touching shafts couplings heated surfaces including exhaust manifolds sharp edges or other obvious hazardous areas 3 Since all machinery vibrates and moves to a certain extent clamps and ties can fatigue with age To ensure continued proper support inspect fasteners frequently and tighten or replace them as necessary 4 If fittings have loosened or cracked or if hoses have ruptured All information subject to change without notice DDC SVC MAN 0075 Copyright 2010 DETROIT DIESEL CORPORATION EPAIO DD PLATFORM OPERATORS MANUAL or worn through take corrective action immediately Inspection of Hoses with Extended Service Life A hose has a finite service life With this in mind inspect hoses as follows 1 Thoroughly inspect all hoses at least every 500 operating hours 1 000 hours for fire resistant fuel and lubricating oil hoses and or annually Look for cover damage and or indications of twisted worn crimped brittle cracked or leaking lines Hoses with their outer cover worn through or with damaged metal reinforcements should be considered unfit for further service 2 Replace all hoses in and out of machinery during major overhaul and or after a maximum of five 5 years of service NOTE Fire resistant fuel and l
18. DIESEL CORPORATION ENGINE STORAGE convenient apply the rust preventive compound to the engine flywheel If not disengage the clutch mechanism to prevent the clutch disc from sticking to the flywheel NOTE Do not apply oil grease or any wax base compound to the flywheel The cast iron will absorb these substances which can sweat out during operation and cause the clutch to slip 14 Drain the engine cooling system If the engine will be exposed to freezing temperatures install genuine Detroit Diesel Power Cool antifreeze or an equivalent ethylene glycol base or propylene glycol base antifreeze solution that provides the required freeze boil over and inhibitor protection Refer to the Detroit Diesel POWER COOL section in this guide 15 Drain the preservative oil from the engine crankcase Reinstall and torque the 3 4 14 square magnetic drain plug to 45 50 Nm 33 77 lb ft 16 Remove and clean the battery and battery cables with a baking soda water solution and rinse with fresh water Do not allow the soda solution to enter the 138 battery Add distilled water to the electrolyte if necessary and fully charge the battery Store the battery in a cool never below 0 C or 32 F dry place Keep the battery fully charged and check the level and specific gravity of the electrolyte regularly 17 Insert heavy paper strips between the pulleys and drive belts to prevent sticking 18 Seal a
19. MAN 0075 Copyright 2010 DETROIT DIESEL CORPORATION EPAIO DD PLATFORM OPERATORS MANUAL Long Haul Maintenance Intervals EPA10 i Inspect external hardware and connections every Aftertreatment Device a 6 months or at oil change intervals s A Check Engine Light will illuminate when ash requires removal Normal DPF ash clean intervals Diesel Particulate Filter are 300 000 miles 480 000 km 9 000 hours to 400 000 miles 640 000 km 10 250 hours DEF Pump Filter Replace filter every 250 000 miles 400 000 km DEF Pump Air Bladder Refill bladder with air every 24 months Whichever comes first Detroit Diesel highly recommends replacing the DPF with a reliabilt DPF to ensure maximum replacement life Note DOC and SCR catalysts do not require maintenance tCurrently Davco is the only frame mounted filtration system compatible for Detroit Diesel Engines Inspect Davco at 50 000 miles 80 000 km and replace based on regular inspections or at 100 000 miles 160 000 km Refer to section Routine Preventive Maintenance for a description of all items R Replace l Inspect service correct or replace as necessary EPA07 Maintenance Tables Severe Service Maintenance Intervals EPA07 Miles X 1000 25 50 75 100 125 150 175 200 Km X 1000 40 80 120 160 200 240 280 320 Hours 640 1280 1925 2565 3205 3850 4490 5130 Item Procedure mago RT R R R RR
20. Min Mar UM Low FULL 18001 4a All information subject to change without notice NOTICE If the oil level is constantly above normal and excess oil has not been added to the crankcase consult with an authorized Detroit Diesel service outlet for the cause Fuel or coolant dilution of lubricating oil can result in serious engine damage NOTE If the engine operating temperature is below 60 C 140 F the engine must be on a level surface and then shut down for 60 minutes for an accurate oil level reading Otherwise the engine must be brought up to an operating temperature of 60 C 140 F parked on a level surface and then shut down for five minutes for an accurate oil level reading 2 Add the proper grade of oil to maintain the satisfactory range on the dipstick All diesel engines are designed to use some oil so the periodic addition of oil is normal Before adding lubricating oil refer to section How To Select Lubricating Oil 87 DDC SVC MAN 0075 Copyright 2010 DETROIT DIESEL CORPORATION MAINTENANCE NOTICE Do not add oil if the oil reading is in the crosshatch area on the dipstick There are approximately 3 8 L 4 0 qt from the fill mark to the full mark Overfilling the oil pan can cause engine damage Monitoring the Lubricating Oil Filter The engines are equipped with a single cartridge style oil filter 1 that is part of the oil coolant module Incorporated into the
21. The information and specifications in this publication are based on the information in effect at the time of approval for printing Contact an authorized Detroit Diesel service outlet for information on the latest revision The right is reserved to make changes at any time without obligation Detroit Diesel engines are built in accordance with sound technological principles and based on state of the art technology Despite this the engine may constitute a risk of damage to property or injury to persons if it is not used for its intended purpose The engine should not be modified or converted in an incorrect manner or the safety instructions included in this manual disregarded DDC SVC MAN 0075 Copyright 2010 DETROIT DIESEL CORPORATION NOTICE Coolant must be inhibited with the recommended Supplemental Coolant Additives SCA listed in the How To Procedures section of this engine Operator Manual In addition the engine can be equipped with a coolant filter as an installed option or as an after sale item Failure to check and maintain SCA levels at required concentrations will result in severe damage corrosion to the engine cooling system and related components WARRANTY The applicable engine warranty is contained in the booklet Warranty Information for Detroit Diesel Engines available from authorized Detroit Diesel service outlets Keep this Operator Manual with the engine installat
22. a major engine fault that may result in engine damage Engine derate and or shutdown sequence will be initiated Solid yellow indicates a regeneration is required Blinking yellow derate and or shutdown are possible as soot load continues to increase Lamp will shut off during parked regeneration Lamp is yellow Indicates exhaust temperature is above a preset limit and unit is operating at low vehicle speed below 5 mph 8 kph When the engine speed is elevated for a parked regeneration lamp will flash once every 10 seconds Yellow lamp Indicates a failure of an Emission Control device May illuminate at the same time as the Amber Warning Lamp Vehicle can be driven to end of shift Call for service Move the vehicle to the nearest safe location and shut down the engine Call for service Lamp Solid regeneration is required Lamp Flashing regeneration is required immediately Vehicle can be driven Lamp Solid for Extended Period Longer than 40 Minutes call for service Vehicle can be driven to end of the shift Call for service All information subject to change without notice DDC SVC MAN 0075 Copyright 2010 DETROIT DIESEL CORPORATION EPAIO DD PLATFORM OPERATORS MANUAL Lamp Lamp Solid Lamp Flashing Diagnostic Request Switch is used to activate the AWL to flash inactive codes Flashes last 90 seconds before idle shutdown if programmed for override Flashes whe
23. activated deactivate the brake system immediately if this occurs The engine brake will only operate when the Accelerator Pedal is fully released Disengaging the clutch will prevent the engine brake from operating The engine brake will supply braking power even when in Cruise Control The Motor Control Module will control the amount of engine braking with respect to the Cruise Control set speed The maximum amount 44 of braking low medium high is selected with the dash switches Engine Protection The electronic engine control protection system monitors all engine sensors electronic components and recognizes system malfunctions If a critical fault is detected the AWL Check Engine and RSL Stop Engine illuminate The malfunction codes are logged into the MCM s memory The standard parameters which are monitored for engine protection are low coolant level high coolant temperature low oil pressure and high oil temperature AA WARNING PERSONAL INJURY To avoid injury from engine shutdown in an unsafe situation ensure the operator knows how to override the stop engine condition on a DDEC equipped unit All information subject to change without notice DDC SVC MAN 0075 Copyright 2010 DETROIT DIESEL CORPORATION EPAIO DD PLATFORM OPERATORS MANUAL NOTICE Engines equipped with the power down shutdown option have a system override button or switch to allow engine operation
24. air inlet restriction to exceed 20 in H O 5 0 kPa under any engine operating conditions A clogged air cleaner element will cause excessive intake restriction and reduced air supply to the engine resulting in increased fuel consumption inefficient engine operation and reduced engine life 4 Inspect the entire air system for leaks daily a Look especially for torn air inlet piping or boots and loose or damaged clamps Have worn or damaged parts repaired or replaced as required b Retighten loose connections 94 Replacement of Air Cleaner Element Replace dry type air cleaner elements when the maximum allowable air intake restriction has been reached Refer to section When to Service the Dry Type Air Cleaner for additional information Monitoring the Exhaust System Inspect the Exhaust System as follows 1 Check the exhaust manifold retaining bolts and other connections for tightness 2 Check the exhaust pipe rain cap for proper operation if so equipped Monitoring the Aftertreatment System Periodically remove the accumulated ash derived from engine lubricating oil from the ATS This ash does not oxidize in the filter during the regeneration process and must be removed through a cleaning procedure NOTE All Detroit Diesel ATS equipped engines will illuminate a dashboard warning lamp indicating the need for ash cleaning All information subject to change without notice DDC
25. complete network of Detroit Diesel service outlets in the U S and Canada plus many outlets worldwide that are prepared to meet your parts and service needs Service by trained personnel Sales team to help determine your specific power requirements In many areas emergency service 24 hours a day Complete parts support Product information and literature 141 DDC SVC MAN 0075 Copyright 2010 DETROIT DIESEL CORPORATION CUSTOMER ASSISTANCE We recognize however that despite the best intentions of everyone concerned misunderstandings may occur Normally any situation that arises in connection with the sale operation or service of your product will be handled by the authorized service outlet in your area in the U S and Canada check the Yellow Pages or the service locator at www detroitdiesel com for Detroit Diesel service outlet nearest you 142 All information subject to change without notice DDC SVC MAN 0075 Copyright 2010 DETROIT DIESEL CORPORATION EPAIO DD PLATFORM OPERATORS MANUAL SPECIFICATIONS This section lists the various Detroit Diesel Genuine Coolant engine products Fuel and Lubricating Oil Filters Consult with a Detroit Diesel Distributor to obtain the proper fuel filters and lubricating oil filters Engine Oil Capacities The engine oil capacities for the DD Platform Engine On Highway Vehicle application are listed in the following Table
26. coolant temperature and others from the MCM 39 DDC SVC MAN 0075 Copyright 2010 DETROIT DIESEL CORPORATION ELECTRONIC ENGINE CONTROL SYSTEM DDEC 10 From this data instructions are computed for controlling the engine and transmitted to the CPC via the proprietary datalink The ACM monitors the Aftertreatment System ATS When a malfunction or other problem is detected the system selects an appropriate response to deliver to the operator Electronic Engine Control System DDEC 10 Features The electronic engine control system offers a variety of features and options designed to warn the operator of any engine or Aftertreatment System ATS malfunction Options can range from warning panel lights to automatic reduction in engine power followed by automatic engine shutdown The electronic engine control system has the ability to perform diagnostics for self checks and continuous monitoring of other system components Depending on the application the electronic engine control system can monitor oil temperature coolant temperature oil pressure fuel pressure coolant level and remote sensors if used 40 The electronic engine control system activates the AWL Check Engine and the RSL Stop Engine to provide a visual warning of a system malfunction Cruise Control Cruise Control is available with any Detroit Diesel Electronically Controlled engine Cruise Control will operate in either Engine
27. for a short period of time Using the override button so the engine does not shut down in 30 seconds but operates for an extended period may result in engine damage This system features a 30 second stepped power shutdown sequence or an immediate speed reduction without shutdown in the event a major engine malfunction occurs such as low oil pressure high oil or coolant temperature or low coolant level California Engine Idle Limiting 2010 Detroit Diesel engines built with the California 50 state EPA certification are allowed to idle indefinitely when idle speed is below 900 RPM For California 50 state EPA certification engines that idle above 900 RPM the California Engine Idle Limiting feature is enabled The engine will generally shut down after five minutes of continuous idling when the transmission is in neutral or park and the parking brake is set or after 15 minutes when the transmission is in neutral or park and the parking brake is not set The automatic shutdown All information subject to change without notice feature that is applied above 900 RPM is required for all California certified engines with the exception of engines used in specific vehicle types which the state of California has determined to be exempt from the idle shutdown requirement These include buses school buses recreational vehicles medium duty vehicles military tactical vehicles and authorized emergency vehicles as they ar
28. in the idle position Monitor all gauges or indicator lamps 11 Check the filter housings for signs of leakage NOTE In addition to the cleaning procedure other components of the cooling system should be checked periodically to keep the engine operating at peak efficiency Checking the Hoses Check the hoses as follows 1 Inspect the cooling system hoses and replace any hose that shows obvious signs of damage or feels abnormally soft or hard 2 Replace damaged clamps 3 Correct all external leaks as soon as detected NOTE If Detroit Diesel Genuine antifreeze coolant or equivalent fully formulated pre charged antifreeze is used a pre charged element is not required All information subject to change without notice DDC SVC MAN 0075 Copyright 2010 DETROIT DIESEL CORPORATION EPAIO DD PLATFORM OPERATORS MANUAL 4 Check coolant inhibitor levels at the intervals listed in this manual Refer to section Scheduled Maintenance Intervals How to Service the Dry Type Air Cleaner Maintain the air cleaner as follows 1 Replace dry type air cleaner elements when the maximum allowable air cleaner restriction 20 in H O 5 0 kPa has been reached Some air cleaners are equipped with a restriction indicator which aids in determining the servicing interval 2 Do not clean and or reuse dry paper type air cleaner elements unless the cleaning method used removes clogging without damaging the element
29. leak at one filter complete that repair and test the system for leaks after priming the fuel system Refer to section Priming the Fuel System Filters are an integral part of the fuel system Proper filter selection and maintenance are important to satisfactory engine operation and service life Filters should be used All information subject to change without notice to maintain a clean system not to clean up a contaminated system The scheduled maintenance intervals for the appropriate duty cycles are listed in this manual AA WARNING PERSONAL INJURY To prevent the escape of high pressure fuel that can penetrate skin ensure the engine has been shut down for a minimum of 10 minutes before servicing any component within the high pressure circuit Residual high fuel pressure may be present within the circuit NOTICE At cold temperatures 40 C or 40 F DO NOT remove the filter elements from the caps unless the intent is to replace the filter elements Repeated removals at cold temperatures may break the filter element tabs Removal of the Final Filter Remove the final filter as follows 1 Using a 36 mm socket unscrew the final filter cap 109 DDC SVC MAN 0075 Copyright 2010 DETROIT DIESEL CORPORATION HOW TO PROCEDURES NOTICE Installation of the Final Filter Do not tilt the final filter when Install the final filter as follows removing it from the housing Possible damage to the fina
30. notice 27 DDC SVC MAN 0075 Copyright 2010 DETROIT DIESEL CORPORATION INSTRUCTIONS FOR STARTING THE ENGINE AA WARNING PERSONAL INJURY To avoid injury when working near or on an operating engine remove loose items of clothing and jewelry Tie back or contain long hair that could be caught in any moving part causing injury You will notice that the AWL RSL MIL DPF Regen lamp and HEST lamp will come on This is the result of the DDEC computer diagnosing the system to ensure everything is functional including the light bulbs for the warning lights If everything is OK all lights will go out in approximately five seconds The lights must go out before starting the engine If starting a vehicle the operator s foot must be off the accelerator pedal before starting the engine NOTICE If the warning lights stay on or do not come on momentarily after turning on the ignition contact the Detroit Diesel Customer Support Center at 1 800 445 1980 Operating the engine under these circumstances may result in engine damage 28 Starting an Engine with an Electric Starter Start an engine equipped with an electric starting motor as follows 1 Place the transmission in neutral and set the parking brake NOTICE To prevent serious starting motor damage do not press the starter switch after the engine has started 2 With foot off the accelerator pedal turn on the ignition switch and st
31. outside of the prefilter bottom seal 4 Install the prefilter into the fuel filter module 5 Turn the cap counterclockwise until a click sound is made then turn clockwise and hand tighten 6 Torque prefilter cap to 15 20 N m 11 15 lb ft 7 Once all required filters have been changed prime the fuel system using the fuel priming valve or the hand primer Refer to section Priming the Fuel System 8 Start the engine with the accelerator pedal in the idle position Monitor the oil pressure gauge or indicator lamp Keep the engine running at a idling speed until a stable oil pressure reading of 14 psi 97 kPa or more is maintained for one minute 9 Check for leaks 10 Allow the engine to reach operating temperature of 60 C 140 F 112 NOTICE Increasing engine speed above idle before oil pressure has stabilized may cause severe engine damage 11 Increase engine speed to 1800 rpm for three minutes 12 Return the engine to idle and allow to idle for approximately one minute then shut down the engine 13 Check for leaks Removal of the Water Separator Coalescer Remove the water separator coalescer as follows 1 Using a 36 mm socket unscrew the water separator coalescer cap NOTICE Do not tilt the water separator coalescer when removing it from the housing Possible damage to the water separator coalescer or stand pipe may occur 2 Pull the cap and water s
32. pure water and 1 3 automotive grade urea The following sections provide information regarding DEF availability specifications handling and storage and certain SCR system diagnostic features EPA10 DEF Availability DEF is available in bulk quantities at roadside truck stop service centers DEF is also available in various 66 container sizes at Detroit Diesel service outlets truck dealerships and many truck service centers DEF is available in container sizes as small as 2 5 gallons for convenient storage in your vehicle for emergency use For locations where DEF may be purchased call the Detroit Diesel Customer Service Center at 1 800 445 1980 EPA10 DEF Specifications DEF is manufactured to strict quality standards to ensure proper emissions control Only DEF that meets DIN70700 or ISO 22241 1 specifications can be used The American Petroleum Institute has developed a quality certification program to ensure the quality of DEF available at service outlets EPA10 DEF Handling and Storage When stored at temperatures between 10 and 90 F minus 12 and 32 C DEF has a minimum shelf life of 12 months For best shelf life it is recommended that DEF containers be stored in a controlled environment All information subject to change without notice DDC SVC MAN 0075 Copyright 2010 DETROIT DIESEL CORPORATION EPAIO DD PLATFORM OPERATORS MANUAL EPA10 DEF System Anti Tampering Feature The diagnosti
33. some inhibitors in the coolant can cause a gel or crystalline deposit that reduces heat transfer and coolant flow The deposit called dropout takes the color of the coolant when wet but appears as a white or gray powder when dry It can pick up solid particles in the coolant and become gritty causing excessive wear of water pump seals and other cooling system components AA WARNING PERSONAL INJURY To avoid injury when using caustic cleaning agents follow the chemical manufacturers usage disposal and safety instructions Remove the wet gel using a nonacid alkali type heavy duty cleaner such as Detroit Diesel Genuine Cooling System On Line Cleaner sodium nitrite sodium tetraborate Refer to section Detroit Diesel Genuine Cooling System Cleaners NOTE If the gel is allowed to dry it is necessary to disassemble the engine and clean it with a caustic solution or physically clean individual components All information subject to change without notice Chronic Coolant System Problems The most commonly seen coolant system problems result from maintenance and formulation factors such as Hard water Dilution of the coolant by the addition of untreated water Over dosage or under dosage of corrosion inhibitors Improper corrosion inhibitor most often phosphated Mixing Supplemental Coolant Additives Improper testing Detroit Diesel Cooling Syste
34. system as follows 1 Place the transmission in neutral and set the parking brake NOTE Change the coolant filter only after the vehicle has cooled and no residual pressure is present 2 Clean outside of the coolant filter housing 127 DDC SVC MAN 0075 Copyright 2010 DETROIT DIESEL CORPORATION HOW TO PROCEDURES AA WARNING HOT COOLANT To avoid scalding from the expulsion of hot coolant never remove the cooling system pressure cap while the engine is at operating temperature Wear adequate protective clothing face shield rubber gloves apron and boots Remove the cap slowly to relieve pressure NOTE Use care to prevent foreign objects from entering the filter housing 3 Using a 36 mm socket unscrew cap and filter and allow the coolant to drain into the housing After draining remove the assembly from the housing 4 Remove the filter from the plastic cap by placing the filter on a solid surface and apply pressure on the plastic cap at an angle 5 Remove coolant filter O ring and discard it Lightly lubricate a new O ring with clean engine oil and install it on the filter cap 6 Check filter housing for any debris and remove if necessary 7 Insert a new filter element into the cap 128 8 Insert element and cap assembly into the housing Torque the cap to 55 60 Nm 41 44 lb ft 9 Check coolant level and adjust if necessary 10 Start engine with the accelerator pedal
35. the air flow may be noticeable to the tuned attentive ear The turbocharger operates at higher boost pressure forcing EGR gas flow through the EGR plumbing In some situations the driver may believe he she has experienced a charge air cooler system leak Even connecting trailer light and air hoses the driver may hear a different tone exhaust and under hood with the engine idling If equipped with a turbo boost gauge the driver may occasionally note intake manifold pressure exceeds 35 psi 6 89 kPa Idling The common belief that idling a diesel engine causes no engine damage is wrong Idling produces sulfuric acid which is absorbed by the lubricating oil and eats into bearings rings valve All information subject to change without notice stems and engine surfaces If you must idle the engine for cab heat or cooling the high idle function of the Cruise Control switches should be used An idle speed of 900 rpm should be enough to provide cab heat in above 0 C 32 F ambients 53 DDC SVC MAN 0075 Copyright 2010 DETROIT DIESEL CORPORATION ENGINE BRAKE SYSTEM ENGINE BRAKE SYSTEM The engine is equipped with an engine brake Before operating the vehicle you must familiarize yourself with the engine brake system to obtain optimum benefit from it Engine brake control systems may vary slightly depending on the engine brake configuration and cab design However basic operator controls are similar for all mo
36. the coolant temperature has been high idle the engine for five minutes without load If any of the following conditions occur shut down the engine immediately 36 NOTICE An engine running at full output or with high coolant temperature after a high load operation should idle for five minutes without load Shutting down without idling may cause damage to the turbocharger The oil pressure swings back and forth or falls sharply Engine power and rpm fall even though the accelerator pedal remains steady The exhaust pipe gives off heavy smoke The coolant and or oil temperature climb abnormally Abnormal sounds suddenly occur in the engine or turbocharger Emergency Running Mode DD Platform engines are equipped with an electronic motor control system which monitors the engine as it is running All information subject to change without notice DDC SVC MAN 0075 Copyright 2010 DETROIT DIESEL CORPORATION EPAIO DD PLATFORM OPERATORS MANUAL NOTICE To prevent possible serious engine damage have any faults corrected without delay by an authorized service location As soon as an engine fault is detected it is evaluated and one of the following measures is initiated In conjunction with any dashboard or instrument panel display the code for the electronic control unit reporting the fault can be read immediately on the display
37. the engine be processed for storage as soon as possible after removal from operation The engine should be stored in a building that is dry and can be heated during the winter months Moisture absorbing chemicals are available commercially for use when excessive dampness prevails in the storage area Temporary Storage 30 Days or Less To protect the engine for a temporary period of time 30 days or less follow this procedure All information subject to change without notice 1 With the engine at ambient temperature and cool to the touch drain engine crankcase oil into a suitable container Dispose of the oil in an environmentally friendly manner according to state and or federal EPA recommendations 2 Fill the crankcase to the proper level with the recommended viscosity and grade of oil 3 Fill the fuel tank with the recommended grade of fuel oil Operate the engine for two 2 minutes at 1200 rpm and no load Do not drain the fuel system or the crankcase after this run 4 Check the air cleaner and service it if necessary 5 If freezing weather is expected during the storage period check the antifreeze coolant for required freeze and inhibitor protection Add antifreeze solution to the cooling system in accordance with Detroit Diesel s recommendations Refer to section How to Select Coolant in this guide NOTE If an antifreeze solution is not required during storage flush the cooling system
38. to approximately 60 C 140 F and then run it about five minutes longer d Drain the hot water 5 Fill the cooling system with new coolant For detailed procedures see the vehicle chassis maintenance manual For types of coolant refer to section How to Select Coolant for the 118 listing of required intervals using the recommended coolants How to Select Coolant This section covers selection of the required coolant for the engine Coolant Definitions To help ensure complete understanding of the information the definitions of the following terms are listed in the following Table All information subject to change without notice DDC SVC MAN 0075 Copyright 2010 DETROIT DIESEL CORPORATION EPAIO DD PLATFORM OPERATORS MANUAL Coolant Terms Ethylene Glycol containing a corrosion inhibitor Antifreeze package and which meets an appropriate heavy duty specification i e TMC RP 329 Type A or ASTM Standard D6210 Type A for ethylene glycol The fluid mixture circulating in the engine cooling Coolant system typically a mixture of 50 water and 50 antifreeze Drop Out Precipitated sludge or deposit formation on cooling system components Contains all the necessary inhibitors to protect a diesel engine and does not therefore require a pre charge of Supplemental Coolant Additive before its first use Fully Formulated Antifreeze The coolant that is used in a new or rebuilt engine or Initial Fill Coo
39. will reduce fuel cetane number and increase combustion temperatures AA WARNING FIRE To avoid increased risk of a fuel fire do not mix gasoline and diesel fuel Drain and clean tanks which contain a mixture of gasoline and diesel fuel as soon as possible Detroit Diesel will not be responsible for any detrimental effects resulting from adding drained lubricating oil or gasoline to the diesel fuel Fuel Additives with Sulfur or Sulfated Ash Do not use non approved fuel additives containing sulfur or sulfated ash All information subject to change without notice DDC SVC MAN 0075 Copyright 2010 DETROIT DIESEL CORPORATION EPAIO DD PLATFORM OPERATORS MANUAL How to Replace the Fuel Filters NOTICE If you have just changed the engine oil and filter you MUST start the engine and confirm proper oil pressure before changing the fuel filters If no oil pressure is shown after approximately 10 seconds stop the engine and determine the cause Running the engine with no oil pressure could result in engine damage Start the engine with the accelerator pedal in the idle position Monitor the oil pressure gauge or indicator lamp Keep the engine running at idling speed until the oil pressure reading is 14 psi 97 kPa or more NOTE If you are replacing all three fuel filters it is not necessary to run the engine and test for leaks after installing each individual fuel filter However if repairing a
40. with a good soluble oil 3 5 by volume rust inhibitor to prevent 135 DDC SVC MAN 0075 Copyright 2010 DETROIT DIESEL CORPORATION ENGINE STORAGE rusting of the outside diameter of the cylinder liners AA WARNING EYE INJURY To avoid injury from flying debris when using compressed air wear adequate eye protection face shield or safety goggles and do not exceed 276 kPa 40 psi air pressure 6 Clean the exterior of the engine except electrical parts with fuel oil and dry with compressed air 7 Seal all engine openings The material used must be waterproof vapor proof and possess sufficient physical strength to resist puncture and damage from the expansion of entrapped air An engine prepared in this manner can be returned to service in a short time by removing the seals at the engine openings and by checking the engine coolant fuel oil lubricating oil and transmission oil levels Extended Storage More than 30 Days To prepare an engine for extended storage more than 30 days follow this procedure 136 Drain the cooling system and flush with clean soft water Refill with clean soft water and add a rust inhibitor to the cooling system Circulate the coolant by operating the engine until normal operating temperature is reached Stop the engine With the engine at ambient temperature and cool to the touch drain the engine crankcase oil into a suitable contain
41. 2010 DETROIT DIESEL CORPORATION EPAIO DD PLATFORM OPERATORS MANUAL Abnormal Engine Operation Abnormal Engine Operation Symptoms and Probable Causes Rough Running or Frequent Stalling Misfiring cylinder Insufficient fuel Probable Causes Low Power Detonation High return fuel temperature Low compression DDEC malfunction High air inlet restriction ex haust back pressure Engine application High air inlet temperature High altitude operation Incorrect engine gear train timing Low coolant temperature Oil picked up by inlet airstream Faulty injector operation Incorrect injector height x setting All information subject to change without notice 1 3 3 DDC SVC MAN 0075 Copyright 2010 DETROIT DIESEL CORPORATION TROUBLESHOOTING Abnormal Operating Conditions Abnormal Operating Condition Symptoms and Probable Causes High Lubri cation Oil Low Oil Consump Pressure tion X Probable Causes Loose connections Cracked lines Damaged gaskets or seal rings Lubrication oil loss at breather tube Lubrication oil loss at dipstick tube Leaking oil cooler Leaking valve stem seals Worn broken oil control rings Scored liner and or piston Excessive engine installation angle Crankcase overfilled Oilin air tanks air compressor malfunction X Plugged crankcase breather x Heil AE ENEE DE EE Improper engine oil viscosity fuel in the oil _ __ ___X Faulty oil pressur
42. 3 200 PPM the coolant must be drained and replaced with new Always maintain the engine coolant A thorough cleaning of the coolant to meet Detroit Diesel cooling system may be required specifications Do not use another manufacturer s test kit to measure the Supplemental Coolant Additive concentration of Detroit Diesel maintenance products Only use water that meets the specifications listed in this manual Distilled demineralized reverse osmosis or de ionized water is preferred Refer to section Water Requirements Premix coolant makeup solutions to the proper concentration before adding to the cooling system The proper dosage of inhibitors must be included in the coolant at initial fill for all Detroit Diesel Do not mix Organic Acid engines This dosage is usually Technology and other coolants in included in the fully formulated the same engine antifreeze used or it may need to be added if water alone or Do not use automotive coolants 126 All information subject to change without notice DDC SVC MAN 0075 Copyright 2010 DETROIT DIESEL CORPORATION EPAIO DD PLATFORM OPERATORS MANUAL Where antifreeze boil over protection is required use only antifreeze that meets TMC RP 329 Type A specification or ASTM Standard D 6210 Type A for Ethylene Glycol Always maintain coolant at the proper level Do not us
43. 75 Copyright 2010 DETROIT DIESEL CORPORATION ENGINE MODEL AND SERIAL NUMBER DESIGNATION The following illustration is an EPA10 certification exemption label DETROIT DIESEL S IMPORTANT ENGINE INFORMATION FUEL RATE AT AVD HP 327 0 MM3 STROKE INITIAL INJECTION TIMING 10 7 DEG BTC ENGINE FAMILY ADDXH14 8EED UNIT 888 ADV HP 560 1800 RPM DISP 14 8 LITERS MIN IDLE 600 RPM FEL G BHP HR VALVE LASH EXHAUST 0 6 MM INTAKE 0 4 MM MODEL DD15 DELEGATED ASSEMBLY THIS ENGINE CONFORMS TO U S EPA amp CALI FORNIA REGULATIONS APPLICABLE TO 2010 MODEL YEAR NEW HEAVY DUTY DIESEL CYCLE ENGINES THIS ENGINE HAS A PRIMARY SER VICE APPLICATION AS A HEAVY HEAVY DUTY ENGINE THIS ENGINE IS NOT CERTIFIED FOR USE IN AN URBAN BUS AS DEFINED AT 40 CFR 86 093 2 SALE OF THIS ENGINE FOR USE INAN URBAN BUS IS A VIOLATION OF FEDERAL LAW UNDER THE CLEAN AIR ACT THIS ENGINE IS CERTIFIED TO OPERATE ON ULTRA LOW SULFUR DIESEL FUEL d990003b 20 All information subject to change without notice DDC SVC MAN 0075 Copyright 2010 DETROIT DIESEL CORPORATION EPAIO DD PLATFORM OPERATORS MANUAL INSTRUCTIONS FOR STARTING THE ENGINE The following is an engine starting guide under several different circumstances First Time Start Recommendations When preparing to start a new or newly overhauled engine which has been in storage perform all of the operations listed below Failure to follow these instructions may result i
44. 960 000 km Drain and clean system 4 years or Engine Overhaul Refill with new coolant Propylene glycol is an acceptable substitute for ethylene glycol Coolants Not Recommended Antifreezes and Coolants Containing Phosphate Coolants containing phosphate are not recommended Drop out overheating The following coolants are not recommended for use in Detroit Diesel engines 122 All information subject to change without notice DDC SVC MAN 0075 Copyright 2010 DETROIT DIESEL CORPORATION EPAIO DD PLATFORM OPERATORS MANUAL and water pump seal failures can result from the use of coolant or inhibitor packages based on phosphate Automotive Type Coolants These coolants generally contain high levels of phosphate and silicate offer no liner pitting protection and are not suitable for use in Detroit Diesel engines Methyl Alcohol Based Antifreeze Methyl Alcohol Based Antifreeze must not be used because of its effect on the non metallic components of the cooling system and its low boiling point Glycol Based Coolants Formulated for HVAC These coolants formulated for Heating Ventilation Air Conditioning HVAC should not be used These coolants generally contain high levels of phosphates which can deposit on hot internal engine surfaces and reduce heat transfer Additives Not Recommended The following additives are not recommended for use in Detroit Diesel engines Soluble Oil Additives
45. CALIFORNIA Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer birth defects and other reproductive harm EPAIO DD PLATFORM OPERATORS MANUAL To the Operator This manual contains instructions on the safe operation and preventive maintenance of your Detroit Diesel engine used in vehicle applications Maintenance instructions cover routine engine services such as lubricating oil and filter changes in enough detail to permit self servicing if desired The operator should become familiar with the contents of this manual before operating the engine or carrying out maintenance procedures Power driven equipment is only as safe as the person operating the controls You are urged as the operator of this diesel engine to keep fingers and clothing away from the revolving belts drive shafts pulleys etc on the engine installation Throughout this manual CAUTIONS and WARNINGS regarding personal safety and NOTICES regarding engine performance or service life will appear To avoid personal injury and ensure long engine service life always heed these instructions Whenever possible it will benefit you to rely on an authorized Detroit Diesel service outlet for all your service needs from maintenance to major parts replacement Authorized service outlets worldwide stock factory original parts All information subject to change without notice
46. COL BASED COOLANTS FORMULATED FOR HVAC 123 ADDITIVES NOT RECOMMENDED iese see ee ee se ee ee ee ee ee ee 123 SOLUBLE OIL ADDITIVES sees ee dee ee se ee ee ee ee ee ee ee ee 123 CHROMATE ADDITIVES paart aneii se ee ee ee es ee ese ee ee ee ee ee ee ee 123 TESTING FOR SUPPLEMENTAL COOLANT ADDITIVES 124 REMOVAL OF DROPOUT ees ese ee ee ee ge ee ee ee ke ee ee ee ke ee ee 125 CHRONIC COOLANT SYSTEM PROBLEMS oee 125 viii All information subject to change without notice DDC SVC MAN 0075 Copyright 2010 DETROIT DIESEL CORPORATION EPAIO DD PLATFORM OPERATORS MANUAL DETROIT DIESEL COOLING SYSTEM MAINTENANCE PRODUCTS aioi N EI EE Ion 125 DETROIT DIESEL GENUINE COOLANT SUPPLEMENTAL COOLANT ADDITIVES eee ai ee ee etree ee ee ee ee 125 SUMMARY OF COOLANT RECOMMENDATIONS osa 126 COOLANT LIFE OF GLYCOL COOLANT eee 127 HOW TO REPLACE THE COOLANT FILTER ee 127 CHECKING THE HOSES ees ee eed ee ee ee ee a ee ee ee ee ee ee ee ee 128 HOW TO SERVICE THE DRY TYPE AIR CLEANER ne 129 TROUBLESHOOTING i e or es Ee ies E Gee gee ae Ve ee aa gee N De Ee deed 130 ABNORMAL COOLANT TEMPERATURE ee ees teste ee see ees ee 130 HARD STARTING visie ss eg EES uch eet teva Ed ERR Dk Eie 131 AFTERTREATMENT SYSTEM OPERATING CHARACTERIS dle EN EI NE EE EE tetas 132 ABNORMAL ENGINE OPERATION uu eee eee ee ee ees ee ee ee ee 133 ABNORMAL OPERATING CONDITIONS ees see ee ee eee 134 ENGINE STORAGE sso es Pe de ees e
47. Contact your local Detroit Diesel service center if you need more specific information NOTE There are approximately 3 8 L 4 0 qt from the fill mark to the full mark Overfilling the oil pan can cause engine damage Engine Oil Capacities Description Total Engine Oil Volume Main Galleries Average Oil and Filter Change Detroit Diesel Genuine Coolant Engine Products Maintenance of the cooling system requires the chemical makeup of the system to be balanced All information subject to change without notice 36 6 L 38 7 qt 39 5 L 41 7 qt 44 5 47 0 NA 3 0 L 3 1 qt 3 0 3 1 NA 41 6 44 0 NA Detroit Diesel Genuine Fully Formulated Inhibited Ethylene Glycol Coolants The part numbers and sizes of concentrated and pre blended 50 50 Detroit Diesel Genuine Coolants are listed in the following Tables 143 DDC SVC MAN 0075 Copyright 2010 DETROIT DIESEL CORPORATION SPECIFICATIONS Detroit Diesel Genuine Fully Formulated Inhibited Ethylene Glycol Coolants 23512138 One Gallon Jug 6 Per Case 23512139 55 Gallon Drum Concentrated Detroit Diesel Genuine Supplemental Coolant Additive Need Release Filters Detroit Diesel Genuine Supplemental Coolant Addi tive Need Release Filters Detroit Diesel NF2091 For 0 8 Gallon Systems Genuine Inhibited Ethylene Glycol 23516489 For 8 20 Gallon Systems Coolant 144 All information subject to change without notice DDC SVC MA
48. DE OPTION sees ee ee ee ee ee ee ee ee ee ee ee 37 MOMENTARY OVERRIDE e eed ee ee ee se see ee ee ee ke ee ee ee ke ee ee 37 COLD WEATHER OPERATION ee ee ee ee ee ee ee ee ee ee see dee ee ee ee 37 WINTER FRONTS soii eed ese E I Ee ee ee ee ee ee ee ae ee 38 ELECTRONIC ENGINE CONTROL SYSTEM DDEC 10 39 ELECTRONIC ENGINE CONTROL SYSTEM DDEC 10 FEATURES ege N EA RE ER EE peda 40 CRUISE CONT ROL seisin EG See Ge Ee ee ee Ge ee Ee diia 40 DATA RECORDING CAPABILITY ee ee ee ee ee ke ee ee 42 iv All information subject to change without notice DDC SVC MAN 0075 Copyright 2010 DETROIT DIESEL CORPORATION EPAIO DD PLATFORM OPERATORS MANUAL ENGINE SR EE EE EE N ENGINE PROTECTION imiraa eed ee see ee ee ee ee ee ee ee ee ee ee ee dee CALIFORNIA ENGINE IDLE LIMITING ees ee IDLE SHUTDOWN TIMER ELECTRONIC ENGINE CONTROL SYSTEM DDEC 10 OPERATION BE EE EE RE STOP ENGINE OVERRIDE SWITCH ee ee ees ee ee see ee ee see ee ee IMMEDIATE SPEED REDUCTION ee ees ee ee ee ee ee ee ee see ee RED STOP LAMP esse ee bid detrital EE DEE dE ata DIAGNOSTIC TOOL iii gee ane den Boe GES EE De SEE ee atada FLASHING MALFUNCTION CODES ee ee ese ee ee ee ee ee READING FAULT CODES ee ees ee see ee ee ee ee ee ee ee ee ee ee AGTIVEGODES i s tee a eebe Ed Seg tied INACTIVE CODES isi Ee ses Ee ge ede nei iin EE au ieee ek bedes CRUISE CONTROL DRIVING TIPS ese ee ee ee ee ee ee ee
49. Detroit Diesel s recommendations on how to select lubricating oil diesel fuel and coolant Also included are basic engine maintenance procedures which can be performed by the operator NOTICE The manufacturer s warranty applicable to the engine provides in part that the provisions of such warranty shall not apply to any engine unit that has been subject to misuse negligence or accident Accordingly malfunctions attributable to neglect or failure to follow the manufacturer s fuel or lubricating recommendations may not be within the coverage of the warranty How To Select Lubricating Oil NOTICE Lubricating oil must have a sulfated ash level less than 1 0 wt currently referred to as CJ 4 oil All information subject to change without notice RVIC GAR amp gt 47442 Lubricant Requirements API CJ 4 oils are recommended for use in the engine Detroit Diesel currently will allow API CI 4 Plus oil having sulfated ash levels of 1 4 or less Cold Weather Starting At ambient temperatures below 10 C 14 F SAE 5W 30 10W 30 5W 40 or 10W 40 oils may be used provided they are API CJ 4 and have demonstrated field performance in Detroit Diesel engines These oils must possess a High Temperature High Shear Viscosity of 3 7 cP minimum 101 DDC SVC MAN 0075 Copyright 2010 DETROIT DIESEL CORPORATION HOW TO PROCEDURES NOTICE Monograde oils should not be used in the engin
50. EC 10 system will not allow you to hurt or over fuel the engine at low or lug engine speeds There is enough oil pressure to withstand hard pulls at low engine speeds Engine Brake and Cruise Control Your engine is equipped with both Cruise Control and an engine brake the engine brake can operate automatically while you are in Cruise Control If the Cruise Control Engine Brake function is turned ON in the DDEC 10 system programming the engine brake will come on low when your set road speed increases a few mph kph above your cruise set speed If your speed continues to increase the DDEC 10 system will increase the engine brake s braking power progressively When the vehicle returns to the set cruise speed the engine brake will turn off until you need them For safety reasons don t use Cruise Control when it is not possible to keep the vehicle at constant speed due to Winding roads Heavy traffic Slippery pavement 52 DDC SVC MAN 0075 Descending grades calling for engine brake assistance For an explanation of the engine brake system and recommendations for proper operation Engine Brake System in this manual Shifting Hints Depending on your transmission model the gear split may vary from 400 to 500 rpm The electronic governor provides almost no overrun capability and if the transmission is downshifted too early you will experience a temporary
51. ERATORS MANUAL AA WARNING FIRE To avoid injury from fire from a buildup of volatile vapors keep the engine area well ventilated during operation AA WARNING PERSONAL INJURY To avoid injury from rotating belts and fans do not remove and discard safety guards AA WARNING PERSONAL INJURY To avoid injury from slipping and falling immediately clean up any spilled liguids Compressed Air Observe the following cautions when using compressed air All information subject to change without notice AA WARNING EYE INJURY To avoid injury from flying debris when using compressed air wear adequate eye protection face shield or safety goggles and do not exceed 276 kPa 40 psi air pressure Cooling System Observe the following cautions when servicing the cooling system AA WARNING HOT COOLANT To avoid scalding from the expulsion of hot coolant never remove the cooling system pressure cap while the engine is at operating temperature Wear adequate protective clothing face shield rubber gloves apron and boots Remove the cap slowly to relieve pressure AA WARNING PERSONAL INJURY To avoid injury from slipping and falling immediately clean up any spilled liguids DDC SVC MAN 0075 Copyright 2010 DETROIT DIESEL CORPORATION CAUTION SUMMARY Electrical System AA WARNING PERSONAL INJURY Observe the following cautions when jump starting an engine charging a bat
52. L The incomplete combustion of fuel in a cold engine will cause crankcase oil dilution formation of lacquer or gummy deposits on the valves pistons and rings and rapid accumulation of sludge in the engine When prolonged idling is necessary maintain at least 900 rpm Stopping the Engine Stop an engine under normal operating conditions as follows 1 Reduce engine speed to idle and put all shift levers in the neutral position 2 Allow the engine to run between idle and 1000 rpm with no load for five minutes This allows the engine to cool and permits the turbocharger to slow down After five minutes shut down the engine NOTICE Do not stop a turbocharged engine immediately after a high speed operation Allow a sufficient cool down period of about five minutes to prevent the turbocharger from continuing to turn without an oil supply to the bearings or damage can result All information subject to change without notice NOTE Cool down idling needs to take place after pulling off an interstate When finding a parking spot or backing into a dock immediate shutdown should be avoided Shutting the engine off immediately retains more block heat than if the engine runs at idle for five minutes Emergency Jump Starting The engine s electronic system operates on 12 volts DC If a DD Platform engine with an electric starting motor requires emergency jump starting DO NOT EXCEED 16 VOLTS DC AA WA
53. M AFTERTREATMENT SYSTEM EPAO7 Aftertreatment In order to meet EPA07 emissions regulations the traditional muffler was replaced by a new Aftertreatment Device ATD The EPA07 ATD consists of a Diesel Oxidation Catalyst DOC and a Diesel Particulate Filter DPF Together these two components burn off collected particulate matter in a process called regeneration The key to successful regeneration is high exhaust temperature for an extended period of time Without adequate temperatures for regeneration the filter will continue to trap particulates and eventually plug In order to avoid plugging Detroit Diesel has designed an actively regenerated ATD 62 All information subject to change without notice DDC SVC MAN 0075 Copyright 2010 DETROIT DIESEL CORPORATION EPAIO DD PLATFORM OPERATORS MANUAL 11 13 12 d140009 1 Doser Block Assembly 8 DOC Outlet Temperature Sensor 2 Intake Throttle Valve 9 Sensor Junction Box 3 Charge Air Cooler 10 DPF Outlet Temperature Sensor 4 EGR Valve 11 DPF Outlet Pressure Sensor 5 EGR Actuator 12 Diesel Particulate Filter 6 Fuel Doser Valve 13 DPF Inlet Pressure Sensor 7 DOC Inlet Temperature Sensor 14 Diesel Oxidation Catalyst All information subject to change without notice 63 DDC SVC MAN 0075 Copyright 2010 DETROIT DIESEL CORPORATION AFTERTREATMENT SYSTEM EPA10 Aftertreatment To meet EPA10 emission regulations the traditional muffler was replaced
54. Miles X 1000 25 50 75 100 125 150 Km X 1000 40 80 120 160 200 240 Hours 640 1280 1925 2565 3205 3850 Procedure ten O reee Et ES SE SE SE NS tubrcatngonrmer LST RR RR ET Refer to section How to Select Coolant Coolant for the listing of required intervals using the recommended coolants Cooling System Filter if equipped Fuel Filters without Frame mounted Filter Fee RR ETER Coalescer Water E T Final Filter Filter 78 All information subject to change without notice DDC SVC MAN 0075 Copyright O 2010 DETROIT DIESEL CORPORATION EPAIO DD PLATFORM OPERATORS MANUAL Severe Service Maintenance Intervals EPA10 Fuel Filters with Frame mounted Filter Frame mounted Filtert GER IE RE re N WE TEEN EEN HEEN PR EEN 2000012 Separator Praline gt EE EN EE EEN Adjust at 100 000 miles 160 000 km at 500 000 Valve Lash Adjustment miles 800 000 km and then every 500 000 miles 800 000 km thereafter Air System Eelere EC SSES EER E EEN ES SR pasten EEN NEE ENE EE EIE Aiternreatment Devices Inspect external hardware and connections every 6 months or at oil change intervals A Check Engine Light will illuminate when ash requires removal Normal DPF ash clean intervals are 300 000 miles 480 000 km 9 000 hours to 400 000 miles 640 000 km 10 250 hours DEF Pump Filter Replace filter every 150 000 miles 240 000 km DEF Pump Air Bladder DEF Pump Air B
55. N 0075 Copyright 2010 DETROIT DIESEL CORPORATION EPAIO DD PLATFORM OPERATORS MANUAL Detroit Diesel Genuine Cooling System Cleaners Detroit Diesel Genuine Cooling System Cleaners Part 200164 One Half Gallon One Half Gallon Jug 6 Per Case 6 Per Case On Line Cleaner 200105 5 Gallon Pail 200155 55 Gallon Drum 201549 Twin Pack 2 Per Case Detroit Diesel Genuine Fluid Analysis Products Detroit Diesel Genuine Fluid Testing and Analysis Products EES Part Hi Indicates Nitrite Molybdate amp Glycol 23519401 Levels 3 Way Coolant Test Strips Single Foil Packs Indicates Nitrite Molybdate amp Glycol 23519402 3 Way Coolant Test Strips Bottle of 50 Levels Indicates Nitrite Molybdate amp Glycol 23522774 3 Way Coolant Test Strips Bottle of 10 Levels Complete Inhibited Ethylene Glycol Coolant 23516921 Coolant Analysis Bottle Carton of 6 Analysis Organic DEER 23523398 Laboratory Coolant Analysis Analysis All information subject to change without notice 145 DDC SVC MAN 0075 Copyright 2010 DETROIT DIESEL CORPORATION
56. OSION To avoid injury from battery explosion when jump starting the engine do not attach the cable end to the negative terminal of the disabled battery 3 If necessary visit the nearest authorized dealer to have the alternator voltage and output checked 4 Do a load test on the batteries 5 Replace components as needed Monitoring the Oil Pressure When the engine has reached its normal operating temperature the engine oil pressure must not drop below the following values 55 psi 380 kPa at rated speed 14 psi 97 kPa at idling speed If oil pressure drops below these values stop the engine and determine the cause 35 DDC SVC MAN 0075 Copyright 2010 DETROIT DIESEL CORPORATION INSTRUCTIONS FOR STARTING THE ENGINE Excessive Idling Never allow the engine to idle for more than 30 minutes Excessive idling can cause oil to leak from the turbocharger Changing the Idle Speed The idle speed range of the DD Platform engine is 600 to 900 rpm if the parameters in the CPC are set to the default range Change the idle speed as follows 1 Turn the cruise control switch to the ON position 2 To increase the idle speed push the RSM ACC switch until the idle reaches the desired rpm 3 To decrease the idle speed push the SET CST switch until the idle reaches the desired rpm Shutting Down the Engine after High Load Operation If the engine has been running at full output or
57. PA recommendations Fill the new filters with No 1 diesel fuel or pure kerosene and install on the engine 8 Operate the engine for five 5 minutes to circulate the clean fuel throughout the engine Be sure the engine fuel system is full 9 Stop the engine and allow to cool Then disconnect the fuel return line and the inlet line at the primary filter and securely All information subject to change without notice plug both to retain the fuel in the engine 10 Transmission Follow the manufacturer s recommendations for prolonged storage 11 Power Take Off If equipped follow manufacturer s recommendations for prolonged storage NOTICE Failure to properly seal off the turbocharger air inlet and exhaust outlet openings before engine storage may permit air drafts to circulate through the turbocharger and rotate the turbine compressor shaft without an adequate flow of lubricating oil to the center housing bearings resulting in severe bearing damage 12 Turbocharger Since turbocharger bearings are pressure lubricated through the external oil line leading from the oil filter adaptor while the engine is operating no further attention is required However the turbocharger air inlet and turbine exhaust outlet connection should be sealed off with moisture resistant tape 13 Apply a non friction rust preventive compound to all exposed engine parts If 137 DDC SVC MAN 0075 Copyright 2010 DETROIT
58. RNING BATTERY EXPLOSION To avoid injury from battery explosion when jump starting the engine do not attach the cable end to the negative terminal of the disabled battery 31 DDC SVC MAN 0075 Copyright 2010 DETROIT DIESEL CORPORATION INSTRUCTIONS FOR STARTING THE ENGINE AA WARNING Battery Explosion and Acid Burn To avoid injury from battery explosion or contact with battery acid work in a well ventilated area wear protective clothing and avoid sparks or flames near the battery If you come in contact with battery acid Flush your skin with water Apply baking soda or lime to help neutralize the acid Flush your eyes with water Get medical attention immediately NOTICE Jump starting with voltages greater than those indicated or reversing battery polarity may damage the MCM NOTICE Failure to connect jumper cables in the proper sequence can result in alternator and or equipment damage Before attempting to jump start the engine the jumper 32 cables must be connected properly positive to positive and negative to chassis or suitable ground The proper sequence is to connect negative to negative ground last Routine Engine Start Following are procedures for a routine everyday engine start AA WARNING ENGINE EXHAUST To avoid injury from inhaling engine exhaust always operate the engine in a well ventilated area Engine exhau
59. Regen Only 0 Disabled This option allows the DPF Regen Switch to request a parked regeneration if the parked regeneration entry conditions are met This option also allows MCM initiated over the road regenerations to occur EPA07 DPF Stationary Regen Only 1 Enabled This option only allows a parked regeneration to occur by using the DPF Regeneration Switch The MCM will be unable to initiate an active over the road regeneration when this option is enabled All information subject to change without notice Copyright 2010 DETROIT DIESEL CORPORATION EPAIO DD PLATFORM OPERATORS MANUAL Service Record It is mandatory that customers or distributors maintain a proper record of the particulate filter servicing and cleaning This record is an agent to warranty considerations The record must include information such as Date of cleaning or replacement Vehicle mileage at the time of cleaning or replacement Particulate filter part number and serial number All information subject to change without notice 71 DDC SVC MAN 0075 Copyright 2010 DETROIT DIESEL CORPORATION INSTRUMENT PANEL LAMPS INSTRUMENT PANEL LAMPS camp Lamp Name Description Results Amber Warning Lamp AWL Red Stop Lamp RSL DPF Regen Lamp High Exhaust System Temperature Lamp HEST Malfunction Indicator Lamp MIL 72 Indicates a fault with the engine controls Indicates
60. S DD13 Engine Components For a general view of the Detroit Diesel engines and major components see the following 4 1 7 d010067a 1 EGR Actuator 5 Turbocharger 2 Exhaust Manifold 6 Fuel Doser Valve 3 EGR Cooler 7 Crankcase Breather 4 Coolant Outlet Nipple 12 All information subject to change without notice DDC SVC MAN 0075 Copyright 2010 DETROIT DIESEL CORPORATION EPAIO DD PLATFORM OPERATORS MANUAL 1 Water Pump 8 Fuel Doser Block 2 Oil Coolant Module 9 Single Stage Air Compressor 3 Delta P Sensor 10 Fuel Filter Module 4 Oil Filter 11 MCM 5 Engine Cover 12 Thermostat 6 Intake Manifold 13 Engine Serial Number Location 7 High Pressure Fuel Pump All information subject to change without notice 13 DDC SVC MAN 0075 Copyright 2010 DETROIT DIESEL CORPORATION DD PLATFORM ENGINE COMPONENTS DD15 Engine Components d010022a 1 Axial Power Turbine 4 Turbocharger 2 EGR Cooler 5 Crankcase Breather 3 EGR Valve Actuator 6 Fuel Doser Valve 14 All information subject to change without notice DDC SVC MAN 0075 Copyright 2010 DETROIT DIESEL CORPORATION EPAIO DD PLATFORM OPERATORS MANUAL 13 12 d010023a 1 Water Pump 8 Dual Stage Air Compressor 2 Oil Coolant Module 9 Power Steering Pump Location 3 Oil Filter 10 Fuel Filter Module 4 Fuel Rail under cover 11 Motor Control Module MCM 5 Air Intake Manifold 12 Thermostat 6 High Pressure Fuel Pump 13 Engine Serial Number Locatio
61. SH 108 HOW TO REPLACE THE FUEL FILTERS 1 0 0 esse sees se see ee ees se see 109 REMOVAL OF THE FINAL FILTER sees ees se see ee ees ee see ee ee ee 109 INSTALLATION OF THE FINAL FILTER nccesser 110 REMOVAL OF THE PREFILTER i iese esse see ee ees ee see ees ee ee ee ee ee 111 INSTALLATION OF THE PREFILTER iese ee ee ee se see ee ee ee ee 111 REMOVAL OF THE WATER SEPARATOR COALESCER 112 INSTALLATION OF THE WATER SEPARATOR COALESCER 113 ENGINE OUT OF FUEL HOW TO RESTART ccecce 114 HOW TO CLEAN AN ENGINE ees ee se ee ee ee ee ee eed ee ee ee ee ee ee ee ee 115 CLEANING WITH HIGH PRESSURE EQUIPMENT ncen 115 CLEANING THE ENGINE ou sesse ee ee ees ee ee ge ee ee ee ge eed ee ee ge ee ee 116 HOW TO CLEAN THE COOLING SYSTEM secese 116 DEGREASING THE COOLING SYSTEM eee 117 HOW TO SELECT COOLANT esse ese ee ee ee ee ee ee ee de ee ee 118 COOLANT DEFINITIONS AA 118 APPROVED COOLANTS esse ee ee se ee ee ee ee ke ee ee ke ee ee ee ee 119 ETHYLENE GLYCOL AND WATER PLUS SUPPLEMENTAL COOLANT ADDITIVE INHIBITOR neeesser 120 MIXING AND USING ETHYLENE GLYCOL ANTIFREEZE 120 WATER REQUIREMENTS 1 0 0 ee ees ee ee ee ee ee ee ese ee ee ee eke ee ee 121 COOLANT MAINTENANCE INTERVALS esse see ee ee se see ee 122 COOLANTS NOT RECOMMENDED 122 ANTIFREEZES AND COOLANTS CONTAINING PHOSPHATE use det Er GE deet Ne EE ERR 122 AUTOMOTIVE TYPE COOLANTS oeer 123 METHYL ALCOHOL BASED ANTIFREEZE ose 123 GLY
62. SVC MAN 0075 Copyright 2010 DETROIT DIESEL CORPORATION EPAIO DD PLATFORM OPERATORS MANUAL Inspection of the Air Compressor The air compressor incorporates three of the major systems of a diesel engine air lubrication and cooling Inspect the air compressor looking for air oil and coolant leaks NOTE Because the air compressor facilitates air lubricating oil and coolant flow a failed air compressor could result in contamination between these three fluids When failed an air compressor can produce excessive crankcase pressure or allow an engine to ingest lubricating oil Monitoring the Fuel and Fuel Tank To prevent fuel and fuel tank problems the following measures are recommended 1 Keep the fuel tank filled to reduce condensation 42538 All information subject to change without notice 2 Before adding fuel refer to section How to Select Diesel Fuel 3 Refill the tank at the end of each day s operation to prevent condensation from contaminating the fuel Condensation formed in a partially filled tank promotes the growth of microorganisms that can clog fuel filters and restrict fuel flow 4 To prevent microbe growth add a biocide to the fuel tank or primary fuel supply only as needed 5 Open the drain at the bottom of the fuel tank every 30 000 miles 50 000 kilometers to drain off any water and or sediment AA WARNING PERSONAL INJURY To avoid injury from improper use
63. a 150 gallon tank would require a minimum of 15 gallons of fuel NOTE If a vehicle is on uneven ground more fuel may be required 2 Operate hand primer for three minutes or 250 strokes 3 Crank engine for 20 seconds 4 If engine does not start allow for a 60 second cool down and repeat previous step NOTE The starting cycle can be repeated up to three times All information subject to change without notice DDC SVC MAN 0075 Copyright 2010 DETROIT DIESEL CORPORATION EPAIO DD PLATFORM OPERATORS MANUAL 5 Start the engine with the accelerator pedal in the idle position Monitor the oil pressure gauge or indicator lamp Keep the engine running at an idling speed until a stable oil pressure reading of 14 psi 97 kPa or more is maintained for one minute 6 Check for leaks 7 Allow the engine to reach operating temperature of 60 C 140 F Increasing engine speed above idle before oil pressure has stabilized may cause severe engine damage 8 Increase engine speed to 1800 rpm for three minutes 9 Return the engine to idle and allow to idle for approximately one minute then shut down the engine 10 Check for leaks 11 If engine still fails to start contact an authorized Detroit Diesel repair facility How to Clean an Engine Important Observance of all environmental protection regulations is required All information subject to change without notice Cleaning with High P
64. al injury or 8 E SE vehicle property damage or both Failure to keep the vehicle within could cause personal injury safe control speed limits while descending a grade may result in vehicle or property damage or both 3 Do not exceed the safe control speed of your vehicle Example You could descend a 6 grade under control only at 10 mph 16 kph without an engine brake but at 25 mph 40 kph with an engine brake You could not descend that same hill at 50 mph 80 kph and still expect to remain under control Get to know how much slowing power your engine brake can provide So get to know your engine brake system before climbing hills and do not exceed a safe control speed 4 Check your progressive braking switch often for proper position LOW MED HIGH since road conditions can change quickly Never skip a step when operating the progressive braking switch Always go from OFF to LOW and then to a higher position when on slippery roads All information subject to change without notice 57 DDC SVC MAN 0075 Copyright 2010 DETROIT DIESEL CORPORATION ENGINE BRAKE SYSTEM Operating on Wet or Slippery Pavement Operate the engine brake system as follows NOTE Experience with the engine brake system on dry pavement is recommended before attempting to use it on wet or slippery roads 1 On wet or slippery pavement start with the master switch in the OFF position and use the gear you would normally use u
65. alfunction Fuse blown or missing x Insufficient Fuel Supply EISE WEE oe N S S X f Ke SCT E N S N X f Loose fuel connections J x Cracked fuel lines ILL XxX Obstructed fuelfiltersiines J x Faulty fuel pumps J J x Faulty injector operation x Restricted fuel fitting missing J x DDEC Malfunction IL __ x ee da check valve or shutoff valve hea E EE valves Worn piston ringsliners TL TCX Leaking cylinder head gasket xX Improper intake or exhaust valve adjustments K lt gt lt gt lt gt lt gt lt Ead Ead Eas x lt All information subject to change without notice 131 DDC SVC MAN 0075 Copyright 2010 DETROIT DIESEL CORPORATION TROUBLESHOOTING Aftertreatment System Operating Characteristics EPA07 engines that meet EPA 2007 emissions standards and EPA10 engines that meet EPA 2010 emissions standards are equipped with an ATS that prevents 95 of the particulate matter soot from leaving the exhaust This will eliminate the use of visible smoke diagnostics unless there is a system failure issue White smoke or steam at start up or during cold weather operation is still a characteristic of engine operation Abnormal amounts of black blue smoke may merit further investigation 132 All information subject to change without notice DDC SVC MAN 0075 Copyright
66. ally available from Detroit Diesel recommended and other manufacturers as either a concentrated antifreeze or as a premixed antifreeze The premixed antifreeze is ready for use while the concentrated coolant must be mixed with water prior to use Detroit Diesel Genuine Coolant P N 23512138 is the preferred ethylene glycol coolant If other commercial brands of ethylene glycol are used they must be equivalent to the Detroit Diesel Genuine Coolant Fully formulated antifreeze does not require a dosage of Supplemental Coolant Additive prior to initial use 120 Detroit Diesel Genuine Coolant Mixing and Using Ethylene Glycol Antifreeze Use ethylene glycol antifreeze as follows 1 If a concentrated ethylene glycol antifreeze is purchased mix the antifreeze with water meeting the required quality standards and fill the cooling system Refer to section Water Requirements 2 Ifa pre diluted fully formulated coolant is purchased fill the cooling system without dilution NOTE For best overall performance a coolant consisting of 50 concentration of antifreeze 50 antifreeze 50 water is recommended An antifreeze concentration over 67 67 antifreeze 33 water is not recommended due to poor heat transfer reduced freeze protection Inhibited Ethylene Glycol IEG only and possible silicate dropout Also an antifreeze concentration below 33 33 antifreeze 67 water offers too All information
67. and determine the cause Running the engine with no oil pressure could result in engine damage 6 Start the engine with the accelerator pedal in the idle position Monitor the oil pressure gauge or indicator lamp Keep the engine running at idling speed until the oil pressure reading is 14 psi 97 kPa or more 7 Allow engine to reach operating temperature 60 C 140 F NOTICE Increasing engine speed above idle before oil pressure has stabilized may cause severe engine damage 8 Increase engine speed to 1800 rpm for three minutes 9 Return the engine to idle and allow to idle for approximately 25 DDC SVC MAN 0075 Copyright 2010 DETROIT DIESEL CORPORATION INSTRUCTIONS FOR STARTING THE ENGINE one minute then shut down the engine 10 Check for leaks Repair if necessary Checking Other Engine and ATS Related Parts Check the engine compartment as follows Make sure the transmission is filled to the proper level with the fluid recommended by the gear manufacturer Do not overfill The diesel exhaust fluid DEF must be checked and filled regularly with DEF meeting Detroit Diesel s quality specification Make sure cable connections to the storage batteries are clean and tight 26 AA WARNING Battery Explosion and Acid Burn To avoid injury from battery explosion or contact with battery acid work in a well ventilated area wear protect
68. and pipe unions on the engine for tightness Shut down the engine and tighten them if necessary b Check the oil feed and return lines at the turbocharger for leaks Shut down the engine and tighten them if necessary 4 Shut down the engine 33 DDC SVC MAN 0075 Copyright 2010 DETROIT DIESEL CORPORATION INSTRUCTIONS FOR STARTING THE ENGINE 5 Check the oil level using the oil dipstick The oil level is measured using the crosshatch area on the dipstick If the oil reading is between the crosshatch area then the oil is at the proper level for engine operation SATISFACTORY OIL LEVEL RANGE Min SS Max ANINI LOW FULL d180014a NOTE If the engine operating temperature is below 60 C 140 F the engine must be on a level surface and then shut down for 60 minutes for an accurate oil level reading Otherwise the engine must be brought up to an operating temperature of 60 C 140 F parked on a level surface and then shut down for five minutes for an accurate oil level reading 6 Check all the mounting fasteners on the engine for tightness Checking the Coolant Level Cold Check Check coolant level as follows 34 1 Ensure that all coolant plugs in the bottom of the radiator and on the radiator outlet pipe are secure and tight 2 Check the coolant level The cooling system is correctly filled when the coolant is between the full and low marks on the surge tank Check
69. and primer Refer to section Priming the Fuel System 113 DDC SVC MAN 0075 Copyright 2010 DETROIT DIESEL CORPORATION HOW TO PROCEDURES 8 Start the engine with the accelerator pedal in the idle position Monitor the oil pressure gauge or indicator lamp Keep the engine running at a idling speed until a stable oil pressure reading of 14 psi 97 kPa or more is maintained for one minute 9 Check for leaks 10 Allow the engine to reach operating temperature of 60 C 140 F NOTICE Increasing engine speed above idle before oil pressure has stabilized may cause severe engine damage 11 Increase engine speed to 1800 rpm for three minutes 12 Return the engine to idle and allow to idle for approximately one minute then shut down the engine 13 Check for leaks Engine Out of Fuel How to Restart When an engine has run out of fuel there is a definite procedure to follow when restarting it 114 NOTICE Never use the starting motor and fuel pump to prime the fuel filters Prolonged use of the starting motor and fuel pumps to prime the fuel system can result in damage to the starter fuel pump and injectors Refer to section Priming the Fuel System Use the following procedure to prime the fuel system 1 Fill the fuel tank with the recommended grade of fuel If only partial filling is possible add a minimum of 10 of the total tank volume of fuel to the tank For example
70. are no longer satisfied If there are no active or inactive faults the number 3 is flashed once followed by a gap of 3 seconds Reading Fault Codes To read the fault codes press and hold the Stop Engine Override Diagnostic Request Switch All information subject to change without notice 1 FLASH eme O as O aae 1 FLASH 1FLASH 1FLASH LONG SHORT SHORT PAUSE PAUSE PAUSE 1 1 2 SEC 1 2 SEC 1 2 SEC 47709 Active codes will be flashed on the RSL Stop Engine first followed by inactive codes being flashed on the AWL Check Engine The codes will continue to flash and repeat as long as the Diagnostic Request Switch is held in the ON position Both CPC and MCM faults are included Active Codes The active codes will be flashed on the RSL Stop Engine in the order of most recent to least recent occurrence based on engine hours Inactive Codes The inactive codes will be flashed on the AWL Check Engine in the order of most recent to least recent occurrence based on engine hours 49 DDC SVC MAN 0075 Copyright 2010 DETROIT DIESEL CORPORATION ELECTRONIC ENGINE CONTROL SYSTEM DDEC 10 Cruise Control Driving Tips For added driver convenience and comfort DDEC 10 also features a Cruise Control option that works just like the system in your car It can be operated in any gear above 1100 rpm or road speed faster than 20 mph 32 kph up to the rated engine speed It also can be programmed to ho
71. ark on the dipstick Use only the heavy duty oils recommended in the How to Replace the Lubricating Oil and Oil Filter section in this manual NOTICE Do not add oil if the oil reading is in the crosshatch area There are approximately 3 8 L 4 0 qt from the fill mark to the full mark Overfilling the oil pan can cause engine damage SATISFACTORY OIL LEVEL RANGE Min Max INN LOW FULL d180014a 30 INSTRUCTIONS FOR STARTING THE ENGINE Checking the Turbocharger Check the turbocharger as follows 1 Make a visual inspection of the turbocharger for oil leaks exhaust leaks excessive noise or vibration 2 If a leak unusual noise or vibration is noted stop the engine immediately Do not restart the engine until the cause of the concern has been investigated and corrected Axial Power Turbine Check the axial power turbine for excessive noise or vibration Stop the engine immediately if unusual noise or vibration is noted Do not restart the engine until the cause of the concern has been investigated and corrected Avoid Unnecessary Idling Whenever possible unnecessary idling should be avoided During long engine idling periods with the transmission in neutral the engine coolant temperature may fall below the normal operating range All information subject to change without notice DDC SVC MAN 0075 Copyright 2010 DETROIT DIESEL CORPORATION EPAIO DD PLATFORM OPERATORS MANUA
72. art the engine 3 If the engine does not start after 20 seconds stop Try again after waiting about 60 seconds 4 Monitor the oil pressure gauge immediately after starting the engine NOTICE Do not increase engine speed if the oil pressure gauge indicates no oil pressure Shut down the engine within approximately ten seconds to avoid engine damage Check to determine the cause of the problem NOTE Do not place the engine under full load until it reaches operating temperature Colder engine temperatures will cause All information subject to change without notice DDC SVC MAN 0075 Copyright 2010 DETROIT DIESEL CORPORATION EPAIO DD PLATFORM OPERATORS MANUAL the engine to preset idle up to 900 rpm Even at a high idle condition you do not have to wait for engine warm up and return to normal 600 rpm idle to drive the truck Running the Engine While the engine is operating monitoring the battery charge indicator light the oil pressure and avoiding excessive idling is recommended Checking the Oil Pressure Monitor the oil pressure as follows 1 Observe the oil pressure gauge immediately after starting the engine An oil pressure gauge that registers pressure 23 psi 160 kPa at idle speed is a good indicator that all moving parts are getting lubrication 2 If no pressure is indicated within 10 to 15 seconds stop the engine and check the lubrication system 3 The oil pressure should not d
73. as Ee ee eg dee De wads eed Bee ee dee 135 PREPARING ENGINE FOR STORAGE ees ee ee ee ee ee ee ee ee ee 135 TEMPORARY STORAGE 30 DAYS OR LESS ees ees esse see 135 EXTENDED STORAGE MORE THAN 30 DAYS nnn 136 PROCEDURE FOR RESTORING TO SERVICE AN ENGINE THAT HAS BEEN IN EXTENDED STORAGE neeesser 139 CUSTOMER ASSISTANCE ee ee ee ee ee ee ee ee ee see ee ee ee ee ee ee ee 141 USING ROAD SERVICE IN THE U S OR CANADA esse see 141 AVAILABILITY OF DETROIT DIESEL SERVICE OUTLETS 141 SPECIFICATIONS ccoo ER aut oe og de ERA ee ES kent Eed 143 FUEL AND LUBRICATING OIL FILTERS 0 0 ee 143 ENGINE OIL CAPACITIES 0 2 eee ee ees ee ee see ee ee ese ee ese ee ee ee ee ee 143 DETROIT DIESEL GENUINE COOLANT ENGINE PRODUCTS 143 DETROIT DIESEL GENUINE FULLY FORMULATED INHIBITED ETHYLENE GLYCOL COOLANTS eee eee tenet ee ee ee 143 DETROIT DIESEL GENUINE SUPPLEMENTAL COOLANT ADDITIVE NEED RELEASE FILTERS 0 eee 144 DETROIT DIESEL GENUINE COOLING SYSTEM CLEANERS 145 DETROIT DIESEL GENUINE FLUID ANALYSIS PRODUCTS 145 All information subject to change without notice ix DDC SVC MAN 0075 Copyright 2010 DETROIT DIESEL CORPORATION TABLE OF CONTENTS X All information subject to change without notice DDC SVC MAN 0075 Copyright 2010 DETROIT DIESEL CORPORATION EPAIO DD PLATFORM OPERATORS MANUAL INTRODUCTION This manual is intended for use by the operator of a Detroit Diesel engine u
74. ating Down a Long Steep Grade An explanation of control speed may be helpful in understanding how to use the engine brake system while descending a grade Control Speed is the constant speed at which the forces pushing the vehicle forward on a grade are equal to the forces holding it back without using the vehicle service brakes In other words this is the speed the vehicle will maintain without using the service brakes or fueling Use the following guidelines when descending a long steep grade 1 Before beginning the descent determine if your engine brake system is operating properly by lifting your foot briefly off the accelerator pedal You should feel the system activate 2 Ensure the progressive braking switch is in the appropriate power position LOW MED HIGH All information subject to change without notice DDC SVC MAN 0075 Copyright 2010 DETROIT DIESEL CORPORATION EPAIO DD PLATFORM OPERATORS MANUAL AA caution b WARNING BRAKE FADE PERSONAL INJURY Failure to keep the vehicle within safe control speed limits while descending a grade may result in loss of vehicle control which To avoid injury do not over apply the vehicle service brakes when descending a long steep grade Excessive use of the vehicle brakes will cause them to heat up reducing their stopping ability This condition referred to as brake fade may result in loss of braking which NOTICE could lead to person
75. c system monitors for faults in DEF system components and monitors the DEF supply pressure If the diagnostics detect that components critical to the SCR or DEF supply system are disconnected which could indicate tampering or if the diagnostics detect abnormal system pressures indicative of DEF supply blockage the warning lamp will illuminate and the control system will initiate time and mileage counters If the detected problem is not corrected in 500 miles 800 kilometers or 10 hours of operation the available engine torque will be reduced and the vehicle speed will be limited to 55 mph 88 kph If the problem remains uncorrected for an additional 1 500 miles 2 400 kilometers or 30 hours the vehicle speed will be limited to 5 mph 8 kph at the next fuel refill Operating Requirements Oxidation of particulate matter is the key to filter performance This requires that the catalyzing agent platinum coated passages provide optimum enhancement to the oxidation process The following requirements must be met otherwise the ATD warranty may be compromised All information subject to change without notice NOTICE Do not use kerosene or fuel blended with used lube oil Use Ultra Low Sulfur Fuel ULSF with 15 ppm sulfur content or less based on ASTM D2622 test procedure Lube oil must have a sulfated ash level less than 1 0 wt currently referred to as CJ 4 oil Detroit Diesel currently rec
76. can be equipped with a coolant filter inhibitor system as an installed option or as an after sale item Coolant Drain Interval A coolant system properly maintained and protected with supplemental coolant inhibitors can be operated up to the intervals listed At these intervals the coolant must be drained and disposed of in an environmentally responsible manner according to state and or federal EPA recommendations Inspection of the Radiator Inspect the radiator as follows 1 Inspect the exterior of the radiator core every 30 000 miles 50 000 km or 12 months 90 2 If necessary clean the exterior using a quality grease solvent such as mineral spirits and dry with compressed air Do not use fuel oil kerosene or gasoline AA WARNING EYE INJURY To avoid injury from flying debris when using compressed air wear adequate eye protection face shield or safety goggles and do not exceed 276 kPa 40 psi air pressure NOTE It may be necessary to clean the exterior of the radiator more frequently if the engine is being operated in extremely dusty or dirty areas 3 If the low coolant level sensor is installed in the top tank of the radiator test for proper operation every 100 000 miles 160 000 km or 12 months whichever comes first Authorized Detroit Diesel distributors are properly equipped to perform this service All information subject to change without notice DDC SVC MAN 0075 Copy
77. computer senses the changing engine condition Diagnostic Tool The diagnostic tool for Detroit Diesel Electronic Control DDEC 10 is the Detroit Diesel Diagnostic Link DDDL 7 X DDDL 7 X requirements are listed earlier in the manual refer to section Data Recording Capability Once the malfunction has been corrected the DDEC 10 system will return the engine to normal operation 47 DDC SVC MAN 0075 Copyright 2010 DETROIT DIESEL CORPORATION ELECTRONIC ENGINE CONTROL SYSTEM DDEC 10 The temperature of air in the intake system is increased with the addition of EGR DDEC 10 is programmed to reduce fueling power for a short time to reduce air and coolant temperatures when necessary DDEC 10 will store an information code that this event occurred but no corrective action is required as this action is designed to maintain operation without a noticeable affect on vehicle performance Flashing Malfunction Codes All malfunction codes are four digits The malfunction code recorded in the computer memory will remain until it is erased by a technician The flashing malfunction code can also be obtained by the operator To support flashing codes a Stop Engine Override Diagnostic Request Switch must be configured and the AWL Check Engine and RSL Stop Engine must be hard wired The CPC cannot flash these lamps if they are not hard wired The flashing code feature may be activated by satisfying one of the fo
78. coolant refer to section How to Select Coolant for the listing of required intervals using the recommended coolants Checking for Coolant Leaks Perform daily visual checks for cooling system leaks Look for an accumulation of coolant when the engine is running and when it is stopped All information subject to change without notice AA 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 NOTE Coolant leaks may be more apparent on a engine when it is cold Coolant Inhibitors The inhibitors in antifreeze solutions must be replenished with an approved corrosion inhibitor supplement when indicated by testing the coolant Refer to section How to Select Coolant for the listing of required intervals using the recommended coolants for required test intervals inhibitor levels and approved inhibitors 89 DDC SVC MAN 0075 Copyright 2010 DETROIT DIESEL CORPORATION MAINTENANCE NOTICE Coolant must be inhibited with the recommended Supplemental Coolant Additives listed in this manual Failure to check and maintain Supplemental Coolant Additive levels at required concentrations will result in severe damage corrosion to the engine cooling system and related components The cooling system is protected by a Supplemental Coolant Additive element In addition the engine
79. d state if the diesel tank is filled DEF levels will trigger a decrease without filling the DEF tank vehicle in engine performance The use of speed will be limited to 5 mph until improper fluid will trigger a decrease DEF is detected in the tank System BE Gauge Lamp Combination Response DEF level is less than 10 DEF level is less than 5 Flashing Vehicle speed limited to 55 mph Engine is derated DEF level is EMPTY Flashing Vehicle speed f limited to 55 mph Engine is derated DEF level is EMPTY and IGNORED Vehicle speed limited to 5 mph Engine is derated 74 All information subject to change without notice DDC SVC MAN 0075 Copyright 2010 DETROIT DIESEL CORPORATION Flashing EPAIO DD PLATFORM OPERATORS MANUAL DRIVER NOTIFICATIONS AND ACTIONS Notifications and Description Driver Action High Exhaust System No change in driving style Temperature HEST Lamp required SOLID Exhaust is at high When parked keep vehicle at a temperature and vehicle is safe distance from people and at low speed or parked flammable materials or vapors FLASHING A Parked Regeneration is in process and the system is not up to temperature Malfunction Indicator Vehicle can be driven to end of Lamp MIL shift If the MIL remains on after Indicates a failure of an 3 drive cycles call for service Emission Control Device May illuminate at the same time as the Check Engine Lamp DPF Regeneration La
80. dels Driver Control Switches Vehicles with manual transmissions allow the driver to turn the engine brake on and off and select a Low Medium or High level of braking Low Med High Switch The Low setting on this switch activates two brake cylinders yielding about one third engine braking horsepower The Medium activates four cylinders supplying about two thirds engine braking horsepower The High setting activates all six cylinders providing full engine braking horsepower Engine Brake Activation Conditions The engine braking system only permits fully automatic operation 54 when the following conditions are met Engine Brake switch is on An Engine Brake level Low Med High is selected Vehicle meets the programmed minimum speed The Clutch Pedal is out The Accelerator Pedal is at zero percent activation Engine Brake Operation NOTICE Always allow the engine to reach full normal operating temperature before activating the engine brake system to ensure positive engine brake engagement The engine brake system depends on a full pressure flow of warm engine lubricating oil for proper lubrication of moving parts and optimum performance All information subject to change without notice DDC SVC MAN 0075 Copyright 2010 DETROIT DIESEL CORPORATION EPAIO DD PLATFORM OPERATORS MANUAL A CAUTION LOSS OF VEHICLE CONTROL To av
81. drive wheels begin to lock or there is fishtail motion after the Engine Brake is activated deactivate the brake system immediately if this occurs AA WARNING BODILY INJURY To avoid injury from an explosion do not use ether or starting fluid on engines eduipped with a manifold grid heater All information subject to change without notice DDC SVC MAN 0075 Copyright 2010 DETROIT DIESEL CORPORATION EPAIO DD PLATFORM OPERATORS MANUAL Preventive Maintenance Observe the following cautions when performing preventive maintenance AA WARNING PERSONAL INJURY To avoid injury when working near or on an operating engine remove loose items of clothing and jewelry Tie back or contain long hair that could be caught in any moving part causing injury AA WARNING PERSONAL INJURY To avoid injury when working on or near an operating engine wear protective clothing eye protection and hearing protection AA WARNING HOT OIL To avoid injury from hot oil do not operate the engine with the rocker cover s removed All information subject to change without notice AA 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 CAUTION USED ENGINE OIL To avoid injury to skin from contact with the contaminants in used engine oil wear protective gloves and apron AA WARNING PERSONAL INJURY
82. e regardless of API service classification Monograde oils gel at lower ambient temperatures reducing lubricant flow and do not provide adequate lubricity at higher engine operating temperatures resulting in severe engine damage The oils must be API CJ 4 and have demonstrated field performance in Detroit Diesel engines Detroit Diesel will allow CI 4 Plus oil having sulfated ash levels of 1 4 or less Use of Synthetic Oils Synthetic oils may be used in Detroit Diesel engines provided they are API licensed and meet the performance and chemical requirements of non synthetic oils outlined in this publication Synthetic oils offer improved low temperature flow properties high temperature oxidation resistance and improved fuel mileage However they are generally more costly than non synthetic oils Product information about synthetic oils should be reviewed carefully Performance additive systems often respond differently in synthetic oils 102 NOTE Synthetic oil does not permit extension of recommended oil drain intervals Use of Supplemental Additives Lubricants meeting the Detroit Diesel specifications outlined in this publication already contain a balanced additive treatment Supplemental additives are generally not necessary and can even be harmful These additives may be marketed as either oil treatments or engine treatments and are discouraged from use in Detroit Diesel engines Engine damage r
83. e defined by the state of California Owners of these vehicle types that wish to have the shutdown feature disabled should consult with California authorities to determine if their vehicles qualify for the exemption Non California 49 state EPA certification engines non California engines have the automatic shutdown feature disabled Idle Shutdown Timer This feature is an optional 1 80 minute idle shutdown system Its purpose is to conserve fuel by eliminating excessive idling and allowing a turbocharger cool down period To activate the shutdown the transmission must be in neutral with the vehicle parking brakes set and the engine in idle or fast idle mode 45 DDC SVC MAN 0075 Copyright 2010 DETROIT DIESEL CORPORATION ELECTRONIC ENGINE CONTROL SYSTEM DDEC 10 Electronic Engine Control System DDEC 10 Operation NOTE This engine is equipped with DDEC 10 software This software generally assures optimal engine performance The installation of software upgrades may cause minor changes in features and engine performance Since the DDEC 10 system is electronic a battery is required to operate the computer The system operates at 12 volts However in the event of a power supply malfunction the system will continue to operate at reduced voltage When this occurs the AWL Check Engine will come on i OBE E E DIAGNOSTIC AMBER RED REQUEST STOP AGING STOP ENGINE LAMP OVERRIDE SWITCH 47471
84. e ee 97 ENGINE STEAM CLEANING ees see ee ees ee ee ee ee ee ee ee dee 98 BATTERY CHARGING ALTERNATOR ees ee see ee ees ee see ee 99 INSPECTION OF THE ALTERNATOR e ees ee ee ee ees ee ee ee 99 LUBRICATING THE FAN HUB ees ese ees ee ee ee ese ee ese ee ee ee ee ee 100 CHECKING THE VIBRATION DAMPER 100 HOW TO PROCEDURES ee ee ee ee ee ee ee ee ee ee etter trans ee ee ee 101 HOW TO SELECT LUBRICATING OIL ees ee ee ee ee ee ee ee ee 101 LUBRICANT REQUIREMENTS eee ee see ee etree ee ee ee ee ee 101 COLD WEATHER STARTING o oo see ees ee ee ee ee ee ee ee ee ee ee ee ee ee 101 USE OF SYNTHETIC OILS siirsin ee ee ee dee ee ee dee ee ee ee ee ee 102 USE OF SUPPLEMENTAL ADDITIVES esse see ee ee ese ee ee see 102 REQUIREMENTS FOR CHANGING OIL o oo ees 102 DISPOSAL OF WASTE OIL eect ee ee teense ee ee ee etree ee ee ee ee 103 HOW TO REPLACE THE LUBRICATING OIL AND OIL FILTER 103 HOW TO SELECT DIESEL FUEL 0 etree 106 QUALITY EE 106 FUEL CONTAMINATION 000 0 eee eee ee ee ee ee ee ee ee ee ee ee ee 107 All information subject to change without notice DDC SVC MAN 0075 Copyright 2010 DETROIT DIESEL CORPORATION vii TABLE OF CONTENTS BIODIESEL FUEL succionar did 107 PROHIBITED ADDITIVES iese sesse see ees ee ee eke ee ee ee ee ee ee see ee ee ee 108 USED LUBRICATING OIL ee ee ee ee ee ee ee ek ee 108 GASOLINE RE RE ER N EE EN 108 FUEL ADDITIVES WITH SULFUR OR SULFATED A
85. e regulator vave X Worn crankshaft camshaft or connecting rod bearings Loose connections X Cracked lines TX Damaged gaskets or seal rings x Lubrication oil loss at breather tube X Lubrication oil loss at dipstick tube X Leaking oil cooler o X Leaking valve stemseals x Worn broken oil control rings x Scored liner and orpiston _ x Excessive engine installation angle x Crankcase overfiled X RYE RI Faulty oil pressure relief valve Air leaks in oil pump suction side Worn or damaged oilpump_____ _ __ __x Faulty oilpressuregauge X Faulty electrical components for gauge x Plugged oil line or orice So x Indicates high crankcase pressure Wat lt Xx x lt 134 All information subject to change without notice DDC SVC MAN 0075 Copyright 2010 DETROIT DIESEL CORPORATION EPAIO DD PLATFORM OPERATORS MANUAL ENGINE STORAGE When an engine is to be stored or removed from operation for a period of time special precautions should be taken to protect the interior and exterior of the engine transmission and other parts from rust accumulation and corrosion The parts requiring attention and the recommended preparations are given below Preparing Engine for Storage It will be necessary to remove all rust or corrosion completely from any exposed part before applying rust preventive compound Therefore it is recommended that
86. e the following in Detroit Diesel engine cooling systems e Soluble Oil e High Silicate Automotive Type Antifreeze e Chromate Supplemental Coolant Additives e Methoxy Propanol Based Coolant e Methyl Alcohol Based Coolant e Sealer Additives or Coolant Containing Sealer Additives e HVAC Coolant e Phosphate Inhibited Coolant e Nitrited Organic Acid Technology Coolant Coolant Life of Glycol Coolant A properly maintained cooling system filled with phosphate free coolant consisting of a 50 50 mix of antifreeze and water per TMC RP 329 Type A EG specifications can be operated to the limits recommended The proper maintenance involves All information subject to change without notice periodic evaluation using Detroit Diesel Genuine Fluid Analysis 3 Way Coolant Test Strips and the addition of Supplemental Coolant Additive as needed indicated by the strip test To verify coolant acceptability submit a sample for laboratory analysis once a year Submit the sample in a Detroit Diesel Genuine Fluid Analysis Coolant Test Bottle Refer to section Detroit Diesel Genuine Fluid Analysis Products for required part number listings in this manual How to Replace the Coolant Filter The engine is equipped with a coolant filter The coolant filter contains supplemental corrosion inhibitors Refer to section Scheduled Maintenance Intervals for the interval to replace the coolant filter Service the cooling
87. ection How to Select Diesel Fuel NOTICE Prolonged use of the starting motor and engine fuel pumps to prime the fuel system can result in damage to the starter fuel pumps and injectors Refer to section Priming the Fuel System If the shutoff valve is even partially closed it may cause erratic engine operation due to an inadequate supply of fuel to the fuel pump AA WARNING BODILY INJURY To avoid injury from an explosion do not use ether or starting fluid on engines eduipped with a manifold grid heater 24 NEVER use ether as a starting aid to run the engine Doing so will result in injector damage If an external starting aid is used such as a starting fluid the heat generated by the external fuel source will cause the injector tips to be damaged when the fuel cools them The injector piston and bushing can be scored from running without lubrication To ensure prompt starting and even running the fuel system must be primed if air has entered the fuel system Priming is done by operating the manual hand priming pump located on the fuel filter module or connecting an external priming pump to the priming port on the fuel filter module Refer to section Priming the Fuel System Authorized Detroit Diesel service outlets are properly equipped for this type of service Priming is required if the fuel system has been serviced Drain off any water that has accumulated Water in fuel can seri
88. edules but should never be extended Adjusting the Valve Lash Perform a valve lash adjustment as scheduled for the appropriate engine duty cycle For EPA10 engines refer to section EPA10 Maintenance Tables For EPA07 engines refer to section EPA07 Maintenance Tables NOTE Proper valve lash clearance allows the engine to produce the best possible performance with the lowest emissions Valve lash adjustments should be performed by an authorized Detroit Diesel maintenance or repair facility 91 DDC SVC MAN 0075 Copyright O 2010 DETROIT DIESEL CORPORATION MAINTENANCE Monitoring the Belts The engine is equipped with two engine belt tensioners to ensure the belts are neither too tight nor too loose Belts that are too tight impose extra loads on the crankshaft fan and alternator bearings shortening both belt and bearing life A loose belt will slip and generate excessive heat that may cause damage to the belt and accessory drive components 92 All information subject to change without notice DDC SVC MAN 0075 Copyright 2010 DETROIT DIESEL CORPORATION EPAIO DD PLATFORM OPERATORS MANUAL 1 Inspect the belt tensioner for wear or damage AA WARNING PERSONAL INJURY To avoid injury from rotating belts and fans do not remove and discard safety guards 2 If damage is found it may need to be replaced by an authorized Detroit Diesel maintenance or repair facility Serpentine Belts Two po
89. ee ENGINE BRAKE AND CRUISE CONTROL eee SHIFTING HINTS satiric acta iia ennai EE ES IDLIN LEE ENGINE BRAKE SYSTEM eee ee ee ee ee ee ee ee ee ee ee ee DRIVER CONTROL SWITCHES ees ee see tee ee ee ee ee ee ee ee ee LOW MED HIGH SWITCH ee ee ee ee ee ee ee ee ee dee ee ee ee ee ee ee ee ee ENGINE BRAKE ACTIVATION CONDITIONS ee ENGINE BRAKE OPERATION teas ee ee ee ee ANTI LOCK BRAKING SYSTEMS ees see dee ee ee ee ee ee ee ee ee ee OPERATING ON FLAT DRY PAVEMENT ees ees ese ee see ee ee see ee ee OPERATING DOWN A LONG STEEP GRADE ee ees see OPERATING ON WET OR SLIPPERY PAVEMENT oseese ENGINE SYSTEMS eelere eines olde nacelle FUELSYSTEM AS AE lit din ee Ee ee ea ee ee Cada ee an tian LUBRICATION SYSTEM uuu eee ee ee ee a ee ee ee ee ee ee ee ee ee AIRSYSTEM so Se itt aah EE etn Ge EE Ge de ean aarti COOLING SYSTEM ii it eet es dain ndtv dl aes ELECTRICAL SYS TEM erdege Eeer ENEE EES EXHAUST SYSTEM uni nea ehh We deel Een EXHAUST GAS RECIRCULATION SYSTEM eee AFTERTREATMENT SYSTEM eee etter etree erent All information subject to change without notice DDC SVC MAN 0075 Copyright 2010 DETROIT DIESEL CORPORATION TABLE OF CONTENTS EPAO7 AFTERTREATMENT ee esse ee ee ee ee ee ee ee ee ee ede ee ee ee ee ee ee ee 62 EPA10 AFTERTREATMENT ee esse ee ee ee ee ee ee ee ee eed ede ee ee ee ee ee ee ee 64 EPA10 DIESEL EXHAUST FLUID DEF AND SCR SYSTEM RI enne 66 EPA10 DEF AVAILABILITY ese see
90. ee ees ee ge ee ee ee ee ee ee ee ee ge ee ee ee 66 EPA10 DEF SPECIFICATIONS ees see ees ees ee ee ee ee see ge ee ee 66 EPA10 DEF HANDLING AND STORAGE secese 66 EPA10 DEF SYSTEM ANTI TAMPERING FEATURE oaae 67 OPERATING REQUIREMENTS sees esse see ee ee ee see ee ee ee see ee ee ee ee 67 EPA10 DIESEL EXHAUST FLUID TANK esse ee ee ee see ee ees se ee ee 67 MAINTENANCE ii ies GE as EE Ee Bee Re EE Re lla diosa 68 PARKED REGENERATION PROCEDURE aeee 69 EPA07 HAZARDOUS APPLICATIONS oseese 70 EPA07 DPF STATIONARY REGEN ONLY O DISABLED 70 EPA07 DPF STATIONARY REGEN ONLY 1 ENABLED 70 SERVICE RECORD iese see sedes seed ee ge see ede idad 71 INSTRUMENT PANEL LAMPS ee ees ee ee ee ees ee ee ge ee ee ee ee ee ee 72 EPA10 DEF FLUID LEVEL WARNINGS LAMPS l 74 DRIVER NOTIFICATIONS AND ACTIONS le 75 MAINTENANCE RE ME NE OR ER 71 SCHEDULED MAINTENANCE INTERVALS eee 71 MAINTENANCE SCHEDULE APPLICATIONS se ees esse 77 SEVERE SERVICE iis ds eed eg dee ed eed ie ee due ee ee de Edge dee de 71 SHORT HAUL tias EE 71 Ke ed DIE 71 SCHEDULE USE ec geer seg ee Ge KEEP ati 71 EPA10 MAINTENANCE TABLES iese ee dee ee ee ee dee ee ee ee ee ee ee ee ee 78 EPAO7 MAINTENANCE TABLES ee esse dee ee ee ee dee ee ee ee ee ee ee ee ee 83 ROUTINE PREVENTIVE MAINTENANCE oseere 87 MONITORING THE LUBRICATING OIL seenen 87 MONITORING THE LUBRICATING OIL FILTER eee 88 MONITORING THE COOLING SYSTEM e
91. een 88 CHECKING FOR COOLANT LEAKS ieee 89 COOLANT INHIBITORS ee ee andeis ee ee ee ia raana 89 COOLANT DRAIN INTERVAL ese ee ees se ee ee ee ee ee ee ee ee ee ee 90 INSPECTION OF THE RADIATOR 0 0 sesse sesse se ees ee ee ee ee dee 90 vi All information subject to change without notice DDC SVC MAN 0075 Copyright 2010 DETROIT DIESEL CORPORATION EPAIO DD PLATFORM OPERATORS MANUAL MONITORING THE COOLING SYSTEM FILTER ee 91 MONITORING THE FUEL FILTERS 0 eee 91 ADJUSTING THE VALVE LASH cece ee ee ee see ee dee ee 91 MONITORING THE BELTS ees ees ee ees ee ee see ee ee see ee dee ee ee ee ee ee 92 SERPENTINE BELTS srair ers e er Re ae dek eee dee a GE ee eke Ee nad 93 REPLACEMENT OF BELTS see eed ee ee ee ee ee ee ee dee ee 93 INSPECTION OF THE AIR INTAKE SYSTEM ees ee see esse ee 93 MONITORING THE AIR CLEANER esse ee sesse ee ee ee ees ee ee ee 93 REPLACEMENT OF AIR CLEANER ELEMENT onene 94 MONITORING THE EXHAUST SYSTEM ee 94 MONITORING THE AFTERTREATMENT SYSTEM en 94 INSPECTION OF THE AIR COMPRESSOR eee 95 MONITORING THE FUEL AND FUEL TANK nessen 95 FUEL LINES FLEXIBLE HOSES eee 96 INSPECTION FOR FUEL LEAKS ese ee ees ee ee ee ee ee see ee ee 96 INSPECTION OF HOSES AND FITTINGS ue 96 INSPECTION OF HOSES WITH EXTENDED SERVICE Bld ER ER Ree 97 INSPECTION OF TURBOCHARGER AND CHARGE AIR COOLER weenie Aare ae a 97 INSPECTION OF THE BATTERY ees ee see ee ee ee ee ee ee ee se
92. ees ee ee dee ee ee ee ede ee ee ee 29 INSPECTION DURING IDLING ee ee ee ee ee 29 CHECKING THE TRANSMISSION ee esse ee ee ees ee see ee ee dee 29 CHECKING FOR FLUID LEAKS 0 0 ese ee ee see ee ee ee dee ee ee ee ee 29 CHECKING THE CRANKCASE sees ees ee ees ee ee ee eed ee ee ee ee ee 30 CHECKING THE TURBOCHARGER LL sees ee ee ee ee ee ee ee ee ee 30 AXIAL POWER TURBINE esse ee ee ee see ee ee ee ee ee ee ee ee ee ee ee ee 30 AVOID UNNECESSARY IDLING ese ee ee se see ee ee ee ee ee ee ee 30 STOPPING THE ENGINE ees se see ee ee ee ee ee ee ee ee ee ee ee ee dee ee ee ee 31 EMERGENCY JUMP STARTING e ee ese dee ee ee see ee ee ee ee ee ee ee ee 31 ROUTINE ENGINE START ese ees dee see ee ee ee ee ee ee ee ee ee ee ee dee ee ee ee 32 STARTING THE ENGINE ROUTINELY seese 33 CHECKING THE COOLANT LEVEL COLD CHECK aaee 34 CHECKING THE COOLANT LEVEL HOT CHECK eses 34 MONITORING ENGINE OPERATION ese ee ee ee see ee ee ee ee 35 MONITORING THE BATTERY CHARGING SYSTEM ccoo 35 MONITORING THE OIL PRESSURE ees esse see ees ese se see ee ee ee 35 EXCESSIVE IDLING ees se ees ees ee see ee ee ee ke ee ee ee kke ee ee ee ke ee ee 36 CHANGING THE IDLE SPEED ooo sees se ee ee ee ee see ee ee ee ee ee ee ee ee 36 SHUTTING DOWN THE ENGINE AFTER HIGH LOAD OPERATION MEE EE OR EE NE EE N 36 EMERGENCY RUNNING MODE ee ese dee ees ee ee dee ee ee ee ede ee ee ee 36 STOP ENGINE OVERRI
93. eparator coalescer straight up and allow the fuel to drain back All information subject to change without notice DDC SVC MAN 0075 Copyright 2010 DETROIT DIESEL CORPORATION EPAIO DD PLATFORM OPERATORS MANUAL 3 Remove the water separator coalescer 1 from the Water Separator Coalescer cap 2 by placing the filter on a solid surface and apply pressure on the Water Separator Coalescer cap at an angle d470022 4 Discard the filter 5 Inspect inside the housing for any large debris and clean it out if needed 6 Discard Water Separator Coa lescer cap seal ring Installation of the Water Separator Coalescer Install the water separator coalescer as follows 1 Snap a new water separator coalescer into the Water Separator Coalescer cap All information subject to change without notice 2 Install a new Water Separator Coalescer cap seal ring 3 Apply a light coat of petroleum based lithium grease to the Water Separator Coalescer cap seal ring and to the lower seal 1 on the water separator coalescer filter F d470019 4 Install the water separator coalescer into the fuel filter module 5 Tum the cap counterclockwise until a click sound is made then turn clockwise and hand tighten 6 Torque water separator coalescer cap to 55 60 Nm 41 44 ft lb 7 Once all required filters have been changed prime the fuel system using the fuel priming valve or the h
94. er Remove the oil filters Dispose of the oil and filters in an environmentally friendly manner according to state and or federal EPA recommendations Replace the drain plug and torque to 45 50 Num 33 77 lb ft Install new lubricating oil filters Fill the crankcase to the proper level with Tectyl 930A preservative lubricating oil or an equivalent 30 weight preservative lubricating oil meeting Mil L 21260C Grade 2 Specification Drain the fuel tank Refill with enough clean No diesel fuel to permit the engine to operate for about ten 10 minutes If draining the fuel tank is not convenient All information subject to change without notice DDC SVC MAN 0075 Copyright 2010 DETROIT DIESEL CORPORATION EPAIO DD PLATFORM OPERATORS MANUAL use a separate portable supply of recommended fuel NOTE If engines are stored where condensation of water in the fuel tank may be a problem additives containing methyl carbitol or butyl cellusolve may be added to the fuel Follow manufacturer s instructions for treatment Where biological contamination of fuel may be a problem add a biocide such as Biobor JF or equivalent to the fuel When using a biocide follow the manufacturer s concentration recommendations and observe all cautions and warnings 7 Drain the fuel system and remove the fuel filters Dispose of used filters in an environmentally responsible manner according to state and or federal E
95. ervice over the road transport applies to vehicles that annually travel more than 60 000 miles 96 000 kilometers and average greater than 6 miles per gallon with minimal city stop and go operation Schedule Use Complete each maintenance operation at the required interval The intervals are based on a collaboration of field and fleet data For a more accurate analysis of when fluids should be changed such as engine oil refer to publication Engine Requirements Lubricating Oil Fuel and Filters and publication Coolant Selections for Detroit Diesel Engines available from authorized Detroit Diesel distributors TA DDC SVC MAN 0075 Copyright 2010 DETROIT DIESEL CORPORATION MAINTENANCE Each maintenance table shows Additives listed in this manual which maintenance operation must Refer to section How to Select be performed at the recommended Coolant interval in miles kilometers and hours Refer to section Routine Preventive Maintenance for a description of the NOTE maintenance to be performed for Failure to check and maintain related items Supplemental Coolant Additive levels at required concentrations EPA10 Maintenance Tables will result in severe damage corrosion to the engine cooling NOTE system and related components Coolant must be inhibited with the recommended Supplemental Coolant Actual fuel filter life will vary based on fuel quality Severe Service Maintenance Intervals EPA10
96. esulting from the use of such materials is not covered by your Detroit Diesel warranty Detroit Diesel will not provide statements beyond this publication relative to their use Requirements for Changing Oil The length of time an engine may operate before an oil change depends upon the lubricant and fuel used engine oil consumption and the operating cycle For EPA10 engines refer to section EPA10 Maintenance Tables for the tables listing the recommended oil change intervals For EPAO7 engines refer to section EPAO7 Maintenance Tables for the tables listing the recommended oil change intervals All information subject to change without notice DDC SVC MAN 0075 Copyright 2010 DETROIT DIESEL CORPORATION EPAIO DD PLATFORM OPERATORS MANUAL A CAUTION USED ENGINE OIL To avoid injury to skin from contact with the contaminants in used engine oil wear protective gloves and apron Disposal of Waste Oil Used lubricating oil and filters require deposal in an environmentally responsible manner according to federal EPA and or state recommendations The disposal of waste oil may be best addressed by the engine oil supplier who may accept responsibility for proper disposal of this material as part of the business of providing lubricant How To Replace the Lubricating Oil and Oil Filter The oil filter is an integral part of the lubrication system Proper filter selection and maintenance are important to satis
97. factory engine performance and service life The filter should be used to maintain a clean system not to clean up a contaminated system The maintenance intervals for the appropriate duty cycle are listed in tables in this manual For EPA10 engines refer to section EPA10 Maintenance Tables For EPA07 All information subject to change without notice engines refer to section EPA07 Maintenance Tables Change the oil and replace the lubricating oil filter as follows NOTE If the used oil was contaminated by fuel or coolant it may be necessary to take the vehicle to a certified Detroit Diesel Service Center The Service Center may drain the oil and then remove the oil pan oil pump and oil pump intake manifold to drain the remaining oil held back by the backflow valve It is important to remove all contaminated oil from the engine 1 Place the transmission in neutral and set the parking brake 2 Clean outside of the oil filter housing NOTE Change the engine oil only when the engine oil temperature is approximately 60 C 140 F Changing cold oil will result in extended drain times 3 Using a 36 mm socket unscrew the oil filter cap and filter and allow the oil to drain into the housing After draining is 103 DDC SVC MAN 0075 Copyright 2010 DETROIT DIESEL CORPORATION HOW TO PROCEDURES complete remove the assembly from the housing NOTE Use care to prevent foreign objects from enterin
98. from occurring NOTE The Stop Engine Override Switch and the Diagnostic Request Switch are the same NOTE Holding down the Stop Engine Override Switch will not prevent the engine shutdown sequence You must continue to reset the automatic shutdown system by pressing the Stop Engine Override Switch at intervals of approximately 15 to 20 seconds It takes 30 seconds from the time the automatic shutdown sequence begins until engine shutdown Therefore the operator must press the override switch just prior to engine shutdown and continue to do so until the vehicle can be brought to a stop in a safe location Immediate Speed Reduction The immediate speed reduction option will bring engine rpm back to a predetermined speed but will not shut down the engine The engine should not be restarted after it has been shut down by the engine protection system unless All information subject to change without notice the problem has been located and corrected Red Stop Lamp The conditions that will cause the RSL Stop Engine to come on are High coolant temperature Loss of coolant High oil temperature Low oil pressure Auxiliary shutdown Whenever the AWL Check Engine or the RSL comes on the DDEC 10 system will determine where the problem is and will then store this information in its memory If the malfunction is intermittent the lights will come on and go off as the
99. g and serious engine damage Engine speed and power are varied under Cruise Control to maintain the set vehicle speed The vehicle speed must be above Minimum Cruise Set Speed and below Maximum Cruise Set Speed It is recommended that Max Cruise Set Speed be set to the default to allow proper operation of other features such as Fuel Economy Incentive and PasSmart The Vehicle Speed Limit should be used to limit vehicle throttle speed The Cruise Control cannot limit vehicle speeds on downgrades if available engine braking effort is exceeded nor can it maintain speed on upgrades if power requirements exceed engine power capability 41 DDC SVC MAN 0075 Copyright 2010 DETROIT DIESEL CORPORATION ELECTRONIC ENGINE CONTROL SYSTEM DDEC 10 When the SPD CNTL is in the ON position Cruise Control is engaged by momentarily contacting the SET CST Switch As a check after each engine start the electronic engine control looks for a one time activation of the clutch if equipped and service brake before it allows the Cruise Control to be enabled The Motor Control Module MCM must also recognize that the Cruise Enable Switch has changed If the Cruise Enable Switch is OFF it needs to be turned ON If the Cruise Enable Switch is ON it must be turned OFF then ON for cruise to operate Holding the switch in the SET CST position allows the vehicle to slow to a lower speed Toggling the switch will result in a one mile per ho
100. g the filter housing 4 104 Remove the filter element by pressing and twisting the side and detaching it from the cap Remove the oil filter O ring and discard Lightly coat a new O ring with clean engine oil and install it on the filter cap Check the filter housing for any debris and remove if necessary Insert a new filter element into the oil filter cap Insert the filter element and cap assembly into the housing Torque the cap to 40 50 Nm 30 37 lb ft Drain oil from the oil pan as follows a Place a suitable receptacle 48 L 50 qt or more beneath the oil drain plug on the underside of the oil pan b Carefully unscrew the oil drain plug and allow the oil to drain out o SS Inspect the plug seal ring for damage and replace if necessary 11 Install the oil drain plug Tighten the plug to 45 Num 33 lb ft Add new engine oil through the oil fill tube in the amount listed in the following table Verify the oil level reading is between the full and fill marks on the dipstick All information subject to change without notice DDC SVC MAN 0075 Copyright O 2010 DETROIT DIESEL CORPORATION EPAIO DD PLATFORM OPERATORS MANUAL NOTICE Do not add oil if the oil reading is between the crosshatch area on the dipstick There are approximately 3 8 L 4 0 qt from the fill mark to the full mark Overfilling the oil pan can cause engine damage Oil Chan
101. ge Quantities Oil Change Condition DI EE NOTICE 13 Check the filter housing for signs of leakage If no oil pressure is shown after approximately 10 seconds stop the 14 Stop the engine Check the oil engine and determine the cause level again per the following Running engine with no oil pressure guidelines If necessary add oil could result in engine damage no more than 3 8 L 4 0 qt at a time up to the maximum fill level on the oil dipstick 12 Start the engine with the accelerator pedal in the idle position Monitor the oil pressure gauge or indicator lamp Keep the engine running at idling speed until the oil pressure reading is 14 psi 97 kPa or more All information subject to change without notice 105 DDC SVC MAN 0075 Copyright 2010 DETROIT DIESEL CORPORATION HOW TO PROCEDURES NOTICE Do not add oil if the oil reading is between the crosshatch area on the dipstick There are approximately 3 8 L 4 0 qt from the fill mark to the full mark Overfilling the oil pan can cause engine damage NOTE If the engine operating temperature is below 60 C 140 F the engine must be on a level surface and then shut down for 60 minutes for an accurate oil level reading Otherwise the engine must be brought up to an operating temperature of 60 C 140 F parked on a level surface and then shut down for five minutes for an accurate oil level reading How to Select Diesel Fuel All DD Platform e
102. housing is a drain back port which allows residual oil to be returned to the oil pan when the filter is removed This design including the cartridge style element allows for a more environmentally safe oil change d200005 Perform the following maintenance on the Lubricating Oil Filter 88 Replace the oil filters when recommended by the appropriate maintenance table For EPA10 engines refer to section EPA10 Maintenance Tables For EPA07 engines refer to section EPA07 Maintenance Tables Make a visual check of all lubricating oil lines for wear and or chafing If any indication of wear is evident replace the oil lines and correct the cause Check for oil leaks after starting the engine Monitoring the Cooling System The cooling system must be full for proper operation of the engine All information subject to change without notice DDC SVC MAN 0075 Copyright 2010 DETROIT DIESEL CORPORATION EPAIO DD PLATFORM OPERATORS MANUAL AA WARNING HOT COOLANT To avoid scalding from the expulsion of hot coolant never remove the cooling system pressure cap while the engine is at operating temperature Wear adequate protective clothing face shield rubber gloves apron and boots Remove the cap slowly to relieve pressure 1 Check the coolant level daily and maintain it between the full and low marks on the surge tank 2 Add coolant as required but do not overfill Before adding
103. ide establishes preventive maintenance intervals These recommendations should be followed as closely as possible to obtain long life and optimum performance from your engine When performed on a regular basis changing the engine oil coolant and filters is the least costly way of obtaining safe and reliable vehicle operation Added benefits and savings occur when you check that the valves fuel injectors oil and cooling circuits are in good working order during oil changes The intervals shown apply only to the maintenance functions described These functions should be coordinated with other regularly scheduled maintenance Scheduled Maintenance Intervals Before placing your new vehicle in service determine the correct maintenance schedule application for your intended use of the vehicle Maintenance Schedule Applications There are three types of maintenance schedules for the On Highway Vehicle applications Severe Service Short Haul Service and Long Haul Service All information subject to change without notice Severe Service Severe service applies to vehicles that annually travel up to 30 000 miles 48 000 kilometers and average less than 5 miles per gallon or that operate under severe conditions Short Haul Short Haul service applies to vehicles that annually travel up to 30 000 60 000 miles 48 000 96 000 kilometers and average between 5 1 and 5 9 miles per gallon Long Haul Long Haul s
104. ing the Coolant Level Hot Check Check the coolant levels as follows 1 Allow the engine to run for approximately five minutes at a moderate speed 2 After the coolant temperature reaches 50 C 122 F recheck the coolant level in the surge tank 3 Add more coolant if necessary Open the heater valves before adding coolant All information subject to change without notice DDC SVC MAN 0075 Copyright 2010 DETROIT DIESEL CORPORATION EPAIO DD PLATFORM OPERATORS MANUAL AA WARNING HOT COOLANT To avoid scalding from the expulsion of hot coolant never remove the cooling system pressure cap while the engine is at operating temperature Wear adequate protective clothing face shield rubber gloves apron and boots Remove the cap slowly to relieve pressure 4 Do not close the heater valves until the engine has been run briefly and the coolant level again checked and corrected as necessary Monitoring Engine Operation While the engine is operating monitor the battery charge indicator light and the oil pressure Excessive idling should be avoided Monitoring the Battery Charging System The battery charge indicator light must go out once the engine starts If the indicator light comes on while the engine is running do the following 1 Shut down the engine All information subject to change without notice 2 Test the charging system per OEM guidelines AA WARNING BATTERY EXPL
105. ion at all times It contains important operating maintenance and safety instructions 11 Trademark Information DDC Detroit Diesel DDEC Optimized Idle Diagnostic Link BlueTec POWER Trac POWER COOL and POWER GUARD are registered trademarks of Detroit Diesel Corporation All other trademarks used are the property of their respective owners All information subject to change without notice DDC SVC MAN 0075 Copyright 2010 DETROIT DIESEL CORPORATION EPAIO DD PLATFORM OPERATORS MANUAL TABLE OF CONTENTS INTRODUCTION eege Eed 1 NON GENUINE AND REBUILT COMPONENT QUALITY ALERT 1 PERSONNEL REQUIREMENTS ie esse dee ee ee ee dee ee ee ee ee ee ee ede 2 ENGINE CONVERSIONS AND MODIFICATIONS nsee 2 CAUTION SUMMARY ee ed ee ee AR ee ee ee Re ee ee ee ee 3 ENGINE OPERATION 3 PREVENTIVE MAINTENANCE ees se ee see ee ee eed ee ee ee ee ee ee ee ge ee ee 5 COMPRESSED AIR iste lata ee ees ler Se be ee mila 7 Ve EE RO 7 ELECTRICAL SYSTEM Hi Ee GE we ee etree elite 8 AIRINTAKE SYSTEM ss ER di aia Ee eae 8 LUBRICATING OIL AND FILTERS 0 ese see ee ee ee ee ee ee ee ee ee 9 PUBL SYSTEM lucran bis 9 AFTERTREATMENT SYSTEM ees ee ee ee see ge ee dee ee see ee ee ee ee ee dee 10 DD PLATFORM ENGINE COMPONENTS 12 DD13 ENGINE COMPONENTS ese ese ee ee ee ee see ee ee ee ee ee ee ee ee 12 DD15 ENGINE COMPONENTS ese ese dee ee ee ieee ee ee ee ee ee ee 14 DD16 ENGINE COMPONENTS
106. ished blend meets the fuel properties ASTM Standard D975 or EN 590 specification 107 DDC SVC MAN 0075 Copyright 2010 DETROIT DIESEL CORPORATION HOW TO PROCEDURES Detroit Diesel is responsible for the materials and workmanship of its engines Failures attributed to the use of fuels which do not meet industry standards are not the fault of Detroit Diesel and will not be covered by Detroit Diesel product warranty While Detroit Diesel supports the use of B5 the use of unacceptable quality fuel that does not meet industry standards can result in warranty evocation Prohibited Additives The following fuel additives are not allowed and MUST NOT be mixed with diesel fuel Used Lubricating Oil Do not use fuel blended with used lubricating oil Detroit Diesel specifically prohibits the use of used lubricating oil in diesel fuel NOTICE Do not burn used lubricating oil in fuel It will cause the diesel particulate filter to prematurely plug with ash Used lubricating oil contains combustion acids and particulate materials which can severely erode fuel injector components resulting in loss of power and increased exhaust emissions In addition the use of 108 drained lubricating oil will increase maintenance requirements due to filter plugging and combustion deposits Gasoline The addition of gasoline to diesel fuel will create a serious fire hazard The presence of gasoline in diesel fuel
107. ith a formulated antifreeze or coolant Detroit Diesel Genuine Fluid Analysis This can result in dropout and or the 3 Way Test Strip formation of deposits e Test nitrite concentration Ethylene Glycol 20 000 miles 32 000 km with test strip Add SCA or Water or 3 months E dilute coolant as needed Conventional Drain and clean system Corrosion Inhibitor 300 000 miles 480 000 km GE y i Refill with new coolant si 300 000 miles 48 000 km Add POWER COOL Plus Ethylene Glycol Water OAT or 10 000 hours extender Inhibit 600 000 miles 960 000 km Drain and clean system ARI nor 4 years or Engine Overhaul Refill with new coolant Ethylene Glycol 990 000 miles 48 000 km Add NOAT extender Water NOAT Or 10 000 hours Inhibit 600 000 miles 960 000 km Drain and clean system ded aie 4 years or Engine Overhaul Refill with new coolant Test nitrite concentration Water Only 20 000 miles 32 000 km in test strip Add SCA or p 3 months or 500 hours Conventional dilute coolant as needed Corrosion Inhibitor Drain and clean system Engine Overhaul Sie Refill with new coolant 300 000 miles 480 000 km Add POWER COOL Plus Water Only OAT 2 years or 10 000 hours extender Inhibitor 600 000 miles 960 000 km Drain and clean system 4 years or Engine Overhaul Refill with new coolant 300 000 miles 480 000 km Water Only 2 years or 10 000 hours EE extender NOAT Inhibitor 600 000 miles
108. ive clothing and avoid sparks or flames near the battery If you come in contact with battery acid Flush your skin with water Apply baking soda or lime to help neutralize the acid Flush your eyes with water Get medical attention immediately All information subject to change without notice DDC SVC MAN 0075 Copyright 2010 DETROIT DIESEL CORPORATION EPAIO DD PLATFORM OPERATORS MANUAL Check for cracks in the battery cases 1 for tightness of the cable AA WARNING clamps 2 at the terminals and for corrosion of the terminals 3 Service or replace as needed To avoid injury from explosion never use ether with an engine s electrical cold starting system EXPLOSION EPA07 engines only An electrical grid heater is used as a cold weather starting aid if the ambient temperature is below 4 C 40 F To start the engine the transmission should be in neutral and the ignition key turned to ON AA WARNING ENGINE EXHAUST d540077 To avoid injury from inhaling engine exhaust always operate To provide corrosion protection the engine in a well ventilated apply dielectric grease liberally to area Engine exhaust is toxic the terminal pads First Time Start of the Engine Before starting the engine the first time perform an inspection of the engine systems Refer to section System Checks All information subject to change without
109. ix gasoline and diesel fuel 10 AA WARNING FIRE To avoid injury from fire caused by heated diesel fuel vapors Keep those people who are not directly involved in servicing away from the engine Stop the engine immediately if a fuel leak is detected Do not smoke or allow open flames when working on an operating engine Wear adeduate protective clothing face shield insulated gloves and apron etc To prevent a buildup of potentially volatile vapors keep the engine area well ventilated during operation Aftertreatment System Observe the following cautions when servicing the Aftertreatment System ATS Be advised that these two labels are attached to the Aftertreatment Device ATD All information subject to change without notice DDC SVC MAN 0075 Copyright 2010 DETROIT DIESEL CORPORATION EPAIO DD PLATFORM OPERATORS MANUAL A CAUTION EXTERNAL AND INTERNAL BSURFACE TEMPERATURES BREMAIN HOT AFTER ENGINE HAS BEEN SHUTDOWN PROTECTIVE CLOTHING REQUIRED WHILE SERVICING 47158 E EN NE EAVY DEV CE BPROPERLY SUPPORT AND g ATTACE LIFTING EQUIPMENT TO FREVEN THE DEVICE FROM FALL HO WH INSTALLING OR SERVICING 47157 All information subject to change without notice 11 DDC SVC MAN 0075 Copyright 2010 DETROIT DIESEL CORPORATION DD PLATFORM ENGINE COMPONENTS DD PLATFORM ENGINE COMPONENT
110. l an air inlet screen shield over the turbocharger air inlet The shield prevents contact with rotating parts AA WARNING FIRE Lubricating Oil and Filters To avoid injury from fire from a buildup of volatile vapors keep the engine area well ventilated Observe the following cautions when replacing the engine lubricating oil and filter during operation AA WARNING Fuel System Observe the following cautions when PERSONAL INJURY fueling the vehicle or working with To avoid injury from slipping and the fuel system falling immediately clean up any spilled liquids AA WARNING FIRE To avoid injury from combustion of heated lubricating oil vapors stop the engine immediately if an oil leak is detected All information subject to change without notice 9 DDC SVC MAN 0075 Copyright 2010 DETROIT DIESEL CORPORATION CAUTION SUMMARY AA WARNING FIRE To avoid injury from fire keep all potential ignition sources away from diesel fuel including open flames sparks and electrical resistance heating elements Do not smoke when refueling AA WARNING PERSONAL INJURY To prevent the escape of high pressure fuel that can penetrate skin ensure the engine has been shut down for a minimum of 10 minutes before servicing any component within the high pressure circuit Residual high fuel pressure may be present within the circuit AA WARNING FIRE To avoid increased risk of a fuel fire do not m
111. l filter or stand pipe may occur 1 Install a new final filter cap seal ring 2 Snap new final filter into the final filter cap 2 Pull the cap and final filter straight up and allow the fuel to drain back 3 Apply a light coat of petroleum based lithium grease to the cap seal ring 1 and to the 3 Remove the final filter 2 from lower seal on the final filter the final filter cap 1 by placing the filter on a solid surface and apply pressure on the final filter cap at an angle we d470021 4 Install the final filter into the fuel filter module d470020 5 Turn the cap counterclockwise f until a click sound is made then 4 Discard the filter turn clockwise and hand tighten 5 Inspect inside the housing for any 6 Torque final filter cap to large debris and clean if needed 55 60 Num 40 44 Ib ft 6 Discard final filter cap seal ring 7 Once all required filters have been changed prime the fuel system using the fuel priming valve or 1 10 All information subject to change without notice DDC SVC MAN 0075 Copyright 2010 DETROIT DIESEL CORPORATION EPAIO DD PLATFORM OPERATORS MANUAL the hand primer Refer to section Priming the Fuel System 8 Start the engine with the accelerator pedal in the idle position Monitor the oil pressure gauge or indicator lamp Keep the engine running at a idling speed until a stable oil pressure reading of 14 psi 97 kPa or more is
112. l go out 69 DDC SVC MAN 0075 Copyright 2010 DETROIT DIESEL CORPORATION AFTERTREATMENT SYSTEM Initiate DPF Switch When the parked regeneration request is accepted the Diesel Particulate Filter DPF Regeneration lamp will turn ON one time for one second and then turn off for the remainder of the parked regeneration The High Exhaust System Temperature HEST lamp will flash for one second every ten seconds and eventually become solid when the tailpipe temperature is above 525 C 977 F The engine speed will increase to 1100 RPM for all DD Platform engines The regeneration will take 30 40 minutes The regeneration is complete when the engine returns to low idle and the DPF lamp remains OFF The HEST lamp will remain ON but the vehicle may be driven NOTE A parked regeneration will STOP and the engine will return to low idle if any of the following happens The key is turned to the OFF position The vehicle is put into gear The clutch is cycled 70 DDC SVC MAN 0075 The parking brake is released EPA07 Hazardous Applications The MCM should be configured to not allow automatically triggered over the road regenerations DPF Manual Regen Only Enable Enabled NOTE This is for hazardous applications only There are two CPC options DPF Stationary Regen Only 0 Disabled DPF Stationary Regen Only 1 Enabled EPA07 DPF Stationary
113. ladder Air Bladder Refill bladder with air every 24 months Whichever comes first Detroit Diesel highly recommends replacing the DPF with a reliabilt DPF to ensure maximum replacement life Note DOC and SCR catalysts do not require maintenance tCurrently Davco is the only frame mounted filtration system compatible for Detroit Diesel Engines Inspect Davco at 50 000 miles 80 000 Diesel Particulate Filter All information subject to change without notice 79 DDC SVC MAN 0075 Copyright 2010 DETROIT DIESEL CORPORATION MAINTENANCE km and replace based on regular inspections or at 100 000 miles 160 000 km Refer to section Routine Preventive Maintenance for a description of all items R Replace Inspect service correct or replace as necessary NOTE Actual fuel filter life will vary based on fuel quality Short Haul Maintenance Intervals EPA10 Miles X 1000 35 70 105 140 175 Km X 1000 55 110 165 220 275 Hours 895 1795 2690 3590 4485 Procedure ptm Procedure O S OU LubricatingO R R ROT OR OR Lubricating Oil Fitter R R R R OR Refer to section How to Select Coolant Coolant for the listing of required intervals using the recommended coolants Cooling System Filter if equipped Fuel Filters without Frame mounted Filter reme ST RT AR TARTAR 5000 00 Separator imanes gt RI RI RI RIET Fuel Filters with Frame mounted Filter Frame mo
114. lant any time the cooling system is emptied and then refilled with coolant Organic Acid Technology An inhibitor system based on organic acid inhibitors instead of traditional North American inhibitor formulations Supplemental Coolant Additive Supplemental Coolant Additives are used in a preventive maintenance program to prevent corrosion cavitation and the formation of deposits Approved Coolants NOTICE Required specifications for water and To avoid engine damage from ethylene glycol inhibitor packages and inadequate or over concentrated inhibitor concentration are included in coolant the required specifications this section must be adhered to before the coolant is replaced The approved and preferred coolants for the engine are listed in the following table All information subject to change without notice 11 9 DDC SVC MAN 0075 Copyright 2010 DETROIT DIESEL CORPORATION HOW TO PROCEDURES Initial Fill Coolant Options Coolant Fill Option Ethylene Glycol amp Water Corrosion Inhibitors Ethylene Glycol amp Water Nitrited Organic Acid Technology Inhibitors Required Coolant Once installed this coolant should be maintained according to the recommended procedures Refer to section Maintenance Ethylene Glycol and Water Plus Supplemental Coolant Additive Inhibitor These products are available as fully formulated phosphate free Extended Service Interval coolants They are commerci
115. ld your road speed at or below the maximum vehicle speed The switch to energize Cruise Control is usually mounted on the instrument panel El Ea ED SET ENG Ger GELD BRK 47521 Turn the switch ON to energize the system Remember as a check after each engine start DDEC 10 looks for a one time activation of the clutch if equipped and service brake before DDEC 10 allows Cruise Control to be enabled DDEC 10 must also see or recognize that the Cruise Enable Switch has changed If the Cruise Enable Switch 50 is OFF it needs to be turned ON If the Cruise Enable Switch is left in the ON position at key OFF the switch must be cycled OFF then ON for DDEC 10 to see a status change to allow Cruise Control activation The status of DDEC 10 inputs to activate Cruise Control at key ON is listed in the following table All information subject to change without notice DDC SVC MAN 0075 Copyright 2010 DETROIT DIESEL CORPORATION EPAIO DD PLATFORM OPERATORS MANUAL Input Status to Activate Cruise Control Input Status Before Cruise Con trol Ac tivates Input Status at Service Brake Switch Clutch Release Switch Manual Trans only Cruise Control Enable Switch Once Cruise Control is enabled and you reach your road speed press the SET Switch to activate Cruise Control The cruise light will come on To increase road speed in one mile per hour 1 6 kilometer per hour increment
116. le vessel control the operator of a DDEC eduipped engine must not use or read any diagnostic tool while the vehicle vessel is moving On slippery roads wet pavement ice or snow covered roads loose gravel etc All information subject to change without notice 3 DDC SVC MAN 0075 Copyright 2010 DETROIT DIESEL CORPORATION CAUTION SUMMARY AA WARNING PERSONAL INJURY Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer birth defects and other reproductive harm Always start and operate an engine in a well ventilated area If operating an engine in an enclosed area vent the exhaust to the outside Do not modify or tamper with the exhaust system or emission control system AA WARNING PERSONAL INJURY To avoid injury from engine shutdown in an unsafe situation ensure the operator knows how to override the stop engine condition on a DDEC equipped unit A CAUTION LOSS OF VEHICLE CONTROL To avoid injury from loss of vehicle control do not activate the Engine Brake system under the following conditions On wet or slippery pavement unless the vehicle is equipped with ABS anti lock braking system and you have had prior experience driving under these conditions When driving without a trailer bobtailing or pulling an empty trailer If the tractor
117. level If necessary top off by filling engine oil no more than 3 8 L 4 0 qt at a time through the oil fill cap to the satisfactory fill range on the oil dipstick Do not overfill For lubricating oil recommendations refer to section How To Select Lubricating Oil Checking the Oil Level Check the oil level as follows 1 Check the oil level using the oil dipstick The oil level is measured using the crosshatch area on the dipstick If the oil reading is in the crosshatch area All information subject to change without notice DDC SVC MAN 0075 Copyright 2010 DETROIT DIESEL CORPORATION EPAIO DD PLATFORM OPERATORS MANUAL NOTICE Do not add oil if the oil reading is in the crosshatch area on the dipstick then the oil is at the proper level for engine operation NOTE If the engine operating temperature is below 60 C 140 F the engine must be on a level surface and then shut down for 60 minutes for an accurate oil level reading Otherwise the engine must be brought up to an operating temperature of 60 C 140 F parked on a level surface and then shut down for five minutes for an accurate oil level reading 2 If necessary top off by filling engine oil no more than 3 8 L 4 0 qt at a time through the oil fill cap to the satisfactory fill range on the oil dipstick Do not overfill For detailed procedures refer to section How To Replace the Lubricating Oil and Oil Filter in this manual D
118. ling ensure that engine using a steam cleaner or there is no standing water in high pressure washer with mild any electrical connectors before soap and warm water seating the plug How to Clean the Cooling System Avoid all of the electrical connections with direct water or steam spray or Important Collect the used coolant damage can result cleaning solutions and washing liquids and dispose of them in an environmentally responsible manner 3 Once the engine is clean blow the electrical connectors dry with compressed air to remove most of 1 First remove debris such as the standing water dust insects from the fins of the radiator grille Clean as follows 116 All information subject to change without notice DDC SVC MAN 0075 Copyright O 2010 DETROIT DIESEL CORPORATION EPAIO DD PLATFORM OPERATORS MANUAL Degreasing the Cooling System AA WARNING EYE INJURY Degrease as follows 1 Fill the cooling system with a 5 To avoid injury from flying debris solution 1 6 ounces per guart when using compressed air wear 50 grams per liter of water of adequate eye protection face a mildly alkaline cleaning agent shield or safety goggles and do such as sodium carbonate not exceed 276 kPa 40 psi air 2 Run the engine at moderate speed until the thermostat starts to open at an operating temperature of approximately 60 C 140 F Then run it for about five minutes NOTICE longer Shut down the engine a
119. ll engine openings including the exhaust outlet with moisture resistant tape Use cardboard plywood or metal covers where practical 19 Clean and dry the exterior painted surfaces of the engine and spray with a suitable liquid automobile body wax a synthetic resin varnish or a rust preventive compound 20 Protect the engine with a good weather resistant tarpaulin and store it under cover preferably in a dry building which can be heated during the winter months Outdoor storage of the engine is not recommended If units must be kept out of doors follow the preparation and storage instructions already given Protect units with quality weather resistant tarpaulins or other suitable covers arranged to provide for air circulation All information subject to change without notice DDC SVC MAN 0075 Copyright 2010 DETROIT DIESEL CORPORATION EPAIO DD PLATFORM OPERATORS MANUAL NOTICE Do not use plastic sheeting for outdoor storage Enough moisture can condense on the inside of the plastic to rust ferrous metal surfaces and pit aluminum surfaces If a unit is stored outside for any extended period of time severe corrosion damage can result NOTE Plastic is fine for indoor storage The stored engine should be inspected periodically If there are any indications of rust or corrosion corrective steps must be taken to prevent damage to the engine parts Perform a complete inspection at the end of one year a
120. llowing conditions Engine speed is lt 100 rpm and the Stop Engine Override Switch is put in the ON position 48 Idle Governor is active and the Stop Engine Override Switch is put in the ON position Vehicle speed is lt 3 mph and Parking Brake is activated and the Stop Engine Override Switch is put in the ON position The flashing code feature is deactivated once the Stop Engine Override Switch is returned to the OFF position or the listed conditions are no longer satisfied All information subject to change without notice DDC SVC MAN 0075 Copyright 2010 DETROIT DIESEL CORPORATION EPAIO DD PLATFORM OPERATORS MANUAL Only one light will be flashing codes at any time All codes will be flashed twice The inter digit pause is 1 5 seconds The pause between codes is 3 5 seconds The same 3 5 second pause occurs as the switch is made from RSL Stop Engine to AWL Check Engine RED RSL 1 FLASH 1 FLASH QQ 1 FLASH 1 FLASH OKO SHORT LONG SHORT LONG PAUSE PAUSE PAUSE PAUSE 1 2 SEC 1 1 2 SEC 1 2 SEC 1 1 2 SEC 2 CODE 2213 ACTIVE When code flashing is initiated the active codes will be flashed on the RSL Stop Engine Then the inactive codes will be flashed on the AWL Check Engine When all the inactive codes have been flashed the process of flashing all the active codes followed by all the inactive codes will repeat until the conditions for code flashing
121. loss of pulling power until the engine speed falls below rated speed In general when using a 7 or 9 speed transmission you should always downshift between 1150 and 1250 rpm for the DD13 and between 1000 and 1100 rpm for the DD15 This is true even on steep grades with heavy loads When using an 18 15 or 13 speed transmission you will need to downshift at an rpm that allows less than rated rpm before throttle application in the next gear down You may want to limit engine speed to 1900 rpm in all gears The DD13 engine provides horsepower through 2000 rpm but fuel economy is not as efficient above 1800 rpm The DD15 engine provides horsepower through 2100 rpm but fuel economy is not as efficient above 1800 rpm All information subject to change without notice Copyright 2010 DETROIT DIESEL CORPORATION EPAIO DD PLATFORM OPERATORS MANUAL If you decide to drive at a lower rpm for improved fuel economy don t let different engine noises throw you off guard The engine sounds quiet at 1400 rpm almost as if it had quit pulling Depending on the air intake arrangement you may also experience a chuffing sound as the engine starts to pull hard at lower rpm This is normal and caused by the velocity changes of the air flow within the air intake plumbing Electronic engines can actually deliver more fuel at lower engine speeds than at rated speed The engine has been designed for a very quiet operation but
122. ly V belts are used on the engine for On Highway Vehicle applications One belt drives the fan hub 3 and the other belt drives the remaining accessories To provide proper running tension the current engine uses an automatic fan hub belt tensioner 1 and an accessory belt tensioner 2 Automatic belt tensioners reguire no adjustment All information subject to change without notice Replacement of Belts Replace the drive belts every 2 000 hours or 300 000 miles 480 000 km Inspection of the Air Intake System Perform the following maintenance on the Air Intake System 1 Inspect all the connections in the air system to make sure they are tight and leak free 2 Check all hoses and ducting for punctures deterioration or other damage and replace if necessary Monitoring the Air Cleaner The engine is equipped with an engine mounted air cleaner that is flat in design to accommodate various vehicle packages 1 Inspect the air cleaner element every 50 000 miles 80 000 km 93 DDC SVC MAN 0075 Copyright 2010 DETROIT DIESEL CORPORATION MAINTENANCE or more often if the engine is operating under severe dust conditions Replace the element if necessary 2 Check the gaskets for deterioration and replace if necessary 3 If the dry type air cleaner is equipped with an aspirator check for aspirator damage or clogging Clean repair or replace as necessary NOTICE Do not allow the
123. ly destroyed To avoid equipment damage the following conditions must be met AA WARNING Battery Explosion and Acid Burn To avoid injury from battery explosion or contact with battery acid work in a well ventilated area wear protective clothing and avoid sparks or flames near the battery If you come in contact with battery acid Flush your skin with water Apply baking soda or lime to help neutralize the acid Flush your eyes with water Get medical attention immediately All information subject to change without notice Avoid grounding the output terminal Grounding an alternator output wire or terminal which is always hot regardless of whether or not the engine is running and accidentally reversing the battery polarity will result in equipment damage Do not reverse battery connections Never disconnect the battery while the alternator is operating Disconnecting the battery can result in damage to the battery diodes In applications which have two sets of batteries switching from one set to the other while the engine is running will momentarily disconnect the batteries If a booster battery is to be used batteries must be connected correctly negative to negative positive to positive Never use a fast charger with the batteries connected or as a booster for battery output For informatio
124. m Maintenance Products The following products are available to do maintenance on the cooling system Detroit Diesel Genuine Coolant Supplemental Coolant Additives Detroit Diesel Genuine Coolant Supplemental Coolant Additives are water soluble chemical compounds These products are available in coolant filter elements liquid packages and in fully formulated Detroit Diesel Genuine Coolant antifreeze 125 DDC SVC MAN 0075 Copyright 2010 DETROIT DIESEL CORPORATION HOW TO PROCEDURES Summary of Coolant Recommendations The Detroit Diesel coolant recommendations for the engine are AA WARNING HOT COOLANT To avoid scalding from the expulsion of hot coolant never remove the cooling system pressure cap while the engine is at operating temperature Wear adequate protective clothing face shield rubber gloves if less than 50 antifreeze is used The user is urged to use the full text of this section to determine the proper dosage Mixing of different manufacturers technologies brands could cause cooling system problems Maintain the inhibitor at the prescribed concentration Test the nitrite concentration by using a titration kit or Detroit Diesel Genuine Fluid Analysis 3 Way Coolant Test Strips Add Supplemental Coolant Additives only if the nitrite concentration is below 900 PPM apron and boots Remove the NOTE cap slowly to relieve pressure If the nitrite concentration exceeds
125. mp Perform a Parked Regeneration Solid Indicates that a OR bring vehicle to highway Regeneration may be speeds to enable Automatic needed Regeneration of the filter Flashing Indicates that a Regeneration is required as soon as possible Diesel Particulate Filter reaching system limits All information subject to change without notice 75 DDC SVC MAN 0075 Copyright 2010 DETROIT DIESEL CORPORATION DRIVER NOTIFICATIONS AND ACTIONS Notifications and Description Driver Action DPF Regeneration Lamp A Parked Regeneration must Check Engine Lamp be performed ENGINE DERATED If the Parked Regeneration exits Indicates the Diesel and the lamps remain on repeat FLASHING Particulate Filter has the Parked Regeneration If the reached system limits second attempt fails call for service DPF Regeneration Lamp A Parked Regeneration must Check Engine Lamp Stop be performed Engine Lamp If the Parked Regeneration exits ENGINE SHUTDOWN and the lamps remain on repeat FLASHING Indicates the Diesel the Parked Regeneration If the Particulate Filter has second attempt fails call for exceeded system limits service Note Engine can be restarted but a Parked Regeneration must be initiated within 30 seconds or the engine will shutdown He All information subject to change without notice DDC SVC MAN 0075 Copyright 2010 DETROIT DIESEL CORPORATION EPAIO DD PLATFORM OPERATORS MANUAL MAINTENANCE The following gu
126. mpering with the fuel injection system and engine electronics could also affect engine power output or exhaust emission levels Compliance with the manufacturer s settings and with statutory environmental protection regulations cannot then be guaranteed All information subject to change without notice DDC SVC MAN 0075 Copyright 2010 DETROIT DIESEL CORPORATION EPAIO DD PLATFORM OPERATORS MANUAL CAUTION SUMMARY The following cautions must be observed by the operator of the AA WARNING vehicle or eguipment in which this HOT EXHAUST engine is installed and or by those performing basic engine preventive maintenance Failure to read and heed these cautions and exercise reasonable care for personal safety and the safety of others when operating the vehicle eguipment or performing basic engine preventive maintenance may result in personal injury and engine and or vehicle eguipment damage 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 A CAUTION Engine Operation LOSS OF VEHICLE CONTROL operating the engine vehicle control do not use cruise control under these conditions When it is not possible to keep the vehicle at a constant speed on winding roads in heavy traffic in traffic that varies in speed etc AA WARNING PERSONAL INJURY To avoid injury from loss of vehic
127. n 7 Doser Block All information subject to change without notice 15 DDC SVC MAN 0075 Copyright 2010 DETROIT DIESEL CORPORATION DD PLATFORM ENGINE COMPONENTS DD16 Engine Components 3 5 d010100 1 Axial Power Turbine 4 Turbocharger 2 EGR Cooler 5 Crankcase Breather 3 EGR Valve Actuator 6 Fuel Doser Valve 16 All information subject to change without notice DDC SVC MAN 0075 Copyright 2010 DETROIT DIESEL CORPORATION EPAIO DD PLATFORM OPERATORS MANUAL d010101 1 Water Pump 8 Dual Stage Air Compressor 2 Oil Coolant Module 9 Power Steering Pump Location 3 Oil Filter 10 Fuel Filter Module 4 Fuel Rail under cover 11 Motor Control Module MCM 5 Air Intake Manifold 12 Thermostat 6 High Pressure Fuel Pump 13 Engine Serial Number Location 7 Doser Block All information subject to change without notice 17 DDC SVC MAN 0075 Copyright 2010 DETROIT DIESEL CORPORATION ENGINE MODEL AND SERIAL NUMBER DESIGNATION ENGINE MODEL AND SERIAL NUMBER DESIGNATION The following information covers engine model number serial number and certification label Engine Model and Serial Number The fourteen digit engine model and manufacturing serial number is etched on a pad located on the left front of the engine cylinder block above the date and time of manufacture Using 471901S0005703 as an example 471 engine type DD15 901 vehicle application Freightliner S assembly
128. n serious engine damage Be sure you are familiar with all of the instruments gauges and controls which are needed to operate the engine Note especially the location and function of the following Oil pressure gauge Low oil pressure warning light Coolant temperature gauge High coolant temperature warning light Water in fuel warning light in the side of the fuel filter module Air restriction indicator Watch for any signs of engine problems when starting or driving If the engine overheats uses excessive fuel or lubricating oil vibrates misfires makes unusual noises or All information subject to change without notice shows an unusual loss of power turn the engine off as soon as possible and determine the cause of the problem Engine damage may be avoided by a quick response to early indications of problems When starting the engine in cold weather refer to section How to Select Coolant System Checks Perform the following system checks before starting for the first time Checking the Cooling System Check the cooling system as follows 1 Make sure all drain cocks in the cooling system are installed drain cocks are often removed for shipping and are closed tightly 2 Fill the coolant overflow surge tank with Detroit Diesel Genuine Coolant until coolant level stays between the low and full coolant marks on the tank For more detailed recommendati
129. n idle shutdown or the Optimized Idle shutdown occurs At the start of every ignition cycle bulb check When an electronic system fault occurs Problem should be diagnosed as soon as possible Flashes when Engine Protection Shutdown occurs Diagnostic Request Switch is used to activate the RSL to flash active codes At the start of every ignition cycle bulb check A potential engine damaging fault is detected When a regeneration is At the start of every ignition required immediately if the cycle bulb check lamp flashing is ignored a Regeneration is required derate and or shutdown could occur At the start of every ignition cycle bulb check Flashes every 10 seconds Vehicle speed is less than when the DPF outlet reaches 5 mph and the DPF outlet a temperature greater than temperature is greater 525 C 977 F than 525 C 977 F At the start of every ignition cycle a bulb check For any emission related Never flashes fault light out when the fault is inactive All information subject to change without notice 73 DDC SVC MAN 0075 Copyright 2010 DETROIT DIESEL CORPORATION EPA10 DEF FLUID LEVEL WARNINGS LAMPS EPA10 DEF FLUID LEVEL WARNINGS LAMPS Four light bar segments indicate in engine performance In empty and DEF level in 25 increments Low ignore
130. n on the alternator assembly contact an authorized distributor depending on manufacturer Inspection of the Alternator Check the alternator as follows 1 Inspect the terminals for corrosion and loose connections and wiring 99 DDC SVC MAN 0075 Copyright 2010 DETROIT DIESEL CORPORATION MAINTENANCE for damage and frayed insulation Have wiring repaired or replaced as required 2 Check torque on alternator mounting bolts and bracketing every 30 000 miles 50 000 km Retighten if necessary Lubricating the Fan Hub If the fan bearing hub assembly has a grease fitting use a hand grease gun to lubricate the bearings with one shot of quality lithium based multipurpose grease every 120 000 miles 200 000 km Care should be taken not to overfill the bearing housing Checking the Vibration Damper Check the vibration damper as follows 1 Inspect the viscous vibration damper 1 periodically and replace if dented or leaking 100 2 Heat from normal engine operation may over a period of time cause the fluid within the damper to break down and lose its dampening properties For this reason replace the viscous vibration damper at time of normal major engine overhaul regardless of apparent condition All information subject to change without notice DDC SVC MAN 0075 Copyright 2010 DETROIT DIESEL CORPORATION EPAIO DD PLATFORM OPERATORS MANUAL HOW TO PROCEDURES This section covers
131. nd Clean at moderate air pressures allow it to cool to approximately only to avoid damaging the radiator 50 C 112 F grille fins pressure 3 Drain all the cleaning solution 2 Remove the debris by blowing them through with compressed air or spraying them out with water Work from the rear of the radiator in the opposite direction of the normal cooling air flow 3 Drain the coolant when the engine is cold For detailed procedures see the vehicle chassis maintenance manual For types of coolant refer to section How to Select Coolant for the listing of required intervals using the recommended coolants 4 If the HVAC unit is connected to the cooling system open the regulating valves all the way All information subject to change without notice 11 7 DDC SVC MAN 0075 Copyright 2010 DETROIT DIESEL CORPORATION HOW TO PROCEDURES AA WARNING HOT COOLANT To avoid scalding from the expulsion of hot coolant never remove the cooling system pressure cap while the engine is at operating temperature Wear adequate protective clothing face shield rubber gloves apron and boots Remove the cap slowly to relieve pressure 4 Flush the cleaning solution from the cooling system a Immediately after draining the cleaning solution flush the system with clean water b Once the clean water has drained fill the system again with clean water c Run the engine Allow the engine to warm up
132. nd apply additional treatment as required Procedure for Restoring to Service an Engine that Has Been in Extended Storage If an engine has been in extended storage prepare it for service as follows 1 Remove the covers and tape from all the openings of the engine fuel tank and electrical equipment Do not overlook the exhaust outlet 2 Remove the plugs from the inlet and outlet fuel lines and reconnect the lines to their proper positions All information subject to change without notice 3 Wash the exterior of the engine with fuel oil to remove the rust preventive Do not wash electrical components 4 Remove the rust preventive from the flywheel Flush any soluble oil rust inhibitor if used in the cooling system 5 Remove the paper strips from between the pulleys and drive belts 6 Fill the crankcase to the proper level with the required grade of lubricating oil Use a pressure lubricator to insure all bearings and rocker shafts are lubricated 7 Fill the fuel tank with the required fuel 8 Close all drain cocks and fill the engine cooling system with clean soft water and required inhibitors If the engine is to be exposed to freezing temperatures install genuine Detroit Diesel Power Cool antifreeze or an equivalent ethylene glycol base or propylene glycol base antifreeze solution which provides required freeze boil over and inhibitor protection Refer to section How to Select Coolant 9
133. nder these conditions 58 A CAUTION LOSS OF VEHICLE CONTROL To avoid injury from loss of vehicle control do not activate the Engine Brake system under the following conditions On wet or slippery pavement unless the vehicle is equipped with ABS anti lock braking system and you have had prior experience driving under these conditions When driving without a trailer bobtailing or pulling an empty trailer If the tractor drive wheels begin to lock or there is fishtail motion after the Engine Brake is activated deactivate the brake system immediately if this occurs NOTE On single trailers or combinations a light air application of the trailer brakes may be desirable to help keep the trailer stretched out Follow the manufacturer s recommended operating procedure when using your trailer brakes All information subject to change without notice DDC SVC MAN 0075 Copyright 2010 DETROIT DIESEL CORPORATION EPAIO DD PLATFORM OPERATORS MANUAL 2 If the vehicle is maintaining traction place the selective braking switch in the LOW position and turn ON the engine brake system If the drive wheels are maintaining traction and you desire greater slowing power move the braking switch to the next highest position However if the tractor drive wheels begin to lock or there is a fishtail motion turn the engine brake system OFF immediately and do not activate i
134. ners used 60 when the maximum allowable air restriction has been reached Cooling System A radiator thermo modulated fan cooling system is used on the engine This system has a centrifugal type coolant pump to circulate coolant within the engine One full blocking type thermostat located in the coolant module attached to the left side of the cylinder block controls the flow of coolant The coolant module incorporates the oil cooler oil filter coolant filter and coolant pump Electrical System The electrical system consists of a starting motor starting switch battery charging alternator storage batteries and necessary wiring Exhaust System Hot exhaust gas from the exhaust manifolds is used to drive the turbocharger All information subject to change without notice DDC SVC MAN 0075 Copyright 2010 DETROIT DIESEL CORPORATION EPAIO DD PLATFORM OPERATORS MANUAL Exhaust Gas Recirculation System The EGR system consists of an EGR cooler EGR valve and actuator The EGR actuator opens and closes the EGR valve to allow hot exhaust gas to enter the EGR cooler Heat is extracted from the exhaust gas resulting in cooler exhaust gas to the cylinders EGR lowers the temperature of the exhaust from the engine therefore reducing exhaust gas emissions to acceptable levels All information subject to change without notice 61 DDC SVC MAN 0075 Copyright 2010 DETROIT DIESEL CORPORATION AFTERTREATMENT SYSTE
135. nge without notice Copyright 2010 DETROIT DIESEL CORPORATION EPAIO DD PLATFORM OPERATORS MANUAL CUSTOMER ASSISTANCE The satisfaction and goodwill of the owners of Detroit Diesel engines are of primary concern to Detroit Diesel and its distributor dealer organizations Contact the Customer Support Center at 1 313 592 5800 Using Road Service in the U S or Canada If you require road service for any reason in the U S or Canada you may call the 1 800 445 1980 customer assistance phone number An operator will assist you in determining what type of service is required Not all problems are engine related and not all problems are covered by engine or vehicle warranties YOU MAY BE RESPONSIBLE FOR REPAIR EXPENSES Before calling Customer Assistance please do the following 1 Check the coolant level Check the fuel level Check the DDEC fuses Check for fuel leaks DD A UU N Make sure manual shutoff valve if installed on the fuel filter adaptor or fuel supply line is open 6 Check the oil level on the dipstick All information subject to change without notice 7 Check the diagnostic codes 8 If you call have the following information available Engine serial number e Vehicle make model and VIN e Odometer mileage kilometers or hour meter hours e Vehicle owner company name Availability of Detroit Diesel Service Outlets As the owner of a Detroit Diesel product you have a
136. ngines are designed to operate on Ultra Low Sulfur Diesel ULSD fuel ULTRA LOW SULFUR HIGHWAY DIESEL FUEL 15 ppm Sulfur Maximum Required for use in all model year 2007 and later highway diesel vehicles and engines Recommended for use in all diesel vehicles and engines 47705 106 DDC SVC MAN 0075 Quality Fuel quality is an important factor in obtaining satisfactory engine performance long engine life and acceptable exhaust emission levels In general fuels meeting the properties of ASTM Standard D 975 grades 1 D and 2 D have provided satisfactory performance The fuels used must be clean completely distilled stable and noncorrosive For more information regarding the significance of these properties and selection of the proper fuel All information subject to change without notice Copyright O 2010 DETROIT DIESEL CORPORATION EPAIO DD PLATFORM OPERATORS MANUAL NOTICE Use only Ultra Low Sulfur Diesel ULSD fuel 15 PPM sulfur content maximum based on ASTM Standard D 2622 test procedure Using fuel other than ULSD will damage the Aftertreatment Device Fuel Contamination Generally fuel contamination occurs as the result of improper fuel handling The most common types of contamination are water dirt and microbial growth black slime The formation of varnishes and gums resulting from poor stability or extended storage stale fuel also affects fuel quali
137. nnected by a proprietary datalink through which all necessary data and information can be exchanged The MCM monitors both the engine and the datalink When a malfunction or other problem is detected the system selects an appropriate response for example the emergency running mode may be activated The MCM processes the data received from the CPC for example the position of the accelerator pedal and engine brake All information subject to change without notice This data is evaluated together with the data from the sensors on the engine such as coolant and fuel temperature and oil and charge pressure The data is then compared to the characteristic maps or lines stored in the MCM From this data quantity and timing of injection are calculated The CPC broadcasts all information on datalinks A certified service center technician can access the CPC via the datalink using the Detroit Diesel Diagnostic Link DDDL electronic diagnostic tool The CPC communicates with the MCM unit installed on the vehicle over the proprietary datalink Data for specific applications is stored in the CPC Examples include idle speed maximum running speed and speed limitation The CPC receives data from several sources Examples include Accelerator pedal position engine brake switch Anti lock brake system and other electronic control units Oil pressure
138. ns a parked regeneration may need to occur The driver will be notified of the need for a Diesel Particulate Filter DPF regeneration by illumination of the DPF Regeneration Lamp The DPF Regeneration Lamp may illuminate after the vehicle has idled for an extended period of time NOTE If the DDEC electronics have not requested the initiation of a parked regeneration the DPF Regeneration Lamp is not illuminated the Regen request switch is disabled NOTE The driver MUST stay with the vehicle throughout the regeneration process All information subject to change without notice NOTE Not all vehicles may be equipped with a Regen request switch due to application or user specification NOTE The procedure will take 30 to 40 minutes depending on engine type and the amount of soot accumulated in the DPF To initiate a parked regeneration perform the following 1 Keep engine at slow idle cannot be in PTO mode 2 Transmission is in neutral with parking brake ON 3 Cycle the parking brake from OFF to ON NOTE Air tank pressure must be high enough for the parking brake switch to hold in the OFF position 4 Press and release clutch pedal if equipped with clutch pedal 5 Cycle transmission to DRIVE and back to NEUTRAL if not equipped with clutch pedal 6 Hold DPF Switch in the ON position for five 5 seconds and then release engine speed will increase and DPF Regeneration Lamp wil
139. o not overfill AA WARNING PERSONAL INJURY To avoid injury from slipping and falling immediately clean up any spilled liguids All information subject to change without notice There are approximately 3 8 L 4 0 qt from the fill mark to the full mark Overfilling the oil pan can cause engine damage SATISFACTORY OIL LEVEL RANGE Min seses Max UIT NN LOW FULL d180014a After an Extended Storage An engine in storage for an extended period of time over winter for example may accumulate water in the oil pan through normal condensation of moisture always present in the air on the cold internal surfaces of the engine NOTICE Failure to eliminate water diluted lubricating oil may lead to serious engine damage at startup Lubrication oil diluted by water cannot provide adequate bearing protection at engine startup For this reason Detroit Diesel recommends replacing the engine lubricating oil and filters after extended storage 23 DDC SVC MAN 0075 Copyright 2010 DETROIT DIESEL CORPORATION INSTRUCTIONS FOR STARTING THE ENGINE NOTICE Fuel System Checks Make sure the fuel shutoff valve if used is open Fill the tanks with the recommended fuel Keeping tanks full reduces water condensation and helps keep fuel cool which is important to engine performance Full tanks also reduce the chance for microbe black slime growth For fuel recommendations refer to s
140. oid injury from loss of vehicle control do not activate the Engine Brake system under the following conditions On wet or slippery pavement unless the vehicle is equipped with ABS anti lock braking system and you have had prior experience driving under these conditions When driving without a trailer bobtailing or pulling an empty trailer If the tractor drive wheels begin to lock or there is fishtail motion after the Engine Brake is activated deactivate the brake system immediately if this occurs Under normal driving conditions the engine brake system is left in the ON position However this should change if roads become wet or slippery All information subject to change without notice NOTICE Do not attempt to double clutch the transmission while the engine brake system is turned on Shifting gears without pressing the clutch or using the engine brake to reduce engine rpm may result in serious powertrain damage After it is switched on the engine brake system is automatically activated each time you remove your feet completely from the clutch pedal and accelerator pedal The engine brake automatically deactivates itself when you press the clutch pedal while shifting gears NOTE Some systems may be programmed to activate themselves only when the brake pedal is pressed so read your vehicle owner s manual thoroughly to find out if you have this option
141. ommends CJ 4 oil and will allow CI 4 Plus oil having sulfated ash levels of 1 4 or less NOTICE Not following the operating requirements may result in damage to the ATD or accelerated ash plugging of the diesel particulate filter EPA10 Diesel Exhaust Fluid Tank The Diesel Exhaust Fluid DEF tank holds the DEF supply The filler neck has a smaller diameter 19 mm than the filler neck of the diesel fuel tank and is fitted with a magnetic insert so that diesel fuel cannot be mistakenly added to the DEF tank 67 DDC SVC MAN 0075 Copyright 2010 DETROIT DIESEL CORPORATION AFTERTREATMENT SYSTEM The DEF you should use with your Detroit Diesel product will be API American Petroleum Institute certified and meet the specifications ISO 22241 1 and DIN70700 These are two widely accepted standards in use for qualifying DEF for use in exhaust aftertreatment systems DEF Diesel Exhaust Fluid will be sold at over 2 500 locations throughout North America These include Detroit Diesel Distributors Freightliner Truck Dealers Western Star Truck Dealers Travel Centers of America Truck Stops Petro Stopping Centers Pilot Travel Centers If diesel fuel is added to the DEF tank or DEF is added to the diesel fuel tank immediately contact your Certified Detroit Diesel Service Center for further instructions Maintenance A high amount of black smoke emit
142. ons see the How to Select Coolant section in this manual 3 Entrapped air must be purged after filling the cooling system To do this allow the engine to warm up with the pressure cap 21 DDC SVC MAN 0075 Copyright 2010 DETROIT DIESEL CORPORATION INSTRUCTIONS FOR STARTING THE ENGINE NOTICE Insufficient lubrication at startup can cause serious damage to engine components removed With the transmission in neutral increase engine speed to 1000 rpm and add coolant to the surge tank as required 4 Check to make sure the front of the radiator and charge air cooler if equipped are unblocked and free of debris Lubrication System Checks The lubricating oil film on the rotating parts and bearings of a new or newly overhauled engine or one which has been in storage for six months or more may be insufficient when the engine is started for the first time Pre lubricating the Engine To ensure an immediate flow of oil to all bearing surfaces at initial engine startup prepare the engines as follows 1 Charge the engine lubrication system with lubricating oil using a commercially available pressure pre lubricator 22 Do not add oil if the oil reading falls on the crosshatch area of the dipstick There are approximately 3 8 L 4 0 qt from the fill mark to the full mark Overfilling the oil pan can cause engine damage 2 After pre lubricating check the engine oil
143. or Parallel port 1 free USB port Internet or Mainframe Connection to DDC Server for updates Translator Boxes Detroit Diesel Multilink Nexiq Magic Key Nexig USB Link EPAIO DD PLATFORM OPERATORS MANUAL Recom mended Hard ware Windows 2000 or Windows XP Pentium 4 1 5 GHz 512 MB RAM 40 Gigabyte Hard Drive with 5 Gigabytes free 32 x CD DVD ROM Monitor and graphics card supporting 1280 x 1024 resolution and 32 bit color Parallel port or 3 free USB ports Internet or Mainframe Connection to DDC Server for updates Translator Box Nexiq USB Link All information subject to change without notice DDC SVC MAN 0075 Copyright 2010 DETROIT DIESEL CORPORATION Engine Brake The engine brake is enabled by a dash mounted ON OFF Switch with a separate intensity switch to select low medium or high braking power 43 ELECTRONIC ENGINE CONTROL SYSTEM DDEC 10 A CAUTION LOSS OF VEHICLE CONTROL To avoid injury from loss of vehicle control do not activate the Engine Brake system under the following conditions On wet or slippery pavement unless the vehicle is equipped with ABS anti lock braking system and you have had prior experience driving under these conditions When driving without a trailer bobtailing or pulling an empty trailer If the tractor drive wheels begin to lock or there is fishtail motion after the Engine Brake is
144. or Vehicle Speed Mode and maintain a targeted speed mph or rpm by increasing or decreasing fueling The targeted speed can be selected and adjusted with dash mounted switches El Ea ENG BRK SETI CST S 47521 Cruise Control may also be programmed to permit fast idle using the Cruise Control switches All information subject to change without notice DDC SVC MAN 0075 Copyright 2010 DETROIT DIESEL CORPORATION EPAIO DD PLATFORM OPERATORS MANUAL With the engine at normal idle transmission in neutral and service brakes on press the SPD CNTL Switch and use the RSM ACC Switch The engine rpm should increase to a predefined speed The engine rpm can be raised or lowered from this point using the SET CST and RSM ACC switches Cruise Control will maintain the set speed under normal road and load conditions A CAUTION LOSS OF VEHICLE CONTROL To avoid injury from the loss of vehicle control do not use cruise control under these conditions When it is not possible to keep the vehicle at a constant speed on winding roads in heavy traffic in traffic that varies in speed etc On slippery roads wet pavement ice or snow covered roads loose gravel etc All information subject to change without notice NOTICE When descending a hill with Cruise Control OFF do not allow the engine to exceed 2300 rpm Failure to observe this can result in over speedin
145. ously affect engine performance and may cause engine damage Adding Fuel When adding fuel pay attention to the following All information subject to change without notice DDC SVC MAN 0075 Copyright 2010 DETROIT DIESEL CORPORATION EPAIO DD PLATFORM OPERATORS MANUAL NOTICE Always use Ultra Low Sulfur Fuel ULSF with 15 PPM sulfur content or less based on ASTM Standard D 2622 test procedure Higher sulfur levels will damage the Engine Aftertreatment System Add winter or summer grade fuel according to the season of the year Work in the cleanest conditions possible Prevent water from entering the fuel tank For further information refer to section How to Select Diesel Fuel Priming the Fuel System Prime the fuel system as follows 1 Operate the hand primer on module for three minutes or 250 strokes or use an external priming source such as tool J 47912 or ESOC 350 2 Crank the engine for 20 seconds 3 Wait 60 seconds for starter cool down 4 If engine does not start repeat step 2 and step 3 The starting cycle can be repeated up to three times All information subject to change without notice 5 If engine still fails to start continue as follows a Use DDDL to check for fault codes repair as necessary b Repeat step 2 and step 3 NOTICE If no oil pressure is shown after approximately 10 seconds stop the engine
146. ow to Select Coolant 3 Coolant for the listing of required intervals using the recommended coolants 4 Cooling System Filter Fuel Filters NEE EEN e TR e e e e ee Coalescer Water Separator Prarie Tefal e e e a ry Adjust at 60 000 mi 100 000 km at 180 000 mi 300 000 km and then at every 180 000 mi 300 000 km or nearest maintenance interval a OO RR EE WE WEE E 8 Airsystem LIT 9 arciesner ITT 10 Exhaust system CTT Inspect external hardware and connections at every oil change Remove ash at 300 000 miles 480 000 km or 9 000 hours ER O E ELA A E EA E Whichever comes first All items are described in Routine Preventive Maintenance R Replace Inspect service correct or replace as necessary Initial Valve Lash Adjustment Aftertreatment Device All information subject to change without notice 85 DDC SVC MAN 0075 Copyright 2010 DETROIT DIESEL CORPORATION MAINTENANCE Long Haul Service Maintenance Intervals EPA07 Miles X 1000 50 100 150 200 250 300 Km X 1000 80 160 240 320 400 480 Hours 1280 2565 3845 5125 6410 7690 i Libreatngor R TR TR RR R 2 Lubricating outer R R R R R jr Refer to section How to Select Coolant 3 Coolant for the listing of required intervals using the recommended coolants 4 Cooling System Filter rR I ee eee EE Fuel Filters ret CO TR RIA A AA eee Separator
147. plant Detroit Diesel 0005703 serial number d000027 Engine Serial Number The MCM part number and engine serial number is located on the MCM label il i mem N A00544631 Engine Certification Label A certification exemption label is attached to the valve rocker cover This label certifies that the engine conforms to federal and certain state emissions regulations for its particular application It also gives the operating conditions under which certification was made The following illustration is an EPA07 certification exemption label All information subject to change without notice DDC SVC MAN 0075 Copyright 2010 DETROIT DIESEL CORPORATION EPAIO DD PLATFORM OPERATORS MANUAL Important Engine Information This engine conforms to U S EPA and California regulations applicable to 2007 model year new heavy duty engines This engine has a primary intended service application as a heavy duty engine This engine is not certified for use in an urban bus as defined at 40 CFR 86 093 2 Sale of this engine for use in an urban bus is a violation of federal law under the Clean Air Act This engine is certified to operate on ultra low sulfur diesel fuel Fuel rate at adv Hp mma stroke Adv Hp Valve Lash Initial injection timing deg Bic Disp Exhaust Engine Family Min Idle Intake Model Mfg Date Unit 47716 All information subject to change without notice 19 DDC SVC MAN 00
148. ressure Equipment Use the high pressure cleaning equipment as follows 1 Information on suitable cleaning and protective products is available from any authorized dealer Note the equipment manufacturer s operating instructions NOTICE To prevent damage to engine components keep the water moving at all times while cleaning Never direct water onto electrical components plug connectors seals or flexible hoses 2 Use the following minimum working distance between the high pressure nozzle and the surface being cleaned 115 DDC SVC MAN 0075 Copyright 2010 DETROIT DIESEL CORPORATION HOW TO PROCEDURES amp caution b WARNING EYE INJURY EYE INJURY To avoid injury from flying debris when using compressed air wear adequate eye protection face shield or safety goggles and do not exceed 276 kPa 40 psi air pressure To avoid injury from flying debris wear a face shield or goggles e Approximately 28 in 700 mm for circular pattern jets e Approximately 12 in 300 mm for 25 degree flat jets and NOTE dirt cutters Do not use compressed air or pressurized water to clean or dry the Cleaning the Engine engine if any part of the engine is disassembled Power clean the engine as follows 1 Allow engine to cool down to 4 Allow the engine to dry room temperature before spraying completely before making the engine any kind of repair 2 Thoroughly clean the entire 5 When reassemb
149. right 2010 DETROIT DIESEL CORPORATION EPAIO DD PLATFORM OPERATORS MANUAL Monitoring the Cooling System Filter Install a new cooling system filter at the distance intervals indicated by each specific Maintenance Interval chart Refer to Scheduled Maintenance Intervals Monitoring the Fuel Filters The engine is equipped with a prefilter that filters down to 100 microns a water separator coalescer that separates water and a final filter which filters material from 3 to 5 microns The final filter is 98 effective at filtering material at 5 microns When servicing these elements all three filters should be changed at the same time All three elements are located within the fuel filter module located on the left side of the engine 1 Located at the base of the fuel filter module is a water level sensor Check the water level sensor each day 2 When water level reaches a predetermined height the LED indicators on the front of the sensor change from green to red At this time remove the water from the module by opening the water drain valve at the bottom of the module 3 Replace the fuel filters using the Maintenance All information subject to change without notice Tables schedule For EPA10 engines refer to section EPA10 Maintenance Tables For EPA07 engines refer to section EPA07 Maintenance Tables NOTE Filter change intervals may be shortened to conform with established preventive maintenance sch
150. rop below 78 psi 540 kPa at 1800 rpm and normal operating pressure should be higher If oil pressure does not fall within these guidelines check it with a manual gauge All information subject to change without notice AA WARNING HOT OIL To avoid injury from hot oil do not operate the engine with the rocker cover s removed Warming Up the Engine Run the engine at part throttle for about five minutes to allow it to warm up before applying a load Inspection During Idling While the engine is idling inspect the transmission and crankcase for fluid leaks On DD15 and DD16 engines check the APT for oil leaks Checking the Transmission While the engine is idling check the automatic transmission if equipped for proper oil level and add oil as required Checking for Fluid Leaks Check for fluid leaks as follows 1 Look for coolant fuel or lubricating oil leaks 2 If any leaks are found shut down the engine immediately and have the leaks repaired after the engine has cooled 29 DDC SVC MAN 0075 Copyright 2010 DETROIT DIESEL CORPORATION Checking the Crankcase Check the crankcase as follows 1 If the engine oil was replaced stop the engine after normal operating temperature has been reached Allow the oil to drain back into the crankcase for about 60 minutes then check the oil level 2 Ifnecessary add oil no more than 3 8 L 4 0 qt at a time to bring the level to the proper m
151. s press the RSM ACC Switch To reduce road speed press and hold the SET CST Switch until the lower speed is reached Cruise Control is deactivated by slightly pressing the service brakes All information subject to change without notice clutch pedal or trailer brake The ON OFF Switch will also deactivate Cruise Control Cruise Control will maintain vehicle speed even on upgrades unless power requirements demand a downshift If the Cruise Control Engine Brake function is turned ON the Cruise Control will limit your speed on downgrades Most likely Cruise Control will feel stronger than driving with the accelerator pedal because of the instantaneous and wide open throttle response That s why Cruise Control use is not suggested during slippery driving conditions Use Cruise Control after downshifting on a hill to pull the hill Hitting the RSM ACC Switch not the SET Switch will keep the truck accelerating in the lower gears up to the rated engine speed Cruise Control will disengage below 1000 rpm or 20 mph 32 kph road speed When using Cruise Control if you want to pull the engine below 1000 rpm remember to hold the accelerator pedal to the floor to keep the engine pulling at wide open throttle The engine will pull down to about 1050 rpm 51 DDC SVC MAN 0075 Copyright 2010 DETROIT DIESEL CORPORATION ELECTRONIC ENGINE CONTROL SYSTEM DDEC 10 Remember The electronic data programmed into the DD
152. sed in On Highway Vehicle applications Non Genuine and Rebuilt Component Quality Alert Electronic engine controls have been instrumental in aiding engine manufacturers in meeting the stringent emission requirements of the U S Environmental Protection Agency EPA and the California Air Resources Board CARB and also in meeting the ever increasing performance demands of the customer Maintenance procedures must be followed in order to continue satisfactory performance and durability and to ensure coverage of the engine under the manufacturer s warranty Many of these maintenance procedures also ensure that the engine continues to comply with applicable emissions standards Proper maintenance procedures using specific components engineered to comply with emissions regulations may be performed by an authorized Detroit Diesel distributor or dealer an independent outlet or the operator or owner The owner is responsible for determining the suitability of components to maintain emissions All information subject to change without notice compliance during the engine s useful emission life Detroit Diesel cautions that the indiscriminate rebuilding of precision components without the benefit of specifications specialized equipment and knowledge of the electronic operating system will jeopardize performance or lead to more serious problems and can take the engine outside of compliance with U S EPA or CARB emissions
153. st is toxic All information subject to change without notice DDC SVC MAN 0075 Copyright 2010 DETROIT DIESEL CORPORATION EPAIO DD PLATFORM OPERATORS MANUAL AA WARNING PERSONAL INJURY To avoid injury when working near or on an operating engine remove loose items of clothing and jewelry Tie back or contain long hair that could be caught in any moving part causing injury Starting the Engine Routinely Before a routine start see the daily checks for your engine in the Maintenance section of this manual NOTICE Before starting the engine carefully read all operating instructions in this manual and do all the recommended pre trip inspections and daily maintenance Check the coolant engine oil and fuel levels and drain contaminants from the water separator coalescer Start the engine as follows NOTE If you drain water from the water separator coalescer you have to prime the fuel system with the built in hand primer about 50 strokes Refer to section Priming the Fuel System All information subject to change without notice NOTE As a Safety function the electronic engine control system may be wired to start the engine only If the transmission is in neutral This feature is vehicle application specific 1 Turn on the ignition switch 2 With the accelerator pedal in the idle position start the engine 3 Check the engine for leaks a Check all hoses hose clamps
154. standards There are several other components in an engine such as turbocharger camshaft piston fuel doser valve fuel doser block diesel particulate filter DPF diesel exhaust fluid pump for EPA10 engines which are specifically designed and manufactured to exacting standards for emissions compliance It is important that these components if replaced modified or substituted can be verified to ensure that the engine remains in compliance with emissions standards The use of inadequately engineered manufactured or tested components in repair or rebuild of the engine may be in violation of the federal Clean Air Act and applicable U S EPA or CARB regulations DDC SVC MAN 0075 Copyright 2010 DETROIT DIESEL CORPORATION INTRODUCTION Furthermore modern engines exhibit operating parameters which require the use of proper fluids such as fuel coolant and lubricating oil to maintain long engine life The use of fluids that do not meet Detroit Diesel specifications may result in premature wear or engine failure Personnel Requirements Work on the engine should be carried out only by skilled technicians who have been instructed in the specific skills necessary for the type of work being performed Engine Conversions and Modifications The function and safety of the engine could be affected if unauthorized modifications are made to it Detroit Diesel will not accept responsibility for any resulting damage Ta
155. subject to change without notice DDC SVC MAN 0075 Copyright 2010 DETROIT DIESEL CORPORATION EPAIO DD PLATFORM OPERATORS MANUAL correct by using Detroit Diesel Genuine Fluid Analysis 3 Way Coolant Test Strip If chemical analysis is used elements in the coolant must fall within the following limits little freeze and or corrosion protection and is not recommended 3 Always verify that the freeze point and nitrite concentration of the antifreeze water mixture are Fully Formulated Glycol Coolant Concentration Limits with TMC RP 329 Chemistry Type A 50 50 Coolant Water Mixture Water Requirements Distilled reverse osmosis purified or de ionized water which eliminates the adverse effects of minerals in tap water is preferred High levels of dissolved chlorides sulfates magnesium and calcium in some tap water causes scale deposits and or corrosion resulting in water pump failures and poor heat transfer leading to overheating If tap water is used the mineral content in the water must be below the following maximum allowable limits eee eee Total Hardness All information subject to change without notice 121 DDC SVC MAN 0075 Copyright 2010 DETROIT DIESEL CORPORATION HOW TO PROCEDURES NOTICE Coolant Maintenance Do not add additional supplemental coolant additives to new fully Intervals Check the nitrite concentration at the regular intervals listed in the following table w
156. t 100 000 miles 160 000 km Refer to section Routine Preventive Maintenance for a description of all items R Replace l Inspect service correct or replace as necessary NOTE Actual fuel filter life will vary based on fuel quality All information subject to change without notice 81 DDC SVC MAN 0075 Copyright O 2010 DETROIT DIESEL CORPORATION MAINTENANCE Long Haul Maintenance Intervals EPA10 Miles X 1000 50 100 150 200 250 300 Km X 1000 80 160 240 320 400 480 Hours 1280 2565 3845 5125 6410 7690 Procedure prem Procedure S S O Lubricating ot OR RR OR RT OR Lubricating oit Fiter R R_ R R R R_ Refer to section How to Select Coolant Coolant for the listing of required intervals using the recommended coolants Cooling System Filter if equipped Fuel Filters without Frame mounted Filter ese RR RTARTA R e EEE Separator rare RR RR RIET Fuel Filters with Frame mounted Filter Fuel Den with Frame mounted Fiter framemeunes ries R RTARTA AR R WETEN EE EE PR Pt RR Ser TD Te Separator C erare i fs EE CO O aR Adjust at 100 000 miles 160 000 km at 500 000 Valve Lash Adjustment miles 800 000 km and then every 500 000 miles 800 000 km thereafter EEN e ONE TR LEEN HEEN HEEN HEEN HEEN HEEN HEES ICO tf HEEN EEN HEEN HEES EEN EEN fi fi fs fr ft 82 All information subject to change without notice DDC SVC
157. t until road conditions improve Check your progressive braking switch often for proper position LOW MED HIGH since road conditions can change quickly Never skip a step when operating the progressive braking system Always go from OFF to LOW and then to a higher position All information subject to change without notice DDC SVC MAN 0075 Copyright 2010 DETROIT DIESEL CORPORATION 59 ENGINE SYSTEMS ENGINE SYSTEMS Fuel System The fuel system consists of DDEC 10 control system common rail fuel injectors low and high pressure pumps fuel filter module prefilter water separator coalescer final filter and the necessary connecting fuel lines The common rail system with injectors provides amplification for better fuel atomization Lubrication System The lubrication system consists of an oil pump oil cooler cartridge style oil filter pressure regulator valve and oil pressure sensor Clean pressurized oil is fed to all components via passages in the engine block and cylinder head Air System Outside air enters the engine through the air filter and is drawn to the turbocharger and then is compressed and forced through the air to air charge cooler heat exchanger and is cooled Next it flows to the intake manifold and into the cylinders where it mixes with atomized fuel from the injectors For optimum engine protection from dust and other airborne contaminants service the dry type air clea
158. tery or working with the To avoid injury from accidental vehicle application electrical system engine startup while servicing the engine disconnect disable the starting system AA WARNING ELECTRICAL SHOCK Air Intake System To avoid injury from electrical shock do not touch battery terminals alternator terminals or wiring cables while the engine is _ A WARNING PERSONAL INJURY To avoid injury from hot surfaces WARNING wear protective gloves or allow engine to cool before removing Battery Explosion and Acid Burn any component Observe the following cautions when working on the air intake system To avoid injury from battery explosion or contact with battery acid work in a well ventilated area wear protective clothing and avoid sparks or flames near the battery If you come in contact with battery acid Flush your skin with water Apply baking soda or lime to help neutralize the acid Flush your eyes with water Get medical attention immediately 8 All information subject to change without notice DDC SVC MAN 0075 Copyright 2010 DETROIT DIESEL CORPORATION EPAIO DD PLATFORM OPERATORS MANUAL AA WARNING AA WARNING PERSONAL INJURY FIRE To avoid injury from contact To avoid injury from fire do not with rotating parts when an smoke or allow open flames when engine is operating with the air working on an operating engine inlet piping removed instal
159. ting from the vehicle or illumination of the Amber Warning Lamp or Red Stop Lamp are indications of a system problem Should this occur consult your local Detroit Diesel Service Center 68 Illumination of the Malfunction Indicator Lamp MIL Lamp indicates a failure of an emissions control device The MIL may illuminate along with other ATS warning lamps Call for service to repair the fault Illumination of the Diesel Particulate Filter DPF Regeneration Lamp indicates that a parked regeneration is required There is a need to periodically remove accumulated ash derived from engine lube oil from the filter This ash does not oxidize in the filter during the regeneration process and must be removed through a cleaning procedure All Detroit Diesel ATD equipped engines will illuminate a dashboard warning lamp indicating the need for ash cleaning All information subject to change without notice DDC SVC MAN 0075 Copyright 2010 DETROIT DIESEL CORPORATION EPAIO DD PLATFORM OPERATORS MANUAL Parked Regeneration Procedure Regeneration of the ATS is fundamental for the oxidation of soot This process happens during the normal operation cycle of the vehicle it can occur both passively and actively Regardless of this the operator will see no difference in vehicle performance or vehicle control If the ATS is not capable of completing an over the road regeneration due to duty cycle constraints or other restrictio
160. ty The best treatment for contamination is prevention by maintaining a clean storage system and choosing a reputable fuel supplier Supplemental additives are not recommended due to potential injector system or engine damage Our experience has been that such additives increase operating costs without providing benefit The use of supplemental fuel additives does not necessarily void the engine warranty However repair expenses which result from fuel system or engine component malfunctions or damage attributed to their use will not be covered All information subject to change without notice These products should be accompanied by performance data supporting their merit as well as the warranty statement It is not the policy of Detroit Diesel to test evaluate approve or endorse such products Biodiesel Fuel Detroit Diesel supports biodiesel as a renewable fuel Biodiesel fuels are mono alkyl esters of long chain fatty acids commonly referred to as Fatty Acid Methyl Esters and are derived from renewable resources through a chemical process called transesterification Detroit Diesel approves the use of biodiesel fuel blends up to 5 maximum by volume in diesel fuel providing the following three conditions are met The biodiesel used in the blend meets ASTM Standard D6751 or EN 14214 specification The biodiesel used in the blend is sourced from a BQ 9000 Accredited Producer The fin
161. ubricating oil hose assemblies do not require automatic replacement after five years of service or at major overhaul but should be inspected carefully before being put back into service Inspection of Turbocharger and Charge Air Cooler Inspect turbocharger and charge air cooler as follows All information subject to change without notice 1 Visually inspect the turbocharger mountings intake and exhaust ducting and connections for leaks daily N Check the lubricating oil inlet and outlet lines for leaks or restrictions to oil flow AA WARNING PERSONAL INJURY To avoid injury from hot surfaces wear protective gloves or allow engine to cool before removing any component 3 Check the turbocharger for unusual noise or vibration and if excessive stop the engine and do not operate until the cause is determined 4 Periodically inspect the air to air charge air cooler for buildup of dirt mud or other debris Clean as necessary 5 Check the charge air cooler duct work and flexible connections for leaks and repair or replace as required Inspection of the Battery Inspect the battery as follows 1 Check for cracks in the battery cases 1 for tightness of the 97 DDC SVC MAN 0075 Copyright 2010 DETROIT DIESEL CORPORATION MAINTENANCE cable clamps 2 at the terminals and for corrosion of the terminals 3 Service or replace as needed d540077 AA WARNING PERSONAL INJURY
162. untedFitert R R R R R TE DEE SC ER E ER Coalescer Water Separator 80 All information subject to change without notice DDC SVC MAN 0075 Copyright 2010 DETROIT DIESEL CORPORATION EPAIO DD PLATFORM OPERATORS MANUAL Short Haul Maintenance Intervals EPA10 ora Haul Maintenance Intervals EPAI0 ie ee aed Adjust at 100 000 miles 160 000 km at Valve Lash Adjustment 500 000 miles 800 000 km and then every 500 000 miles 800 000 km thereafter NE EENS WS airsystem EN EN ENE por poto ot Air cleaner tr pro poto ot Exhaust System tT ot poto ot Inspect external hardware and connections Aftertreatment Device every 6 months or at oil change intervals A Check Engine Light will illuminate when ash requires removal Normal DPF Diesel Particulate Filter ash clean intervals are 300 000 miles 480 000 km 9 000 hours to 400 000 miles 640 000 km 10 250 hours A Replace filter every 175 000 miles DEF Pump Filter 280 000 km DEF DEF Pump Air Bladder Air Bladder Refill bladder with air every 24 months Whichever comes first Detroit Diesel highly recommends replacing the DPF with a reliabilt DPF to ensure maximum replacement life Note DOC and SCR catalysts do not require maintenance TCurrently Davco is the only frame mounted filtration system compatible for Detroit Diesel Engines Inspect Davco at 50 000 miles 80 000 km and replace based on regular inspections or a
163. ur 1 6 kph decrease in vehicle speed If Cruise Control has been disabled toggling the RSM ACC Switch restores the vehicle to the previously set cruise speed Cruise Control can be overridden at any time with the accelerator pedal if the vehicle is operating at less than the programmed Max Road Speed Additionally using either the brake or the clutch will disable Cruise Control Data Recording Capability The electronic engine control system DDEC 10 contains the ability to extract detailed data on engine use and 42 performance using DDEC Reports software This detailed data or DDEC Data is stored in the CPC and contains information on engine performance such as fuel economy idle time and time in top gear Critical incidents such as detailed diagnostic data records and hard braking events are also stored DDEC Data can be downloaded using DDEC Reports software to produce reports DDEC Reports software is part of the Detroit Diesel Diagnostic Link DDDL 7 X software package DDDL 7 X requirements are listed in the following Table All information subject to change without notice DDC SVC MAN 0075 Copyright 2010 DETROIT DIESEL CORPORATION DDDL 7 X System Requirements Minimum Hardware Windows 2000 or Windows XP Pentium 3 Processor 400 MHz 256 MB RAM 10 Gigabyte Hard drive with 1 Gigabyte free 8 x CD ROM Drive Monitor and graphics card supporting 1024 x 768 resolution and 16 bit col
164. wn as soot and NOx generated by the engine The following illustration shows the Selective Catalyst Reduction module All information subject to change without notice DDC SVC MAN 0075 Copyright 2010 DETROIT DIESEL CORPORATION EPAIO DD PLATFORM OPERATORS MANUAL d140254 1 Exhaust Outlet 6 Sensor Box with Pressure Sensors 2 SCR Outlet Temperature Sensor 7 DPF Outlet Pressure Sensor Port 3 SCR Outlet NOx Sensor Port 8 Diesel Exhaust Fluid Nozzle 4 SCR Inlet Temperature Sensor 9 5 Exhaust Inlet Diesel Exhaust Fluid Metering Unit All information subject to change without notice 65 DDC SVC MAN 0075 Copyright 2010 DETROIT DIESEL CORPORATION AFTERTREATMENT SYSTEM The 1 BOX configuration where the Diesel Oxidation Catalyst DOC Diesel Particulate Filter DPF and the Selective Catalytic Reduction SCR Catalyst are contained in one single enclosed box The 2 Box configuration where the Diesel Oxidation Catalyst DOC Diesel Particulate Filter DPF and the SCR Catalyst are located in separate components and are mounted either vertically horizontally or both EPA10 Diesel Exhaust Fluid DEF and SCR System Diagnostics The SCR aftertreatment system for this engine requires Diesel Exhaust Fluid DEF to maintain exhaust emissions at levels compliant with emissions standards DEF is a simple non toxic and inexpensive pre mixed fluid composed of 2 3

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