DETROIT GHG17 DD Operator'S Manual Download

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DDC-SVC-MAN-0192

GHG17 DD Medium Duty
Operators 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.

Summary of Contents for GHG17 DD

Page 1: ...ators 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: ... Control System Features 35 Changing the Idle Speed 35 Stop Engine Override Option 35 Engine Brake 35 Anti Lock Braking Systems 36 Engine Protection 36 California Engine Idle Limiting 36 Idle Shutdown Timer 37 Engine Systems 38 Engine Systems 38 GHG17 Medium Duty Aftertreatment System 40 GHG17 Medium Duty Aftertreatment System 40 Diesel Exhaust Fluid Information 41 Diesel Exhaust Fluid Information...

Page 3: ...tor 71 Monitoring the Fuel Filters 72 Adjusting the Valve Lash 72 Monitoring the Belt Tensioner 73 Poly V Belt Inspection 73 Inspection of the Air Intake System 75 Monitoring the Air Cleaner 75 Monitoring the Exhaust System 76 Monitoring the Aftertreatment System 76 Inspection of the Air Compressor 76 Monitoring the Fuel and Fuel Tank 76 Inspection of Hoses and Fittings for Fuel Leaks 77 Inspectio...

Page 4: ...al Coolant Information 108 Appendix C Detroit Cooling System Maintenance Products 110 Customer Assistance 113 Availability of Detroit Service Outlets 113 Detroit Genuine Coolant Engine Products 114 Detroit Genuine Coolant Engine Products 114 Engine Oil Capacities 116 Engine Oil Capacities 116 Table of Contents 4 All information subject to change without notice Copyright 2022 DETROIT DIESEL CORPORA...

Page 5: ...alifornia Proposition 65 Warning and Engine Idle Notice GHG17 DD Medium Duty Operators Manual All information subject to change without notice 5 DDC SVC MAN 0192 Copyright 2022 DETROIT DIESEL CORPORATION ...

Page 6: ...inate 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 in an engine such as turbocharger camshaft piston fuel doser valve ...

Page 7: ...ns Table 1 Acronyms and Abbreviations ACM Aftertreatment Control Module kW Kilowatt API American Petroleum Institute L Liter ATD Aftertreatment Device lb Pound ATF Automatic Transmission Fluid m Meter ATS Aftertreatment System MCM Motor Control Module CAC Charge Air Cooler MIL Malfunction Indicator Lamp CAN Controller Area Network mpg Miles per Gallon CARB California Air Resources Board mph Miles ...

Page 8: ...Catalyst Reduction GHG Greenhouse Gas SEL Stop Engine Light GHG14 Greenhouse Gas and Fuel Efficiency Regulations SEO Stop Engine Override GVWR Gross Vehicle Weight Rating S N Serial Number HEST High Exhaust System Temperature SRS Synchronous Reference Sensor in Inch SRT Standard Repair Time inH2O Inches of Water TCM Transmission Control Module inHg Inches of Mercury TDC Top Dead Center ISO Interna...

Page 9: ...e to major parts replacement Authorized service outlets worldwide stock factory original parts The information and specifications in this publication are based on the information in effect at the time of approval for printing Contact an authorized Detroit service outlet for information on the latest revision The right is reserved to make changes at any time without obligation Detroit engines are b...

Page 10: ...Trademark Information DDC Detroit DDEC Optimized Idle Diagnostic Link BlueTec POWER Trac POWER COOL and POWER GUARD are registered trademarks of Detroit Diesel Corporation All other trademarks used are the property of their respective owners To the Operator 10 All information subject to change without notice Copyright 2022 DETROIT DIESEL CORPORATION DDC SVC MAN 0192 ...

Page 11: ...s of vehicle vessel control the operator of a DDEC equipped engine must not use or read any diagnostic tool while the vehicle vessel is moving WARNING HOT EXHAUST During parked regeneration the exhaust gases will be extremely HOT and could cause a fire if directed at combustible materials The vehicle must be parked outside CAUTION LOSS OF VEHICLE CONTROL To avoid injury from the loss of vehicle co...

Page 12: ...t unless the vehicle is equipped with ABS anti lock braking system and you have had prior experience driving under these conditions When driving without a trailer bobtailing or pulling an empty trailer If the tractor drive wheels begin to lock or there is fishtail motion after the Engine Brake is activated deactivate the brake system immediately if this occurs WARNING BODILY INJURY To avoid injury...

Page 13: ...protective gloves and apron WARNING PERSONAL INJURY To avoid injury when using caustic cleaning agents follow the chemical manufacturers usage disposal and safety instructions 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 use care when working around moving belts and rot...

Page 14: ...or allow open flames when working on an operating engine WARNING FIRE To avoid injury from fire from a buildup of volatile vapors keep the engine area well ventilated during operation WARNING PERSONAL INJURY To avoid injury from rotating belts and fans do not remove and discard safety guards WARNING PERSONAL INJURY To avoid injury from slipping and falling immediately clean up any spilled liquids ...

Page 15: ...rical shock do not touch battery terminals alternator terminals or wiring cables while the engine is operating WARNING Battery Explosion and Acid Burn To avoid injury from battery explosion or contact with battery acid work in a well ventilated area wear protective clothing and avoid sparks or flames near the battery If you come in contact with battery acid Flush your skin with water Apply baking ...

Page 16: ...iquids WARNING FIRE To avoid injury from combustion of heated lubricating oil vapors stop the engine immediately if an oil leak is detected WARNING FIRE To avoid injury from fire do not smoke or allow open flames when working on an operating engine WARNING FIRE To avoid injury from fire from a buildup of volatile vapors keep the engine area well ventilated during operation Fuel System Observe the ...

Page 17: ...ctly involved in servicing away from the engine Stop the engine immediately if a fuel leak is detected Do not smoke or allow open flames when working on an operating engine Wear 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 Aftertreatment System Observe the following ...

Page 19: ...ents see the following Table 3 DD5 Left Side View 1 Water Pump 2 Coolant Thermostat 3 Fuel Rail 4 Hydrocarbon Doser Block 5 High Pressure Fuel Pump 6 Single Stage Air Compressor 7 Motor Control Module MCM 8 Fuel Filter Module 9 Exhaust Gas Recirculation EGR Valve GHG17 DD Medium Duty Operators Manual All information subject to change without notice 19 DDC SVC MAN 0192 Copyright 2022 DETROIT DIESEL...

Page 20: ...AC Inlet Pipe 6 Coolant Inlet Elbow 7 Oil Coolant Module 8 Turbocharger 9 Wastegate Actuator Fuel Doser Injector Valve DD8 Engine Components For general views of the Detroit DD8 engine and major components see the following Engine Indentification 20 All information subject to change without notice Copyright 2022 DETROIT DIESEL CORPORATION DDC SVC MAN 0192 ...

Page 21: ... Rail 4 High Pressure Fuel Pump 5 Air Compressor 6 Motor Control Module MCM 7 Fuel Filter Module 8 Exhaust Gas Recirculation EGR Valve GHG17 DD Medium Duty Operators Manual All information subject to change without notice 21 DDC SVC MAN 0192 Copyright 2022 DETROIT DIESEL CORPORATION ...

Page 22: ... 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 934913C0043228 as an example 934 engine model Medium Duty 4 cyl for MDEG NAFTA DD5 913 application high level identifier C asse...

Page 23: ...ing serial number is located on the left front of the engine cylinder block Using 936913C0043228 as an example 936 engine model DD8 913 application high level identifier C assembly plant C for Mannheim Germany S for Detroit Michigan 0043228 production serial number GHG17 DD Medium Duty Operators Manual All information subject to change without notice 23 DDC SVC MAN 0192 Copyright 2022 DETROIT DIES...

Page 24: ...over This label certifies that 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 a GHG17 engine certification label Engine Indentification 24 All information subject to change without notice Copyright 2022 DETROIT DIESEL CORPORATION DDC SVC MAN 0192 ...

Page 25: ...Figure 7 GHG17 Engine Certification Label GHG17 DD Medium Duty Operators Manual All information subject to change without notice 25 DDC SVC MAN 0192 Copyright 2022 DETROIT DIESEL CORPORATION ...

Page 26: ...k the oil level as follows WARNING PERSONAL INJURY To avoid injury from slipping and falling immediately clean up any spilled liquids NOTICE Do not add oil if the oil reading is in the crosshatch area on the dipstick There are approximately 4 0 L 4 2 qt from the fill mark to the full mark Overfilling the oil pan can cause engine damage NOTE If the engine operating temperature is below 60 C 140 F t...

Page 27: ... 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 oil level will be at the BOTTOM of bend 1 For the minimum oil level it is noted at the TOP of bend 2...

Page 28: ...nd even running the fuel system must be primed if air has entered the fuel system Priming is done by operating the manual hand priming pump located on the frame mounted fuel filter or connecting an external priming pump to the priming port on the fuel filter module Authorized Detroit service outlets are properly equipped for this type of service Priming is required if the fuel system has been serv...

Page 29: ... corrosion protection apply dielectric grease liberally to the terminal pads Starting the Engine 1 Place the transmission in neutral and set the parking brake NOTICE To prevent serious starter motor damage release the ignition switch immediately after the engine has started 2 Turn on the ignition switch 3 Wait for the engine system indicator lights on the instrument panel to go out 4 With foot off...

Page 30: ...with a manifold grid heater Temperatures below 20 C 4 F may require a block heater and oil pan heater Winter Fronts Winter fronts on DD engines are seldom necessary due to the modern design of the engine cooling system The coolant thermostat is on the outlet side of the cooling system on the DD Platform engine and regulates coolant flow to the radiator into the engine The thermostat regulates cool...

Page 31: ...ll cause vehicle downtime and lost productivity There are two specific situations where a winter front may be temporarily needed To improve cab heating while idling under extreme cold ambient temperature When the ambient temperature remains below 30 C 22 F and the engine is unable to maintain running coolant temperature of 80 C 175 F during normal over the road operation If either of the above sit...

Page 32: ...pply malfunction the system will continue to operate at reduced voltage When this occurs the AWL Check Engine will come on The engine will only operate at reduced rpm until the battery voltage reaches a point where the MCM will no longer function and the engine shuts down Should the AWL Check Engine come on for any reason the vehicle can still be operated and the driver can proceed to the required...

Page 33: ...e You must continue to reset the automatic shutdown system by pressing the Stop Engine Override Switch at intervals of approximately 15 to 20 seconds It takes 30 seconds from the time the automatic shutdown sequence begins until engine shutdown Therefore the operator must press the override switch just prior to engine shutdown and continue to do so until the vehicle can be brought to a stop in a s...

Page 34: ...ghts will come on and go off as the computer senses the changing engine condition Detroit Diesel Electronic Control System Operation 34 All information subject to change without notice Copyright 2022 DETROIT DIESEL CORPORATION DDC SVC MAN 0192 ...

Page 35: ...er CAUTION LOSS OF VEHICLE CONTROL To avoid injury from loss of vehicle control do not activate the Engine Brake system under the following conditions On wet or slippery pavement unless the vehicle is equipped with ABS anti lock braking system and you have had prior experience driving under these conditions When driving without a trailer bobtailing or pulling an empty trailer If the tractor drive ...

Page 36: ... codes are logged into the MCM s memory The standard parameters which are monitored for engine protection are low coolant level high coolant temperature low oil pressure and high oil temperature WARNING PERSONAL INJURY To avoid injury from engine shutdown in an unsafe situation ensure the operator knows how to override the stop engine condition on a DDEC equipped unit NOTICE Engines equipped with ...

Page 37: ...d by the state of California Owners of these vehicle types that wish to have the shutdown feature disabled should consult with California authorities to determine if their vehicles qualify for the exemption Non California 49 state EPA certification engines non California engines have the automatic shutdown feature enabled In California and Opt in states extended idling above 900 rpm is not allowed...

Page 38: ...ers where it mixes with atomized fuel from the injectors For optimum engine protection from dust and other airborne contaminants service the dry type air cleaners 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 Two th...

Page 39: ...ns in accordance with EPA regulations 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 Engines for on ...

Page 40: ...tic Reduction SCR system consists of an Aftertreatment Control Module ACM a tank for Diesel Exhaust Fluid DEF a DEF pump an airless DEF dosing unit and an SCR module DEF is pumped to the airless dosing unit through a high pressure DEF line at 10 bar 145 psi The DEF dosing unit injects a fine mist of atomized DEF into the SCR hydrolysis chamber to produce a chemical reaction This chemical reaction ...

Page 41: ...rtification program to ensure the quality of DEF available at service outlets Diesel Exhaust Fluid Handling and Storage When stored at temperatures between 10 and 90 F minus 12 and 32 C DEF has a maximum shelf life of 12 months For best shelf life it is recommended that Diesel Exhaust Fluid DEF containers be stored in a controlled environment Diesel Exhaust Fluid System Anti Tampering Feature The ...

Page 42: ...ovide optimum enhancement to the oxidation process The following requirements must be met otherwise the Aftertreatment Device ATD warranty may be compromised Use Ultra Low Sulfur Diesel Fuel ULSD with 15 ppm sulfur content or less based on ASTM D2622 test procedure Lube oil must have a sulfated ash level less than 1 0 wt currently referred to as API FA 4 CK 4 and CJ 4 oil Detroit currently recomme...

Page 43: ...use in exhaust aftertreatment systems DEF Diesel Exhaust Fluid will be sold at over 2 500 locations throughout North America These locations include Detroit Distributors Freightliner Truck Dealers Western Star Truck Dealers Travel Centers of America Truck Stops Petro Stopping Centers Pilot Travel Centers Additional Diesel Exhaust Fluid DEF sales locations can be found at www afdc energy gov afdc l...

Page 44: ...mps Call for service to repair the fault Illumination of the Diesel Particulate Filter DPF Regeneration Lamp indicates that a parked regeneration is required There is a need to periodically remove accumulated ash derived from engine lube oil from the filter This ash does not oxidize in the filter during the regeneration process and must be removed through a cleaning procedure All Detroit ATD equip...

Page 45: ... or user specification NOTE The procedure will take approximately 30 to 45 minutes depending on engine type and the amount of soot accumulated in the DPF When the parked regeneration request is accepted the Diesel Particulate Filter DPF Regeneration lamp will turn ON one time for one second and then turn off for the remainder of the parked regeneration The High Exhaust System Temperature HEST lamp...

Page 46: ...is in process and the system is coming up to temperature 1 Keep engine at idle cannot be in Fast Idle or PTO Mode Put transmission in neutral if equipped with an automatic transmission 2 Set park brake 3 Hold DPF Switch to the ON position for five seconds and then release engine speed will increase and DPF lamp will go out Performing a Parked Regeneration GHG17 46 All information subject to change...

Page 47: ...his record is an agent to warranty considerations The record must include information such as Date of cleaning or replacement Vehicle mileage at the time of cleaning or replacement Particulate filter part number and serial number s GHG17 DD Medium Duty Operators Manual All information subject to change without notice 47 DDC SVC MAN 0192 Copyright 2022 DETROIT DIESEL CORPORATION ...

Page 48: ... Call for service Lamp Solid Lamp Flashing At the start of every ignition cycle bulb check When an electronic system fault occurs Fault should be diagnosed as soon as possible Flashes last 90 seconds before idle shutdown if programmed for override Flashes when idle shutdown or the optimized idle shutdown occurs Red Stop Lamp Instrument Panel Lamps 48 All information subject to change without notic...

Page 49: ...esults Diesel Particulate Filter Regeneration Lamp Solid yellow indicates a regeneration is required Blinking yellow derate and or shutdown are possible as soot load continues to increase Lamp will shut off during parked regeneration Lamp Solid regeneration is required Lamp Flashing regeneration is required immediately Lamp Solid Lamp Flashing At the start of every ignition cycle bulb check Regene...

Page 50: ...perature is greater than 525 C 977 F Flashes every 10 seconds when the Selective Catalytic Reduction SCR Catalyst is not up to temperature Malfunction Indicator Lamp Table 11 Lamp Lamp Name Description Results Malfunction Indicator Lamp MIL Yellow lamp Indicates a failure of an Emission Control device May illuminate at the same time as the Amber Warning Lamp Vehicle can be driven to end of the shi...

Page 51: ...ter needs service Never Water In Fuel Lamp WIF Table 13 Lamp Lamp Name Description Results Water In Fuel WIF Lamp Yellow lamp indicates that the fuel water separator has reached its capacity and needs to be drained Engine water separator must be drained or an engine derate will occur Lamp Solid Lamp Flashing At the start of every ignition cycle a bulb check Water separator has reached it maximum c...

Page 52: ...e The use of improper DEF fluid will trigger a decrease in the engine s performance In an empty or an ignored state and the diesel fuel tank is filled without filling the DEF tank the vehicle s speed will be limited to 5 mph until DEF is detected in the DEF tank Figure 8 Driver Card Diesel Exhaust Fluid Level Warning Lamps 52 All information subject to change without notice Copyright 2022 DETROIT ...

Page 53: ...g style required When parked keep vehicle at a safe distance from people and flammable materials or vapors Malfunction Indicator Lamp Table 15 Instrument Panel Lamp Notifications and Description Driver Action Malfunction Indicator Lamp MIL Indicates a failure of an emission control device May illuminate at the same time as the Check Engine Lamp CEL Vehicle can be driven to end of shift If the MIL ...

Page 54: ...l Particulate Filter Regeneration Lamp and the Check Engine Lamp Table 17 Instrument Panel Lamp Notifications and Description Driver Action Diesel Particulate Filter DPF regeneration lamp Check Engine Lamp CEL ENGINE DERATED Indicates the Diesel Particulate Filter DPF has reached system limits A parked regeneration must be performed Reference model year specific section Performing a Parked Regener...

Page 55: ... system limits A parked regeneration must be performed Reference model year specific section Performing a Parked Regeneration If the parked regeneration exits and the lamps remain on repeat the parked regeneration If the second attempt fails call for service Note Engine can be restarted but a parked regeneration must be initiated within 30 seconds or the engine will shutdown GHG17 DD Medium Duty O...

Page 56: ...f when fluids should be changed such as engine oil refer to DDCSN for publication Engine Requirements Lubricating Oil Fuel and Filters DDC SVC BRO 0001 and publication Coolant Selections for Detroit Engines DDC SVC BRO 0002 available from authorized Detroit distributors and dealers Each maintenance table shows which maintenance operation must be performed at the recommended interval in miles kilom...

Page 57: ...l Equipment Manufacturer OEM component Replacement with an aftermarket part may lead to shortened maintenance intervals and excessive noise Drive belts wear differently based on environmental conditions and vehicle duty cycle If the vehicle is operated in extremely hot or cold climates or is exposed to significant dust debris road salt lifetime of the belts may be significantly reduced Fuel Filter...

Page 58: ...pressor The air compressor incorporates three of the major systems of a diesel engine air lubrication and coolant Proper inspection of air compressor would include inspecting for air oil and coolant leaks A failed air compressor can create inadequate internal sealing resulting in excessive crankcase pressure or allowing an engine to ingest oil Aftertreatment System ATS There is a need to periodica...

Page 59: ...me cause the vibration damper to break down and lose its dampening properties For this reason the vibration damper must be replaced at time of normal major engine overhaul regardless of apparent condition GHG17 DD Medium Duty Operators Manual All information subject to change without notice 59 DDC SVC MAN 0192 Copyright 2022 DETROIT DIESEL CORPORATION ...

Page 60: ...t Standard Life Maintain every 45 000 miles 72 000 km 1 500 hrs 12 months Replace every 300 000 miles 482 000 km 3 000 hrs 24 months Coolant Extended Life Maintain every 90 000 miles 145 000 km 1 500 hrs 12 months Replace every 600 000 miles 965 000 km 6 000 hrs 48 months Fuel Filters frame and engine Replace every 45 000 mi 72 000 km 1 500 hrs 18 months Valve Lash Adjustment Adjust every 90 000 m...

Page 61: ...er to Routine Preventive Maintenance for a description of all items DD5 Long Haul Long Haul service over the road transport applies to vehicles that annually travel more than 60 000 miles 96 000 km and average greater than 12 0 miles per gallon with minimal city stop and go operation Examples of Long Haul service are regional delivery that is mostly freeway mileage interstate transport and any roa...

Page 62: ... Davco 245 or Racor 6600 are the only frame mounted filtration systems compatible for Detroit Engines Refer to Routine Preventive Maintenance for a description of all items DD5 Severe Service Severe service applies to vehicles that average below 10 0 miles per gallon or that operate under severe conditions Examples of Severe Service are idle time over 40 load factor over 55 operation on extremely ...

Page 63: ...ce including excess fuel consumption and decreased engine life Normal DPF ash clean interval is less than 190 000 mi 306 000 km 6 300 hrs DEF Pump Filter Replace every 500 000 miles 805 000 km 10 000 hrs 3 years Air Compressor Inspect every 35 000 mi 56 000 km 1 000 hrs 12 months Whichever comes first Note Reaching the Davco change line supersedes these intervals Detroit highly recommends exchangi...

Page 64: ...ent Devices Inspect external hardware and connections every 6 months or at oil change intervals Diesel Particulate Filter A Check Engine Indicator or mileage time intervals indicate when ash cleaning is required Use DETROIT Diesel Corporation s authorized DPF cleaning procedure Failure to follow this procedure could result in engine and or aftertreatment damage causing degraded vehicle performance...

Page 65: ...km 2 000 hrs Air Cleaner Refer to vehicle maintenance procedures Exhaust System Inspect every 60 000 miles 96 000 km 2 000 hrs Aftertreatment Devices Inspect external hardware and connections every 6 months or at oil change intervals Diesel Particulate Filter A Check Engine Indicator or mileage time intervals indicate when ash cleaning is required Use DETROIT Diesel Corporation s authorized DPF cl...

Page 66: ...0 miles 72 000 km 1 500 hrs 12 months Coolant Standard Life Inspect every 45 000 miles 72 000 km 1 500 hrs 12 months Replace every 300 000 miles 480 000 km 3 000 hrs 24 months Coolant Extended Life Inspect every 90 000 miles 145 000 km 1 500 hrs 12 months Replace every 600 000 miles 965 000 km 6 000 hrs 48 months Fuel Filters frame and engine Replace every 45 000 miles 72 000 km 1 500 hrs 12 month...

Page 67: ...ngine life Normal DPF ash clean interval is every 150 000 miles 241 000 km 5 000 hrs DEF Pump Filter Replace every 500 000 miles 805 000 km 10 000 hrs 3 years Air Compressor Inspect every 45 000 miles 72 000 km 1 500 hrs 12 months Whichever comes first Note Reaching the Davco change line supersedes these intervals Detroit highly recommends exchanging the DPF with a Detroit genuine DPF to ensure ma...

Page 68: ...er grade of oil to maintain the correct level on the dipstick Remove the dipstick from the guide tube Before adding lubricating oil refer to 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 ...

Page 69: ...ration 5 Add the proper grade of oil to maintain the satisfactory range on the dipstick All diesel engines are designed to use some oil so the periodic addition of oil is normal Before adding lubricating oil refer to How to Select Lubricating Oil Monitoring the Lubricating Oil Filter The engines are equipped with a single cartridge style oil filter 3 that is part of the oil coolant module 4 Incorp...

Page 70: ...per operation of the engine 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 at the full level 2 Add coolant as required ...

Page 71: ...ed 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 i...

Page 72: ...place filters solely because of this condition Replace filters between normal service intervals only if required by troubleshooting The engine is equipped with a prefilter that filters down to 100 microns a coalescer final filter that separates water DD8 only the DD5 is not equipped with a water coalescing filter and filters down to two microns When servicing these elements both filters should be ...

Page 73: ...tenance is required Poly V Belt Inspection Periodically inspect the belts based on the damage guide below If any damage is noted replace both belts Fan and Accessory Belts A precision wear gauge available from Gates is the preferred method of determining belt wear GHG17 DD Medium Duty Operators Manual All information subject to change without notice 73 DDC SVC MAN 0192 Copyright 2022 DETROIT DIESE...

Page 74: ... V Belt Inspection Concerns ABRASION CHUNK OUT IMPROPER INSTALL CRACKING Routine Preventive Maintenance 74 All information subject to change without notice Copyright 2022 DETROIT DIESEL CORPORATION DDC SVC MAN 0192 ...

Page 75: ...ce on the Air Intake System 1 Inspect all the connections in the air system to make sure they are tight and leak free 2 Check all hoses and ducting for punctures deterioration or other damage and replace if necessary GHG17 DD Medium Duty Operators Manual All information subject to change without notice 75 DDC SVC MAN 0192 Copyright 2022 DETROIT DIESEL CORPORATION ...

Page 76: ...from the engine s lubricating oil needs to be removed from the ATS This ash does not oxidize in the filter during the regeneration process and must be removed through a cleaning procedure Inspection of the Air Compressor The air compressor incorporates three of the major systems of a diesel engine air lubrication and cooling Inspect the air compressor looking for air oil and coolant leaks Monitori...

Page 77: ...the fuel tank suction and return lines Since fuel tanks are susceptible to road hazards leaks in this area may best be detected by checking for an accumulation of fuel under the tank WARNING HOT OIL To avoid injury from hot oil do not operate the engine with the rocker cover s removed NOTE Leaks are not only detrimental to machine operation but they can also result in added expense caused by the n...

Page 78: ...nspect turbocharger and charge air cooler as follows 1 Visually inspect the turbocharger mountings intake and exhaust ducting and connections for leaks daily 2 Check the lubricating oil inlet and outlet lines for leaks or restrictions to oil flow WARNING PERSONAL INJURY To avoid injury from hot surfaces wear protective gloves or allow engine to cool before removing any component 3 Check the turboc...

Page 79: ...ible b Replace any battery that fails to hold a charge 5 Periodically check battery connections for corrosion and tightness a If necessary remove connections and wire brush any corrosion from terminals and cable ends b Replace damaged wiring Steam Cleaning the Engine NOTICE Do not apply steam or solvent directly to the battery charging alternator starting motor DDEC components sensors or other ele...

Page 80: ...battery while the alternator is operating Disconnecting the battery can result in damage to the battery diodes In applications which have two sets of batteries switching from one set to the other while the engine is running will momentarily disconnect the batteries If a booster battery is to be used batteries must be connected correctly negative to negative positive to positive Never use a fast ch...

Page 81: ...n and lose its dampening properties For this reason replace the viscous vibration damper at time of normal major engine overhaul regardless of apparent condition GHG17 DD Medium Duty Operators Manual All information subject to change without notice 81 DDC SVC MAN 0192 Copyright 2022 DETROIT DIESEL CORPORATION ...

Page 82: ...f API service classification Monograde oils gel at lower ambient temperatures reducing lubricant flow and do not provide adequate lubricity at higher engine operating temperatures resulting in severe engine damage For picking a lubricant for low temperature applications refer to the section How to Select Lubricating Oil See DDC SVC BRO 0001 Use of Synthetic Oils NOTE Synthetic oil does not permit ...

Page 83: ...ld be used to maintain a clean system not to clean up a contaminated system The maintenance intervals for the appropriate duty cycle are listed in tables in this manual 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 th...

Page 84: ...sealing washer for the M22 plug must be replaced once removed The plastic bottom drain plug must also be replaced once removed These components are included in the oil filter kit released for service 12 Install the oil pan drain plug with a new O ring and torque the plug Install the M22 oil pan drain plug if removed with a new seal washer and torque the plug to 45 N m 33 lb ft for plastic oil pans...

Page 85: ... If the engine operating temperature is below 60 C 140 F the engine must be on a level surface and then shut down for 60 minutes for an accurate oil level reading Otherwise the engine must be brought up to an operating temperature of 60 C 140 F parked on a level surface and then shut down for 20 minutes for an accurate oil level reading 15 Check the filter housing for signs of leakage 16 Stop the ...

Page 86: ...mination Generally fuel contamination occurs as the result of improper fuel handling The most common types of contamination are water dirt and microbial growth black slime The formation of varnishes and gums resulting from poor stability or extended storage stale fuel also affects fuel quality The best treatment for contamination is prevention by maintaining a clean storage system and choosing a r...

Page 87: ... prematurely plug with ash Used Lubricating Oil Do not use fuel blended with used lubricating oil Detroit specifically prohibits the use of used lubricating oil in diesel fuel Used lubricating oil contains combustion acids and particulate materials which can severely erode fuel injector components resulting in loss of power and increased exhaust emissions In addition the use of drained lubricating...

Page 88: ...test the system for leaks after priming the fuel system Filters are an integral part of the fuel system Proper filter selection and maintenance are important to satisfactory engine operation and service life Filters should be used to maintain a clean system not to clean up a contaminated system The scheduled maintenance intervals for the appropriate duty cycles are listed in this manual WARNING PE...

Page 89: ...l Prefilter Install the fuel prefilter as follows NOTE If a filter service is being performed replace all other filters before priming 1 Install a new prefilter cap seal ring on to the prefilter cap 2 Snap new prefilter into the prefilter cap 3 Apply a thin coat of petroleum based lithium grease to the prefilter cap seal ring and the prefilter seals 1 GHG17 DD Medium Duty Operators Manual All info...

Page 90: ...m Removal of the Final Filter Remove the final filter as follows NOTICE The high pressure fuel pump is oil lubricated which causes small amounts of oil to migrate into return fuel It is normal for fuel filters to darken over time due to the presence of this oil 1 Shut off the engine apply the parking brake chock the wheels and perform any other applicable safety steps How to Procedures 90 All info...

Page 91: ...ing it from the housing Possible damage to the final filter or stand pipe may occur 5 Pull the cap and final filter 1 straight up and allow the fuel to drain back 6 Discard the final filter 7 Inspect inside the housing for any large debris clean housing as needed 8 Discard final filter cap seal ring Installation of the Final Filter Install the final filter as follows GHG17 DD Medium Duty Operators...

Page 92: ... lb ft NOTE If a filter service is being performed replace all other filters before priming 6 Once all required filters have been changed prime the fuel system Refer to section Priming the Fuel System Engine Out of Fuel How to Restart NOTICE Prolonged use of the starting motor to prime the fuel system can result in damage to the starter Use the following procedure to prime the fuel system NOTE If ...

Page 93: ... 140 F NOTICE Increasing engine speed above idle before oil pressure has stabilized may cause severe engine damage 11 Increase engine speed to 1500 rpm for ONE 1 minute 12 Reduce engine speed and run at idle for ONE 1 additional minute 13 Shut down the engine 14 Check for leaks 15 If engine still fails to start contact an authorized Detroit repair facility Priming the Fuel System Using the Hand Pr...

Page 94: ...st is toxic 5 With the accelerator pedal in the idle position start the engine 6 Crank engine for 20 seconds NOTE The starting cycle can be repeated up to three times 7 If engine does not start allow for a 60 second cool down and repeat previous step 8 Monitor the oil pressure gauge or indicator lamp Keep the engine running at an idling speed until a stable oil pressure reading of 345 kPa 50 psi o...

Page 95: ...o cool down to room temperature before spraying the engine NOTICE Avoid all of the electrical connections with direct water or steam spray or damage can result 2 Thoroughly clean the entire engine using a steam cleaner or high pressure washer with mild soap and warm water WARNING EYE INJURY To avoid injury from flying debris when using compressed air wear adequate eye protection face shield or saf...

Page 96: ... 3 Drain the coolant when the engine is cold Refer to section Cooling System Drain Procedure For detailed procedures see the vehicle chassis maintenance manual For types of coolant refer to the How to Select Coolant section for the listing of required intervals using the recommended coolants 4 If the HVAC unit is connected to the cooling system open the regulating valves all the way 5 Fill the coo...

Page 97: ...ires that these types of coolants to be free of nitrite and phosphate Detroit has found that ELC s containing nitrite may lead to a breakdown of the coolant and subsequent damage to the cooling system These types of coolants should not be mixed with Standard Life Coolants If an ELC antifreeze coolant and SLC antifreeze coolants are mixed damage may not result but the long life advantages of the EL...

Page 98: ...r Cool or refer to 93K217 list of approved coolants at DDCSN DDC Freightliner com Propylene Glycol based antifreeze coolant SLC corrosion inhibitors No Detroit product available Refer to 93K217 list of approved coolants at DDCSN DDC Freightliner com Ethylene Glycol based antifreeze coolant ELC inhibitors Detroit Power Cool Plus or refer to 93K217 list of approved coolants at DDCSN DDC Freightliner...

Page 99: ... following coolants are not to be used in Detroit engines Automotive Passenger car type coolants must not be used in Detroit engines because they offer no liner pitting protection Also these types of coolants generally contain high levels of phosphates and silicates Methyl alcohol based antifreeze must not be used in Detroit engines because of its effects on the nonmetallic components of the cooli...

Page 100: ...bitors Phosphate has tendency to form deposits on surfaces transferring high heat which ultimately affect cooling capabilities Phosphate deposits on water pump seals will result in coolant leakage across seal faces Maintenance Maintenance This section describes procedures needed to maintain the proper coolant level and concentration Topping Off Coolant The coolant level should be checked daily and...

Page 101: ...centration The suggested mixing ratio is 50 50 50 antifreeze 50 water for regular climate or 60 40 60 antifreeze 40 water for colder climates Changing Coolant Technologies Follow cooling system flushing recommendations outlined in Coolant Change section To ensure there is no mixing between the old technology and new technology full chemical analysis should be conducted If possible coordinate with ...

Page 102: ...al information regarding the engine performance A factory coolant analysis program is available through authorized Detroit service outlets To verify coolant acceptability submit a sample for coolant analysis according to Table Extended Life Coolant However a laboratory meeting ISO 17025 requirements may be used in place of the Detroit Genuine Parts Program laboratory OAT Detection Strips OAT Detec...

Page 103: ... year 5 Every 70 000 miles 112 000 km or 1 year 5 Every 50 000 miles 80 000 km or 1 year 5 DD13 130 000 miles 210 000 km or 1 year 5 110 000 miles 178 000 km or 1 year 5 80 000 miles 128 000 km or 1 year 5 70 000 miles 112 000 km or 1 year 5 DD15 150 000 miles 242 000 km or 1 year 5 120 000 miles 194 000 km or 1 year 5 90 000 miles 144 000 km or 1 year 5 70 000 miles 112 000 km or 1 year 5 DD16 No...

Page 104: ... with minimal city stop and go operation 3 Short Haul service applies to vehicles that annually travel up to 30 000 to 60 000 miles 48 000 to 96 000 km and average between 5 1 and 5 9 miles per gallon 4 Severe service applies to vehicles that annually travel up to 30 000 miles 48 000 km and average less than 5 miles per gallon or that operate under severe conditions Severe service also applies to ...

Page 105: ...Haul service applies to vehicles that annually travel up to 60 000 miles 96 000 km and average between 10 1 and 11 9 miles per gallon and operate under normal conditions Examples of Short Haul service are operation primarily in cities and densely populated areas local transport with infrequent freeway travel or a high percentage of stop and go travel 4 Severe service applies to vehicles that avera...

Page 106: ...ge 3 Short Haul service applies to vehicles that annually travel up to 60 000 miles 96 000 km and average between 6 5 and 8 5 miles per gallon and operate under normal conditions Examples of Short Haul service are operation primarily in cities and densely populated areas local transport with infrequent freeway travel or a high percentage of stop and go travel 4 Severe service applies to vehicles t...

Page 107: ...transfers heat from the engine by circulation Extended Life Coolant ELC AKA Long Life Coolant or Organic Acid Technology These types of coolants have been formulated to extend the service interval of the coolant Example of ELC is Power Cool Plus Fully Formulated Antifreeze that contains all the necessary inhibitors to protect a diesel engine and does not therefore require a pre charge of Supplemen...

Page 108: ...e long life advantages of the ELC antifreeze coolant will be lost In this event the coolant should be re inhibited with OAT inhibitors and confirmed by analysis or else it must be maintained as an SLC antifreeze coolant Water Only Coolants Series 50 55 and 60 only In warm climates where freeze protection is not required water only with corrosion inhibitors is approved for use Water only systems ne...

Page 109: ... If tap water is used the mineral content in the water must be below the maximum concentration listed in the table below Table 33 Maximum Mineral Concentration in Water Minerals Maximum Concentration Parts per Million Grains per Gallon Chlorides 40 2 5 Sulfates 100 5 8 Total Dissolved Solids 340 20 Magnesium Calcium Content 170 10 Figure 9 Procedure To Evaluate The Quality Of Water Recycled Antifr...

Page 110: ...s are not recommended Appendix C Detroit Cooling System Maintenance Products Table 34 Detroit Extended Life Coolant Ethylene Glycol based Coolant Type Part Number Description Concentrate OWI 23539616 One Gallon Jug 4 Per Case Canada OWI 23519397 One Gallon Jug 6 Per Case OWI 23519394 55 Gallon Drum Pre Diluted 50 50 OWI 2359617 One Gallon Jug 4 Per Case Canada OWI 23519396 One Gallon Jug 6 Per Cas...

Page 111: ...se OWI 23512139 55 Gallon Drum OWI 23513503 Bulk Delivery 1000 Gallon min Pre Diluted 50 50 OWI 23539623 One Gallon Jug 4 Per Case Canada OWI 23528203 One Gallon Jug 6 Per Case OWI 23518918 55 Gallon Drum OWI 23538603 275 Gallon Tote Table 37 Detroit Genuine Coolant 2000 Supplemental Coolant Additives SCA Coolant Type Part Number Description IEG Detroit Genuine Coolant PIC 23507858 Pint Bottle 12 ...

Page 112: ...ivalent 23507189 16 Ounce 4 Pint Equivalent 23508427 32 Ounce 8 Pint Equivalent 23508428 53 Ounce 13 Pint Equivalent Table 40 Detroit Genuine Coolant Cooling System Cleaners Coolant Type Part Number Description All Types PIC 201549 Twin pack 2 Per Case Standard Life Coolant Only PIC 200164 One Half Gallon Jug 6 Per Case PIC 200105 5 Gallon Pail PIC 200155 55 Gallon Drum Table 41 Detroit Genuine Fl...

Page 113: ...te parts support Product information and literature We recognize however that despite the best intentions of everyone concerned misunderstandings may occur Normally any situation that arises in connection with the sale operation or service of your product will be handled by the authorized service outlet in your area in the U S and Canada check the Yellow Pages or the service locator at www demandd...

Page 114: ...Delivery 1 000 Gallon 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 43 Detroit Genuine Supplemental Coolant Additive Need Release Filters Coolan...

Page 115: ...ber 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 Cool...

Page 116: ...ll mark to the full mark NOTICE Overfilling the oil pan can cause engine damage Table 46 Engine Oil Capacities Medium Duty Engines DD5 DD8 Total Dry Engine Oil Volume 19 5 L 20 6 qt 28 5 L 30 1 qt Oil and Filter Change 17 5 L 18 5 qt 25 5 L 26 9 qt Remaining in Engine after Oil Drain Includes Filter Removal 2 0 L 2 1 qt 3 0 L 3 2 qt Dip Stick Min to Max Range 4 0 L 4 2 qt 4 0 L 4 2 qt Sump Oil Vol...

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