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SERIES 40 ENGINE OPERATOR'S GUIDE

WARRANTY PERIOD

Warranty Limitations

(Whichever Occurs First)

Repair Charges to Be

Paid by Owner

Item

MONTHS

MILES/KILO-

METERS

PARTS

LABOR

Engine

0 – 60

0 – 50,000

Miles

0 – 80,000

Kilometers

No Charge

No Charge

Accessories

0 – 24

0 – 50,000

Miles

0 – 80,000

Kilometers

No Charge

No Charge

Table 40 Warranty Period – Fire Truck or Crash Vehicle Applications

Like Replacement Engine

Engine(s) supplied by DDC as a
replacement for an Engine still under
warranty will assume the identity of
the Engine being replaced and be
entitled to the remaining warranty
coverage.

Service Supplies

The cost of service supplies such as
coolant, oil and

fi

lters which are not

reusable due to warranted repairs is
covered by this warranty.

Engine Removal and Reinstallation

Reasonable labor costs for Engine
removal and reinstallation, when
necessary to make a warranty repair,
are covered by this warranty.

THIS WARRANTY DOES NOT
COVER:

Repairs Due to Accidents, Misuse,
Alteration, Storage Damage,
Negligence or Certain Modifications

Repairs due to an accident, misuse,
alteration, misapplication, storage
damage, negligence or modi

fi

cation

exceeding DDC speci

fi

cations are not

covered by this warranty.

Maintenance

DDC is not responsible for the cost of
maintenance or repairs due to lack of
performance of required maintenance
services as recommended by DDC, or
the failure to use fuel, oil, lubricants, or
coolant meeting DDC-recommended
speci

fi

cations. Performance of

the required maintenance and use of
proper fuel, oil, lubricants, and coolant
are the responsibility of the owner.
Refer to section MAINTENANCE
SCHEDULES in this guide for details.

All information subject to change without notice.

(Rev. May 2004)

133

DDC-SVC-MAN-0057 0305

Copyright © 2003 DETROIT DIESEL CORPORATION

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Summary of Contents for EPA04 Series 40

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Page 3: ... Throughout this guide CAUTIONS regarding personal safety and NOTICES regarding engine performance or service life will appear To avoid personal injury and ensure long engine service life always heed these instructions Whenever possible it will benefit you to rely on an authorized Detroit Diesel service outlet for all your service needs from maintenance to major parts replacement Authorized servic...

Page 4: ...t Diesel service outlets Keep this Operator s Guide with the engine installation at all times It contains important operating maintenance and safety instructions Trademark Information Detroit Diesel DDC DDEC reliabilt POWER COOL POWER Trac and POWER GUARD are registered trademarks of Detroit Diesel Corporation Series 40 is a trademark of Detroit Diesel Corporation Delco Remy is a registered tradem...

Page 5: ...EM CHECKS 19 FUEL SYSTEM CHECKS 20 OTHER CHECKS 21 STARTING THE ENGINE 22 ENGINE DIAGNOSTIC BUTTON 23 INITIAL ENGINE START 23 EMERGENCY JUMP STARTING 24 RUNNING THE ENGINE 26 OIL PRESSURE 26 WARM UP 26 INSPECTION 26 AVOID UNNECESSARY IDLING 27 STOPPING THE ENGINE 27 NORMAL STOPPING 27 SHUTDOWN WARNING LIGHT AND BUZZER 27 ROAD OPERATION 28 COLD WEATHER OPERATION 28 HOT WEATHER OPERATION 29 EXTENDED...

Page 6: ...NHIBITORS 58 COOLANT DRAIN INTERVAL 58 ITEM 5 TURBOCHARGER AIR TO AIR CHARGE COOLER 60 ITEM 6 BATTERY 60 ITEM 7 DRIVE BELTS 61 ITEM 8 AIR COMPRESSOR 62 ITEM 9 AIR CLEANER 62 AIR CLEANER REPLACEMENT 63 ITEM 10 LUBRICATING OIL FILTERS 63 ITEM 11 FUEL FILTERS 64 FUEL FILTER AND STRAINER 64 FUEL PRO 382 FILTERS 66 ITEM 12 WATER PUMP COOLANT INHIBITOR ELEMENT 66 WATER PUMP 66 COOLANT INHIBITOR ELEMENT ...

Page 7: ...EQUIREMENTS 73 THE USE OF SUPPLEMENTAL ADDITIVES 74 B WHEN TO CHANGE OIL 75 OIL DRAIN INTERVALS 75 DISPOSING OF WASTE OIL 76 C HOW TO REPLACE THE LUBE OIL FILTER 76 REPLACE SPIN ON TYPE OIL FILTER 77 D HOW TO SELECT FUEL OIL 78 QUALITY 78 FUEL CONTAMINATION 79 PROHIBITED ADDITIVES 79 USED LUBRICATING OIL 79 GASOLINE 79 E HOW TO REPLACE THE FUEL FILTER 80 REPLACE FUEL FILTER AND STRAINER 80 PRIME T...

Page 8: ...TERVAL 101 CHRONIC COOLANT SYSTEM PROBLEMS 102 MAINTENANCE PRODUCTS 102 POWER COOL SCAS 102 POWER COOL COOLANT FILTER ELEMENTS 102 POWER COOL CLEANERS 102 SUMMARY OF COOLANT RECOMMENDATIONS 103 H HOW TO REPLACE THE COOLANT FILTER 105 I HOW TO DRAIN AND FLUSH THE COOLING SYSTEM 106 J WHEN TO SERVICE THE DRY TYPE AIR CLEANER 108 BASIC TROUBLESHOOTING 109 ENGINE STORAGE 116 PREPARING ENGINE FOR STORA...

Page 9: ...43 FULLY FORMULATED IEG COOLANT 143 LATIN AMERICAN COOLANT 143 2000 SUPPLEMENTAL COOLANT ADDITIVE 144 3000 SUPPLEMENTAL COOLANT ADDITIVE 144 3000 SUPPLEMENTAL ADDITIVE COOLANT FILTERS 145 SUPPLEMENTAL ADDITIVE NEED RELEASE FILTERS 145 PLUS EXTENDED LIFE OAT COOLANT 146 PLUS EXTENDER FOR POWER COOL PLUS OAT COOLANT 146 PLUS OAT INHIBITOR FOR WATER ONLY SYSTEMS 147 COOLING SYSTEM CLEANERS 147 COOLAN...

Page 10: ...TABLE OF CONTENTS viii All information subject to change without notice Rev May 2004 DDC SVC MAN 0057 0305 Copyright 2003 DETROIT DIESEL CORPORATION ...

Page 11: ...ents engineered to comply with emissions regulations may be performed by an authorized Detroit Diesel distributor or dealer an independent outlet or the operator or owner The owner is responsible for determining the suitability of components to maintain emissions compliance during the engine s useful emission life Electronic controls and components have significantly increased in sophistication bu...

Page 12: ...mponents in repair or rebuild of the engine may be in violation of the federal Clean Air Act and applicable U S EPA Environmental Protection Agency or CARB California Air Resources Board regulations Furthermore modern engines exhibit operating parameters which require the use of proper fluids such as fuel coolant and lubricating oil to maintain long engine life The use of fluids that do not meet D...

Page 13: ...hicle 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 To avoid injury from loss of vehicle control do not activate the Engine Brake system under the following conditions On wet or slippery pavement unless the vehicle is equipped with ABS anti lock braking system and you have had prio...

Page 14: ...gine To avoid injury when working near or on an operating engine remove loose items of clothing jewelry tie back or contain long hair that could be caught in any moving part causing injury To avoid injury when working on or near an operating engine wear protective clothing eye protection and hearing protection To avoid injury from hot oil do not operate the engine with the rocker cover s removed T...

Page 15: ...ive clothing face shield or safety goggles rubber gloves apron and boots To avoid injury from hot surfaces allow engine to cool before removing any component Wear protective gloves To avoid injury use care when working around moving belts and rotating parts on the engine To avoid injury from contact with rotating parts when an engine is operating with the air inlet piping removed install an air in...

Page 16: ... Lubricating oil is relatively harmless at ambient temperatures To avoid injury from rotating belts and fans do not remove and discard safety guards To avoid injury when using caustic cleaning agents follow the chemical manufacturers usage disposal and safety instructions 3 Observe the following cautions when using compressed air To avoid injury from flying debris when using compressed air wear ad...

Page 17: ...rom flames explosion and toxicants when using ether the following precautions must be taken Do not smoke when servicing ether system Work in well ventilated area Do not work near open flames pilot flames gas or oil heaters or sparks Do not weld or carry an open flame near the ether system if you smell ether or otherwise suspect a leak 5 Observe the following cautions when jump starting an engine c...

Page 18: ...tery terminals alternator terminals or wiring cables while the engine is operating 6 Observe the following cautions when fueling the vehicle replacing fuel filters or working with the engine fuel system To avoid increased risk of a fuel fire do not mix gasoline and diesel fuel To avoid injury from fire keep all potential ignition sources away from diesel fuel open flames sparks and electrical resi...

Page 19: ...res 7 Observe the following cautions when servicing the cooling system To avoid injury from the expulsion of hot coolant never remove the cooling system pressure cap while the engine is at operating temperature Remove the cap slowly to relieve pressure Wear adequate protective clothing face shield or safety goggles rubber gloves apron and boots To avoid injury from slipping and falling immediately...

Page 20: ...involved in servicing away from the engine Stop the engine immediately if an oil leak is detected Do not allow open flames or smoke when working on an operating engine Wear adequate protective clothing face shield insulated gloves apron etc to avoid burns To prevent a buildup of potentially volatile vapors keep the engine area well ventilated during operation Lubricating oil is relatively harmless...

Page 21: ...injector nozzles Operators of these engines should refer to Series 40 Engine Operators Guide 6SE516 for preventive maintenance information Engines built from 1998 present are direct fuel injected with hydraulically actuated electronically controlled unit injectors This operator s guide covers these current engines Component Locations The following figures show the locations of major engine compone...

Page 22: ...over 3 Camshaft Position Sensor 8 Vibration Damper 4 Coolant Temperature Sensor 9 Mounting Bracket 5 Thermostat Figure 1 Major Component Locations Front View 12 All information subject to change without notice Rev May 2004 DDC SVC MAN 0057 0305 Copyright 2003 DETROIT DIESEL CORPORATION ...

Page 23: ...ll Tube 5 Fuel Supply Pump 14 Flywheel Housing 6 31 Pin Connector 15 Oil Pan 7 Wiring Harness Connector 16 Fuel Filter 8 Valve Cover Intake Manifold 17 Air Compressor if equipped 9 Lifting Eye 2 18 Injection Pressure Regulating Valve Figure 2 Major Component Locations Left Side View All information subject to change without notice Rev May 2004 13 DDC SVC MAN 0057 0305 Copyright 2003 DETROIT DIESEL...

Page 24: ...ube 9 Coolant Filter 4 Exhaust Manifold 10 Water Inlet 5 Turbocharger 11 Oil Cooler 6 Valve Cover Intake Manifold 12 Oil Pan Figure 3 Major Component Locations Right Side View 14 All information subject to change without notice Rev May 2004 DDC SVC MAN 0057 0305 Copyright 2003 DETROIT DIESEL CORPORATION ...

Page 25: ... Draft Tube 2 Oil Fill Tube 5 Turbocharger 3 Oil Level Gage 6 Flywheel Housing Figure 4 Major Component Locations Rear View All information subject to change without notice Rev May 2004 15 DDC SVC MAN 0057 0305 Copyright 2003 DETROIT DIESEL CORPORATION ...

Page 26: ...ER LOCATIONS Figure 5 Model Serial Number and Emission Label Former Location Figure 6 Model Serial Number and Emission Label Current Location 16 All information subject to change without notice Rev May 2004 DDC SVC MAN 0057 0305 Copyright 2003 DETROIT DIESEL CORPORATION ...

Page 27: ...achined pad on the right side of the block and directly above the oil cooler See Figure 6 Turbocharger Identification The turbocharger identification plate is located on the flat inboard face of the compressor housing See Figure 7 Figure 7 Turbocharger Identification non wastegate turbo shown All information subject to change without notice Rev May 2004 17 DDC SVC MAN 0057 0305 Copyright 2003 DETR...

Page 28: ...stem or emission control system To avoid injury when working near or on an operating engine remove loose items of clothing jewelry tie back or contain long hair that could be caught in any moving part causing injury Cooling System Checks 1 Make sure all drain cocks in the cooling system are installed drain cocks are often removed for shipping and are closed tightly 2 Remove the radiator pressure c...

Page 29: ...surfaces at initial engine startup the engine lubrication system should be charged with a commercially available pressure pre lubricator If this is impractical rocker cover should be removed and clean lubricating oil should be poured over the rocker arms The oil should be the same weight and viscosity as that used in the crankcase After pre lubricating replace rocker cover and add additional oil t...

Page 30: ...ks full reduces water condensation and helps keep fuel cool which is important to engine performance Full tanks also reduce the chance for microbe black slime growth For fuel recommendations refer to section D How to Select Fuel Oil in the How To section of this guide Make sure the fuel shutoff valve if used is open NOTICE Do not use the engine starting system to prime the fuel system before initi...

Page 31: ...d before initial engine start Use this procedure NOTE Authorized Detroit Diesel service outlets are properly equipped and have the trained technicians to perform this service NOTICE Failure to disconnect the CMP camshaft position sensor before priming the engine may allow the engine to start during priming which could result in severe engine damage 1 Disconnect the CMP camshaft position sensor to ...

Page 32: ...t cracked torn worn or glazed Starting the Engine Before starting the engine the first time refer to section Preparations for Starting the Engine the First Time in the Operating Instructions section and perform the operations listed To avoid injury from flames explosion and toxicants when using ether the following precautions must be taken Do not smoke when servicing ether system Work in well vent...

Page 33: ...n is available in the Series 40 Troubleshooting Manual 6SE241 available from authorized Detroit Diesel distributors Initial Engine Start Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer birth defects and other reproductive harm Always start and operate an engine in a well ventilated area If operating an engine in an enclosed area vent the exha...

Page 34: ... make sure the engine is ready to start before activating the air starter Start an engine equipped with an air starter as follows 1 Check the pressure in the air storage tank If necessary add air to bring the pressure up to at least the recommended minimum for starting 2 With foot OFF the foot pedal turn the ignition key to the start position and press and hold the starter button until the engine ...

Page 35: ...ake 3 Bring the assisting vehicle close to the disabled vehicle but do not allow vehicles to touch Stop the engine on the assisting vehicle 4 Shut off all lights heater air conditioner and any other electrical loads in both vehicles 5 Connect the first jumper cable to the positive terminal of the dead battery and the positive terminal of the booster battery Connect the second jumper cable to the n...

Page 36: ...tomatic transmission if equipped for proper oil level and add oil as required Fluid Leaks Look for coolant fuel or lubricating oil leaks If any are found shut down the engine immediately and have the leaks repaired after the engine has cooled Crankcase If the engine oil was replaced stop the engine after normal operating temperature has been reached Allow the oil to drain back into the crankcase f...

Page 37: ...bocharger as it will continue to turn without an oil supply to the bearings 2 Allow the engine to run between idle and 1000 rpm with no load for four or five minutes This allows the engine to cool and permits the turbocharger to slow down After four or five minutes shut down the engine Shutdown Warning Light and Buzzer Vehicles may be equipped with an automatic engine shutdown system that will sto...

Page 38: ...the engine when descending a long and steep grade The electronic governor has no control over engine speed when it is being pushed by the loaded vehicle Operate in a gear that will permit an engine speed not in excess of high idle rpm Cold Weather Operation Observe the following instructions before operating the engine in temperatures of 32 F 0 C 1 Ensure batteries are of sufficient size and are f...

Page 39: ...from the fuel water separator if equipped Fill the fuel tank with required fuel to prevent condensation Refer to section D How to Select Fuel Oil in this guide 4 Keep the external surfaces of the engine radiator and accessories clean to avoid dirt buildup which could lead to engine overheating Extended Idling Periods Avoid extended idling especially at low engine speeds The low idle speed for Seri...

Page 40: ... C NOTE The lower CAP rpm limit for engines with automatic transmissions minimizes the possibility of vehicle lurch should the operator place the shift lever in gear without first applying the service brakes to lower the idle speed to 700 rpm The cycle described above will continue until one or a combination of any of the following occurs Engine load is greater than 25 Brake pedal is applied or br...

Page 41: ... Figure 10 Figure 10 Typical Series 40 Engine Mounted ECM This system functions much like the DDEC system but is configured differently and uses its own unique diagnostic codes The diagnostic codes for Series 40 engines are listed in Table 1 Table 2 Table 3 and Table 4 All information subject to change without notice Rev May 2004 31 DDC SVC MAN 0057 0305 Copyright 2003 DETROIT DIESEL CORPORATION ...

Page 42: ...jection Control Press Signal Out of Range HIGH 131 APS IVS Accelerator Position Signal Out of Range LOW 132 APS IVS Accelerator Position Signal Out of Range HIGH 133 APS IVS Accelerator Position Signal In range Fault 134 APS IVS Accelerator Position and Idle Validation Disagree 135 APS IVS Idle Validation Switch Circuit Fault 141 VSS Vehicle Speed Signal Out of Range LOW 142 VSS Vehicle Speed Sign...

Page 43: ...t of Range LOW 221 SCCS Cruise PTO Control Switch Circuit Fault 225 EOP EOP Sensor Signal In Range Fault 226 HPS Hydraulic Press Sensor Signal Out of Range HIGH 231 ATA ATA Data Communication Link Error 236 ECLECL Switch Circuit Fault 241 IPR Injection Control Press Regulator OCC Self Test Failed 244 EDL Engine to Trans Data Line OCC Self Test Failed 246 FAN Engine Fan OCC Self Test Fault 256 RSE ...

Page 44: ...r Reduced Matched to Cooling System Performance 331 IPR Injection Control Press Above System Working Range 332 ICP Injection Control Press Above Spec with Engine Off 333 IPR Injection Control Press Above Below Desired Level 334 IPR_SYS ICP Unable to Achieve Setpoint in Time Poor Performance 335 IPR_SYS ICP Unable to Build Pressure During Cranking 336 HGE 421 426 INJ High Side to Low Side Open Cyl ...

Page 45: ...ing Program Engine 622 ECM Engine Using Field Default Rating 623 ECM Invalid Engine Rating Code ECM Programming 624 ECM Field Default Active 626 ECM Unexpected Reset Fault 631 ECM ROM Read Only Memory Self Test Fault 632 ECM RAM Memory CPU Self Test Fault 655 ECM Programmable Parameter List Level Incomplete 661 ECM RAM Programmable Parameter List Corrupt 664 ECM Calibration Level Incompatible 665 ...

Page 46: ...hrough the radiator and charge cooler Electrical System The electrical system consists of the starting motor starting switch battery charging alternator storage batteries and necessary wiring Air Induction System The air induction system consists of the air cleaner air to air charge cooler some applications compressor side of the turbocharger valve cover intake manifold and intake valves Outside a...

Page 47: ...le engines are listed in Table 14 Table 15 and Table 16 Recommended maintenance intervals for Series 40 generator drive engines are listed in Table 17 Table 18 and Table 19 NOTICE Failure to check and maintain SCA supplemental coolant additive levels at required concentrations will result in severe damage corrosion to the engine cooling system and related components Coolant must be inhibited with ...

Page 48: ...ooler I I 6 Battery I 7 Drive Belt I 8 Air Compressor I I I I 9 Air Cleaner 10 Lube Oil Filters R R 11 Fuel Filters R 12 Water Pump Inhibitor Level I 14 Air System I I I I See item in text I Inspect service correct or replace as necessary R Replace Table 5 Motor Coach Daily 6 000 Mile 12 000 Mile and 18 000 Mile Checks 38 All information subject to change without notice Rev May 2004 DDC SVC MAN 00...

Page 49: ...iles 160 000 km 8 Air Compressor I I I I I I I I I I 9 Air Cleaner I I I I I I I I I I 10 Lube Oil Filter Replace when lubricating oil is changed 11 Fuel Filters R R 12 Water Pump Inhibitor Level I I I I I I I I I I 13 Cranking Motor Follow manufacturer s recommendations 14 Air System I I I I I I I I I I 15 Exhaust System I I I I I I I I I I See item in text I Inspect service correct or replace as...

Page 50: ...ery oil change Replace every 60 000 miles 23 Thermostats Seals I 24 Crankcase Breather I 25 Engine Tune Up I 26 Idler Pulley Inspect every 45 000 miles 72 000 km Replace every 60 000 miles 96 000 km 27 Vibration Damper Inspect once a year Replace at major engine overhaul or earlier if dented or damaged See item in text I Inspect service correct or replace as necessary R Replace Table 7 Motor Coach...

Page 51: ...oler I I 6 Battery I I 7 Drive Belt I I I 8 Air Compressor I 9 Air Cleaner I I I I I 10 Lube Oil Filters R R R R 11 Fuel Filters R R 12 Water Pump Inhibitor Level I I See item in text I Inspect service correct or replace as necessary R Replace Table 8 Transit Coach Daily 6 000 Mile 12 000 Mile and 18 000 Mile and 24 000 Mile Checks All information subject to change without notice Rev May 2004 41 D...

Page 52: ... 100 000 miles 160 000 km 8 Air Compressor I I I I I I I I I I 9 Air Cleaner I I I I I I I I I I 10 Lube Oil Filters Replace when lubricating oil is changed 11 Fuel Filters R R R R R 12 Water Pump Inhibitor Level I I I I I I I I I I 13 Cranking Motor Follow manufacturer s recommendations 14 Air System I I I I I I I I I I See item in text I Inspect service correct or replace as necessary R Replace ...

Page 53: ...y 6 000 miles or every oil change Replace every 60 000 miles 23 Thermostats Seals I I I 24 Crankcase Breather I I I 25 Engine Tune Up I I I 26 Idler Pulley Inspect every 45 000 miles 72 000 km Replace every 60 000 miles 96 000 km 27 Vibration Damper Inspect once a year Replace at major engine overhaul or earlier if dented or damaged See item in text I Inspect service correct or replace as necessar...

Page 54: ...sor I 9 Air Cleaner I 10 Lube Oil Filters R 11 Fuel Filters R 12 Water Pump Inhibitor Level I 17 Radiator I 19 Battery Charging Alternator I See item in text I Inspect service correct or replace as necessary R Replace Table 11 Stationary or Construction Industrial Engine Daily 100 Hour 150 Hour 200 Hour and 300 Hour Checks 44 All information subject to change without notice Rev May 2004 DDC SVC MA...

Page 55: ...Air Compressor I I I I I I I I I I 9 Air Cleaner I I I I I I I I I I 10 Lube Oil Filters Replace when lubricating oil is changed 11 Fuel Filters R R R R R 12 Water Pump Inhibitor Level I I I I I I I I I I 13 Cranking Motor Follow manufacturer s recommendations 14 Air System I I I I I I I I I I See item in text I Inspect service correct or replace as necessary R Replace Table 12 Stationary or Const...

Page 56: ...0 hours 23 Thermostats Seals 24 Crankcase Breather I 25 Engine Tune Up I 26 Idler Pulley Inspect every 1 500 hours Replace every 2 000 hours 27 Vibration Damper Inspect once a year Replace at major engine overhaul or earlier if dented or damaged See item in text I Inspect service correct or replace as necessary R Replace Table 13 Stationary or Construction Industrial Regular Maintenance Intervals ...

Page 57: ...t I 8 Air Compressor I I 9 Air Cleaner I I 10 Lube Oil Filter R 11 Fuel Filters 12 Water Pump Inhibitor Level I 17 Radiator I 19 Battery Charging Alternator I See item in text I Inspect service correct or replace as necessary R Replace Table 14 Fire Fighting Crash Rescue and Emergency Vehicle Engine Daily 100 Hour and 300 Hour Checks All information subject to change without notice Rev May 2004 47...

Page 58: ...rs 8 Air Compressor I I I I I 9 Air Cleaner 10 Lube Oil Filters Replace when lubricating oil is changed 11 Fuel Filters R R 12 Water Pump Inhibitor Level I I I I I 13 Cranking Motor Follow manufacturer s recommendations 14 Air System I I I I I 15 Exhaust System I I I I I See item in text I Inspect service correct or replace as necessary R Replace Table 15 Fire Fighting Crash Rescue and Emergency V...

Page 59: ...Seals 24 Crankcase Breather I 25 Engine Tune Up I 26 Idler Pulley Inspect every 45 000 miles 72 000 km or 1 500 hours Replace every 60 000 miles 96 000 km or 2 000 hours 27 Vibration Damper Inspect once a year Replace at major engine overhaul or earlier if dented or damaged See item in text I Inspect service correct or replace as necessary R Replace Table 16 Fire Fighting Crash Rescue and Emergenc...

Page 60: ...essure I I Load Test P See item in text I Inspect service correct or replace as necessary P Perform Perform these items at time of load test Load test should be at least 35 of the unit s full rated output Refer to generator set manufacturer s instructions Table 17 Generator Set Engine Prime Daily and Standby Monthly Maintenance Intervals 50 All information subject to change without notice Rev May ...

Page 61: ...2 000 hours 9 Air Cleaner I I I I I I I I 10 Lube Oil Filters Replace when lubricating oil is changed 11 Fuel Filters Prime Replace every 500 hours or 6 months whichever comes first Standby Replace every 300 hours or 1 year whichever comes first 12 Water Pump Inhibitor Level I 13 Cranking Motor Follow manufacturer s recommendations See item in text I Inspect service correct or replace as necessary...

Page 62: ...23 Thermostat Seals R 24 Crankcase Breather I 25 Engine Tune Up I 26 Idler Pulley Inspect every 1 500 hours Replace every 2 000 hours 27 Vibration Damper Inspect once a year Replace at major engine overhaul or earlier if dented or leaking See item in text I Inspect service correct or replace as necessary R Replace Table 19 Generator Set Engine Regular Maintenance Intervals continued 52 All informa...

Page 63: ...to Service after Extended Storage in this guide Preventive maintenance other than the Daily checks should be performed by authorized Detroit Diesel service outlets These outlets have the trained personnel and special tools to properly perform all services Item 1 Lubricating Oil Check the oil level daily with the engine stopped If the engine has just been stopped and is warm wait approximately 20 m...

Page 64: ...oil has not been added to the crankcase consult with an authorized Detroit Diesel service outlet for the cause Fuel or coolant dilution of lubricating oil can result in serious engine damage Before adding lubricating oil refer to section A How to Select Lubricating Oil in this guide Change lubricating oil and filters at the intervals listed in Table 20 when using fuel with a sulfur content of less...

Page 65: ...ximum Oil Drain Filter Change Intervals Diesel Fuel Sulfur Content Less Than 0 05 Mass The length of time an engine may operate before an oil change depends upon the lubricant and fuel used engine oil consumption and the operating cycle The maximum interval at which the engine may operate before the oil and filters must be changed is listed in Table 20 Oil analysis may be used to determine whether...

Page 66: ...ter and or sediment Every 120 000 miles 192 000 kilometers 12 months or 600 hours for construction industrial applications tighten all fuel tank mountings and brackets At the same time check the seal in the fuel tank cap the breather hole in the cap and the condition of the flexible fuel lines Repair or replace the parts as necessary NOTICE Galvanized steel fuel tanks fittings pipes or supply line...

Page 67: ...ttings have loosened or cracked or if hoses have ruptured or worn through take corrective action immediately Hose Service Life A hose has a finite service life With this in mind all hoses should be thoroughly inspected at least every 500 operating hours 1 000 hours for fire resistant fuel and lubricating oil hoses and or annually Look for cover damage and or indications of twisted worn crimped bri...

Page 68: ...n the engine is running and when it is stopped Coolant leaks may be more apparent on a engine when it is cold Coolant Inhibitors NOTICE Coolant must be inhibited with the recommended SCA s supplemental coolant additives listed in this guide In addition the engine can be equipped with a coolant filter inhibitor system as an installed option or as an after sale item Failure to check and maintain SCA...

Page 69: ...ation with a need release filter must be used At this time the cooling system must be completely drained and cleaned before refill A 50 50 mix of OAT organic acid technology coolant and water With proper maintenance coolant can be operated 4 years 600 000 miles 960 000 km or 10 000 operating hours whichever comes first 3 At this time the cooling system must be completely drained and cleaned before...

Page 70: ...n matted crushed oil soaked or otherwise damaged insulation blankets must be replaced immediately Wastegated Turbochargers The turbocharger wastegate actuator is factory calibrated and is not adjustable NOTE If lack of engine performance is noted after high mileage operation the turbocharger wastegate should be checked for proper operation Authorized Detroit Diesel distributors have the trained pe...

Page 71: ...emove connections and wire brush any corrosion from terminals and cable ends Replace damaged wiring Item 7 Drive Belt Inspect the serpentine drive belt after every oil change Replace belt every 100 000 miles 160 000 km on vehicle engines or every 2 000 hours on construction industrial and stationary engines Replace earlier if belt shows signs of excessive wear or damage Always replace the drive be...

Page 72: ...the air strainer For air strainer replacement contact the nearest servicing dealer Replace hair type elements with the polyurethane type if available The air compressor mounting bolts should be tightened every 12 months or 30 000 miles 48 000 km for vehicle engines or every 300 hours for stationary and industrial engines Item 9 Air Cleaner Check the air cleaner restriction indicator daily and serv...

Page 73: ...r cleaner elements should be replaced after one year of service or when the maximum allowable air intake restriction has been reached whichever comes first Refer to section J When to Service the Dry Type Air Cleaner in this guide for additional information Item 10 Lubricating Oil Filter To avoid injury from slipping and falling immediately clean up any spilled liquids Install new spin on oil filte...

Page 74: ...er If equipped drain the fuel water separator daily See Figure 17 for a typical fuel filter and strainer installation Replace the fuel filter and clean the strainer at the intervals listed in the maintenance tables or every other oil change For change intervals refer to Maintenance Intervals For change procedure refer to section Replace Fuel Filter and Strainer 64 All information subject to change...

Page 75: ...tenance schedules but should never be extended One method of determining when filters are plugged to the extent that they need replacing is based on the fuel pressure at the cylinder head fuel inlet fitting Fuel pressure should be no less than 60 psi 414 kPa at normal operating speed Change the fuel filters whenever the fuel pressure at the inlet fitting falls below this level All information subj...

Page 76: ...n hole under normal conditions do not replace the water pump Coolant Inhibitor Element The coolant must be tested at required intervals and the coolant inhibitor element replaced if required 1 Spin on Inhibitor Element 2 Filter Adaptor Figure 18 Installing Coolant Inhibitor Element Required test intervals are listed in Table 28 For SCA test procedures refer to section G How to Select Coolant and t...

Page 77: ...lectrical equipment may result Item 17 Radiator The exterior of the radiator core should be inspected every 30 000 miles 48 000 km 12 months or 300 hours stationary and industrial engines and cleaned if necessary To avoid injury from flying debris when using compressed air wear adequate eye protection face shield or safety goggles and do not exceed 40 psi 276 kPa air pressure Use a quality grease ...

Page 78: ...lternator The diodes and transistors in the alternator circuit are very sensitive and can be easily destroyed To avoid injury from battery explosion or contact with battery acid work in a well ventilated area wear protective clothing and avoid sparks or flames near the battery Always establish correct polarity before connecting cables to the battery or battery circuit If you come in contact with b...

Page 79: ...ed every 60 000 miles 96 000 km or 600 hours Tighten and or repair as necessary Item 21 Crankcase Pressure The crankcase pressure should be checked and recorded at the intervals in the maintenance schedules Crankcase pressure should be no higher than 6 in water 1 5 kPa at maximum no load speed with the breather restrictor tool installed Item 22 Fan Hub The fan hub assembly includes a sealed bearin...

Page 80: ...and adjustment These intervals are listed in Table 22 Item 25 Engine Tune Up There is no scheduled interval for performing an engine tune up However the valve lash must be measured and if necessary adjusted at the regular intervals listed in Table 22 Engine Application Valve Lash Measurement Adjustment Interval Motor Coach Every 60 000 Miles 96 000 km or 24 Months Transit Coach Every 45 000 Miles ...

Page 81: ...nes use rubber bushed vibration dampers except generator sets which use viscous dampers Figure 20 Typical Rubber Bushed Vibration Damper Rubber Bushed Damper Inspect damper see Figure 20 once a year Replace if rubber streaking on the damper face exceeds guidelines contact a DDC distributor for guidelines or if deep splits appear in the rubber member Deep splits can allow chunks of rubber to break ...

Page 82: ... severe ECM electronic control module damage To avoid damage to vehicle electronic components disconnect both the positive and the negative battery cables prior to electric welding Attach the welder s ground cable as close as possible to the joint being welded If it is necessary to weld close to an electronic component the component should be temporarily removed Whenever welding is done on any par...

Page 83: ...er lubricating oil is important to achieve the long and trouble free service which Detroit Diesel engines are designed to provide The proper lubricating oil for all Detroit Diesel engines is selected based on SAE viscosity grade and API American Petroleum Institute service designation Only oils licensed to display the API service mark should be used See Figure 22 Lubricant Requirements Figure 22 A...

Page 84: ...ble high alkalinity TBN lubricants are recommended High sulfur fuels require modification to oil drain intervals For further information refer to publication Engine Requirements Lubricating Oil Fuel and Filters 7SE270 available from authorized Detroit Diesel distributors The Use of Supplemental Additives Lubricants meeting the Detroit Diesel specifications outlined in this publication already cont...

Page 85: ...of a higher TBN oil See the information listed in Table 23 For detailed information refer to publication Engine Requirements Lubricating Oil Fuel and Filters 7SE270 available from authorized Detroit Diesel distributors Engine Application Drain Interval Motor Coach City Transit Coach 12 000 Miles 19 200 km Fire Truck or Crash Rescue Vehicle 6 000 Miles 9 600 km 300 Hours or 1 Year whichever comes f...

Page 86: ...ilter Filters are an integral part of the lubricating oil system Proper filter selection and maintenance are important to satisfactory engine performance and service life Filters should be used to maintain a clean system not to clean up a contaminated system Filter part numbers arelisted in Table 43 in the Specifications section of this guide 1 Oil Cooler Assembly 3 Oil Filter Header part of oil c...

Page 87: ...nner according to federal EPA and or state recommendations 4 Clean the filter gasket contact surface of the adaptor head with a clean lint free cloth 5 Fill the new filter with clean lubricating oil and lightly coat the filter gasket with the same oil NOTICE Do not overtighten filters Overtightening may crack or distort the filter adaptor 6 Start the new filter on the adaptor head and tighten by h...

Page 88: ...ded to the crankcase consult with an authorized Detroit Diesel service outlet for the cause Fuel or coolant dilution of lube oil can result in severe engine damage D How to Select Fuel Oil Quality Fuel quality is an important factor in obtaining satisfactory engine performance long engine life and acceptable exhaust emission levels Detroit Diesel engines are designed to operate on most diesel fuel...

Page 89: ...ce data supporting their merit It is not the policy of Detroit Diesel Corporation to test evaluate approve or endorse such products Prohibited Additives The following fuel additives are not allowed and MUST NOT be mixed with diesel fuel Used Lubricating Oil Detroit Diesel specifically prohibits the use of used lubricating oil in diesel fuel Used lubricating oil contains combustion acids and partic...

Page 90: ...ingle cartridge and a filter adaptor header which includes threaded inserts to accept the spin on cartridge The header also includes a fuel priming pump and air bleed screw for manual priming of the system after filter replacement See Figure 25 NOTE An optional fuel water separator may be installed in the system piping ahead of the fuel strainer Replace Fuel Filter and Strainer To avoid injury fro...

Page 91: ... Bleed Screw 7 Seal Ring 4 Fuel Strainer Header 8 See Through Body Figure 25 Typical Fuel Filter and Strainer Installation 6 Inspect the strainer for damage or plugging and clean or replace as required Clean the cover Replace the O ring if damaged NOTE Install the strainer into the cover with the open end toward the filter header All information subject to change without notice Rev May 2004 81 DDC...

Page 92: ...er an additional one half turn by hand or as indicated on the filter NOTICE Do not overtighten the filter Overtightening may crack or distort the adaptor head 11 If previously closed open the fuel shutoff valve NOTICE Failure to disconnect the CMP camshaft position sensor before priming the engine may allow the engine to start during priming which could result in severe engine damage 12 Refer to P...

Page 93: ...r 15 seconds each Reapply the primer pump after each crank cycle 4 Once the primer pump is hard to depress usually three crank and hand prime cycles reconnect the CMP Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer birth defects and other reproductive harm Always start and operate an engine in a well ventilated area If operating an engine in ...

Page 94: ...y hand NOTICE To avoid damaging the bowl or the filter do not use tools when tightening 8 Apply a light coating of clean fuel oil or grease to the new O ring seal on the top of the replacement filter Thread the filter and bowl assembly onto the filter header and tighten by hand until snug 9 To eliminate air from the filter operate the primer pump on the filter header until the fuel purges at the f...

Page 95: ...Using filter collar vent cap wrench part number 232002 or equivalent remove the collar by turning counter clockwise Remove the cover filter spring and cover seal ring by lifting straight up and over the filter element 6 Remove the element from the center stud fuel outlet pipe by pulling upward and twisting slightly NOTE Current filter elements include an integral sealing grommet If a former elemen...

Page 96: ...l is installed on the vent cap reinstall the cap and tighten by hand NOTICE To avoid cover or vent cap damage do not use tools to tighten the vent cap 12 Open the fuel shutoff valve if equipped 13 The fuel system must be primed before starting the engine Refer to section Prime the Fuel System and Start the Engine 14 After starting the engine allow the lubrication system to reach its normal operati...

Page 97: ...en restarting it Spin On Filter Use the following procedure for an engine with a spin on filter 1 Fill the fuel tank with the recommended grade of fuel If only partial filling is possible add a minimum of 10 gallons 38 liters of fuel to the tank 2 Close the fuel shutoff valve if installed on the filter header and remove the spin on fuel filter Fill with clean fuel through the fuel inlet holes the ...

Page 98: ...lug and tighten by hand only NOTICE To avoid cover or vent cap damage do not use tools to tighten the vent cap NOTICE Do not allow the fuel level in the see thru cover to fall below the top of the collar since this may lead to interruption of the fuel flow and engine stalling 2 Start the engine and allow the lubrication system to reach its normal operating pressure then increase engine speed to hi...

Page 99: ...oolant 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 SCAs are used in a preventive maintenance program to prevent corrosion cavitation and the formation of d...

Page 100: ...ufacturers as either a concentrated antifreeze or as a pre mixed antifreeze The pre mixed antifreeze is ready for use while the concentrated coolant must be mixed with water prior to use Detroit Diesel Power Cool engine coolant part number 23512138 is the preferred ethylene glycol coolant If other commercial brands of ethylene glycol are used they must be equivalent to the Power Cool see following...

Page 101: ...cooling system Figure 27 Coolant Freezing and Boiling Temperatures Versus Inhibited Ethylene Glycol IEG Concentration Sea Level Figure 28 Coolant Freezing and Boiling Temperatures Versus Inhibited Propylene Glycol IPG Concentration Sea Level All information subject to change without notice Rev May 2004 91 DDC SVC MAN 0057 0305 Copyright 2003 DETROIT DIESEL CORPORATION ...

Page 102: ...freeze water mixture are correct by using a POWER Trac 3 Way Coolant Test Strip If chemical analysis is used elements in the coolant must fall within the limits listed in Table 25 Fully Formulated Glycol Coolant Concentration Limits Boron 125 500 PPM Nitrite 900 3200 PPM Nitrate 200 3200 PPM Silicon 50 250 PPM Phosphorous 0 PPM pH 8 0 11 0 Table 25 Fully Formulated Glycol Coolant Limits with TMC R...

Page 103: ...t not as an OAT Organic Acid Technology coolant Detroit Diesel markets a OAT inhibited ethylene glycol coolant DDC Power Cool Plus which contains all the required additives If a non DDC OAT antifreeze is used it must conform to TMC 338 specification Do not add extender to new OAT antifreeze or coolant Water Only SCA or Water Only OAT Inhibitor In warm climates a coolant based on water with corrosi...

Page 104: ...e osmosis purified or de ionized water which eliminates the adverse effects of minerals in tap water is preferred High levels of dissolved chlorides sulfates magnesium and calcium in some tap water causes scale deposits and or corrosion These deposits have been shown to result in water pump failures and poor heat transfer resulting in overheating If tap water is used the mineral content in the wat...

Page 105: ...col based coolants formu lated for heating ventilation air conditioning HVAC should not be used These coolants generally contain high levels of phosphates which can deposit on hot internal engine surfaces and reduce heat transfer Additives Not Recommended The following additives are not recommended for use in Series 40 engines 1 Soluble oil additives are not approved for use in Detroit Diesel engi...

Page 106: ...nd By Generator Set 200 Hours or Yearly whichever comes first Table 28 Required Coolant Inhibitor Test Intervals To avoid injury from the expulsion of hot coolant never remove the cooling system pressure cap while the engine is at operating temperature Remove the cap slowly to relieve pressure Wear adequate protective clothing face shield or safety goggles rubber gloves apron and boots If topping ...

Page 107: ...eter formation of mineral deposits Cavitation protection to protect wet sleeve cylinder liners Maintenance Intervals Check the nitrite concentration at the regular intervals listed in Table 29 with a Power Trac 3 Way Test Strip All information subject to change without notice Rev May 2004 97 DDC SVC MAN 0057 0305 Copyright 2003 DETROIT DIESEL CORPORATION ...

Page 108: ...ycol Water OAT Inhibitor A 600 000 Miles 960 000 km B 4 Years or 10 000 Hours Drain and clean system Replace with new coolant A 20 000 Miles 32 000 km or 3 Months B 500 Hours or 3 Months Test nitrite concentration with test strip Add SCA or dilute coolant as needed Water Only SCA Inhibitor A 300 000 Miles 480 000 km B 2 Years or 4 000 Hours Drain and clean system Replace with new coolant A 300 000...

Page 109: ...In this case the EG or PG should contain no inhibitors and should conform to ASTM D4985 This will dilute the over concentrated inhibitors NOTE In non OAT systems nitrite concentration of 5000 PPM or higher on a Series 40 engine suggests problematic additive over concentration This condition must be corrected by immediate draining and flushing of the cooling system Refill the system with new fully ...

Page 110: ...place and tighten the test strip container cap after each use Discard unused strips if they have turned light pink or tan A factory coolant analysis program is available through authorized Detroit Diesel service outlets Part numbers are listed in Table 55 in the Specifications section To verify coolant acceptability submit a sample for coolant analysis every two 2 years 300 000 miles 480 000 km or...

Page 111: ...onents Coolant Extender Inhibitor Additive for OAT Coolant The inhibitors in OAT coolant must also be maintained but less often than traditional SCA type coolants A portable test is available to test the levels of OAT inhibitors in coolant Where this is not used fleet testing has determined that a OAT coolant extender package should be added to the coolant at 300 000 miles 480 000 km two 2 years o...

Page 112: ...atible with hard water than Power Cool 2000 SCA Power Cool Coolant Filter Elements Power Cool coolant filter elements spin on canisters are available in various sizes suitable for cooling systems of varying capacities Selection of the proper element size is vital when pre charging non fully formulated coolant at initial fill and at maintenance intervals A fully formulated antifreeze must not have ...

Page 113: ...rent manufacturers technologies brands could cause cooling system problems 4 Maintain the inhibitor at the prescribed concentration Test the nitrite concentration by using a titration kit or Detroit Diesel Power Trac 3 Way Coolant Test Strips Add SCA only if the nitrite concentration is below 900 PPM Do not use SCA in OAT coolant and do not use Power Trac 3 Way Coolant Test Strips to test OAT cool...

Page 114: ...ant may be operated 600 000 miles 960 000 km four 4 years or until overhaul whichever comes first At this time the system must be completely drained thoroughly cleaned and refilled OAT Coolants require the addition of an extender at 300 000 miles 480 000 km two 2 years or 5 000 hours whichever comes first Use 1 pint of extender for every 20 gallons of coolant Other Coolants Other properly maintain...

Page 115: ...nt temperature and cool to the touch carefully remove the radiator or deaeration tank pressure cap to relieve pressure in the cooling system 2 Close the manual shutoff valve on the coolant filter header by turning handle clockwise In the closed position the handle will be pointing straight up 3 Loosen and remove the coolant filter by turning counter clockwise using a filter strap wrench See Figure...

Page 116: ...at operating temperature Remove the cap slowly to relieve pressure Wear adequate protective clothing face shield or safety goggles rubber gloves apron and boots 1 With the engine cool slowly loosen and remove the pressure cap from the radiator or deaeration tank Place a suitable container under the radiator and drain the previous solution from the engine and radiator Dispose of the coolant in an e...

Page 117: ...ller neck or the level indicated on the deaeration tank NOTICE If the engine overheats and the coolant level is satisfactory the cooling system may require cleaning with a descaling solvent and backflushing Authorized Detroit Diesel service outlets are properly equipped to perform these services In addition to the cleaning procedure other components of the cooling system should be checked periodic...

Page 118: ...15 inches of water 3 7 kPa has been reached or annually whichever comes first Some air cleaners are equipped with a restriction indicator which aids in determining the servicing interval Cleaning and or reusing dry paper type air cleaner elements is not recommended unless the cleaning method used removes clogging without damaging the element Inspection and cleaning of elements must be done in acco...

Page 119: ...toms are listed in Table 30 Objectionable exhaust symptoms are listed in Table 31 Abnormal engine operation symptoms are listed in Table 32 Abnormal operating condition symptoms are listed in Table 33 Abnormal coolant temperature symptoms are listed in Table 34 All information subject to change without notice Rev May 2004 109 DDC SVC MAN 0057 0305 Copyright 2003 DETROIT DIESEL CORPORATION ...

Page 120: ... or missing X Insufficient Fuel Supply Air in fuel X Out of fuel X Loose fuel connections X Cracked fuel lines X Obstructed fuel filters lines X Faulty fuel pump X Faulty injector operation X Restricted fuel fitting missing X Electronic control system malfunction X Installation operation of fuel check valve or shutoff valve X Low Compression Worn intake and exhaust valves X Worn piston rings liner...

Page 121: ... Engine Cranks But Will Not Start Leaking cylinder head gasket X Improper intake or exhaust valve adjustments X Table 30 Hard Starting Symptoms and Probable Causes All information subject to change without notice Rev May 2004 111 DDC SVC MAN 0057 0305 Copyright 2003 DETROIT DIESEL CORPORATION ...

Page 122: ...n exhaust manifold or turbocharger X Faulty injector timing X Faulty oil control rings X Excessive installation angle X Excessive oil in crankcase X High ambient temperature X Thin air high altitude X Cetane rating of fuel too low X Air in the fuel system X Table 31 Objectionable Exhaust Symptoms and Probable Causes 112 All information subject to change without notice Rev May 2004 DDC SVC MAN 0057...

Page 123: ...riction ex haust back pressure X Engine application X High air inlet temperature X High altitude operation X Incorrect engine gear train timing X Low coolant temperature X Oil picked up by inlet airstream X Faulty injector operation X Incorrect injector height setting X X Table 32 Abnormal Engine Operation Symptoms and Probable Causes All information subject to change without notice Rev May 2004 1...

Page 124: ...gged 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 connecting rod bearings X Missing cup plugs in rocker arm shaft X Faulty oil pressure relief valve X Air leaks in oil pump suction side X Worn or damaged oil pump X Faulty oil pressure gage X Faulty electrical components for gage X Plugged oil ...

Page 125: ...d fan failure to disengage fan X Obstruction in front of radiator 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 Table 34 Abnormal Coolant Temperature Symptoms and Probable Causes All information subject to change without notice Rev May 2004 115 DDC SVC MAN ...

Page 126: ...the engine at ambient temperature and cool to the touch drain engine crankcase oil into a suitable container Dispose of the oil in an environmentally friendly manner according to state and or federal EPA recommendations 2 Fill the crankcase to the proper level with the recommended viscosity and grade of oil 3 Fill the fuel tank with the recommended grade of fuel oil Operate the engine for two 2 mi...

Page 127: ... Days To prepare an engine for extended storage more than 30 days follow this procedure 1 Drain the cooling system and flush with clean soft water Refill with clean soft water and add a rust inhibitor to the cooling system 2 Circulate the coolant by operating the engine until normal operating temperature is reached 3 Stop the engine 4 With the engine at ambient temperature and cool to the touch dr...

Page 128: ...e engine for five 5 minutes to circulate the clean fuel throughout the system and ensure the system is full 9 Stop the engine and allow to cool Then disconnect the fuel return line and the inlet line at the fuel 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 manufact...

Page 129: ...of lubricating oil to the center housing bearings This can result in severe bearing damage 17 Seal all engine openings including the turbocharger air and exhaust outlets and the valve cover intake manifold opening Use moisture resistant tape and cardboard plywood or metal covers where practical 18 Clean and dry the exterior painted surfaces of the engine and spray with a suitable liquid automobile...

Page 130: ...connect the lines to their proper positions 3 Wash or steam clean the exterior of the engine to remove the rust preventive if previously applied Do not wash or apply steam to electrical components 4 Remove the rust preventive from the flywheel Flush any soluble oil rust inhibitor if used in the cooling system 5 Remove the paper strips from between the pulleys and serpentine drive belt or reinstall...

Page 131: ... using a new gasket and torque inlet pipe flange bolts to specifications 14 Refer to section Lubrication System Checks in section Preparations for Starting the Engine the First Time Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer birth defects and other reproductive harm Always start and operate an engine in a well ventilated area If operatin...

Page 132: ... distributor or service outlet nearest you Description Form No Series 40 Service Manual 6SE410 Series 40 Troubleshooting Manual 6SE241 U S and Canada Distributor Dealer Directory 6SE280 International Distributor Dealer Directory 6SE281 Lube Oil Fuel and Filter Requirements 7SE270 Coolant Requirements for Engine Cooling Systems 7SE298 Technician s Guide Used Lubricating Oil Analysis 7SE398 Technici...

Page 133: ...vailable Engine serial and model numbers Refer to section ENGINE MODEL AND SERIAL NUMBER LOCATIONS for location Vehicle equipment or generator set make and model Accumulated miles kilometers or hours of operation Vehicle equipment or generator set owner company name Customer Assistance The satisfaction and goodwill of the owners of Detroit Diesel engines are of primary concern to Detroit Diesel Co...

Page 134: ...tributorship with whom the dealer has a service agreement Step Two When it appears that your problem cannot be readily resolved at the distributor level without additional assistance contact the Detroit Diesel Regional Product Support Manager or Operations Manager responsible for your local distributor You will be assisted by a member of the manager s staff depending upon the nature of your proble...

Page 135: ...ggested that you follow the above steps in sequence when experiencing a problem See Figure 31 for the Detroit Diesel NAFTA On Highway Regions See Figure 32 for the Detroit Diesel MTU Off Highway Sales and Customer Assurance Center The addresses and phone fax numbers for the on highway regional offices are listed in Table 36 The addresses and phone fax numbers for the Detroit Diesel MTU Off Highway...

Page 136: ...ataway New Jersey 169 Old New Brunswick Road Piscataway NJ 08854 Phone 732 926 9622 Fax 732 926 8522 CANADIAN REGION London Ontario Detroit Diesel of Canada Ltd 150 Dufferin Ave Suite 701 London ON N5A 5N6 Phone 519 661 0149 Fax 519 661 0171 Table 36 Detroit Diesel North American NAFTA On Highway Offices 126 All information subject to change without notice Rev May 2004 DDC SVC MAN 0057 0305 Copyri...

Page 137: ...3400 Outer Drive West Detroit MI 48239 4001 Telephone 313 592 7459 Fax 313 592 5158 Government Sales BX11 13400 Outer Drive West Detroit MI 48239 4001 Telephone 313 592 5708 Fax 313 592 5158 Customer Assurance M24 13400 Outer Drive West Detroit MI 48239 4001 Telephone 313 592 5550 Fax 313 592 5717 Table 37 DDC MTU Off Highway Sales and Customer Assurance Center Offices All information subject to c...

Page 138: ...nt Singapore 629979 Phone 65 686 15922 Fax 65 686 11550 PACIFIC REGION Off Highway Australia 11 13 Garling Road Kings Park NSW 2148 Beaumaris Victoria 3193 Australia Phone 612 8822 7000 Fax 612 8822 7083 AUSTRALIAN REGION On Highway P O Box 1472 Canterbury Victoria 3124 Australia Phone 61 39 836 0775 Fax 61 39 836 0770 MEXICO On Off Highway Detroit Diesel Allison de Mexico S A Av Santa Rosa 58 Col...

Page 139: ...he WARRANTY PERIOD resulting from defects in material or workmanship Repairs To obtain warranty repairs you must request the needed repairs within the WARRANTY PERIOD from an authorized DDC service outlet Only new genuine parts or remanufactured parts or components supplied or approved by DDC will be used DDC may at its discretion replace rather than repair components A reasonable time must be all...

Page 140: ... not reusable due to warranted repairs is covered by this warranty Engine Removal and Reinstallation Reasonable labor costs for Engine removal and reinstallation when necessary to make a warranty repair are covered by this warranty THIS WARRANTY DOES NOT COVER Repairs Due to Accidents Misuse Alteration Storage Damage Negligence or Certain Modifications Repairs due to an accident misuse alteration ...

Page 141: ...nce of REPAIRS is the exclusive Owner s remedy under this warranty DDC does not authorize any person to assume or create for it any other obligation or liability in connection with the Engine or the Accessories THIS LIMITED WARRANTY AND THE EMISSIONS WARRANTY ARE THE ONLY WARRANTIES APPLICABLE TO THE ENGINE AND ACCESSORIES AS USED IN MOTOR COACH MOTOR HOME AND TRANSIT COACH APPLICATIONS DETROIT DI...

Page 142: ...RRANTY PERIOD resulting from defects in material or workmanship Repairs To obtain warranty repairs you must request the needed repairs within the WARRANTY PERIOD from an authorized DDC service outlet Only new genuine parts or remanufactured parts or components supplied or approved by DDC will be used DDC may at its discretion replace rather than repair components A reasonable time must be allowed ...

Page 143: ...ble labor costs for Engine removal and reinstallation when necessary to make a warranty repair are covered by this warranty THIS WARRANTY DOES NOT COVER Repairs Due to Accidents Misuse Alteration Storage Damage Negligence or Certain Modifications Repairs due to an accident misuse alteration misapplication storage damage negligence or modification exceeding DDC specifications are not covered by thi...

Page 144: ...Engine or the Accessories THIS LIMITED WARRANTY AND THE EMISSIONS WARRANTY ARE THE ONLY WARRANTIES APPLICABLE TO THE ENGINE AND ACCESSORIES AS USED IN FIRE TRUCK OR CRASH VEHICLE APPLICATIONS DETROIT DIESEL CORPORATION MAKES NO OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE DETROIT DIESEL CORPORATION SHALL NOT BE LIABLE FOR...

Page 145: ...s To obtain warranty repairs you must request the needed repairs within the WARRANTY PERIOD from an authorized DDC service outlet Only new genuine parts or remanufactured parts or components supplied or approved by DDC will be used DDC may at its discretion replace rather than repair components A reasonable time must be allowed to perform the warranty repair after taking the engine to the authoriz...

Page 146: ...ngine still under warranty will assume the identity of the Engine being replaced and be entitled to the remaining warranty coverage Service Supplies The cost of service supplies such as coolant oil and filters which are not reusable due to warranted repairs is covered by this warranty Mechanic s Travel Expenses DDC will pay reasonable travel expenses for the repairing mechanic to travel to and fro...

Page 147: ...al Damages DDC is not responsible for incidental or consequential costs or expenses which the owner may incur as a result of malfunction or failure covered by this warranty such as communication expenses meals lodging overtime towing loss of use of the Engine or vehicle downtime loss of time inconvenience cargo loss or damage and other similar costs and expenses Other Limitations The performance o...

Page 148: ...or the limitation or exclusion of incidental or consequential damages so the above may not apply to you This warranty gives you specific legal rights and you may also have other rights which may vary from state to state 138 All information subject to change without notice Rev May 2004 DDC SVC MAN 0057 0305 Copyright 2003 DETROIT DIESEL CORPORATION ...

Page 149: ...rkmanship Repairs To obtain warranty repairs you must request the needed repairs within the WARRANTY PERIOD from an authorized DDC service outlet Only new genuine parts or remanufactured parts or components supplied or approved by DDC will be used DDC may at its discretion replace rather than repair components A reasonable time must be allowed to perform the warranty repair after taking the engine...

Page 150: ...e Power Generator Set Like Replacement Engine Engine s supplied by DDC as a replacement for an Engine still under warranty will assume the identity of the Engine being replaced and be entitled to the remaining warranty coverage Service Supplies The cost of service supplies such as coolant oil and filters which are not reusable due to warranted repairs is covered by this warranty Mechanic s Travel ...

Page 151: ...S in this guide for details Incidental or Consequential Damage This warranty does not cover any economic loss including without limitation communication expenses meals lodging loss of use of the Engine loss of time inconvenience overtime transportation of the Engine or any other cost or expense resulting from a defect covered by this warranty Other Limitations THIS LIMITED WARRANTY IS THE ONLY WAR...

Page 152: ...ies 40 Fuel and Lubricating Oil Filter Requirements Engine Oil Capacity OIL PAN CAPACITY All Series 40 off highway oil pans front sump and rear sump require the same amount of engine oil 22 quarts to the ADD mark Without oil filter 24 quarts to the FULL mark Without oil filter TOTAL OIL CAPACITY OF THE ENGINE 28 quarts to the FULL mark with filter installed and filter and oil galleries charged Tab...

Page 153: ...918 55 Gallon Drum 23528544 330 Gallon Tote Pre Blended 50 50 23513503 Bulk Delivery 1 000 Gallon Min Table 45 POWER COOL Fully Formulated IEG Coolant POWER COOL LATIN AMERICAN COOLANT Coolant Type Part Number Description 23524737 1 Gallon Jug 6 Per Case 23524923 55 Gallon Drum Pre Blended 67 33 23524924 Bulk Delivery 1 000 Gallon Minimum Table 46 POWER COOL Latin American Coolant All information ...

Page 154: ...WER COOL 2000 Supplemental Coolant Additive POWER COOL 3000 SUPPLEMENTAL COOLANT ADDITIVE Coolant Type Part Number Description 23507854 Pint Bottle 12 Per Case 23507855 Half Gallon Jug 6 Per Case 23507856 5 Gallon Pail For POWER COOL IEG Coolant 23507857 55 Gallon Drum Table 48 POWER COOL 3000 Supplemental Coolant Additive 144 All information subject to change without notice Rev May 2004 DDC SVC M...

Page 155: ...ER COOL IEG Coolant 23508428 53 Ounce 13 Pint Equivalent Table 49 POWER COOL 3000 Supplemental Additive Coolant Filters POWER COOL SUPPLEMENTAL ADDITIVE NEED RELEASE COOLANT FILTERS Coolant Type Part Number Description 23516488 For 0 8 Gallon Systems For POWER COOL IEG Coolant 23516489 For 8 20 Gallon Systems Table 50 POWER COOL SUPPLEMENTAL ADDITIVE NEED RELEASE COOLANT FILTERS All information su...

Page 156: ...e Blended 50 50 23519399 Bulk Delivery 1 000 Gallon Min Table 51 POWER COOL Plus Extended Life OAT Coolant POWER COOL PLUS EXTENDER FOR USE WITH POWER COOL PLUS OAT COOLANT Coolant Type Part Number Description For Power Cool Plus 23519400 Quart Bottle 6 Per Case Table 52 POWER COOL Plus Extender for Use with POWER COOL Plus OAT Coolant 146 All information subject to change without notice Rev May 2...

Page 157: ... 6000 OAT Inhibitor for Water Only Systems POWER COOL COOLING SYSTEM CLEANERS Coolant Type Part Number Description 200164 On Half Gallon Jug 6 Per Case 200105 5 Gallon Pail On Line Cleaner 200155 55 Gallon Drum Twin Pack 201549 Twin Pack 2 Per Case Table 54 Power Cool Cooling System Cleaners All information subject to change without notice Rev May 2004 147 DDC SVC MAN 0057 0305 Copyright 2003 DETR...

Page 158: ...Test Strips Bottle of 50 Indicates Nitrite Molybdate Glycol Levels 23522774 3 Way Coolant Test Strips Bottle of 10 Complete IEG IPG Coolant Analysis 23516921 Coolant Analysis Bottle Carton of 6 Organic Coolant Analysis 23523398 Laboratory Coolant Analysis Bottle Carton of 6 Table 55 Power Trac Coolant Testing and Analysis Products 148 All information subject to change without notice Rev May 2004 D...

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