DDC-SVC-MAN-0075.PDF - EPA10 DD Platform Operators Manual€¦ · 25.02.2013 · EPA10 DD PLATFORM OPERATORS MANUAL To the Operator This manual contains instructions on the safe

EPA10 DD PLATFORM OPERATORS MANUAL

To the Operator

This manual contains instructionson the safe operation and preventivemaintenance of your Detroit Dieselengine used in vehicle applications.Maintenance instructions coverroutine engine services such aslubricating oil and filter changes inenough detail to permit self-servicing,if desired.

The operator should become familiarwith the contents of this manual beforeoperating the engine or carrying outmaintenance procedures.

Power-driven equipment is onlyas safe as the person operating thecontrols. You are urged, as theoperator of this diesel engine, to keepfingers and clothing away from therevolving belts, drive shafts, pulleys,etc. on the engine installation.

Throughout this manual CAUTIONSand WARNINGS regarding personalsafety and NOTICES regardingengine performance or service lifewill appear. To avoid personal injuryand ensure long engine service life,always heed these instructions.

Whenever possible, it will benefityou to rely on an authorized DetroitDiesel service outlet for all yourservice needs from maintenance tomajor parts replacement. Authorizedservice outlets worldwide stockfactory-original parts.

The information and specificationsin this publication are based on theinformation in effect at the time ofapproval for printing. Contact anauthorized Detroit Diesel serviceoutlet for information on the latestrevision. The right is reserved tomake changes at any time withoutobligation.

Detroit Diesel engines are built inaccordance with sound technologicalprinciples and based on state-of-the-arttechnology.

Despite this, the engine may constitutea risk of damage to property or injuryto persons if it is not used for itsintended purpose.

The engine should not be modified orconverted in an incorrect manner orthe safety instructions included in thismanual disregarded.

All information subject to change without notice. iDDC-SVC-MAN-0075 Copyright © 2010 DETROIT DIESEL CORPORATION

NOTICE:

Coolant must be inhibited withthe recommended SupplementalCoolant Additives (SCA) listed inthe “How-To Procedures” sectionof this engine Operator Manual.In addition, the engine can beequipped with a coolant filter as aninstalled option or as an after-saleitem. Failure to check andmaintain SCA levels at requiredconcentrations will result insevere damage (corrosion) tothe engine cooling system andrelated components.

WARRANTY

The applicable engine warranty iscontained in the booklet “WarrantyInformation for Detroit DieselEngines,” available from authorizedDetroit Diesel service outlets.

Keep this Operator Manualwith the engine installation atall times. It contains importantoperating, maintenance, and safetyinstructions.

Trademark Information

DDC®, Detroit Diesel®, DDEC®,Optimized Idle®, Diagnostic Link®,BlueTec®, POWER Trac®, POWERCOOL®, and POWER GUARD®are registered trademarks of DetroitDiesel Corporation. All othertrademarks used are the property oftheir respective owners.

ii All information subject to change without notice.DDC-SVC-MAN-0075 Copyright © 2010 DETROIT DIESEL CORPORATION


TABLE OF CONTENTS

INTRODUCTION .................................................................................. 1NON-GENUINE AND REBUILT COMPONENT QUALITY ALERT .. 1PERSONNEL REQUIREMENTS ..................................................... 2ENGINE CONVERSIONS AND MODIFICATIONS .......................... 2

CAUTION SUMMARY .......................................................................... 3ENGINE OPERATION ..................................................................... 3PREVENTIVE MAINTENANCE ....................................................... 5COMPRESSED AIR ......................................................................... 7COOLING SYSTEM ......................................................................... 7ELECTRICAL SYSTEM ................................................................... 8AIR INTAKE SYSTEM ...................................................................... 8LUBRICATING OIL AND FILTERS .................................................. 9FUEL SYSTEM ................................................................................ 9AFTERTREATMENT SYSTEM ........................................................ 10

DD PLATFORM ENGINE COMPONENTS .......................................... 12DD13 ENGINE COMPONENTS ...................................................... 12DD15 ENGINE COMPONENTS ...................................................... 14DD16 ENGINE COMPONENTS ...................................................... 16

ENGINE MODEL AND SERIAL NUMBER DESIGNATION ................ 18ENGINE MODEL AND SERIAL NUMBER ....................................... 18ENGINE SERIAL NUMBER ............................................................. 18ENGINE CERTIFICATION LABEL ................................................... 18

INSTRUCTIONS FOR STARTING THE ENGINE ................................ 21FIRST TIME START RECOMMENDATIONS ................................... 21SYSTEM CHECKS .......................................................................... 21CHECKING THE COOLING SYSTEM ........................................ 21LUBRICATION SYSTEM CHECKS ............................................. 22PRE-LUBRICATING THE ENGINE ......................................... 22CHECKING THE OIL LEVEL .................................................. 22AFTER AN EXTENDED STORAGE ........................................ 23

FUEL SYSTEM CHECKS ............................................................ 24

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ADDING FUEL ........................................................................ 24PRIMING THE FUEL SYSTEM ............................................... 25

CHECKING OTHER ENGINE AND ATS RELATED PARTS ....... 26FIRST TIME START OF THE ENGINE ............................................ 27STARTING AN ENGINE WITH AN ELECTRIC STARTER .......... 28

RUNNING THE ENGINE ................................................................. 29CHECKING THE OIL PRESSURE .............................................. 29WARMING UP THE ENGINE ...................................................... 29INSPECTION DURING IDLING ................................................... 29CHECKING THE TRANSMISSION ............................................. 29CHECKING FOR FLUID LEAKS ................................................. 29CHECKING THE CRANKCASE .................................................. 30CHECKING THE TURBOCHARGER .......................................... 30AXIAL POWER TURBINE ........................................................... 30AVOID UNNECESSARY IDLING ................................................. 30

STOPPING THE ENGINE ................................................................ 31EMERGENCY JUMP STARTING .................................................... 31ROUTINE ENGINE START .............................................................. 32STARTING THE ENGINE ROUTINELY ....................................... 33CHECKING THE COOLANT LEVEL (COLD CHECK) ................ 34CHECKING THE COOLANT LEVEL (HOT CHECK) .................. 34

MONITORING ENGINE OPERATION ............................................. 35MONITORING THE BATTERY CHARGING SYSTEM ................ 35MONITORING THE OIL PRESSURE .......................................... 35EXCESSIVE IDLING ................................................................... 36

CHANGING THE IDLE SPEED ....................................................... 36SHUTTING DOWN THE ENGINE AFTER HIGH LOADOPERATION .................................................................................... 36EMERGENCY RUNNING MODE .................................................... 36STOP ENGINE OVERRIDE OPTION .............................................. 37MOMENTARY OVERRIDE .......................................................... 37

COLD WEATHER OPERATION ...................................................... 37WINTER FRONTS ....................................................................... 38

ELECTRONIC ENGINE CONTROL SYSTEM (DDEC 10) .................. 39ELECTRONIC ENGINE CONTROL SYSTEM (DDEC 10)FEATURES ...................................................................................... 40CRUISE CONTROL ..................................................................... 40DATA RECORDING CAPABILITY ............................................... 42

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ENGINE BRAKE .......................................................................... 43ENGINE PROTECTION .............................................................. 44CALIFORNIA ENGINE IDLE LIMITING ....................................... 45IDLE SHUTDOWN TIMER .......................................................... 45

ELECTRONIC ENGINE CONTROL SYSTEM (DDEC 10)OPERATION .................................................................................... 46STOP ENGINE OVERRIDE SWITCH ......................................... 46IMMEDIATE SPEED REDUCTION ............................................. 47RED STOP LAMP ........................................................................ 47DIAGNOSTIC TOOL .................................................................... 47FLASHING MALFUNCTION CODES ...................................... 48READING FAULT CODES ...................................................... 49ACTIVE CODES ...................................................................... 49INACTIVE CODES .................................................................. 49

CRUISE CONTROL DRIVING TIPS ................................................ 50ENGINE BRAKE AND CRUISE CONTROL .................................... 52SHIFTING HINTS ............................................................................. 52IDLING ............................................................................................. 53

ENGINE BRAKE SYSTEM .................................................................. 54DRIVER CONTROL SWITCHES ..................................................... 54LOW/MED/HIGH SWITCH .......................................................... 54

ENGINE BRAKE ACTIVATION CONDITIONS ................................ 54ENGINE BRAKE OPERATION ........................................................ 54ANTI-LOCK BRAKING SYSTEMS ................................................... 55OPERATING ON FLAT, DRY PAVEMENT ....................................... 56OPERATING DOWN A LONG, STEEP GRADE .............................. 56OPERATING ON WET OR SLIPPERY PAVEMENT ........................ 58

ENGINE SYSTEMS ............................................................................. 60FUEL SYSTEM ................................................................................ 60LUBRICATION SYSTEM ................................................................. 60AIR SYSTEM ................................................................................... 60COOLING SYSTEM ......................................................................... 60ELECTRICAL SYSTEM ................................................................... 60EXHAUST SYSTEM ........................................................................ 60EXHAUST GAS RECIRCULATION SYSTEM .................................. 61

AFTERTREATMENT SYSTEM ............................................................ 62

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TABLE OF CONTENTS

EPA07 AFTERTREATMENT ............................................................ 62EPA10 AFTERTREATMENT ............................................................ 64EPA10 DIESEL EXHAUST FLUID (DEF) AND SCR SYSTEMDIAGNOSTICS ................................................................................ 66EPA10 DEF AVAILABILITY .......................................................... 66EPA10 DEF SPECIFICATIONS ................................................... 66EPA10 DEF HANDLING AND STORAGE ................................... 66EPA10 DEF SYSTEM ANTI-TAMPERING FEATURE ................. 67

OPERATING REQUIREMENTS ...................................................... 67EPA10 DIESEL EXHAUST FLUID TANK ......................................... 67MAINTENANCE ............................................................................... 68PARKED REGENERATION PROCEDURE ..................................... 69EPA07 HAZARDOUS APPLICATIONS ....................................... 70EPA07 DPF STATIONARY REGEN ONLY = 0-DISABLED ..... 70EPA07 DPF STATIONARY REGEN ONLY = 1-ENABLED ...... 70

SERVICE RECORD ......................................................................... 71

INSTRUMENT PANEL LAMPS ........................................................... 72

EPA10 DEF FLUID LEVEL WARNINGS LAMPS ................................ 74

DRIVER NOTIFICATIONS AND ACTIONS ......................................... 75

MAINTENANCE ................................................................................... 77SCHEDULED MAINTENANCE INTERVALS ................................... 77MAINTENANCE SCHEDULE APPLICATIONS ........................... 77SEVERE SERVICE ................................................................. 77SHORT HAUL ......................................................................... 77LONG HAUL ............................................................................ 77

SCHEDULE USE ............................................................................. 77EPA10 MAINTENANCE TABLES .................................................... 78EPA07 MAINTENANCE TABLES .................................................... 83ROUTINE PREVENTIVE MAINTENANCE ...................................... 87MONITORING THE LUBRICATING OIL ...................................... 87MONITORING THE LUBRICATING OIL FILTER ........................ 88MONITORING THE COOLING SYSTEM .................................... 88CHECKING FOR COOLANT LEAKS ...................................... 89COOLANT INHIBITORS .......................................................... 89COOLANT DRAIN INTERVAL ................................................. 90INSPECTION OF THE RADIATOR ......................................... 90

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MONITORING THE COOLING SYSTEM FILTER ....................... 91MONITORING THE FUEL FILTERS ............................................ 91ADJUSTING THE VALVE LASH .................................................. 91MONITORING THE BELTS ......................................................... 92SERPENTINE BELTS ............................................................. 93REPLACEMENT OF BELTS ................................................... 93

INSPECTION OF THE AIR INTAKE SYSTEM ............................ 93MONITORING THE AIR CLEANER ............................................ 93REPLACEMENT OF AIR CLEANER ELEMENT ..................... 94

MONITORING THE EXHAUST SYSTEM ................................... 94MONITORING THE AFTERTREATMENT SYSTEM ................... 94INSPECTION OF THE AIR COMPRESSOR ............................... 95MONITORING THE FUEL AND FUEL TANK .............................. 95FUEL LINES, FLEXIBLE HOSES ................................................ 96INSPECTION FOR FUEL LEAKS ........................................... 96INSPECTION OF HOSES AND FITTINGS ............................. 96INSPECTION OF HOSES WITH EXTENDED SERVICELIFE ......................................................................................... 97

INSPECTION OF TURBOCHARGER AND CHARGE AIRCOOLER ...................................................................................... 97INSPECTION OF THE BATTERY ............................................... 97ENGINE (STEAM CLEANING) .................................................... 98BATTERY-CHARGING ALTERNATOR ....................................... 99INSPECTION OF THE ALTERNATOR .................................... 99

LUBRICATING THE FAN HUB .................................................... 100CHECKING THE VIBRATION DAMPER ..................................... 100

HOW-TO PROCEDURES .................................................................... 101HOW TO SELECT LUBRICATING OIL ............................................ 101LUBRICANT REQUIREMENTS .................................................. 101COLD WEATHER STARTING ..................................................... 101USE OF SYNTHETIC OILS ......................................................... 102USE OF SUPPLEMENTAL ADDITIVES ...................................... 102

REQUIREMENTS FOR CHANGING OIL ........................................ 102DISPOSAL OF WASTE OIL ........................................................ 103

HOW TO REPLACE THE LUBRICATING OIL AND OIL FILTER .... 103HOW TO SELECT DIESEL FUEL ................................................... 106QUALITY ..................................................................................... 106FUEL CONTAMINATION ............................................................. 107

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BIODIESEL FUEL ................................................................... 107PROHIBITED ADDITIVES ........................................................... 108USED LUBRICATING OIL ....................................................... 108GASOLINE .............................................................................. 108FUEL ADDITIVES WITH SULFUR OR SULFATED ASH ........ 108

HOW TO REPLACE THE FUEL FILTERS ....................................... 109REMOVAL OF THE FINAL FILTER ............................................. 109INSTALLATION OF THE FINAL FILTER ..................................... 110REMOVAL OF THE PREFILTER ................................................. 111INSTALLATION OF THE PREFILTER ......................................... 111REMOVAL OF THE WATER SEPARATOR/COALESCER .......... 112INSTALLATION OF THE WATER SEPARATOR/COALESCER .. 113

ENGINE OUT OF FUEL — HOW TO RESTART ............................. 114HOW TO CLEAN AN ENGINE ......................................................... 115CLEANING WITH HIGH-PRESSURE EQUIPMENT ................... 115CLEANING THE ENGINE ........................................................... 116

HOW TO CLEAN THE COOLING SYSTEM .................................... 116DEGREASING THE COOLING SYSTEM ................................... 117

HOW TO SELECT COOLANT ......................................................... 118COOLANT DEFINITIONS ............................................................ 118APPROVED COOLANTS ............................................................ 119ETHYLENE GLYCOL AND WATER PLUS SUPPLEMENTALCOOLANT ADDITIVE INHIBITOR .......................................... 120MIXING AND USING ETHYLENE GLYCOL ANTIFREEZE .... 120WATER REQUIREMENTS ...................................................... 121COOLANT MAINTENANCE INTERVALS ............................... 122

COOLANTS NOT RECOMMENDED .......................................... 122ANTIFREEZES AND COOLANTS CONTAININGPHOSPHATE ........................................................................... 122AUTOMOTIVE TYPE COOLANTS .......................................... 123METHYL ALCOHOL-BASED ANTIFREEZE ........................... 123GLYCOL-BASED COOLANTS FORMULATED FOR HVAC ... 123

ADDITIVES NOT RECOMMENDED ........................................... 123SOLUBLE OIL ADDITIVES ..................................................... 123CHROMATE ADDITIVES ........................................................ 123

TESTING FOR SUPPLEMENTAL COOLANT ADDITIVES ......... 124REMOVAL OF DROPOUT .......................................................... 125CHRONIC COOLANT SYSTEM PROBLEMS ............................. 125

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DETROIT DIESEL COOLING SYSTEM MAINTENANCEPRODUCTS ................................................................................. 125DETROIT DIESEL GENUINE COOLANT SUPPLEMENTALCOOLANT ADDITIVES ........................................................... 125

SUMMARY OF COOLANT RECOMMENDATIONS .................... 126COOLANT LIFE OF GLYCOL COOLANT ............................... 127

HOW TO REPLACE THE COOLANT FILTER ................................. 127CHECKING THE HOSES ............................................................ 128

HOW TO SERVICE THE DRY TYPE AIR CLEANER ...................... 129

TROUBLESHOOTING ......................................................................... 130ABNORMAL COOLANT TEMPERATURE ....................................... 130HARD STARTING ............................................................................ 131AFTERTREATMENT SYSTEM OPERATING CHARACTERIS-TICS ................................................................................................. 132ABNORMAL ENGINE OPERATION ................................................ 133ABNORMAL OPERATING CONDITIONS ....................................... 134

ENGINE STORAGE ............................................................................. 135PREPARING ENGINE FOR STORAGE .......................................... 135TEMPORARY STORAGE (30 DAYS OR LESS) ......................... 135EXTENDED STORAGE (MORE THAN 30 DAYS) ...................... 136PROCEDURE FOR RESTORING TO SERVICE AN ENGINETHAT HAS BEEN IN EXTENDED STORAGE ............................. 139

CUSTOMER ASSISTANCE ................................................................. 141USING ROAD SERVICE IN THE U.S. OR CANADA ...................... 141AVAILABILITY OF DETROIT DIESEL SERVICE OUTLETS ........... 141

SPECIFICATIONS ................................................................................ 143FUEL AND LUBRICATING OIL FILTERS ........................................ 143ENGINE OIL CAPACITIES .......................................................... 143

DETROIT DIESEL GENUINE COOLANT ENGINE PRODUCTS .... 143DETROIT DIESEL GENUINE FULLY FORMULATED INHIBITEDETHYLENE GLYCOL COOLANTS .............................................. 143DETROIT DIESEL GENUINE SUPPLEMENTAL COOLANTADDITIVE NEED RELEASE FILTERS ........................................ 144DETROIT DIESEL GENUINE COOLING SYSTEM CLEANERS 145DETROIT DIESEL GENUINE FLUID ANALYSIS PRODUCTS ... 145

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TABLE OF CONTENTS

x All information subject to change without notice.DDC-SVC-MAN-0075 Copyright © 2010 DETROIT DIESEL CORPORATION


INTRODUCTION

This manual is intended for useby the operator of a Detroit Dieselengine used in On-Highway Vehicleapplications.

Non-Genuine and RebuiltComponent Quality Alert

Electronic engine controls havebeen instrumental in aiding enginemanufacturers in meeting thestringent emission requirements ofthe U.S. Environmental ProtectionAgency (EPA) and the CaliforniaAir Resources Board (CARB) andalso in meeting the ever-increasingperformance demands of the customer.

Maintenance procedures mustbe followed in order to continuesatisfactory performance anddurability and to ensure coverage ofthe engine under the manufacturer'swarranty. Many of these maintenanceprocedures also ensure that theengine continues to comply withapplicable emissions standards.Proper maintenance procedures, usingspecific components engineered tocomply with emissions regulations,may be performed by an authorizedDetroit Diesel distributor or dealer,an independent outlet or the operatoror owner. The owner is responsiblefor determining the suitability ofcomponents to maintain emissions

compliance during the engine's usefulemission life.

Detroit Diesel cautions that theindiscriminate rebuilding of precisioncomponents, without the benefit ofspecifications, specialized equipment,and knowledge of the electronicoperating system, will jeopardizeperformance or lead to more seriousproblems, and can take the engineoutside of compliance with U.S. EPAor CARB emissions standards.

There are several other componentsin an engine, such as turbocharger,camshaft, piston, fuel doser valve,fuel doser block, diesel particulatefilter (DPF), diesel exhaust fluidpump (for EPA10 engines), whichare specifically designed andmanufactured to exacting standardsfor emissions compliance. It isimportant that these components, ifreplaced, modified or substituted, canbe verified to ensure that the engineremains in compliance with emissionsstandards. The use of inadequatelyengineered, manufactured or testedcomponents in repair or rebuild ofthe engine may be in violation of thefederal Clean Air Act and applicableU.S. EPA or CARB regulations.

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INTRODUCTION

Furthermore, modern engines exhibitoperating parameters which requirethe use of proper fluids, such asfuel, coolant and lubricating oil, tomaintain long engine life. The use offluids that do not meet Detroit Dieselspecifications may result in prematurewear or engine failure.

Personnel Requirements

Work on the engine should be carriedout only by skilled technicians whohave been instructed in the specificskills necessary for the type of workbeing performed.

Engine Conversions andModifications

The function and safety of the enginecould be affected if unauthorizedmodifications are made to it. DetroitDiesel will not accept responsibilityfor any resulting damage.

Tampering with the fuel injectionsystem and engine electronics couldalso affect engine power output orexhaust emission levels. Compliancewith the manufacturer's settingsand with statutory environmentalprotection regulations cannot then beguaranteed.

2 All information subject to change without notice.DDC-SVC-MAN-0075 Copyright © 2010 DETROIT DIESEL CORPORATION


CAUTION SUMMARY

The following cautions must beobserved by the operator of thevehicle or equipment in which thisengine is installed and/or by thoseperforming basic engine preventivemaintenance. Failure to read andheed these cautions and exercisereasonable care for personal safetyand the safety of others whenoperating the vehicle/equipmentor performing basic enginepreventive maintenance may resultin personal injury and engineand/or vehicle/equipment damage.

Engine Operation

Observe the following cautions whenoperating the engine.

PERSONAL INJURY

To avoid injury from loss ofvehicle/vessel control, theoperator of a DDEC equippedengine must not use or readany diagnostic tool while thevehicle/vessel is moving.

HOT EXHAUST

During parked regeneration theexhaust gases will be extremelyHOT and could cause a fireif directed at combustiblematerials. The vehicle must beparked outside.

LOSS OF VEHICLE CONTROL

To avoid injury from the loss ofvehicle control, do not use cruisecontrol under these conditions:

□ When it is not possible tokeep the vehicle at a constantspeed (on winding roads, inheavy traffic, in traffic thatvaries in speed, etc.).

□ On slippery roads(wet pavement, ice-orsnow-covered roads, loosegravel, etc.).


CAUTION SUMMARY

PERSONAL INJURY

Diesel engine exhaust and someof its constituents are known tothe State of California to causecancer, birth defects, and otherreproductive harm.

□ Always start and operate anengine in a well ventilatedarea.

□ If operating an engine inan enclosed area, vent theexhaust to the outside.

□ Do not modify or tamperwith the exhaust system oremission control system.

PERSONAL INJURY

To avoid injury from engineshutdown in an unsafe situation,ensure the operator knows howto override the stop enginecondition on a DDEC-equippedunit.


To avoid injury from loss ofvehicle control, do not activatethe Engine Brake system underthe following conditions:

□ On wet or slippery pavement,unless the vehicle is equippedwith ABS (anti-lock brakingsystem) and you have hadprior experience drivingunder these conditions.

□ When driving without a trailer(bobtailing) or pulling anempty trailer.

□ If the tractor drive wheelsbegin to lock or there isfishtail motion after theEngine Brake is activated,deactivate the brake systemimmediately if this occurs.

BODILY INJURY

To avoid injury from an explosion,do not use ether or starting fluidon engines equipped with amanifold (grid) heater.



Preventive Maintenance

Observe the following cautions whenperforming preventive maintenance.

PERSONAL INJURY

To avoid injury when workingnear or on an operating engine,remove loose items of clothingand jewelry. Tie back or containlong hair that could be caught inany moving part causing injury.

PERSONAL INJURY

To avoid injury when workingon or near an operating engine,wear protective clothing,eye protection, and hearingprotection.

HOT OIL

To avoid injury from hot oil, donot operate the engine with therocker cover(s) removed.

FIRE

To avoid injury from fire, containand eliminate leaks of flammablefluids as they occur. Failure toeliminate leaks could result infire.

USED ENGINE OIL

To avoid injury to skin fromcontact with the contaminants inused engine oil, wear protectivegloves and apron.

PERSONAL INJURY

To avoid injury when usingcaustic cleaning agents, followthe chemical manufacturersusage, disposal, and safetyinstructions.


CAUTION SUMMARY

PERSONAL INJURY

To avoid injury from hot surfaces,wear protective gloves, or allowengine to cool before removingany component.

PERSONAL INJURY

To avoid injury, use care whenworking around moving belts androtating parts on the engine.

FIRE

To avoid injury from combustionof heated lubricating-oil vapors,stop the engine immediately if anoil leak is detected.

PERSONAL INJURY

To avoid injury from contactwith rotating parts when anengine is operating with the airinlet piping removed, install anair inlet screen shield over theturbocharger air inlet. The shieldprevents contact with rotatingparts.

HOT COOLANT

To avoid scalding from theexpulsion of hot coolant, neverremove the cooling systempressure cap while the engine isat operating temperature. Wearadequate protective clothing(face shield, rubber gloves,apron, and boots). Remove thecap slowly to relieve pressure.

FIRE

To avoid injury from fire, do notsmoke or allow open flames whenworking on an operating engine.



FIRE

To avoid injury from fire from abuildup of volatile vapors, keepthe engine area well ventilatedduring operation.

PERSONAL INJURY

To avoid injury from rotating beltsand fans, do not remove anddiscard safety guards.

PERSONAL INJURY

To avoid injury from slipping andfalling, immediately clean up anyspilled liquids.

Compressed Air

Observe the following cautions whenusing compressed air.

EYE INJURY

To avoid injury from flying debriswhen using compressed air, wearadequate eye protection (faceshield or safety goggles) and donot exceed 276 kPa (40 psi) airpressure.

Cooling System

Observe the following cautions whenservicing the cooling system.

HOT COOLANT


PERSONAL INJURY



CAUTION SUMMARY

Electrical System

Observe the following cautions whenjump starting an engine, charginga battery, or working with thevehicle/application electrical system.

ELECTRICAL SHOCK

To avoid injury from electricalshock, do not touch batteryterminals, alternator terminals, orwiring cables while the engine isoperating.

Battery Explosion and Acid Burn

To avoid injury from batteryexplosion or contact with batteryacid, work in a well ventilatedarea, wear protective clothing,and avoid sparks or flames nearthe battery. If you come in contactwith battery acid:

□ Flush your skin with water.

□ Apply baking soda or lime tohelp neutralize the acid.

□ Flush your eyes with water.

□ Get medical attentionimmediately.

PERSONAL INJURY

To avoid injury from accidentalengine startup while servicingthe engine, disconnect/disablethe starting system.

Air Intake System

Observe the following cautions whenworking on the air intake system.

PERSONAL INJURY




PERSONAL INJURY

To avoid injury from contactwith rotating parts when anengine is operating with the airinlet piping removed, install anair inlet screen shield over theturbocharger air inlet. The shieldprevents contact with rotatingparts.

Lubricating Oil and Filters

Observe the following cautions whenreplacing the engine lubricating oiland filter.

PERSONAL INJURY


FIRE

To avoid injury from combustionof heated lubricating-oil vapors,stop the engine immediately if anoil leak is detected.

FIRE

To avoid injury from fire, do notsmoke or allow open flames whenworking on an operating engine.

FIRE

To avoid injury from fire from abuildup of volatile vapors, keepthe engine area well ventilatedduring operation.

Fuel System

Observe the following cautions whenfueling the vehicle or working withthe fuel system.


CAUTION SUMMARY

FIRE

To avoid injury from fire, keep allpotential ignition sources awayfrom diesel fuel, including openflames, sparks, and electricalresistance heating elements. Donot smoke when refueling.

PERSONAL INJURY

To prevent the escape of highpressure fuel that can penetrateskin, ensure the engine hasbeen shut down for a minimumof 10 minutes before servicingany component within the highpressure circuit. Residual highfuel pressure may be presentwithin the circuit.

FIRE

To avoid increased risk of a fuelfire, do not mix gasoline anddiesel fuel.

FIRE

To avoid injury from fire causedby heated diesel-fuel vapors:

□ Keep those people who are notdirectly involved in servicingaway from the engine.

□ Stop the engine immediately ifa fuel leak is detected.

□ Do not smoke or allow openflames when working on anoperating engine.

□ Wear adequate protectiveclothing (face shield,insulated gloves and apron,etc.).

□ To prevent a buildup ofpotentially volatile vapors,keep the engine area wellventilated during operation.

Aftertreatment System

Observe the following cautions whenservicing the Aftertreatment System(ATS). Be advised that these two labelsare attached to the AftertreatmentDevice (ATD).




DD PLATFORM ENGINE COMPONENTS


DD13 Engine Components

For a general view of the DetroitDiesel engines and major components,see the following:

1. EGR Actuator 5. Turbocharger

2. Exhaust Manifold 6. Fuel Doser Valve

3. EGR Cooler 7. Crankcase Breather

4. Coolant Outlet Nipple



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




1. Axial Power Turbine 4. Turbocharger


3. EGR Valve / Actuator 6. Fuel Doser Valve



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




1. Axial Power Turbine 4. Turbocharger


3. EGR Valve / Actuator 6. Fuel Doser Valve



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


ENGINE MODEL AND SERIAL NUMBER DESIGNATION


The following information coversengine model number, serial number,and certification label.

Engine Model and SerialNumber

The fourteen-digit engine model andmanufacturing serial number is etchedon a pad located on the left front ofthe engine cylinder block, above thedate and time of manufacture. Using471901S0005703 as an example:

□ 471 = engine type (DD15)

□ 901 = vehicle application(Freightliner)

□ S = assembly plant (Detroit Diesel)

□ 0005703 = serial number

Engine Serial Number

The MCM part number and engineserial number is located on the MCMlabel.

Engine Certification Label

A certification exemption label isattached to the valve rocker cover.This label certifies that the engineconforms to federal and certain stateemissions regulations for its particularapplication. It also gives the operatingconditions under which certificationwas made.

The following illustration is an EPA07certification exemption label.





The following illustration is an EPA10certification exemption label.



INSTRUCTIONS FOR STARTING THE ENGINE

The following is an engine startingguide under several differentcircumstances.

First Time StartRecommendations

When preparing to start a new (ornewly overhauled engine which hasbeen in storage), perform all of theoperations listed below. Failure tofollow these instructions may result inserious engine damage.

Be sure you are familiar with all ofthe instruments, gauges, and controlswhich are needed to operate theengine.

Note especially the location andfunction of the following:

□ Oil pressure gauge

□ Low oil pressure warning light

□ Coolant temperature gauge

□ High coolant temperature warninglight

□ Water-in-fuel warning light in theside of the fuel filter module

□ Air restriction indicator

Watch for any signs of engineproblems when starting or driving. Ifthe engine overheats, uses excessivefuel or lubricating oil, vibrates,misfires, makes unusual noises, or

shows an unusual loss of power, turnthe engine off as soon as possible anddetermine the cause of the problem.Engine damage may be avoided by aquick response to early indications ofproblems.

When starting the engine in coldweather, refer to section How to SelectCoolant.

System Checks

Perform the following system checksbefore starting for the first time.

Checking the Cooling System

Check the cooling system as follows:

1. Make sure all drain cocks inthe cooling system are installed(drain cocks are often removedfor shipping) and are closedtightly.

2. Fill the coolant overflow surgetank with Detroit Diesel GenuineCoolant until coolant level staysbetween the low and full coolantmarks on the tank. For moredetailed recommendations, seethe “How to Select Coolant”section in this manual.

3. Entrapped air must be purgedafter filling the cooling system.To do this, allow the engine towarm up with the pressure cap



removed. With the transmissionin neutral, increase engine speedto 1000 rpm and add coolant tothe surge tank as required.

4. Check to make sure the front ofthe radiator and charge air cooler(if equipped) are unblocked andfree of debris.

Lubrication System Checks

The lubricating oil film on the rotatingparts and bearings of a new or newlyoverhauled engine, or one which hasbeen in storage for six months ormore, may be insufficient when theengine is started for the first time.

Pre-lubricating the Engine —To ensure an immediate flow of oil toall bearing surfaces at initial enginestartup, prepare the engines as follows:

1. Charge the engine lubricationsystem with lubricating oil using acommercially-available pressurepre-lubricator.

NOTICE:

□ Insufficient lubrication at startupcan cause serious damage toengine components.

□ Do not add oil if the oil readingfalls on the crosshatch areaof the dipstick. There areapproximately 3.8 L (4.0 qt)from the fill mark to the full mark.Overfilling the oil pan can causeengine damage.

2. After pre-lubricating, check theengine oil level. If necessary,top off by filling engine oil nomore than 3.8 L (4.0 qt) at atime through the oil fill cap tothe satisfactory fill range on theoil dipstick. Do not overfill. Forlubricating oil recommendations,refer to section How To SelectLubricating Oil.

Checking the Oil Level — Checkthe oil level as follows:

1. Check the oil level using theoil dipstick. The oil level ismeasured using the crosshatcharea on the dipstick. If the oilreading is in the crosshatch area,



then the oil is at the proper levelfor engine operation.

NOTE:If the engine operating temperature isbelow 60° C (140° F), the engine mustbe on a level surface and then shutdown for 60 minutes for an accurate oillevel reading. Otherwise, the enginemust be brought up to an operatingtemperature of 60° C (140° F), parkedon a level surface and then shut downfor five minutes for an accurate oillevel reading.

2. If necessary, top off by fillingengine oil no more than 3.8 L(4.0 qt) at a time through theoil fill cap to the satisfactory fillrange on the oil dipstick. Do notoverfill. For detailed procedures,refer to section “How To Replacethe Lubricating Oil and Oil Filter”in this manual. Do not overfill.

PERSONAL INJURY


NOTICE:

Do not add oil if the oil reading is inthe crosshatch area on the dipstick.There are approximately 3.8 L (4.0qt) from the fill mark to the full mark.Overfilling the oil pan can causeengine damage.

After an Extended Storage —An engine in storage for an extendedperiod of time (over winter, forexample) may accumulate water in theoil pan through normal condensationof moisture (always present in the air)on the cold, internal surfaces of theengine.

NOTICE:

Failure to eliminate water-dilutedlubricating oil may lead to seriousengine damage at startup.

Lubrication oil diluted by water cannotprovide adequate bearing protectionat engine startup. For this reason,Detroit Diesel recommends replacingthe engine lubricating oil and filtersafter extended storage.



Fuel System Checks

Make sure the fuel shutoff valve(if used) is open. Fill the tanks withthe recommended fuel. Keepingtanks full reduces water condensationand helps keep fuel cool, which isimportant to engine performance.Full tanks also reduce the chance formicrobe (black slime) growth. Forfuel recommendations, refer to sectionHow to Select Diesel Fuel.

NOTICE:

Prolonged use of the starting motorand engine fuel pumps to prime thefuel system can result in damageto the starter, fuel pumps, andinjectors. Refer to section Primingthe Fuel System.

If the shutoff valve is even partiallyclosed, it may cause erratic engineoperation due to an inadequatesupply of fuel to the fuel pump.

BODILY INJURY


NOTICE:

NEVER use ether as a starting aidto run the engine. Doing so willresult in injector damage.

If an external starting aid is used, suchas a starting fluid, the heat generatedby the external fuel source will causethe injector tips to be damaged whenthe fuel cools them. The injectorpiston and bushing can be scored fromrunning without lubrication.

To ensure prompt starting and evenrunning, the fuel system must beprimed if air has entered the fuelsystem. Priming is done by operatingthe manual hand priming pumplocated on the fuel filter module orconnecting an external priming pumpto the priming port on the fuel filtermodule. Refer to section Priming theFuel System.

Authorized Detroit Diesel serviceoutlets are properly equipped for thistype of service.

Priming is required if the fuel systemhas been serviced.

Drain off any water that hasaccumulated. Water in fuel canseriously affect engine performanceand may cause engine damage.

Adding Fuel — When adding fuel,pay attention to the following:



NOTICE:

Always use Ultra-Low Sulfur Fuel(ULSF) with 15 PPM sulfur contentor less, based on ASTM StandardD 2622 test procedure. Highersulfur levels will damage theEngine Aftertreatment System.

□ Add winter or summer grade fuelaccording to the season of theyear.

□ Work in the cleanest conditionspossible.

□ Prevent water from entering thefuel tank.

For further information,refer to section How to SelectDiesel Fuel.

Priming the Fuel System —Prime the fuel system as follows:

1. Operate the hand primer onmodule for three minutes or250 strokes, or use an externalpriming source such as toolJ-47912 or ESOC 350.

2. Crank the engine for 20 seconds.

3. Wait 60 seconds for starter cooldown.

4. If engine does not start, repeatstep 2 and step 3. The startingcycle can be repeated up to threetimes.

5. If engine still fails to start,continue as follows:

[a] Use DDDL to check for faultcodes, repair as necessary.

[b] Repeat step “2” and step “3.”

NOTICE:

If no oil pressure is shown afterapproximately 10 seconds, stop theengine and determine the cause.Running the engine with no oilpressure could result in enginedamage.

6. Start the engine with theaccelerator pedal in the idleposition. Monitor the oil pressuregauge or indicator lamp. Keepthe engine running at idlingspeed until the oil pressurereading is 14 psi (97 kPa) ormore.

7. Allow engine to reach operatingtemperature 60° C (140° F).

NOTICE:

Increasing engine speed above idlebefore oil pressure has stabilizedmay cause severe engine damage.

8. Increase engine speed to 1800 rpmfor three minutes.

9. Return the engine to idle andallow to idle for approximately



one minute, then shut down theengine.

10. Check for leaks. Repair ifnecessary.

Checking Other Engine and ATSRelated Parts

Check the engine compartment asfollows:

□ Make sure the transmission isfilled to the proper level with thefluid recommended by the gearmanufacturer. Do not overfill.

□ The diesel exhaust fluid(DEF) must be checked andfilled regularly with DEFmeeting Detroit Diesel's qualityspecification.

□ Make sure cable connections tothe storage batteries are clean andtight.









□ Check for cracks in the batterycases (1), for tightness of the cableclamps (2) at the terminals, andfor corrosion of the terminals (3).Service or replace as needed.

□ To provide corrosion protection,apply dielectric grease liberally tothe terminal pads.

First Time Start of theEngine

Before starting the engine the firsttime, perform an inspection of theengine systems. Refer to sectionSystem Checks.

EXPLOSION

To avoid injury from explosion,never use ether with an engine’selectrical cold starting system.

EPA07 engines only: An electricalgrid heater is used as a cold weatherstarting aid if the ambient temperatureis below 4° C (40° F).

To start the engine, the transmissionshould be in neutral and the ignitionkey turned to ON.

ENGINE EXHAUST

To avoid injury from inhalingengine exhaust, always operatethe engine in a well-ventilatedarea. Engine exhaust is toxic.



PERSONAL INJURY


You will notice that the AWL, RSL,MIL, DPF Regen lamp, and HESTlamp will come on. This is the resultof the DDEC computer diagnosingthe system to ensure everything isfunctional, including the light bulbsfor the warning lights. If everythingis OK, all lights will go out inapproximately five seconds.

The lights must go out beforestarting the engine. If starting avehicle, the operator's foot mustbe off the accelerator pedal beforestarting the engine.

NOTICE:

If the warning lights stay on, ordo not come on momentarily afterturning on the ignition, contactthe Detroit Diesel CustomerSupport Center at 1–800-445-1980.Operating the engine under thesecircumstances may result in enginedamage.

Starting an Engine with anElectric Starter

Start an engine equipped with anelectric starting motor as follows:

1. Place the transmission in neutral,and set the parking brake.

NOTICE:

To prevent serious starting motordamage, do not press the starterswitch after the engine has started.

2. With foot off the acceleratorpedal, turn on the ignition switchand start the engine.

3. If the engine does not start after20 seconds, stop. Try again afterwaiting about 60 seconds.

4. Monitor the oil pressure gaugeimmediately after starting theengine.

NOTICE:

Do not increase engine speed if theoil pressure gauge indicates no oilpressure. Shut down the enginewithin approximately ten secondsto avoid engine damage. Check todetermine the cause of the problem.

NOTE:Do not place the engine under full loaduntil it reaches operating temperature.Colder engine temperatures will cause



the engine to preset idle up to 900rpm. Even at a high idle condition, youdo not have to wait for engine warmup and return to normal 600 rpm idleto drive the truck.

Running the Engine

While the engine is operating,monitoring the battery chargeindicator light, the oil pressure,and avoiding excessive idling isrecommended.

Checking the Oil Pressure

Monitor the oil pressure as follows:

1. Observe the oil pressure gaugeimmediately after starting theengine. An oil pressure gaugethat registers pressure 23 psi(160 kPa) at idle speed is a goodindicator that all moving parts aregetting lubrication.

2. If no pressure is indicated within10 to 15 seconds, stop the engineand check the lubrication system.

3. The oil pressure should notdrop below 78 psi (540 kPa) at1800 rpm, and normal operatingpressure should be higher. If oilpressure does not fall within theseguidelines, check it with a manualgauge.

HOT OIL


Warming Up the Engine

Run the engine at part throttle forabout five minutes to allow it to warmup before applying a load.

Inspection During Idling

While the engine is idling, inspect thetransmission and crankcase for fluidleaks. On DD15 and DD16 engines,check the APT for oil leaks.

Checking the Transmission

While the engine is idling, check theautomatic transmission (if equipped)for proper oil level and add oil asrequired.

Checking for Fluid Leaks

Check for fluid leaks as follows:

1. Look for coolant, fuel, orlubricating oil leaks.

2. If any leaks are found, shut downthe engine immediately and havethe leaks repaired after the enginehas cooled.



Checking the Crankcase

Check the crankcase as follows:

1. If the engine oil was replaced,stop the engine after normaloperating temperature has beenreached. Allow the oil to drainback into the crankcase for about60 minutes, then check the oillevel.

2. If necessary, add oil no more than3.8 L (4.0 qt) at a time to bringthe level to the proper mark on thedipstick. Use only the heavy-dutyoils recommended in the “How toReplace the Lubricating Oil andOil Filter” section in this manual.

NOTICE:

Do not add oil if the oil readingis in the crosshatch area. Thereare approximately 3.8 L (4.0 qt)from the fill mark to the full mark.Overfilling the oil pan can causeengine damage.

Checking the Turbocharger

Check the turbocharger as follows:

1. Make a visual inspection ofthe turbocharger for oil leaks,exhaust leaks, excessive noise, orvibration.

2. If a leak, unusual noise, orvibration is noted, stop the engineimmediately. Do not restart theengine until the cause of theconcern has been investigatedand corrected.

Axial Power Turbine

Check the axial power turbine forexcessive noise or vibration. Stop theengine immediately if unusual noise orvibration is noted. Do not restart theengine until the cause of the concernhas been investigated and corrected.

Avoid Unnecessary Idling

Whenever possible, unnecessaryidling should be avoided.

During long engine idling periodswith the transmission in neutral, theengine coolant temperature may fallbelow the normal operating range.



The incomplete combustion offuel in a cold engine will causecrankcase oil dilution, formation oflacquer or gummy deposits on thevalves, pistons, and rings, and rapidaccumulation of sludge in the engine.When prolonged idling is necessary,maintain at least 900 rpm.

Stopping the Engine

Stop an engine under normal operatingconditions as follows:

1. Reduce engine speed to idle andput all shift levers in the neutralposition.

2. Allow the engine to run betweenidle and 1000 rpm with no loadfor five minutes. This allowsthe engine to cool and permitsthe turbocharger to slow down.After five minutes, shut down theengine.

NOTICE:

Do not stop a turbocharged engineimmediately after a high-speedoperation. Allow a sufficientcool-down period of about fiveminutes to prevent the turbochargerfrom continuing to turn without an oilsupply to the bearings or damagecan result.

NOTE:Cool-down idling needs to take placeafter pulling off an interstate. Whenfinding a parking spot or backing intoa dock, immediate shutdown shouldbe avoided. Shutting the engine offimmediately retains more block heatthan if the engine runs at idle for fiveminutes.

Emergency Jump Starting

The engine's electronic systemoperates on 12 volts DC. If a DDPlatform engine with an electricstarting motor requires emergencyjump starting, DO NOT EXCEED 16VOLTS DC.

BATTERY EXPLOSION

To avoid injury from batteryexplosion when jump starting theengine, do not attach the cableend to the negative terminal ofthe disabled battery.









NOTICE:

Jump starting with voltages greaterthan those indicated or reversingbattery polarity may damage theMCM.

NOTICE:

Failure to connect jumper cablesin the proper sequence can resultin alternator and/or equipmentdamage.

Before attempting to jumpstart the engine, the jumper

cables must be connectedproperly; positive-to-positive,and negative-to-chassis or suitableground. The proper sequence is toconnect negative to negative groundlast.

Routine Engine Start

Following are procedures for a routineeveryday engine start.

ENGINE EXHAUST




PERSONAL INJURY


Starting the Engine Routinely

Before a routine start, see thedaily checks for your engine in the“Maintenance” section of this manual.

NOTICE:

Before starting the engine, carefullyread all operating instructionsin this manual and do all therecommended pre-trip inspectionsand daily maintenance. Check thecoolant, engine oil, and fuel levels,and drain contaminants from thewater separator/coalescer.

Start the engine as follows:

NOTE:If you drain water from the waterseparator/coalescer, you have toprime the fuel system with the built-inhand primer (about 50 strokes).Refer to section Priming the FuelSystem.

NOTE:As a safety function, the electronicengine control system may be wired tostart the engine only If the transmissionis in neutral. This feature is vehicleapplication specific.

1. Turn on the ignition switch.

2. With the accelerator pedal in theidle position, start the engine.

3. Check the engine for leaks.

[a] Check all hoses, hose clamps,and pipe unions on the enginefor tightness. Shut down theengine and tighten them ifnecessary.

[b] Check the oil feed and returnlines at the turbocharger forleaks. Shut down the engineand tighten them if necessary.

4. Shut down the engine.



5. Check the oil level using theoil dipstick. The oil level ismeasured using the crosshatcharea on the dipstick. If the oilreading is between the crosshatcharea, then the oil is at the properlevel for engine operation.


6. Check all the mounting fastenerson the engine for tightness.

Checking the Coolant Level(Cold Check)

Check coolant level as follows:

1. Ensure that all coolant plugs inthe bottom of the radiator and onthe radiator outlet pipe are secureand tight.

2. Check the coolant level. Thecooling system is correctly filledwhen the coolant is between thefull and low marks on the surgetank.

Checking the Coolant Level (HotCheck)

Check the coolant levels as follows:

1. Allow the engine to run forapproximately five minutes at amoderate speed.

2. After the coolant temperaturereaches 50° C (122° F), recheckthe coolant level in the surge tank.

3. Add more coolant if necessary.Open the heater valves beforeadding coolant.



HOT COOLANT


4. Do not close the heater valvesuntil the engine has been runbriefly and the coolant levelagain checked and corrected asnecessary.

Monitoring EngineOperation

While the engine is operating, monitorthe battery charge indicator light andthe oil pressure. Excessive idlingshould be avoided.

Monitoring the Battery ChargingSystem

The battery charge indicator lightmust go out once the engine starts.

If the indicator light comes onwhile the engine is running, do thefollowing:

1. Shut down the engine.

2. Test the charging system, perOEM guidelines.

BATTERY EXPLOSION

To avoid injury from batteryexplosion when jump starting theengine, do not attach the cableend to the negative terminal ofthe disabled battery.

3. If necessary, visit the nearestauthorized dealer to have thealternator voltage and outputchecked.

4. Do a load test on the batteries.

5. Replace components as needed.

Monitoring the Oil Pressure

When the engine has reached itsnormal operating temperature, theengine oil pressure must not dropbelow the following values:

□ 55 psi (380 kPa) at rated speed

□ 14 psi (97 kPa) at idling speed

If oil pressure drops below thesevalues, stop the engine and determinethe cause.



Excessive Idling

Never allow the engine to idle formore than 30 minutes. Excessiveidling can cause oil to leak from theturbocharger.

Changing the Idle Speed

The idle speed range of the DDPlatform engine is 600 to 900 rpm ifthe parameters in the CPC are set tothe default range.

Change the idle speed as follows:

1. Turn the cruise control switch tothe ON position.

2. To increase the idle speed, pushthe RSM/ACC switch until theidle reaches the desired rpm.

3. To decrease the idle speed, pushthe SET/CST switch until the idlereaches the desired rpm.

Shutting Down the Engineafter High Load Operation

If the engine has been running at fulloutput or the coolant temperature hasbeen high, idle the engine for fiveminutes without load. If any of thefollowing conditions occur, shut downthe engine immediately:

NOTICE:

An engine running at full output orwith high coolant temperature aftera high load operation should idle forfive minutes without load. Shuttingdown without idling may causedamage to the turbocharger.

□ The oil pressure swings back andforth or falls sharply.

□ Engine power and rpm fall, eventhough the accelerator pedalremains steady.

□ The exhaust pipe gives off heavysmoke.

□ The coolant and/or oil temperatureclimb abnormally.

□ Abnormal sounds suddenly occurin the engine or turbocharger.

Emergency Running Mode

DD Platform engines are equippedwith an electronic motor controlsystem which monitors the engine asit is running.



NOTICE:

To prevent possible serious enginedamage, have any faults correctedwithout delay by an authorizedservice location.

As soon as an engine fault is detected,it is evaluated and one of the followingmeasures is initiated.

□ In conjunction with any dashboardor instrument panel display, thecode for the electronic controlunit reporting the fault can be readimmediately on the display.

□ If the fault is serious enough toimpair normal operation, theelectronic control unit switchesover to a “limp home” mode. Thelimp home speed is dependenton engine control parameters andcould be as low as 1000 rpm. Thisallows you to safely move thevehicle to a service location or asafe stopping area.

Stop Engine OverrideOption

The Stop Engine Override Optionis used for a momentary override.The electronic engine control systemwill record the number of times theoverride is activated after an enginefault occurs.

Momentary Override

A Stop Engine Override Switchis used to override the shutdownsequence. This override resets the 60second (30 second for oil pressure)shutdown timer, restoring power tothe level when the RSL/Stop Enginewas illuminated. The switch must berecycled after five seconds to obtain asubsequent override.

NOTE:The operator has the responsibility totake action to avoid engine damage.

Cold Weather Operation

Special precautions must be takenduring cold weather. To protect yourengine, special cold weather handlingis required for fuel, engine oil, coolant,and batteries.

For EPA07 engines with a gridheater:



BODILY INJURY


The engine does not require startingaids down to 10° C (50° F).Temperatures below –20° C (–4° F),will require a block heater and oil panheater.

Winter Fronts

A winter front may be used to improvecab heating while idling. At least 25%of the grill opening should remainopen in sectioned stripes that runperpendicular to the charge air coolertube flow direction. This assures evencooling across each tube and reducesheader to tube stress and possiblefailure. Winter fronts should only beused when the ambient temperatureremains below -12° C (10° F).



ELECTRONIC ENGINE CONTROL SYSTEM (DDEC 10)

All engines for 2010 are equipped withan electronic control system calledDetroit Diesel Electronic Control(DDEC 10).

The electronic engine control systemregulates the fuel injection quantityand timing using solenoid valves,allowing extremely low-emissionoperation. Besides the engine and itsrelated sensors, the system has threeother control modules:

□ Motor Control Module (MCM)

□ Common Powertrain Controller(CPC)

□ Aftertreatment Control Module(ACM)

The three control units are connectedby a proprietary datalink throughwhich all necessary data andinformation can be exchanged.

The MCM monitors both the engineand the datalink. When a malfunctionor other problem is detected, thesystem selects an appropriateresponse; for example, the emergencyrunning mode may be activated.

□ The MCM processes the datareceived from the CPC, forexample, the position of theaccelerator pedal and enginebrake.

□ This data is evaluated togetherwith the data from the sensorson the engine, such as coolantand fuel temperature and oil andcharge pressure. The data is thencompared to the characteristicmaps or lines stored in the MCM.From this data, quantity andtiming of injection are calculated.

The CPC broadcasts all informationon datalinks. A certified service centertechnician can access the CPC viathe datalink using the Detroit DieselDiagnostic Link (DDDL) electronicdiagnostic tool.

□ The CPC communicates with theMCM unit installed on the vehicleover the proprietary datalink.

□ Data for specific applications isstored in the CPC. Examplesinclude idle speed, maximumrunning speed, and speedlimitation.

The CPC receives data from severalsources. Examples include:

□ Accelerator pedal position, enginebrake switch

□ Anti-lock brake system and otherelectronic control units

□ Oil pressure, coolant temperatureand others, from the MCM



From this data, instructions arecomputed for controlling the engineand transmitted to the CPC via theproprietary datalink.

The ACMmonitors the AftertreatmentSystem (ATS). When a malfunction orother problem is detected, the systemselects an appropriate response todeliver to the operator.

Electronic Engine ControlSystem (DDEC 10)Features

The electronic engine control systemoffers a variety of features and optionsdesigned to warn the operator ofany engine or Aftertreatment System(ATS) malfunction.

Options can range from warning panellights to automatic reduction in enginepower followed by automatic engineshutdown.

The electronic engine controlsystem has the ability to performdiagnostics for self-checks andcontinuous monitoring of othersystem components.

Depending on the application, theelectronic engine control systemcan monitor oil temperature, coolanttemperature, oil pressure, fuelpressure, coolant level and remotesensors (if used).

The electronic engine controlsystem activates the AWL/CheckEngine and the RSL/Stop Engine toprovide a visual warning of a systemmalfunction.

Cruise Control

Cruise Control is available withany Detroit Diesel ElectronicallyControlled engine. Cruise Controlwill operate in either Engine orVehicle Speed Mode and maintaina targeted speed (mph or rpm) byincreasing or decreasing fueling. Thetargeted speed can be selected andadjusted with dash-mounted switches.

Cruise Control may also beprogrammed to permit fast idleusing the Cruise Control switches.



With the engine at normal idle,transmission in neutral and servicebrakes on, press the SPD CNTLSwitch, and use the RSM/ACCSwitch. The engine rpm shouldincrease to a predefined speed. Theengine rpm can be raised or loweredfrom this point using the SET/CSTand RSM/ACC switches.

Cruise Control will maintain the setspeed under normal road and loadconditions.


To avoid injury from the loss ofvehicle control, do not use cruisecontrol under these conditions:

□ When it is not possible tokeep the vehicle at a constantspeed (on winding roads, inheavy traffic, in traffic thatvaries in speed, etc.).

□ On slippery roads(wet pavement, ice-orsnow-covered roads, loosegravel, etc.).

NOTICE:

When descending a hill with CruiseControl OFF, do not allow theengine to exceed 2300 rpm. Failureto observe this can result in overspeeding and serious enginedamage.

Engine speed and power are variedunder Cruise Control to maintain theset vehicle speed. The vehicle speedmust be above Minimum Cruise SetSpeed and below Maximum CruiseSet Speed. It is recommended thatMax Cruise Set Speed be set to thedefault to allow proper operation ofother features such as Fuel EconomyIncentive and PasSmart. The VehicleSpeed Limit should be used to limitvehicle throttle speed.

The Cruise Control cannot limitvehicle speeds on downgrades ifavailable engine braking effort isexceeded, nor can it maintain speedon upgrades if power requirementsexceed engine power capability.



When the SPD CNTL is in the ONposition, Cruise Control is engaged bymomentarily contacting the SET/CSTSwitch. As a check after each enginestart, the electronic engine controllooks for a one-time activation of theclutch (if equipped) and service brakebefore it allows the Cruise Controlto be enabled. The Motor ControlModule (MCM) must also recognizethat the Cruise Enable Switch haschanged. If the Cruise Enable Switchis OFF, it needs to be turned ON. If theCruise Enable Switch is ON, it mustbe turned OFF then ON for cruise tooperate.

Holding the switch in the SET/CSTposition allows the vehicle to slow to alower speed. Toggling the switch willresult in a one mile-per-hour (1.6 kph)decrease in vehicle speed. If CruiseControl has been disabled, togglingthe RSM/ACC Switch restores thevehicle to the previously set cruisespeed.

Cruise Control can be overridden atany time with the accelerator pedal ifthe vehicle is operating at less thanthe programmed Max Road Speed.Additionally, using either the brake orthe clutch will disable Cruise Control.

Data Recording Capability

The electronic engine control system(DDEC 10) contains the ability toextract detailed data on engine use and

performance using DDEC Reportssoftware. This detailed data (orDDEC Data) is stored in the CPCand contains information on engineperformance such as fuel economy,idle time, and time in top gear. Criticalincidents such as detailed diagnosticdata records and hard braking eventsare also stored. DDEC Data can bedownloaded using DDEC Reportssoftware to produce reports.

DDEC Reports software is part ofthe Detroit Diesel Diagnostic Link(DDDL 7.X) software package.DDDL 7.X requirements are listed inthe following Table.



DDDL 7.X SystemRequirements

MinimumHardware

Recom-mended Hard-

ware

Windows 2000or Windows XP

Windows 2000or Windows XP

Pentium 3Processor, 400MHz

Pentium 4, 1.5GHz

256 MB RAM 512 MB RAM

10 GigabyteHard drive with 1Gigabyte free

40 GigabyteHard Drive with5 Gigabytes free

8 x CD ROMDrive

32 x CD/DVDROM

Monitor andgraphics cardsupporting 1024x 768 resolutionand 16 bit color

Monitor andgraphics cardsupporting1280 x 1024resolution and32 bit color

Parallel port, 1free USB port

Parallel port or 3free USB ports

Internet orMainframeConnection toDDC Server (forupdates)

Internet orMainframeConnection toDDC Server (forupdates)

TranslatorBoxes (DetroitDiesel Multilink,Nexiq MagicKey, NexiqUSB-Link)

TranslatorBox (NexiqUSB-Link)

Engine Brake

The engine brake is enabled by adash-mounted ON/OFF Switch with aseparate intensity switch to select low,medium, or high braking power.








The engine brake will only operatewhen the Accelerator Pedal is fullyreleased. Disengaging the clutchwill prevent the engine brake fromoperating.

The engine brake will supply brakingpower even when in Cruise Control.The Motor Control Module willcontrol the amount of engine brakingwith respect to the Cruise Controlset speed. The maximum amount

of braking (low, medium, high) isselected with the dash switches.

Engine Protection

The electronic engine controlprotection system monitors all enginesensors, electronic components, andrecognizes system malfunctions. Ifa critical fault is detected, the AWL(Check Engine) and RSL (StopEngine) illuminate. The malfunctioncodes are logged into the MCM'smemory.

The standard parameters which aremonitored for engine protectionare low coolant level, high coolanttemperature, low oil pressure, andhigh oil temperature.

PERSONAL INJURY

To avoid injury from engineshutdown in an unsafe situation,ensure the operator knows howto override the stop enginecondition on a DDEC-equippedunit.



NOTICE:

Engines equipped with the powerdown/shutdown option have asystem override button or switch toallow engine operation for a shortperiod of time. Using the overridebutton so the engine does not shutdown in 30 seconds but operatesfor an extended period may result inengine damage.

This system features a 30-second,stepped-power shutdown sequence,or an immediate speed reductionwithout shutdown in the event a majorengine malfunction occurs, such aslow oil pressure, high oil or coolanttemperature, or low coolant level.

California Engine Idle Limiting

2010 Detroit Diesel engines builtwith the California (50-state) EPAcertification are allowed to idleindefinitely when idle speed is below900 RPM.

For California (50-state) EPAcertification engines that idle above900 RPM, the California Engine IdleLimiting feature is enabled. Theengine will generally shut down afterfive minutes of continuous idling whenthe transmission is in neutral or parkand the parking brake is set or after 15minutes when the transmission is inneutral or park and the parking brakeis not set. The automatic shutdown

feature that is applied above 900RPM is required for all Californiacertified engines with the exceptionof engines used in specific vehicletypes which the state of Californiahas determined to be exempt fromthe idle shutdown requirement.These include buses, school buses,recreational vehicles, medium dutyvehicles, military tactical vehicles,and authorized emergency vehiclesas they are defined by the state ofCalifornia. Owners of these vehicletypes that wish to have the shutdownfeature disabled should consult withCalifornia authorities to determineif their vehicles qualify for theexemption.

Non-California (49-state) EPAcertification engines (non-Californiaengines) have the automatic shutdownfeature disabled.

Idle Shutdown Timer

This feature is an optional 1 –80 minute idle shutdown system.Its purpose is to conserve fuel byeliminating excessive idling andallowing a turbocharger cool-downperiod. To activate the shutdown, thetransmission must be in neutral withthe vehicle parking brakes set and theengine in idle or fast-idle mode.



Electronic Engine ControlSystem (DDEC 10)Operation

NOTE:This engine is equipped with DDEC10 software. This software generallyassures optimal engine performance.The installation of software upgradesmay cause minor changes in featuresand engine performance.

Since the DDEC 10 system iselectronic, a battery is required tooperate the computer. The systemoperates at 12 volts. However, in theevent of a power supply malfunction,the system will continue to operate atreduced voltage. When this occurs,the AWL (Check Engine) will comeon.

The engine will only operate atreduced rpm until the battery voltagereaches a point where the MCM willno longer function and the engineshuts down.

Should the AWL (Check Engine)come on for any reason, the vehiclecan still be operated and the driver canproceed to the required destination.This condition should be reportedto an authorized Detroit Dieseldistributor or dealer.

NOTICE:

When the RSL (Stop Engine) comeson, the system has detected amajor malfunction in the engine thatrequires immediate attention. It isthe operator's responsibility toshut down the engine to avoidserious damage.

The engine can be configured togive a warning only, to ramp down(reduce power) or to shut down. Rampdown will reduce engine rpm to apredetermined speed, but will not shutdown the engine. With the 30-secondshutdown option, the engine willbegin a 30-second, stepped powerdown sequence until it shuts downcompletely.

The “Stop Engine Override” featurecan be activated in the case wherethe vehicle is operating in a criticallocation.

Stop Engine Override Switch

This feature allows the operator tooverride the automatic stop enginesequence.



This is done by pressing the StopEngine Override Switch every 15 to 20seconds to prevent engine shutdownfrom occurring.

NOTE:The Stop Engine Override Switch andthe Diagnostic Request Switch are thesame.

NOTE:Holding down the Stop EngineOverride Switch will not prevent theengine shutdown sequence. Youmust continue to reset the automaticshutdown system by pressing the StopEngine Override Switch at intervals ofapproximately 15 to 20 seconds.

It takes 30 seconds from the time theautomatic shutdown sequence beginsuntil engine shutdown. Therefore,the operator must press the overrideswitch just prior to engine shutdownand continue to do so until the vehiclecan be brought to a stop in a safelocation.

Immediate Speed Reduction

The immediate speed reduction optionwill bring engine rpm back to apredetermined speed, but will not shutdown the engine.

The engine should not be restartedafter it has been shut down by theengine protection system, unless

the problem has been located andcorrected.

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 DDEC10 system will determine where theproblem is and will then store thisinformation in its memory.

If the malfunction is intermittent, thelights will come on and go off as thecomputer senses the changing enginecondition.

Diagnostic Tool

The diagnostic tool for DetroitDiesel Electronic Control (DDEC10) is the Detroit Diesel DiagnosticLink (DDDL 7.X). DDDL 7.Xrequirements are listed earlier inthe manual, refer to section DataRecording Capability.

Once the malfunction has beencorrected, the DDEC 10 system willreturn the engine to normal operation.



The temperature of air in the intakesystem is increased with the additionof EGR. DDEC 10 is programmed toreduce fueling (power) for a short timeto reduce air and coolant temperatureswhen necessary.

DDEC 10 will store an informationcode that this event occurred, butno corrective action is required asthis action is designed to maintainoperation without a noticeable affecton vehicle performance.

Flashing Malfunction Codes —All malfunction codes are four digits.The malfunction code recorded in thecomputer memory will remain until itis erased by a technician.

The flashing malfunction code canalso be obtained by the operator.To support flashing codes, a StopEngine Override/Diagnostic RequestSwitch must be configured and theAWL (Check Engine) and RSL (StopEngine) must be hard-wired. The CPCcannot flash these lamps if they arenot hard-wired.

The flashing code feature may beactivated by satisfying one of thefollowing conditions:

□ Engine speed is <100 rpm and theStop Engine Override Switch isput in the ON position.

□ Idle Governor is active and theStop Engine Override Switch isput in the ON position.

□ Vehicle speed is <3 mph andParking Brake is activated and theStop Engine Override Switch isput in the ON position.

The flashing code feature isdeactivated once the Stop EngineOverride Switch is returned to theOFF position or the listed conditionsare no longer satisfied.



Only one light will be flashing codesat any time. All codes will be flashedtwice. The inter-digit pause is 1.5seconds. The pause between codes

is 3.5 seconds. The same 3.5-secondpause occurs as the switch is madefrom RSL (Stop Engine) to AWL(Check Engine).

When code flashing is initiated,the active codes will be flashed onthe RSL (Stop Engine). Then theinactive codes will be flashed on theAWL (Check Engine). When all theinactive codes have been flashed, theprocess of flashing all the active codesfollowed by all the inactive codes willrepeat until the conditions for codeflashing are no longer satisfied.

If there are no active or inactive faults,the number 3 is flashed once followedby a gap of 3 seconds.

Reading Fault Codes — To readthe fault codes, press and hold theStop Engine Override / DiagnosticRequest Switch.

Active codes will be flashed on theRSL (Stop Engine) first, followed byinactive codes being flashed on theAWL (Check Engine). The codes willcontinue to flash and repeat as long asthe Diagnostic Request Switch is heldin the ON position. Both CPC andMCM faults are included.

Active Codes — The active codeswill be flashed on the RSL (StopEngine) in the order of most recentto least recent occurrence based onengine hours.

Inactive Codes — The inactivecodes will be flashed on the AWL(Check Engine) in the order of mostrecent to least recent occurrence basedon engine hours.



Cruise Control DrivingTips

For added driver convenience andcomfort, DDEC 10 also features aCruise Control option that works justlike the system in your car. It can beoperated in any gear above 1100 rpmor road speed faster than 20 mph (32kph), up to the rated engine speed. Italso can be programmed to hold yourroad speed at or below the maximumvehicle speed. The switch to energizeCruise Control is usually mounted onthe instrument panel.

Turn the switch ON to energize thesystem. Remember as a check aftereach engine start, DDEC 10 looks fora one-time activation of the clutch (ifequipped) and service brake beforeDDEC 10 allows Cruise Control to beenabled.

DDEC 10 must also see or recognizethat the Cruise Enable Switch haschanged. If the Cruise Enable Switch

is OFF it needs to be turned ON. Ifthe Cruise Enable Switch is left in theON position at key OFF, the switchmust be cycled OFF then ON forDDEC 10 to see a status change toallow Cruise Control activation. Thestatus of DDEC 10 inputs to activateCruise Control at key ON is listed inthe following table.



Input Status to ActivateCruise Control

InputInput

Status atKey ON

InputStatusBeforeCruiseCon-trol Ac-tivates

ServiceBrakeSwitch

ON OFF

ClutchReleaseSwitch(ManualTrans.only)

ON OFF

CruiseControlEnableSwitch

OFF ON

Once Cruise Control is enabledand you reach your road speed,press the SET Switch to activateCruise Control. The cruise lightwill come on. To increase roadspeed in one mile-per-hour (1.6kilometer-per-hour) increments, pressthe RSM/ACC Switch. To reduce roadspeed, press and hold the SET/CSTSwitch until the lower speed isreached.

Cruise Control is deactivated byslightly pressing the service brakes,

clutch pedal, or trailer brake. TheON/OFF Switch will also deactivateCruise Control.

Cruise Control will maintain vehiclespeed even on upgrades, unless powerrequirements demand a downshift.If the Cruise Control/Engine Brakefunction is turned ON, the CruiseControl will limit your speed ondowngrades. Most likely, CruiseControl will feel stronger than drivingwith the accelerator pedal becauseof the instantaneous and wide-openthrottle response. That's why CruiseControl use is not suggested duringslippery driving conditions.

Use Cruise Control after downshiftingon a hill to pull the hill. Hittingthe RSM/ACC Switch (not theSET Switch) will keep the truckaccelerating in the lower gears up tothe rated engine speed.

Cruise Control will disengage below1000 rpm or 20 mph (32 kph) roadspeed. When using Cruise Control,if you want to pull the engine below1000 rpm, remember to hold theaccelerator pedal to the floor to keepthe engine pulling at wide-openthrottle. The engine will pull down toabout 1050 rpm.



Remember: The electronic dataprogrammed into the DDEC 10system will not allow you to hurt orover fuel the engine at low or “lug”engine speeds. There is enough oilpressure to withstand hard pulls at lowengine speeds.

Engine Brake and CruiseControl

Your engine is equipped withboth Cruise Control and an enginebrake; the engine brake can operateautomatically while you are in CruiseControl. If the Cruise Control/EngineBrake function is turned ON in theDDEC 10 system programming, theengine brake will come on “low”when your set road speed increasesa few mph (kph) above your cruiseset speed. If your speed continues toincrease, the DDEC 10 system willincrease the engine brake's brakingpower progressively. When thevehicle returns to the set cruise speed,the engine brake will turn off until youneed them.

For safety reasons, don't use CruiseControl when it is not possible to keepthe vehicle at constant speed due to:

□ Winding roads

□ Heavy traffic

□ Slippery pavement

□ Descending grades calling forengine brake assistance

For an explanation of the enginebrake system and recommendationsfor proper operation, “Engine BrakeSystem” in this manual.

Shifting Hints

Depending on your transmissionmodel, the gear split may vary from400 to 500 rpm. The electronicgovernor provides almost no overruncapability; and, if the transmissionis downshifted too early, you willexperience a temporary loss of pullingpower until the engine speed fallsbelow rated speed.

In general, when using a 7- or 9-speedtransmission, you should alwaysdownshift between 1150 and 1250rpm for the DD13 and between 1000and 1100 rpm for the DD15. This istrue even on steep grades with heavyloads. When using an 18-, 15-, or13-speed transmission, you will needto downshift at an rpm that allows“less than rated” rpm before throttleapplication in the next gear down.You may want to limit engine speedto 1900 rpm in all gears. The DD13engine provides horsepower through2000 rpm, but fuel economy is not asefficient above 1800 rpm. The DD15engine provides horsepower through2100 rpm, but fuel economy is not asefficient above 1800 rpm.



If you decide to drive at a lower rpmfor improved fuel economy, don't letdifferent engine noises throw youoff guard. The engine sounds quietat 1400 rpm, almost as if it had quitpulling. Depending on the air intakearrangement, you may also experiencea “chuffing” sound as the engine startsto pull hard at lower rpm. This isnormal and caused by the velocitychanges of the air flow within the airintake plumbing. Electronic enginescan actually deliver more fuel at lowerengine speeds than at rated speed.

The engine has been designed fora very quiet operation, but the airflow may be noticeable to the tuned,attentive ear. The turbochargeroperates at higher boost pressureforcing EGR gas flow through theEGR plumbing. In some situationsthe driver may believe he/she hasexperienced a charge air cooler systemleak. Even connecting trailer lightand air hoses, the driver may hear adifferent tone (exhaust and under hoodwith the engine idling.) If equippedwith a turbo boost gauge, the drivermay occasionally note intake manifoldpressure exceeds 35 psi (6.89 kPa).

Idling

The common belief that idling a dieselengine causes no engine damage iswrong. Idling produces sulfuric acid,which is absorbed by the lubricatingoil and eats into bearings, rings, valve

stems and engine surfaces. If youmust idle the engine for cab heat orcooling, the high idle function ofthe Cruise Control switches shouldbe used. An idle speed of 900 rpmshould be enough to provide cab heatin above 0° C (32° F) ambients.


ENGINE BRAKE SYSTEM

ENGINE BRAKE SYSTEM

The engine is equipped with an enginebrake. Before operating the vehicle,you must familiarize yourself withthe engine brake system to obtainoptimum benefit from it. Enginebrake control systems may varyslightly, depending on the enginebrake configuration and cab design.However, basic operator controls aresimilar for all models.

Driver Control Switches

Vehicles with manual transmissionsallow the driver to turn the enginebrake on and off and select a Low,Medium, or High level of braking.

Low/Med/High Switch

The “Low” setting on this switchactivates two brake cylinders, yieldingabout one-third engine brakinghorsepower. The “Medium” activatesfour cylinders, supplying abouttwo-thirds engine braking horsepower.The “High” setting activates allsix cylinders, providing full enginebraking horsepower.

Engine Brake ActivationConditions

The engine braking system onlypermits fully automatic operation

when the following conditions aremet:

□ Engine Brake switch is on.

□ An Engine Brake level(Low/Med/High) is selected.

□ Vehicle meets the programmedminimum speed.

□ The Clutch Pedal is out.

□ The Accelerator Pedal is at zeropercent activation.

Engine Brake Operation

NOTICE:

Always allow the engine to reachfull normal operating temperaturebefore activating the engine brakesystem to ensure positive enginebrake engagement.

The engine brake system dependson a full-pressure flow of warmengine lubricating oil for properlubrication of moving parts andoptimum performance.








Under normal driving conditions theengine brake system is left in the ONposition. However, this should changeif roads become wet or slippery.

NOTICE:

Do not attempt to “double clutch”the transmission while the enginebrake system is turned on. Shiftinggears without pressing the clutch orusing the engine brake to reduceengine rpm may result in seriouspowertrain damage.

After it is switched on, the enginebrake system is automaticallyactivated each time you remove yourfeet completely from the clutch pedaland accelerator pedal. The enginebrake automatically deactivates itselfwhen you press the clutch pedal whileshifting gears.

NOTE:Some systems may be programmedto activate themselves only when thebrake pedal is pressed, so read yourvehicle owner's manual thoroughly tofind out if you have this option.

Anti-Lock BrakingSystems

Vehicles equipped with ABS have theability to turn the engine brake OFFif a wheel-slip condition is detected.The engine brake will automaticallyturn itself ON once the wheel slip isno longer detected.


ENGINE BRAKE SYSTEM

The DDEC 10 system will deactivatethe engine brake system when theengine speed falls below a preset rpmor when the vehicle slows down toa preset speed, depending on DDECprogramming. This prevents stallingthe engine. The engine brake can alsobe used with vehicle Cruise Controlturned ON.

Operating on Flat, DryPavement

Use the following guidelines whendriving on flat, dry pavement:

1. If driving on flat, dry, openstretches with a light load andgreater slowing power is notrequired, place the progressivebraking switch in the LOWposition.

2. If you find you are still usingthe service brakes, move theprogressive braking switch to ahigher position until you do notneed to use the service brakes toslow the vehicle down.

3. If you are carrying a heavier loadand road traction is good, movethe progressive braking switch tothe HIGH position.

4. Check your progressive brakingswitch often for proper position,since road conditions can changequickly. Never skip a step whenoperating the progressive braking

switch. Always go from OFFto LOW, and then to a higherposition.

Operating Down a Long,Steep Grade

An explanation of “control speed”may be helpful in understanding howto use the engine brake system whiledescending a grade. Control Speedis the constant speed at which theforces pushing the vehicle forward ona grade are equal to the forces holdingit back, without using the vehicleservice brakes. In other words, thisis the speed the vehicle will maintainwithout using the service brakes orfueling.

Use the following guidelines whendescending a long, steep grade:

1. Before beginning the descent,determine if your engine brakesystem is operating properly bylifting your foot briefly off theaccelerator pedal. You shouldfeel the system activate.

2. Ensure the progressive brakingswitch is in the appropriate powerposition (LOW/MED/HIGH).



BRAKE FADE

To avoid injury, do not overapply the vehicle service brakeswhen descending a long, steepgrade. Excessive use of thevehicle brakes will cause themto heat up, reducing theirstopping ability. This condition,referred to as “brake fade”, mayresult in loss of braking, whichcould lead to personal injury orvehicle/property damage or both.

3. Do not exceed the safe controlspeed of your vehicle. Example:You could descend a 6% grade,under control only at 10 mph (16kph) without an engine brake, butat 25 mph (40 kph) with an enginebrake. You could not descendthat same hill at 50 mph (80 kph)and still expect to remain undercontrol. Get to know how muchslowing power your engine brakecan provide. So get to knowyour engine brake system beforeclimbing hills and do not exceeda safe control speed.

PERSONAL INJURY

Failure to keep the vehicle withinsafe control speed limits whiledescending a grade may resultin loss of vehicle control, whichcould cause personal injury.

NOTICE:

Failure to keep the vehicle withinsafe control speed limits whiledescending a grade may result invehicle or property damage or both

4. Check your progressive brakingswitch often for proper position(LOW/MED/HIGH), sinceroad conditions can changequickly.Never skip a step whenoperating the progressive brakingswitch. Always go from OFFto LOW and then to a higherposition when on slippery roads.


ENGINE BRAKE SYSTEM

Operating on Wet orSlippery Pavement

Operate the engine brake system asfollows:

NOTE:Experience with the engine brakesystem on dry pavement isrecommended before attemptingto use it on wet or slippery roads.

1. On wet or slippery pavement,start with the master switch in theOFF position and use the gearyou would normally use underthese conditions.






NOTE:On single trailers or combinations,a light air application of the trailerbrakes may be desirable to helpkeep the trailer stretched out. Followthe manufacturer's recommendedoperating procedure when using yourtrailer brakes.



2. If the vehicle is maintainingtraction, place the selectivebraking switch in the LOWposition and turn ON the enginebrake system. If the drive wheelsare maintaining traction and youdesire greater slowing power,move the braking switch to thenext highest position.

3. However, if the tractor drivewheels begin to lock or there isa fishtail motion, turn the enginebrake system OFF immediatelyand do not activate it until roadconditions improve.

4. Check your progressive brakingswitch often for proper position(LOW/MED/HIGH), since roadconditions can change quickly.Never skip a step when operatingthe progressive braking system.Always go from OFF to LOWand then to a higher position.


ENGINE SYSTEMS

ENGINE SYSTEMS

Fuel System

The fuel system consists of DDEC10 control system, common rail,fuel injectors, low and high pressurepumps, fuel filter module, prefilter,water separator/coalescer, final filter,and the necessary connecting fuellines. The common rail system withinjectors provides amplification forbetter fuel atomization.

Lubrication System

The lubrication system consists of anoil pump, oil cooler, cartridge-style oilfilter, pressure regulator valve, and oilpressure sensor. Clean, pressurized oilis fed to all components via passagesin the engine block and cylinder head.

Air System

Outside air enters the engine throughthe air filter and is drawn to theturbocharger and then is compressed,and forced through the air-to-aircharge cooler (heat exchanger) and iscooled. Next, it flows to the intakemanifold and into the cylinders, whereit mixes with atomized fuel from theinjectors.

For optimum engine protection fromdust and other airborne contaminants,service the dry-type air cleaners used

when the maximum allowable airrestriction has been reached.

Cooling System

A radiator/thermo-modulated fancooling system is used on the engine.This system has a centrifugal-typecoolant pump to circulate coolantwithin the engine. One full-blockingtype thermostat located in the coolantmodule attached to the left side ofthe cylinder block controls the flowof coolant. The coolant moduleincorporates the oil cooler, oil filter,coolant filter, and coolant pump.

Electrical System

The electrical system consists ofa starting motor, starting switch,battery-charging alternator, storagebatteries, and necessary wiring.

Exhaust System

Hot exhaust gas from the exhaustmanifolds is used to drive theturbocharger.



Exhaust Gas RecirculationSystem

The EGR system consists of anEGR cooler, EGR valve and actuator.The EGR actuator opens and closesthe EGR valve to allow hot exhaustgas to enter the EGR cooler. Heatis extracted from the exhaust gas,resulting in cooler exhaust gas tothe cylinders. EGR lowers thetemperature of the exhaust from theengine, therefore, reducing exhaustgas emissions to acceptable levels.


AFTERTREATMENT SYSTEM


EPA07 Aftertreatment

In order to meet EPA07 emissionsregulations, the traditional mufflerwas replaced by a new AftertreatmentDevice (ATD). The EPA07 ATDconsists of a Diesel Oxidation Catalyst(DOC) and a Diesel ParticulateFilter (DPF). Together, these twocomponents burn off collectedparticulate matter in a processcalled “regeneration.” The key tosuccessful regeneration is highexhaust temperature for an extendedperiod of time. Without adequatetemperatures for regeneration, thefilter will continue to trap particulatesand eventually plug. In order to avoidplugging, Detroit Diesel has designedan actively-regenerated ATD.



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



EPA10 Aftertreatment

To meet EPA10 emission regulations,the traditional muffler was replacedby an Aftertreatment Device (ATD).The ATD consists of a DieselOxidation Catalyst (DOC), a DieselParticulate Filter (DPF), and aSelective Catalyst Reduction (SCR)system. These components burnoff collected particulate matter in aprocess called “regeneration” andreduce nitrous oxides (NOx). Thekey to successful regeneration is highexhaust temperature for an extendedperiod of time. Without adequatetemperatures for regeneration, thefilter will continue to trap particulatesand eventually plug. In order to avoidDPF plugging, Detroit Diesel uses anactively regenerated AftertreatmentSystem (ATS).

The exhaust from an on-highwaydiesel engine produces levels ofnitrous oxide (NOx) that must bereduced. To meet EPA10 emissionstandards, a Selective CatalystReduction (SCR) system has beenadded to the current ATS. The SCRsystem consists of an AftertreatmentControl Module (ACM), a tank forDiesel Exhaust Fluid (DEF), a DEFpump module, an air control unit, aDEF metering unit, a DEF injector,and an SCR module. DEF is pumpedthrough the metering unit to a DEFinjector. The DEF injector metersDEF into the SCR module to produce

a chemical reaction. This chemicalreaction converts nitrous oxides(NOx) present in the exhaust streaminto water vapor and nitrogen.

There are two different configurationsavailable for different types ofapplications. Both configurationsreduce the particulate matter morecommonly known as soot and NOxgenerated by the engine.

The following illustration shows theSelective Catalyst Reduction module.



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. Diesel Exhaust Fluid Metering Unit

5. Exhaust Inlet



□ The “1-BOX™” configurationwhere the Diesel OxidationCatalyst (DOC) / DieselParticulate Filter (DPF) andthe Selective Catalytic Reduction(SCR Catalyst) are contained inone single enclosed box.

□ The “2-Box” configuration wherethe Diesel Oxidation Catalyst(DOC ) / Diesel Particulate Filter(DPF) and the (SCR Catalyst) arelocated in separate componentsand are mounted either vertically,horizontally, or both.

EPA10 Diesel ExhaustFluid (DEF) and SCRSystem Diagnostics

The SCR aftertreatment system forthis engine requires Diesel ExhaustFluid (DEF) to maintain exhaustemissions at levels compliant withemissions standards. DEF is asimple, non-toxic and inexpensivepre-mixed fluid composed of 2/3pure water and 1/3 automotivegrade urea. The following sectionsprovide information regarding DEFavailability, specifications, handlingand storage, and certain SCR systemdiagnostic features.

EPA10 DEF Availability

DEF is available in bulk quantities atroadside truck stop service centers.DEF is also available in various

container sizes at Detroit Dieselservice outlets, truck dealerships, andmany truck service centers. DEF isavailable in container sizes as small as2.5 gallons for convenient storage inyour vehicle for emergency use.

For locations where DEF maybe purchased, call the DetroitDiesel Customer Service Center atl–800-445-1980.

EPA10 DEF Specifications

DEF is manufactured to strictquality standards to ensure properemissions control. Only DEF thatmeets DIN70700 or ISO 22241-1specifications can be used. TheAmerican Petroleum Institute hasdeveloped a quality certificationprogram to ensure the quality of DEFavailable at service outlets.

EPA10 DEF Handling andStorage

When stored at temperatures between10° and 90° F (minus 12° and 32°C), DEF has a minimum shelf life of12 months. For best shelf life it isrecommended that DEF containers bestored in a controlled environment.



EPA10 DEF SystemAnti-Tampering Feature

The diagnostic system monitors forfaults in DEF system components andmonitors the DEF supply pressure. Ifthe diagnostics detect that componentscritical to the SCR or DEF supplysystem are disconnected (whichcould indicate tampering), or if thediagnostics detect abnormal systempressures indicative of DEF supplyblockage, the warning lamp willilluminate and the control system willinitiate time and mileage counters. Ifthe detected problem is not correctedin 500 miles (800 kilometers) or10 hours of operation, the availableengine torque will be reduced and thevehicle speed will be limited to 55mph (88 kph). If the problem remainsuncorrected for an additional 1,500miles (2,400 kilometers) or 30 hours,the vehicle speed will be limited to 5mph (8 kph) at the next fuel refill.

Operating Requirements

Oxidation of particulate matter isthe key to filter performance. Thisrequires that the catalyzing agent(platinum-coated passages) provideoptimum enhancement to the oxidationprocess. The following requirementsmust be met; otherwise the ATDwarranty may be compromised:

NOTICE:

Do not use kerosene or fuel blendedwith used lube oil.

□ Use Ultra-Low Sulfur Fuel (ULSF)with 15 ppm sulfur content orless, based on ASTM D2622 testprocedure.

□ Lube oil must have a sulfated ashlevel less than 1.0 wt %; currentlyreferred to as CJ-4 oil. DetroitDiesel currently recommendsCJ-4 oil, and will allow CI-4 Plusoil having sulfated ash levels of1.4% or less.

NOTICE:

Not following the operatingrequirements may result in damageto the ATD or accelerated ashplugging of the diesel particulatefilter.

EPA10 Diesel ExhaustFluid Tank

The Diesel Exhaust Fluid (DEF) tankholds the DEF supply. The filler neckhas a smaller diameter (19 mm) thanthe filler neck of the diesel fuel tankand is fitted with a magnetic insert sothat diesel fuel cannot be mistakenlyadded to the DEF tank.



The DEF you should use with yourDetroit Diesel product will be API(American Petroleum Institute)certified and meet the specificationsISO 22241-1 and DIN70700. Theseare two widely accepted standardsin use for qualifying DEF for use inexhaust aftertreatment systems. DEF(Diesel Exhaust Fluid) will be sold atover 2,500 locations throughout NorthAmerica. These include:

□ Detroit Diesel Distributors

□ Freightliner Truck Dealers

□ Western Star Truck Dealers

□ Travel Centers of America TruckStops

□ Petro Stopping Centers

□ Pilot Travel Centers

If diesel fuel is added to the DEF tankor DEF is added to the diesel fuel tank,immediately contact your CertifiedDetroit Diesel Service Center forfurther instructions.

Maintenance

A high amount of black smokeemitting from the vehicle orillumination of the Amber WarningLamp or Red Stop Lamp areindications of a system problem.Should this occur, consult your localDetroit Diesel Service Center.

Illumination of the MalfunctionIndicator Lamp (MIL) Lamp indicatesa failure of an emissions controldevice. The MIL may illuminatealong with other ATS warning lamps.Call for service to repair the fault.

Illumination of the Diesel ParticulateFilter (DPF) Regeneration Lampindicates that a parked regeneration isrequired.

There is a need to periodically removeaccumulated ash, derived from enginelube oil, from the filter. This ashdoes not oxidize in the filter duringthe regeneration process and mustbe removed through a cleaningprocedure. All Detroit Diesel ATDequipped engines will illuminate adashboard warning lamp indicatingthe need for ash cleaning.



Parked RegenerationProcedure

Regeneration of the ATS isfundamental for the oxidation ofsoot. This process happens duringthe normal operation cycle of thevehicle; it can occur both passivelyand actively. Regardless of this,the operator will see no differencein vehicle performance or vehiclecontrol. If the ATS is not capableof completing an over-the-roadregeneration due to duty cycleconstraints or other restrictions, aparked regeneration may need tooccur. The driver will be notified ofthe need for a Diesel Particulate Filter(DPF) regeneration by illumination ofthe DPF Regeneration Lamp.

The DPF Regeneration Lamp mayilluminate after the vehicle has idledfor an extended period of time.

NOTE:If the DDEC electronics have notrequested the initiation of a parkedregeneration (the DPF RegenerationLamp is not illuminated), the Regenrequest switch is disabled.

NOTE:The driver MUST stay with the vehiclethroughout the regeneration process.

NOTE:Not all vehicles may be equippedwith a Regen request switch due toapplication or user specification.

NOTE:The procedure will take 30 to40 minutes (depending on engine typeand the amount of soot accumulatedin the DPF).

To initiate a parked regeneration,perform the following:

1. Keep engine at slow idle (cannotbe in PTO mode).

2. Transmission is in neutral withparking brake ON.

3. Cycle the parking brake fromOFF to ON.

NOTE:Air tank pressure must be high enoughfor the parking brake switch to hold inthe OFF position.

4. Press and release clutch pedal (ifequipped with clutch pedal).

5. Cycle transmission to DRIVEand back to NEUTRAL (if notequipped with clutch pedal).

6. Hold DPF Switch in the ONposition for five (5) seconds andthen release (engine speed willincrease and DPF RegenerationLamp will go out).



When the parked regeneration requestis accepted, the Diesel ParticulateFilter (DPF) Regeneration lamp willturn ON one time for one second andthen turn off for the remainder ofthe parked regeneration. The HighExhaust System Temperature (HEST)lamp will flash for one second everyten seconds and eventually becomesolid when the tailpipe temperature isabove 525° C (977° F).

The engine speed will increase to 1100RPM for all DD Platform engines.The regeneration will take 30-40minutes. The regeneration is completewhen the engine returns to low idleand the DPF lamp remains OFF. TheHEST lamp will remain ON, but thevehicle may be driven.

NOTE:A parked regeneration will STOP andthe engine will return to low idle if anyof the following happens:

□ The key is turned to the OFFposition

□ The vehicle is put into gear

□ The clutch is cycled

□ The parking brake is released

EPA07 Hazardous Applications

The MCM should be configured tonot allow automatically triggeredover-the-road regenerations (DPFManual 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 RegenOnly = 0-Disabled — This optionallows the DPF Regen Switchto request a parked regenerationif the parked regeneration entryconditions are met. This option alsoallows MCM-initiated over-the-roadregenerations to occur.

EPA07 DPF Stationary RegenOnly = 1-Enabled — This optiononly allows a parked regeneration tooccur by using the DPF RegenerationSwitch. The MCM will be unableto initiate an active over-the-roadregeneration when this option isenabled.



Service Record

It is mandatory that customers ordistributors maintain a proper recordof the particulate filter servicing andcleaning. This record is an agent towarranty considerations. The recordmust include information such as:

□ Date of cleaning or replacement

□ Vehicle mileage at the time ofcleaning or replacement

□ Particulate filter part number andserial number


INSTRUMENT PANEL LAMPS

INSTRUMENT PANEL LAMPS

Lamp Lamp Name Description Results

AmberWarning Lamp

(AWL)

Indicates a fault with theengine controls.

Vehicle can bedriven to end of shift.Call for service.

Red StopLamp (RSL)

Indicates a major enginefault that may result inengine damage. Enginederate and/or shutdownsequence will be initiated.

Move the vehicleto the nearest safelocation and shutdown the engine.Call for service.

DPF RegenLamp

Solid yellow indicates aregeneration is required.Blinking yellow, derateand/or shutdown arepossible as soot loadcontinues to increase.Lamp will shut off duringparked regeneration.

Lamp Solid -regeneration isrequiredLamp Flashing- regenerationis requiredimmediately.

High ExhaustSystem

TemperatureLamp (HEST)

Lamp is yellow. Indicatesexhaust temperature isabove a preset limit andunit is operating at lowvehicle speed (below5 mph [8 kph]). When theengine speed is elevatedfor a parked regeneration,lamp will flash once every10 seconds.

Vehicle can bedriven.Lamp Solid forExtended Period(Longer than 40Minutes) - call forservice.

MalfunctionIndicatorLamp (MIL)

Yellow lamp Indicates afailure of an EmissionControl device. Mayilluminate at the same timeas the Amber WarningLamp.

Vehicle can bedriven to end ofthe shift. Call forservice.



Lamp Lamp Solid Lamp Flashing

□ At the start of every ignitioncycle (bulb check).

□ When an electronic systemfault occurs. (Problemshould be diagnosed assoon as possible.)

□ Diagnostic Request Switchis used to activate the AWLto flash inactive codes.

□ Flashes last 90 secondsbefore idle shutdown ifprogrammed for override.

□ Flashes when idleshutdown or the OptimizedIdle shutdown occurs.


□ A potential enginedamaging fault isdetected.

□ Flashes when EngineProtection Shutdownoccurs.

□ Diagnostic Request Switchis used to activate the RSLto flash active codes.


□ Regeneration is required.

When a regeneration isrequired immediately (if thelamp flashing is ignored), aderate and/or shutdown couldoccur.


□ Vehicle speed is less than5 mph and the DPF outlettemperature is greaterthan 525° C (977° F).

Flashes every 10 secondswhen the DPF outlet reachesa temperature greater than

525° C (977° F).

□ At the start of every ignitioncycle (a bulb check)

□ For any emission relatedfault (light out when thefault is inactive)

Never flashes


EPA10 DEF FLUID LEVEL WARNINGS LAMPS

EPA10 DEF FLUID LEVEL WARNINGS LAMPS

Four light bar segments indicateDEF level in 25% increments. LowDEF levels will trigger a decreasein engine performance. The use ofimproper fluid will trigger a decrease

in engine performance. In empty andignored state, if the diesel tank is filledwithout filling the DEF tank, vehiclespeed will be limited to 5 mph untilDEF is detected in the tank.

SystemResponse

Gauge/Lamp Combination

DEF level is lessthan 10%.

DEF level is lessthan 5%.

Vehicle speedlimited to 55 mph.Engine is derated.

DEF level isEMPTY.

Vehicle speedlimited to 55 mph.Engine is derated.

DEF level isEMPTY andIGNORED.Vehicle speedlimited to 5 mph.Engine is derated.



DRIVER NOTIFICATIONS AND ACTIONS

Notifications and Description Driver Action

High Exhaust SystemTemperature (HEST) LampSOLID: Exhaust is at hightemperature and vehicle isat low speed or parked.FLASHING: A ParkedRegeneration is in processand the system is not up totemperature.

No change in driving stylerequired.When parked, keep vehicle at asafe distance from people andflammable materials or vapors.

Malfunction IndicatorLamp (MIL)Indicates a failure of anEmission Control Device.May illuminate at the sametime as the Check EngineLamp.

Vehicle can be driven to end ofshift. If the MIL remains on after3 drive cycles, call for service.

DPF Regeneration LampSolid: Indicates that aRegeneration may beneeded.Flashing: Indicates that aRegeneration is required assoon as possible.Diesel Particulate Filterreaching system limits.

Perform a Parked RegenerationOR bring vehicle to highwayspeeds to enable AutomaticRegeneration of the filter.


DRIVER NOTIFICATIONS AND ACTIONS

Notifications and Description Driver Action

FLASHING

DPF Regeneration Lamp /Check Engine LampENGINE DERATEDIndicates the DieselParticulate Filter hasreached system limits.

A Parked Regeneration mustbe performed.If the Parked Regeneration exitsand the lamps remain on, repeatthe Parked Regeneration. If thesecond attempt fails, call forservice.

FLASHING

DPF Regeneration Lamp /Check Engine Lamp / StopEngine LampENGINE SHUTDOWNIndicates the DieselParticulate Filter hasexceeded system limits.

A Parked Regeneration mustbe performed.If the Parked Regeneration exitsand the lamps remain on, repeatthe Parked Regeneration. If thesecond attempt fails, call forservice.Note: Engine can be restartedbut a Parked Regenerationmust be initiated within 30seconds or the engine willshutdown.



MAINTENANCE

The following guide establishespreventive maintenance intervals.These recommendations shouldbe followed as closely as possibleto obtain long life and optimumperformance from your engine. Whenperformed on a regular basis, changingthe engine oil, coolant, and filters isthe least costly way of obtaining safeand reliable vehicle operation. Addedbenefits and savings occur when youcheck that the valves, fuel injectors,oil and cooling circuits are in goodworking order during oil changes.

The intervals shown apply only tothe maintenance functions described.These functions should be coordinatedwith other regularly scheduledmaintenance.

Scheduled MaintenanceIntervals

Before placing your new vehiclein service, determine the correctmaintenance schedule application foryour intended use of the vehicle.

Maintenance ScheduleApplications

There are three types of maintenanceschedules for the On-HighwayVehicle applications; Severe Service,Short-Haul Service, and Long-HaulService.

Severe Service — Severe serviceapplies to vehicles that annually travelup to 30,000 miles (48,000 kilometers)and average less than 5 miles pergallon or that operate under severeconditions.

Short Haul — Short Haul serviceapplies to vehicles that annuallytravel up to 30,000-60,000 miles(48,000-96,000 kilometers) andaverage between 5.1 and 5.9 milesper gallon.

Long Haul — Long Haul service(over-the-road transport) applies tovehicles that annually travel morethan 60,000 miles (96,000 kilometers)and average greater than 6 miles pergallon with minimal city stop-and-gooperation.

Schedule Use

Complete each maintenance operationat the required interval. The intervalsare based on a collaboration of fieldand fleet data. For a more accurateanalysis of when fluids should bechanged, such as engine oil, refer topublication Engine Requirements –Lubricating Oil, Fuel and Filters, andpublication Coolant Selections forDetroit Diesel Engines, available fromauthorized Detroit Diesel distributors.


MAINTENANCE

Each maintenance table showswhich maintenance operation mustbe performed at the recommendedinterval (in miles, kilometers, andhours).

NOTE:Failure to check and maintainSupplemental Coolant Additivelevels at required concentrationswill result in severe damage(corrosion) to the engine coolingsystem and related components.Coolant must be inhibited with therecommended Supplemental Coolant

Additives listed in this manual.Refer to section How to SelectCoolant.

Refer to section Routine PreventiveMaintenance for a description of themaintenance to be performed forrelated items.

EPA10 Maintenance Tables

NOTE:Actual fuel filter life will vary based onfuel quality.

Severe Service Maintenance Intervals (EPA10)Miles X 1000/ 25/ 50/ 75/ 100/ 125/ 150/Km X 1000/ 40/ 80/ 120/ 160/ 200/ 240/Hours* 640 1280 1925 2565 3205 3850Item Procedure

Lubricating Oil R R R R R R

Lubricating Oil Filter R R R R R R

CoolantRefer to section “How to Select Coolant"for the listing of required intervals using the

recommended coolants.

Cooling System Filter (ifequipped)

R

Fuel Filters without Frame-mounted Filter

Prefilter R R R R R R

Coalescer (WaterSeparator)

R R R R R R

Final Filter R R R R R R



Severe Service Maintenance Intervals (EPA10)

Fuel Filters with Frame-mounted Filter

Frame-mounted Filter† R R R R R R

Prefilter I I R I I R


I I R I I R

Final Filter I I R I I R

Valve Lash AdjustmentAdjust at 100,000 miles (160,000 km), at 500,000miles (800,000 km), and then every 500,000

miles (800,000 km) thereafter.

Belts I I I I R I

Air System I I I I I I

Air Cleaner I I I I I I

Exhaust System I I I I I I

Aftertreatment DevicesInspect external hardware and connections every

6 months or at oil change intervals.

Diesel Particulate Filter

A “Check Engine Light” will illuminate when ashrequires removal. Normal DPF ash clean intervalsare 300,000 miles (480,000 km) 9,000 hours to400,000 miles (640,000 km) 10,250 hours.**

DEF Pump Filter Replace filter every 150,000 miles (240,000 km).

DEF Pump Air Bladder Refill bladder with air every 24 months.

Air Compressor I I I I I I

*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.†Currently, Davco is the only frame-mounted filtration system compatible

for Detroit Diesel Engines. Inspect Davco at 50,000 miles (80,000


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 ofall items.

R – Replace.I – Inspect, service, correct, or replace as necessary.NOTE:Actual fuel filter life will vary based onfuel 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

Item Procedure

Lubricating Oil R R R R R

Lubricating Oil Filter R R R R R

CoolantRefer to section “How to Select Coolant”for the listing of required intervals using

the recommended coolants.


R


Prefilter R R R R R


R R R R R

Final Filter R R R R R


Frame-mounted Filter† R R R R R

Prefilter I I R I I


I I R I I



Short Haul Maintenance Intervals (EPA10)

Final Filter I I R I I

Valve Lash AdjustmentAdjust at 100,000 miles (160,000 km), at500,000 miles (800,000 km), and then every500,000 miles (800,000 km) thereafter.

Belts I I I I R

Air System I I I I I

Air Cleaner I I I I I

Exhaust System I I I I I

Aftertreatment DeviceInspect external hardware and connectionsevery 6 months or at oil change intervals.


A “Check Engine Light” will illuminatewhen ash requires removal. Normal DPFash clean intervals are 300,000 miles

(480,000 km) 9,000 hours to 400,000 miles(640,000 km) 10,250 hours.**

DEF Pump FilterReplace filter every 175,000 miles

(280,000 km).


Air Compressor I I I I I



for Detroit Diesel Engines. Inspect Davco at 50,000 miles (80,000km), and replace based on regular inspections or at 100,000 miles(160,000 km).


R – Replace.I – Inspect, service, correct, or replace as necessary.NOTE:Actual fuel filter life will vary based onfuel quality.


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

Item Procedure

Lubricating Oil R R R R R R

Lubricating Oil Filter R R R R R R

CoolantRefer to section “How to Select Coolant”for the listing of required intervals using the

recommended coolants.


R R R




R R R R R R



Frame-mounted Filter† R R R R R R

Prefilter I I R I I R


I I R I I R

Final Filter I I R I I R

Valve Lash AdjustmentAdjust at 100,000 miles (160,000 km), at 500,000miles (800,000 km), and then every 500,000

miles (800,000 km) thereafter.

Belts I I I I I R

Air System I I I I I I

Air Cleaner I I I I I I

Exhaust System I I I I I I



Long Haul Maintenance Intervals (EPA10)

Aftertreatment DeviceInspect external hardware and connections every

6 months or at oil change intervals.


A “Check Engine Light” will illuminate when ashrequires removal. Normal DPF ash clean intervalsare 300,000 miles (480,000 km) 9,000 hours to400,000 miles (640,000 km) 10,250 hours.**

DEF Pump Filter Replace filter every 250,000 miles (400,000 km).


Air Compressor I I I I I I



for Detroit Diesel Engines. Inspect Davco at 50,000 miles (80,000km), and replace based on regular inspections or at 100,000 miles(160,000 km).


R – Replace.I – Inspect, service, correct, or replace as necessary.

EPA07 Maintenance Tables

Severe Service Maintenance Intervals (EPA07)

Miles X 1000/Km X 1000/

25/40/

50/80/

75/120/

100/160/

125/200/

150/240/

175/280/

200/320/

Hours* 640 1280 1925 2565 3205 3850 4490 5130

Item Procedure

1. Lubricating Oil R R R R R R R R

2. Lubricating Oil Filter R R R R R R R R


MAINTENANCE

3. CoolantRefer to section “How to Select Coolant”for the listing of required intervals using


4. Cooling System Filter R

5. Fuel Filters

Prefilter R R R R R R R R

Coalescer(Water Separator) R R R R R R R R

Final Filter R R R R R R R R

6.Initial Valve LashAdjustment

Adjust at 60,000 mi (100,000 km), at 180,000mi (300,000 km), and then at every 180,000 mi(300,000 km) or nearest maintenance interval.

7. Belts I I I I I I I R

8. Air System I I I I I I I I

9. Air Cleaner I I I I I I I I

10. Exhaust System I I I I I I I I

11. Aftertreatment DeviceInspect external hardware and connections atevery oil change. Remove ash at 300,000 miles

(480,000 km) or 9,000 hours.*

12. Air Compressor I I I I I I I I

* Whichever comes first.All items are described in Routine Preventive Maintenance.R – Replace.I – Inspect, service, correct, or replace as necessary.



Short Haul Service Maintenance Intervals (EPA07)

Miles X 1000/Km X 1000/

35/55/

70/110/

105/165/

140/220/

175/275/

210/330

245/385/

280/440/

Hours* 895 1795 2690 3590 4485 5380 6280 7180

Item Procedure

1. Lubricating Oil R R R R R R R R

2. Lubricating Oil Filter R R R R R R R R



4.Cooling SystemFilter

R

5. Fuel Filters

Prefilter R R R R R R R R

Coalescer(Water Separator) R R R R R R R R

Final Filter R R R R R R R R



7. Belts I I I I I I I R

8. Air System I I I I I I I I

9. Air Cleaner I I I I I I I I

10. Exhaust System I I I I I I I I

11.AftertreatmentDevice

Inspect external hardware and connections atevery oil change. Remove ash at 300,000 miles

(480,000 km) or 9,000 hours.*

12. Air Compressor I I I I I I I I



MAINTENANCE

Long Haul Service Maintenance Intervals (EPA07)

Miles X 1000/Km X 1000/

50/80/

100/160/

150/240/

200/320/

250/400/

300/480/

Hours* 1280 2565 3845 5125 6410 7690

Item Procedure

1. Lubricating Oil R R R R R R

2. Lubricating Oil Filter R R R R R R



4. Cooling System Filter R

5. Fuel Filters


Coalescer(Water Separator) R R R R R R




7. Belts I I I I I R

8. Air System I I I I I I

9. Air Cleaner I I I I I I

10. Exhaust System I I I I I I

11. Aftertreatment DeviceInspect external hardware and connections atevery oil change. Remove ash at 300,000 miles

(480,000 km) or 9,000 hours.*

12. Air Compressor I I I I I I




Routine PreventiveMaintenance

This section describes the items listedin the maintenance interval tables.

The “Daily” instructions apply toroutine or daily starting of the engine.They do not apply to a new engineor one that has been operated for aconsiderable period of time.

Monitoring the Lubricating Oil

Perform the following maintenance onthe lubricating oil:

1. Check the oil level daily. Withthe engine stopped, use the oildipstick and measure the oillevel on crosshatch area on thedipstick. If the oil reading is inthe crosshatch area, then the oilis at the proper level for engineoperation.

NOTICE:

If the oil level is constantly abovenormal and excess oil has not beenadded to the crankcase, consultwith an authorized Detroit Dieselservice outlet for the cause. Fuel orcoolant dilution of lubricating oil canresult in serious engine damage.


2. Add the proper grade of oil tomaintain the satisfactory range onthe dipstick. All diesel enginesare designed to use some oil, sothe periodic addition of oil isnormal. Before adding lubricatingoil, refer to section How To SelectLubricating Oil.


MAINTENANCE

NOTICE:

Do not add oil if the oil reading is inthe crosshatch area on the dipstick.There are approximately 3.8 L (4.0qt) from the fill mark to the full mark.Overfilling the oil pan can causeengine damage.

Monitoring the Lubricating OilFilter

The engines are equipped with asingle cartridge-style oil filter (1)that is part of the oil/coolant module.Incorporated into the housing isa drain back port which allowsresidual oil to be returned to theoil pan when the filter is removed.This design, including the cartridgestyle element, allows for a moreenvironmentally-safe oil change.

Perform the following maintenance onthe Lubricating Oil Filter:

1. Replace the oil filters whenrecommended by the appropriatemaintenance table. For EPA10engines, refer to section EPA10Maintenance Tables. For EPA07engines, refer to section EPA07Maintenance Tables.

2. Make a visual check of alllubricating oil lines for wearand/or chafing. If any indicationof wear is evident, replace the oillines and correct the cause.

3. Check for oil leaks after startingthe engine.

Monitoring the Cooling System

The cooling system must be full forproper operation of the engine.



HOT COOLANT


1. Check the coolant level daily andmaintain it between the full andlow marks on the surge tank.

2. Add coolant as required, butdo not overfill. Before addingcoolant, refer to section “Howto Select Coolant” for the listingof required intervals using therecommended coolants.

Checking for Coolant Leaks —Perform daily visual checks forcooling system leaks. Look for anaccumulation of coolant when theengine is running and when it isstopped.

PERSONAL INJURY

To avoid injury before startingand running the engine, ensurethe vehicle is parked on a levelsurface, parking brake is set, andthe wheels are blocked.

NOTE:Coolant leaks may be more apparenton a engine when it is cold.

Coolant Inhibitors — Theinhibitors in antifreeze solutions mustbe replenished with an approvedcorrosion inhibitor supplementwhen indicated by testing the coolant.Refer to section How to Select Coolantfor the listing of required intervalsusing the recommended coolants forrequired test intervals, inhibitor levels,and approved inhibitors.


MAINTENANCE

NOTICE:

Coolant must be inhibited withthe recommended SupplementalCoolant Additives listed in thismanual. Failure to check andmaintain Supplemental CoolantAdditive levels at requiredconcentrations will result insevere damage (corrosion) tothe engine cooling system andrelated components.

The cooling system is protected bya Supplemental Coolant Additiveelement. In addition, the engine can beequipped with a coolant filter/inhibitorsystem as an installed option or as anafter-sale item.

Coolant Drain Interval — Acoolant system properly maintainedand protected with supplementalcoolant inhibitors can be operatedup to the intervals listed. Atthese intervals the coolant mustbe drained and disposed of in anenvironmentally responsible manneraccording to state and/or federal(EPA) recommendations.

Inspection of the Radiator —Inspect the radiator as follows:

1. Inspect the exterior of the radiatorcore every 30,000 miles (50,000km) or 12 months.

2. If necessary, clean the exteriorusing a quality grease solvent,such as mineral spirits, and drywith compressed air. Do not usefuel oil, kerosene, or gasoline.

EYE INJURY


NOTE:It may be necessary to clean theexterior of the radiator more frequentlyif the engine is being operated inextremely dusty or dirty areas.

3. If the low coolant level sensoris installed in the top tank of theradiator, test for proper operationevery 100,000 miles (160,000km) or 12 months, whichevercomes first. Authorized DetroitDiesel distributors are properlyequipped to perform this service.



Monitoring the Cooling SystemFilter

Install a new cooling system filter atthe distance intervals indicated by eachspecific Maintenance Interval chart.Refer to Scheduled MaintenanceIntervals.

Monitoring the Fuel Filters

The engine is equipped with a prefilterthat filters down to 100 microns,a water separator/coalescer thatseparates water, and a final filter whichfilters material from 3 to 5 microns.The final filter is 98% effective atfiltering material at 5 microns. Whenservicing these elements, all threefilters should be changed at the sametime. All three elements are locatedwithin the fuel filter module locatedon the left side of the engine.

1. Located at the base of the fuelfilter module is a water levelsensor. Check the water levelsensor each day.

2. When water level reaches apredetermined height, the LEDindicators on the front of thesensor change from green to red.At this time, remove the waterfrom the module by opening thewater drain valve at the bottom ofthe module.

3. Replace the fuel filtersusing the Maintenance

Tables schedule. For EPA10engines, refer to section EPA10Maintenance Tables. For EPA07engines, refer to section EPA07Maintenance Tables.

NOTE:Filter change intervals may beshortened to conform with establishedpreventive maintenance schedules,but should never be extended.

Adjusting the Valve Lash

Perform a valve lash adjustmentas scheduled for the appropriateengine duty cycle. For EPA10engines, refer to section EPA10Maintenance Tables. For EPA07engines, refer to section EPA07Maintenance Tables.

NOTE:Proper valve lash clearance allowsthe engine to produce the bestpossible performance with the lowestemissions. Valve lash adjustmentsshould be performed by an authorizedDetroit Diesel maintenance or repairfacility.


MAINTENANCE

Monitoring the Belts

The engine is equipped with twoengine belt tensioners to ensure thebelts are neither too tight nor tooloose. Belts that are too tight imposeextra loads on the crankshaft, fan, andalternator bearings shortening bothbelt and bearing life. A loose beltwill slip and generate excessive heatthat may cause damage to the belt andaccessory drive components.



1. Inspect the belt tensioner for wearor damage.

PERSONAL INJURY

To avoid injury from rotating beltsand fans, do not remove anddiscard safety guards.

2. If damage is found it may needto be replaced by an authorizedDetroit Diesel maintenance orrepair facility.

Serpentine Belts — Twopoly-V-belts are used on the enginefor On-Highway Vehicle applications.One belt drives the fan hub (3) andthe other belt drives the remainingaccessories. To provide properrunning tension, the current engineuses an automatic fan hub belttensioner (1) and an accessorybelt tensioner (2). Automatic belttensioners require no adjustment.

Replacement of Belts — Replacethe drive belts every 2,000 hours or300,000 miles (480,000 km).

Inspection of the Air IntakeSystem

Perform the following maintenanceon the Air Intake System:

1. Inspect all the connections in theair system to make sure they aretight and leak-free.

2. Check all hoses and ducting forpunctures, deterioration, or otherdamage and replace, if necessary.

Monitoring the Air Cleaner

The engine is equipped with anengine-mounted air cleaner that is flatin design to accommodate variousvehicle packages.

1. Inspect the air cleaner elementevery 50,000 miles (80,000 km)


MAINTENANCE

or more often if the engine isoperating under severe dustconditions. Replace the element,if necessary.

2. Check the gaskets fordeterioration and replace, ifnecessary.

3. If the dry type air cleaner isequipped with an aspirator, checkfor aspirator damage or clogging.Clean, repair or replace, asnecessary.

NOTICE:

Do not allow the air inlet restriction toexceed 20 in. H

2O (5.0 kPa) under

any engine operating conditions.A clogged air cleaner element willcause excessive intake restrictionand reduced air supply to theengine resulting in increased fuelconsumption, inefficient engineoperation, and reduced engine life.

4. Inspect the entire air system forleaks daily.

[a] Look especially for torn airinlet piping or boots andloose or damaged clamps.Have worn or damagedparts repaired or replaced, asrequired.

[b] Retighten loose connections.

Replacement of Air CleanerElement — Replace dry type aircleaner elements when the maximumallowable air intake restriction hasbeen reached. Refer to section "Whento Service the Dry Type Air Cleaner"for additional information.

Monitoring the Exhaust System

Inspect the Exhaust System as follows:

1. Check the exhaust manifoldretaining bolts and otherconnections for tightness.

2. Check the exhaust pipe raincap for proper operation, if soequipped.

Monitoring the AftertreatmentSystem

Periodically remove the accumulatedash, derived from engine lubricatingoil, from the ATS. This ash doesnot oxidize in the filter duringthe regeneration process and mustbe removed through a cleaningprocedure.

NOTE:All Detroit Diesel ATS-equippedengines will illuminate a dashboardwarning lamp indicating the need forash cleaning.



Inspection of the AirCompressor

The air compressor incorporates threeof the major systems of a diesel engine(air, lubrication, and cooling).

Inspect the air compressor looking forair, oil, and coolant leaks.

NOTE:Because the air compressor facilitatesair, lubricating oil, and coolant flow, afailed air compressor could result incontamination between these threefluids. When failed, an air compressorcan produce excessive crankcasepressure or allow an engine to ingestlubricating oil.

Monitoring the Fuel and FuelTank

To prevent fuel and fuel tankproblems, the following measures arerecommended:

1. Keep the fuel tank filled to reducecondensation.

2. Before adding fuel,refer to section How to SelectDiesel Fuel.

3. Refill the tank at the end ofeach day's operation to preventcondensation from contaminatingthe fuel. Condensation formed ina partially filled tank promotes thegrowth of microorganisms thatcan clog fuel filters and restrictfuel flow.

4. To prevent microbe growth, add abiocide to the fuel tank or primaryfuel supply only as needed.

5. Open the drain at the bottom ofthe fuel tank every 30,000 miles(50,000 kilometers) to drain offany water and/or sediment.

PERSONAL INJURY

To avoid injury from improper useof chemicals, follow the chemicalmanufacturer’s usage, handling,and disposal instructions.Observe all manufacturer’scautions.


MAINTENANCE

NOTICE:

Never use galvanized steel fueltanks, fittings, pipes, or supply lines.The fuel reacts chemically with thezinc coating to form powdery flakesthat can quickly clog the fuel filtersand damage the fuel pumps andinjectors.

6. Every 120,000 miles (200,000kilometers) or 12 months, tightenall fuel tank mountings andbrackets. At the same time, checkthe seal in the fuel tank cap, thebreather hole in the cap, andthe condition of the flexible fuellines. Repair or replace the parts,as necessary.

Fuel Lines, Flexible Hoses

A pre-start inspection of hoses andfuel lines is recommended.

Inspection for Fuel Leaks —Make a visual check for fuel leaksat all engine-mounted fuel lines andconnections, and at the fuel tanksuction and return lines. Since fueltanks are susceptible to road hazards,leaks in this area may best be detectedby checking for an accumulation offuel under the tank.

HOT OIL


NOTE:Leaks are not only detrimental tomachine operation, but they can alsoresult in added expense caused by theneed to replace lost fluids.

Inspection of Hoses andFittings — Check hoses daily as partof the pre-start inspection.

1. Examine hoses for leaks, andcheck all fittings, clamps and tiescarefully.

2. Make sure hoses are not restingon or touching shafts, couplings,heated surfaces including exhaustmanifolds, sharp edges, or otherobvious hazardous areas.

3. Since all machinery vibrates andmoves to a certain extent, clampsand ties can fatigue with age. Toensure continued proper support,inspect fasteners frequentlyand tighten or replace them asnecessary.

4. If fittings have loosened orcracked, or if hoses have ruptured



or worn through, take correctiveaction immediately.

Inspection of Hoses withExtended Service Life — A hosehas a finite service life. With this inmind, inspect hoses as follows:

1. Thoroughly inspect all hoses atleast every 500 operating hours(1,000 hours for fire-resistant fueland lubricating oil hoses) and/orannually. Look for cover damageand/or indications of twisted,worn, crimped, brittle, cracked orleaking lines. Hoses with theirouter cover worn through or withdamaged metal reinforcementsshould be considered unfit forfurther service.

2. Replace all hoses in and out ofmachinery during major overhauland/or after a maximum of five(5) years of service.

NOTE:Fire-resistant fuel and lubricatingoil hose assemblies do not requireautomatic replacement after five yearsof service or at major overhaul, butshould be inspected carefully beforebeing put back into service.

Inspection of Turbocharger andCharge Air Cooler

Inspect turbocharger and charge aircooler as follows:

1. Visually inspect the turbochargermountings, intake and exhaustducting, and connections for leaksdaily.

2. Check the lubricating oil inletand outlet lines for leaks orrestrictions to oil flow.

PERSONAL INJURY


3. Check the turbocharger forunusual noise or vibration and,if excessive, stop the engine anddo not operate until the cause isdetermined.

4. Periodically inspect the air-to-aircharge air cooler for buildup ofdirt, mud, or other debris. Cleanas necessary.

5. Check the charge air cooler, ductwork, and flexible connectionsfor leaks and repair or replace asrequired.

Inspection of the Battery

Inspect the battery as follows:

1. Check for cracks in the batterycases (1), for tightness of the


MAINTENANCE

cable clamps (2) at the terminals,and for corrosion of the terminals(3). Service or replace as needed.

PERSONAL INJURY

To avoid injury from accidentalengine startup while servicingthe engine, disconnect/disablethe starting system.

2. Keep the terminal surface clean.

3. Inspect the cables, clamps andhold-down brackets regularly.Clean and reapply a light coatingof petroleum jelly when needed.Have corroded or damaged partsreplaced.

4. If the engine is to be out of servicefor more than 30 days, removethe batteries and store in a cool,dry place.

[a] Keep batteries fully charged,if possible.

[b] Replace any battery that failsto hold a charge.

5. Periodically check batteryconnections for corrosion andtightness.

[a] If necessary, removeconnections and wire brushany corrosion from terminalsand cable ends.

[b] Replace damaged wiring.

Engine (Steam Cleaning)

The engine and engine compartmentshould be steam cleaned every 60,000miles (100,000 km) or 2,000 hours,whichever comes first.



NOTICE:

Do not apply steam or solventdirectly to the battery-chargingalternator, starting motor, DDECcomponents, sensors or otherelectrical components, as damagemay result.

Battery-Charging Alternator

Precautions must be taken whenworking on or around the alternator.The diodes and transistors in thealternator circuit are very sensitiveand can be easily destroyed.

To avoid equipment damage, thefollowing conditions must be met:







□ Avoid grounding the outputterminal. Grounding an alternatoroutput wire or terminal (whichis always “hot,” regardlessof whether or not the engineis running) and accidentallyreversing the battery polarity willresult in equipment damage.

□ Do not reverse battery connections.

□ Never disconnect the batterywhile the alternator is operating.Disconnecting the battery canresult in damage to the batterydiodes. In applications whichhave two sets of batteries,switching from one set to theother while the engine is runningwill momentarily disconnect thebatteries.

□ If a booster battery is to be used,batteries must be connectedcorrectly (negative to negative,positive to positive).

□ Never use a fast charger with thebatteries connected or as a boosterfor battery output.

For information on the alternatorassembly, contact an authorizeddistributor, depending onmanufacturer.

Inspection of the Alternator —Check the alternator as follows:

1. Inspect the terminals for corrosionand loose connections and wiring


MAINTENANCE

for damage and frayed insulation.Have wiring repaired or replaced,as required.

2. Check torque on alternatormounting bolts and bracketingevery 30,000 miles (50,000 km).Retighten if necessary.

Lubricating the Fan Hub

If the fan bearing hub assembly has agrease fitting, use a hand grease gunto lubricate the bearings with one shotof quality lithium-based, multipurposegrease every 120,000 miles (200,000km).

Care should be taken not to overfillthe bearing housing.

Checking the Vibration Damper

Check the vibration damper asfollows:

1. Inspect the viscous vibrationdamper (1) periodically andreplace if dented or leaking.

2. Heat from normal engineoperation may, over a period oftime, cause the fluid within thedamper to break down and loseits dampening properties. Forthis reason, replace the viscousvibration damper at time ofnormal major engine overhaul,regardless of apparent condition.



HOW-TO PROCEDURES

This section covers Detroit Diesel'srecommendations on how to selectlubricating oil, diesel fuel, andcoolant. Also included are basicengine maintenance procedures whichcan be performed by the operator.

NOTICE:

The manufacturer's warrantyapplicable to the engine providesin part that the provisions ofsuch warranty shall not apply toany engine unit that has beensubject to misuse, negligence oraccident. Accordingly, malfunctionsattributable to neglect or failure tofollow the manufacturer's fuel orlubricating recommendations maynot be within the coverage of thewarranty.

How To Select LubricatingOil

NOTICE:

Lubricating oil must have a sulfatedash level less than 1.0 wt %;currently referred to as CJ-4 oil.

Lubricant Requirements

API CJ-4 oils are recommended foruse in the engine.

Detroit Diesel currently will allowAPI CI-4 Plus oil having sulfated ashlevels 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 havedemonstrated field performance inDetroit Diesel engines. These oilsmust possess a High Temperature/ High Shear Viscosity of 3.7 cPminimum.


HOW-TO PROCEDURES

NOTICE:

Monograde oils should not beused in the engine, regardlessof API service classification.Monograde oils gel at lower ambienttemperatures, reducing lubricantflow, and do not provide adequatelubricity at higher engine operatingtemperatures resulting in severeengine damage.

The oils must be API CJ-4 and havedemonstrated field performance inDetroit Diesel engines.

Detroit Diesel will allow CI-4 Plus oilhaving sulfated ash levels of 1.4% orless.

Use of Synthetic Oils

Synthetic oils may be used in DetroitDiesel engines, provided they are APIlicensed and meet the performanceand chemical requirements ofnon-synthetic oils outlined in thispublication. Synthetic oils offerimproved low-temperature flowproperties, high-temperature oxidationresistance, and improved fuel mileage.However, they are generally morecostly than non-synthetic oils.

Product information about syntheticoils should be reviewed carefully.Performance additive systems oftenrespond differently in synthetic oils.

NOTE:Synthetic oil does not permit extensionof recommended oil drain intervals.

Use of Supplemental Additives

Lubricants meeting the DetroitDiesel specifications outlined in thispublication already contain a balancedadditive treatment. Supplementaladditives are generally not necessaryand can even be harmful. Theseadditives may be marketed as eitheroil treatments or engine treatments andare discouraged from use in DetroitDiesel engines.

Engine damage resulting from theuse of such materials is not coveredby your Detroit Diesel warranty.Detroit Diesel will not providestatements beyond this publicationrelative to their use.

Requirements forChanging Oil

The length of time an engine mayoperate before an oil change dependsupon the lubricant and fuel used,engine oil consumption, and theoperating cycle. For EPA10 engines,refer to section EPA10 MaintenanceTables for the tables listing therecommended oil change intervals.For EPA07 engines, refer to sectionEPA07 Maintenance Tables for thetables listing the recommended oilchange intervals.



USED ENGINE OIL

To avoid injury to skin fromcontact with the contaminants inused engine oil, wear protectivegloves and apron.

Disposal of Waste Oil

Used lubricating oil and filtersrequire deposal in an environmentallyresponsible manner, accordingto federal (EPA) and/or staterecommendations. The disposal ofwaste oil may be best addressed by theengine oil supplier, who may acceptresponsibility for proper disposal ofthis material as part of the business ofproviding lubricant.

How To Replace theLubricating Oil and OilFilter

The oil filter is an integral partof the lubrication system. Properfilter selection and maintenanceare important to satisfactory engineperformance and service life. The filtershould be used to maintain a cleansystem, not to clean up a contaminatedsystem. The maintenance intervals forthe appropriate duty cycle are listedin tables in this manual. For EPA10engines, refer to section EPA10Maintenance Tables. For EPA07

engines, refer to section EPA07Maintenance Tables.

Change the oil and replace thelubricating oil filter as follows:

NOTE:If the used oil was contaminated byfuel or coolant, it may be necessary totake the vehicle to a certified DetroitDiesel Service Center. The ServiceCenter may drain the oil and thenremove the oil pan, oil pump, andoil pump intake manifold to drain theremaining oil held back by the backflowvalve. It is important to remove allcontaminated oil from the engine.


2. Clean outside of the oil filterhousing.

NOTE:Change the engine oil only whenthe engine oil temperature isapproximately 60° C (140° F).Changing cold oil will result inextended drain times.

3. Using a 36-mm socket, unscrewthe oil filter cap and filter andallow the oil to drain into thehousing. After draining is


HOW-TO PROCEDURES

complete, remove the assemblyfrom the housing.

NOTE:Use care to prevent foreign objectsfrom entering the filter housing.

4. Remove the filter element bypressing and twisting the side anddetaching it from the cap.

5. Remove the oil filter O-ringand discard. Lightly coat a newO-ring with clean engine oil andinstall it on the filter cap.

6. Check the filter housing for anydebris and remove if necessary.

7. Insert a new filter element intothe oil filter cap.

8. Insert the filter element andcap assembly into the housing.Torque the cap to 40-50 N·m(30-37 lb·ft).

9. Drain oil from the oil pan asfollows:

[a] Place a suitable receptacle,48 L (50 qt) or more, beneaththe oil drain plug on theunderside of the oil pan.

[b] Carefully unscrew the oildrain plug, and allow the oilto drain out.

[c] Inspect the plug seal ringfor damage and replace ifnecessary.

10. Install the oil drain plug. Tightenthe plug to 45 N·m (33 lb·ft).

11. Add new engine oil through theoil fill tube in the amount listed inthe following table. Verify the oillevel reading is between the fulland fill marks on the dipstick.



NOTICE:

Do not add oil if the oil reading isbetween the crosshatch area on thedipstick. There are approximately3.8 L (4.0 qt) from the fill mark to thefull mark. Overfilling the oil pan cancause engine damage.

Oil Change Quantities

DD13 DD15

Oil Change Condition AmountL (Qt)

Amount L (Qt)

Oil and Filter Change — Cold Engine 35.5 L(37.5 qt)

40.5 L (42.8 qt)

Oil and Filter Change — Hot Engine 36.6 L(38.7 qt)

41.6 L (44.0 qt)

Sump Oil Change Only 35.0 L(37.0 qt)

40.0 L (42.3 qt)

NOTICE:

If no oil pressure is shown afterapproximately 10 seconds, stop theengine and determine the cause.Running engine with no oil pressurecould result in engine damage.

12. Start the engine with theaccelerator pedal in the idleposition. Monitor the oil pressuregauge or indicator lamp. Keepthe engine running at idling speeduntil the oil pressure reading is 14psi (97 kPa) or more.

13. Check the filter housing for signsof leakage.

14. Stop the engine. Check the oillevel again per the followingguidelines. If necessary, add oilno more than 3.8 L (4.0 qt) at atime up to the maximum fill levelon the oil dipstick.


HOW-TO PROCEDURES

NOTICE:

Do not add oil if the oil reading isbetween the crosshatch area on thedipstick. There are approximately3.8 L (4.0 qt) from the fill mark to thefull mark. Overfilling the oil pan cancause engine damage.


How to Select Diesel Fuel

All DD Platform engines are designedto operate on Ultra-Low Sulfur Diesel(ULSD) fuel.

Quality

Fuel quality is an important factorin obtaining satisfactory engineperformance, long engine life, andacceptable exhaust emission levels.

In general, fuels meeting the propertiesof ASTM Standard D 975 (grades 1-Dand 2-D) have provided satisfactoryperformance.

The fuels used must be clean,completely distilled, stable, andnoncorrosive. For more informationregarding the significance of theseproperties and selection of the properfuel.



NOTICE:

Use only Ultra-Low Sulfur Diesel(ULSD) fuel (15 PPM sulfur contentmaximum), based on ASTMStandard D 2622 test procedure.Using fuel other than ULSD willdamage the Aftertreatment Device.

Fuel Contamination

Generally, fuel contaminationoccurs as the result of improper fuelhandling. The most common typesof contamination are water, dirt, andmicrobial growth (“black slime”).The formation of varnishes andgums resulting from poor stability orextended storage (“stale fuel”) alsoaffects fuel quality. The best treatmentfor contamination is prevention bymaintaining a clean storage systemand choosing a reputable fuel supplier.

Supplemental additives are notrecommended due to potentialinjector system or engine damage.Our experience has been that suchadditives increase operating costswithout providing benefit.

The use of supplemental fuel additivesdoes not necessarily void the enginewarranty. However, repair expenseswhich result from fuel system orengine component malfunctions ordamage attributed to their use willnot be covered.

These products should beaccompanied by performancedata supporting their merit as wellas the warranty statement. It is notthe policy of Detroit Diesel to test,evaluate, approve, or endorse suchproducts.

Biodiesel Fuel — Detroit Dieselsupports biodiesel as a renewable fuel.Biodiesel fuels are mono-alkyl estersof long chain fatty acids commonlyreferred to as Fatty Acid MethylEsters and are derived from renewableresources through a chemical processcalled transesterification. DetroitDiesel approves the use of biodieselfuel blends up to 5% maximum byvolume in diesel fuel providing thefollowing three conditions are met:

□ The biodiesel used in the blendmeets ASTM Standard D6751 orEN 14214 specification.

□ The biodiesel used in the blendis sourced from a BQ-9000Accredited Producer.

□ The finished blend meets the fuelproperties ASTM Standard D975or EN 590 specification.


HOW-TO PROCEDURES

Detroit Diesel is responsible for thematerials and workmanship of itsengines. Failures attributed to the useof fuels which do not meet industrystandards are not the fault of DetroitDiesel and will not be covered byDetroit Diesel product warranty.While Detroit Diesel supports the useof B5, the use of unacceptable qualityfuel that does not meet industrystandards can result in warrantyevocation.

Prohibited Additives

The following fuel additives are notallowed and MUST NOT be mixedwith diesel fuel:

Used Lubricating Oil — Do not usefuel blended with used lubricating oil.Detroit Diesel specifically prohibitsthe use of used lubricating oil in dieselfuel.

NOTICE:

Do not burn used lubricating oilin fuel. It will cause the dieselparticulate filter to prematurely plugwith ash.

Used lubricating oil containscombustion acids and particulatematerials which can severely erodefuel injector components, resulting inloss of power and increased exhaustemissions. In addition, the use of

drained lubricating oil will increasemaintenance requirements due to filterplugging and combustion deposits.

Gasoline — The addition ofgasoline to diesel fuel will create aserious fire hazard. The presenceof gasoline in diesel fuel will reducefuel cetane number and increasecombustion temperatures.

FIRE

To avoid increased risk of a fuelfire, do not mix gasoline anddiesel fuel.

Drain and clean tanks which contain amixture of gasoline and diesel fuel assoon as possible.

Detroit Diesel will not be responsiblefor any detrimental effects resultingfrom adding drained lubricating oil orgasoline to the diesel fuel.

Fuel Additives with Sulfuror Sulfated Ash — Do notuse non-approved fuel additivescontaining sulfur or sulfated ash.



How to Replace the FuelFilters

NOTICE:

If you have just changed the engineoil and filter, you MUST start theengine and confirm proper oil

pressure before changing the fuelfilters. If no oil pressure is shownafter approximately 10 seconds,stop the engine and determine thecause. Running the engine with nooil pressure could result in enginedamage. Start the engine withthe accelerator pedal in the idleposition. Monitor the oil pressuregauge or indicator lamp. Keepthe engine running at idling speeduntil the oil pressure reading is14 psi (97 kPa) or more.

NOTE:If you are replacing all three fuel filters,it is not necessary to run the engineand test for leaks after installingeach individual fuel filter. However, ifrepairing a leak at one filter, completethat repair and test the system forleaks after priming the fuel system.Refer to section Priming the FuelSystem.

Filters are an integral part of thefuel system. Proper filter selectionand maintenance are important tosatisfactory engine operation andservice life. Filters should be used

to maintain a clean system, not toclean up a contaminated system. Thescheduled maintenance intervals forthe appropriate duty cycles are listedin this manual.

PERSONAL INJURY

To prevent the escape of highpressure fuel that can penetrateskin, ensure the engine hasbeen shut down for a minimumof 10 minutes before servicingany component within the highpressure circuit. Residual highfuel pressure may be presentwithin the circuit.

NOTICE:

At cold temperatures (-40° C or-40° F), DO NOT remove the filterelements from the caps unlessthe intent is to replace the filterelements. Repeated removals atcold temperatures may break thefilter element tabs.

Removal of the Final Filter

Remove the final filter as follows:

1. Using a 36-mm socket, unscrewthe final filter cap.


HOW-TO PROCEDURES

NOTICE:

Do not tilt the final filter whenremoving it from the housing.Possible damage to the final filter orstand pipe may occur.

2. Pull the cap and final filter straightup and allow the fuel to drainback.

3. Remove the final filter (2) fromthe final filter cap (1) by placingthe filter on a solid surface andapply pressure on the final filtercap at an angle.

4. Discard the filter.

5. Inspect inside the housing for anylarge debris and clean if needed.

6. Discard final filter cap seal ring.

Installation of the Final Filter

Install the final filter as follows:

1. Install a new final filter cap sealring.

2. Snap new final filter into the finalfilter cap.

3. Apply a light coat ofpetroleum-based lithium greaseto the cap seal ring (1) and to thelower seal on the final filter.

4. Install the final filter into the fuelfilter module.

5. Turn the cap counterclockwiseuntil a “click” sound is made, thenturn clockwise and hand tighten.

6. Torque final filter cap to55-60 N·m (40-44 lb·ft).

7. Once all required filters have beenchanged, prime the fuel systemusing the fuel priming valve or



the hand primer. Refer to sectionPriming the Fuel System.

8. Start the engine with theaccelerator pedal in the idleposition. Monitor the oil pressuregauge or indicator lamp. Keep theengine running at a idling speeduntil a stable oil pressure readingof 14 psi (97 kPa) or more ismaintained for one minute.

9. Check for leaks.

10. Allow the engine to reachoperating temperature of 60° C(140° F).

NOTICE:


11. Increase engine speed to 1800rpm for three minutes.

12. Return the engine to idle andallow to idle for approximatelyone minute, then shut down theengine.

13. Check for leaks.

Removal of the Prefilter

Remove the prefilter as follows:

1. Using a 36 mm socket, unscrewthe prefilter cap.

NOTICE:

Do not tilt the prefilter whenremoving it from the housing.Possible damage to the prefilter orstand pipe may occur.

2. Pull the cap and prefilter straightup and out of the fuel filterhousing.

3. Remove the prefilter from theprefilter 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 theprefilter cap (1).

NOTE:The prefilter should snap into the capin two positions. The tabs (3) shouldalign with the slot in the prefilter cap(5).


HOW-TO PROCEDURES

2. Apply a thin coat ofpetroleum-based lithium greaseto the prefilter cap seal ring (2).

3. Apply a thin coat ofpetroleum-based lithium greaseto the inside and outside of theprefilter bottom seal.

4. Install the prefilter into the fuelfilter module.


6. Torque prefilter cap to 15-20 N·m(11-15 lb·ft).

7. Once all required filters have beenchanged, prime the fuel systemusing the fuel priming valve orthe hand primer. Refer to sectionPriming the Fuel System.


9. Check for leaks.


NOTICE:





Removal of the WaterSeparator/Coalescer

Remove the water separator/coalesceras follows:

1. Using a 36–mm socket, unscrewthe water separator/coalescer cap.

NOTICE:

Do not tilt the waterseparator/coalescer whenremoving it from the housing.Possible damage to the waterseparator/coalescer or stand pipemay occur.

2. Pull the cap and waterseparator/coalescer straightup and allow the fuel to drainback.



3. Remove the waterseparator/coalescer (1) fromthe Water Separator/Coalescercap (2) by placing the filter on asolid surface and apply pressureon the Water Separator/Coalescercap at an angle.

4. Discard the filter.

5. Inspect inside the housing for anylarge debris and clean it out ifneeded.

6. Discard Water Separator/Coa-lescer cap seal ring.

Installation of the WaterSeparator/Coalescer

Install the water separator/coalesceras follows:

1. Snap a new waterseparator/coalescer into theWater Separator/Coalescer cap.

2. Install a new WaterSeparator/Coalescer cap sealring.

3. Apply a light coat ofpetroleum-based lithium grease totheWater Separator/Coalescer capseal ring and to the lower seal (1)on the water separator/coalescerfilter.

4. Install the waterseparator/coalescer into thefuel filter module.


6. Torque water separator/coalescercap to 55-60 N·m (41-44 ft·lb).

7. Once all required filters have beenchanged, prime the fuel systemusing the fuel priming valve orthe hand primer. Refer to sectionPriming the Fuel System.


HOW-TO PROCEDURES


9. Check for leaks.


NOTICE:





Engine Out of Fuel — Howto Restart

When an engine has run out of fuel,there is a definite procedure to followwhen restarting it.

NOTICE:

Never use the starting motor andfuel pump to prime the fuel filters.Prolonged use of the starting motorand fuel pumps to prime the fuelsystem can result in damage to thestarter, fuel pump, and injectors.Refer to section Priming the FuelSystem.

Use the following procedure to primethe fuel system:

1. Fill the fuel tank with therecommended grade of fuel. Ifonly partial filling is possible, adda minimum of 10% of the totaltank volume of fuel to the tank.For example, a 150-gallon tankwould require a minimum of 15gallons of fuel.

NOTE:If a vehicle is on uneven ground, morefuel may be required.

2. Operate hand primer for threeminutes or 250 strokes.

3. Crank engine for 20 seconds.

4. If engine does not start, allow fora 60-second cool down and repeatprevious step.

NOTE:The starting cycle can be repeated upto three times.



5. Start the engine with theaccelerator pedal in the idleposition. Monitor the oil pressuregauge or indicator lamp. Keepthe engine running at an idlingspeed until a stable oil pressurereading of 14 psi (97 kPa) or moreis maintained for one minute.

6. Check for leaks.


NOTICE:





11. If engine still fails to start, contactan authorized Detroit Dieselrepair facility.

How to Clean an Engine

Important: Observance of allenvironmental protection regulationsis required.

Cleaning with High-PressureEquipment

Use the high-pressure cleaningequipment as follows:

1. Information on suitable cleaningand protective products isavailable from any authorizeddealer. Note the equipmentmanufacturer's operatinginstructions.

NOTICE:

To prevent damage to enginecomponents, keep the watermoving at all times while cleaning.Never direct water onto electricalcomponents, plug connectors, sealsor flexible hoses.

2. Use the following minimumworking distance between thehigh-pressure nozzle and thesurface being cleaned:


HOW-TO PROCEDURES

EYE INJURY

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

• Approximately 28 in. (700mm) for circular pattern jets

• Approximately 12 in. (300mm) for 25-degree flat jets anddirt cutters

Cleaning the Engine

Power clean the engine as follows:

1. Allow engine to cool down toroom temperature before sprayingthe engine.

2. Thoroughly clean the entireengine using a steam cleaner orhigh pressure washer with mildsoap and warm water.

NOTICE:

Avoid all of the electrical connectionswith direct water or steam spray ordamage can result.

3. Once the engine is clean, blowthe electrical connectors dry withcompressed air to remove most ofthe standing water.

EYE INJURY


NOTE:Do not use compressed air orpressurized water to clean or dry theengine if any part of the engine isdisassembled.

4. Allow the engine to drycompletely before makingany kind of repair.

5. When reassembling, ensure thatthere is no standing water inany electrical connectors beforeseating the plug.

How to Clean the CoolingSystem

Important: Collect the used coolant,cleaning solutions, and washingliquids and dispose of them in anenvironmentally responsible manner.

Clean as follows:

1. First remove debris (such asdust, insects) from the fins of theradiator grille.



EYE INJURY


NOTICE:

Clean at moderate air pressuresonly to avoid damaging the radiatorgrille fins.

2. Remove the debris by blowingthem through with compressed airor spraying them out with water.Work from the rear of the radiator(in the opposite direction of thenormal cooling air flow).

3. Drain the coolant whenthe engine is cold. Fordetailed procedures, see thevehicle/chassis maintenancemanual. For types of coolant,refer to section How to SelectCoolant for the listing of requiredintervals using the recommendedcoolants.

4. If the HVAC unit is connectedto the cooling system, open theregulating valves all the way.

Degreasing the Cooling System

Degrease as follows:

1. Fill the cooling system with a 5%solution (1.6 ounces per quart[50 grams per liter] of water) ofa mildly alkaline cleaning agent,such as sodium carbonate.

2. Run the engine at moderate speeduntil the thermostat starts to open,at an operating temperature ofapproximately 60° C (140° F).Then run it for about five minuteslonger. Shut down the engine andallow it to cool to approximately50° C (112° F).

3. Drain all the cleaning solution.


HOW-TO PROCEDURES

HOT COOLANT


4. Flush the cleaning solution fromthe cooling system.

[a] Immediately after drainingthe cleaning solution, flushthe system with clean water.

[b] Once the clean water hasdrained, fill the system againwith clean water.

[c] Run the engine. Allowthe engine to warm up toapproximately 60° C (140°F), and then run it about fiveminutes longer.

[d] Drain the hot water.

5. Fill the cooling system with newcoolant. For detailed procedures,see the vehicle/chassismaintenance manual. Fortypes of coolant, refer to sectionHow to Select Coolant for the

listing of required intervals usingthe recommended coolants.

How to Select Coolant

This section covers selection of therequired coolant for the engine.

Coolant Definitions

To help ensure completeunderstanding of the information, thedefinitions of the following terms arelisted in the following Table.



Coolant Terms

Term Definition

Antifreeze

Ethylene Glycol containing a corrosion inhibitorpackage and which meets an appropriate heavy-dutyspecification (i.e., TMC RP-329 Type A or ASTMStandard D6210 Type A for ethylene glycol).

CoolantThe fluid mixture circulating in the engine coolingsystem, typically a mixture of 50% water and 50%antifreeze.

Drop–OutPrecipitated sludge or deposit formation on coolingsystem components.

Fully FormulatedAntifreeze

Contains all the necessary inhibitors to protect a dieselengine, and does not, therefore, require a pre-charge ofSupplemental Coolant Additive before its first use.

Initial–Fill CoolantThe coolant that is used in a new or rebuilt engine, orany time the cooling system is emptied and then refilledwith coolant.

OATOrganic Acid Technology. An inhibitor system basedon organic acid inhibitors instead of traditional NorthAmerican inhibitor formulations.

SCA

Supplemental Coolant Additive. Supplemental CoolantAdditives are used in a preventive maintenanceprogram to prevent corrosion, cavitation, and theformation of deposits.

Approved Coolants

Required specifications for water andethylene glycol inhibitor packages andinhibitor concentration are included inthis section.

NOTICE:

To avoid engine damage frominadequate or over concentratedcoolant, the required specificationsmust be adhered to before thecoolant is replaced.

The approved and preferred coolantsfor the engine are listed in thefollowing table.


HOW-TO PROCEDURES

Initial Fill Coolant Options

Coolant Fill Option Product

Ethylene Glycol & Water + CorrosionInhibitors *

Detroit Diesel Genuine Coolant

Ethylene Glycol & Water + NitritedOrganic Acid Technology Inhibitors

--

*Required CoolantOnce installed, this coolantshould be maintained accordingto the recommended procedures.Refer to section Maintenance.

Ethylene Glycol and WaterPlus Supplemental CoolantAdditive Inhibitor — Theseproducts are available as fullyformulated, phosphate-free, ExtendedService Interval coolants. They arecommercially available from DetroitDiesel (recommended) and othermanufacturers as either a concentratedantifreeze or as a premixed antifreeze.The premixed antifreeze is ready foruse, while the concentrated coolantmust be mixed with water prior to use.

Detroit Diesel Genuine Coolant (P/N:23512138) is the preferred ethyleneglycol coolant. If other commercialbrands of ethylene glycol are used,they must be equivalent to the DetroitDiesel Genuine Coolant.

Fully formulated antifreeze does notrequire a dosage of SupplementalCoolant Additive prior to initial use.

Mixing and Using EthyleneGlycol Antifreeze — Use ethyleneglycol antifreeze as follows:

1. If a concentrated ethyleneglycol antifreeze is purchased,mix the antifreeze with watermeeting the required qualitystandards and fill the coolingsystem. Refer to section WaterRequirements.

2. If a pre-diluted, fully-formulatedcoolant is purchased, fill thecooling system without dilution.

NOTE:For best overall performance, a coolantconsisting of 50% concentration ofantifreeze (50% antifreeze, 50%water) is recommended. Anantifreeze concentration over 67%(67% antifreeze, 33% water) is notrecommended due to poor heattransfer, reduced freeze protection(Inhibited Ethylene Glycol [IEG] only),and possible silicate dropout. Also, anantifreeze concentration below 33%(33% antifreeze, 67% water) offers too



little freeze and/or corrosion protectionand is not recommended.

3. Always verify that the freezepoint and nitrite concentration ofthe antifreeze/water mixture are

correct by using Detroit DieselGenuine Fluid Analysis 3–WayCoolant Test Strip. If chemicalanalysis is used, elements inthe coolant must fall within thefollowing limits.

Fully Formulated Glycol Coolant Concentration Limits with TMCRP-329 Chemistry Type A (50/50 Coolant/Water Mixture)

Boron 125 – 500 PPM

Nitrite 900 – 3200 PPM

Nitrate 200 – 1000 PPM

Silicon 50 – 150 PPM

Phosphorous 0 PPM

pH 8.0 – 11.0

Water Requirements —Distilled, reverse osmosis-purified,or de-ionized water which eliminatesthe adverse effects of minerals in tapwater is preferred.

High levels of dissolved chlorides,sulfates, magnesium, and calcium in

some tap water causes scale depositsand/or corrosion resulting in waterpump failures and poor heat transfer,leading to overheating. If tap wateris used, the mineral content in thewater must be below the followingmaximum allowable limits.

Satisfactory Water Limits – Make-Up Water Only

Maximum Allowable

Parts per Million Grains per Gallon

Chlorides 40 2.5

Sulfates 100 5.8

Total Dissolved Solids 340 20

Total Hardness –Magnesium and Calcium

170 10


HOW-TO PROCEDURES

NOTICE:

Do not add additional supplementalcoolant additives to new, fullyformulated antifreeze or coolant.This can result in dropout and/or theformation of deposits.

Coolant MaintenanceIntervals — Check the nitriteconcentration at the regular intervalslisted in the following table with aDetroit Diesel Genuine Fluid Analysis3–Way Test Strip.

Coolant Interval Action

20,000 miles (32,000 km)or 3 months

Test nitrite concentrationwith test strip. Add SCA ordilute coolant as needed.

Ethylene Glycol*/ Water +Conventional

Corrosion Inhibitor 300,000 miles (480,000 km)Drain and clean system.Refill with new coolant.

300,000 miles (48,000 km)or 10,000 hours

Add POWER COOL Plusextender.

Ethylene Glycol*/ Water + OAT

Inhibitor600,000 miles (960,000 km),4 years, or Engine Overhaul

Drain and clean system.Refill with new coolant.

300,000 miles (48,000 km)or 10,000 hours

Add NOAT extender.Ethylene Glycol*/ Water + NOAT

Inhibitor600,000 miles (960,000 km),4 years, or Engine Overhaul


20,000 miles (32,000 km),3 months, or 500 hours

Test nitrite concentrationwith test strip. Add SCA ordilute coolant as needed.

Water Only +Conventional

Corrosion InhibitorEngine Overhaul


300,000 miles (480,000 km),2 years, or 10,000 hours

Add POWER COOL Plusextender.Water Only + OAT

Inhibitor 600,000 miles (960,000 km),4 years, or Engine Overhaul


300,000 miles (480,000 km),2 years, or 10,000 hours

Add NOAT extender.Water Only +NOAT Inhibitor 600,000 miles (960,000 km),

4 years, or Engine OverhaulDrain and clean system.Refill with new coolant.

* Propylene glycol is an acceptable substitute for ethylene glycol.Coolants Not Recommended

The following coolants are notrecommended for use in Detroit Dieselengines.

Antifreezes and CoolantsContaining Phosphate —Coolants containing phosphate are notrecommended. Drop out, overheating,



and water pump seal failures can resultfrom the use of coolant or inhibitorpackages based on phosphate.

Automotive Type Coolants —These coolants generally contain highlevels of phosphate and silicate, offerno liner pitting protection, and arenot suitable for use in Detroit Dieselengines.

Methyl Alcohol-BasedAntifreeze —Methyl Alcohol-BasedAntifreeze must not be used becauseof its effect on the non-metalliccomponents of the cooling system andits low boiling point.

Glycol-Based CoolantsFormulated for HVAC —These coolants formulated forHeating/Ventilation/Air Conditioning(HVAC) should not be used. Thesecoolants generally contain high levelsof phosphates, which can depositon hot internal engine surfaces andreduce heat transfer.

Additives Not Recommended

The following additives are notrecommended for use in Detroit Dieselengines.

Soluble Oil Additives — Theseadditives are not approved for use inDetroit Diesel engine cooling systems.

A small amount of oil adverselyaffects heat transfer. For example, a1.25% concentration of soluble oilincreases fire deck temperature 6%.A 2.50% concentration increases firedeck temperature 15%. The use ofsoluble oil additives may result inengine overheating and/or failure.

Chromate Additives — Theseadditives are not approved for usein Detroit Diesel engine coolingsystems. Chromate additives canform chromium hydroxide, commonlycalled “green slime.” This, in turn,can result in engine damage due topoor heat transfer. Cooling systemsoperated with chromium-inhibitedcoolant must be chemically cleanedwith a recommended cooling systemcleaner/conditioner (or equivalentsulfamic acid/sodium carbonatecleaner) and flushed. Refer to sectionDetroit Diesel Genuine CoolingSystem Cleaners.


HOW-TO PROCEDURES

Testing for SupplementalCoolant Additives

Detroit Diesel Genuine Fluid Analysis3–Way Coolant Test Strips shouldbe used to measure nitrite and glycolconcentrations. Refer to sectionDetroit Diesel Genuine FluidAnalysis Products for part numbers.Cavitation/corrosion is indicatedon the strip by the level of nitriteconcentration. Freeze/boil overprotection is determined by glycolconcentration.

HOT COOLANT


For best results, take the test while thecoolant is between 10.0 – 60° C (50– 140° F). Wait at least 60, but notlonger than 75 seconds, before readingthe nitrite level.

Use the test strips as follows:

1. Dip the strip into coolant forone second. Remove and shakebriskly to eliminate excess fluid.

2. Immediately compare the pad end(% glycol) to the color chart onthe container.

3. Sixty seconds (one minute) afterdipping, compare the nitrite padto the color chart.

NOTE:Color change of the additive indicator(middle pad) indicates the presence ofinhibitor that is not approved by DetroitDiesel.

4. Promptly replace and tighten thetest strip container cap after eachuse. Discard unused strips if theyhave turned light pink or tan.

NOTE:A factory coolant analysis program isavailable through authorized DetroitDiesel service outlets. Refer to “DetroitDiesel Genuine Coolant Products” forpart numbers.



Removal of Dropout

Excessive amounts of some inhibitorsin the coolant can cause a gel orcrystalline deposit that reduces heattransfer and coolant flow. The deposit,called “dropout,” takes the color ofthe coolant when wet, but appears as awhite or gray powder when dry. It canpick up solid particles in the coolantand become gritty, causing excessivewear of water pump seals and othercooling system components.

PERSONAL INJURY

To avoid injury when usingcaustic cleaning agents, followthe chemical manufacturersusage, disposal, and safetyinstructions.

Remove the wet gel using a nonacid(alkali) type heavy-duty cleaner,such as Detroit Diesel GenuineCooling System On-Line Cleaner(sodium nitrite/sodium tetraborate).Refer to section Detroit DieselGenuine Cooling System Cleaners.

NOTE:If the gel is allowed to dry, it isnecessary to disassemble theengine and clean it with a causticsolution or physically clean individualcomponents.

Chronic Coolant SystemProblems

The most commonly seen coolantsystem problems result frommaintenance and formulation factorssuch as:

□ Hard water

□ Dilution of the coolant by theaddition of untreated water

□ Over dosage or under dosage ofcorrosion inhibitors

□ Improper corrosion inhibitor (mostoften phosphated)

□ Mixing Supplemental CoolantAdditives

□ Improper testing

Detroit Diesel Cooling SystemMaintenance Products

The following products are availableto do maintenance on the coolingsystem.

Detroit Diesel GenuineCoolant Supplemental CoolantAdditives — Detroit Diesel GenuineCoolant Supplemental CoolantAdditives are water-soluble chemicalcompounds. These products areavailable in coolant filter elements,liquid packages, and in fullyformulated Detroit Diesel GenuineCoolant antifreeze.


HOW-TO PROCEDURES

Summary of CoolantRecommendations

The Detroit Diesel coolantrecommendations for the engineare:

HOT COOLANT


□ Always maintain the enginecoolant to meet Detroit Dieselspecifications.

□ Only use water that meets thespecifications listed in thismanual. Distilled, demineralized(reverse osmosis) or de-ionizedwater is preferred. Refer to sectionWater Requirements.

□ The proper dosage of inhibitorsmust be included in the coolantat initial fill for all Detroit Dieselengines. This dosage is usuallyincluded in the fully formulatedantifreeze used, or it may needto be added if water alone or

if less than 50% antifreeze isused.The user is urged to usethe full text of this section todetermine the proper dosage.Mixing of different manufacturers'technologies (brands) could causecooling system problems.

□ Maintain the inhibitor at theprescribed concentration. Testthe nitrite concentration byusing a titration kit or DetroitDiesel Genuine Fluid Analysis3-Way Coolant Test Strips. AddSupplemental Coolant Additivesonly if the nitrite concentration isbelow 900 PPM.

NOTE:If the nitrite concentration exceeds3,200 PPM, the coolant must bedrained and replaced with newcoolant. A thorough cleaning of thecooling system may be required.

□ Do not use another manufacturer'stest kit to measure theSupplemental Coolant Additiveconcentration of Detroit Dieselmaintenance products.

□ Premix coolant makeup solutionsto the proper concentration beforeadding to the cooling system.

□ Do not mix Organic AcidTechnology and other coolants inthe same engine.

□ Do not use automotive coolants.



□ Where antifreeze/boil overprotection is required, use onlyantifreeze that meets TMCRP-329 Type A specification orASTM Standard D 6210 TypeA for Ethylene Glycol. Alwaysmaintain coolant at the properlevel.

□ Do not use the following in DetroitDiesel engine cooling systems:

• Soluble Oil

• High Silicate, Automotive-Type Antifreeze

• Chromate SupplementalCoolant Additives

• Methoxy Propanol-BasedCoolant

• Methyl Alcohol-Based Coolant

• Sealer Additives or CoolantContaining Sealer Additives

• HVAC Coolant

• Phosphate-Inhibited Coolant

• Nitrited Organic AcidTechnology Coolant

Coolant Life of Glycol Coolant —A properly maintained coolingsystem, filled with phosphate-freecoolant consisting of a 50/50 mix ofantifreeze and water per TMC RP-329“Type A” (EG) specifications can beoperated to the limits recommended.The proper maintenance involves

periodic evaluation using DetroitDiesel Genuine Fluid Analysis 3-WayCoolant Test Strips and the additionof Supplemental Coolant Additive asneeded, indicated by the strip test. Toverify coolant acceptability, submita sample for laboratory analysisonce a year. Submit the sample in aDetroit Diesel Genuine Fluid AnalysisCoolant Test Bottle. Refer to sectionDetroit Diesel Genuine Fluid AnalysisProducts for required part numberlistings in this manual.

How to Replace theCoolant Filter

The engine is equipped with acoolant filter. The coolant filtercontains supplemental corrosioninhibitors. Refer to section ScheduledMaintenance Intervals for the intervalto replace the coolant filter.

Service the cooling system as follows:


NOTE:Change the coolant filter only after thevehicle has cooled and no residualpressure is present.

2. Clean outside of the coolant filterhousing.


HOW-TO PROCEDURES

HOT COOLANT


NOTE:Use care to prevent foreign objectsfrom entering the filter housing.

3. Using a 36-mm socket, unscrewcap and filter and allow thecoolant to drain into the housing.After draining, remove theassembly from the housing.

4. Remove the filter from the plasticcap by placing the filter on a solidsurface and apply pressure on theplastic cap at an angle.

5. Remove coolant filter O-ring anddiscard it. Lightly lubricate a newO-ring with clean engine oil andinstall it on the filter cap.

6. Check filter housing for anydebris and remove if necessary.

7. Insert a new filter element intothe cap.

8. Insert element and cap assemblyinto the housing. Torque the capto 55-60 N·m (41-44 lb·ft).

9. Check coolant level and adjust ifnecessary.

10. Start engine with the acceleratorpedal in the idle position. Monitorall gauges or indicator lamps.

11. Check the filter housings for signsof leakage.

NOTE:In addition to the cleaning procedure,other components of the coolingsystem should be checked periodicallyto keep the engine operating at peakefficiency.

Checking the Hoses

Check the hoses as follows:

1. Inspect the cooling system hosesand replace any hose that showsobvious signs of damage or feelsabnormally soft or hard.

2. Replace damaged clamps.

3. Correct all external leaks as soonas detected.

NOTE:If Detroit Diesel Genuineantifreeze/coolant (or equivalent fullyformulated, pre-charged antifreeze isused, a pre-charged element is notrequired.



4. Check coolant inhibitor levels atthe intervals listed in this manual.Refer to section ScheduledMaintenance Intervals.

How to Service the DryType Air Cleaner

Maintain the air cleaner as follows:

1. Replace dry type air cleanerelements when the maximumallowable air cleaner restriction[20 in. H

2O (5.0 kPa)] has

been reached. Some aircleaners are equipped with arestriction indicator which aidsin determining the servicinginterval.

2. Do not clean and/or reuse drypaper-type air cleaner elementsunless the cleaning methodused removes clogging withoutdamaging the element.

3. Inspect and clean the elements inaccordance with the air cleanermanufacturer's recommendations,if any.


TROUBLESHOOTING

TROUBLESHOOTING

This section covers basictroubleshooting of engine operationor performance malfunctions andtheir probable causes. In addition tooperating the engine carefully and

maintaining it properly, make sure tocorrect any malfunction promptly.

Abnormal CoolantTemperature

Abnormal Coolant Temperature Symptoms and Probable Causes

Probable CausesAboveNormal

BelowNormal

Restricted cooling system passages X —

Restricted radiator core passages X —

Slipping fan drive belts X —

Faulty temperature-controlled fan X —

Obstruction in front of radiator or intercooler X —

Low coolant level X —

Damaged hoses X —

Faulty thermostat X —

Faulty water pump X —

Faulty radiator pressure cap X —

Air in coolant X —

Thermostat not fully closed — X

Leakage around thermostat seal — X

Faulty temperature-controlled fan — X



Hard Starting

Hard Starting Symptoms and Probable Causes

Probable CausesEngineWill NotRotate

LowCrankingSpeed

EngineCranks ButWill Not Start

Low Battery Voltage X X —Loose cranking motorconnections

X — —

Faulty cranking motor X X —Faulty cranking motor switch X X XInternal seizure X — —Improper lubricating oil — X —Circuit breaker/electroniccontrol malfunction

— — X

Fuse blown or missing — — XInsufficient Fuel SupplyAir in fuel — — XOut of fuel — — XLoose fuel connections — — XCracked fuel lines — — XObstructed fuel filters/lines — — XFaulty fuel pumps — — XFaulty injector operation — — XRestricted fuel fitting missing — — XDDEC Malfunction — — XInstallation/operation of fuelcheck valve or shutoff valve

— — X

Low CompressionWorn intake and exhaustvalves

— — X

Worn piston rings/liners — — XLeaking cylinder head gasket — — XImproper intake or exhaustvalve adjustments

— — X


TROUBLESHOOTING

Aftertreatment SystemOperating Characteristics

EPA07 engines that meet EPA 2007emissions standards and EPA10engines that meet EPA 2010 emissionsstandards are equipped with an ATSthat prevents 95% of the particulatematter (soot) from leaving the exhaust.This will eliminate the use of visiblesmoke diagnostics unless there is asystem failure issue. White smoke orsteam at start up or during cold weatheroperation is still a characteristic ofengine operation. Abnormal amountsof black/blue smoke may merit furtherinvestigation.



Abnormal EngineOperation

Abnormal Engine Operation Symptoms and Probable Causes

Probable Causes

RoughRunning orFrequentStalling

Low Power Detonation

Misfiring cylinder X X —

Insufficient fuel X X —

High return fuel temperature X X —

Low compression X X —

DDEC malfunction X X —

High air inlet restriction/ex-haust back pressure

— X —

Engine application — X —

High air inlet temperature — X —

High altitude operation — X —

Incorrect engine gear traintiming

— X —

Low coolant temperature — — X

Oil picked up by inlet airstream — — X

Faulty injector operation — — X

Incorrect injector heightsetting

— X X


TROUBLESHOOTING

Abnormal OperatingConditions

Abnormal Operating Condition Symptoms and Probable Causes

Probable Causes

High Lubri-cation OilConsump-

tion

Low OilPressure

Loose connections X —

Cracked lines X —

Damaged gaskets or seal rings X —

* Lubrication oil loss at breather tube X —

* Lubrication oil loss at dipstick tube X —

Leaking oil cooler X —

Leaking valve stem seals X —

Worn/broken oil control rings X —

Scored liner and/or piston X —

Excessive engine installation angle X —

Crankcase overfilled X —

Oil in air tanks (air compressor malfunction) X —

Plugged crankcase breather X —

Oil level low — X

Improper engine oil viscosity (fuel in the oil) — X

Faulty oil pressure regulator valve — X

Worn crankshaft, camshaft or connectingrod bearings

— X

Faulty oil pressure relief valve — X

Air leaks in oil pump (suction side) — X

Worn or damaged oil pump — X

Faulty oil pressure gauge — X

Faulty electrical components (for gauge) — X

Plugged oil line or orifice — X

* Indicates high crankcase pressure



ENGINE STORAGE

When an engine is to be stored orremoved from operation for a periodof time, special precautions shouldbe taken to protect the interior andexterior of the engine, transmissionand other parts from rust accumulationand corrosion. The parts requiringattention and the recommendedpreparations are given below.

Preparing Engine forStorage

It will be necessary to remove allrust or corrosion completely fromany exposed part before applying rustpreventive compound. Therefore,it is recommended that the enginebe processed for storage as soon aspossible after removal from operation.

The engine should be stored ina building that is dry and can beheated during the winter months.Moisture-absorbing chemicals areavailable commercially for use whenexcessive dampness prevails in thestorage area.

Temporary Storage (30 Days orLess)

To protect the engine for a temporaryperiod of time (30 days or less), followthis procedure:

1. With the engine at ambienttemperature and cool to the touch,drain engine crankcase oil into asuitable container. Dispose of theoil in an environmentally friendlymanner, according to state and/orfederal (EPA) recommendations.

2. Fill the crankcase to the properlevel with the recommendedviscosity and grade of oil.

3. Fill the fuel tank with therecommended grade of fuel oil.Operate the engine for two (2)minutes at 1200 rpm and no load.Do not drain the fuel system orthe crankcase after this run.

4. Check the air cleaner and serviceit, if necessary.

5. If freezing weather is expectedduring the storage period,check the antifreeze/coolant forrequired freeze and inhibitorprotection. Add antifreezesolution to the cooling systemin accordance with DetroitDiesel's recommendations.Refer to section How to SelectCoolant in this guide.

NOTE:If an antifreeze solution is not requiredduring storage, flush the coolingsystem with a good soluble oil (3% –5% by volume) rust inhibitor to prevent


ENGINE STORAGE

rusting of the outside diameter of thecylinder liners.

EYE INJURY


6. Clean the exterior of the engine(except electrical parts) with fueloil and dry with compressed air.

7. Seal all engine openings. Thematerial used must be waterproof,vapor-proof and possess sufficientphysical strength to resistpuncture and damage from theexpansion of entrapped air.

An engine prepared in this manner canbe returned to service in a short timeby removing the seals at the engineopenings and by checking the enginecoolant, fuel oil, lubricating oil andtransmission oil levels.

Extended Storage (More than 30Days)

To prepare an engine for extendedstorage (more than 30 days), followthis procedure:

1. Drain the cooling system andflush with clean, soft water. Refillwith clean, soft water and adda rust inhibitor to the coolingsystem.

2. Circulate the coolant by operatingthe engine until normal operatingtemperature is reached.

3. Stop the engine.

4. With the engine at ambienttemperature and cool to the touch,drain the engine crankcase oilinto a suitable container. Removethe oil filters. Dispose of the oiland filters in an environmentallyfriendly manner, accordingto state and/or federal (EPA)recommendations. Replace thedrain plug and torque to 45-50N·m (33-77 lb·ft).

5. Install new lubricating oilfilters. Fill the crankcase tothe proper level with Tectyl®930A preservative lubricatingoil or an equivalent 30-weightpreservative lubricating oilmeeting Mil-L-21260C, Grade 2Specification.

6. Drain the fuel tank. Refill withenough clean No. 1 diesel fuel topermit the engine to operate forabout ten (10) minutes. If drainingthe fuel tank is not convenient,



use a separate, portable supply ofrecommended fuel.

NOTE:If engines are stored wherecondensation of water in the fueltank may be a problem, additivescontaining methyl carbitol or butylcellusolve may be added to the fuel.Follow manufacturer's instructionsfor treatment. Where biologicalcontamination of fuel may be aproblem, add a biocide such asBiobor® JF (or equivalent) to thefuel. When using a biocide, followthe manufacturer's concentrationrecommendations and observe allcautions and warnings.

7. Drain the fuel system and removethe fuel filters. Dispose of usedfilters in an environmentallyresponsible manner, accordingto state and/or federal (EPA)recommendations. Fill the newfilters with No. 1 diesel fuel orpure kerosene and install on theengine.

8. Operate the engine for five (5)minutes to circulate the clean fuelthroughout the engine. Be surethe engine fuel system is full.

9. Stop the engine and allow tocool. Then disconnect the fuelreturn line and the inlet line atthe primary filter and securely

plug both to retain the fuel in theengine.

10. Transmission: Follow themanufacturer's recommendationsfor prolonged storage.

11. Power Take-Off: If equipped,follow manufacturer'srecommendations for prolongedstorage.

NOTICE:

Failure to properly seal off theturbocharger air inlet and exhaustoutlet openings before enginestorage may permit air drafts tocirculate through the turbochargerand rotate the turbine/compressorshaft without an adequate flow oflubricating oil to the center housingbearings resulting in severe bearingdamage.

12. Turbocharger: Sinceturbocharger bearings arepressure lubricated through theexternal oil line leading fromthe oil filter adaptor while theengine is operating, no furtherattention is required. However,the turbocharger air inlet andturbine exhaust outlet connectionshould be sealed off withmoisture-resistant tape.

13. Apply a non-friction rustpreventive compound to allexposed engine parts. If


ENGINE STORAGE

convenient, apply the rustpreventive compound to theengine flywheel. If not, disengagethe clutch mechanism to preventthe clutch disc from sticking tothe flywheel.

NOTE:Do not apply oil, grease or anywax-base compound to the flywheel.The cast iron will absorb thesesubstances, which can “sweat” outduring operation and cause the clutchto slip.

14. Drain the engine cooling system.If the engine will be exposedto freezing temperatures, installgenuine Detroit Diesel PowerCool antifreeze or an equivalentethylene glycol-base or propyleneglycol-base antifreeze solutionthat provides the required freeze,boil over and inhibitor protection.Refer to the Detroit DieselPOWER COOL section in thisguide.

15. Drain the preservative oil fromthe engine crankcase. Reinstalland torque the 3/4” – 14 square,magnetic drain plug to 45-50 N·m(33-77 lb·ft).

16. Remove and clean the batteryand battery cables with a bakingsoda-water solution and rinsewith fresh water. Do not allowthe soda solution to enter the

battery. Add distilled water tothe electrolyte (if necessary) andfully charge the battery. Store thebattery in a cool (never below 0°C or 32° F) dry place. Keep thebattery fully charged and checkthe level and specific gravity ofthe electrolyte regularly.

17. Insert heavy paper strips betweenthe pulleys and drive belts toprevent sticking.

18. Seal all engine openings,including the exhaust outlet,with moisture-resistant tape. Usecardboard, plywood or metalcovers where practical.

19. Clean and dry the exterior paintedsurfaces of the engine and spraywith a suitable liquid automobilebody wax, a synthetic resinvarnish, or a rust preventivecompound.

20. Protect the engine with a goodweather-resistant tarpaulin andstore it under cover, preferablyin a dry building which can beheated during the winter months.

Outdoor storage of the engine is notrecommended. If units must be keptout of doors, follow the preparationand storage instructions alreadygiven. Protect units with quality,weather-resistant tarpaulins (or othersuitable covers) arranged to providefor air circulation.



NOTICE:

Do not use plastic sheeting foroutdoor storage. Enough moisturecan condense on the inside of theplastic to rust ferrous metal surfacesand pit aluminum surfaces. If a unitis stored outside for any extendedperiod of time, severe corrosiondamage can result.

NOTE:Plastic is fine for indoor storage.

The stored engine should be inspectedperiodically. If there are anyindications of rust or corrosion,corrective steps must be taken toprevent damage to the engine parts.Perform a complete inspection at theend of one year and apply additionaltreatment as required.

Procedure for Restoring toService an Engine that Has Beenin Extended Storage

If an engine has been in extendedstorage, prepare it for service asfollows:

1. Remove the covers and tape fromall the openings of the engine, fueltank and electrical equipment. Donot overlook the exhaust outlet.

2. Remove the plugs from the inletand outlet fuel lines and reconnectthe lines to their proper positions.

3. Wash the exterior of the enginewith fuel oil to remove therust preventive. Do not washelectrical components.

4. Remove the rust preventive fromthe flywheel. Flush any solubleoil rust inhibitor (if used) in thecooling system.

5. Remove the paper strips frombetween the pulleys and drivebelts.

6. Fill the crankcase to the properlevel with the required grade oflubricating oil. Use a pressurelubricator to insure all bearingsand rocker shafts are lubricated.

7. Fill the fuel tank with the requiredfuel.

8. Close all drain cocks and fill theengine cooling system with clean,soft water and required inhibitors.If the engine is to be exposedto freezing temperatures, installgenuine Detroit Diesel PowerCool antifreeze or an equivalentethylene glycol-base or propyleneglycol-base antifreeze solutionwhich provides required freeze,boil over, and inhibitor protection.Refer to section How to SelectCoolant.

9. Install and connect the battery.Make sure the average specificgravity of the battery is 1.260


ENGINE STORAGE

or higher. Charge the battery, ifnecessary.

10. Service the air cleaner, if required.

11. Transmission: Follow themanufacturer's recommendationscovering the return of thetransmission to service.

12. Power Take-Off: If equipped,follow the manufacturer'srecommendations covering thereturn of the power take-off toservice.

13. Turbocharger: Remove thecovers from the turbochargerair inlet and turbine outletconnections. Reconnectpiping as required. Prelubethe turbocharger center bearinghousing. Refer to sectionLubrication System Checks ofthis guide.

ENGINE EXHAUST


14. After all preparations arecompleted, start the engine.

NOTE:The small amount of rust preventivewhich remains in the fuel systemwill cause smoky exhaust for a fewminutes.

NOTE:Before subjecting the engine to a loador high speed, allow it to reach normaloperating temperature.

15. Check for trouble codes.

[a] If there are no codes, performa parked regeneration.

[b] If there are codes, repair whatis necessary then perform aparked regeneration.



CUSTOMER ASSISTANCE

The satisfaction and goodwill of theowners of Detroit Diesel engines are ofprimary concern to Detroit Diesel andits distributor/dealer organizations.

Contact the Customer Support Centerat 1–313-592-5800.

Using Road Service in theU.S. or Canada

If you require road service for anyreason in the U.S. or Canada, you maycall the 1–800–445–1980 customerassistance phone number. An operatorwill assist you in determining whattype of service is required. Not allproblems are engine related and notall problems are covered by engineor vehicle warranties. YOU MAYBE RESPONSIBLE FOR REPAIREXPENSES.

Before calling Customer Assistance,please do the following:

1. Check the coolant level.

2. Check the fuel level.

3. Check the DDEC fuses.

4. Check for fuel leaks.

5. Make sure manual shutoff valve(if installed) on the fuel filteradaptor or fuel supply line isopen.

6. Check the oil level on the dipstick.

7. Check the diagnostic codes.

8. If you call, have the followinginformation available:

• Engine serial number

• Vehicle make, model, and VIN

• Odometer mileage (kilometers)or hour meter hours

• Vehicle owner/company name

Availability of DetroitDiesel Service Outlets

As the owner of a Detroit Dieselproduct, you have a complete networkof Detroit Diesel service outlets in theU.S. and Canada, plus many outletsworldwide that are prepared to meetyour parts and service needs:

□ Service by trained personnel

□ Sales team to help determine yourspecific power requirements

□ In many areas, emergency service24 hours a day

□ Complete parts support

□ Product information and literature


CUSTOMER ASSISTANCE

We recognize however, that despitethe best intentions of everyoneconcerned, misunderstandings mayoccur. Normally, any situation thatarises in connection with the sale,operation or service of your productwill be handled by the authorizedservice outlet in your area (in theU.S. and Canada, check the YellowPages or the service locator atwww.detroitdiesel.com for DetroitDiesel service outlet nearest you).



SPECIFICATIONS

This section lists the various DetroitDiesel Genuine Coolant engineproducts.

Fuel and Lubricating OilFilters

Consult with a Detroit DieselDistributor to obtain the proper fuelfilters and lubricating oil filters.

Engine Oil Capacities

The engine oil capacities for the DDPlatform Engine On-Highway Vehicleapplication are listed in the followingTable. Contact your local DetroitDiesel service center if you need morespecific information.

NOTE:There are approximately 3.8 L (4.0qt) from the fill mark to the full mark.Overfilling the oil pan can causeengine damage.

Engine Oil Capacities

Quantities

DescriptionDD13 DD15 DD16

Total Engine Oil Volume 39.5 L (41.7 qt) 44.5 (47.0) NA

Main Galleries 3.0 L (3.1 qt) 3.0 (3.1) NA

Average Oil and FilterChange

36.6 L (38.7 qt) 41.6 (44.0) NA

Detroit Diesel GenuineCoolant Engine Products

Maintenance of the cooling systemrequires the chemical makeup of thesystem to be balanced.

Detroit Diesel Genuine FullyFormulated Inhibited EthyleneGlycol Coolants

The part numbers and sizes ofconcentrated and pre-blended 50:50Detroit Diesel Genuine Coolants arelisted in the following Tables.


SPECIFICATIONS

Detroit Diesel Genuine Fully Formulated InhibitedEthylene Glycol Coolants

Coolant Type Part Number Description

23512138 One Gallon Jug – 6 Per Case

23512139 55 Gallon Drum

23529295 330 Gallon ToteConcentrated

23512140 Bulk Delivery – 1,000 Gallon Min.

23528203 One Gallon Jug – 6 Per Case


23528544 330 Gallon Tote

Pre-blended50:50

23513503 Bulk Delivery – 1,000 Gallon Min.

Detroit Diesel GenuineSupplemental Coolant AdditiveNeed Release Filters

Detroit Diesel Genuine Supplemental Coolant Addi-tive Need Release Filters

Coolant Type Part Number Description

NF2091 For 0 – 8 Gallon SystemsDetroit DieselGenuine InhibitedEthylene Glycol

Coolant23516489 For 8 – 20 Gallon Systems



Detroit Diesel Genuine CoolingSystem Cleaners

Detroit Diesel Genuine Cooling System Cleaners

Coolant TypePart

NumberDescription

200164 One-Half Gallon Jug – 6 Per Case

200105 5 Gallon PailOn-Line Cleaner


Twin Pack 201549 Twin Pack – 2 Per Case

Detroit Diesel Genuine FluidAnalysis Products

Detroit Diesel Genuine Fluid Testing and Analysis Products

ApplicationPart

NumberDescription

Indicates Nitrite,Molybdate & Glycol

Levels23519401

3-Way Coolant Test Strips (SingleFoil Packs)


Levels23519402 3-Way Coolant Test Strips (Bottle of 50)


Levels23522774 3-Way Coolant Test Strips (Bottle of 10)

Complete InhibitedEthylene Glycol Coolant

Analysis23516921 Coolant Analysis Bottle (Carton of 6)

Organic CoolantAnalysis

23523398 Laboratory Coolant Analysis


DDC-SVC-MAN-0075.PDF - EPA10 DD Platform Operators Manual€¦ · 25.02.2013 · EPA10 DD PLATFORM OPERATORS MANUAL To the Operator This manual contains instructions on the safe

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