DDC SVC Man 0189
DDC SVC Man 0189
DDC SVC Man 0189
Table of Contents
California Proposition 65 Warning and Engine Idle Notice......................... 5
Forward............................................................................................................. 6
Introduction.................................................................................................... 6
Non-Genuine and Rebuilt Component Quality Alert.................................... 6
Personnel Requirements................................................................................ 6
Engine Conversions and Modifications......................................................... 7
To the Operator................................................................................................. 8
Caution Summary........................................................................................... 10
Engine Identification...................................................................................... 17
Engine Components - EPA07, EPA10, GHG14 DD Platform..................... 17
Engine Components - GHG17 DD Platform............................................... 24
Engine Model and Serial Number Designation........................................... 30
Operating Instructions for Starting the Engine........................................... 40
First Time Start Preparations....................................................................... 40
Detroit Diesel Electronic Controls (DDEC) System.................................... 58
DDEC VI System - EPA07.......................................................................... 58
DDEC 10 System - EPA10/GHG14............................................................ 61
Detroit Diesel Electronic Control System Operation.................................. 64
Detroit Diesel Electronic Control System Features..................................... 68
Accelerating the Vehicle.............................................................................. 72
Cruise Control.............................................................................................. 72
Engine Brake and Cruise Control................................................................ 75
DD Platform Shifting................................................................................... 75
Idling............................................................................................................ 76
Engine Brake System...................................................................................... 77
Driver Control Switches.............................................................................. 77
Clutch Pedal and Throttle Position Controls............................................... 77
Engine Brake Activation Conditions........................................................... 77
Engine Brake Operation............................................................................... 78
Anti-Lock Braking Systems........................................................................ 79
Operating on Flat, Dry Pavement................................................................ 79
Operating Down a Long, Steep Grade......................................................... 79
Operating on Wet or Slippery Pavement..................................................... 80
Engine Systems............................................................................................... 82
EPA07 Aftertreatment Device....................................................................... 84
EPA10 Aftertreatment System...................................................................... 85
GHG14 Aftertreatment System..................................................................... 88
GHG17 Aftertreatment System..................................................................... 89
Diesel Exhaust Fluid Information................................................................. 91
Aftertreatment Device Operating Requirements........................................ 92
EPA10 Diesel Exhaust Fluid (DEF) Purge Cycle......................................... 93
EPA10/GHG14/GHG17 Diesel Exhaust Fluid Tank................................... 94
Aftertreatment Maintenance......................................................................... 95
2 All information subject to change without notice.
Copyright © 2018 DETROIT DIESEL CORPORATION DDC-SVC-MAN-0189
DD Heavy Duty Platform Operators Manual
Forward
Introduction
This manual is intended for use by the operator of a Detroit™ engine used in On-
Highway Vehicle applications.
Personnel Requirements
Work on the engine should be carried out only by skilled technicians who have
been instructed in the specific skills necessary for the type of work being
performed.
To the Operator
This manual contains instructions on the safe operation and preventive maintenance
of your Detroit™ engine used in vehicle applications. Maintenance instructions
cover routine engine services such as lubricating oil and filter changes in enough
detail to permit self-servicing, if desired.
The operator should become familiar with the contents of this manual before
operating the engine or carrying out maintenance procedures.
Power-driven equipment is only as safe as the person operating the controls. You
are urged, as the operator of this diesel engine, to keep fingers and clothing away
from the revolving belts, drive shafts, pulleys, etc. on the engine installation.
Throughout this manual CAUTIONS and WARNINGS regarding personal safety
and NOTICES regarding engine performance or service life will appear. To avoid
personal injury and ensure long engine service life, always heed these instructions.
Whenever possible, it will benefit you to rely on an authorized Detroit™ service
outlet for all your service needs from maintenance 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 built in accordance with sound technological principles and
based on state-of-the-art technology.
Despite this, the engine may constitute a risk of damage to property or injury to
persons if it is not used for its intended purpose.
The engine should not be modified or converted in an incorrect manner or the
safety instructions included in this manual disregarded.
Keep this Operator Manual with the engine installation at all times. It contains
important operating, maintenance, and safety instructions.
Table 1.
WARRANTY
The applicable engine warranty is contained in the booklet “Warranty Information for
Detroit™ Engines,” available from authorized Detroit™ service outlets.
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.
Caution Summary
The following cautions must be observed by the operator of the vehicle or
equipment in which this engine is installed and/or by those performing basic engine
preventive maintenance. Failure to read and heed these cautions and exercise
reasonable care for personal safety and the safety of others when operating the
vehicle/equipment or performing basic engine preventive maintenance may result
in personal injury and engine and/or vehicle/equipment damage.
Engine Operation
Observe the following cautions when operating the engine.
Preventive Maintenance
Observe the following cautions when performing preventive maintenance.
WARNING: FIRE
To avoid injury from fire, contain and eliminate leaks of flammable
fluids as they occur. Failure to eliminate leaks could result in fire.
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.
Compressed Air
Observe the following cautions when using compressed air.
Cooling System
Observe the following cautions when servicing the cooling system.
Electrical System
Observe the following cautions when jump starting an engine, charging a battery, or
working with the vehicle/application electrical system.
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 following cautions when fueling the vehicle or working with the fuel
system.
WARNING: FIRE
To avoid injury from fire, keep all potential ignition sources away
from diesel fuel, including open flames, sparks, and electrical
resistance heating elements. Do not smoke when refueling.
WARNING: FIRE
To avoid increased risk of a fuel fire, do not mix gasoline and
diesel fuel.
WARNING: FIRE
To avoid injury from fire caused by heated diesel-fuel vapors:
• Keep those people who are not directly involved in servicing
away from the engine.
• Stop the engine immediately if a fuel leak is detected.
• Do not smoke or allow open flames when working on an
operating engine.
• Wear 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 cautions when servicing the Aftertreatment System (ATS).
Be advised that these two labels are attached to the Aftertreatment Device (ATD).
Engine Identification
For a general view of the Detroit™ DD13 engines and major components, see the
following:
For a general view of the Detroit™ DD15 Turbo-compound (TC) and DD15
Asymmetrical Turbo (AT) engines and major components, see the following:
For a general view of the Detroit™ DD16 engines and major components, see the
following:
Table 2.
HDEP MODEL BREAKDOWN
DESCRIP- ENGINE DISPLACE- YEAR DDEC
APPLICATION
TION MODEL MENT SERIES
14.8 L WESTERN
EPA07 DD15 472900S
(DD15) STAR
14.8 L
EPA07 DD15 472901S FREIGHTLINER
(DD15)
14.8 L
EPA07 DD15 472902S STERLING
(DD15)
EXPORT
14.8 L
EPA07 DD15 472907S (usually
(DD15)
Australia)
2007 - 09
EXPORT Euro IV VI
EURO IV 14.8 L (EPA07)
472908S (usually Chile/
DD15 (DD15)
Mexico)
12.8 L
EPA07 DD13 471901S FREIGHTLINER
(DD13)
12.8 L
EPA07 DD13 471910S STERLING
(DD13)
EXPORT
12.8 L
EPA07 DD13 471915S (usually
(DD13)
Australia)
Table 3.
HDEP MODEL BREAKDOWN
DESCRIP- ENGINE DISPLACE- YEAR DDEC
APPLICATION
TION MODEL MENT SERIES
14.8 L
EPA10 DD15 472903S FREIGHTLINER
(DD15)
14.8 L WESTERN
EPA10 DD15 472904S
(DD15) STAR
12.8 L
EPA10 DD13 471903S FREIGHTLINER
(DD13)
12.8 L COACH
EPA10 DD13 471905C
(DD13) (EVOBUS)
12.8 L WESTERN
EPA10 DD13 471911S
(DD13) STAR
12.8 L FREIGHTLINER 2010 - 12
EPA10 DD13 471913S 10
(DD13) M2 (EPA10)
12.8 L
EPA10 DD13 471914S FIRETRUCK
(DD13)
12.8 L COACH (MCI &
EPA10 DD13 471917S
(DD13) VAN HOOL)
12.8 L
EPA10 DD13 471920S MTU
(DD13)
15.6 L
EPA10 DD16 473901S FREIGHTLINER
(DD16)
15.6 L WESTERN
EPA10 DD16 473902S
(DD16) STAR
Table 4.
HDEP MODEL BREAKDOWN
DESCRIP- ENGINE DISPLACE- YEAR DDEC
APPLICATION
TION MODEL MENT SERIES
EPA10
14.8 L ASSYMETRIC
GHG14 472906S
(DD15) TURBO (AT)
DD15
EPA10
14.8 L TURBOCOMPO
GHG14 472909S
(DD15) UND (TC)
DD15
EPA10 FUEL ECON
12.8 L
GHG14 471927S PACKAGE 0
(DD13)
DD13 (FE0)
EPA10
12.8 L COACH
GHG14 471932C
(DD13) (EVOBUS) 2013
DD13
(EPA10 13
EPA10 GHG14)
12.8 L PIERCE
GHG14 471933S
(DD13) FIRETRUCK
DD13
EPA10
12.8 L COACH (MCI &
GHG14 471934S
(DD13) VAN HOOL)
DD13
EPA10
12.8 L
GHG14 471935S MTU
(DD13)
DD13
EPA10
15.6 L TURBOCOMPO
GHG14 473908S
(DD16) UND (TC)
DD16
Table 5.
HDEP MODEL BREAKDOWN
DESCRIP- ENGINE DISPLACE- YEAR DDEC
APPLICATION
TION MODEL MENT SERIES
EPA10
14.8 L ASSYMETRIC
GHG17 472910S
(DD15) TURBO (AT)
DD15
EPA10
12.8 L
GHG17 471928S TRUCK (FE1)
(DD13)
DD13
EPA10
12.8 L COACH
GHG17 471938C
(DD13) (EVOBUS)
DD13
EPA10
12.8 L PIERCE 2016
GHG17 471940S
(DD13) FIRETRUCK (EPA10 13
DD13
GHG17)
MCI, VAN
EPA10
12.8 L HOOL,
GHG17 471941S
(DD13) OSHKOSH,
DD13
FCCC
EPA10
12.8 L
GHG17 471942S MTU
(DD13)
DD13
EPA10
15.6 L TURBOCOMPO
GHG17 473910S
(DD16) UND (TC)
DD16
System Checks
Perform the following system checks before starting for the first time.
NOTICE:
• Insufficient lubrication at startup can cause serious damage to engine
components.
• Do not add oil if the oil reading falls on the crosshatch area of the
dipstick. There are approximately 5.0 L (5.2 qt) from the fill mark to the
full mark. Overfilling the oil pan can cause engine damage.
NOTICE: Do not add oil if the oil reading is in the crosshatch area on the
dipstick. There are approximately 5.0 L (5.2 qt) from the fill mark to the full
mark. Overfilling the oil pan can cause engine damage.
1. Check the oil level daily with the engine stopped and on a level surface. If
the engine has just been stopped and is warm, wait approximately 20
minutes to allow the oil to drain back into the oil pan before checking.
2. Add oil to maintain the correct level on the dipstick. Use only the heavy-
duty oils recommended in the "How to Replace the Lubricating Oil and Oil
Filter" section in this manual.
NOTE: The dipstick has a positive locking device such as a lever or twist-
lock design that must be disengaged before pulling the dipstick out of the
guide tube.
3. Remove the dipstick from the guide tube. Use a shop rag to wipe off the end
of the dipstick.
4. Wait 15 seconds to allow any crankcase pressure to dissipate through the
guide tube and let the oil level settle in the oil pan.
5. Reinstall the dipstick and make sure it is fully inserted into the guide tube.
6. Remove the dipstick and read the oil level dipstick.
7. The figure shows a comparison between the bends on the dipstick and a
crosshatch pattern on a conventional dipstick. Note the exact area noted on
the bends. For example, the 'maximum' oil level will be at the BOTTOM of
that bend. For the 'minimum' oil level, it is noted at the TOP of the bend. If
the oil level is below the 'minimum' bend, add oil to bring it up the
'maximum' level. Do NOT fill beyond the maximum fill level on the
dipstick, since overfilling may result in high oil consumption and possible
severe engine damage.
An engine in storage for an extended period of time (over winter, for example) may
accumulate water in the oil pan through normal condensation of moisture (always
present in the air) on the cold, internal surfaces of the engine.
Lubrication oil diluted by water cannot provide adequate bearing protection at
engine startup. For this reason, Detroit™ recommends replacing the engine
lubricating oil and filters after extended storage.
If the shutoff valve is even partially closed, it may cause erratic engine
operation due to an inadequate supply of fuel to the fuel pump.
NOTICE: NEVER use ether as a starting aid to run the engine. Doing so will
result in injector damage.
If an external starting aid is used, such as a starting fluid, the heat generated by the
external fuel source will cause the injector tips to be damaged when the fuel cools
them. The injector piston and bushing can be scored from running without
lubrication.
To ensure prompt starting and even running, the fuel system must be primed if air
has entered the fuel system. Priming is done by operating the manual hand priming
pump located on the fuel filter module or connecting an external priming pump to
the priming port on the fuel filter module.
Authorized Detroit™ service outlets are properly equipped for this type of service.
Priming is required if the fuel system has been serviced.
Drain off any water that has accumulated. Water in fuel can seriously affect engine
performance and may cause engine damage.
Adding Fuel
When adding fuel, pay attention to the following:
NOTICE: Always use Ultra-Low Sulfur Diesel Fuel (ULSD) with 15 PPM
sulfur content or less, based on ASTM Standard D2622 test procedure.
Higher sulfur levels will damage the engine Aftertreatment System (ATS).
• Add winter or summer grade fuel according to the season of the year.
• Work in the cleanest conditions possible.
• Prevent water from entering the fuel tank.
For further information, Refer to section "How to Select Diesel Fuel".
6. Start the engine with the accelerator pedal in the idle position. Monitor the
oil pressure gauge or indicator lamp. Keep the engine running at idling
speed until the oil pressure reading is 14 psi (97 kPa) or more.
7. Allow engine to reach operating temperature 60ºC (140ºF).
NOTICE: Increasing engine speed above idle before oil pressure has
stabilized may cause severe engine damage.
9. Return the engine to idle and allow to idle for approximately one minute,
then shut down the engine.
10. Check for leaks. Repair if necessary.
WARNING: EXPLOSION
To avoid injury from explosion, never use ether with an engine's
electrical cold starting system.
Before starting the engine the first time, perform an inspection of the engine
systems.
EPA07 engines only: An electrical grid heater is used as a cold weather starting aid
if the ambient temperature is below 4ºC (40ºF).
To start the engine, the transmission should be in neutral and the ignition key
turned to ON.
You will notice that the Amber Warning Lamp (AWL), Red Stop Lamp (RSL),
Malfunction Indicator Lamp (MIL), Diesel Particulate Filter (DPF) Regeneration
lamp, and High Exhaust Temperature (HEST) lamp will come on. This is the result
of the DDEC computer diagnosing the system to ensure everything is functional,
including the light bulbs for the warning lights. If everything is OK, all lights will
go out in approximately five seconds.
The lights must go out before starting the engine. If starting a vehicle, the
operators foot must be OFF the accelerator pedal before starting the engine.
NOTICE: If the warning lights stay on, or do not come on momentarily after
turning on the ignition, contact the Detroit™ Customer Support Center at
1-800-445-1980. Operating the engine under these circumstances may
result in engine damage.
5. If the engine does not start after 20 seconds, stop. Try again after waiting
about 60 seconds.
NOTICE: Do not increase engine speed if the oil pressure gauge indicates
no oil pressure. Shut down the engine within approximately ten seconds to
avoid engine damage. Check to determine the cause of the problem.
NOTE: Do not place the engine under full load until it reaches operating
temperature. Colder engine temperatures will cause the engine to preset
idle up to 900 rpm. Even at a high idle condition, you do not have to wait for
engine warm up and return to normal 600 rpm idle to drive the truck.
6. Monitor the oil pressure gauge immediately after starting the engine.
1. Observe the oil pressure gauge immediately after starting the engine. An oil
pressure gauge that registers pressure 14 psi (96 kPa) at idle speed and
normal operating temperature is a good indicator that all moving parts are
getting lubrication.
2. If no pressure is indicated within 10 to 15 seconds, stop the engine and
check the lubrication system at normal operating temperature.
3. The oil pressure should not drop below 55 psi (380 kPa) at 1800 rpm, at
normal operating temperature. If oil pressure does not fall within these
guidelines, check it with a manual gauge.
2. If necessary, add no more oil than 5.0 L (5.2 qt) at a time to bring the level
to the proper mark on the dipstick. Use only the heavy-duty oils
recommended in the "How to Replace the Lubricating Oil and Oil Filter"
section in this manual.
1. Reduce engine speed to idle and put all shift levers in the neutral position.
NOTE: Cool-down idling needs to take place after pulling off an interstate.
When finding a parking spot or backing into a dock, immediate shutdown
should be avoided. Shutting the engine off immediately retains more block
heat than if the engine runs at idle for five minutes.
2. Allow the engine to run between idle and 1000 rpm with no load for five
minutes. This allows the engine to cool and permits the turbocharger to slow
down. After five minutes, shut down the engine.
Before attempting to jump start the engine, the jumper cables must be connected
properly; positive-to-positive, and negative-to-chassis or suitable ground. The
proper sequence is to connect negative to negative ground last.
NOTICE: Before starting the engine, carefully read all operating instructions
in this manual and do all the recommended pre-trip inspections and daily
maintenance. Check the coolant, engine oil, and fuel levels, and drain
contaminants from the water separator/coalescer.
NOTE: If you drain water from the water separator/coalescer, you have to
prime the fuel system with the built-in hand primer (about 50 strokes).
6. Check the oil level using the oil dipstick. The oil level is measured using the
crosshatch area on the dipstick. If the oil reading within the crosshatch area,
then the oil is at the proper level for engine operation.
3. Add more coolant if necessary. Open the heater valves before adding
coolant.
4. Do not close the heater valves until the engine has been running briefly and
the coolant level is again checked and corrected as necessary.
3. If necessary, visit the nearest authorized dealer to have the alternator voltage
and output checked.
4. Do a load test on the batteries.
5. Replace components as needed.
Excessive Idling
Never allow the engine to idle for more than 30 minutes. Excessive idling can
cause oil to leak from the turbocharger.
Momentary Override
A Stop Engine Override Switch is used to override the shutdown sequence. This
override resets the 60 second (30 second for oil pressure) shutdown timer, restoring
power to the level when the RSL/Stop Engine was illuminated. The switch must be
recycled after five seconds to obtain a subsequent override.
NOTE: The operator has the responsibility to take action to avoid engine
damage.
NOTICE: To avoid engine damage, DO NOT use any type of aerosol spray,
e.g., ether, starting fluid or brake cleaner to aid in starting the engine.
The engine does not require starting aids down to 10°C (50°F). Temperatures below
-20°C (-4°F), will require a block heater and oil pan heater.
Winter Fronts
Winter fronts on DD engines are seldom necessary due to the modern design of the
engine cooling system. The coolant thermostat is on the inlet side of the cooling
system on the DD Platform engine and regulates coolant flow from the radiator into
the engine. The thermostat regulates coolant flow to control the temperature of the
coolant within the coolant circuit. The following benefits are a result from
regulating the coolant at the inlet temperature side of the engine:
• Reduced thermal cycling of the engine
• Operating temperature is reached faster
• Improved vehicle heating because of better temperature regulation
Further information on the thermostat function may be found in the Coolant
Thermostat section of the EPA07/10/GHG14 Engine Manual (DDC-SVC-
MAN-0081).
Use of a winter front on a DD Platform engine, particularly those that are fully
closed, will cause performance issues and is not recommended on DD Platform
engines. Winter fronts can result in the following:
• Excessive fan run time due to higher Charge Air Cooler (CAC) outlet
temperatures resulting from low air flow through the CAC
• Increased fuel consumption
• Failure of the DEF system heaters to turn on when needed due to incorrect
temperature calculations resulting in fault codes, poor performance of the
Aftertreatment System, and power reduction
• Failure of critical emission equipment that will result in vehicle speed
inducement to a maximum of 5 mph
Use of a winter front should be avoided as this has been shown to cause false fault
codes with the engine and aftertreatment system. This has also been linked to
specific component failures that will 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 situations is encountered, then a winter front may be
temporarily used. A minimum of 25% of the grill must be open in sectioned stripes
that run perpendicular to the charge air cooler tube flow direction. This assures
even cooling across each tube and reduces header-to-tube stress and possible
failure.
These data are evaluated together with the data from the sensors on the engine,
such as coolant and fuel temperature and oil and charge pressure. The data is then
compared to the characteristic maps or lines stored in the MCM. From these data,
quantity and timing of injection are calculated.
NOTE: To obtain a replacement MCM, all the data given on the MCM label
are required.
The MCM data label has the 10 digit engine serial number.
1. Connector 1 3. Connector 3
2. Connector 2 4. Connector 4
Figure 24. Common Powertrain Controller
1. Connector 1 2. Connector 2
Figure 25. Motor Control Module 2- EPA10
The MCM processes the data received from the Common Powertrain Controller
(CPC), for example the position of the Accelerator Pedal (AP), engine brake, etc.
These data are evaluated together with the data from the sensors on the engine,
such as coolant and fuel temperature and oil and charge pressure. The data is then
compared to the characteristic maps or lines stored in the MCM. From these data,
quantity and timing of injection are calculated.
NOTE: To obtain a replacement MCM, all the data given on the MCM label
are required.
The MCM data label has the 10 digit engine serial number.
1. Connector 1 3. Connector 3
2. Connector 2 4. Connector 4
Figure 27. Common Powertrain Controller
Since the DDEC system is electronic, a battery is required to operate the computer.
The system operates at 12 volts. However, in the event of a power supply
malfunction, the system will continue to operate at reduced voltage. When this
occurs, the AWL (Check Engine) will come on.
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 destination. This condition
should be reported to an authorized Detroit™ distributor or dealer.
NOTICE: When the RSL (Stop Engine) comes on, the system has detected
a major malfunction in the engine that requires immediate attention. It is
the operator's responsibility to shut down the engine to avoid serious
damage.
The engine can be configured to give a warning only, to ramp down (reduce power)
or to shut down. Ramp down will reduce engine rpm to a predetermined speed, but
will not shut down the engine. With the 30-second shutdown option, the engine will
begin a 30-second, stepped power down sequence until it shuts down completely.
The "Stop Engine Override" feature can be activated in the case where the vehicle
is operating in a critical location.
NOTE: The Stop Engine Override Switch and the Diagnostic Request
Switch (EPA07 function only) are the same.
NOTE: Holding down the Stop Engine Override Switch will not prevent the
engine shutdown sequence. You must continue to reset the automatic
shutdown system by pressing the Stop Engine Override Switch at intervals
of approximately 15 to 20 seconds.
It takes 30 seconds from the time the automatic shutdown sequence begins until
engine shutdown. Therefore, the operator must press the override switch just prior
to engine shutdown and continue to do so until the vehicle can be brought to a stop
in a safe location.
Diagnostic Tool
The diagnostic tool for Detroit Diesel Electronic Control (DDEC 10 and newer) is
the DiagnosticLink ® 8.x. DiagnosticLink requirements are listed earlier in the
manual under Data Recording Capability.
Once the malfunction has been corrected, the DDEC system will return the engine
to normal operation.
The air temperature in the intake system is increased with the addition of EGR.
DDEC is programmed to reduce fueling (power) for a short time to reduce air and
coolant temperatures when necessary.
DDEC will store an information code when this event occurs, but no corrective
action is required. This action is designed to maintain operation without a
noticeable effect on vehicle performance.
All malfunction codes are four digits. The malfunction code recorded in the
computer memory will remain until it is erased by a technician.
The flashing malfunction code can also be obtained by the operator. To support
flashing codes, a Stop Engine Override/Diagnostic Request Switch must be
configured and the AWL (Check Engine) and RSL (Stop Engine) must be hard-
wired. The CPC cannot flash these lamps if they are not hard-wired.
The flashing code feature may be activated by satisfying one of the following
conditions:
• Engine speed is less than 100 rpm and the Stop Engine Override Switch is put in
the ON position.
• Idle Governor is active and the Stop Engine Override Switch is put in the ON
position.
• Vehicle speed is less than three mph. Parking Brake is activated and the Stop
Engine Override Switch is put in the ON position.
The flashing code feature is deactivated once the Stop Engine Override Switch is
returned to the OFF position or the listed conditions are no longer satisfied.
Only one light will be flashing codes at any time. All codes will be flashed twice.
The inter-digit pause is 1.5 seconds. The pause between codes is 3.5 seconds. The
same 3.5-second pause occurs as the switch is made from RSL (Stop Engine) to
AWL (Check Engine).
When code flashing is initiated, the active codes will be flashed on the RSL (Stop
Engine). Then the inactive codes will be flashed on the AWL (Check Engine).
When all the inactive codes have been flashed, the process of flashing all the active
codes followed by all the inactive codes will repeat until the conditions for code
flashing are no longer satisfied.
If there are no active or inactive faults, the number 3 is flashed once followed by a
gap of three seconds.
NOTE: EPA10 and newer can be outfitted with an OEM smart dash which
does not require driver interaction to display malfunction lamps. Malfunction
lamps will display across the information screen if equipped.
To read the fault codes, press and hold the Stop Engine Override / Diagnostic
Request Switch.
Active codes will be flashed on the RSL (Stop Engine) first, followed by inactive
codes being flashed on the AWL (Check Engine). The codes will continue to flash
and repeat as long as the Diagnostic Request Switch is held in the ON position.
Both CPC and MCM faults are included.
Active Codes
The active codes will be flashed on the RSL (Stop Engine) in the order of most
recent to least recent occurrence based on engine hours.
Inactive Codes
The inactive codes will be flashed on the AWL (Check Engine) in the order of most
recent to least recent occurrence based on engine hours.
Depending on the application, the electronic engine control system can monitor oil
temperature, coolant temperature, oil pressure, fuel pressure, coolant level and
remote sensors (if used).
The electronic engine control system activates the Amber Warning Lamp (AWL) /
Check Engine and the Red Stop Lamp (RSL) / Stop Engine to provide a visual
warning of a system malfunction.
Engine Brake
The engine brake is enabled by a dash-mounted ON/OFF Switch with a separate
intensity switch to select low, medium, or high braking power.
The engine brake will only operate when the Accelerator Pedal is fully released.
Disengaging the clutch will prevent the engine brake from operating.
The engine brake will supply braking power even when in Cruise Control. The
Motor Control Module will control the amount of engine braking with respect to
the Cruise Control set speed. The maximum amount of braking (low, medium,
high) is selected with the dash or steering wheel switches.
Engine Protection
The electronic engine control protection system monitors all engine sensors,
electronic components, and recognizes system malfunctions. If a critical fault is
detected, the AWL (Check Engine) and RSL (Stop Engine) illuminate. The
malfunction codes are logged into the MCM's memory.
The standard parameters which are monitored for engine protection are low coolant
level, high coolant temperature, low oil pressure, and high oil temperature.
Cruise Control
For added driver convenience and comfort, DDEC also features a Cruise Control
option that works just like the system in your car. It can be operated in any gear
above 1100 rpm or road speed faster than 20 mph (32 kph), up to the rated engine
speed. It also can be programmed to hold your road speed at or below the
maximum vehicle speed. The switch to energize Cruise Control is usually mounted
on the instrument panel or steering wheel.
Engine speed and power are varied under Cruise Control to maintain the set vehicle
speed. The vehicle speed must be above Min Cruise Set Speed and below Max
Cruise Set Speed. It is recommended that Max Cruise Set Speed be set to the
default to allow proper operation of other features such as Fuel Economy Incentive
and PasSmart. The Vehicle Speed Limit should be used to limit vehicle throttle
speed.
Turn the switch ON to energize the system. Remember as a check after each engine
start, DDEC looks for a one-time activation of the clutch (if equipped) and service
brake before DDEC allows Cruise Control to be enabled.
DDEC must also see or recognize that the Cruise Enable Switch has changed. If the
Cruise Enable Switch is OFF it needs to be turned ON. If the Cruise Enable Switch
is left in the ON position at key OFF, the switch must be cycled OFF then ON for
DDEC to see a status change to allow Cruise Control activation. The status of
DDEC inputs to activate Cruise Control at key ON is listed in the following table.
Table 6.
Input Status to Activate Cruise Control
Input Status Before Cruise
Input Input Status at Key ON
Control Activates
Service Brake Switch ON OFF
Clutch Release Switch
ON OFF
(Manual Trans. only)
Cruise Control Enable Switch OFF ON
Once Cruise Control is enabled and you reach your road speed, press the SET
Switch to activate Cruise Control. The cruise light will come on. To increase road
speed toggling the switch will result in a one mile-per-hour (1.6 kph) increase or
decrease in vehicle speed. If Cruise Control has been disabled, toggling the
RSM/ACC Switch restores the vehicle to the previously set cruise speed. , press the
RSM/ACC Switch. To reduce road speed, press and hold the SET/CST Switch until
the lower speed is reached.
Cruise Control can be overridden at any time with the throttle pedal if the vehicle is
operating at less than the programmed Max Road Speed.
Cruise Control is deactivated by slightly pressing the service brakes, clutch pedal,
or trailer brake. The ON/OFF Switch will also deactivate Cruise Control.
Cruise Control will maintain vehicle speed even on upgrades, unless power
requirements demand a downshift. If the Cruise Control/Engine Brake function is
turned ON, the Cruise Control will limit your speed on downgrades. Most likely,
Cruise Control will feel stronger than driving with the accelerator pedal because of
the instantaneous and wide-open throttle response. That's why Cruise Control use is
not suggested during slippery driving conditions.
Use Cruise Control after downshifting on a hill to pull the hill. Hitting the
RSM/ACC Switch (not the SET Switch) will keep the truck accelerating in the
lower gears up to the rated engine speed.
Cruise Control will maintain the set speed under normal road and load conditions.
It cannot limit vehicle speeds on down grades if available engine braking effort is
exceeded, nor can it maintain speed on upgrades if power requirements exceed
engine power capability.
Cruise Control will disengage below 1000 rpm or 20 mph (32 kph) road speed.
When using Cruise Control, if you want to pull the engine below 1000 rpm,
remember to hold the accelerator pedal to the floor to keep the engine pulling at
wide-open throttle. The engine will pull down to about 1050 rpm.
Remember:The electronic data programmed into the DDEC system will not allow
you to hurt or over fuel the engine at low or lug engine speeds. There is enough oil
pressure to withstand hard pulls at low engine speeds.
Cruise Control may also be programmed to permit fast idle using the Cruise
Control switches.
With the engine at normal idle, transmission in neutral and service brakes on, press
the SPD CNTL Switch, and use the RSM/ACC Switch. The engine rpm should
increase to a pre-defined speed. The engine rpm can be raised or lowered from this
point using the SET/CST and RSM/ACC switches.
DD Platform Shifting
Depending on your transmission model, the gear split may vary from 400 to 500
rpm. The electronic governor provides almost no overrun capability; and, if the
transmission is downshifted too early, you will experience a temporary loss of
pulling power until the engine speed falls below rated speed.
In general, when using a 7- or 9-speed transmission, you should always downshift
between 1150 and 1250 rpm for the DD13 and between 1000 and 1100 rpm for the
DD15 and DD16. This is true even on steep grades with heavy loads. When using
an 18-, 15-, or 13-speed transmission, you will need to downshift at an rpm that
allows "less than rated" rpm before throttle application in the next gear down. You
may want to limit engine speed to 1900 rpm in all gears. DD Platform engines
provide horsepower through 2100 rpm, but fuel economy is not as efficient above
1800 rpm.
If you decide to drive at a lower rpm for improved fuel economy, don’t let different
engine noises throw you off guard. The engine sounds quiet at 1400 rpm, almost as
if it had quit pulling. Depending on the air intake arrangement, you may also
experience a "chuffing" sound as the engine starts to pull hard at lower rpm. This is
normal and caused by the velocity changes of the air flow within the air intake
plumbing. Electronic engines can actually deliver more fuel at lower engine speeds
than at rated speed.
The engine has been designed for a very quiet operation, but the air flow may be
noticeable to the tuned, attentive ear. The turbocharger operates at higher boost
pressure forcing EGR gas flow through the EGR plumbing. In some situations the
driver may believe he/she has experienced a charge air cooler system leak. Even
connecting trailer light and air hoses, the driver may hear a different tone (exhaust
and under hood with the engine idling.) If equipped with a turbo boost gauge, the
driver may occasionally note intake manifold pressure exceeds 35 psi (6.89 kPa).
Idling
The common belief that idling a diesel engine causes no engine damage is wrong.
Idling produces sulfuric acid, which is absorbed by the lubricating oil and eats into
bearings, rings, valve stems and engine surfaces. If you must idle the engine for cab
heat or cooling, the high idle function of the Cruise Control switches should be
used. An idle speed of 900 rpm should be enough to provide cab heat in above 0°C
(32°F) temperatures.
NOTICE: Never exceed 2500 rpm or extensive engine damage can occur.
Under normal driving conditions the engine brake system is left in the ON position.
However, this should change if roads become wet or slippery.
After it is switched on, the engine brake system is automatically activated each time
you remove your feet completely from the clutch pedal and accelerator pedal. The
engine brake automatically deactivates itself when you press the clutch pedal while
shifting gears.
NOTICE: Failure to keep the vehicle within safe control speed limits while
descending a grade may result in vehicle or property damage or both.
3. Do not exceed the safe control speed of your vehicle. Example: You could
descend a 6% grade, under control only at 10 mph (16 kph) without an
engine brake, but at 25 mph (40 kph) with an engine brake. You could not
descend that same hill at 50 mph (80 kph) and still expect to remain under
control. Get to know how much slowing power your engine brake can
provide. So get to know your engine brake system before climbing hills and
do not exceed a safe control speed.
4. Check your progressive braking switch often for proper position
(LOW/MED/HIGH), since road conditions can change quickly. Never skip a
step when operating the progressive braking switch. Always go from OFF to
LOW and then to a higher position when on slippery roads.
1. On wet or slippery pavement, start with the master switch in the OFF position
and use the gear you would normally use under these conditions.
2. If the tractor drive wheels begin to lock or there is fishtail motion after the
Engine Brake is activated, deactivate the brake system immediately if this
occurs.
3. However, if the tractor drive wheels begin to lock or there is a fishtail
motion, turn the engine brake system OFF immediately and do not activate it
until road conditions improve.
4. Check your progressive braking switch often for proper position
(LOW/MED/HIGH), since road conditions can change quickly. Never skip a
step when operating the progressive braking system. Always go from OFF to
LOW and then to a higher position.
Engine Systems
The engine systems are as follows:
Lubrication System
The lubrication system consists of an oil pump, oil cooler, cartridge-style oil filter,
pressure regulator valve, and oil pressure sensor. Clean, pressurized oil is fed to all
components via passages in the engine block and cylinder head.
Air System
Outside air enters the engine through the air filter and is drawn to the turbocharger
and then is compressed, and forced through the air-to-air charge cooler (heat
exchanger) and is cooled. Next, it flows to the intake manifold and into the
cylinders, where it mixes with atomized fuel from the injectors.
For optimum engine protection from dust and other airborne contaminants, service
the dry-type air cleaners used when the maximum allowable air restriction has been
reached.
Cooling System
A radiator/thermo-modulated fan cooling system is used on the engine. This system
has a centrifugal-type coolant pump to circulate coolant within the engine. One
full-blocking type thermostat located in the coolant module attached to the left side
of the cylinder block controls the flow of coolant. The coolant module incorporates
the oil cooler, oil filter, coolant filter (model year 2014 and prior engines only), and
coolant pump.
Electrical System
The electrical system consists of a starting motor, starting switch, battery-charging
alternator, storage batteries, and necessary wiring.
Exhaust System
Hot exhaust gas from the exhaust manifolds is used to drive the turbocharger.
The Selective Catalytic Reduction (SCR) aftertreatment system for this engine
requires Diesel Exhaust Fluid (DEF) to maintain exhaust emissions at levels
compliant with emissions standards. DEF is a simple, non-toxic and inexpensive
pre-mixed fluid composed of 2/3 pure water and 1/3 automotive grade urea. The
following sections provide information regarding DEF availability, specifications,
handling and storage, and certain SCR ani-tampering features.
NOTICE: Do not use kerosene or fuel blended with used lube oil.
Oxidation of particulate matter is the key to filter performance. This requires that
the catalyzing agent (platinum-coated passages) provide optimum enhancement to
the oxidation process. The following requirements must be met; otherwise the
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 recommends DFS 93K223
(API FA-4) for GHG17, GHG14 and EPA10 engines and DFS 93K222 (API
CK-4) for EPA07 engines.
NOTE: For trucks equipped with negative battery disconnect, do not turn
the battery disconnect switch off until the purge light (located on the battery
disconnect switch) turns off.
Aftertreatment Maintenance
A high amount of black smoke emitting from the vehicle or illumination of the
Amber Warning Lamp or Red Stop Lamp are indications of a system problem.
Should this occur, consult your local Detroit™ Service Center.
Illumination of the Malfunction Indicator Lamp (MIL) Lamp indicates a failure of
an emissions control device. The MIL may illuminate along with other ATS
warning lamps. Call for service to repair the fault.
Illumination of the Diesel Particulate Filter (DPF) Regeneration Lamp indicates
that a parked regeneration is required.
There is a need to periodically remove accumulated ash, derived from engine lube
oil, from the filter. This ash does not oxidize in the filter during the regeneration
process and must be removed through a cleaning procedure. All Detroit™ ATD
equipped engines will illuminate a dashboard warning lamp indicating the need for
ash cleaning.
NOTE: Under factory default settings, when the Diesel Particulate Filter
(DPF) Regeneration Lamp is not illuminated, the regeneration request
switch is disabled.
NOTE: The driver MUST stay with the vehicle throughout the regeneration
process.
When the parked regeneration request is accepted, the Diesel Particulate Filter
(DPF) Regeneration lamp will turn ON one time for one second and then turn off
for the remainder of the parked regeneration. The High Exhaust System
Temperature (HEST) lamp will flash for one second every ten seconds and
eventually become solid when the tailpipe temperature is above 525°C (977°F).
The engine speed will increase to 1100 RPM for all DD Platform engines. The
regeneration will take 30-40 minutes. The regeneration is complete when the
engine returns to low idle and the DPF lamp remains OFF. The HEST lamp will
remain ON, but the vehicle may be driven.
NOTE: A parked regeneration will STOP and the engine will return to low
idle if any of the following happens:
• The key is turned to the OFF position
• The vehicle is put into gear
• The clutch is cycled
• The parking brake is released
NOTE: Under factory default settings, when the Diesel Particulate Filter
(DPF) Regeneration Lamp is not illuminated, the regeneration request
switch is disabled.
NOTE: The driver MUST stay with the vehicle throughout the regeneration
process.
When the parked regeneration request is accepted, the Diesel Particulate Filter
(DPF) Regeneration lamp will turn ON one time for one second and then turn off
for the remainder of the parked regeneration. The High Exhaust System
Temperature (HEST) lamp will flash for one second every ten seconds and
eventually become solid when the tailpipe temperature is above 525°C (977°F).
The engine speed will increase to 1100 RPM for all DD Platform engines. The
regeneration will take 30 to 40 minutes. The regeneration is complete when the
engine returns to low idle and the DPF lamp remains OFF. The HEST lamp will
remain ON, but the vehicle may be driven.
NOTE: A parked regeneration will STOP and the engine will return to low
idle if any of the following happens:
• The key is turned to the OFF position
• The vehicle is put into gear
• The clutch is cycled
• The parking brake is released
1. Keep engine at slow idle (cannot be in Fast Idle or PTO Mode). Put
transmission in neutral (if equipped with an automatic transmission, cycle it
into gear and then back to neutral).
NOTICE: Air tank pressure must be high enough for the parking brake
switch to hold in the OFF position.
2. Set park brake (cycle the park brake OFF then ON for CPC R21 or lower
software).
3. Press and release clutch pedal once per ignition cycle (if configured).
4. Hold DPF Switch to the ON position for five seconds and then release
(engine speed will increase and DPF lamp will go out).
NOTE: Under factory default settings, when the Diesel Particulate Filter
(DPF) Regeneration Lamp is not illuminated, the regeneration request
switch is disabled.
NOTE: The driver MUST stay with the vehicle throughout the regeneration
process.
When the parked regeneration request is accepted, the Diesel Particulate Filter
(DPF) Regeneration lamp will turn ON one time for one second and then turn off
for the remainder of the parked regeneration. The High Exhaust System
Temperature (HEST) lamp will flash for one second every ten seconds and
eventually become solid when the tailpipe temperature is above 525°C (977°F).
The engine speed may vary during parked regeneration (depending on engine
displacement, exhaust temperature and the amount of soot accumulated in the
DPF). The regeneration is complete when the engine returns to low idle and the
DPF lamp remains OFF. The HEST lamp will remain ON, but the vehicle may be
driven.
NOTE: A parked regeneration will STOP and the engine will return to low
idle if any of the following happens:
• The key is turned to the OFF position
• The vehicle is put into gear
• The clutch is cycled
• The parking brake is released
1. Keep engine at slow idle (cannot be in Fast Idle or PTO Mode). Put
transmission in neutral (if equipped with an automatic transmission, cycle it
into gear and then back to neutral).
2. Set park brake (cycle the park brake OFF then ON).
3. Press and release clutch pedal once per ignition cycle (if configured).
4. Hold DPF Switch to the ON position for five seconds and then release
(engine speed will increase and DPF lamp will go out).
Hazardous Applications
The MCM should be configured to not allow automatically triggered over-the-road
regenerations (DPF Manual Regen Only Enable = Enabled).
During the time of purchase a customer should notify the dealer of the Hazardous
Application and the request for DPF Stationary Regen Only will be noted in the
purchase order. If the dealer was not notified during the time of purchase an
authorized Detroit™ maintenance or repair facility will need to contact Detroit
Technical Support for an application change.
There are two CPC options:
• DPF Stationary Regen Only = 0-Disabled
• DPF Stationary Regen Only = 1-Enabled
Service Record
It is mandatory that customers or distributors maintain a proper record of the
particulate filter servicing and cleaning. This record is an agent to warranty
considerations. The record must include information such as:
• Date of cleaning or replacement
• Vehicle mileage at the time of cleaning or replacement
• Particulate filter part number and serial number(s)
Table 7.
Lamp Lamp Name Description Results
• At the start of every ignition cycle (bulb • Diagnostic request switch is used to
check). activate the AWL to flash inactive codes.
• When an electronic system fault occurs. (EPA07 function only.)
(Fault should be diagnosed as soon as • Flashes last 90 seconds before idle
possible.) shutdown if programmed for override.
• Flashes when idle shutdown or the
optimized idle shutdown occurs.
Table 8.
Lamp Lamp Name Description Results
• At the start of every ignition cycle (bulb • Flashes when engine protection shutdown
check). occurs.
• A potential engine damaging fault is • Diagnostic request switch is used to
detected. activate the RSL to flash active codes.
(EPA07 function only).
Table 9.
Lamp Lamp Name Description Results
• At the start of every ignition cycle (bulb When a regeneration is required immediately
check). (if the lamp flashing is ignored), a derate
• Regeneration is required. and/or shutdown could occur.
Table 10.
Lamp Lamp Name Description Results
• At the start of every ignition cycle (bulb Flashes every 10 seconds when the
check). Selective Catalytic Reduction ( SCR
• Vehicle speed is less than 5 mph and the Catalyst) is not up to temperature
Diesel Particulate Filter (DPF) outlet
temperature is greater than 525° C (977°
F).
Table 11.
Lamp Lamp Name Description Results
Table 12.
Lamp Lamp Name Description Results
Table 13.
Lamp Lamp Name Description Results
NOTE: Examples are shown as EPA07; all notifications and driver actions
will be the same on the DD platform. If it is determined a parked
regeneration is required, reference model year specific section: "Performing
a Parked Regeneration".
Table 14.
Notifications and
Instrument Panel Lamp Driver Action
Description
Table 15.
Notifications and
Instrument Panel Lamp Driver Action
Description
• Malfunction Indicator
Lamp (MIL)
Vehicle can be driven to
• Indicates a failure of an
end of shift. If the MIL
emission control device.
remains on after three drive
May illuminate at the
cycles, call for service.
same time as the Check
Engine Lamp (CEL).
Table 16.
Instrument Panel Lamp Notifications and
Driver Action
Description
Table 17.
Notifications and
Instrument Panel Lamp Driver Action
Description
• A parked regeneration
must be performed.
• Diesel Particulate Filter
Reference model year
(DPF) regeneration lamp /
specific section:
Check Engine Lamp
"Performing a Parked
(CEL)
Regeneration".
• ENGINE DERATED
• If the parked regeneration
• Indicates the Diesel
exits and the lamps
Particulate Filter (DPF)
remain on, repeat the
has reached system
parked regeneration. If
limits.
the second attempt fails,
call for service.
Table 18.
Notifications and
Instrument Panel Lamp Driver Action
Description
• A parked regeneration
must be performed.
Reference model year
specific section:
"Performing a Parked
• Diesel Particulate Filter
Regeneration".
(DPF) regeneration lamp /
• If the parked regeneration
Check Engine Lamp
exits and the lamps remain
(CEL) / Stop Engine Lamp
on, repeat the parked
(SEL)
regeneration. If the second
• ENGINE SHUTDOWN
attempt fails, call for
• Indicates the Diesel
service.
Particulate Filter (DPF) has
• Note: Engine can be
exceeded system limits.
restarted but a parked
regeneration must be
initiated within 30 seconds
or the engine will
shutdown.
Schedule Use
Complete each maintenance operation at the required interval. The intervals are
based on a collaboration of field and fleet data. For a more accurate analysis of
when fluids should be changed, such as engine oil, refer to publication Engine
Requirements; Lubricating Oil, Fuel and Filters and publication Coolant Selections
for Detroit™ Engines, available from authorized Detroit™ distributors and dealers.
Each maintenance table shows which maintenance operation must be performed at
the recommended interval (in miles, kilometers, and hours).
1. Inspect the radiator, condenser, coolant pump, engine oil cooler, freeze plugs,
and heat exchanger for damage and leaks.
2. Check all cooling system pipes and hoses for damage and leaks; ensure they
are positioned to avoid chafing, and are securely fastened.
3. Check the outside of the radiator and condenser for blockage. Check fins for
damage; straighten them if necessary.
Drive Belt
DD Platform engines utilize a specially designed Ethylene Propylene Diene
Monomer (EPDM) belt material which is exclusive to the Original 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.
Air System
Air Cleaner - The air cleaner restriction indicator (filter minder) should be
inspected per the maintenance intervals or more often if the engine is operated
under severe dusty conditions. Replace the element if the filter minder has reached
maximum allowable restriction. Refer to OEM literature for further details on filter
minders.
NOTICE: Do not allow the air inlet restriction to exceed maximum allowable
restriction.
Table 19.
Air Cleaner Restriction
A clogged air cleaner element will cause excessive air intake restriction and
reduced air supply to the engine resulting in increased fuel consumption, inefficient
engine operation, aftertreatment failure and reduced engine life. High intake
restriction will also cause oil pullover from the turbocharger into the charge air
system.
Inspect the entire air system for leaks daily. Look especially for torn air inlet piping
or boots and loose or damaged clamps. Have worn or damaged parts repaired or
replaced. Retighten loose connections.
Air Cleaner Replacement - Dry type air cleaner elements should be replaced when
the maximum allowable air intake restriction has been reached.
Air-to-Air Charge Cooler - Periodically inspect the air-to-air charge cooler for
buildup of dirt, mud, etc. and wash off using a mild soap solution. Check the charge
cooler, ductwork, and flexible connections for leaks and have repaired or replaced,
as required.
Exhaust System
The exhaust manifold retaining bolts and other connections should be inspected for
leaks. The exhaust pipe rain cap should be checked for proper operation, if so
equipped. With the introduction of an Aftertreatment system, the sealing of the
exhaust system is critical and should be inspected regularly.
Air Compressor
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. Due to inadequate internal sealing air
compressors, when failed, can produce excessive crankcase pressure or allow an
engine to ingest oil.
Vibration Damper
The viscous vibration damper should be inspected periodically and replaced if
dented or leaking. Heat from normal engine operation may, over a period of time,
cause the fluid within the damper to break down and lose its dampening properties.
For this reason the viscous vibration damper must be replaced at time of normal
major engine overhaul, regardless of apparent condition.
EPA07/EPA10/GHG14/GHG17 Preventive
Maintenance Tables - 93K222(CK-4) and
93K223(FA-4)
NOTE: Actual fuel filter life will vary based on fuel quality.
Table 20.
DD13: Maintenance Intervals EPA07/EPA10/GHG14/GHG17 with ULSD Fuel
EPA10/GHG14/GHG17 Using DFS 93K222(CK-4) or 93K223(FA-4) Approved Oils
EPA07 Using DFS 93K222(CK-4) Approved Oils
Component Efficient Long Long Haul Short Haul † Severe †
Haul (6.0-6.9 MPG)*** (5.1-5.9 MPG)*** (Up to 5.0
(7.0 or better MPG)***
MPG)***
Replace every Replace every Replace every Replace every
65,000 mi 55,000 mi 40,000 mi 35,000 mi
Oil Filter
(105,000 km) (89,000 km) (64,000 km) or (56,000 km) or
1000 hrs 750 hrs
Replace every Replace every Replace every Replace every
65,000 mi 55,000 mi 40,000 mi 35,000 mi
Lubricating Oil
(105,000 km) (89,000 km) (64,000 km) or (56,000 km) or
1000 hrs 750 hrs
Replace every Replace every Replace every Replace every
Engine Fuel 65,000 mi 55,000 mi 40,000 mi 35,000 mi
Filter * (105,000 km) (89,000 km) (64,000 km) or (56,000 km) or
1000 hrs 750 hrs
Engine Fuel Replace every Replace every Replace every Replace every
Filter * 100,000 mi 100,000 mi 80,000 mi 70,000 mi
w/ Frame- (161,000 km) (161,000 km) (128,000 km) or (113,000 km) or
Mounted Filter 1000 hrs 750 hrs
Replace every Replace every Replace every Replace every
Frame Mounted 65,000 mi 55,000 mi 40,000 mi 35,000 mi
Fuel Filters ‡ (105,000 km) (89,000 km) (64,000 km) or (56,000 km) or
1000 hrs 750 hrs
Valve Lash Adjust at 100,000 mi (160,000 km), at 500,000 mi (800,000 km), and then
Adjustment every 500,000 mi (800,000 km) thereafter.
Maintain every Maintain every Maintain every Maintain every
65,000 mi 55,000 mi 40,000 mi 35,000 mi
(105,000 km) (89,000 km) or 1 (64,000 km), (56,000 km),
Coolant - Replace every yr 895 hrs or 1 yr 640 hrs or 6
Standard Life 300,000 mi Replace every Replace every months
(482,000 km) 300,000 mi 300,000 mi Replace every
(482,000 km) (482,000 km) 300,000 mi
(482,000 km)
Maintain every Maintain every Maintain every Maintain every
130,000 mi 110,000 mi 80,000 mi 70,000 mi
(210,000 km) or (178,000 km) or (128,000 km) or (112,000 km) or
Coolant -
1 yr 1 yr 1 yr 1 yr
Extended Life
Replace every Replace every Replace every Replace every
600,000 mi 600,000 mi 600,000 mi 600,000 mi
(965,000 km) (965,000 km) (965,000 km) (965,000 km)
Current engine designs no longer use coolant filters. If you have a coolant
Coolant System
filter, you may choose to remove the filter at your next maintenance
Filter (if
interval. For more details reference bulletin 15TS-10Rev (http://ddcsn-
equipped)
ddc.freightliner.com/cps/rde/xbcr/ddcsn/15TS10Rev.pdf).
Table 21.
DD15: Maintenance Intervals EPA07/EPA10/GHG14/GHG17 with ULSD Fuel
EPA10/GHG14/GHG17 Using DFS 93K222(CK-4) or 93K223(FA-4) Approved Oils
EPA07 Using DFS 93K222(CK-4) Approved Oils
Component Efficient Long Long Haul Short Haul † Severe †
Haul (6.0-6.9 MPG)*** (5.1-5.9 MPG)*** (Up to 5.0
(7.0 or better MPG)***
MPG)***
Replace every Replace every Replace every Replace every
75,000 mi 60,000 mi 45,000 mi 35,000 mi
Oil Filter
(121,000 km) (97,000 km) (72,000 km) or (56,000 km) or
1000 hrs 750 hrs
Replace every Replace every Replace every Replace every
75,000 mi 60,000 mi 45,000 mi 35,000 mi
Lubricating Oil
(121,000 km) (97,000 km) (72,000 km) or (56,000 km) or
1000 hrs 750 hrs
Replace every Replace every Replace every Replace every
Engine Fuel 75,000 mi 60,000 mi 45,000 mi 35,000 mi
Filter * (121,000 km) (97,000 km) (72,000 km) or (56,000 km) or
1000 hrs 750 hrs
Engine Fuel Replace every Replace every Replace every Replace every
Filter * 100,000 mi 100,000 mi 90,000 mi 70,000 mi
w/ Frame- (161,000 km) (161,000 km) (144,000 km) or (113,000 km) or
Mounted Filter 1000 hrs 750 hrs
Replace every Replace every Replace every Replace every
Frame Mounted 75,000 mi 60,000 mi 45,000 mi 35,000 mi
Fuel Filters ‡ (121,000 km) (97,000 km) (72,000 km) or (56,000 km) or
1000 hrs 750 hrs
Valve Lash Adjust at 100,000 mi (160,000 km), at 500,000 mi (800,000 km), and then
Adjustment every 500,000 mi (800,000 km) thereafter.
Maintain every Maintain every Maintain every Maintain every
75,000 mi 60,000 mi 45,000 mi 35,000 mi
(121,000 km) (97,000 km) or 1 (72,000 km) 895 (56,000 km) 640
Coolant -
Replace every yr hrs or 1 yr hrs or 6 months
Standard Life
300,000 mi Replace every Replace every Replace every
(482,000 km) 300,000 mi 300,000 mi 300,000 mi
(482,000 km) (482,000 km) (482,000 km)
Maintain every Maintain every Maintain every Maintain every
150,000 mi 120,000 mi 90,000 mi 70,000 mi
(242,000 km) or (194,000 km) or (144,000 km) or (112,000 km) or
Coolant -
1 yr 1 yr 1 yr 1 yr
Extended Life
Replace every Replace every Replace every Replace every
600,000 mi 600,000 mi 600,000 mi 600,000 mi
(965,000 km) (965,000 km) (965,000 km) (965,000 km)
Current engine designs no longer use coolant filters. If you have a coolant
Coolant System
filter, you may choose to remove the filter at your next maintenance
Filter (if
interval. For more details reference bulletin 15TS-10Rev (http://ddcsn-
equipped)
ddc.freightliner.com/cps/rde/xbcr/ddcsn/15TS10Rev.pdf).
Table 22.
DD16: Maintenance Intervals EPA07/EPA10/GHG14/GHG17 with ULSD Fuel
EPA10/GHG14/GHG17 Using DFS 93K222(CK-4) or 93K223(FA-4) Approved Oils
EPA07 Using DFS 93K222(CK-4) Approved Oils
Component Efficient Long Long Haul Short Haul † Severe †
Haul (6.0-6.9 MPG)*** (5.1-5.9 MPG)*** (Up to 5.0
(7.0 or better MPG)***
MPG)***
Not Applicable Replace every Replace every Replace every
55,000 mi 40,000 mi 35,000 mi
Oil Filter
(89,000 km) (64,000 km) or (56,000 km) or
1000 hrs 750 hrs
Not Applicable Replace every Replace every Replace every
55,000 mi 40,000 mi 35,000 mi
Lubricating Oil
(89,000 km) (64,000 km) or (56,000 km) or
1000 hrs 750 hrs
Not Applicable Replace every Replace every Replace every
Engine Fuel 55,000 mi 40,000 mi 35,000 mi
Filter * (89,000 km) (64,000 km) or (56,000 km) or
1000 hrs 750 hrs
Engine Fuel Not Applicable Replace every Replace every Replace every
Filter * 100,000 mi 80,000 mi 70,000 mi
w/ Frame- (161,000 km) (128,000 km) or (113,000 km) or
Mounted Filter 1000 hrs 750 hrs
Not Applicable Replace every Replace every Replace every
Frame Mounted 55,000 mi 40,000 mi 35,000 mi
Fuel Filters ‡ (89,000 km) (64,000 km) or (56,000 km) or
1000 hrs 750 hrs
Valve Lash Adjust at 100,000 mi (160,000 km), at 500,000 mi (800,000 km), and then
Adjustment every 500,000 mi (800,000 km) thereafter.
Not Applicable Replace every Replace every Replace every
55,000 mi 40,000 mi 35,000 mi
(89,000 km) or 1 (64,000 km) 895 (56,000 km),
Coolant - yr hrs or 1 yr 640 hrs or 6
Standard Life Replace every Replace every months
300,000 mi 300,000 mi Replace every
(482,000 km) (482,000 km) 300,000 mi
(482,000 km)
Not Applicable Replace every Replace every Replace every
110,000 mi 80,000 mi 70,000 mi
(178,000 km) or (128,000 km) or (112,000 km) or
Coolant -
1 yr 1 yr 1 yr
Extended Life
Replace every Replace every Replace every
600,000 mi 600,000 mi 600,000 mi
(965,000 km) (965,000 km) (965,000 km)
Current engine designs no longer use coolant filters. If you have a coolant
Coolant System
filter, you may choose to remove the filter at your next maintenance
Filter (if
interval. For more details reference bulletin 15TS-10Rev (http://ddcsn-
equipped)
ddc.freightliner.com/cps/rde/xbcr/ddcsn/15TS10Rev.pdf).
EPA07/EPA10/GHG14/GHG17 Preventive
Maintenance Tables - 93K218(CJ-4)
NOTE: Actual fuel filter life will vary based on fuel quality.
Table 23.
Note : DFS 93K218(CJ-4) oils are being phased out of the market and will be
unavailable in the near future. The component intervals below are only listing intervals
that have changed from the DFS 93K222(CK-4) table.
DD13/DD15/DD16: Maintenance Intervals
EPA07/EPA10/GHG14/GHG17 Using DFS 93K218(CJ-4) Approved Oils with ULSD Fuel
Component Long Haul † Short Haul † Severe † Recreational
(6.0 or better (5.1-5.9 MPG)*** (up to 5.0 Vehicles***
MPG)*** MPG)***
Oil Filter Replace every Replace every Replace every Replace every
50,000 mi 35,000 mi 25,000 mi 25,000 mi
(80,000 km) (55,000 km) (40,000 km) (40,000 km)
or 1280 hrs or 895 hours or 640 hours or 640 hours
Lubricating Oil Replace every Replace every Replace every Replace every
50,000 mi 35,000 mi 25,000 mi 25,000 mi
(80,000 km) (55,000 km) (40,000 km) (40,000 km)
or 1280 hrs or 895 hrs or 640 hrs or 640 hrs
All Other Refer to DFS 93K222(CK-4) table
Components
- †Whichever comes first.
- *Engine fuel filters should be changed at recommended service intervals, or when the "Fuel
Filter Service Lamp" activates on the dashboard. For maximum life of fuel system
components, it is not recommended to exceed 100k miles on engine fuel filters under any
condition.
- ***Fuel Economy represents overall fuel economy (including idle time)
- ‡Currently, only Detroit™ Fuel Filter/Water Separator & Davco 482/485/487 are the only
frame-mounted filtration systems compatible for Detroit™ Engines.
- Refer to "Routine Preventive Maintenance" and "How to Procedures" for a description of all
items.
- NOTE: Actual fuel filter life will vary based on fuel quality.
- NOTE: Diesel Oxidation Catalyst (DOC) and the SCR (Selective Catalytic Reduction)
Catalyst do not require maintenance.
EPA07/EPA10/GHG14/GHG17 Preventive
Maintenance Tables for Recreational Vehicles
NOTE: Actual fuel filter life will vary based on fuel quality.
NOTE: Diesel Oxidation Catalyst (DOC) and the SCR (Selective Catalytic
Reduction) Catalyst do not require maintenance.
Table 24.
Recreational Vehicles (DD13 only): EPA07/EPA10/GHG14/GHG17
EPA10/GHG14/GHG17 Using DFS 93K222(CK-4) or 93K223(FA-4) Approved Oils
EPA07 Using DFS 93K222(CK-4) Approved Oils
Component Intervals †
Oil Filter Replace every 35,000 mi (56,000 km) or 750
hrs
Lubricating Oil Replace every 35,000 mi (56,000 km) or 750
hrs
Engine Fuel Filter * Replace every 35,000 mi (56,000 km) or 750
hrs
Engine Fuel Filter * Replace every 70,000 mi (113,000 km) or
w/ Frame-Mounted Filter 750 hrs
Frame Mounted Fuel Filters ‡ Replace every 35,000 mi (56,000 km) or 750
hrs
Valve Lash Adjustment Adjust at 100,000 mi (160,000 km), at
500,000 mi (800,000 km), and then every
500,000 mi (800,000 km) thereafter.
Coolant - Standard Life Maintain every 35,000 mi (56,000 km), 640
hrs or 6 months
Replace every 300,000 mi (482,000 km)
Coolant - Extended Life Maintain every 70,000 mi (112,000 km) or 1
yr
Replace every 600,000 mi (965,000 km)
Coolant System Filter (if equipped) Current engine designs no longer use
coolant filters. If you have a coolant filter, you
may choose to remove the filter at your next
maintenance interval. For more details
reference bulletin 15TS-10Rev.
Belts Replace every 105,000 mi (165,000 km)
2690 hrs
Air System Inspect at oil change
Air Cleaner Inspect at oil change
Exhaust System Inspect at oil change
Air Compressor Inspect at oil change
2. Add the proper 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 be on a level surface and then shut down for 60 minutes for an
accurate oil level reading. Otherwise, the engine must be brought up to an
operating temperature of 60° C (140° F), parked on a level surface and then
shut down for five minutes for an accurate oil level reading.
3. Reinstall the dipstick and make sure it is fully inserted into the guide tube.
Remove the dipstick and read the oil level dipstick.
NOTICE: Do not add oil if the oil reading is in the crosshatch area on the
dipstick. There are approximately 5.0 L (5.2 qts) from the minimum mark to
the maximum mark on the dipstick. Overfilling the oil pan can cause engine
damage.
NOTICE: If the oil level is constantly above normal and excess oil has not
been added to the crankcase, consult with an authorized Detroit service
outlet for the cause. Fuel or coolant dilution of lubricating oil can result in
serious engine damage.
4. Check the oil level daily. With the engine stopped, use the oil dipstick and
measure the oil level on crosshatch area on the dipstick. Figure below shows
Maximum oil level (1) and Minimum oil level (2). If the oil reading is in the
crosshatch area or between the bends of the dipstick, then the oil is at the
proper level for engine operation.
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."
NOTE: Model year 2014 and prior engines have a coolant filter.
1. Check the coolant level daily and maintain it between the full and low
marks on the surge tank.
2. Add coolant as required, but do not overfill. Before adding coolant, Refer to
section "Coolant Selections and Maintenance" for the listing of required
intervals using the recommended coolants.
Coolant Inhibitors
The inhibitors in antifreeze solutions must be replenished with an approved
corrosion inhibitor supplement when indicated by testing the coolant. Refer to
section "Coolant Selections and Maintenance" for the listing of required intervals
using the recommended coolants for required test intervals, inhibitor levels, and
approved inhibitors.
Install a new cooling system filter at the distance intervals indicated by each
specific Maintenance Interval chart.
• Current engine designs no longer use coolant filters. If you have a coolant filter,
you may choose to remove the filter at your next maintenance interval. For more
details reference bulletin 15TS-10Rev (http://ddcsn-ddc.freightliner.com/cps/rde/
xbcr/ddcsn/15TS10Rev.pdf).
2. When water level reaches a predetermined height, the LED indicators on the
front of the sensor change from green to red. At this time, remove the water
from the module by opening the water drain valve at the bottom of the
module.
NOTE: Filter change intervals may be shortened to conform with
established preventive maintenance schedules, but should never be
extended.
Perform a valve lash adjustment as scheduled for the appropriate engine duty cycle.
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.
Table 25.
Poly-V-Belt Inspection Concerns
ABRASION CHUNK-OUT
Table 26.
Poly-V-Belt Inspection Concerns
PILLING UNEVEN RIB WEAR
Replacement of Belts
DD Platform engines utilize a specially designed EPDM belt material which is
exclusive to the OE component. Replacement with an aftermarket part may lead to
shortened maintenance intervals and excessive noise.
If the vehicle is operated in severely cold/hot temperatures, or is exposed to
significant dust/debris/road salt, the belts may require replacement prior to mileage
specified in the maintenance interval section.
Periodically the accumulated ash derived 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.
NOTICE: Never use galvanized steel fuel tanks, fittings, pipes, or supply
lines. The fuel reacts chemically with the zinc coating to form powdery
flakes that can quickly clog the fuel filters and damage the fuel pumps and
injectors.
NOTE: Leaks are not only detrimental to machine operation, but they can
also result in added expense caused by the need to replace lost fluids
NOTE: Fire-resistant fuel and lubricating oil hose assemblies do not require
automatic replacement after five years of service or at major overhaul, but
should be inspected carefully before being put back into service.
1. Thoroughly inspect all hoses at least every 500 operating hours (1,000 hours
for fire-resistant fuel and lubricating oil hoses) and/or annually. Look for
cover damage and/or indications of twisted, worn, crimped, brittle, cracked or
leaking lines. Hoses with their outer cover worn through or with damaged
metal reinforcements should be considered unfit for further service.
2. Replace all hoses in and out of machinery during major overhaul and/or after
a maximum of five (5) years of service.
3. Check the turbocharger for unusual noise or vibration and, if excessive, stop
the engine and do not operate until the cause is determined.
4. Periodically inspect the air-to-air charge air cooler for buildup of dirt, mud,
or other debris. Clean as necessary.
5. Check the charge air cooler, duct work, and flexible connections for leaks
and repair or replace as required.
1. Check for cracks in the battery cases (1), for tightness of the cable clamps
(2) at the terminals, and for corrosion of the terminals (3). Service or replace
as needed.
The engine and engine compartment should be steam cleaned every 60,000 miles
(100,000 km) or 2,000 hours, whichever comes first.
2. Heat from normal engine operation may, over a period of time, cause the
fluid within the damper to break down and lose its dampening properties.
For this reason, replace the viscous vibration damper at time of normal
major engine overhaul, regardless of apparent condition.
How to Procedures
This section covers the Detroit™ recommendations on how to select lubricating oil,
diesel fuel, and coolant. Also included are basic engine maintenance procedures
which can be performed by the operator.
For optimal fuel economy, use DFS 93K223 approved API FA-4 engine oil.
Detroit Fluid Specification DFS 93K222 (API CK-4) oils are recommended for
use in the engine.
Detroit™ currently will allow DFS 93K218 (API CJ-4) oils with appropriate drain
intervals (see maintenance intervals Refer to section "EPA07/EPA10/GHG14/
GHG17 Preventive Maintenance Tables - 93K218(CJ-4)" ).
For picking a lubricant for low temperature applications, Refer to section "How to
Select Lubricating Oil (GHG17, GHG14, EPA10)" and Refer to section "How to
Select Lubricating Oil (EPA07)" or DDC-SVC-BRO-0001.
Synthetic oils may be used in Detroit™ engines provided they are approved by a
DFS. The use of synthetic oils does not necessarily ensure the extension of the
recommended oil drain intervals beyond the limits.
Oil analysis may be used to determine whether this interval should be shortened,
but it should not be used to lengthen the interval.
The use of fuels with sulfur content above 0.05 mass percent will require a
shortening of drain intervals. For more information refer to DDC-SVC-
BRO-0001.
NOTE: Change the engine oil only when the engine oil temperature is
approximately 60°C (140°F). Changing cold oil will result in extended drain
times.
3. Using a 36-mm socket, unscrew the oil filter cap and filter and allow the oil
to drain into the housing. After draining is complete, remove the assembly
from the housing.
4. Remove the filter element by pressing and twisting the side and detaching it
from the cap.
5. Remove the oil filter cap O-ring and discard. Lightly coat a new O-ring with
clean engine oil and install it on the filter cap.
6. Check the filter housing for any debris and remove if necessary.
7. Insert a new filter element into the oil filter cap.
NOTICE: The oil filter bypass valve is very important to the operation of the
engine. If the valve becomes damaged, the oil filter will be bypassed at all
times. This allows unfiltered debris to flow throughout the entire lubrication
system and may cause severe engine damage.
8. Inspect the oil filter bypass valve (3) in the end of the standpipe (2) in the
oil filter housing. See illustration below. A broken bypass valve (1) is shown
on the right. Repair as necessary.
NOTICE: On some chassis models the air filter housing may interfere with
installing the oil filter cap and filter element straight into the housing. If this
is the case, loosen or remove the air filter housing to allow for proper oil
filter installation. Installing the filter element on an angle may damage the oil
filter standpipe or bypass valve.
9. Insert the filter element and cap assembly into the housing. Torque the cap
to 40 to 50 N·m (30 to 37 lb·ft).
10. Place a suitable drain pan, 47 L (50 qt) or more, under the oil pan.
NOTE: The oil pan contains multiple plugs that may be used for various
options and applications. The oil drain plug is the lowest plug on the oil pan.
11. Carefully unscrew the oil drain plug, and allow the oil to drain out.
12. Discard the oil drain plug sealing O-ring.
13. Install the oil pan drain plug with a new O-ring and torque the plug:
• On a plastic oil pan, torque plug to 45 N·m +/- 7 N·m (33 lb·ft +/- 5
lb·ft).
• On an aluminum oil pan, torque plug to 60 N·m +/- 9 N·m (44 lb·ft +/- 6
lb·ft ).
NOTICE: Do not add oil if the oil reading is between the crosshatch area on
the dipstick. There are approximately 5.0 L (5.2 qt) from the fill mark to the
full mark. Overfilling the oil pan can cause engine damage.
14. Add new engine oil through the oil fill tube in the following amount; Refer
to section "Engine Oil Capacities". Verify the oil level reading is between
the full and fill marks on the dipstick.
15. Start the engine with the accelerator pedal in the idle position (600 rpm).
Monitor the oil pressure gauge or indicator lamp. Keep the engine running
at idling speed (600 rpm) until the oil pressure reading is 10.2 psi (70 kPa)
or more for the DD15/16 and 11.6 psi (80 kPa) or more for the DD13.
16. Check the filter housing for signs of leakage.
NOTICE: Do not add oil if the oil reading is between the crosshatch area on
the dipstick. There are approximately 5.0 L (5.2 qt) from the fill mark to the
full mark. Overfilling the oil pan can cause engine damage.
17. Stop the engine. Check the oil level again per the following guidelines. If
necessary, add oil no more than 5.0 L (5.2 qt) at a time up to the maximum
fill level on the oil dipstick.
For optimum engine operation and maximum service life, diesel fuels meeting the
property requirements listed in the table below are recommended for use.
Quality
NOTICE: Use only Ultra-Low Sulfur Diesel Fuel (ULSD) (15 PPM sulfur
content maximum), based on ASTM Standard D 2622 test procedure. Using
fuel other than ULSD will damage the Aftertreatment Device.
Fuel Contamination
Generally, fuel contamination occurs as the result of improper fuel handling. The
most common types of contamination are water, dirt, and microbial growth "black
slime". The formation of varnishes and gums resulting from poor stability or
extended storage "stale fuel" also affects fuel quality. The best treatment for
contamination is prevention by maintaining a clean storage system and choosing a
reputable fuel supplier.
Supplemental additives are not recommended due to potential injector system
or engine damage. Our experience has been that such additives increase
operating costs without providing benefit.
The use of supplemental fuel additives does not necessarily void the engine
warranty. However, repair expenses which result from fuel system or engine
component malfunctions or damage attributed to their use will not be covered.
Prohibited Additives
The following fuel additives are not allowed and MUST NOT be mixed with
diesel fuel:
NOTICE: Do not burn used lubricating oil in fuel. It will cause the diesel
particulate filter to prematurely plug with ash.
• Used Lubricating Oil 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
oil will increase maintenance requirements due to filter plugging and
combustion deposits.
WARNING: FIRE
To avoid increased risk of a fuel fire, do not mix gasoline and
diesel fuel.
NOTE: If you are replacing all fuel filters, it is not necessary to run the
engine and test for leaks after installing each individual fuel filter. However,
if repairing a leak at one filter, complete that repair and 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.
NOTICE: At cold temperatures (-40° C or -40° F), DO NOT remove the filter
elements from the caps unless the intent is to replace the filter elements.
Repeated removals at cold temperatures may break the filter element tabs.
2. Pull the cap and prefilter straight up and out of the fuel filter housing.
3. Remove the prefilter (1) from the prefilter cap (2) by placing the filter on a
solid surface and apply pressure on prefilter cap (2) at an angle.
NOTE: If a filter service is being performed, replace all other filters before
priming.
NOTICE: Do not tilt the water coalescer/final filter when removing it from
the housing. Possible damage to the water coalescer/final filter or stand
pipe may occur.
NOTE: If a fuel filter service is being performed, replace all other fuel filters
before priming the fuel system.
4. Install the water coalescer/final filter into the fuel filter module.
NOTE: Viewing the fuel filter module from the top, the drain back port is
located at 10 o'clock.
NOTICE: Do not tilt the final filter when removing it from the housing.
Possible damage to the final filter or stand pipe may occur.
NOTICE: Do not tilt the prefilter when removing it from the housing.
Possible damage to the prefilter or stand pipe may occur.
NOTE: The prefilter should snap into the cap in two positions. The tabs (3)
should align with the slot in the prefilter cap (5).
2. Apply a thin coat of petroleum-based lithium grease to the prefilter cap seal
ring (2).
3. Apply a thin coat of petroleum-based lithium grease to the inside and
outside of the prefilter bottom seal.
4. Install the prefilter into the fuel filter module.
5. Turn the cap counterclockwise until a "click" sound is made, then turn
clockwise and hand tighten.
6. Torque prefilter cap to 15 to 20·N·m (11 to15 lb·ft).
7. Once all required filters have been changed, prime the fuel system. Refer to
section "Priming the Fuel System - Three-Filter System".
NOTICE: Never use the starting motor and fuel pump to prime the fuel
filters. Prolonged use of the starting motor and fuel pump to prime the fuel
system can result in damage to the starter, fuel pump, and injectors.
1. Fill the fuel tank with the recommended grade of fuel. If only partial filling
is possible, add a minimum of 10% of the total tank volume of fuel to the
tank. For example, a 150-gallon tank would require a minimum of 15
gallons of fuel.
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 97 kPa (14 psi) or
more is maintained for one minute.
9. Check for leaks.
10. Allow the engine to reach operating temperature of 60° C (140° F).
NOTICE: Increasing engine speed above idle before oil pressure has
stabilized may cause severe engine damage.
2. Thoroughly clean the entire engine using a steam cleaner or high pressure
washer with mild soap and warm water.
NOTE: Do not use compressed air or pressurized water to clean or dry the
engine if any part of the engine is disassembled.
3. Once the engine is clean, blow the electrical connectors dry with
compressed air to remove most of the standing water.
4. Allow the engine to dry completely before making any kind of repair.
5. When reassembling, ensure that there is no standing water in any electrical
connectors before seating the plug.
1. First remove debris (such as dust, insects) from the fins of the radiator
grille.
Table 27.
DD5, DD8, DD13, DD15, and DD16 Coolant Fill Options
Engine Series Coolant Fill Options Product
Detroit Power Cool or refer to
Ethylene Glycol based
93K217
antifreeze coolant + SLC
list of approved coolants at
corrosion inhibitors
DDCSN.com
No Detroit™ product
Propylene Glycol based available. Refer to
antifreeze coolant + SLC 93K217 list of approved
corrosion inhibitors coolants at
DDCSN.com
DD5, DD8, DD13, DD15,
DD16 Detroit Power Cool Plus or
Ethylene Glycol based refer to
antifreeze coolant + ELC 93K217 list of approved
inhibitors coolants at
DDCSN.com
No Detroit™ product
Propylene Glycol based available. Refer to
antifreeze coolant + ELC 93K217 list of approved
inhibitors coolants at
DDCSN.com
Table 28.
Legacy Engine Coolant Fill Options
Engine Series Coolant Fill Options Product
Detroit Power Cool or refer to
Ethylene Glycol based
93K217
antifreeze coolant + SLC
list of approved coolants at
corrosion inhibitors
DDCSN.com
No Detroit™ product
Propylene Glycol based available. Refer
antifreeze coolant + SLC to 93K217 list of approved
corrosion inhibitors coolants at
DDCSN.com
Deionized Water + Detroit
Water based coolant + SLC
Genuine
corrosion inhibitors 1
Series 50, Series 55, Coolant 3000
Series 60, MBE900, Detroit Power Cool Plus or
MBE4000 Ethylene Glycol based refer to
antifreeze coolant + ELC 93K217 list of approved
inhibitors coolants at
DDCSN.com
No Detroit™ product
Propylene Glycol based available. Refer
antifreeze coolant + ELC to 93K217 list of approved
inhibitors coolants at
DDCSN.com
Deionized Water + Detroit
Water based coolant + ELC
Genuine
inhibitors 1
Coolant Plus 6000
1Water-only coolant systems offer no freeze protection and should not be used where
ambient temperatures can fall to 0°C (32°F).
Additional approved coolant products can be found on the Detroit 93K217 list at
DDCSN.com (https://ddcsn-ddc.freightliner.com/cps/rde/xchg/ddcsn/).
• Protect against cavitation damage to both cylinder liners and water pumps.
• Provide a corrosion/erosion-resistant environment.
• Prevent formation of scale or sludge deposits.
• Be compatible with cooling system hose and seal materials.
• Provide adequate freeze protection.
The rest of this section will describe the requirements for the proper usage of the
water, antifreeze, and corrosion inhibitors. It will also describe the coolants and
additives that are not recommended by Detroit™ and have been proven harmful to
Detroit™ engines.
Maintenance
Laboratory Testing
Laboratory testing is the best practice for determining ELC coolant quality and will
provide vital 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.
ELC Enhancers/Extenders
ELC enhancers/extenders can be used to extend the life of the coolant. These
products should be added to your anti-freeze coolant when corrosion inhibitors fall
below manufacturer's recommendations. Detroit™ recommends consultation with
your coolant manufacturer's technical representative for proper application.
Drain, Flush, and Refill Procedure (See Appendix C for Product Part
number)
When coolant has reached the end of life, it is recommended to properly clean your
cooling system of any scale, deposits or any other contaminants that may reduce
the efficiency of the heat transfer. The coolant must be drained completely
including the block, radiator, and HVAC system. Next, flush the system with fresh,
clean water. Replace drain fittings. Mix required amount of Penray 2010 cleaner in
a 5-gallon pail of water and pour into radiator inlet. Fill system completely with
clean water. Re-circulate cleaning solution by idling engine for 2 hours after top
hose is hot. Temperature should be 88° to 95°C (190 to 203ºF) to allow the
thermostat to open.
Drain cleaning solution from the system. The radiator, block and HVAC system
must both be drained. Flush with clean water (through the radiator inlet) for 3 to 5
minutes. Replace drain fittings. Mix required Penray 2011 in a 5-gallon pail and
pour into radiator inlet (1 pound per 4 gallons cooling system capacity). Fill system
completely with clean water. Re-circulate the Penray 2011 conditioning solution by
idling engine for 15 minutes after the top hose is hot (thermostat opens if it wasn’t
removed). Drain the Penray 2011 solution from the system. The radiator, block
and HVAC system must both be drained. Flush with clean water for 3-5 minutes.
Keep flushing as long as water looks “rusty” or “turbid.” Replace drain fittings.
Recharge cooling system with the appropriate ratio of clean water and the proper
antifreeze for your application.
Laboratory Testing
As an alternative to the test strips, 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 "Standard Life Coolant".
Drain, Flush, and Refill Procedure (See Appendix C for Product Part
Number)
When coolant has reached the end of life, it is recommended to properly clean your
cooling system of any scale, deposits or any other contaminants that may reduce
the efficiency of the heat transfer. The coolant must be drained completely
including the block, radiator, and HVAC system. Next, flush the system with fresh,
clean water. Replace drain fittings. Mix required amount of Penray 2010 cleaner in
a 5-gallon pail of water and pour into radiator inlet. Fill system completely with
clean water. Re-circulate cleaning solution by idling engine for 2 hours after top
hose is hot. Temperature should be 88° to 95°C (190 to 203ºF) to allow the
thermostat to open.
Drain cleaning solution from the system. The radiator, block and HVAC system
must both be drained. Flush with clean water (through the radiator inlet) for 3 to 5
minutes. Replace drain fittings. Mix required Penray 2011 in a 5-gallon pail and
pour into radiator inlet (1 pound per 4 gallons cooling system capacity). Fill system
completely with clean water. Re-circulate the Penray 2011 conditioning solution by
idling engine for 15 minutes after the top hose is hot (thermostat opens if it wasn’t
removed). Drain the Penray 2011 solution from the system. The radiator, block
and HVAC system must both be drained. Flush with clean water for 3-5 minutes.
Keep flushing as long as water looks “rusty” or “turbid.” Replace drain fittings.
Recharge cooling system with the appropriate ratio of clean water and the proper
antifreeze for your application.
Appendix A - Definitions
Appendix A - Definitions
Antifreeze:
A substance that is added to the water in a vehicle’s cooling system that lowers the
freeze point to prevent freezing. The two most common antifreezes are ethylene
glycol (EG) and propylene glycol (PG).
Coolant:
A fluid that 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 Supplemental Coolant Additive before
its first use.
Initial-Fill:
The coolant that is used in a new or rebuilt engine, or used any time the cooling
system is emptied and then refilled with new coolant.
Standard Life Coolant (SLC): AKA - Fully-Formulated or Conventional
Coolant:
These types of coolants use supplemental coolant additives (SCA) to protect
against corrosion or mechanical wear. Example of SLC is Power Cool.
Supplemental Coolant Additive:
An additive used in a preventive maintenance program to prevent corrosion,
cavitation, and the formation of deposits.
WATER REQUIREMENTS
Distilled 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, sludge 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
water must be below the maximum concentration listed in the table below.
Table 29.
Maximum Mineral Concentration in Water
Maximum Concentration
Minerals
Parts per Million Grains per Gallon
Chlorides 40 2.5
Magnesium + Calcium
170 10
Content
Table 30.
Detroit™ Extended Life Coolant (Ethylene Glycol-based)
Coolant Type Part Number Description
One Gallon Jug - 4 Per Case
OWI 23539616
(Canada)
Concentrate
OWI 23519397 One Gallon Jug- 6 Per Case
OWI 23519394 55-Gallon Drum
One Gallon Jug - 4 Per Case
OWI 2359617
(Canada)
Table 31.
Detroit Genuine Coolant Plus Extender (for use with Detroit Genuine Coolant Plus)
Coolant Type Part Number Description
IEG Detroit™ Genuine
One Quart Bottle - 6 Per
Coolant; Series 50 and OWI 23519400
Case
Series 60
Table 32.
Detroit™ Standard Life Coolant (Ethylene Glycol-based)
Coolant Type Part Number Description
One Gallon Jug - 4 Per Case
OWI 23539622
(Canada)
OWI 23512138 One Gallon Jug - 6 Per Case
Concentrate
OWI 23512139 55-Gallon Drum
Bulk Delivery - 1000 Gallon
OWI 23513503
min.
One Gallon Jug - 4 Per Case
OWI 23539623
(Canada)
Table 33.
Detroit™ Genuine Coolant 2000 Supplemental Coolant Additives (SCA)
Coolant Type Part Number Description
PIC 23507858 Pint Bottle - 12 Per Case
IEG Detroit™ Genuine
PIC 23507860 5-Gallon Pail
Coolant
PIC 23507861 55-Gallon Drum
Table 34.
Detroit™ Genuine Coolant 3000 SCAs
Coolant Type Part Number Description
PIC 23507854 Pint Bottle - 12 Per Case
Half Gallon Jugs - 6 Per
IEG Detroit™ Genuine PIC 23507855
Case
Coolant
PIC 23507856 5-Gallon Pail
PIC 23507857 55-Gallon Drum
Table 35.
Detroit Genuine Coolant 3000 SCA Filters (Series 50 and Series 60 Engines Only)
Coolant Type Part Number Description
23507545 4 Ounce (1 Pint Equivalent)
23508425 8 Ounce (2 Pint Equivalent)
23508426 12 Ounce (3 Pint Equivalent)
IEG Detroit™ Genuine
Coolant 23507189 16 Ounce (4 Pint Equivalent)
23508427 32 Ounce (8 Pint Equivalent)
53 Ounce (13 Pint
23508428
Equivalent)
Table 36.
Detroit Genuine Coolant Cooling System Cleaners
Coolant Type Part Number Description
All Types PIC 201549 Twin pack - 2 Per Case
One-Half Gallon Jug - 6 Per
PIC 200164
Case
Standard Life Coolant Only
PIC 200105 5-Gallon Pail
PIC 200155 55-Gallon Drum
Table 37.
Detroit Genuine Fluid Analysis Products
Coolant Type Part Number Description
Standard Life Coolant DDE 23516921 U.S. SLC Test Kit
Extended Life Coolant DDE 23539088 U.S. ELC Test Kit
NOTE: Change the coolant filter only after the vehicle has cooled and no
residual pressure is present.
NOTE: Use care to prevent foreign objects from entering the filter housing.
8. Insert element and cap assembly into the housing. Torque the cap to 55-60
N·m (41-44 lb·ft).
9. Check coolant level and adjust if necessary.
10. Start engine with the accelerator pedal in the idle position. Monitor all
gauges or indicator lamps.
11. Check the filter housings for signs of leakage.
Engine Storage
When an engine is to be stored or removed from operation for a period of time,
special precautions should be taken to protect the interior and exterior of the
engine, transmission and other parts from rust accumulation and corrosion. The
parts requiring attention and the recommended preparations are given below.
6. Clean the exterior of the engine (except electrical parts) with fuel oil and
dry with compressed air.
7. Seal all engine openings. The material used must be waterproof, vapor-
proof and possess sufficient physical strength to resist puncture and damage
from the expansion of entrapped air.
NOTICE: Do not use plastic sheeting for outdoor storage. Enough moisture
can condense on the inside of the plastic to rust ferrous metal surfaces and
pit aluminum surfaces. If a unit is stored outside for any extended period of
time, severe corrosion damage can result.
The stored engine should be inspected periodically. If there are any indications of
rust or corrosion, corrective steps must be taken to prevent damage to the engine
parts. Perform a complete inspection at the end of one year and apply additional
treatment as required.
To prepare an engine for extended storage (more than 30 days), follow this
procedure:
1. Drain the cooling system. Refer to section "Cooling System Drain
Procedure", 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. Refer to section "Cooling System Fill Procedure".
3. Stop the engine.
4. With the engine at ambient temperature and cool to the touch, drain the
engine crankcase oil into a suitable container. Remove the oil filters.
Dispose of the oil and filters in an environmentally friendly manner,
according to state and/or federal (EPA) recommendations. Replace the drain
plug and torque to 45-50 N·m (33-77 lb·ft).
5. Install new lubricating oil filters. Fill the crankcase to the proper level with
Tectyl® 930A preservative lubricating oil or an equivalent 30-weight
preservative lubricating oil meeting Mil-L-21260C, Grade 2 Specification.
NOTE: If engines are stored where condensation of water in the fuel tank
may be a problem, additives containing methyl carbitol or butyl cellusolve
may be added to the fuel. Follow manufacturer's instructions for treatment.
Where biological contamination of fuel may be a problem, add a biocide
such as Biobor® JF (or equivalent) to the fuel. When using a biocide, follow
the manufacturer's concentration recommendations and observe all
cautions and warnings.
6. Drain the fuel tank. Refill with enough clean No. 1 diesel fuel to permit the
engine to operate for about ten (10) minutes. If draining the fuel tank is not
convenient, use a separate, portable supply of recommended fuel.
7. Drain the fuel system and remove the fuel filters. Dispose of used filters in
an environmentally responsible manner, according to state and/or federal
(EPA) recommendations. Fill the new filters with No. 1 diesel fuel or pure
kerosene and install on the engine.
8. Operate the engine for five (5) minutes to circulate the clean fuel throughout
the engine. Be sure the engine fuel system is full.
9. Stop the engine and allow to cool. Then disconnect the fuel return line and
the inlet line at the primary filter and securely plug both to retain the fuel in
the engine.
10. Transmission: Follow the manufacturer's recommendations for prolonged
storage.
11. Power Take-Off: If equipped, follow manufacturer's recommendations for
prolonged storage.
NOTE: Failure to properly seal off the turbocharger air inlet and exhaust
outlet openings before engine storage may permit air drafts to circulate
through the turbocharger and rotate the turbine/compressor shaft without an
adequate flow of lubricating oil to the center housing bearings resulting in
severe bearing damage.
13. Apply a non-friction rust preventive compound to all exposed engine parts.
If convenient, apply the rust preventive compound to the engine flywheel. If
not, disengage the clutch mechanism to prevent the clutch disc from
sticking to the flywheel.
14. Drain the engine cooling system. If the engine will be exposed to freezing
temperatures, install genuine Detroit Power Cool antifreeze or an equivalent
ethylene glycol-base or propylene glycol-base antifreeze solution that
provides the required freeze, boil over and inhibitor protection. Refer to
section "Coolant Requirements"
15. Drain the preservative oil from the engine crankcase. Reinstall and torque
the 3/4" – 14 square, magnetic drain plug to 45-50 N·m (33-77 lb·ft).
16. Remove and clean the battery and battery cables with a baking soda-water
solution and rinse with fresh water. Do not allow the soda solution to enter
the battery. Add distilled water to the electrolyte (if necessary) and fully
charge the battery. Store the battery in a cool (never below 0° C or 32° F)
dry place. Keep the battery fully charged and check the level and specific
gravity of the electrolyte regularly.
17. Insert heavy paper strips between the pulleys and drive belts to prevent
sticking.
18. Seal all engine openings, including the exhaust outlet, with moisture-
resistant tape. Use cardboard, plywood or metal covers where practical.
19. Clean and dry the exterior painted surfaces of the engine and spray with a
suitable liquid automobile body wax, a synthetic resin varnish, or a rust
preventive compound.
20. Protect the engine with a good weather-resistant tarpaulin and store it under
cover, preferably in a dry building which can be heated during the winter
months.
Customer Assistance
service outlet in your area (in the U.S. and Canada, check the Yellow Pages or the
service locator at www.demanddetroit.com for Detroit™ service outlet nearest
you).
Table 38.
Detroit Genuine Fully Formulated Inhibited Ethylene Glycol Coolants
Table 39.
Detroit Genuine Supplemental Coolant Additive Need Release Filters
Table 40.
Detroit Genuine Cooling System Cleaners
Table 41.
Detroit Genuine Fluid Testing
and Analysis Products
NOTE: There are approximately 5.0 L (5.2 qts) of oil represented from the
fill mark to the full mark.
Table 42.
Engine Oil Capacities
Truck - EPA07/
DD13 DD15 DD16
EPA10/GHG14
Total Dry Engine Oil
44.0 L (46.5 qt) 49.0 L (51.8 qt) 49.0 L (51.8 qt)
Volume
Oil and Filter Change 38.0 L (40.1 qt) 43.0 L (45.4 qt) 43.0 L (45.4 qt)
Remaining in Engine
after Oil Drain
6.0 L (6.3 qt) 6.0 L (6.3 qt) 6.0 L (6.3 qt)
(Includes Filter
Removal)
Dip Stick Min. to
5.0 L (5.2 qt) 5.0 L (5.2 qt) 5.0 L (5.2 qt)
Max. Range
Sump Oil Volume 35.0 L (37.0 qt) 40.0 L (42.3 qt) 40.0 L (42.3 qt)
Table 43.
Coach EPA10 DD13 GHG14 DD13
Total Dry Engine Oil
51.0 L (53.8 qt) 47.0 L (49.7 qt)
Volume
Oil and Filter Change 45.0 L (47.6 qt) 40.0 L (42.3 qt)
Remaining in Engine
after Oil Drain
6.0 L (6.3 qt) 6.0 L (6.3 qt)
(Includes Filter
Removal)
Dip Stick Min. to
5.0 L (5.2 qt) 5.0 L (5.2 qt)
Max. Range
Sump Oil Volume 42.0 L (44.4 qt) 37.0 L (39.1 qt)
Table 44.
Engine Oil Capacities - GHG17 Only
Parameter DD13 Truck DD13 Coach DD15 Truck DD16 Truck
Service Fill (Oil
and Filter 38.0 L (40.0 qt) 45.0 L (48.0 qt) 43.0 L (45.0 qt) 43.0 L (45.0 qt)
Change)
Oil Pan
Capacity, High 35.0 L (37.0 qt) 42.0 L (44.0 qt) 40.0 L (42.0 qt) 40.0 L (42.0 qt)
Limit
Oil Pan
Capacity, Low 30.0 L (32.0 qt) 37.0 L (39.0 qt) 35.0 L (37.0 qt) 35.0 L (37.0 qt)
Limit