Detroit Diesel DD15 EuroIV Operator'S Manual Download

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Troubleshooting

This section covers basic troubleshooting of engine operation or performance
malfunctions and their probable causes. In addition to operating the engine
carefully and maintaining it properly, make sure to correct any malfunction
promptly.

Abnormal Coolant Temperature

This section explains Abnormal Coolant Temperature Symptoms and Probable
Causes.

Table 10.

Abnormal Coolant Temperature Symptoms and Probable Causes

Probable Causes

Above Normal

Below Normal

Restricted cooling system passages

—

Restricted radiator core passages

—

Slipping fan drive belts

—

Faulty temperature-controlled fan

—

Obstruction in front of radiator or intercooler

—

Low coolant level

—

Damaged hoses

—

Faulty thermostat

—

Faulty water pump

—

Faulty radiator pressure cap

—

Air in coolant

—

Thermostat not fully closed

—

Leakage around thermostat seal

—

Faulty temperature-controlled fan

—

Hard Starting

This section explains hard starting.

DD Platform EuroIV Operators Manual

All information subject to change without notice.

103

DDC-SVC-MAN-0175

Summary of Contents for DD15 EuroIV

Page 1: ...tors Manual Specifications are subject to change without notice Detroit Diesel Corporation is registered to ISO 9001 2001 Copyright Detroit Diesel Corporation All rights reserved Detroit Diesel Corporation is a Daimler company Printed in U S A ...

Page 2: ...ling 50 Engine Brake System 51 Driver Control Switches 51 Clutch Pedal and Throttle Position Controls 51 Engine Brake Activation Conditions 51 Engine Brake Operation 51 Anti Lock Braking Systems 52 Operating on Flat Dry Pavement 53 Operating Down a Long Steep Grade 53 Operating on Wet or Slippery Pavement 54 Engine Systems 56 Preventive Maintenance Intervals 58 Preventive Maintenance Intervals 58 ...

Page 3: ...uel 81 How to Replace the Fuel Filters 83 Engine Out of Fuel How to Restart 89 How to Clean an Engine 90 How to Clean the Cooling System 91 Degreasing the Cooling System 92 How to Select Coolant 92 How to Replace the Coolant Filter 100 Checking the Hoses 101 How to Service the Dry Type Air Cleaner 101 Troubleshooting 103 Abnormal Coolant Temperature 103 Hard Starting 103 Abnormal Engine Operation ...

Page 4: ...he engine s useful emission life Detroit cautions that the indiscriminate rebuilding of precision components without the benefit of specifications specialized equipment and knowledge of the electronic operating system will jeopardize performance or lead to more serious problems and can take the engine outside of compliance with U S EPA or CARB emissions standards There are several other components...

Page 5: ...d modifications are made to it Detroit will not accept responsibility for any resulting damage Tampering with the fuel injection system and engine electronics could also affect engine power output or exhaust emission levels Compliance with the manufacturer s settings and with statutory environmental protection regulations cannot then be guaranteed DD Platform EuroIV Operators Manual All informatio...

Page 6: ...tion and specifications in this publication are based on the information in effect at the time of approval for printing Contact an authorized Detroit service outlet for information on the latest revision The right is reserved to make changes at any time without obligation Detroit engines are built in accordance with sound technological principles and based on state of the art technology Despite th...

Page 7: ...mark Information DDC Detroit DDEC Optimized Idle Diagnostic Link POWER Trac POWER COOL and POWER GUARD are registered trademarks of Detroit Diesel Corporation All other trademarks used are the property of their respective owners DD Platform EuroIV Operators Manual All information subject to change without notice 7 DDC SVC MAN 0175 Copyright 2014 DETROIT DIESEL CORPORATION ...

Page 8: ...injury from the loss of vehicle control do not use cruise control under these conditions When it is not possible to keep the vehicle at a constant speed on winding roads in heavy traffic in traffic that varies in speed etc On slippery roads wet pavement ice or snow covered roads loose gravel etc WARNING PERSONAL INJURY Diesel engine exhaust and some of its constituents are known to the State of Ca...

Page 9: ...d grid heater Preventive Maintenance Observe the following cautions when performing preventive maintenance WARNING PERSONAL INJURY To avoid injury when working near or on an operating engine remove loose items of clothing and jewelry Tie back or contain long hair that could be caught in any moving part causing injury WARNING PERSONAL INJURY To avoid injury when working on or near an operating engi...

Page 10: ... the engine immediately if an oil leak is detected WARNING PERSONAL INJURY To avoid injury from contact with rotating parts when an engine is operating with the air inlet piping removed install an air inlet screen shield over the turbocharger air inlet The shield prevents contact with rotating parts WARNING HOT COOLANT To avoid scalding from the expulsion of hot coolant never remove the cooling sy...

Page 11: ...psi air pressure Cooling System Observe the following cautions when servicing the cooling system WARNING HOT COOLANT To avoid scalding from the expulsion of hot coolant never remove the cooling system pressure cap while the engine is at operating temperature Wear adequate protective clothing face shield rubber gloves apron and boots Remove the cap slowly to relieve pressure WARNING PERSONAL INJURY...

Page 12: ...sconnect disable the starting system Air Intake System Observe the following cautions when working on the air intake system WARNING PERSONAL INJURY To avoid injury from hot surfaces wear protective gloves or allow engine to cool before removing any component WARNING PERSONAL INJURY To avoid injury from contact with rotating parts when an engine is operating with the air inlet piping removed instal...

Page 13: ...injury from fire keep all potential ignition sources away from diesel fuel including open flames sparks and electrical resistance heating elements Do not smoke when refueling WARNING PERSONAL INJURY To prevent the escape of high pressure fuel that can penetrate skin ensure the engine has been shut down for a minimum of 10 minutes before servicing any component within the high pressure circuit Resi...

Page 14: ...leak is detected Do not smoke or allow open flames when working on an operating engine Wear adequate protective clothing face shield insulated gloves and apron etc To prevent a buildup of potentially volatile vapors keep the engine area well ventilated during operation Caution Summary 14 All information subject to change without notice Copyright 2014 DETROIT DIESEL CORPORATION DDC SVC MAN 0175 ...

Page 15: ...major components see the following 1 Axial Power Turbine 2 Exhaust Gas Recirculation EGR Cooler 3 Exhaust Gas Recirculation EGR Valve Actuator 4 Turbocharger 5 Crankcase Breather 6 Fuel Doser Valve Figure 1 DD15 Left Side View DD Platform EuroIV Operators Manual All information subject to change without notice 15 DDC SVC MAN 0175 Copyright 2014 DETROIT DIESEL CORPORATION ...

Page 16: ...mation covers engine model number serial number and certification label Engine Model and Serial Number The fourteen digit engine model and manufacturing serial number is etched on a pad located on the left front of the engine cylinder block above the date and time of manufacture Using 472908S0005703 as an example 472 engine model DD15 EuroIV 908 vehicle application Freightliner EuroIV S assembly p...

Page 17: ...r Control Module and Engine Serial Number The Motor Control Module MCM part number and Engine Serial Number ESN are located on the MCM label DD Platform EuroIV Operators Manual All information subject to change without notice 17 DDC SVC MAN 0175 Copyright 2014 DETROIT DIESEL CORPORATION ...

Page 18: ...tifies the engine conforms to federal and state emissions regulations for its application It gives the operating conditions under which certification was made The following illustration is an EPA07 engine certification exemption label Engine Identification 18 All information subject to change without notice Copyright 2014 DETROIT DIESEL CORPORATION DDC SVC MAN 0175 ...

Page 19: ...Figure 5 EuroIV Engine Certification Exemption Label DD Platform EuroIV Operators Manual All information subject to change without notice 19 DDC SVC MAN 0175 Copyright 2014 DETROIT DIESEL CORPORATION ...

Page 20: ...of the problem Engine damage may be avoided by a quick response to early indications of problems When starting the engine in cold weather Refer to section Cold Weather Operation System Checks Perform the following system checks before starting for the first time Checking the Cooling System Check the cooling system as follows 1 Make sure all drain cocks in the cooling system are installed drain coc...

Page 21: ...o Replace the Lubricating Oil and Oil Filter section in this manual 3 After pre lubricating check the engine oil level If necessary top off by filling engine oil no more than 5 0 L 5 2 qt at a time through the oil fill cap to the satisfactory fill range on the oil dipstick Do not overfill Checking and Monitoring the Oil Level Check the oil level as follows WARNING PERSONAL INJURY To avoid injury f...

Page 22: ...sure to dissipate through the guide tube and let the oil level settle in the oil pan 5 Reinstall the dipstick and make sure it is fully inserted into the guide tube 6 Remove the dipstick and read the oil level dipstick 7 The figure shows a comparison between the bends on the dipstick and a crosshatch pattern on a conventional dipstick Note the exact area noted on the bends For example the maximum ...

Page 23: ...n at engine startup For this reason Detroit recommends replacing the engine lubricating oil and filters after extended storage Fuel System Checks Make sure the fuel shutoff valve if used is open Fill the tanks with the recommended fuel Keeping tanks full reduces water condensation and helps keep fuel cool which is important to engine performance Full tanks also reduce the chance for microbe black ...

Page 24: ...ly equipped for this type of service Priming is required if the fuel system has been serviced Drain off any water that has accumulated Water in fuel can seriously affect engine performance and may cause engine damage Adding Fuel When adding fuel pay attention to the following Add winter or summer grade fuel according to the season of the year Work in the cleanest conditions possible Prevent water ...

Page 25: ...ºF NOTICE Increasing engine speed above idle before oil pressure has stabilized may cause severe engine damage 8 Increase engine speed to 1800 rpm for three minutes 9 Return the engine to idle and allow to idle for approximately one minute then shut down the engine 10 Check for leaks Repair if necessary Checking Other Engine Parts Check the engine compartment as follows Make sure the transmission ...

Page 26: ... injury from inhaling engine exhaust always operate the engine in a well ventilated area Engine exhaust is toxic WARNING PERSONAL INJURY To avoid injury when working near or on an operating engine equipped with an hydraulic clutch fan remove loose items of clothing and jewelry Tie back or contain long hair that could be caught in any moving part causing injury The hydraulic fan may start without w...

Page 27: ...he engine system indicator lights on the instrument panel to go out 4 With foot off the accelerator pedal start the engine 5 If the engine does not start after 20 seconds stop Try again after waiting about 60 seconds NOTICE Do not increase engine speed if the oil pressure gauge indicates no oil pressure Shut down the engine within approximately ten seconds to avoid engine damage Check to determine...

Page 28: ...p before applying a load Inspection During Idling While the engine is idling inspect the transmission and crankcase for fluid leaks On DD15 engines check the Axial Power Turbine APT for oil leaks Checking the Transmission While the engine is idling check the automatic transmission if equipped for proper oil level and add oil as required Checking for Fluid Leaks Check for fluid leaks as follows 1 L...

Page 29: ...ow to Replace the Lubricating Oil and Oil Filter section in this manual Checking the Turbocharger Check the turbocharger as follows 1 Make a visual inspection of the turbocharger for oil leaks exhaust leaks excessive noise or vibration 2 If a leak unusual noise or vibration is noted stop the engine immediately Do not restart the engine until the cause of the concern has been investigated and corre...

Page 30: ...t the turbocharger from continuing to turn without an oil supply to the bearings or damage can result 1 Reduce engine speed to idle and put all shift levers in the neutral position NOTE Cool down idling needs to take place after pulling off an interstate When finding a parking spot or backing into a dock immediate shutdown should be avoided Shutting the engine off immediately retains more block he...

Page 31: ...to positive and negative to chassis or suitable ground The proper sequence is to connect negative to negative ground last Routine Engine Start The following are procedures for a routine engine start WARNING ENGINE EXHAUST To avoid injury from inhaling engine exhaust always operate the engine in a well ventilated area Engine exhaust is toxic WARNING PERSONAL INJURY To avoid injury when working near...

Page 32: ...engine for leaks a Check all hoses hose clamps and pipe unions on the engine for tightness Shut down the engine and tighten them if necessary b Check the oil feed and return lines at the turbocharger for leaks Shut down the engine and tighten them if necessary 5 Shut down the engine NOTE If the engine operating temperature is below 60ºC 140ºF the engine must be on a level surface and then shut dow...

Page 33: ...system is correctly filled when the coolant is between the full and low marks on the surge tank Checking the Coolant Level Hot Check Check the coolant levels as follows 1 Allow the engine to run for approximately five minutes at a moderate speed 2 After the coolant temperature reaches 50 C 122 F recheck the coolant level in the surge tank DD Platform EuroIV Operators Manual All information subject...

Page 34: ...he engine starts If the indicator light comes on while the engine is running do the following 1 Shut down the engine 2 Test the charging system per OEM guidelines WARNING BATTERY EXPLOSION To avoid injury from battery explosion when jump starting the engine do not attach the cable end to the negative terminal of the disabled battery 3 If necessary visit the nearest authorized dealer to have the al...

Page 35: ...e swings back and forth or falls sharply Engine power and rpm fall even though the accelerator pedal remains steady The exhaust pipe gives off heavy smoke The coolant and or oil temperature climb abnormally Abnormal sounds suddenly occur in the engine or turbocharger Emergency Running Mode The engine is equipped with an electronic motor control system which monitors the engine as it is running NOT...

Page 36: ...wn timer restoring power to the level when the RSL Stop Engine was illuminated The switch must be recycled after five seconds to obtain a subsequent override NOTE The operator has the responsibility to take action to avoid engine damage Cold Weather Operation Special precautions must be taken during cold weather To protect your engine special cold weather handling is required for fuel engine oil c...

Page 37: ...o the charge air cooler tube flow direction This assures even cooling across each tube and reduces header to tube stress and possible failure Winter fronts should only be used when the ambient temperature remains below 12 C 10 F DD Platform EuroIV Operators Manual All information subject to change without notice 37 DDC SVC MAN 0175 Copyright 2014 DETROIT DIESEL CORPORATION ...

Page 38: ... and J1939 datalinks where it can be read by the diagnostic tool The engine control system monitors both the engine and the datalink When a malfunction or other problem is detected the system selects an appropriate response for example the emergency running mode may be activated The Accelerator Pedal Assembly AP eliminates the need for any throttle linkage Motor Control Module Description The Moto...

Page 39: ...CPC communicates with any other Motor Control Module MCM unit installed on the vehicle over the J1939 data link Data for specific applications is stored in the CPC These include idle speed maximum running speed and speed limitation From these data instructions are computed for controlling the engine and transmitted to the CPC via the proprietary datalink The CPC receives data from the following so...

Page 40: ...s may cause minor changes in features and engine performance Since the DDEC system is electronic a battery is required to operate the computer The system operates at 12 volts However in the event of a power supply malfunction the system will continue to operate at reduced voltage When this occurs the AWL Check Engine will come on Detroit Diesel Electronic Controls DDEC System 40 All information su...

Page 41: ...ne can be configured to give a warning only to ramp down reduce power or to shut down Ramp down will reduce engine rpm to a predetermined speed but will not shut down the engine With the 30 second shutdown option the engine will begin a 30 second stepped power down sequence until it shuts down completely The Stop Engine Override feature can be activated in the case where the vehicle is operating i...

Page 42: ...nd corrected Red Stop Lamp The conditions that will cause the RSL Stop Engine to come on are High coolant temperature Loss of coolant High oil temperature Low oil pressure Auxiliary shutdown If the malfunction is intermittent the lights will come on and go off as the computer senses the changing engine condition Diagnostic Tool The diagnostic tool for Detroit Diesel Electronic Control is the Detro...

Page 43: ...sition The flashing code feature is deactivated once the Stop Engine Override Switch is returned to the OFF position or the listed conditions are no longer satisfied Only one light will be flashing codes at any time All codes will be flashed twice The inter digit pause is 1 5 seconds The pause between codes is 3 5 seconds The same 3 5 second pause occurs as the switch is made from RSL Stop Engine ...

Page 44: ...onitoring of other system components Depending on the application the electronic engine control system can monitor oil temperature coolant temperature oil pressure fuel pressure coolant level and remote sensors if used The electronic engine control system activates the Amber Warning Lamp AWL Check Engine and the Red Stop Lamp RSL Stop Engine to provide a visual warning of a system malfunction Data...

Page 45: ...dia diagnostics Bluetooth functionality NOT approved at this time Engine Brake The engine brake is enabled by a dash mounted ON OFF Switch with a separate intensity switch to select low medium or high braking power CAUTION LOSS OF VEHICLE CONTROL To avoid injury from loss of vehicle control do not activate the Engine Brake system under the following conditions On wet or slippery pavement unless th...

Page 46: ...ne operation for a short period of time Using the override button so the engine does not shut down in 30 seconds but operates for an extended period may result in engine damage This system features a 30 second stepped power shutdown sequence or an immediate speed reduction without shutdown in the event a major engine malfunction occurs such as low oil pressure high oil or coolant temperature or lo...

Page 47: ...tem in your car It can be operated in any gear above 1100 rpm or road speed faster than 20 mph 32 kph up to the rated engine speed It also can be programmed to hold your road speed at or below the maximum vehicle speed The switch to energize Cruise Control is usually mounted on the instrument panel or steering wheel Engine speed and power are varied under Cruise Control to maintain the set vehicle...

Page 48: ...ruise Control has been disabled toggling the RSM ACC Switch restores the vehicle to the previously set cruise speed press the RSM ACC Switch To reduce road speed press and hold the SET CST Switch until the lower speed is reached Cruise Control can be overridden at any time with the throttle pedal if the vehicle is operating at less than the programmed Max Road Speed Cruise Control is deactivated b...

Page 49: ...ontrol may also be programmed to permit fast idle using the Cruise Control switches With the engine at normal idle transmission in neutral and service brakes on press the SPD CNTL Switch and use the RSM ACC Switch The engine rpm should increase to a pre defined speed The engine rpm can be raised or lowered from this point using the SET CST and RSM ACC switches Engine Brake and Cruise Control Your ...

Page 50: ...fing sound as the engine starts to pull hard at lower rpm This is normal and caused by the velocity changes of the air flow within the air intake plumbing Electronic engines can actually deliver more fuel at lower engine speeds than at rated speed The engine has been designed for a very quiet operation but the air flow may be noticeable to the tuned attentive ear The turbocharger operates at highe...

Page 51: ...n this switch activates all six cylinders providing full engine brake horsepower NOTE There is very little difference in the exhaust sound when the engine brakes are activated in either the medium or high position Clutch Pedal and Throttle Position Controls Engine brakes have two additional controls one activated by the position of the clutch pedal and the other activated by the position of the th...

Page 52: ...r pulling an empty trailer If the tractor drive wheels begin to lock or there is fishtail motion after the Engine Brake is activated deactivate the brake system immediately if this occurs Under normal driving conditions the engine brake system is left in the ON position However this should change if roads become wet or slippery NOTICE Do not attempt to double clutch the transmission while the engi...

Page 53: ...ive braking switch to the HIGH position Check your progressive braking switch often for proper position since road conditions can change quickly Never skip a step when operating the progressive braking switch Always go from OFF to LOW and then to a higher position Operating Down a Long Steep Grade An explanation of speed may be helpful in understanding how to use the engine brake system while desc...

Page 54: ...brake You could not descend that same hill at 50 mph 80 kph and still expect to remain under control Get to know how much slowing power your engine brake can provide So get to know your engine brake system before climbing hills and do not exceed a safe control speed 4 Check your progressive braking switch often for proper position LOW MED HIGH since road conditions can change quickly Never skip a ...

Page 55: ...keep the trailer stretched out Follow the manufacturer s recommended operating procedure when using your trailer brakes 2 If the tractor drive wheels begin to lock or there is fishtail motion after the Engine Brake is activated deactivate the brake system immediately if this occurs 3 However if the tractor drive wheels begin to lock or there is a fishtail motion turn the engine brake system OFF im...

Page 56: ...borne contaminants service the dry type air cleaners used when the maximum allowable air restriction has been reached Cooling System A radiator thermo modulated fan cooling system is used on the engine This system has a centrifugal type coolant pump to circulate coolant within the engine One full blocking type thermostat located in the coolant module attached to the left side of the cylinder block...

Page 57: ...ions The EGR system has been optimized to dramatically cut NOx formation by routing a measured amount of exhaust flow to the cylinders to lower combustion temperatures Lower temperatures result in lower NOx levels without the negative effects of retarding engine timing The EGR valve has been moved to the top of the engine for improved serviceability DD Platform EuroIV Operators Manual All informat...

Page 58: ... and Filters and publication Coolant Selections for Detroit Engines available from authorized Detroit distributors Each maintenance table shows which maintenance operation must be performed at the recommended interval in miles kilometers and hours NOTE Failure to check and maintain Supplemental Coolant Additive levels at required concentrations will result in severe damage corrosion to the engine ...

Page 59: ...same mileage intervals Proper valve lash clearance allows the engine to produce the best possible performance with the lowest emissions Valve lash adjustments should be performed by an authorized Detroit maintenance or repair facility Drive Belt Belts should be neither too tight nor too loose Belts that are too tight impose extra loads on the crankshaft fan and or alternator bearings shortening bo...

Page 60: ...Water Separator Incorporated into the fuel filter module is a fuel water separator The separator removes emulsified water as well as droplets and is located in the lower compartment of the fuel filter module A water in fuel WIF sensor indicates when trapped water needs to be drained NOTICE Do not over tighten the water drain valve Failure to properly tighten the water drain valve may cause damage ...

Page 61: ...ent should be inspected per the maintenance intervals or more often if the engine is operated under severe dust conditions Replace the element if necessary Check the gaskets for deterioration and replace if necessary If the dry type air cleaner is equipped with an aspirator check for aspirator damage or clogging Clean repair or replace as necessary NOTICE Do not allow the air inlet restriction to ...

Page 62: ...systems of a diesel engine air lubrication and coolant Proper inspection of air compressor would include inspecting for air oil and coolant leaks Due to inadequate internal sealing air compressors when failed can produce excessive crankcase pressure or allow an engine to ingest oil Vibration Damper The viscous vibration damper should be inspected periodically and replaced if dented or leaking Heat...

Page 63: ... 000 miles 160 000 km at 500 000 miles 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 Air Compressor I I I I I I Whichever comes first Currently Davco 482 is the only frame mounted filtration system compatible for Detroit Engines Refer to Routine Preventive Maintenance for a description of al...

Page 64: ... How to Select Lubricating Oil NOTICE Do NOT fill beyond the maximum fill level on the dipstick since overfilling may result in high oil consumption and possible severe engine damage NOTE If the engine operating temperature is below 60 C 140 F the engine must be on a level surface and then shut down for 60 minutes for an accurate oil level reading Otherwise the engine must be brought up to an oper...

Page 65: ...o use some oil so the periodic addition of oil is normal Before adding lubricating oil refer to How to Select Lubricating Oil Monitoring the Lubricating Oil Filter The engines are equipped with a single cartridge style oil filter 1 that is part of the oil coolant module Incorporated into the housing is a drain back port which allows residual oil to be returned to the oil pan when the filter is rem...

Page 66: ...ine WARNING HOT COOLANT To avoid scalding from the expulsion of hot coolant never remove the cooling system pressure cap while the engine is at operating temperature Wear adequate protective clothing face shield rubber gloves apron and boots Remove the cap slowly to relieve pressure 1 Check the coolant level daily and maintain it between the full and low marks on the surge tank 2 Add coolant as re...

Page 67: ...ted in this manual Failure to check and maintain Supplemental Coolant Additive levels at required concentrations will result in severe damage corrosion to the engine cooling system and related components The cooling system is protected by a Supplemental Coolant Additive element In addition the engine can be equipped with a coolant filter inhibitor system as an installed option or as an after sale ...

Page 68: ...e distance intervals indicated by each specific Maintenance Interval chart Refer to section Preventive Maintenance Tables Monitoring the Fuel Filters Monitoring the Fuel System Filters The engine is equipped with a prefilter that filters down to 100 microns a coalescer final filter that separates water and filters down to 3 to 5 microns When servicing these elements all two filters should be chang...

Page 69: ...that may cause damage to the belt and accessory drive components WARNING PERSONAL INJURY To avoid injury from rotating belts and fans do not remove and discard safety guards 1 Inspect the belt tensioner for wear or damage 2 If damage is found it may need to be replaced by an authorized Detroit maintenance or repair facility Monitoring the Serpentine Belts Two poly V belts 8 and 9 are used on the e...

Page 70: ...cleaner element every 50 000 miles 80 000 km or more often if the engine is operating under severe dust conditions Replace the element if necessary 2 Check the gaskets for deterioration and replace if necessary 3 If the dry type air cleaner is equipped with an aspirator check for aspirator damage or clogging Clean repair or replace as necessary NOTICE Do not allow the air inlet restriction to exce...

Page 71: ...or air oil and coolant leaks Monitoring the Fuel and Fuel Tank To prevent fuel and fuel tank problems the following measures are recommended 1 Keep the fuel tank filled to reduce condensation 2 Before adding fuel Refer to section How to Select Diesel Fuel 3 Refill the tank at the end of each day s operation to prevent condensation from contaminating the fuel Condensation formed in a partially fill...

Page 72: ...al to machine operation but they can also result in added expense caused by the need to replace lost fluids Inspection of Hoses and Fittings Check hoses daily as part of the pre start inspection Examine hoses for leaks and check all fittings clamps and ties carefully Make sure hoses are not resting on or touching shafts couplings heated surfaces including exhaust manifolds sharp edges or other obv...

Page 73: ...G PERSONAL INJURY To avoid injury from hot surfaces wear protective gloves or allow engine to cool before removing any component 3 Check the turbocharger for unusual noise or vibration and if excessive stop the engine and do not operate until the cause is determined 4 Periodically inspect the air to air charge air cooler for buildup of dirt mud or other debris Clean as necessary 5 Check the charge...

Page 74: ...attery connections for corrosion and tightness a If necessary remove connections and wire brush any corrosion from terminals and cable ends b Replace damaged wiring Steam Cleaning the Engine NOTICE Do not apply steam or solvent directly to the battery charging alternator starting motor DDEC components sensors or other electrical components as damage may result The engine and engine compartment sho...

Page 75: ...ttery can result in damage to the battery diodes In applications which have two sets of batteries switching from one set to the other while the engine is running will momentarily disconnect the batteries If a booster battery is to be used batteries must be connected correctly negative to negative positive to positive Never use a fast charger with the batteries connected or as a booster for battery...

Page 76: ...peration may over a period of time cause the fluid within the damper to break down and lose its dampening properties For this reason replace the viscous vibration damper at time of normal major engine overhaul regardless of apparent condition Routine Preventive Maintenance 76 All information subject to change without notice Copyright 2014 DETROIT DIESEL CORPORATION DDC SVC MAN 0175 ...

Page 77: ...or failure to follow the manufacturer s fuel or lubricating recommendations may not be within the coverage of the warranty How to Select Lubricating Oil NOTICE Detroit POWER GUARD Oil Specification 93K214 is recommended for all EuroIV cooled EGR equipped engines without aftertreatment devices or any engine operating on Low Sulfur fuel 500 ppm These engines meet 2002 to 2006 model year emission req...

Page 78: ...l mileage However they are generally more costly than non synthetic oils Product information about synthetic oils should be reviewed carefully Performance additive systems often respond differently in synthetic oils Use of Supplemental Additives Lubricants meeting the Detroit specifications outlined in this publication already contain a balanced additive treatment Supplemental additives are genera...

Page 79: ...isted in tables in this manual Change the oil and replace the lubricating oil filter as follows NOTE If the used oil was contaminated by fuel or coolant it may be necessary to take the vehicle to a certified Detroit Service Center The Service Center may drain the oil and then remove the oil pan oil pump and oil pump intake manifold to drain the remaining oil held back by the backflow valve It is i...

Page 80: ...stick There are approximately 5 0 L 5 2 qt from the fill mark to the full mark Overfilling the oil pan can cause engine damage 11 Add new engine oil through the oil fill tube in the following amount Refer to section Engine Oil Capacities Verify the oil level reading is between the full and fill marks on the dipstick WARNING PERSONAL INJURY To avoid injury before starting and running the engine ens...

Page 81: ...surface and then shut down for five minutes for an accurate oil level reading 13 Check the filter housing for signs of leakage 14 Stop the engine Check the oil level again per the following guidelines If necessary add oil no more than 5 0 L 5 2 qt at a time up to the maximum fill level on the oil dipstick How to Select Diesel Fuel All EuroIV DD engines are designed to operate on Low Sulfur Diesel ...

Page 82: ...age Our experience has been that such additives increase operating costs without providing benefit The use of supplemental fuel additives does not necessarily void the engine warranty However repair expenses which result from fuel system or engine component malfunctions or damage attributed to their use will not be covered Biodiesel 1 General recommendations and guidelines Detroit supports biodies...

Page 83: ...roved fuel additives containing sulfur or sulfated ash How to Replace the Fuel Filters NOTICE If you have just changed the engine oil and filter you MUST start the engine and confirm proper oil pressure before changing the fuel filters If no oil pressure is shown after approximately 10 seconds stop the engine and determine the cause Running the engine with no oil pressure could result in engine da...

Page 84: ...d removals at cold temperatures may break the filter element tabs Removal of the Fuel Prefilter Remove the prefilter as follows 1 Using a 36 mm socket unscrew the prefilter cap 2 Pull the cap and prefilter straight up and out of the fuel filter housing 3 Remove the prefilter 1 from the prefilter cap 2 by placing the filter on a solid surface and apply pressure on prefilter cap 2 at an angle 4 Disc...

Page 85: ...ghten 6 Torque prefilter cap to 55 60 N m 41 44 ft lb 7 Once all required filters have been changed prime the fuel system using the ESOC 350 J 47912 or the engine mounted hand primer WARNING ENGINE EXHAUST To avoid injury from inhaling engine exhaust always operate the engine in a well ventilated area Engine exhaust is toxic WARNING PERSONAL INJURY To avoid injury before starting and running the e...

Page 86: ...r leaks Removal of the Water Coalescer Final Filter Remove the water coalescer final filter as follows NOTICE Do not tilt the water coalescer final filter when removing it from the housing Possible damage to the water coalescer final filter or stand pipe may occur 1 Using a 36mm socket unscrew the water coalescer final filter cap 2 Pull the cap and water coalescer final filter straight up and allo...

Page 87: ...Install a new seal ring on to water coalescer final filter cap 2 Snap a new water coalescer final filter into the water coalescer final filter cap 3 Apply a light coat of Parker super O lube or petroleum based lithium grease to the water coalescer final filter cap seal ring and drain back plug seal ring C Apply a heavy coat of Parker super O lube or petroleum based lithium grease to the upper A an...

Page 88: ...of lubricant to use on the upper and lower seals 4 Install the water coalescer final filter into the fuel filter module How to Procedures 88 All information subject to change without notice Copyright 2014 DETROIT DIESEL CORPORATION DDC SVC MAN 0175 ...

Page 89: ...ith the accelerator pedal in the idle position Monitor the oil pressure gauge or indicator lamp Keep the engine running at an idling speed until a stable oil pressure reading of 97 kPa 14 psi or more is maintained for one minute 9 Check for leaks 10 Allow the engine to reach operating temperature of 60 C 140 F NOTICE Increasing engine speed above idle before oil pressure has stabilized may cause s...

Page 90: ...stable oil pressure reading of 97 kPa 14 psi or more is maintained for one minute 9 Check for leaks 10 Allow the engine to reach operating temperature of 60 C 140 F NOTICE Increasing engine speed above idle before oil pressure has stabilized may cause severe engine damage 11 Increase engine speed to 1800 RPM for three minutes 12 Return the engine to idle and allow to idle for approximately one min...

Page 91: ...TE Do not use compressed air or pressurized water to clean or dry the engine if any part of the engine is disassembled 3 Once the engine is clean blow the electrical connectors dry with compressed air to remove most of the standing water 4 Allow the engine to dry completely before making any kind of repair 5 When reassembling ensure that there is no standing water in any electrical connectors befo...

Page 92: ...tem with a 5 solution 1 6 ounces per quart 50 grams per liter of water of a mildly alkaline cleaning agent such as sodium carbonate 2 Run the engine at moderate speed until the thermostat starts to open at an operating temperature of approximately 60 C 140 F Then run it for about five minutes longer Shut down the engine and allow it to cool to approximately 50 C 112 F 3 Drain all the cleaning solu...

Page 93: ...olant Additive before its first use Initial Fill Coolant The coolant that is used in a new or rebuilt engine or any time the cooling system is emptied and then refilled with coolant OAT Organic Acid Technology An inhibitor system based on organic acid inhibitors instead of traditional North American inhibitor formulations SCA Supplemental Coolant Additive Supplemental Coolant Additives are used in...

Page 94: ...or to initial use Mixing and Using Ethylene Glycol Antifreeze Use ethylene glycol antifreeze as follows If a concentrated ethylene glycol antifreeze is purchased mix the antifreeze with water meeting the required quality standards and fill the cooling system If a pre diluted fully formulated coolant is purchased fill the cooling system without dilution NOTE For best overall performance a coolant c...

Page 95: ...r is used the mineral content in the water must be below the following maximum allowable limits Table 8 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 NOTICE Do not add additional supplemental coolant additives to new fully formulated antif...

Page 96: ...em Refill with new coolant Water Only Conventional Corrosion Inhibitor 20 000 miles 32 000 km 3 months or 500 hours Test nitrite concentration with test strip Add SCA or dilute coolant as needed Engine Overhaul Drain and clean system Refill with new coolant Water Only OAT Inhibitor 300 000 miles 480 000 km 2 years or 10 000 hours Add POWERCOOL Plus extender 600 000 miles 960 000 km 4 years or Engi...

Page 97: ...or example a 1 25 concentration of soluble oil increases fire deck temperature 6 A 2 50 concentration increases fire deck temperature 15 The use of soluble oil additives may result in engine overheating and or failure Chromate Additives These additives are not approved for use in Detroit engine cooling systems Chromate additives can form chromium hydroxide commonly called green slime This in turn ...

Page 98: ...d dropout takes the color of the coolant when wet but appears as a white or gray powder when dry It can pick up solid particles in the coolant and become gritty causing excessive wear of water pump seals and other cooling system components WARNING PERSONAL INJURY To avoid injury when using caustic cleaning agents follow the chemical manufacturers usage disposal and safety instructions NOTE If the ...

Page 99: ...eze is used The user is urged to use the full text of this section to determine the proper dosage Mixing of different manufacturers technologies brands could cause cooling system problems Maintain the inhibitor at the prescribed concentration Test the nitrite concentration by using a titration kit or Detroit Genuine Fluid Analysis 3 Way Coolant Test Strips Add Supplemental Coolant Additives only i...

Page 100: ...ine is equipped with a coolant filter The coolant filter contains supplemental corrosion inhibitors Refer to the EPA07 or EPA10 Preventative Maintenance Tables for the interval in which to replace the coolant filter Refer to section EPA07 DD Series Preventive Maintenance Tables Refer to section EPA10 GHG14 DD Series Preventive Maintenance Tables NOTE In addition to the cleaning procedure other com...

Page 101: ...ne exhaust is toxic WARNING PERSONAL INJURY To avoid injury before starting and running the engine ensure the vehicle is parked on a level surface parking brake is set and the wheels are blocked 10 Start engine with the accelerator pedal in the idle position Monitor all gauges or indicator lamps 11 Check the filter housings for signs of leakage Checking the Hoses Check the hoses as follows 1 Inspe...

Page 102: ...triction indicator which aids in determining the servicing interval 2 Do not clean and or reuse dry paper type air cleaner elements unless the cleaning method used removes clogging without damaging the element 3 Inspect and clean the elements in accordance with the air cleaner manufacturer s recommendations if any How to Procedures 102 All information subject to change without notice Copyright 201...

Page 103: ...Causes Above Normal Below Normal 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 s...

Page 104: ...uel X Loose fuel connections X Cracked fuel lines X Obstructed fuel filters lines X Faulty fuel pumps X Faulty injector operation X Restricted fuel fitting missing X DDEC Malfunction X Installation operation of fuel check valve or shutoff valve X Low Compression Worn intake and exhaust valves X Worn piston rings liners X Leaking cylinder head gasket X Improper intake or exhaust valve adjustments X...

Page 105: ...et airstream X Faulty injector operation X Incorrect injector height setting X X Abnormal Operating Conditions This section explains Abnormal Operating Condition Symptoms and Probable Causes Table 13 Abnormal Operating Condition Symptoms and Probable Causes Probable Causes High Lubrication Oil Consumption Low Oil Pressure Loose connections X Cracked lines X Damaged gaskets or seal rings X Lubricat...

Page 106: ...ne oil viscosity fuel in the oil X Faulty oil pressure regulator valve X Worn crankshaft camshaft or connecting rod 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 Troubleshooting 106 All information subje...

Page 107: ...To protect the engine for a temporary period of time 30 days or less follow this procedure 1 With the engine at ambient temperature and cool to the touch drain engine crankcase oil into a suitable container Dispose of the oil in an environmentally friendly manner according to state and or federal EPA recommendations 2 Fill the crankcase to the proper level with the recommended viscosity and grade ...

Page 108: ...corrosion damage can result NOTE Plastic is fine for indoor storage The stored engine should be inspected periodically If there are any indications of rust or corrosion corrective steps must be taken to prevent damage to the engine parts Perform a complete inspection at the end of one year and apply additional treatment as required To prepare an engine for extended storage more than 30 days follow...

Page 109: ...rculate the clean fuel throughout the engine Be sure the engine fuel system is full 9 Stop the engine and allow to cool Then disconnect the fuel return line and the inlet line at the primary filter and securely plug both to retain the fuel in the engine 10 Transmission Follow the manufacturer s recommendations for prolonged storage 11 Power Take Off If equipped follow manufacturer s recommendation...

Page 110: ...ngs including the exhaust outlet with moisture resistant tape Use cardboard plywood or metal covers where practical 19 Clean and dry the exterior painted surfaces of the engine and spray with a suitable liquid automobile body wax a synthetic resin varnish or a rust preventive compound 20 Protect the engine with a good weather resistant tarpaulin and store it under cover preferably in a dry buildin...

Page 111: ...ff to service 13 Turbocharger Remove the covers from the turbocharger air inlet and turbine outlet connections Reconnect piping as required Pre lube the turbocharger center bearing housing Refer to section Lubrication System Checks 14 Fill the cooling system Refer to section Cooling System Fill Procedure WARNING ENGINE EXHAUST To avoid injury from inhaling engine exhaust always operate the engine ...

Page 112: ...uel leaks Make sure manual shutoff valve if installed on the fuel filter adaptor or fuel supply line is open Check the oil level on the dipstick Check the diagnostic codes If you call have the following information available Engine serial number Vehicle make model and VIN Odometer mileage kilometers or hour meter hours Vehicle owner company name Availability of Detroit Service Outlets As the owner...

Page 113: ...he sale operation or service of your product will be handled by the authorized service outlet in your area in Latin America check the service locator at www demanddetroit com for Detroit service outlet nearest you DD Platform EuroIV Operators Manual All information subject to change without notice 113 DDC SVC MAN 0175 Copyright 2014 DETROIT DIESEL CORPORATION ...

Page 114: ...n Min Pre blended 50 50 23528203 One Gallon Jug 6 Per Case 23518918 55 Gallon Drum 23528544 330 Gallon Tote 23513503 Bulk Delivery 1 000 Gallon Min Detroit Genuine Supplemental Coolant Additive Need Release Filters Detroit Genuine Supplemental Coolant Additive Need Release Filters are shown below Table 15 Detroit Genuine Supplemental Coolant Additive Need Release Filters Coolant Type Part Number D...

Page 115: ...mber Description Indicates Nitrite Molybdate Glycol Levels 23519401 3 Way Coolant Test Strips Single Foil Packs Indicates Nitrite Molybdate Glycol Levels 23519402 3 Way Coolant Test Strips Bottle of 50 Indicates Nitrite Molybdate Glycol Levels 23522774 3 Way Coolant Test Strips Bottle of 10 Complete Inhibited Ethylene Glycol Coolant Analysis 23516921 Coolant Analysis Bottle Carton of 6 Organic Coo...

Page 116: ... 51 8 qt Oil and Filter Change 38 0 L 40 1 qt 43 0 L 45 4 qt 43 0 L 45 4 qt Remaining in Engine after Oil Drain Includes Filter Removal 6 0 L 6 3 qt 6 0 L 6 3 qt 6 0 L 6 3 qt Dip Stick Min to Max Range 5 0 L 5 2 qt 5 0 L 5 2 qt 5 0 L 5 2 qt Sump Oil Volume 35 0 L 37 0 qt 40 0 L 42 3 qt 40 0 L 42 3 qt Table 19 Coach EPA10 DD13 GHG14 DD13 Total Dry Engine Oil Volume 51 0 L 53 8 qt 47 0 L 49 7 qt Oil...

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