DDC-SVC-MAN-0057.PDF - EPA04 Series 40 Engine Operator's …...SERIES 40 ENGINE OPERATOR'S GUIDE...

SERIES 40 ENGINE OPERATOR'S GUIDE

To the Operator

This guide contains instructions onthe safe operation and preventivemaintenance of your DetroitDiesel Series 40™ engine usedin motor coach, transit coach,construction/industrial, emergencyvehicle and power generatorset applications. Maintenanceinstructions cover routine engineservices such as lube oil and filterchanges in enough detail to permitself-servicing, if desired.

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

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

Throughout this guide CAUTIONSregarding personal safety andNOTICES regarding engineperformance or service life willappear. To avoid personal injury andensure long engine service life, alwaysheed these instructions.

Whenever possible, it will benefityou to rely on an authorized DetroitDiesel service outlet for all yourservice needs from maintenance to

major parts replacement. Authorizedservice outlets worldwide stockfactory-original parts and havethe specialized equipment andexperienced, trained personnelto provide prompt preventivemaintenance and skilled enginerepairs.

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

All information subject to change without notice. (Rev. May 2004) iDDC-SVC-MAN-0057 0305 Copyright © 2003 DETROIT DIESEL CORPORATION

NOTICE:Failure to check and maintainSCA (supplemental coolantadditive) levels at requiredconcentrations will result insevere damage (corrosion)to the engine cooling systemand related components.Coolant must be inhibited with therecommended SCAs listed in thisguide.Refer to section G. How toSelect Coolant. In addition, theengine can be equipped with acoolant filter/inhibitor system as aninstalled option or as an after-saleitem.

WARRANTYThe applicable engine warranty forSeries 40 engines is contained in theWarranty Information section of thisoperator's guide. Individual enginewarranty information booklets areavailable from authorized DetroitDiesel service outlets.

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

Trademark Information

Detroit Diesel®, DDC®, DDEC®,reliabilt®, POWER COOL®, POWERTrac® and POWER GUARD® areregistered trademarks of DetroitDiesel Corporation. Series 40™is a trademark of Detroit DieselCorporation. Delco Remy® is aregistered trademark of Delco RemyAmerica, Inc.Fuel Pro®, Sea Pro®,and Mega Filter® are registeredtrademarks of Davco Manufacturing,L.L.C.. PowerBand® is a registeredtrademark of Gates Rubber Company.Biobor® is a registered trademark ofUnited States Borax and ChemicalCorporation. All other trademarksused are the property of theirrespective owners.

ii All information subject to change without notice. (Rev. May 2004)DDC-SVC-MAN-0057 0305 Copyright © 2003 DETROIT DIESEL CORPORATION


TABLE OF CONTENTS

INTRODUCTION .................................................................................. 1NON-GENUINE AND REBUILT COMPONENT QUALITY ALERT .. 1

CAUTION SUMMARY .......................................................................... 3

GENERAL INFORMATION .................................................................. 11ENGINE FEATURES ....................................................................... 11COMPONENT LOCATION ............................................................... 11

ENGINE MODEL AND SERIAL NUMBER LOCATIONS .................... 16TURBOCHARGER IDENTIFICATION ............................................. 17

OPERATING INSTRUCTIONS ............................................................ 18PREPARATIONS FOR FIRST TIME ENGINE START ..................... 18

COOLING SYSTEM CHECKS .................................................... 18LUBRICATION SYSTEM CHECKS ............................................. 19FUEL SYSTEM CHECKS ............................................................ 20OTHER CHECKS ........................................................................ 21

STARTING THE ENGINE ................................................................ 22ENGINE DIAGNOSTIC BUTTON ................................................ 23INITIAL ENGINE START ............................................................. 23

EMERGENCY JUMP STARTING .................................................... 24RUNNING THE ENGINE ................................................................. 26

OIL PRESSURE .......................................................................... 26WARM-UP ................................................................................... 26INSPECTION ............................................................................... 26AVOID UNNECESSARY IDLING ................................................. 27

STOPPING THE ENGINE ................................................................ 27NORMAL STOPPING .................................................................. 27

SHUTDOWN WARNING LIGHT AND BUZZER .............................. 27ROAD OPERATION ......................................................................... 28COLD WEATHER OPERATION ...................................................... 28HOT WEATHER OPERATION ......................................................... 29EXTENDED IDLING PERIODS ....................................................... 29

SERIES 40 ELECTRONIC CONTROL SYSTEM ................................ 31

All information subject to change without notice. (Rev. May 2004) iiiDDC-SVC-MAN-0057 0305 Copyright © 2003 DETROIT DIESEL CORPORATION

TABLE OF CONTENTS

SERIES 40 ENGINE SYSTEMS .......................................................... 36FUEL SYSTEM ................................................................................ 36LUBRICATION SYSTEM ................................................................. 36COOLING SYSTEM ......................................................................... 36ELECTRICAL SYSTEM ................................................................... 36AIR INDUCTION SYSTEM .............................................................. 36EXHAUST SYSTEM ........................................................................ 36

MAINTENANCE SCHEDULES ............................................................ 37MAINTENANCE INTERVALS .......................................................... 37

LUBRICATION AND PREVENTIVE MAINTENANCE INTERVALS .... 53ITEM 1 – LUBRICATING OIL ........................................................... 53ITEM 2 – FUEL AND FUEL TANK ................................................... 55ITEM 3 – FUEL LINES, FLEXIBLE HOSES ..................................... 56

PRE-START INSPECTION .......................................................... 56HOSE SERVICE LIFE ................................................................. 57

ITEM 4 – COOLING SYSTEM ......................................................... 58COOLANT LEVEL ....................................................................... 58COOLANT INHIBITORS .............................................................. 58COOLANT DRAIN INTERVAL ..................................................... 58

ITEM 5 – TURBOCHARGER, AIR-TO-AIR CHARGE COOLER ..... 60ITEM 6 – BATTERY ......................................................................... 60ITEM 7– DRIVE BELTS ................................................................... 61ITEM 8 – AIR COMPRESSOR ......................................................... 62ITEM 9 – AIR CLEANER .................................................................. 62

AIR CLEANER REPLACEMENT ................................................. 63ITEM 10 – LUBRICATING OIL FILTERS ......................................... 63ITEM 11 – FUEL FILTERS ............................................................... 64

FUEL FILTER AND STRAINER .................................................. 64FUEL PRO® 382 FILTERS .......................................................... 66

ITEM 12 – WATER PUMP, COOLANT INHIBITOR ELEMENT ....... 66WATER PUMP ............................................................................ 66COOLANT INHIBITOR ELEMENT .............................................. 66

ITEM 13 – CRANKING MOTOR ...................................................... 66ITEM 14 – AIR SYSTEM .................................................................. 67ITEM 15 – EXHAUST SYSTEM ....................................................... 67ITEM 16 – ENGINE (STEAM CLEAN) ............................................. 67ITEM 17 – RADIATOR ..................................................................... 67

iv All information subject to change without notice. (Rev. May 2004)DDC-SVC-MAN-0057 0305 Copyright © 2003 DETROIT DIESEL CORPORATION


ITEM 18 – OIL PRESSURE ............................................................. 68ITEM 19 – BATTERY-CHARGING ALTERNATOR .......................... 68

BOSCH & DELCO-REMY SERVICE REQUIREMENTS ............. 68ALTERNATOR PRECAUTIONS .................................................. 68

ITEM 20 – ENGINE AND TRANSMISSION MOUNTS .................... 69ITEM 21 – CRANKCASE PRESSURE ............................................ 69ITEM 22 – FAN HUB ........................................................................ 69ITEM 23 – THERMOSTAT AND SEAL ............................................ 70ITEM 24 – CRANKCASE BREATHER ............................................. 70ITEM 25 – ENGINE TUNE-UP ......................................................... 70ITEM 26 – IDLER PULLEY .............................................................. 71ITEM 27 – VIBRATION DAMPER .................................................... 71

WELDING PRECAUTION ........................................................... 72

HOW-TO SECTION .............................................................................. 73A. HOW TO SELECT LUBRICATING OIL ....................................... 73

LUBRICANT SELECTION IN NORTH AMERICA ....................... 73LUBRICANT REQUIREMENTS .................................................. 73THE USE OF SUPPLEMENTAL ADDITIVES .............................. 74

B. WHEN TO CHANGE OIL ............................................................. 75OIL DRAIN INTERVALS .............................................................. 75DISPOSING OF WASTE OIL ...................................................... 76

C. HOW TO REPLACE THE LUBE OIL FILTER ............................. 76REPLACE SPIN-ON TYPE OIL FILTER ...................................... 77

D. HOW TO SELECT FUEL OIL ...................................................... 78QUALITY ..................................................................................... 78FUEL CONTAMINATION ............................................................. 79PROHIBITED ADDITIVES ........................................................... 79

USED LUBRICATING OIL ....................................................... 79GASOLINE ............................................................................. 79

E. HOW TO REPLACE THE FUEL FILTER ..................................... 80REPLACE FUEL FILTER AND STRAINER ................................. 80PRIME THE FUEL SYSTEM ....................................................... 82REPLACE FUEL/WATER SEPARATOR ELEMENT .................... 84REPLACE FUEL PRO FILTER ELEMENT .................................. 84

F. ENGINE OUT OF FUEL — HOW TO RESTART ......................... 87G. HOW TO SELECT COOLANT .................................................... 89

DEFINITIONS .............................................................................. 89APPROVED COOLANTS ............................................................ 89

All information subject to change without notice. (Rev. May 2004) vDDC-SVC-MAN-0057 0305 Copyright © 2003 DETROIT DIESEL CORPORATION

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EG OR PG & WATER + SCA INHIBITOR ............................... 90MIXING EG OR PG ANTIFREEZE AND WATER ................... 90RECYCLED ANTIFREEZE .................................................... 92EG OR PG & WATER + OAT INHIBITOR ............................... 93WATER ONLY + SCA OR WATER ONLY + OAT INHIBITOR 93WATER REQUIREMENTS ..................................................... 94

COOLANTS NOT RECOMMENDED .......................................... 95ADDITIVES NOT RECOMMENDED ........................................... 95MAINTENANCE ........................................................................... 96

COOLANT INHIBITOR TEST INTERVALS ............................ 96SUPPLEMENTAL ADDITIVES ................................................ 96MAINTENANCE INTERVALS .................................................. 97

SCA TEST PROCEDURES ......................................................... 99NEED-RELEASE FILTERS (NON-OAT SYSTEMS) .................... 100DROPOUT ................................................................................... 101EXTENDER ADDITIVE FOR OAT COOLANT ............................ 101

OAT COOLANT DRAIN INTERVAL ........................................ 101CHRONIC COOLANT SYSTEM PROBLEMS ............................. 102MAINTENANCE PRODUCTS ..................................................... 102

POWER COOL SCAS ............................................................. 102POWER COOL COOLANT FILTER ELEMENTS .................... 102POWER COOL CLEANERS ................................................... 102

SUMMARY OF COOLANT RECOMMENDATIONS .................... 103H. HOW TO REPLACE THE COOLANT FILTER ............................ 105I. HOW TO DRAIN AND FLUSH THE COOLING SYSTEM ............ 106J. WHEN TO SERVICE THE DRY TYPE AIR CLEANER ................ 108

BASIC TROUBLESHOOTING ............................................................. 109

ENGINE STORAGE ............................................................................. 116PREPARING ENGINE FOR STORAGE .......................................... 116

TEMPORARY STORAGE (30 DAYS OR LESS) ......................... 116EXTENDED STORAGE (MORE THAN 30 DAYS) ...................... 117RESTORING ENGINE TO SERVICE .......................................... 120

SERVICE PUBLICATIONS .................................................................. 122

DETROIT DIESEL CUSTOMER ASSISTANCE .................................. 123

vi All information subject to change without notice. (Rev. May 2004)DDC-SVC-MAN-0057 0305 Copyright © 2003 DETROIT DIESEL CORPORATION


MOTOR COACH, MOTOR HOME AND TRANSIT BUS ENGINEWARRANTY ......................................................................................... 129

FIRE TRUCK OR CRASH VEHICLE ENGINE WARRANTY .............. 132

CONSTRUCTION/INDUSTRIAL ENGINE WARRANTY ..................... 135

PRIME AND STAND-BY POWER GENERATOR SET ENGINEWARRANTY ......................................................................................... 139

SPECIFICATIONS ................................................................................ 142FUEL AND LUBRICATING OIL FILTER REQUIREMENTS ............ 142ENGINE OIL CAPACITY .................................................................. 142POWER COOL ENGINE PRODUCTS ............................................ 143

FULLY FORMULATED IEG COOLANT ....................................... 143LATIN AMERICAN COOLANT .................................................... 1432000 SUPPLEMENTAL COOLANT ADDITIVE ........................... 1443000 SUPPLEMENTAL COOLANT ADDITIVE ........................... 1443000 SUPPLEMENTAL ADDITIVE COOLANT FILTERS ............ 145SUPPLEMENTAL ADDITIVE NEED-RELEASE FILTERS .......... 145PLUS EXTENDED LIFE OAT COOLANT .................................... 146PLUS EXTENDER FOR POWER COOL PLUS OAT COOLANT 146PLUS OAT INHIBITOR FOR WATER-ONLY SYSTEMS ............. 147COOLING SYSTEM CLEANERS ................................................ 147COOLANT TESTING AND ANALYSIS PRODUCTS ................... 148

All information subject to change without notice. (Rev. May 2004) viiDDC-SVC-MAN-0057 0305 Copyright © 2003 DETROIT DIESEL CORPORATION

TABLE OF CONTENTS

viii All information subject to change without notice. (Rev. May 2004)DDC-SVC-MAN-0057 0305 Copyright © 2003 DETROIT DIESEL CORPORATION


INTRODUCTION

This guide is intended for use by theoperator of a Detroit Diesel Series40™ engine used in one of thefollowing applications:

□ Transit Coaches

□ Construction/Industrial

□ Generator Set

Non-Genuine and RebuiltComponent Quality AlertIn recent years, electronic enginecontrols have been instrumentalin aiding engine manufacturers inmeeting the stringent emissionrequirements of the U.S.Environmental Protection Agency(U.S. EPA) and the California AirResources Board (CARB) andalso in meeting the ever-increasingperformance demands of the customer.

Maintenance procedures are tobe followed in order to continuesatisfactory performance anddurability and to ensure coverage ofthe engine under the manufacturer'swarranty. Many of these maintenanceprocedures also ensure that the enginecontinues to comply with applicableemissions standards. The U.S.EPA specifically defines an engine's“useful emission life” — currentlyestablished as 290,000 miles (464,000kilometers) for on-highway engines.

Proper maintenance procedures, usingspecific components engineered tocomply with emissions regulations,may be performed by an authorizedDetroit Diesel distributor or dealer,an independent outlet or the operatoror owner. The owner is responsiblefor determining the suitability ofcomponents to maintain emissionscompliance during the engine's usefulemission life.

Electronic controls and componentshave significantly increased insophistication, but the fundamentalobjective remains the same — precisetiming and delivery of fuel. The veryheart of the Detroit Diesel electroniccontrols is the electronic unit injector(EUI). The proper functioning of theEUI is absolutely paramount if thebenefits of electronic controls are to berealized. Detroit Diesel Corporationhas built over 650,000 engines withelectronic unit injectors — more thananyone else in the business.

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

All information subject to change without notice. (Rev. May 2004) 1DDC-SVC-MAN-0057 0305 Copyright © 2003 DETROIT DIESEL CORPORATION

INTRODUCTION

There are other components inan engine, such as turbocharger,camshaft, piston, etc., whichare specifically designed andmanufactured to exacting standardsfor emissions compliance. It isimportant that these components, ifreplaced, modified or substituted, canbe verified to ensure that the engineremains in compliance with emissionsstandards. The use of inadequatelyengineered, manufactured or testedcomponents in repair or rebuild ofthe engine may be in violation of thefederal Clean Air Act and applicableU.S. EPA (Environmental ProtectionAgency) or CARB (California AirResources Board) regulations.

Furthermore, modern engines exhibitoperating parameters which requirethe use of proper fluids, such asfuel, coolant and lubricating oil, tomaintain long engine life. The use offluids that do not meet Detroit DieselCorporation specifications may resultin early wear out or engine failure.

2 All information subject to change without notice. (Rev. May 2004)DDC-SVC-MAN-0057 0305 Copyright © 2003 DETROIT DIESEL CORPORATION


CAUTION SUMMARY

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

1. Observe the following cautionswhen operating the engine:

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

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

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

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

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

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

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

Failure to observe theseprecautions may result inloss of vehicle control and/orpersonal injury.


CAUTION SUMMARY

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

□ Always start and operate anengine in a well ventilatedarea.

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

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

2. Observe the following cautionswhen performing basicpreventive maintenance onthe engine:

To avoid injury when workingnear or on an operating engine,remove loose items of clothing,jewelry, tie back or contain longhair that could be caught in anymoving part causing injury.

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

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

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



To avoid injury from contact withthe contaminants in used engineoil, wear protective gloves andapron.

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

To avoid injury from the expulsionof hot coolant, never remove thecooling system pressure capwhile the engine is at operatingtemperature. Remove the capslowly to relieve pressure. Wearadequate protective clothing(face shield or safety goggles,rubber gloves, apron, and boots).

To avoid injury from hot surfaces,allow engine to cool beforeremoving any component. Wearprotective gloves.

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

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


CAUTION SUMMARY

To avoid injury from fire causedby heated lubricating-oil vapors:

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

□ Stop the engine immediately ifan oil leak is detected.

□ Do not allow open flames orsmoke when working on anoperating engine.

□ Wear adequate protectiveclothing (face shield,insulated gloves, apron,etc.) to avoid burns.

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

Lubricating oil is relativelyharmless at ambienttemperatures.

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

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

3. Observe the following cautionswhen using compressed air:

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

4. Observe the following cautionswhen using starting aids:



To avoid injury from flames,explosion, and toxicants whenusing ether, the followingprecautions must be taken:

□ Always wear goggles whentesting.

□ If fluid enters the eyes or iffumes irritate the eyes, washeyes with large quantities ofclean water for 15 minutes.A physician, preferably aneye specialist, should becontacted.

□ Contents of cylinder are underpressure. Store cylindersin a cool dry area. Do notincinerate, puncture orattempt to remove cores fromcylinders.


□ Do not smoke when servicingether system.

□ Work in well-ventilated area.

□ Do not work near open flames,pilot flames (gas or oilheaters), or sparks.

□ Do not weld or carry an openflame near the ether system ifyou smell ether or otherwisesuspect a leak.

5. Observe the following cautionswhen jump starting an engine,charging a battery, or workingwith the vehicle/applicationelectrical system:

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


CAUTION SUMMARY

To avoid injury from batteryexplosion or contact with batteryacid, work in a well-ventilatedarea, wear protective clothing,and avoid sparks or flamesnear the battery. Alwaysestablish correct polarity beforeconnecting cables to the batteryor battery circuit. If you come incontact with battery acid:

□ Flush your skin with water.

□ Apply baking soda or lime tohelp neutralize the acid.

□ Flush your eyes with water.

□ Get medical attentionimmediately.

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

6. Observe the following cautionswhen fueling the vehicle,replacing fuel filters or workingwith the engine fuel system.

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

To avoid injury from fire, keep allpotential ignition sources awayfrom diesel fuel, open flames,sparks, and electrical resistanceheating elements. Do not smokewhen refueling.




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


□ Stop the engine immediately ifa fuel leak is detected.


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


Diesel fuel is relatively harmlessat ambient temperatures.

7. Observe the following cautionswhen servicing the coolingsystem:



8. Observe the following cautionswhen working on the engine airintake system:



CAUTION SUMMARY

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

9. Observe the following cautionswhen replacing the enginelubricating oil and filters:

To avoid injury from fire causedby heated lubricating-oil vapors:


□ Stop the engine immediately ifan oil leak is detected.


□ Wear adequate protectiveclothing (face shield,insulated gloves, apron,etc.) to avoid burns.


Lubricating oil is relativelyharmless at ambienttemperatures.




GENERAL INFORMATION

Engine FeaturesThe Series 40 is a family ofinline six-cylinder, 4-stroke cycle,water-cooled, turbocharged engineswhich may be equipped with achassis-mounted, air-to-air chargecooler system.

Engines built prior to 1998 useda mechanical, high-pressure fuelpump and individual injector nozzles.Operators of these engines should referto Series 40 Engine Operators Guide6SE516 for preventive maintenanceinformation.

Engines built from 1998 – present aredirect fuel injected with hydraulicallyactuated, electronically controlled unitinjectors. This operator's guide coversthese current engines.

Component LocationsThe following figures show thelocations of major engine components.


GENERAL INFORMATION

1. Water Pump Pulley 6. Fan Pulley

2. Auto Belt Tensioner 7. Front Cover

3. Camshaft Position Sensor 8. Vibration Damper

4. Coolant Temperature Sensor 9. Mounting Bracket

5. Thermostat

Figure 1 Major Component Locations, Front View



1. High Pressure Oil Pump 10. High-Pressure Oil/Fuel Manifold

2. Oil Temperature Sensor 11. Fuel Filter Header

3. Injector Pressure Sensor 12. Fuel Strainer

4. Wiring Harness 13. Oil Fill Tube

5. Fuel Supply Pump 14. Flywheel Housing

6. 31-Pin Connector 15. Oil Pan

7. Wiring Harness Connector 16. Fuel Filter

8. Valve Cover/ Intake Manifold 17. Air Compressor (if equipped)

9. Lifting Eye (2) 18. Injection Pressure RegulatingValve

Figure 2 Major Component Locations, Left Side View


GENERAL INFORMATION

1. Oil Filter 7. Lifting Eye (2)

2. Flywheel Housing 8. Alternator Bracket

3. Road Draft Tube 9. Coolant Filter

4. Exhaust Manifold 10. Water Inlet

5. Turbocharger 11. Oil Cooler

6. Valve Cover/Intake Manifold 12. Oil Pan

Figure 3 Major Component Locations, Right Side View



1. Flywheel 4. Road Draft Tube

2. Oil Fill Tube 5. Turbocharger

3. Oil Level Gage 6. Flywheel Housing

Figure 4 Major Component Locations, Rear View


ENGINE MODEL AND SERIAL NUMBER LOCATIONS

ENGINE MODEL AND SERIAL NUMBER LOCATIONS

Figure 5 Model, Serial Number and Emission Label – Former Location

Figure 6 Model, Serial Number and Emission Label – Current Location



The engine model and serial numberswere previously laser etched on theleft side, center of the cylinder block.See Figure 5. Beginning in late year2000, these numbers were relocatedto a machined pad on the right side ofthe block, and directly above the oilcooler. See Figure 6.

TurbochargerIdentificationThe turbocharger identification plateis located on the flat, inboard face ofthe compressor housing. See Figure 7.

Figure 7 Turbocharger Identification (non-wastegate turbo shown)


OPERATING INSTRUCTIONS


Preparations for Startingthe Engine the First TimeWhen preparing to start a new ornewly overhauled engine which hasbeen in storage, perform all of theoperations listed below. Failure tofollow these instructions may resultin serious engine damage. Before aroutine start, see the “Daily” checksfor your engine. Refer to sectionMAINTENANCE SCHEDULES.





To avoid injury when workingnear or on an operating engine,remove loose items of clothing,jewelry, tie back or contain longhair that could be caught in anymoving part causing injury.

Cooling System Checks

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

2. Remove the radiator pressurecontrol cap and fill with genuineDetroit Diesel Power Coolantifreeze or an equivalent qualityethylene glycol or propyleneglycol-base antifreeze solutionin the required concentration.In extremely hot environments,properly inhibited water maybe used in the summer. Keepthe coolant level at the bottomof the filler neck to allow forexpansion of the coolant. Formore detailed recommendations,



refer to section G. How to SelectCoolant in this guide.

NOTE:Entrapped air must be purged afterfilling the cooling system. To do this,allow the engine to warm up withthe pressure cap removed. Withthe transmission in neutral, increaseengine speed above 1,000 rpm andadd coolant to the radiator as required.

3. Check to make sure the front ofthe radiator and air-to-air chargecooler are unblocked and free ofdebris.

Lubrication System Checks

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

NOTICE:Insufficient lubrication at startup cancause serious damage to enginecomponents.

To insure an immediate flow ofoil to all bearing surfaces at initialengine startup, the engine lubricationsystem should be charged with acommercially available pressurepre-lubricator. If this is impractical,

rocker cover should be removedand clean lubricating oil should bepoured over the rocker arms. Theoil should be the same weight andviscosity as that used in the crankcase.After pre-lubricating, replace rockercover and add additional oil to bringthe level to the proper mark on thedipstick. See Figure 8.

Figure 8 Check Lube Oil LevelBefore Starting

NOTE:The current oil level gage is identifiedby the words “Operating Range” and“Add” separated by a cross-hatchedarea. When using this dipstick, keepthe oil level within the cross-hatchedarea.

NOTE:The former oil level gage has the word“Full” above the upper gage line andthe word “Add” below the lower gageline. When using this dipstick, maintainthe oil level between the “Full” and“Add” gage lines.



NOTICE:To avoid engine damage, neveroperate the engine when the oil levelis outside the cross-hatched areaon the current dipstick or outside thearea between the “Add” and “Full”gage lines on the former dipstick.

For lubricant recommendation,refer to section A. How to SelectLubricating Oil in the How To sectionof this guide.

Extended Storage – An enginein storage for an extended periodof time (over winter, for example)may accumulate water in the oilpan through normal condensation ofmoisture (always present in the air)on the cold, internal surfaces of theengine. Lube oil diluted by watercannot provide adequate bearingprotection at engine startup. For thisreason, Detroit Diesel recommendsreplacing the engine lubricating oiland filters after extended storage.

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

Fuel System Checks

Fill the tanks with the recommendedfuel. Keeping tanks full reduces water

condensation and helps keep fuelcool, which is important to engineperformance. Full tanks also reducethe chance for microbe (black slime)growth. For fuel recommendations,refer to section D. How to Select FuelOil in the How To section of thisguide. Make sure the fuel shutoffvalve (if used) is open.

NOTICE:Do not use the engine startingsystem to prime the fuel systembefore initial engine start. This canresult in damage to the starter, fuelpump and injectors tips and maycause erratic engine operation dueto the amount of air in the lines andfilters from the fuel supply tank tothe cylinder head.Engines equipped with startingdevices dependent on compressedair or gas reservoirs should alwaysbe primed before initial startup.Otherwise, reserve pressure canbe exhausted and injectors may bedamaged from lack of lubricationand cooling.Under no circumstances shoulda starting aid such as ether beused to run the engine until thefuel system is primed. Injector tipdamage will result if this methodis used.



NOTICE:Starting an engine taken out ofstorage or one recently overhauledwithout first priming the fuel systemwill result in an overload conditionthat can damage the injector tips.To avoid injector tip damage, thefuel system must be primed beforeinitial engine startup.

If the engine is equipped with afuel/water separator, drain off anywater that has accumulated. Waterin fuel can seriously affect engineperformance and may cause enginedamage. Detroit Diesel recommendsinstallation of a fuel/water separatorwherever water contamination is aconcern.

If previously disconnected, reconnectcharge air cooler piping to valvecover/intake manifold.

To insure prompt starting, evenrunning and avoid injector tip damage,the fuel system must be primed beforeinitial engine start. Use this procedure:

NOTE:Authorized Detroit Diesel serviceoutlets are properly equipped andhave the trained technicians to performthis service.

NOTICE:Failure to disconnect the CMP(camshaft position sensor) beforepriming the engine may allow theengine to start during priming,which could result in severe enginedamage.

1. Disconnect the CMP (camshaftposition sensor) to prevent theengine from starting.

2. Using the manual priming pumpon the fuel filter header, fill thesystem with clean fuel until theprimer pump is hard to depress.

3. Crank the engine three times for15 seconds each. Reapply theprimer pump after each crankcycle.

4. Once the primer pump is hard todepress (usually three crank andhand prime cycles), reconnect theCMP.

Other Checks

Check the hydrometer “eye” ofmaintenance-free batteries for charge.See Figure 9.



Figure 9 Check “Eye” ofMaintenance-FreeBatteries

If lead-acid or low-maintenancebatteries are used, make sure batteryelectrolyte level is normal.

Make sure cable connections to thestorage batteries are clean and tight.

Check the turbocharger for signs ofoil or exhaust leaks. Leaks should becorrected before starting the engine.

Check engine mounting bolts fortightness. Bolts should be retightened,if necessary.

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

Check drive belts to make sure theyare in good condition (not cracked,torn, worn or glazed).

Starting the EngineBefore starting the engine the firsttime, refer to section Preparations forStarting the Engine the First Time inthe Operating Instructions sectionand perform the operations listed.


□ Do not smoke when servicingether system.

□ Work in well-ventilated area.

□ Do not work near open flames,pilot flames (gas or oilheaters), or sparks.

□ Do not weld or carry an openflame near the ether system ifyou smell ether or otherwisesuspect a leak.

The engine may require the use of acold weather starting aid if the ambienttemperature is below 40 °F (4 °C).



Engine Diagnostic Button

The engine diagnostic button, locatedon the vehicle dashboard, is usedto read faults detected by the ECM(electronic control module). TheECM will flash the CEL (check enginelight) to warn of problems with theengine, oil, or coolant and indicateswhich faults have been detected.

Depress and hold the engine diagnosticbutton. Turn the ignition switch tothe ON position and then releasethe engine diagnostic button. DONOT START THE ENGINE. TheECM will begin the self-test tocheck the sensor output circuits. If afault is detected, the CEL will flashrepeatedly, signaling the action faultcode. Additional information on theengine diagnostic button is availablein the Series 40 TroubleshootingManual, 6SE241, available fromauthorized Detroit Diesel distributors.

Initial Engine Start





Electric Starter – Start an engineequipped with an electric startingmotor as follows:

1. Set the parking brake and placethe transmission in NEUTRAL. Ifan automatic transmission, placeit in PARK or NEUTRAL.

2. Depress the clutch pedal, ifequipped. Do not depress theaccelerator pedal.



NOTICE:To prevent serious starting motordamage, do not press the starterswitch again after the engine hasstarted.

3. With foot off of the acceleratorpedal, turn the ignition key tothe START position and crankthe engine. If the vehicle haspush button starting, PRESS andHOLD the starter button.

4. As soon as the engine starts,release the key or starter button,if applicable.

NOTE:If the engine fails to start within 15seconds, release the starter switch andallow the starter to cool for 15 secondsbefore trying again. If the enginefails to start after four attempts or ifit starts and then stops immediately,an inspection should be made todetermine the cause.

Air Starter – Because of the limitedvolume of most compressed airstorage tanks and the relatively shortduration of the cranking cycle, it isimportant to make sure the engine isready to start before activating the airstarter. Start an engine equipped withan air starter as follows:

1. Check the pressure in the airstorage tank. If necessary, add air

to bring the pressure up to at leastthe recommended minimum forstarting.

2. With foot OFF the foot pedal,turn the ignition key to the startposition and press and hold thestarter button until the enginestarts.

NOTE:If the engine fails to start after fourattempts or if it starts and stopsimmediately, an inspection should bemade to determine the cause.

Emergency Jump Starting

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

The Series 40 engine ECM (electroniccontrol module) operates on either12 or 24 volts. When jump startingan engine, do not exceed 18 volts fora 12–volt system or 32 volts for a24–volt system.



NOTICE:Jump starting with voltages greaterthan those indicated or reversingbattery polarity may damage theECM (electronic control module).

Perform the following operations foremergency jump starting:






1. To prevent possible shorting,remove metal rings and watchesand do not allow metal tools tocontact the positive terminal ofthe battery.

2. Place the transmission inNEUTRAL and set the parkingbrake.

3. Bring the assisting vehicle closeto the disabled vehicle, but do notallow vehicles to touch. Stop theengine on the assisting vehicle.

4. Shut off all lights, heater, airconditioner and any otherelectrical loads in both vehicles.

5. Connect the first jumper cable tothe positive (+) terminal of thedead battery and the positive (+)terminal of the booster battery.Connect the second jumper cableto the negative (-) terminal of thebooster battery and an engine bolthead, metal support bracket orother good metallic contact on thedisabled vehicle.

6. Start the engine on the assistingvehicle and allow it to charge thebattery on the disabled vehicle forat least one minute.

7. With foot OFF the foot pedal,turn the ignition key to the startposition and press and hold thestarter button until the enginestarts.

NOTE:If the engine fails to start after fourattempts or if it starts and stopsimmediately, an inspection should bemade to determine the cause.



8. After the engine starts, removejumper cables in reverse order ofattachment.

Running the Engine

Oil Pressure

Observe the oil pressure gageimmediately after starting the engine.A good indicator that all moving partsare getting lubrication is when the oilpressure gage exceeds 137 kPa (20psi) after starting. If oil pressure isless than this or if no oil pressure isindicated, stop the engine, check forthe cause and correct the condition.

After the engine has reached operatingtemperature, the oil pressure shouldbe 276 kPa (40 psi) minimum. If oilpressure does not meet this minimum,stop the engine, check for the causeand correct the condition.

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

Warm-up

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

Inspection

Transmission – While the engineis idling, check the automatictransmission (if equipped) for properoil level and add oil as required.

Fluid Leaks – Look for coolant,fuel or lubricating oil leaks. If anyare found, shut down the engineimmediately and have the leaksrepaired after the engine has cooled.

Crankcase – If the engine oil wasreplaced, stop the engine after normaloperating temperature has beenreached. Allow the oil to drainback into the crankcase for abouttwenty minutes, then check the oillevel. If necessary, add oil to bringthe level to the proper mark on thedipstick. Use only the heavy-duty oilsrecommended. Refer to section A.How to Select Lubricating Oil in thisguide.

Turbocharger – Make a visualinspection of the turbocharger foroil leaks, exhaust leaks, excessivenoise or vibration. Stop the engineimmediately if a leak or unusual noiseor vibration is noted. Do not restartthe engine until the cause of theconcern has been investigated andcorrected. Authorized Detroit Dieselservice outlets are properly equippedto perform this service.



Avoid Unnecessary Idling

Whenever possible, avoid unnecessaryidling.

During long engine idling periodswith the transmission in neutral, theengine coolant temperature may fallbelow the normal operating range.The incomplete combustion of fuelin a cold engine will cause crankcaseoil dilution, formation of lacquer orgummy deposits on the valves, pistons,and rings, and rapid accumulation ofsludge in the engine. When prolongedidling is necessary, maintain at least850 rpm spring/summer and 1200 rpmfall/winter.

Stopping the Engine

Normal Stopping

Stop an engine under normal operatingconditions as follows:

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

NOTICE:Stopping a turbocharged engineimmediately after high-speedoperation without allowing asufficient cool-down period maycause damage to the turbocharger,as it will continue to turn without anoil supply to the bearings.

2. Allow the engine to run betweenidle and 1000 rpm with no loadfor four or five minutes. Thisallows the engine to cool andpermits the turbocharger to slowdown. After four or five minutes,shut down the engine.

Shutdown Warning Lightand BuzzerVehicles may be equipped with anautomatic engine shutdown systemthat will stop the engine in the event ofhigh coolant temperature, low coolantlevel, or low engine oil pressure. TheSEL (stop engine light) and alarmbuzzer and light on the instrumentpanel alert the operator of high coolanttemperature, low coolant level, orlow oil pressure conditions. Shouldtemperature or pressure continue tochange beyond the warning point to apredetermined level, the engine willautomatically shut down.

NOTICE:To avoid engine damage when theoverride feature is selected, theengine should be run no longer thanis absolutely necessary.



Road OperationTo receive satisfactory engineperformance with maximum fueleconomy, the following generalguidelines should be followed whenoperating the vehicle:

□ Start the vehicle in motion byusing the highest gear speed in thetransmission that will move theload without slipping the clutch.

□ Once in motion, acceleratesmoothly and evenly toengine rated speed. Rapidacceleration will result in highfuel consumption with no increasein performance.

□ To avoid “lugging,” do not allowengine speed to drop below peaktorque when pulling at full throttle.

□ When approaching a hill, depressthe accelerator smoothly to startthe climb at full power, thenshift down as needed to maintainmaximum permitted vehiclespeed, depending on conditions.

NOTICE:Do not allow the engine tooverspeed when descending agrade with a load. Operating theengine beyond high idle speed cancause severe damage.

□ Prevent overspeeding of the enginewhen descending a long and steepgrade. The electronic governorhas no control over engine speedwhen it is being pushed by theloaded vehicle. Operate in a gearthat will permit an engine speednot in excess of high idle rpm.

Cold Weather OperationObserve the following instructionsbefore operating the engine intemperatures of 32 °F (0 °C):

1. Ensure batteries are of sufficientsize and are fully charged. Checkthat all other electrical equipmentis in optimum condition.

2. Fill the cooling system withrequired coolant. Periodicallycheck level and top off, ifnecessary. Refer to section G.How to Select Coolant in thisguide.

3. At the end of each day's operation,allow the engine to cool andthen drain the water from thefuel/water separator, if equipped.Fill the fuel tank with requiredfuel to prevent condensation.Refer to section D. How to SelectFuel Oil in this guide.

4. Use the proper lubricating oilfor the ambient temperaturesencountered. Refer to section A.How to Select Lubricating Oil



in this guide. Check the lube oillevel at the start of each day andtop off, if necessary.

5. At temperatures between 10 °F(–12 °C ) and 20 °F (–7 °C), DDCrecommends using an ether-startkit and block heater. An on/offfan is also recommended.

6. At temperatures below 20 °F (–7°C), an ether-start kit, coolantheater and oil pan heater arerequired. Contact an authorizedDetroit Diesel distributor aboutspecial cold weather equipmentand precautions.

Hot Weather OperationObserve the following instructionsbefore operating the engine in hotweather.

1. Ensure the battery has the properamount of electrolyte in eachcell, if not a maintenance–freebattery. Top off cells with distilledwater, or as per manufacturer'sinstructions.

2. Fill the cooling system withrequired coolant. Periodicallycheck level and top off, ifnecessary. Refer to section G.How to Select Coolant in thisguide.

3. At the end of each day's operation,allow the engine to cool andthen drain the water from the

fuel/water separator, if equipped.Fill the fuel tank with requiredfuel to prevent condensation.Refer to section D. How to SelectFuel Oil in this guide.

4. Keep the external surfaces of theengine, radiator and accessoriesclean to avoid dirt buildup, whichcould lead to engine overheating.

Extended Idling PeriodsAvoid extended idling, especiallyat low engine speeds. The low idlespeed for Series 40 vehicle enginesis 700 rpm, while the low idle forconstruction/industrial engines isnormally 800 rpm. If idling for longperiods is necessary, use the optionalelectronic fast idle feature. Dieselengine efficiency is improved whencylinder temperatures remain high.

If cylinder temperatures are too low,the following may occur:

1. Unburned fuel, which has thedark-colored appearance oflubricating oil, may seep fromthe exhaust manifold gasketsand vehicle exhaust systemconnections. This seepageis commonly called exhaust“slobber.”

2. Cylinder temperature will betoo low to allow completecombustion and unburned fuelwill wash lubricating oil from the



cylinder liners. The unburned fuelwill be carried into the lubricatingoil, causing fuel dilution.

3. Carbon deposits will form onfuel injector tips, causing nozzleplugging.

4. Carbon deposits will form on theturbine wheel of the turbocharger,reducing turbocharger efficiency.

A CAP (cold ambient protection)system has been added to the ECMsused on vehicles. This software aidsin engine warm-up and helps maintainoptimum engine heat during extendedidling periods.

After five (5) minutes of idle timewith the intake air temperature below32 °F (0 °C), the CAP will slowlyramp up the engine idle speed to900 rpm (engines with automatictransmissions) or 1400 rpm (engineswith manual transmissions). Enginespeed will increase or decrease toan rpm that will maintain a coolanttemperature of 160 °F (71 °C).

NOTE:The lower CAP rpm limit for engineswith automatic transmissionsminimizes the possibility of vehiclelurch, should the operator place theshift lever in gear without first applyingthe service brakes to lower the idlespeed to 700 rpm.

The cycle described above willcontinue until one or a combination ofany of the following occurs:

□ Engine load is greater than 25%.

□ Brake pedal is applied or brakeswitch fault is detected.

□ Clutch pedal is depressed or clutchpedal switch fault is detected(manual transmission).

□ Shift selector is moved fromneutral to forward or reverse range(automatic transmission).

□ PTO switch, also used forelectronic hand throttle, is turnedon.

□ Accelerator pedal is depressed oraccelerator pedal sensor fault isdetected.

□ Timed idle shutdown is enabled.

□ CTO (coolant temperature sensor)fault is detected.

□ AIT (ambient air intaketemperature) sensor fault isdetected.



SERIES 40 ELECTRONIC CONTROL SYSTEM

Series 40 engines use a consolidatedengine controller (CEC) and diagnosis

system with its own ECM (electroniccontrol module). See Figure 10.

Figure 10 Typical Series 40 Engine-Mounted ECM

This system functions much likethe DDEC system, but is configureddifferently and uses its own uniquediagnostic codes. The diagnosticcodes for Series 40 engines arelisted in Table 1, Table 2 , Table 3, andTable 4.



FlashCode Circuit Description

111 ECM No Errors Detected

112 ECM_PWR Elec. System Voltage B+ Out of Range HIGH

113 ECM_PWR Elec. System Voltage B+ Out of Range LOW

114* ECT Eng. Coolant Temp Signal Out of Range LOW

115* ECT Eng. Coolant Temp Signal Out of Range HIGH

121* MAP Intake Manif. Abs. Press Signal Out of Range HIGH

122* MAPIntake Manif. Abs. Press. Signal Out

of Range LOW

123* MAP Intake Manif. Abs. Press. In range Fault

124* ICP Injection Control Press. Signal Out of Range LOW

125 ICP Injection Control Press. Signal Out of Range HIGH

131* APS/IVS Accelerator Position Signal Out of Range LOW

132* APS/IVS Accelerator Position Signal Out of Range HIGH

133* APS/IVS Accelerator Position Signal In range Fault

134* APS/IVS Accelerator Position and Idle Validation Disagree

135* APS/IVS Idle Validation Switch Circuit Fault

141 VSS Vehicle Speed Signal Out of Range LOW

142 VSS Vehicle Speed Signal Out of Range HIGH

143 CMP Wrong Number of CMP Signal Transitionsfor Cam Rev

144 CMP CMP Signal Noise Deleted* Indicates WARN Lamp on When Fault Set

Table 1 Series 40 Diagnostic Flash Codes




145 CMP CMP Signal Inactive While ICP Has Increased

151 BARO Barometric Press. Signal Out of Range HIGH

152 BARO Barometric Press. Signal Out of Range LOW

154 IAT Air Inlet Temp. Signal Out of Range LOW

155 IAT Air Inlet Temp. Signal Out of Range HIGH

211* EOP Engine Oil Press. Signal Out of Range LOW

212* EOP Engine Oil Press. Signal Out of Range HIGH

213 SCCS Remote Throttle Signal Out of Range LOW

214 SCCS Remote Throttle Signal Out of Range HIGH

215 VSS Vehicle Speed Signal Freq. Out of Range HIGH

216 HPS Hydraulic Press. Signal Out of Range LOW

221 SCCS Cruise-PTO Control Switch Circuit Fault

225 EOP EOP Sensor Signal In-Range Fault

226 HPS Hydraulic Press. Sensor Signal Out of Range HIGH

231 ATA ATA Data Communication Link Error

236 ECLECL Switch Circuit Fault

241 IPR Injection Control Press. Regulator OCCSelf Test Failed

244 EDL Engine to Trans. Data Line OCC Self Test Failed

246 FAN Engine Fan — OCC Self Test Fault

256 RSE Radiator Shutter Enable OCC Fault

262 COL Change Oil Lamp OCC Fault

263 OWL Oil Water Lamp OCC Fault

265 VRE Vehicle Retarder Relay OCC Fault

266 WEL Engine Warning Light OCC Fault* Indicates WARN Lamp on When Fault Set

Table 2 Series 40 Diagnostic Flash Codes (continued)




311* EOT Engine Oil Temp. Signal Out of Range LOW

312* EOT Engine Oil Temp. Signal Out of Range HIGH

313 EOP** Engine Oil Press. Below Warning Level

314 EOP** Engine Oil Press. Below Critical Level

315* — Engine Speed Above Warning Level

316 — Engine Coolant Temp. Unable to ReachCommanded Set Point

321 ECT** Engine Coolant Temp. Above Warning Level

322 ECT** Engine Coolant Temp. Above Critical Level

323 ECL Engine Coolant Below Warning / Critical Level

324 ECT Idle Shutdown Timer Enabled Engine Shutdown

325 ECT“Power Reduced, Matched to Cooling

System Performance”

331* IPRInjection Control Press. Above System

Working Range

332* ICP Injection Control Press. Above Spec with Engine Off

333* IPR Injection Control Press. Above/Below Desired Level

334 IPR_SYS ICP Unable to Achieve Setpoint in Time(Poor Performance)

335 IPR_SYS ICP Unable to Build Pressure During Cranking

336 HGE —

421 – 426 INJHigh Side to Low Side Open (Cyl.

Number Indicated)

431 – 436 INJHigh Side Shorted to Low Side

(Cyl. Number Indicated)

451 – 456 INJHigh Side Shorted to Ground or V Bat.

(Cyl. Number Indicated)* Indicates WARN Lamp on When Fault Set

Table 3 Series 40 Diagnostic Flash Codes (continued)




461 – 466 Perf. Diag. Cylinder Contrib. Test Failed (CylNumber Indicated)

513* INJ Low Side to Bank 1 Open

514* INJ Low Side to Bank 2 Open

515* INJ Bank 1 Low Side Short to Ground or B+

521* INJ Bank 2 Low Side Short to Ground or B+

525 ECM Injector Driver Circuit Fault

612* CMP Incorrect ECM Installed for CMP Timing Wheel

614* ECM EFRC/EECM Configuration Mismatch

621* ECM Engine Using Mfg. Default Rating Program Engine

622* ECM Engine Using Field Default Rating

623* ECM Invalid Engine Rating Code; ECM Programming

624 ECM Field Default Active

626 ECM Unexpected Reset Fault

631 ECM ROM (Read-Only Memory) Self Test Fault

632 ECM RAM Memory - CPU Self Test Fault

655 ECM Programmable Parameter List Level Incomplete

661 ECM RAM Programmable Parameter List Corrupt

664 ECM Calibration Level Incompatible

665 ECM Programmable Parameter Memory Content Corrupt* Indicates WARN Lamp on When Fault Set

Table 4 Series 40 Diagnostic Flash Codes


SERIES 40 ENGINE SYSTEMS

SERIES 40 ENGINE SYSTEMS

Fuel SystemThe fuel system consists ofthe fuel pump, hydraulicallyactivated/electronically controlledunit injector assemblies, fuel pipes,fuel strainer and filter, and fuel lines.

Lubrication SystemThe lubrication system consists of theoil pump, oil cooler, oil strainer andfilter, bypass and pressure regulatorvalves, oil temperature control valve,and lubricating oil lines.

Cooling SystemThe cooling system consists ofa centrifugal-type fresh waterpump, full-blocking thermostat,charge air cooler, radiator, andthermo-modulated fan. The freshwater pump circulates coolant withinthe engine and through the oil cooler,radiator and air-to-air charge cooler.The thermostat installed in a recessin the left-front corner of the cylinderhead controls the flow of coolant,while the thermo-modulated fancontrols the flow of air through theradiator and charge cooler.

Electrical SystemThe electrical system consists ofthe starting motor, starting switch,

battery-charging alternator, storagebatteries and necessary wiring.

Air Induction SystemThe air induction system consists ofthe air cleaner, air-to-air charge cooler(some applications), compressor sideof the turbocharger, valve cover/intakemanifold and intake valves. Outsideair is drawn through the air cleanerand into the turbocharger where it iscompressed. It then flows through theair-to-air charge cooler, into the intakemanifold and into the cylinders whereit mixes with atomized fuel from theinjector nozzles.

Exhaust SystemThe exhaust system consists of theexhaust valves, exhaust manifold,turbine side of the turbocharger,exhaust piping and muffler. Hotexhaust gases flowing from theexhaust manifold into the exhaust riserdrive the turbocharger. Exhaust gasesthen pass through the muffler and outto atmosphere.



MAINTENANCE SCHEDULES

Maintenance IntervalsRecommended maintenance intervalsfor Series 40 motor coach enginesare listed in Table 5, Table 6 andTable 7. Recommended maintenanceintervals for Series 40 transit coachengines are listed in Table 8, Table9, and Table 10. Recommendedmaintenance intervals for Series 40construction/industrial and stationaryengines are listed in Table 11, Table12, and Table 13. Recommendedmaintenance intervals for Series40 fire fighting, crash/rescue, andemergency vehicle engines arelisted in Table 14, Table 15, and Table16. Recommended maintenanceintervals for Series 40 generator driveengines are listed in Table 17, Table18, and Table 19.

NOTICE:Failure to check and maintainSCA (supplemental coolantadditive) levels at requiredconcentrations will result insevere damage (corrosion)to the engine cooling systemand related components.Coolant must be inhibited with therecommended SCAs listed in thisguide. Refer to section G. Howto Select Coolant. In addition, theengine can be equipped with acoolant filter/inhibitor system as aninstalled option or as an after-saleitem.



Item DailyChecks

6,000Miles(9,600Km)

12,000Miles

(19,200Km)

18,000Miles

( 28,800Km)

24,000Miles

( 28,800Km)

1 – Lubricating Oil* I R R

2 – Fuel Tank* I3 – Fuel Lines & FlexHoses* I

4 – Cooling System* I I I I I5 – Turbocharger, A/ACharge Cooler* I I

6 – Battery* I

7– Drive Belt* I8 – Air Compressor* I I I I

9 – Air Cleaner*

10 – Lube Oil Filters* R R

11 – Fuel Filters* R12 – Water Pump/Inhibitor Level* I

14 – Air System* I I I I* – See item in text.I – Inspect, service, correct or replace as necessary.R – Replace.

Table 5 Motor Coach Daily, 6,000 Mile, 12,000 Mile and 18,000Mile Checks



Months 6 12 18 24 30 36 42 48 54 60Item Miles/Km

( X 1000)12/19

24/38

36/58

48/77

60/96

72/115

84/134

96/154

108/173

124/198

1- LubricatingOil*

Replace lubricating oil every 12,000 miles (19,200 km).

2- Fuel Tank* I I I I I4- CoolingSystem* I I

5 -Turbocharger,A/A Charge

Cooler*

I I I I I I I I I I

6 - Battery*

7- Drive Belt*Inspect at each oil change.

Replace every 100,000 miles (160,000 km).8- AirCompressor* I I I I I I I I I I

9 - Air Cleaner* I I I I I I I I I I10 - Lube OilFilter*

Replace when lubricating oil is changed.

11 - Fuel Filters* R R12 - WaterPump/ InhibitorLevel*

I I I I I I I I I I

13 - CrankingMotor* Follow manufacturer's recommendations.

14 - Air System* I I I I I I I I I I15 - ExhaustSystem* I I I I I I I I I I

* – See item in text.I – Inspect, service, correct or replace as necessary.R – Replace.

Table 6 Motor Coach Regular Maintenance Intervals




( X 1000)12/19

24/38

36/58

48/77

60/96

72/115

84/134

96/154

108/173

124/198

16 - Engine(Steam Clean)* I I

17 - Radiator* I I I I I18 - OilPressure* I I

19 - BatteryChargingAlternator*

I I I I I I I I I I

20 - Engine &TransmissionMounts*

I I

21 - CrankcasePressure* I I

22 - Fan Hub*Inspect every 15,000 miles or every oil change.

Replace every 60,000 miles.23 -Thermostats& Seals*

I

24 - CrankcaseBreather* I

25 - EngineTune-Up* I

26 - Idler Pulley* Inspect every 45,000 miles (72,000 km).Replace every 60,000 miles (96,000 km).

27 - VibrationDamper*

Inspect once a year. Replace at major engine overhaulor earlier if dented or damaged.


Table 7 Motor Coach Regular Maintenance Intervals (continued)



Item DailyChecks

6,000Miles(9,600Km)

12,000Miles

(19,200Km)

18,000Miles

(28,800Km)

24,000Miles

(38,400Km)

1 - Lubricating Oil* I R R R R

2 - Fuel Tank* I3 - Fuel Lines & FlexibleHoses* I

4 - Cooling System* I5 - Turbocharger, A/ACharge Cooler* I I

6 - Battery* I I

7 - Drive Belt* I I I8 - Air Compressor* I

9 - Air Cleaner* I I I I I

10 - Lube Oil Filters* R R R R

11 - Fuel Filters* R R12 - Water Pump/Inhibitor Level* I I


Table 8 Transit Coach Daily, 6,000 Mile, 12,000 Mile, and 18,000Mile and 24,000 Mile Checks




( X 1000)15/24

30/48

45/72

60/96

75/120

90/144

105/168

120/192

135/216

150/240

1 - LubricatingOil*

Replace lubricating oil every 12,000 miles (19,200 km).

2 - Fuel Tank* I I I I I4 - CoolingSystem* I I

5 -Turbocharger,A/A ChargeCooler*

I I I I I I I I I I

6 - Battery*

7 - Drive Belt*Inspect at each oil change.

Replace every 100,000 miles (160,000 km).8 - AirCompressor* I I I I I I I I I I

9 - Air Cleaner* I I I I I I I I I I10 - Lube OilFilters*


11 - Fuel Filters* R R R R R12 - WaterPump/ InhibitorLevel*

I I I I I I I I I I


14 - Air System* I I I I I I I I I I* – See item in text.I – Inspect, service, correct or replace as necessary.R – Replace.

Table 9 Transit Coach Regular Maintenance Intervals




( X 1000)15/24

30/48

45/72

60/96

75/120

90/144

105/168

120/192

135/216

150/240

15 - ExhaustSystem* I I I I I I I I I I

16 - Engine(Steam Clean)* I I



I I I I I I I I I I


I I



Replace every 60,000 miles.23 -Thermostats& Seals*

I I I

24 - CrankcaseBreather* I I I

25 - EngineTune-Up* I I I

26 - Idler Pulley* Inspect every 45,000 miles (72,000 km).Replace every 60,000 miles (96,000 km).




Table 10 Transit Coach Regular Maintenance Intervals (continued)



Item DailyChecks

100Hours

150Hours

200Hours

300Hours

450Hours

1 - LubricatingOil* I R

2 - Fuel Tank* I I3 - Fuel Lines& FlexibleHoses*

I

4 - CoolingSystem* I


I

6 - Battery* I

7 - Drive Belt* I8 - AirCompressor* I

9 - AirCleaner* I

10 - Lube OilFilters* R

11 - FuelFilters* R

12 - WaterPump/InhibitorLevel*

I

17 - Radiator* I19 - BatteryChargingAlternator*

I


Table 11 Stationary or Construction/Industrial Engine Daily, 100Hour, 150 Hour, 200 Hour, and 300 Hour Checks



Item Hours 150 300 450 600 750 900 1,050 1,200 1,350 1,5001 - LubricatingOil*

Change lubricating oil every 450 hours or 1 year,whichever comes first.

2 - Fuel Tank* I I I I I4 - CoolingSystem* I I


I I I I I I I I I I

6 - Battery* I I I I I I I I I I

7 - Drive Belt*Inspect at each oil change.Replace every 2,000 hours.

8 - AirCompressor* I I I I I I I I I I

9 - Air Cleaner* I I I I I I I I I I10 - Lube OilFilters*


11 - Fuel Filters* R R R R R12 - WaterPump/ InhibitorLevel*

I I I I I I I I I I


14 - Air System* I I I I I I I I I I* – See item in text.I – Inspect, service, correct or replace as necessary.R – Replace.

Table 12 Stationary or Construction/Industrial Regular MaintenanceIntervals



Item Hours 150 300 450 600 750 900 1,050 1,200 1,350 1,50015 - ExhaustSystem* I I I I I I I I I I

16 - Engine(Steam Clean)*



I I I I I


I I


22 - Fan Hub*Inspect every 150 hours.

Replace every 1,000 hours.23 -Thermostats& Seals*24 - CrankcaseBreather* I


26 - Idler Pulley* Inspect every 1,500 hours.Replace every 2,000 hours.




Table 13 Stationary or Construction/Industrial Regular MaintenanceIntervals (continued)



Item DailyChecks

100 Hours or3,000 Miles( 4,800 Km)

300 Hoursor 6,000

Miles( 9,600 Km)

1 - Lubricating Oil* I R

2 - Fuel Tank* I

3 - Fuel Lines & Flexible Hoses* I4 - Cooling System* I5 - Turbocharger, A/A ChargeCooler* I

6 - Battery* I

7 - Drive Belt* I8 - Air Compressor* I I

9 - Air Cleaner* I I

10 - Lube Oil Filter* R

11 - Fuel Filters*12 - Water Pump/ Inhibitor Level* I

17 - Radiator* I19 - Battery Charging Alternator* I* – See item in text.I – Inspect, service, correct or replace as necessary.R – Replace.

Table 14 Fire Fighting, Crash/Rescue and Emergency VehicleEngine Daily, 100 Hour and 300 Hour Checks



Hours 300 600 900 1,200 1,500Item Miles/Km

(X 1000)6/

1.612/9.6

18/28.8

24/38.4

30/48

1 - Lubricating Oil* Change lubricating oil every 300 hours or 6,000miles (9,600 km), whichever comes first.

2 - Fuel Tank* I I I I I4 - Cooling System* I I5 - Turbocharger, A/ACharge Cooler*6 - Battery* I I I I I


8 - Air Compressor* I I I I I

9 - Air Cleaner*

10 - Lube Oil Filters* Replace when lubricating oil is changed.

11 - Fuel Filters* R R12 - Water Pump/ InhibitorLevel* I I I I I

13 - Cranking Motor* Follow manufacturer's recommendations.14 - Air System* I I I I I15 - Exhaust System* I I I I I* – See item in text.I – Inspect, service, correct or replace as necessary.R – Replace.

Table 15 Fire Fighting, Crash/Rescue and Emergency VehicleEngine Regular Maintenance Intervals



Hours 300 600 900 1,200 1,500Item Miles/Km

(X 1000)6/

1.612/9.6

18/28.8

24/38.4

30/48

16 - Engine (Steam Clean)*

17 - Radiator* I I I I I

18 - Oil Pressure* I I19 - Battery ChargingAlternator* I I I I I

20 - Engine & TransmissionMounts* I I

21 - Crankcase Pressure* I I


Replace every 60,000 miles.

23 - Thermostats & Seals*

24 - Crankcase Breather* I25 - Engine Tune-Up* I

26 - Idler Pulley*

Inspect every 45,000 miles (72,000 km)or 1,500 hours.

Replace every 60,000 miles (96,000km) or 2,000 hours.

27 - Vibration Damper* Inspect once a year. Replace at major engineoverhaul or earlier if dented or damaged.


Table 16 Fire Fighting, Crash/Rescue and Emergency VehicleEngine Regular Maintenance Intervals (continued)



ItemPrimeDaily

StandbyMonthly

1 - Lubricating Oil* I I #

2 - Fuel Tank* I I

3 - Fuel Lines & Flexible Hoses* I4 - Cooling System* I I #5 - Turbocharger, A/A Charge Cooler* I6 - Battery* I

7 - Drive Belt* I I

9 - Cleaner* I I11 - Fuel Filter, Water Separator* I I #

18 - Oil Pressure* I I #

Load Test P* See item in text.I – Inspect, service, correct or replace as necessary.P – Perform# Perform these items at time of load test. Load test should be at

least 35% of the unit's full rated output. Refer to generator setmanufacturer's instructions.

Table 17 Generator Set Engine Prime Daily and Standby MonthlyMaintenance Intervals



HoursItem

150 300 600 900 1,200 1,500 1,800 2,100

1 - LubricatingOil*

Prime: Replace every 300 hours or 3 months,whichever comes first.

Standby: Replace every 450 hours or 1 year,whichever comes first.

2 - Fuel Tank* I3 - Fuel Lines& FlexibleHoses*

I R

4 - CoolingSystem* R


I

6 - Battery* I


9 - Air Cleaner* I I I I I I I I10 - Lube OilFilters*


11 - FuelFilters*

Prime: Replace every 500 hours or 6 months,whichever comes first.

Standby: Replace every 300 hours or 1 year,whichever comes first.

12 - WaterPump/ InhibitorLevel*

I


* See item in text.I – Inspect, service, correct or replace as necessary.R – Replace

Table 18 Generator Set Engine Regular Maintenance Intervals



HoursItem

150 300 600 900 1,200 1,500 1,800 2,10014 - Air System* I15 - ExhaustSystem* I

16 - Engine(Steam Clean)* I

17 - Radiator* I18 - OilPressure* I


I

20 - Engine& GeneratorMounts*

I

21 - CrankcasePressure* I

22 - Fan Hub*Inspect every 150 hours.

Replace every 1,000 hours.23 - Thermostat& Seals* R

24 - CrankcaseBreather* I


26 - Idler Pulley* Inspect every 1,500 hours.Replace every 2,000 hours.


Inspect once a year.Replace at major engine overhaul or earlier if

dented or leaking.* See item in text.I – Inspect, service, correct or replace as necessary.R – Replace

Table 19 Generator Set Engine Regular Maintenance Intervals(continued)



LUBRICATION AND PREVENTIVE MAINTENANCEINTERVALS

The following is intended as aguide for establishing preventivemaintenance intervals. Therecommendations given shouldbe followed as closely as possibleto obtain long life and optimumperformance from your engine.Maintenance intervals indicated aretime (hours) of actual operation.

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

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

For new or stored engines, refer toRestoring an Engine to Service afterExtended Storage in this guide.

Preventive maintenance other than the“Daily” checks should be performedby authorized Detroit Diesel serviceoutlets. These outlets have the trainedpersonnel and special tools to properlyperform all services.

Item 1 – Lubricating OilCheck the oil level daily with theengine stopped. If the engine has

just been stopped and is warm, waitapproximately 20 minutes to allow theoil to drain back into the oil pan beforechecking. Add the proper grade of oilto maintain the correct level on thedipstick.

See Figure 11 for the current oil levelgage. When using this dipstick, keepthe oil level within the cross-hatchedarea.

Figure 11 Current Oil Level Gage

See Figure 12 for the former oil levelgage. When using this dipstick, keepthe oil level between the “Full” and“Add” lines.


LUBRICATION AND PREVENTIVE MAINTENANCE INTERVALS

Figure 12 Former Oil Level Gage

NOTICE:When adding lubricating oil, donot overfill. Oil may be blown outthrough the crankcase breather ifthe crankcase is overfilled. For totalengine oil capacity, refer to sectionEngine Oil Capacity.

All diesel engines are designed to usesome oil, so the periodic addition ofoil is normal.

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

Before adding lubricating oil,refer to section A. How to SelectLubricating Oil in this guide. Change

lubricating oil and filters at theintervals listed in Table 20 whenusing fuel with a sulfur content ofless than 0.05 mass percent. Whenusing fuel with a higher sulfur content,refer to section B. When to ChangeOil.



Service Application Lube Oil and Filter Change Interval*Motor Coach 12,000 Miles (19,200 Kilometers)

City Transit Coach 6,000 Miles (9,600 Kilometers)

Fire Fighting, Crash/Rescue, &Emergency Vehicles

6,000 Miles (9,600 Kilometers), 300Hours or 1 Year, whichever comes first

Stationary or Construction/ Industrial& Agricultural

450 Hours or 1 Year, whichever comesfirst

Stationary Generator – Prime Poweror Continuous

300 Hours or 3 Months, whichevercomes first

Stationary Generator – Standby 450 Hours or 1 Year, whichever comesfirst

* Change both full-flow filters when lube oil is changed.

Table 20 Recommended Maximum Oil Drain/Filter Change Intervals(Diesel Fuel Sulfur Content Less Than 0.05 Mass %)

The length of time an engine mayoperate before an oil change dependsupon the lubricant and fuel used,engine oil consumption, and theoperating cycle. The maximuminterval at which the engine mayoperate before the oil and filtersmust be changed is listed in Table20. Oil analysis may be used todetermine whether this interval shouldbe shortened, but it should not be usedto lengthen the interval.

Item 2 – Fuel and Fuel Tank

Figure 13 Keep Fuel Tank Filled toReduce Condensation

Keep the fuel tank filled to reducecondensation. Before adding fuel,refer to section D. How to Select FuelOil in this guide. See Figure 13.



Refill the tank at the end of each day'soperation to prevent condensationfrom contaminating the fuel.Condensation formed in a partiallyfilled tank promotes the growth ofmicroorganisms that can clog fuelfilters and restrict fuel flow.

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

To prevent microbe growth,add a biocide to the fuel tankor primary fuel supply. Wateraccumulation can be controlled byusing additives containing methylcarbitol or butyl cellusolve. Followmanufacturer's usage, handling andsafety precautions.

Open the drain at the bottom of thefuel tank every 30,000 miles (48,000kilometers) or 300 hours for stationaryand industrial engines to drain off anywater and/or sediment.

Every 120,000 miles (192,000kilometers), 12 months, or 600hours for construction/industrialapplications tighten all fuel tankmountings and brackets. At the same

time, check the seal in the fuel tankcap, the breather hole in the cap andthe condition of the flexible fuellines. Repair or replace the parts, asnecessary.

NOTICE:Galvanized steel fuel tanks, fittings,pipes or supply lines should neverbe used, because the fuel reactschemically with the zinc coating toform powdery flakes that can quicklyclog the fuel filters and damage thefuel pump and injectors.

Item 3 – Fuel Lines,Flexible Hoses

Pre-Start Inspection

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




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

Hoses and Fittings– Check hosesdaily as part of the pre-start inspection.Examine hoses for leaks, and checkall fittings, clamps and ties carefully.Make sure hoses are not restingon or touching shafts, couplings,heated surfaces including exhaustmanifolds, any sharp edges, or otherobviously hazardous areas. Since allmachinery vibrates and moves to acertain extent, clamps and ties canfatigue with age. To ensure continuedproper support, inspect fastenersfrequently and tighten or replace themas necessary. If fittings have loosenedor cracked or if hoses have ruptured orworn through, take corrective actionimmediately.

Hose Service Life

A hose has a finite service life. Withthis in mind, all hoses should bethoroughly inspected at least every

500 operating hours (1,000 hoursfor fire-resistant fuel and lubricatingoil hoses) and/or annually. Lookfor cover damage and/or indicationsof twisted, worn, crimped, brittle,cracked or leaking lines. Hoses withtheir outer cover worn through or withdamaged metal reinforcements shouldbe considered unfit for further service.

All hoses in and out of machineryshould be replaced during majoroverhaul and/or after a maximum offive (5) years of service.

NOTE:Fire-resistant fuel and lube oil hoseassemblies do not require automaticreplacement after five years of serviceor at major overhaul, but should beinspected carefully before being putback into service.



Item 4 – Cooling System


Coolant Level

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

With the engine stopped, check thecoolant level daily and maintain itnear the bottom of the filler neck onthe radiator. On some installationsthis is done by checking an overflowbottle or sight glass. Add coolant asrequired, but do not overfill. Beforeadding coolant, refer to section G.How to Select Coolant in this guide.

Make a daily visual check forcooling system leaks. Look for anaccumulation of coolant when theengine is running and when it isstopped. Coolant leaks may be moreapparent on a engine when it is cold.

Coolant Inhibitors

NOTICE:Coolant must be inhibited with therecommended SCA's (supplementalcoolant additives) listed in thisguide. In addition, the enginecan be equipped with a coolantfilter/inhibitor system as aninstalled option or as an after-saleitem. Failure to check andmaintain SCA levels at requiredconcentrations will result insevere damage (corrosion) tothe engine cooling system andrelated components.

Check the coolant SCA (supplementalcoolant inhibitors) at the intervalslisted in Table 28. The inhibitorsin antifreeze solutions must bereplenished with a non-chromatecorrosion inhibitor supplement whenindicated. Refer to section G. How toSelect Coolant for required inhibitorlevels.

Coolant Drain Interval

Detroit Diesel recommendsreplacing coolant at the intervalslisted in Table 21.



A coolant system properly maintainedand protected with supplementalcoolant inhibitors can be operatedup to the intervals listed. Atthese intervals the coolant must

be drained and disposed of in anenvironmentally responsible manneraccording to state and/or federal(EPA) recommendations.

Coolant Type Coolant Replacement IntervalA 50/50 mix of Power Cool® fullyformulated, inhibited ethylene glycolantifreeze and water or a 50/50 mix offully formulated, inhibited propyleneglycol antifreeze and water

With proper maintenance1 coolantcan be operated 2 years, 300,000miles (480,000 km), or 4,000 hours,whichever comes first. At this time thecooling system must be completelydrained and cleaned before refill.

A 50/50 mix of phosphate-free TMCRP-329 “Type A“ (propylene glycol)antifreeze and water.

With proper maintenance1 coolant canbe operated for the life of the engineuntil overhaul.2 For life to overhaul,pre-charged coolant in combinationwith a need-release filter must beused. At this time the cooling systemmust be completely drained andcleaned before refill.

A 50/50 mix of OAT (organic acidtechnology) coolant and water.

With proper maintenance coolant canbe operated 4 years, 600,000 miles(960,000 km), or 10,000 operatinghours, whichever comes first. 3 Atthis time the cooling system mustbe completely drained and cleanedbefore refill.

1 Proper maintenance involves periodic evaluation using PowerTrac®3-Way Coolant Test Strips and the addition of required SCA, asindicated by the test strip.

2 To verify coolant acceptability, submit a sample to DDC for coolantanalysis every 3 years, 300,000 miles (480,000 km) or 6,000operating hours, whichever comes first. Submit sample usingPowerTrac coolant analysis kit, part number 23516921 (IEG/IPGcoolant) or 23523398 (organic coolant).

3 OAT coolants require the addition of an extender every 2 years,300,000 miles (480,000 km), or 5,000 hours, whichever comes first.Use 1 pint to 20 gallons of OAT coolant.

Table 21 Coolant Drain Intervals



Item 5 – Turbocharger,Air-to-Air Charge Cooler


Visually inspect the turbochargermountings, intake and exhaust ductingand connections for leaks daily. Checkthe lube oil inlet and outlet lines forleaks or restrictions to oil flow. Checkfor unusual noise or vibration and, ifexcessive, stop the engine and do notoperate until the cause is determined.

Periodically inspect the charge aircooler (if used) for buildup of dirt,mud, etc. and wash off. Checkthe charge cooler, ductwork, andflexible connections for leaks andhave repaired or replaced, as required.

Check turbocharger heat-insulatingexhaust system blankets (if used) fordamage on a daily basis. Torn, matted,crushed, oil-soaked or otherwisedamaged insulation blankets must bereplaced immediately.

Wastegated Turbochargers – Theturbocharger wastegate actuatoris factory-calibrated and is notadjustable.

NOTE:If lack of engine performance isnoted after high-mileage operation,the turbocharger wastegate shouldbe checked for proper operation.Authorized Detroit Diesel distributorshave the trained personnel and areproperly equipped to perform thisservice.

Item 6 – Battery

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

Check the hydrometer “eye” ofmaintenance-free batteries for charge.See Figure 14. If lead-acid orlow-maintenance batteries are used,check the specific gravity of each cellevery 150 operating hours. Checkmore frequently in warm weather dueto the more rapid loss of water throughevaporation.



Figure 14 Check “Eye” ofMaintenance-FreeBatteries

Maintain the electrolyte levelaccording to the battery manufacturer'srecommendations, but do not overfill.Overfilling can cause poor batteryperformance or early failure.

Keep the terminal side of the batteryclean. When necessary, wash witha solution of baking soda and water.Rinse with fresh water. Do not allowthe soda solution to enter the cells.

Inspect the cables, clamps andhold-down brackets regularly. Cleanand reapply a light coating ofpetroleum jelly when needed. Havecorroded or damaged parts replaced.

If the engine is to be out of servicefor more than 30 days, remove thebatteries and store in a cool, dryplace. Keep batteries fully charged,

if possible. Replace any battery thatfails to hold a charge.

Periodically check battery connectionsfor corrosion and tightness. Ifnecessary, remove connectionsand wire brush any corrosion fromterminals and cable ends. Replacedamaged wiring.

Item 7– Drive BeltInspect the serpentine drive beltafter every oil change. Replace beltevery 100,000 miles (160,000 km)on vehicle engines or every 2,000hours on construction/industrial andstationary engines. Replace earlier ifbelt shows signs of excessive wear ordamage.

Always replace the drive belt with thequality belt specified for your engineto ensure the belt will be neither tootight nor too loose. A belt that istoo tight imposes extra loads on thecrankshaft, water pump, alternator andfan hub bearings, shortening both beltand bearing life. A loose belt will slipand may cause damage to accessorycomponents.

Before installing the drive belt, checkthe torque on the alternator andbracket mounting bolts. Retighten asrequired. The drive belt idler pulleyshould also be inspected whenever thebelt is removed. Refer to Item 26 –Idler Pulley.



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

Item 8 – Air Compressor

Figure 15 Typical Air CompressorAssembly

All air compressor intake partsshould be removed and cleaned at thefollowing intervals:

□ Motor Coach, Transit Coach,Crash/Rescue, Pick-Up andDelivery Vehicle Engines – 6,000miles (9,600 km)

□ Construction/IndustrialEngines/Stationary Engines–

150 Hours or 4,500 miles (7,200km)

To clean either the hair type or thepolyurethane type compressor airstrainer element, saturate it andsqueeze it in fuel oil or any othercleaning agent that is not detrimentalto the element until it is dirt-free. Thensaturate the element in lubricating oiland squeeze it dry before placing itback into the air strainer.

For air strainer replacement,contact the nearest servicing dealer.Replace hair type elements with thepolyurethane type, if available.

The air compressor mounting boltsshould be tightened every 12 monthsor 30,000 miles (48,000 km) forvehicle engines or every 300 hours forstationary and industrial engines.

Item 9 – Air CleanerCheck the air cleaner restrictionindicator daily and service, if required.Inspect the air cleaner element every12,000 miles (19,200 km) for vehicleengines, or 150 hours for stationaryand industrial engines. Inspect moreoften if the engine is operated undersevere dust conditions. Replace theelement, if necessary. Check thegaskets for deterioration and replace,if necessary. If the dry type air cleaneris equipped with an aspirator, checkfor aspirator damage or clogging.Clean, repair or replace, as necessary.



NOTICE:Do not allow the air inlet restrictionto exceed 20 inches of water (5.0kPa) under any engine operatingconditions. A clogged air cleanerelement will cause excessiveintake restriction and a reducedair supply to the engine. This, inturn, can result in increased fuelconsumption, inefficient engineoperation and reduced engine life.

Inspect the entire air system for leaksdaily. Look especially for torn air inletpiping or boots and loose or damagedclamps. Have worn or damaged partsrepaired or replaced, as required.Retighten loose connections.

Air Cleaner Replacement

Dry type air cleaner elementsshould be replaced after one yearof service or when the maximumallowable air intake restriction hasbeen reached, whichever comes first.Refer to section J. When to Servicethe Dry Type Air Cleaner in this guidefor additional information.

Item 10 – Lubricating OilFilter


Install new spin-on oil filters wheneverthe engine oil is changed. Oil changeintervals are listed in Table 20.Refer to section C. How to Replacethe Lube Oil Filter for procedure.See Figure 16 for typical filterinstallation.

1. Oil CoolerAssembly

3. Oil FilterHeader

2. Oil Filter

Figure 16 Typical Oil FilterInstallation



Make a visual check of all lubricatingoil lines for wear and/or chafing. Ifany indication of wear is evident,replace the oil lines and correct thecause.

Check for oil leaks after starting theengine.

Item 11 – Fuel Filter

Fuel Filter and Strainer

If equipped, drain the fuel/waterseparator daily.

See Figure 17 for a typical fuel filterand strainer installation. Replace thefuel filter and clean the strainer at theintervals listed in the maintenancetables or every other oil change. Forchange intervals, refer to MaintenanceIntervals. For change procedure,refer to section Replace Fuel Filterand Strainer.



1. Spin-on Fuel Filter 5. Strainer Assembly

2. Air Bleed Screw 6. Strainer

3. Air Primer Pump 7. O-Ring

4. Fuel Strainer Header 8. Body

Figure 17 Typical Fuel Filter and Strainer Installation

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

One method of determining whenfilters are plugged to the extent thatthey need replacing is based on thefuel pressure at the cylinder head fuelinlet fitting. Fuel pressure should be

no less than 60 psi (414 kPa) at normaloperating speed.

Change the fuel filters whenever thefuel pressure at the inlet fitting fallsbelow this level.



Fuel Pro® 382 Filters

Install new Fuel Pro® 382 primaryfuel filter elements when the fuellevel in the see-thru cover reaches thetop of the element or after one yearof service, whichever comes first.Refer to section Replace “Fuel Pro®382/382E” Fuel Filter Element.

Item 12 – Water Pump andCoolant Inhibitor Element

Water Pump

Water Pump Drain Hole – The waterpump drain hole should be inspectedevery 6 months to make sure it isopen. A small chemical build-upor streaking at the drain hole mayoccur. This is not an indication ofa defective water pump or seal.Remove the build-up with a milddetergent cleaner and a brush. Ifcoolant does not leak from the drainhole under normal conditions, do notreplace the water pump.

Coolant Inhibitor Element

The coolant must be tested at requiredintervals and the coolant inhibitorelement replaced, if required.

1. Spin-onInhibitorElement

2. FilterAdaptor

Figure 18 Installing CoolantInhibitor Element

Required test intervals arelisted in Table 28 . For SCAtest procedures refer to section G.How to Select Coolant and thenrefer to section SCA Test Proceduresin this guide. Use the coolant filterelement required. Refer to sectionPower Cool Engine Products forelement part number listing. Thevalves mounted on the filter adaptorhead must be opened after the elementis replaced.

Item 13 – Cranking MotorFor cranking motor (starter) assemblyinformation, contact an authorizedDelco Remy® distributor.



Item 14 – Air SystemAll the connections in the air systemshould be checked to make surethey are tight and leak free. Checkall hoses and ducting for punctures,deterioration or other damage andreplace, if necessary.

Item 15 – Exhaust SystemHave the exhaust manifold retainingbolts and other connections checkedfor tightness. Have the exhaust piperain cap checked for proper operation,if so equipped.

Item 16 – Engine (SteamClean)Steam clean the engine and enginecompartment every 60,000 miles(96,000 km) or 2,100 hours,whichever comes first. Steam cleanmore frequently, if operating in dustyor dirty environments.

NOTICE:Do not apply steam or solventdirectly to the battery-chargingalternator, starting motor, electronicengine control components, sensorsor other electrical components, asdamage to electrical equipment mayresult.

Item 17 – RadiatorThe exterior of the radiator coreshould be inspected every 30,000miles (48,000 km), 12 months, or300 hours (stationary and industrialengines) and cleaned, if necessary.


Use a quality grease solvent, suchas mineral spirits, and dry withcompressed air. Fuel oil, kerosene orgasoline should not be used.

It may be necessary to clean theradiator more frequently if the engineis being operated in extremely dustyor dirty areas.

If the low coolant level sensor isinstalled in the top tank of the radiator,it should be tested for proper operationevery 100,000 miles (160,000 km)or 12 months, whichever comes first.Authorized Detroit Diesel distributorsare properly equipped to perform thisservice.



Item 18 – Oil PressureUnder normal operation, oil pressureis noted each time the engine isstarted. In the event the equipmenthas warning lights rather than pressureindicators, the pressure should bechecked and recorded every 60,000miles (96,000 km) for vehicle enginesor every 600 hours for stationary andindustrial engines.

Item 19 – Battery-ChargingAlternator

General Service Requirements

Terminals should be checked forcorrosion and loose connectionsand wiring inspected for damageand frayed insulation. Have wiringrepaired or replaced, as required.

Check torque on alternator mountingbolts and bracketing every 15,000miles (24,000 km) on coach engines orevery 300 hours on all other engines.Retighten, if necessary.

Alternator Precautions

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






1. Avoid grounding the outputterminal. Grounding analternator's output wire orterminal (which is always “hot,”regardless of whether or notthe engine is running) andaccidentally reversing the batterypolarity will result in equipmentdamage.

2. Do not reverse batteryconnections. This can alsocause damage.

3. Never disconnect the batterywhile the alternator is operating.



Disconnecting the battery canresult in damage to the batterydiodes. In applications whichhave two (2) sets of batteries,switching from one set to theother while the engine is runningwill momentarily disconnectthe batteries. This can result inequipment damage.

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

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

For information on the alternatorassembly, contact an authorized DelcoRemy® distributor.

Item 20 – Engine andTransmission MountsThe engine and transmission mountingbolts and the condition of the mountingpads should be checked every 60,000miles (96,000 km) or 600 hours.Tighten and/or repair as necessary.

Item 21 – CrankcasePressureThe crankcase pressure should bechecked and recorded at the intervalsin the maintenance schedules.Crankcase pressure should be no

higher than 6 in. water (1.5 kPa) atmaximum no-load speed with thebreather restrictor tool installed.

Item 22 – Fan HubThe fan hub assembly includesa sealed bearing which is notserviceable.

□ Inspection Interval: Inspect thefan hub for free bearing rotation atthe interval shown in the regularmaintenance interval table foryour engine. If the hub does notspin freely or is noisy (indicatingbearings are “dry” or worn),replace the fan hub.

□ Replacement Interval: Replacethe fan hub at the interval shownin the regular maintenance intervaltable for your engine, regardlessof apparent condition.



Item 23 – Thermostat andSeal

1. Thermostat 3. Cylinder Head

2. Seal

Figure 19 Typical ThermostatInstallation

Replace the thermostat and sealevery 240,000 miles (384,000 km)

on vehicle engines. On non-vehicleengines, replace the thermostat andseal every 4,000 hours or 24 months,whichever comes first.

Item 24 – CrankcaseBreatherThe steel mesh breather pad in thevalve cover/intake manifold shouldbe removed and washed in cleanfuel oil when the valve cover isremoved for valve lash measurementand adjustment. These intervals arelisted in Table 22.

Item 25 – Engine Tune-UpThere is no scheduled interval forperforming an engine tune-up.However, the valve lash must bemeasured and, if necessary, adjusted atthe regular intervals listed in Table 22.

Engine Application Valve Lash Measurement/Adjustment Interval

Motor Coach Every 60,000 Miles (96,000 km)or 24 Months*

Transit Coach Every 45,000 Miles (72,000 km)or 18 Months*

Stationary, Construction/Industrial,Agricultural, or Generator Set Engines

Every 1,500 Hours or 45,000Miles (72,000 km)*

* Whichever comes first.

Table 22 Valve Lash Measurement/Adjustment Schedule



Item 26 – Idler PulleyThe fan belt idler pulley requiresperiodic inspection and replacement.

□ Inspection Interval: Inspectthe idler pulley for free bearingrotation at 45,000 miles (72,000km) on vehicle engines and at 450hours on non-vehicle engines, orwhenever the serpentine belt isremoved. If the pulley does notspin freely or is noisy (indicatingbearings are “dry” or worn),replace the pulley.

□ Replacement Interval: Replacethe idler pulley every 60,000miles (72,000 km) of operationon vehicle engines or every 9,000hours of operation on non-vehicleengines, regardless of apparentcondition.

Item 27 – Vibration DamperAll Series 40 engines userubber-bushed vibration dampers,except generator sets, which useviscous dampers.

Figure 20 Typical Rubber-BushedVibration Damper

□ Rubber-Bushed Damper:Inspect damper (see Figure 20)once a year. Replace if rubber“streaking” on the damper faceexceeds guidelines (contact aDDC distributor for guidelines)or if deep splits appear in therubber member. Deep splitscan allow chunks of rubberto break off from the damper(“chunking”), affecting its balanceand dampening efficiency.

Heat from normal engineoperation will, over a period oftime, cause the rubber member inthe vibration damper to becomebrittle as it ages. For this reasonthe vibration damper must bereplaced at time of normal majorengine overhaul, regardless ofapparent condition.



Figure 21 Typical ViscousVibration Damper

□ Viscous Damper: Inspect damper( see Figure 21) once a year.Replace if dented or leaking. Heatfrom normal engine operationmay, over a period of time,cause the fluid within the damperto break down and lose itsdampening properties. For thisreason the viscous damper must bereplaced at time of normal majorengine overhaul, regardless ofapparent condition.

Welding Precaution

NOTICE:Failure to isolate the electronicengine control systemcomponents from high currentflow can result in severe ECM(electronic control module)damage. To avoid damage tovehicle electronic components,disconnect both the positive (+)and the negative (-) battery cablesprior to electric welding. Attach thewelder's ground cable as close aspossible to the joint being welded.If it is necessary to weld closeto an electronic component, thecomponent should be temporarilyremoved.

Whenever welding is done on anypart of the vehicle, the batteriesmust be disconnected, both powerand ground, which must include allelectronic power feeds. The electroniccomponents may easily be damagedby the high voltage used and the RF(radio frequency) energy present inthe arc.



HOW-TO SECTION

This section covers Detroit Diesel'srecommendations on how to selectlubricating oil, fuel oil, and coolantand includes basic engine maintenanceprocedures which can be performedby the operator.

NOTICE:The manufacturer's warrantyapplicable to Series 40 enginesprovides in part that the provisionsof such warranty shall not applyto any engine unit that has beensubject to misuse, negligence oraccident. Accordingly, malfunctionsattributable to neglect or failure tofollow the manufacturer's fuel orlubricating recommendations maynot be within the coverage of thewarranty.

A. How to SelectLubricating Oil

Lubricant Selection in NorthAmerica

The selection of the proper lubricatingoil is important to achieve the longand trouble-free service which DetroitDiesel engines are designed toprovide. The proper lubricating oil forall Detroit Diesel engines is selectedbased on SAE viscosity grade andAPI (American Petroleum Institute)

service designation. Only oils licensedto display the API service mark shouldbe used. See Figure 22.

Lubricant Requirements

Figure 22 API Lubricant ServiceMark

API CI-4 or CH-4 oils arerecommended for use in all engines.

Engines Built Prior to 1998

Lubricants meeting API ServiceCategory CG-4 may be used inengines built prior to 1998 when APICI-4 or CH-4 oils are not available.

NOTE:The use of CG-4 oils in theseengines may require a reduction inoil drain interval, depending upon theapplication and the fuel sulfur level.


HOW-TO SECTION

Cold Weather Starting

At ambient temperatures below –4°F (–20 °C) when sufficient starterspeed cannot be achieved with SAE15W-40 oils, the use of 5W-XX oilsand 10W-XX oils, where XX is 30 or40, is allowed to improve startability,provided they are API CI-4 or APICI-4 or CH-4 and have demonstratedfield performance in DDC engines.These oils must possess a HT/HS of3.7 minimum.

NOTICE:

Monograde oils should notbe used in Series 40 engines,regardless of API serviceclassification. Monograde oilsgel at lower ambient temperatures,reducing lubricant flow, andthey do not provide adequatelubricity at higher engine operatingtemperatures. These factors canresult in severe engine damage.

When the use of high sulfur fuel(greater than 0.05% mass sulfur) isunavoidable, high alkalinity (TBN)lubricants are recommended. Highsulfur fuels require modificationto oil drain intervals. For furtherinformation, refer to publicationEngine Requirements – LubricatingOil, Fuel and Filters, 7SE270,

available from authorized DetroitDiesel distributors.

The Use of SupplementalAdditives

Lubricants meeting the DetroitDiesel specifications outlined in thispublication already contain a balancedadditive treatment. Supplementaladditives are generally not necessaryand can even be harmful. Theseadditives may be marketed as eitheroil treatments or engine treatmentsand are discouraged from use inDetroit Diesel engines. Enginedamage resulting from the use ofsuch materials is not covered byyour Detroit Diesel Corporationwarranty. Detroit Diesel will notprovide statements beyond thispublication relative to their use.



B. When to Change Oil

Oil Drain Intervals

To avoid injury from contact withthe contaminants in used engineoil, wear protective gloves andapron.

The length of time an engine mayoperate before an oil change dependsupon the lubricant and fuel used,engine oil consumption, and theoperating cycle. The maximum

interval at which the engine mayoperate before the oil and filtersmust be changed is listed in Table23. Oil analysis may be used todetermine whether this interval shouldbe shortened, but it should not be usedto lengthen the interval.

The use of fuels with sulfur contentabove 0.05 mass percent will requirea shortening of drain intervals and/orthe use of a higher TBN oil. Seethe information listed in Table 23.For detailed information refer topublication Engine Requirements –Lubricating Oil, Fuel and Filters(7SE270), available from authorizedDetroit Diesel distributors.

Engine Application Drain IntervalMotor Coach, City Transit Coach 12,000 Miles (19,200 km)

Fire Truck or Crash/Rescue Vehicle 6,000 Miles (9,600 km), 300 Hours or1 Year, whichever comes first

Construction, Industrial or Agriculture 150 Hours, 4,500 Miles (7,200 km) or1 year, whichever comes first

Stationary Generator Set, PrimePower or Continuous


Stationary Generator Set, Standby 150 Hours or 1 Year, whichever comesfirst

Table 23 Maximum Oil Drain and Filter Change Interval (Fuel Sulfur0.05 Weight Percent or Less)


HOW-TO SECTION

Disposing of Waste Oil

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

C. How to Replace theLube Oil FilterFilters are an integral part of thelubricating oil system. Properfilter selection and maintenanceare important to satisfactory engineperformance and service life.Filters should be used to maintaina clean system, not to clean up acontaminated system. Filter partnumbers arelisted in Table 43 in theSpecifications section of this guide.

1. Oil Cooler Assembly 3. Oil Filter Header (part of oil coolerassembly)

2. Oil Filter

Figure 23 Typical Oil Filter Installation



Replace Spin-On Type Oil Filter


Replace spin-on type filter as follows:

1. Place a suitable container underthe engine oil pan, removethe drain plug and drain thelubricating oil. Replace the drainplug and tighten securely.

2. Remove spin-on filter using toolJ 29917 or equivalent and a1/2-in. drive socket wrench andextension. See Figure 24.

1. Oil Filter 2. Oil FilterHeader

Figure 24 Removing Oil Filter

3. Dispose of used oil andfilter in an environmentallyresponsible manner, accordingto federal (EPA) and/or staterecommendations.

4. Clean the filter gasket-contactsurface of the adaptor head with aclean, lint-free cloth.

5. Fill the new filter with cleanlubricating oil and lightly coat thefilter gasket with the same oil.

NOTICE:Do not overtighten filters.Overtightening may crack ordistort the filter adaptor.

6. Start the new filter on the adaptorhead and tighten by hand untilthe gasket touches the mountingadaptor head. Tighten filteran additional one full turn byhand, or as indicated on thefilter.

7. Add oil as required to bring thelevel to the “Full” or “OperatingRange” mark on the dipstick.Refer to Item 1 – Lubricating Oil.


HOW-TO SECTION





8. Start and run the engine for a shortperiod and check for leaks. Afterleaks have been corrected, stopthe engine long enough for oilfrom various parts of the engineto drain back to the crankcase(approximately 20 minutes). Addoil as required to bring the level tothe “Full” or “Operating Range”mark on the dipstick.

NOTICE:If the engine oil level is constantlyabove normal and excess lubeoil has not been added to thecrankcase, consult with anauthorized Detroit Diesel serviceoutlet for the cause. Fuel or coolantdilution of lube oil can result insevere engine damage.

D. How to Select Fuel Oil

Quality

Fuel quality is an important factorin obtaining satisfactory engineperformance, long engine life, andacceptable exhaust emission levels.Detroit Diesel engines are designed tooperate on most diesel fuels marketedtoday.

In general, fuels meeting theproperties of ASTM designationD 975 (grades 1-D and 2-D) haveprovided satisfactory performance.

The fuels used must be clean,completely distilled, stable, andnon-corrosive. For more informationregarding the significance of theseproperties and selection of the properfuel, refer to publication, EngineRequirements – Lubricating Oil, Fueland Filters (7SE270), available fromauthorized Detroit Diesel distributors.



Fuel Contamination

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

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

The use of supplemental fuel additivesdoes not necessarily void the enginewarranty. However, repair expenseswhich result from fuel system orengine component malfunctionsor damage attributed to theiruse will not be covered. Theseproducts should be accompanied byperformance data supporting theirmerit. It is not the policy of DetroitDiesel Corporation to test, evaluate,approve or endorse such products.

Prohibited Additives

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

Used Lubricating Oil — DetroitDiesel specifically prohibits theuse of used lubricating oil in dieselfuel. Used lubricating oil containscombustion acids and particulatematerials which can severely erodefuel injector components, resulting inloss of power and increased exhaustemissions. In addition, the use ofdrained lubricating oil will increasemaintenance requirements due to filterplugging and combustion deposits.

Gasoline —

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

The addition of gasoline to dieselfuel will create a serious fire hazard.

The presence of gasoline in diesel fuelwill reduce fuel cetane number andincrease combustion temperatures.Tanks which contain such mixturesshould be drained and cleaned as soonas possible.


HOW-TO SECTION

Detroit Diesel Corporation will not beresponsible for any detrimental effectsit determines resulted from addingdrained lubricating oil or gasoline tothe diesel fuel.

E. How to Replace the FuelFilterFilters are an integral part of thefuel system. Proper filter selectionand maintenance are important tosatisfactory engine operation andservice life. Filters should be used tomaintain a clean system, not to cleanup a contaminated system. Referto the Specifications section of thisguide for proper filter selection.

A reusable, cylindrical, woven nylonprimary fuel strainer element andreplaceable spin-on type secondaryfuel filter element are used on Series40 engines. The strainer consists ofa cylindrical, woven nylon elementthat installs onto the strainer headerand is protected by a screw-on plasticbody with a replaceable seal ring.See Figure 25.

The spin-on secondary filter consistsof a shell, element and gasket unitizedinto a single cartridge and a filteradaptor header which includesthreaded inserts to accept the spin-oncartridge. The header also includes afuel priming pump and air bleed screwfor manual priming of the system afterfilter replacement.See Figure 25.

NOTE:An optional fuel/water separator maybe installed in the system piping aheadof the fuel strainer.

Replace Fuel Filter and Strainer


Replace spin-on fuel filter elementand strainer as follows:

1. Shut down the engine and allowit to cool.

2. With the engine at ambienttemperature and cool to the touch,place a suitable container underthe filter.

3. A fuel shutoff valve may beinstalled on the discharge sideof the fuel filter adaptor head.If installed, turn the handle onthe shutoff valve to the closedposition (perpendicular to thevalve).

4. Using a suitable band typefilter wrench, remove thefuel filter. Dispose of thefilter in an environmentallyresponsible manner, according



to federal (EPA) and/or staterecommendations. See Figure .

5. Using a 29 mm or 1 1/8–in. deepsocket, carefully remove theplastic fuel strainer cover.

1. Spin-on Fuel Filter 5. Strainer Assembly

2. Priming Pump 6. Strainer Element

3. Air Bleed Screw 7. Seal Ring

4. Fuel Strainer Header 8. See-Through Body

Figure 25 Typical Fuel Filter and Strainer Installation

6. Inspect the strainer for damageor plugging and clean or replace,as required. Clean the cover.Replace the O-ring, if damaged.

NOTE:Install the strainer into the cover withthe open end toward the filter header.


HOW-TO SECTION

NOTICE:Do not use tools to install thestrainer and do not overtighten,since this could distort or crackthe plastic cover, resulting in fuelleakage during engine operation.

7. Insert the strainer into the coverwith the open end facing UP. Withthe O-ring in place, install thestrainer onto the header. Tightensecurely by hand.

8. Wipe the filter adaptor headerwith a clean, lint-free cloth.

9. Fill the new replacement filterwith clean diesel fuel and coat thegasket lightly with the fuel.

10. Thread the new filter onto theadaptor insert until the gasketmakes full contact with theadaptor header and no sidemovement is evident. Tightenfilter an additional one-half turnby hand, or as indicated on thefilter.

NOTICE:Do not overtighten the filter.Overtightening may crack or distortthe adaptor head.

11. If previously closed, open the fuelshutoff valve.


12. Refer to Prime the Fuel Systemand Start the Engine below beforestarting the engine.

Prime the Fuel System and Startthe Engine


Prime the fuel system as follows:



NOTICE:Under no circumstances shouldthe starting motor and fuel pumpbe used to prime the fuel filter.Prolonged used of the starting motorand fuel pump to prime the fuelsystem can result in damage to thestarter, fuel pump and injectors andcause erratic running of the enginedue to the amount of air in the fuellines and filter.

1. Disconnect the CMP (camshaftposition sensor) to prevent theengine from starting. The CMPis installed on the front coverof the engine between the waterpump pulley and the fan pulley.See Figure 1.

2. Operate the manual primer pumpon the filter header until theprimer pump is hard to depress.See Figure 25.

3. Crank the engine three times for15 seconds each. Reapply theprimer pump after each crankcycle.

4. Once the primer pump is hard todepress (usually three crank andhand prime cycles), reconnect theCMP.





NOTICE:To avoid starter damage, do notcrank the engine longer than15 seconds at a time. Allow a15-second starter cool down intervalbetween starting attempts.

5. Start the engine and check forleaks. Shut down the engine.Correct any leaks with the engineoff.


HOW-TO SECTION

Replace Fuel/Water SeparatorElement

If an optional primary filter/waterseparator is installed in the fuel systempiping, replace the element as follows:



3. A fuel shutoff valve may beinstalled on the discharge sideof the fuel/water separator. Ifinstalled, turn the handle onthe shutoff valve to the closedposition (perpendicular to thevalve).

4. Drain off some fuel by openingthe drain valve.

5. Using a strap wrench, removethe element and bowl together,then remove the bowl from theelement. The filter and bowlhave right-hand threads, so turncounter-clockwise to remove.

6. Clean the bowl and the O-ringseal.

7. Apply a light coating of cleanfuel or grease to the O-ring seal,thread the bowl onto the new filterand tighten by hand.

NOTICE:To avoid damaging the bowl orthe filter, do not use tools whentightening.

8. Apply a light coating of clean fueloil or grease to the new O-ringseal on the top of the replacementfilter. Thread the filter and bowlassembly onto the filter headerand tighten by hand until snug.

9. To eliminate air from the filter,operate the primer pump on thefilter header until the fuel purgesat the filter assembly.

10. Refer to section Prime the FuelSystem and Start the Enginebefore starting the engine.

11. Shut down the engine. Correctany leaks with the engine off.

Replace “Fuel Pro® 382/382E”Fuel Filter Element

The Fuel Pro 382/383E diesel fuelfilter system consists of a permanentlymounted fuel processor, a replaceablefilter element and sealing grommetassembly, a filter spring, a see-thrucover and seal, a cover collar, and avent cap and seal. The Fuel Pro 382Esystem also includes a fuel heaterelement, thermostatic switch andwiring harness. See Figure 26.



Figure 26 Fuel Pro 382E FuelProcessor Assembly

Replace the element as follows:



3. A fuel shutoff valve may beinstalled on the discharge side ofthe fuel filter. If installed, turn thehandle on the shutoff valve to the

closed position (perpendicular tothe valve).

4. Open the drain valve at the baseof the fuel processor and drain thefuel until it is below the bottomof the filter in the see-thru cover.Close the drain valve. The fuelmay be returned to the tank.

5. Using filter collar/vent capwrench part number 232002 orequivalent, remove the collarby turning counter-clockwise.Remove the cover, filter springand cover seal ring by liftingstraight up and over the filterelement.

6. Remove the element from thecenter stud (fuel outlet pipe)by pulling upward and twistingslightly.

NOTE:Current filter elements include anintegral sealing grommet. If a formerelement is replaced, make sure theseparate sealing grommet is removedfrom the center stud before installingthe new element.

7. Dispose of the used element andgrommet in an environmentallyresponsible manner, accordingto federal (EPA) and/or staterecommendations.

8. Check to make sure the sealinggrommet is included in the base


HOW-TO SECTION

of the replacement filter element,then install the element onto thecenter stud by pushing down andtwisting slightly.

9. Check to make sure the spring isinstalled at the top of the cover.If missing, this spring must bereplaced to insure proper filteroperation. Wipe the cover lip andcover seal clean.

NOTICE:Do not use a wrench of any kindto tighten the collar, since this maylead to overtightening, which candamage the collar and/or the cover.

10. After making sure the seal isproperly positioned at the base ofthe cover, install the cover andcollar onto the fuel processor.Tighten the collar by hand untilsecure.

11. Using filter collar/vent capwrench 232002 or equivalent,remove the vent cap from the topof the cover by turning the capcounter-clockwise. Fill the coverfull of clean fuel. After makingsure the O-ring seal is installed onthe vent cap, reinstall the cap andtighten by hand.

NOTICE:To avoid cover or vent cap damage,do not use tools to tighten the ventcap.

12. Open the fuel shutoff valve (ifequipped).

13. The fuel system must be primedbefore starting the engine.Refer to section Prime the FuelSystem and Start the Engine.

14. After starting the engine, allowthe lubrication system to reach itsnormal operating pressure, thenincrease engine speed to high idlefor 2 to 3 minutes.

NOTICE:Do not allow the fuel level in thesee-thru cover to fall below the topof the collar, since this may leadto interruption of the fuel flow andengine stalling.

15. After the air is purged and withthe engine still running, loosenthe vent cap. The fuel level inthe cover will start falling. Whenthe fuel level falls to the top ofthe collar, tighten the vent capquickly by hand.

16. Shut down the engine and tightenthe collar again by hand .



17. Restart the engine and check forleaks. Shut down the engine.Correct any leaks with the engineoff.

NOTE:The filter cover will not fill completelyduring engine operation. It willgradually fill over time, and the fuellevel will rise as the filter mediumbecomes clogged. The filter elementdoes not require changing untilthe fuel level has risen to the topof the element, or after one year ofservice, whichever comes first.

F. Engine Out of Fuel —How to Restart

NOTICE:Under no circumstances shouldthe starting motor and fuel pumpbe used to prime the fuel filters.Prolonged used of the starting motorand fuel pump to prime the fuelsystem can result in damage to thestarter, fuel pump and injectors andcause erratic running of the enginedue to the amount of air in the fuellines and filters.

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

Spin-On Filter — Use the followingprocedure for an engine with a spin-onfilter.

1. Fill the fuel tank with therecommended grade of fuel. Ifonly partial filling is possible,add a minimum of 10 gallons (38liters) of fuel to the tank.

2. Close the fuel shutoff valve (ifinstalled) on the filter header andremove the spin-on fuel filter. Fillwith clean fuel through the fuelinlet holes (the outer ring of smallholes on the element) to insurethe fuel is filtered. Thread theelement onto the filter header untilthe gasket makes full contact withthe header and no side movementis evident. Tighten filter anadditional one-half turn by hand,or as indicated on the filter.

3. Open the fuel shutoff valve (ifinstalled).


4. Prime the fuel system as follows:

[a] Disconnect the CMP(camshaft position sensor)


HOW-TO SECTION

to prevent the engine fromstarting.

[b] Operate the manual primerpump on the filter header untilthe primer pump is hard todepress. See Figure 25.

[c] Crank the engine three timesfor 15 seconds each. Reapplythe primer pump after eachcrank cycle.

[d] Once the primer pump ishard to depress (usually threecrank and hand prime cycles),reconnect the CMP.

NOTICE:To avoid starter damage, do notcrank the engine longer than15 seconds at a time. Allow a15-second starter cool down intervalbetween starting attempts.

5. Start the engine and check forleaks.

Fuel Pro Filters — Use the followingprocedure for an engine with Fuel Profilters.

1. Remove the vent cap fromthe top of the filter by turningcounter-clockwise. Fill the coverfull of clean fuel. After makingsure the O-ring seal is installed onthe vent plug, reinstall the plugand tighten by hand only.

NOTICE:To avoid cover or vent cap damage,do not use tools to tighten the ventcap.

NOTICE:Do not allow the fuel level in thesee-thru cover to fall below the topof the collar, since this may leadto interruption of the fuel flow andengine stalling.

2. Start the engine and allow thelubrication system to reach itsnormal operating pressure, thenincrease engine speed to high idlefor 2 to 3 minutes. After the air ispurged and with the engine stillrunning, loosen the vent cap onthe filter cover. the fuel level inthe cover will start falling. Whenthe fuel level falls to the top ofthe collar on the Fuel Pro cover,tighten the vent cap quickly byhand.

NOTE:If the engine fails to start afterreplacement of fuel filters, the fuelsystem will require priming with toolJ 5956 or equivalent. AuthorizedDetroit Diesel distributors are properlyequipped to perform this service.



G. How to Select Coolant

Definitions

This section covers selection ofthe required coolant for Series 40engines. To help ensure completeunderstanding of the information, thedefinitions of the following terms areprovided:

Antifreeze — Ethylene glycolor propylene glycol containing acorrosion inhibitor package and whichmeets an appropriate heavy-dutyspecification (i.e., TMC RP-329 forethylene glycol or TMC RP-330 forpropylene glycol).

Coolant — The fluid mixturecirculating in the engine coolingsystem, typically a mixture of 50%water and 50% antifreeze.

Drop–Out — Precipitated sludge ordeposit formation on cooling systemcomponents.

Fully Formulated Antifreeze —Contains all the necessary inhibitorsto protect a diesel engine, and doesnot, therefore, require a pre-charge ofSCA before its first use.

Initial–Fill Coolant — The coolantthat is used in a new or rebuilt engine,or any time the cooling system isemptied and then refilled with coolant.

OAT — Organic Acid Technology.An inhibitor system based on

organic acid inhibitors, instead oftraditional North American inhibitorformulations.

SCA — Supplemental CoolantAdditive. SCAs are used in apreventive maintenance program toprevent corrosion, cavitation, and theformation of deposits.

Approved Coolants

NOTICE:Required specifications for water,ethylene glycol, propylene glycol,inhibitor packages and inhibitorconcentration are included inthis section. To avoid possibleengine damage from inadequateor overconcentrated coolant,this information should be readthoroughly before the coolant isreplaced.

The approved and preferredcoolants for Series 40 enginesare listed in Table 24. Once installed,these coolants should be maintainedaccording to the procedures discussedunderMaintenance in this section.


HOW-TO SECTION

Coolant Fill Option ProductEthylene Glycol & Water + CorrosionInhibitors 1

DDC Power Cool

Commercial Equivalent of DDC PowerCool

Fully Formulated TMC RP-329 Type AAntifreeze & Water

Propylene Glycol & Water + CorrosionInhibitors 1

Fully Formulated TMC RP-330 Type AAntifreeze & Water

Ethylene Glycol & Water + OATInhibitors

DDC Power Cool Plus

Water Only + Corrosion Inhibitors 2 Water + DDC Power Cool 3000

Water Only + OAT Inhibitors 2 Water + DDC Power Cool Plus 60001 Preferred coolant.2 Water-only coolant systems offer no freeze protection and should not

be used where ambient temperatures can fall to 32° F (0° C).

Table 24 Initial Fill Coolant Options

Ethylene Glycol & Water PlusSCA Inhibitor or PropyleneGlycol & Water Plus SCAInhibitor — These products areavailable as fully formulated,phosphate-free, extended serviceinterval (ESI) coolants. They arecommercially available from DetroitDiesel (recommended) and othermanufacturers as either a concentratedantifreeze or as a pre-mixed antifreeze.The pre-mixed antifreeze is ready foruse, while the concentrated coolantmust be mixed with water prior to use.

Detroit Diesel Power Cool enginecoolant (part number 23512138)is the preferred ethylene glycolcoolant. If other commercial brandsof ethylene glycol are used, theymust be equivalent to the Power Cool

(see following paragraph). DetroitDiesel does not market a propyleneglycol coolant. If a propylene glycolcoolant is used, it must also meet therequirements listed in the followingparagraph.

Fully formulated ethyleneglycol-based, low silicate antifreezeor coolant must meet TMC RP-329“Type A” requirements. Fullyformulated propylene glycol-basedantifreeze or coolant must meet TMCRP-330 “Type A” requirements. Fullyformulated antifreeze does not requirea dosage of SCA (supplementalcoolant additive) prior to initial use.

Mixing EG or PG Antifreezeand Water — If a concentratedethylene glycol (EG) or propylene



glycol (PG) antifreeze is purchased,mix the antifreeze with water meetingthe required quality standardslisted in Table 27 and fill the coolingsystem.

Figure 27 Coolant Freezing andBoiling TemperaturesVersus InhibitedEthylene Glycol (IEG)Concentration (SeaLevel)

Figure 28 Coolant Freezing andBoiling TemperaturesVersus InhibitedPropylene Glycol (IPG)Concentration (SeaLevel)


HOW-TO SECTION

If a pre-diluted, fully formulatedcoolant is purchased, simply fill thecooling system. For best overallperformance, a coolant consistingof 50% concentration of antifreeze(50% antifreeze, 50% water) isrecommended.

An antifreeze concentration over67% (67% antifreeze, 33% water) isnot recommended due to poor heattransfer, reduced freeze protection(IEG only), and possible silicatedropout. An antifreeze concentrationbelow 33% (33% antifreeze, 67%water) offers too little freeze and/or

corrosion protection and is notrecommended.

See Figure 27 for ethylene glycol-basecoolant concentration versus freezingand boiling temperatures. See Figure28 for propylene glycol-base coolantconcentration versus freezing andboiling temperatures.

Always verify that the freeze pointand nitrite concentration of theantifreeze/water mixture are correctby using a POWER Trac® 3–WayCoolant Test Strip. If chemicalanalysis is used, elements in thecoolant must fall within the limitslisted in Table 25.

Fully Formulated Glycol Coolant Concentration Limits

Boron 125 – 500 PPM

Nitrite 900 – 3200 PPM

Nitrate 200 – 3200 PPM

Silicon 50 – 250 PPMPhosphorous 0 PPM

pH 8.0 – 11.0

Table 25 Fully Formulated Glycol Coolant Limits with TMC RP-329,TMC RP-330 Chemistry Type A (50/50 Coolant/WaterMixture)

Recycled Antifreeze — Antifreezeor coolant recycled by reverseosmosis, distillation, and ionexchange, properly re-inhibitedto meet TMC RP-329 Type A orTMC RP-330 Type A requirements,has been demonstrated to provide

service equivalent to virgin antifreeze.Recycled antifreeze or coolants ofthese types are preferred. Otherrecycled coolants, especially coolantsrecycled through filtration processes,are not recommended.



Ethylene Glycol/Water +OAT Inhibitor or PropyleneGlycol/Water + OAT Inhibitor —Ethylene glycol and propyleneglycol are also available with a(Organic Acid Technology) corrosionpackage. These coolants require lessmaintenance over the useful life of theengine. OAT coolants, maintained asdetailed in the Maintenance sectionof this guide, may be operated up to4 years, 600,000 miles (960,000 km),or 10,000 operating hours, whichevercomes first. Refer to sectionMaintenance. The cooling systemshould either be equipped with a“blank” coolant filter, or the coolantfilter and piping may be omitted fromthe system.

OAT fully formulated antifreezesare available as concentrated andpre-mixed. Concentrated antifreezesshould be mixed 50% (50% antifreeze,50% water).

OAT coolants should not be mixedwith conventional coolants. If theyare mixed, no damage will result, butthe long-life advantages of the OATcoolant will be lost. In this event,the coolant should be maintained as afully formulated IEG coolant, not asan OAT (Organic Acid Technology)coolant.

Detroit Diesel markets a OAT-inhibited ethylene glycol coolant,DDC Power Cool Plus, whichcontains all the required additives.

If a non-DDC OAT antifreeze isused, it must conform to TMC 338specification. Do not add extender tonew OAT antifreeze or coolant.

Water Only + SCA or WaterOnly + OAT Inhibitor — Inwarm climates a coolant basedon water with corrosion inhibitorsis approved for use. Water-onlysystems need to be treated with theproper dosage of corrosion inhibitors.Detroit Diesel-approved SCAs orOAT corrosion inhibitors must beadded to the water to provide requiredcorrosion and cavitation erosionprotection. OAT inhibitors such asPower Cool Plus 6000 are availablefor water-only systems. Inhibitorshould be mixed at 7.5% – 10% byvolume with water. For a list of PowerCool products, refer to section PowerCool Engine Products in this guide.Traditional SCA (Power Cool 3000)can also be used to protect the engine.Power Cool 3000 concentration limitsare listed in Table 26.

NOTE:Do not use Power Trac 3–Way TestStrips to test OAT coolant.


HOW-TO SECTION

Power Cool 3000 Coolant Concentration LimitsBoron 125 – 500 PPM

Nitrite 900 – 3200 PPM

Nitrate 0 – 1000 PPM

Silicon 50 – 250 PPMPhosphorous 0 PPM

pH 8.0 – 11.0

Table 26 Power Cool 3000 Concentration Limits (5% Power Cool3000/ 95% Water)

Power Cool 3000 SCA inhibitorsshould be mixed at 5% by volumewith water. This is 1 quart per 5gallons of water. These additionscan be made by adding liquid SCAsavailable in a variety of sizes. Coolantfilters are also available for differentcooling system capacities. Thesefilters release the proper amount ofSCA at initial fill.

Water Requirements —Distilled, reverse osmosis-purified,

or de-ionized water which eliminatesthe adverse effects of minerals intap water is preferred. High levelsof dissolved chlorides, sulfates,magnesium, and calcium in some tapwater causes scale deposits and/orcorrosion. These deposits have beenshown to result in water pump failuresand poor heat transfer, resulting inoverheating. If tap water is used, themineral content in the water must bebelow the maximum allowable limitslisted in Table 27.

Maximum AllowableParts per Million Grains per Gallon

Chlorides 40 2.5

Sulfates 100 5.8

Total Dissolved Solids 340 20

Total Hardness –Magnesium and Calcium

170 10

Table 27 Satisfactory Water Limits – Make-Up Water Only



NOTICE:Do not add additional SCA tonew, fully formulated antifreeze orcoolant. This can result in dropoutand/or the formation of deposits.

Coolants Not Recommended

The following coolants are notrecommended for use in Detroit Dieselengines:

1. All antifreezes and coolantscontaining phosphate arenot recommended. Drop out,overheating and water pump sealfailures can result from the useof coolant or inhibitor packagesbased on phosphate.

2. Automotive type coolantsgenerally contain high levels ofphosphate and silicate, offer noliner pitting protection, and arenot suitable for use in DetroitDiesel engines.

3. Methyl alcohol-based antifreezemust not be used because ofits effect on the non-metalliccomponents of the cooling systemand its low boiling point.

4. Methoxy propanol-basedantifreeze must not be usedbecause it is not compatible withthe fluoroelastomer seals found inthe cooling system.

5. Glycol-based coolants formu-lated for heating/ventilation/airconditioning (HVAC) should notbe used. These coolants generallycontain high levels of phosphates,which can deposit on hot internalengine surfaces and reduce heattransfer.

Additives Not Recommended

The following additives are notrecommended for use in Series 40engines:

1. Soluble oil additives are notapproved for use in Detroit Dieselengine cooling systems. A smallamount of oil adversely affectsheat transfer. For example, a1.25% concentration of solubleoil increases fire deck temperature6%. A 2.50% concentrationincreases fire deck temperature15%. The use of soluble oiladditives may result in engineoverheating and/or failure.

2. Chromate additives are notapproved for use in DetroitDiesel engine cooling systems.Chromate additives can formchromium hydroxide, commonlycalled “green slime.” This,in turn, can result in enginedamage due to poor heat transfer.Cooling systems operated withchromium-inhibited coolant mustbe chemically cleaned with Power


HOW-TO SECTION

Cool dry chemical cooling systemcleaner/conditioner (or equivalentsulfamic acid/sodium carbonatecleaner) and flushed.

Maintenance

This section describes the proceduresfor maintaining the coolant inhibitorlevel and proper concentration.

Coolant Inhibitor Test Intervals— The coolant inhibitor levelshould be checked at the intervalslisted in Table 28.

Service Application Inhibitor Test IntervalMotor Coaches 18,000 Miles (32,000 Kilometers)

City Transit Coaches, Pick-Up andDelivery, Short Trip, and EmergencyVehicles

6,000 Miles (9,600 Kilometers) or 3Months, whichever comes first

Industrial, Continuous– Duty GeneratorSet and All Other Applications, exceptStandby Generator Set


Stand-By Generator Set 200 Hours or Yearly, whichevercomes first

Table 28 Required Coolant Inhibitor Test Intervals


If topping off is needed, add coolantwhich is identical to the initial fillcoolant.

Supplemental Coolant Additivesfor Fully Formulated Coolant— The concentrations of someinhibitors will gradually depleteduring normal engine operation.SCAs replenish the protection forcooling system components. Thecoolant must be maintained with theproper concentration of SCA. DetroitDiesel Power Coolmaintenance SCAsare recommended.



The proper application of SCA willprovide:

□ pH control.

□ Restored inhibitor levels to preventcorrosion.

□ Water softening to deter formationof mineral deposits.

□ Cavitation protection to protectwet sleeve cylinder liners.

Maintenance Intervals — Checkthe nitrite concentration at the regularintervals listed in Table 29 with aPower Trac 3–Way Test Strip.


HOW-TO SECTION

Coolant Interval 1 ActionA. 20,000 Miles (32,000km) or 3 Months*B. 500 Hours or 3 Months*

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

Antifreeze / Water +SCA Inhibitor (DDCPower Cool)

A. 300,000 Miles (480,000km)B. 2 Years or 4,000 Hours*

Drain and clean system.Refill with new coolant.

A. 20,000 Miles (32,000km) or 3 Months*B. 500 Hours or 3 Months*


Ethylene Glycol/ Water + SCAInhibitororPropylene Glycol/ Water + SCAInhibitor

A. 300,000 Miles (480,000km)B. 2 Years or 4,000 Hours*

Drain and clean system.Refill with new coolant.

Test at 1 Year. —

A. 300,000 Miles (480,000km) or 2 Years*B. 5,000 Hours

Add Power Cool PlusExtender

Ethylene Glycol/ Water + OATInhibitororPropylene Glycol/ Water + OATInhibitor

A. 600,000 Miles (960,000km)B.4 Years or 10,000Hours*

Drain and clean system.Replace with new coolant.

A. 20,000 Miles (32,000km) or 3 Months*B. 500 Hours or 3 Months*


Water Only + SCAInhibitor

A. 300,000 Miles (480,000km)B. 2 Years or 4,000 Hours

Drain and clean system.Replace with new coolant.

A. 300,000 Miles (480,000km) or 2 Years*B. 5,000 Hours

Add Power Cool PlusExtender

Water Only + OATCoolant

A. 600,000 Miles (960,000km)B. 4 Years or 10,000 Hours

Clean and drain. Replacewith new coolant.

1 Maintenance interval based on application. Drain interval dependenton proper maintenance.

A. Motor Coaches, City Transit Coaches, Pick-Up and Delivery, ShortTrip and Emergency Vehicles

B. Industrial, Generator Set and Other Applications

Table 29 Coolant Maintenance Intervals



Nitrite levels must be within theranges listed in Table 25.

NOTICE:Failure to properly maintain coolantwith SCA can result in damageto the cooling system and itsrelated components. Conversely,over-concentration of SCA inhibitorcan result in poor heat transfer,leading to engine damage.Always maintain concentrations atrecommended levels. Do not usetraditional SCAs with OAT coolant.

Additional SCA must be added to thecoolant when it becomes depleted, asindicated by a nitrite concentrationof 900 PPM or less. If the nitriteconcentration is greater than 900PPM, do not add additional SCA. Ifthe nitrite concentration is above 3200PPM, the system is over-inhibited andshould be partially drained and filledwith a 50/50 mix of water and EG orPG.

In this case the EG or PG shouldcontain no inhibitors and shouldconform to ASTM D4985. Thiswill dilute the over-concentratedinhibitors.

NOTE:In non-OAT systems, nitriteconcentration of 5000 PPM orhigher on a Series 40 enginesuggests problematic additive

over-concentration. This conditionmust be corrected by immediatedraining and flushing of the coolingsystem. Refill the system with new fullyformulated or pre-charged coolant.Check the nitrite concentration level atthe next maintenance interval with aPower Trac 3–Way Test Strip.

SCA Test Procedures

Detroit Diesel Power Trac 3–WayCoolant Test Strips should beused to measure nitrite andglycol concentrations. Partnumbers are listed in Table 55.Cavitation/corrosion is indicatedon the strip by the level of nitriteconcentration. Freeze/boil overprotection is determined by glycolconcentration.


HOW-TO SECTION


For best results make the test whilethe coolant is between 50° – 140 °F(10.0° – 60 °C). Wait at least 60, butnot longer than 75, seconds beforereading the nitrite level. Use the teststrips as follows:

1. Dip the strip into coolant forone second. Remove and shakebriskly to eliminate excess fluid.

2. Immediately compare the pad end(% glycol) to the color chart onthe container.

3. Sixty seconds (one minute) afterdipping, compare the nitrite padto the color chart.

4. Color change of the additiveindicator (middle pad) indicatesthe presence of inhibitor that isnot approved by Detroit Diesel.

Promptly replace and tighten the teststrip container cap after each use.

Discard unused strips if they haveturned light pink or tan.

A factory coolant analysis programis available through authorizedDetroit Diesel service outlets. Partnumbers are listed in Table 55 in theSpecifications section. To verifycoolant acceptability, submit a samplefor coolant analysis every two (2)years, 300,000 miles (480,000 km),or 10,000 operating hours, whichevercomes first.

Need Release Coolant Filters(Non-OAT Systems)

Spin-on coolant filters are available forDetroit Diesel engines. Membranesin the filters release SCAs beforethe coolant approaches a corrosivecondition, protecting the engine fromcorrosion. The elements release theSCA charge as needed, as opposed tothe maintenance SCA elements, whichinstantaneously release the SCAcharge. Coolant filter elements shouldbe replaced after one (1) year, 120,000miles (192,000 km) or 2,000 operatinghours, whichever comes first.



Dropout

Excessive amounts of some inhibitorsin the coolant can cause a gel orcrystalline deposit that reduces heattransfer and coolant flow. The deposit,called “dropout,” takes the color ofthe coolant when wet, but appears as awhite or gray powder when dry. It canpick up solid particles in the coolantand become gritty, causing excessivewear of water pump seals and othercooling system components.

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

The wet gel can be removed byusing a non-acid (alkali) typeheavy-duty cleaner, such as DetroitDiesel Power Cool On-Line Cleaner(sodium nitrite/sodium tetraborate).Refer to section POWER COOLCOOLING SYSTEM CLEANERSfor part numbers.

NOTE:If the gel is allowed to dry, it isnecessary to disassemble theengine and clean it with a causticsolution or physically clean individualcomponents.

Coolant Extender InhibitorAdditive for “OAT” Coolant

The inhibitors in OAT coolant mustalso be maintained, but less oftenthan traditional SCA-type coolants.A portable test is available to test thelevels of OAT inhibitors in coolant.Where this is not used, fleet testinghas determined that a OAT coolantextender package should be added tothe coolant at 300,000 miles (480,000km), two (2) years, or 5,000 hours,whichever comes first. The propermaintenance dosages for all OATcoolants are listed in Table 29 ,reflecting 0.6% by volume extender.This dosage should be added to thewater-only and the glycol systems atthe same interval.

The proper application of extender toOAT coolant will provide:

□ pH Control

□ Restored inhibitor levels to preventcorrosion

□ Cavitation protection to protectwet sleeve cylinder liners

NOTE:Do not use traditional SCAs inOAT coolant, and do not useOAT extender in traditional coolant.

OAT Coolant Drain Interval —A properly maintained OAT-inhibitedcoolant will last 600,000 miles


HOW-TO SECTION

(960,000 km), four (4) years, or10,000 operating hours, whichevercomes first. At this time the coolantshould be drained, and the coolingsystem should be thoroughly cleaned,flushed, and filled with new, properlyinhibited OAT coolant.

Chronic Coolant SystemProblems

The most commonly seen coolantsystem problems result frommaintenance and formulation factorssuch as:

□ Hard water

□ Dilution of the coolant by theaddition of untreated water

□ Over dosage or under dosage ofcorrosion inhibitors

□ Improper corrosion inhibitor (mostoften phosphated)

□ Mixing SCAs

□ Improper testing

Detroit Diesel Cooling SystemMaintenance Products

Power Cool SCAs — Power CoolSCAs are water-soluble chemicalcompounds. These products areavailable in coolant filter elements,liquid packages, and in fullyformulated Power Cool antifreeze.

NOTE:Power Cool 3000 liquid SCA is morecompatible with hard water thanPower Cool 2000 SCA.

Power Cool Coolant FilterElements — Power Cool coolantfilter elements (spin-on canisters) areavailable in various sizes suitable forcooling systems of varying capacities.Selection of the proper element sizeis vital when pre-charging non-fullyformulated coolant at initial fill andat maintenance intervals. A fullyformulated antifreeze must nothave SCA added at initial fill. Donot use SCA-containing filterswith OAT antifreeze or coolant.The need for maintenance elementsis determined by the results of thenitrite concentration test performedat each cooling system interval. Donot automatically install maintenanceelements at maintenance intervals,unless the nitrite concentration fallsbelow 900 parts per million.

Power Cool Cleaners — PowerCool Liquid On-Line Cleaner is usedfor light deposits. Power Cool DryChemical Cleaner/Conditioner is usedfor heavy deposits or scale.



Summary of CoolantRecommendations


1. Always maintain the enginecoolant to meet Detroit Dieselspecifications.

2. Only use water that meets thespecifications listed in Table 27.Distilled, de-mineralized (reverseosmosis) or de-ionized water ispreferred.

3. The proper dosage of inhibitorsmust be included in the coolantat initial fill for all Detroit Dieselengines. This dosage is usuallyincluded in the fully formulatedantifreeze used, or it may need tobe added if water alone or if lessthan 50% antifreeze is used. Theuser is urged to refer to the fulltext of this section to determinethe proper dosage. Mixingof different manufacturers'

technologies (brands) could causecooling system problems.

4. Maintain the inhibitor at theprescribed concentration. Testthe nitrite concentration by usinga titration kit or Detroit DieselPower Trac 3-Way Coolant TestStrips. Add SCA only if the nitriteconcentration is below 900 PPM.Do not use SCA in OAT coolant,and do not use Power Trac 3-WayCoolant Test Strips to test OATcoolant.

NOTE:If the nitrite concentration exceeds3,200 PPM, the coolant must bedrained and replaced with newcoolant. A thorough cleaning of thecooling system may be required.

5. Do not use another manufacturer'stest kit to measure the SCAconcentration of Detroit Dieselmaintenance products.

6. Pre-mix coolant makeup solutionsto the proper concentration beforeadding to the cooling system.

7. Do not mix OAT and othercoolants in the same engine.

8. Do not use automotive coolants.

9. Where antifreeze/boil overprotection is required, use onlyantifreeze that meets TMCRP-329 “Type A” (EG) orTMC RP-330 “Type A” (PG)


HOW-TO SECTION

specifications. Always maintaincoolant at the proper level.

10. Coolant Life:

□ Glycol Coolant. A properlymaintained cooling system,filled with phosphate-freecoolant consisting of a 50/50mix of antifreeze and waterper TMC RP-329 “TypeA” (EG) or TMC RP-330“Type A” (PG) specificationscan be operated to thelimits recommended. Theproper maintenance involvesperiodic evaluation usingPower Trac 3-Way CoolantTest Strips and the additionof SCA as needed, indicatedby the strip test. To verifycoolant acceptability, submita sample for coolant analysisevery 300,000 miles (480,000km), three (3) years, or 5,000operating hours, whichevercomes first. Submit thesample in a DDC PowerTrac Coolant Test Bottle.Required part numbers arelisted in Table 55.

□ OAT Coolant. A properlymaintained OAT coolant maybe operated 600,000 miles(960,000 km), four (4) years,or until overhaul, whichevercomes first. At this time thesystem must be completely

drained, thoroughly cleaned,and refilled.

□ OAT Coolants require theaddition of an extender at300,000 miles (480,000 km),two (2) years, or 5,000 hours,whichever comes first. Use 1pint of extender for every 20gallons of coolant.

□ Other Coolants. Otherproperly maintained coolantsmay be operated up to250,000 miles (480,000km), two (2) years, or 4,000operating hours, whichevercomes first. At this time thesystem must be completelydrained, thoroughly cleaned,and refilled.

11. Do not use the following inengine cooling systems:

□ Soluble oil

□ High silicate, automotive-typeantifreeze

□ Chromate SCAs

□ Methoxy propanol-basecoolant

□ Methyl alcohol-base coolant

□ Sealer additives or coolantcontaining sealer additives.

□ HVAC coolant

□ Phosphated coolants



H. How to Replace theCoolant FilterThe coolant filter is installed on aheader mounted at the rear of thegear case just above the oil cooler .Replace the coolant filter as follows:


1. With the engine at ambienttemperature and cool to the touch,carefully remove the radiator ordeaeration tank pressure cap torelieve pressure in the coolingsystem.

2. Close the manual shutoff valveon the coolant filter header byturning handle clockwise. In theclosed position, the handle willbe pointing straight up.

3. Loosen and remove thecoolant filter by turningcounter-clockwise using a

filter/strap wrench. See Figure 29.

1. CoolantFilter

2. CoolantFilterHeader

Figure 29 Removing Coolant Filter

4. Lubricate the new coolant filtergasket (1) with clean engine oiland install onto the header (2).See Figure 30.


HOW-TO SECTION

1. CoolantFilterGasket

3. Oil Cooler

2. FilterHeader

Figure 30 Installing Coolant Filter

5. Tighten filter until gasket makesfull contact with the header, thentighten one additional full turn.

6. Inspect the coolant level in theradiator or deaeration tank andtop off with required coolant, ifnecessary. Replace the pressurecap and tighten securely.

7. Open the manual shutoff valveby turning counter-clockwise.In the open position, the handlewill be parallel with the filter andpointing rearward.

I. How to Drain and Flushthe Cooling System


1. With the engine cool, slowlyloosen and remove the pressurecap from the radiator or deaerationtank. Place a suitable containerunder the radiator and drain theprevious solution from the engineand radiator. Dispose of thecoolant in an environmentallyfriendly manner, accordingto state and/or federal (EPA)recommendations.

2. Refill the cooling systemwith clean, soft water and agood cooling system cleaningcompound, such as thoselisted in Table 54 in theSpecifications section. Ifthe engine is warm, fill slowlyto prevent the rapid cooling anddistortion of the metal castings.



3. Start the engine and operate it forfifteen minutes to circulate thesolution thoroughly.

4. Stop the engine and allow it tocool.

5. With the engine cool, drain thecooling system completely.

6. Refill the cooling system withclean, soft water and operate it forfifteen minutes.

7. Stop the engine and allow it tocool.

8. With the engine cool, drain thecleaner residue from the coolingsystem.

9. Refill the system with the requiredcoolant. Refer to section G. Howto Select Coolant.

10. Entrapped air must be purgedafter filling the cooling system.To do this, start the engine andallow it to warm up without thepressure cap installed. With thetransmission in neutral, increaseengine speed above 1000 RPMand add coolant as required.Install the pressure cap after thecoolant level has stabilized atthe bottom of the radiator fillerneck or the level indicated on thedeaeration tank .

NOTICE:If the engine overheats andthe coolant level is satisfactory,the cooling system may requirecleaning with a descaling solventand backflushing. AuthorizedDetroit Diesel service outlets areproperly equipped to perform theseservices.

In addition to the cleaning procedure,other components of the coolingsystem should be checked periodicallyto keep the engine operating at peakefficiency.

Hoses. Cooling system hoses shouldbe inspected and any hose that showsobvious signs of damage or feelsabnormally soft or hard should bereplaced. Damaged clamps shouldalso be replaced. All external leaksshould be corrected as soon asdetected.

NOTE:If Detroit Diesel Power Coolantifreeze/coolant (or equivalent fullyformulated, precharged antifreezeis used, a precharge element is notrequired. Coolant inhibitor levelsmust be checked at the intervalslisted in Table 28.


HOW-TO SECTION

J. When to Service the DryType Air CleanerReplace dry type air cleaner elementswhen the maximum allowable aircleaner restriction (20 inches of wateror 5.0 kPa) has been reached orannually, whichever comes first.

Exception: On engines equipped withboreless turbochargers, such as certaintransit bus applications, replace theelement when the maximum allowableair cleaner restriction of 15 inches ofwater (3.7 kPa) has been reached, orannually, whichever comes first.

Some air cleaners are equipped witha restriction indicator which aids indetermining the servicing interval.

Cleaning and/or reusing dry papertype air cleaner elements is notrecommended unless the cleaningmethod used removes cloggingwithout damaging the element.Inspection and cleaning of elementsmust be done in accordance with theair cleaner element manufacturer'srecommendations, if any.



BASIC TROUBLESHOOTING

This section covers basictroubleshooting of engine operationor performance malfunctions andtheir probable causes. Hard startingsymptoms are listed in Table 30.Objectionable exhaust symptoms arelisted in Table 31. Abnormal engineoperation symptoms are listed in Table32. Abnormal operating conditionsymptoms are listed in Table 33.Abnormal coolant temperaturesymptoms are listed in Table 34.



Probable Causes

Engine WillNot Rotate

LowCrankingSpeed

EngineCranks ButWill NotStart

Low Battery Voltage X X

Loose cranking motorconnections

X

Faulty cranking motor X X

Faulty cranking motor switch X X X

Internal seizure X

Improper lube oil X

Circuit breaker/electronic controlmalfunction

X

Fuse blown or missing X

Insufficient Fuel SupplyAir in fuel X

Out of fuel X

Loose fuel connections X

Cracked fuel lines X

Obstructed fuel filters/lines X

Faulty fuel pump X

Faulty injector operation X

Restricted fuel fitting missing X

Electronic control systemmalfunction

X

Installation/operation of fuelcheck valve or shutoff valve

X

Low CompressionWorn intake and exhaust valves X

Worn piston rings/liners X



Probable Causes

Engine WillNot Rotate

LowCrankingSpeed

EngineCranks ButWill NotStart

Leaking cylinder head gasket X

Improper intake or exhaust valveadjustments

X

Table 30 Hard Starting Symptoms and Probable Causes



Probable Causes

Blackor GraySmoke

BlueSmoke

WhiteSmoke

Damaged or dirty air cleaner X

Improper grade of fuel X

Excessive exhaust back pressure X

Misfiring cylinders X

Lubricating oil not burned incylinder (being burned in exhaustmanifold or turbocharger)

X

Faulty injector timing X

Faulty oil control rings X

Excessive installation angle X

Excessive oil in crankcase X

High ambient temperature X

Thin air (high altitude) X

Cetane rating of fuel too low X

Air in the fuel system X

Table 31 Objectionable Exhaust Symptoms and Probable Causes



Probable Causes

RoughRunning orFrequentStalling

Low Power Detonation

Misfiring cylinder X X

Insufficient fuel X XHigh return fuel temperature X XLow compression X XElectronic control systemmalfunction X X

High air inlet restriction/ex-haust back pressure X

Engine application XHigh air inlet temperature XHigh altitude operation XIncorrect engine gear traintiming X

Low coolant temperature XOil picked up by inlet airstream XFaulty injector operation XIncorrect injector heightsetting X X

Table 32 Abnormal Engine Operation Symptoms and ProbableCauses



Probable CausesHigh Lube OilConsumption

Low OilPressure

Loose connections XCracked, leaking oil lines XDamaged gaskets or seal rings X

Lube oil loss at breather tube * XLube oil loss at dipstick tube * XLeaking oil cooler XLeaking valve stem seals XWorn/broken oil control rings XScored liner and/or piston XExcessive engine installation angle X

Crankcase overfilled XOil in air tanks (air compressormalfunction) X

Plugged crankcase breather X

Oil level low XImproper engine oil viscosity (fuel in theoil) X

Faulty oil pressure regulator valve XWorn crankshaft, camshaft orconnecting rod bearings X

Missing cup plugs in rocker arm shaft XFaulty oil pressure relief valve XAir leaks in oil pump (suction side) XWorn or damaged oil pump XFaulty oil pressure gage XFaulty electrical components (for gage) XPlugged oil line or orifice X

* Indicates high crankcase pressure

Table 33 Abnormal Operating Condition Symptoms and ProbableCauses



Probable Causes AboveNormal

BelowNormal

Restricted cooling system passages XRestricted radiator core passages XSlipping fan drive belt XFaulty thermo-modulated fan (failure to engagefan) X

Faulty thermo-modulated fan (failure todisengage fan) X

Obstruction in front of radiator X

Low coolant level XDamaged hoses XFaulty thermostat XFaulty water pump XFaulty radiator pressure cap X

Air in coolant XThermostat not fully closed XLeakage around thermostat seal X

Table 34 Abnormal Coolant Temperature Symptoms and ProbableCauses


ENGINE STORAGE

ENGINE STORAGE

Preparing Engine forStorageWhen an engine is to be stored orremoved from operation for a periodof time, special precautions shouldbe taken to protect the interior andexterior of the engine, transmissionand other parts from rust accumulationand corrosion. The parts requiringattention and the recommendedpreparations are given below.

All rust or corrosion should beremoved completely from anyexposed part before applying rustpreventive compound. Therefore,DDC recommends processing theengine for storage as soon as possibleafter removing it from service.

The engine should be stored ina building that is dry and can beheated during the winter months.Moisture-absorbing chemicals areavailable commercially for use whenexcessive dampness prevails in thestorage area.

Temporary Storage (30 Days orLess)

To protect the engine for a temporaryperiod of time (30 days or less), followthis procedure:

1. With the engine at ambienttemperature and cool to the touch,

drain engine crankcase oil into asuitable container. Dispose of theoil in an environmentally friendlymanner, according to state and/orfederal (EPA) recommendations.

2. Fill the crankcase to the properlevel with the recommendedviscosity and grade of oil.

3. Fill the fuel tank with therecommended grade of fuel oil.Operate the engine for two (2)minutes at 1200 rpm and no load.Do not drain the fuel system orthe crankcase after this run.

4. Check the air cleaner and serviceit, if necessary.

5. If freezing weather is expectedduring the storage period, checkthe antifreeze/coolant for requiredfreeze and inhibitor protection.Add antifreeze solution to thecooling system in accordancewith DDC's recommendations.Refer to section G. How to SelectCoolant.

NOTE:If an antifreeze solution is not requiredduring storage, flush the coolingsystem with a good, soluble oil (3% –5% by volume) rust inhibitor to preventrusting of the outside diameter of thecylinder liners.




6. Clean the exterior of the engine(except electrical parts) with fueloil and dry with compressed air.

7. Seal all engine openings,including the turbocharger airand exhaust outlets and thevalve cover/intake manifoldopening. The material usedmust be waterproof, vaporproofand possess sufficient physicalstrength to resist puncture anddamage from the expansion ofentrapped air.

An engine prepared in this manner canbe returned to service in a short timeby removing the seals at the engineopenings and reconnecting piping; bychecking the engine coolant, fuel oil,lubricating oil and transmission oillevels; and by priming the fuel systembefore starting.

Extended Storage (More than 30Days)

To prepare an engine for extendedstorage (more than 30 days), followthis procedure:

1. Drain the cooling system andflush with clean, soft water. Refillwith clean, soft water and adda rust inhibitor to the coolingsystem.

2. Circulate the coolant by operatingthe engine until normal operatingtemperature is reached.

3. Stop the engine.

4. With the engine at ambienttemperature and cool to the touch,drain the engine crankcase oilinto a suitable container. Removethe oil filter. Dispose of the oiland filter in an environmentallyfriendly manner, accordingto state and/or federal (EPA)recommendations. Replace theoil drain plug and tighten to 45 –50 N·m (33 – 37 lb-ft) torque.

5. Install a new lubricating oilfilter. Fill the crankcase tothe proper level with Tectyl®930A preservative lubricatingoil or an equivalent 30–weightpreservative lubricating oilmeeting Mil-L-21260C, Grade 2Specification.

6. Drain the fuel tank. Refill withenough clean No. 1 diesel fuel


ENGINE STORAGE

or pure kerosene to permit theengine to operate for about ten(10) minutes. If draining thefuel tank is not convenient, usea separate, portable supply ofrecommended fuel.

NOTE:If engines are stored wherecondensation of water in the fueltank may be a problem, additivescontaining methyl carbitol or butylcellusolve may be added to the fuel.Follow manufacturer's instructionsfor treatment. Where biologicalcontamination of fuel may be aproblem, add a biocide such asBiobor® JF (or equivalent) to thefuel. When using a biocide, followthe manufacturer's concentrationrecommendations and observe allcautions and warnings.

7. Drain the fuel system and removethe fuel filters. Dispose of usedfilters in an environmentallyresponsible manner, accordingto state and/or federal (EPA)recommendations. Fill the newfilters with No. 1 diesel fuel orpure kerosene and install on theengine. Prime the fuel system.

8. Start and operate the engine forfive (5) minutes to circulate theclean fuel throughout the systemand ensure the system is full.

9. Stop the engine and allow to cool.Then disconnect the fuel returnline and the inlet line at the fuelfilter and securely plug both toretain the fuel in the engine.

10. Transmission: Follow themanufacturer's recommendationsfor prolonged storage.

11. Power Take-Off: If equipped,follow manufacturer'srecommendations for prolongedstorage.

12. Apply a non-friction rustpreventive compound to allexposed engine parts. Ifconvenient, apply the rustpreventive compound to theengine flywheel. If not, disengagethe clutch mechanism to preventthe clutch disc from sticking tothe flywheel.

NOTE:Do not apply oil, grease or anywax-base compound to the flywheel.The cast iron will absorb thesesubstances, which can “sweat” outduring engine operation and cause theclutch to slip.

13. Drain the engine cooling system.

14. Drain the preservative oil fromthe engine crankcase. Reinstalland tighten the oil drain plug.



15. Remove and clean the batteryand battery cables with a bakingsoda-water solution and rinsewith fresh water. Do not allowthe soda solution to enter thebattery. Add distilled water tothe electrolyte (if necessary) andfully charge the battery. Store thebattery in a cool (never below 0°C or 32 °F) dry place. Keep thebattery fully charged and checkthe level and specific gravity ofthe electrolyte regularly.

16. Insert heavy paper strips betweenthe pulleys and serpentine drivebelt to prevent sticking or removethe drive belt and store separately.

NOTICE:Failure to properly seal off theturbocharger air inlet and exhaustoutlet openings before enginestorage may permit air drafts tocirculate through the turbochargerand rotate the turbine/compressorshaft without an adequate flow oflubricating oil to the center housingbearings. This can result in severebearing damage.

17. Seal all engine openings,including the turbocharger airand exhaust outlets and the valvecover/intake manifold opening.Use moisture-resistant tape andcardboard, plywood or metalcovers where practical.

18. Clean and dry the exterior paintedsurfaces of the engine and spraywith a suitable liquid automobilebody wax, a synthetic resinvarnish, or a rust preventivecompound.

19. Protect the engine with a goodweather-resistant tarpaulin andstore it under cover, preferablyin a dry building which can beheated during the winter months.

Outdoor storage of the engine is notrecommended. If units must be keptout of doors, follow the preparationand storage instructions alreadygiven. Protect units with quality,weather-resistant tarpaulins (or othersuitable covers) arranged to providefor air circulation.


ENGINE STORAGE

NOTICE:Do not use plastic sheeting foroutdoor storage. Plastic is finefor indoor storage. When usedoutdoors, however, enough moisturecan condense on the inside of theplastic to rust ferrous metal surfacesand pit aluminum surfaces. If a unitis stored outside for any extendedperiod of time, severe corrosiondamage can result.

The stored engine should be inspectedperiodically. If there are anyindications of rust or corrosion,corrective steps must be taken toprevent damage to the engine parts.Perform a complete inspection at theend of one year and apply additionaltreatment as required.

Restoring an Engine to Serviceafter Extended Storage

If an engine has been in extendedstorage, prepare it for service asfollows:

1. Remove the covers and tape fromall the openings of the engine, fueltank and electrical equipment. Donot overlook the turbocharger airand exhaust outlets and the valvecover/intake manifold openings.

2. Remove the plugs from the inletand outlet fuel lines and reconnectthe lines to their proper positions.

3. Wash or steam clean the exteriorof the engine to remove the rustpreventive, if previously applied.Do not wash or apply steam toelectrical components.

4. Remove the rust preventive fromthe flywheel. Flush any solubleoil rust inhibitor (if used) in thecooling system.

5. Remove the paper stripsfrom between the pulleys andserpentine drive belt or reinstallthe drive belt, if previouslyremoved.

6. Fill the crankcase to the properlevel with the required grade oflubricating oil. Use a pressurelubricator to insure all bearingsand rocker shafts are lubricated.

7. Fill the fuel tank with the requiredfuel. Prime the fuel system.

8. Close all drain cocks and fill theengine cooling system with clean,soft water and required inhibitors.If the engine is to be exposedto freezing temperatures, installgenuine Detroit Diesel PowerCool antifreeze or an equivalentethylene glycol-base or propyleneglycol-base antifreeze solutionwhich provides required freeze,boil over, and inhibitor protection.Refer to section G. How to SelectCoolant.



9. Install and connect the battery.Make sure the average specificgravity of the battery is 1.260or higher. Charge the battery, ifnecessary.

10. Service the air cleaner, if required.

11. Transmission: Follow themanufacturer's recommendationscovering the return of thetransmission to service.

12. Power Take-Off: If equipped,follow the manufacturer'srecommendations covering thereturn of the power take-off toservice.

13. Turbocharger:

[a] Remove the tape or coversfrom the turbocharger air andexhaust outlet connectionsand the valve cover/intakemanifold opening. Reconnectpiping as required.

[b] Remove the oil inlettube assembly from theturbocharger center bearinghousing. Prelube bearings bypouring approximately five(5) ounces of clean lubricatingoil into the opening. Reinstallthe oil inlet pipe using a newgasket, and torque inlet pipeflange bolts to specifications.

14. Refer to section LubricationSystem Checks in section

Preparations for Starting theEngine the First Time.





15. After all preparations arecompleted, start the engine.

NOTE:The small amount of rust preventivewhich remains in the fuel systemwill cause smoky exhaust for a fewminutes.

NOTE:Before subjecting the engine to aload or high speed, allow it to reachnormal operating temperature. Thenmonitor the electronic control systemdiagnostic data link for trouble codes.


SERVICE PUBLICATIONS

SERVICE PUBLICATIONS

The service manual covering DetroitDiesel Series 40 engines and variousreference works which may be ofinterest to the owner/operator arelisted in Table 35.

To purchase a copy of any of thesepublications, contact an authorize

Detroit Diesel distributor in the U.S.or Canada. Check the Yellow Pagesunder “Engine, Diesel” or refer to theDistributor and Dealer Directory listedbelow for the distributor or serviceoutlet nearest you.

Description Form No.Series 40 Service Manual 6SE410Series 40 Troubleshooting Manual 6SE241U.S. and Canada Distributor/Dealer Directory 6SE280International Distributor/Dealer Directory 6SE281Lube Oil, Fuel and Filter Requirements 7SE270Coolant Requirements for Engine Cooling Systems 7SE298Technician's Guide – Used Lubricating Oil Analysis 7SE398Technician's Guide – Turbocharger 7SE374Technician's Guide – Cooling System 7SE390

Table 35 Service Publications



DETROIT DIESEL CUSTOMER ASSISTANCE

U.S. and Canada1–800–445–1980

If you require service for any reason inthe U.S. or Canada, you may call the1–800–445–1980 customer assistancephone number. An operator willassist you in determining what type ofservice is required. Not all problemsare engine related and not all problemsare covered by engine warranties.YOU MAY BE RESPONSIBLE FORREPAIR EXPENSES.

Before calling Customer Assistance,please do the following:

□ Check coolant level.

□ Check fuel level.

□ Check for fuel leaks

□ Make sure manual shutoff valve (ifinstalled) on the fuel filter adaptor,fuel processor body or fuel supplyline is open.

□ Check the oil level on the dipstick.

□ Check diagnostic codes againstthose listed in section SERIES40 ELECTRONIC CONTROLSYSTEM.

If you call, have the followinginformation available:

□ Engine serial and model numbers.Refer to section ENGINEMODEL AND SERIAL

NUMBER LOCATIONS forlocation.

□ Vehicle, equipment or generatorset make and model

□ Accumulated miles/kilometers orhours of operation.

□ Vehicle, equipment or generatorset owner/company name

Customer Assistance

The satisfaction and goodwill of theowners of Detroit Diesel engines areof primary concern to Detroit DieselCorporation and its distributor/dealerorganizations. As the owner of aDetroit Diesel product you havea complete network of over 2,000Detroit Diesel service outlets in theU.S. and Canada, plus many outletsworldwide that are prepared to meetyour parts and service needs:

□ Service by trained personnel.

□ Sales team to help determine yourspecific power requirements.

□ In many areas, emergency service24 hours a day.

□ Complete parts support, includingreliabilt® remanufacturedcomponents.

□ Product information and literature.



We recognize, however, that despitethe best intentions of everyoneconcerned, misunderstandings mayoccur. Normally, any situation thatarises in connection with the sale,operation or service of your productwill be handled by the authorizedservice outlet in your area. In the U.S.and Canada, check the Yellow Pagesfor the Detroit Diesel service outletnearest you.

To further assure your completesatisfaction, we have developed thefollowing procedure to be followed inthe event you have a problem that hasnot been handled satisfactorily.

Step One

Discuss your problem with a memberof management from the authorizedservice outlet. Frequently, complaintsare the result of a breakdown incommunication and can quickly beresolved by a member of management.If you have already discussed theproblem with the Sales or ServiceManager, contact the GeneralManager. If your complaint originateswith a dealer, explain the matterto a management member of thedistributorship with whom the dealerhas a service agreement.

Step Two

When it appears that your problemcannot be readily resolved at thedistributor level without additional

assistance, contact the Detroit DieselRegional Product Support Manageror Operations Manager responsiblefor your local distributor. You will beassisted by a member of the manager'sstaff, depending upon the nature ofyour problem.

Prior to this contact, have thefollowing information available:

□ Engine model number*____________________________.

□ Engine serial number*____________________________.

□ Type and make of equipment.

□ Engine delivery date andaccumulated miles or hoursof operation.

□ Nature of problem.

□ Chronological summary ofengine's history.

□ Name and location of authorizedservice outlet.

*Important: Write your enginemodel number and serial numberon the lines provided. Theywill identify your engine andall service parts, plus providewarranty and extended coverageinformation. Refer to sectionENGINE MODEL AND SERIALNUMBER LOCATIONS for locationof engine model and serial numbers.



Step Three

If you are still not satisfied, present theentire matter in writing or by phone to:

Vice President, Customer AssuranceDetroit Diesel Corporation13400 Outer Drive, WestDetroit, MI 48239–4001Phone: 313–592–7357FAX: 313–592–7888

When contacting the Detroit Dieselregional offices or the DDC/MTUOff-Highway Customer AssuranceCenter, please keep in mind thatultimately your problem will likelybe resolved at the distributorship ordealership, utilizing their facilities,equipment, and personnel. Therefore,

it is suggested that you followthe above steps in sequence whenexperiencing a problem.

See Figure 31 for the Detroit DieselNAFTA On-Highway Regions.See Figure 32 for the DetroitDiesel-MTU Off-Highway Sales andCustomer Assurance Center.

The addresses and phone/fax numbersfor the on-highway regional officesare listed in Table 36. The addressesand phone/fax numbers for the DetroitDiesel-MTU Off-Highway Sales andCustomer Assurance Center officesare listed in Table 37. The addressesand phone/fax numbers for DetroitDiesel international regional officesare listed in Table 38.

Figure 31 Detroit Diesel NAFTA On-Highway Regions



Figure 32 DDC-MTU Off-Highway Sales and Customer Assurance Center

WESTERN REGIONIrvine, California7700 Irvine Center, Suite 275Irvine, CA 92618Phone: 949-753-7710Fax: 949-753-7711

EASTERN REGIONPiscataway, New Jersey169 Old New Brunswick RoadPiscataway, NJ 08854Phone: 732-926-9622Fax: 732-926-8522

CANADIAN REGIONLondon, OntarioDetroit Diesel of Canada, Ltd.150 Dufferin Ave., Suite 701London, ON N5A 5N6Phone: 519-661-0149Fax: 519-661-0171

Table 36 Detroit Diesel North American NAFTA On-Highway Offices



Construction, Industrial and MiningSales (BX7)13400 Outer Drive, WestDetroit, MI 48239-4001Telephone: 313-592-5608Fax: 313-592-5625

Marine Sales (BX6)13400 Outer Drive, WestDetroit, MI 48239-4001Telephone: 313-592-5124Fax: 313-592-5137

Powergen and Oilfield Sales (BX11)13400 Outer Drive, WestDetroit, MI 48239-4001Telephone: 313-592-7459Fax: 313-592-5158

Government Sales (BX11)13400 Outer Drive, WestDetroit, MI 48239-4001Telephone: 313-592-5708Fax: 313-592-5158

Customer Assurance (M24)13400 Outer Drive, WestDetroit, MI 48239-4001Telephone: 313-592-5550Fax: 313-592-5717

Table 37 DDC-MTU Off-Highway Sales and Customer AssuranceCenter Offices



EUROPE, MIDDLE EAST, AFRICA(EMA) REGION (On/Off-Highway)The NetherlandsRidderpoort 92984 RidderkerkThe NetherlandsPhone: (31) 180-442-900Fax: (31) 180-419-544

LATIN AMERICAN REGION(Off-Highway)Miami, Florida2277 N.W. 14th StreetLatin America BuildingMiami, Florida 33125-0068Phone: 305-637-1555Fax: 305-637-1580

ASIAN REGION (On-Highway)13400 Outer Drive, WestDetroit, MichiganPhone: 313-592-5990Fax: 313-592-5887

ASIA/PACIFIC REGION(Off-Highway)SingaporeNo. 16 Benoi CrescentSingapore 629979Phone: (65) 686-15922Fax: (65) 686-11550

PACIFIC REGION (Off-Highway)Australia11–13 Garling RoadKings Park, NSW 2148Beaumaris, Victoria 3193AustraliaPhone: (612) 8822-7000Fax: (612) 8822-7083

AUSTRALIAN REGION(On-Highway)P.O. Box 1472Canterbury, Victoria 3124AustraliaPhone: (61) 39-836-0775Fax: (61) 39-836-0770

MEXICO (On/Off-Highway)Detroit Diesel Allison de Mexico, S.A.Av. Santa Rosa 58Col. Ampliacion NorteSan Juan Ixtacala, TlanepantlaC.P. 54160, Edo de MexicoPhone: 525-333-1802Fax: 525-333-1870

Table 38 Detroit Diesel International Off-Highway Regional Offices



LIMITED WARRANTY ON ENGINES USED INMOTOR COACH, MOTOR HOME AND TRANSIT BUSAPPLICATIONS

TERMS OF COVERAGE

Uses

This warranty applies to the first retailpurchaser and subsequent ownersduring the WARRANTY PERIODof new Detroit Diesel Series 40®Engines (referred to as Engine)and attached starting motor, aircompressor and alternator (referredto as Accessories) manufacturedby Detroit Diesel Corporationand/or supplied by Detroit DieselCorporation, Detroit Diesel of CanadaLimited, or Detroit Diesel OverseasDistribution Corporation (all whichare collectively referred to as DDC)which are used in on-highway vehicleapplications, including motor coaches,motor homes and transit busses.

Defects

This warranty covers EngineREPAIRS to correct any malfunctionoccurring during the WARRANTYPERIOD resulting from defects inmaterial or workmanship.

Repairs

To obtain warranty repairs, you mustrequest the needed repairs withinthe WARRANTY PERIOD from anauthorized DDC service outlet. Onlynew genuine parts or remanufactured

parts or components supplied orapproved by DDC will be used. DDCmay, at its discretion, replace ratherthan repair components. A reasonabletime must be allowed to performthe warranty repair after taking theengine to the authorized service outlet.Repairs will be performed duringnormal business hours.

The owner is responsible for thepercentage of repair costs shown in theWARRANTY PERIOD chart below.

Warranty Period

The WARRANTY PERIOD beginson the date the engine is delivered tothe first retail purchaser or put in useprior to sale at retail, whichever dateoccurs first, and ends at the time orhour limits listed in Table 39.


LIMITED WARRANTY ON ENGINES USED IN MOTOR COACH, MOTORHOME AND TRANSIT BUS APPLICATIONS

WARRANTY PERIODWarranty Limitations

(Whichever Occurs First)Repair Charges to Be

Paid by OwnerItem

MONTHS MILES/KILO-METERS PARTS LABOR

Engine 0 – 12

0 – 50,000Miles

0 – 80,000Kilometers

No Charge No Charge

Table 39 Warranty Period – Motor Coach, Motor Home and TransitCoach Applications

Like Replacement Engine

Engine(s) supplied by DDC as areplacement for an Engine still underwarranty will assume the identity ofthe Engine being replaced and beentitled to the remaining warrantycoverage.

Service Supplies

The cost of service supplies such ascoolant, oil and filters which are notreusable due to warranted repairs iscovered by this warranty.

Engine Removal and Reinstallation

Reasonable labor costs for Engineremoval and reinstallation, whennecessary to make a warranty repair,are covered by this warranty.

THIS WARRANTY DOES NOTCOVER:

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

Repairs due to an accident, misuse,alteration, misapplication, storagedamage, negligence or modificationexceeding DDC specifications are notcovered by this warranty.

Braking Devices

DDC is not responsible for the repairof mechanical braking devices that arenot factory-installed or not installedby DDC distributors. Such devices arewarranted by the brake manufacturer.

Maintenance



DDC is not responsible for the cost ofmaintenance or repairs due to lack ofperformance of required maintenanceservices as recommended by DDC, orthe failure to use fuel, oil, lubricants, orcoolant meeting DDC-recommendedspecifications. Performance ofthe required maintenance and use ofproper fuel, oil, lubricants, and coolantare the responsibility of the owner.Refer to section MAINTENANCESCHEDULES in this guide for details.

Incidental or ConsequentialDamages

DDC is not responsible for incidentalor consequential costs or expenseswhich the owner may incur as a resultof malfunction or failure covered bythis warranty, such as communicationexpenses, meals, lodging, overtime,towing, loss of use of the Engine orvehicle (“downtime”), loss of time,inconvenience, cargo loss or damageand other similar costs and expenses.

Other Limitations

The performance of REPAIRS is theexclusive Owner's remedy under thiswarranty. DDC does not authorizeany person to assume or create forit any other obligation or liability inconnection with the Engine or theAccessories.

THIS LIMITED WARRANTY ANDTHE EMISSIONS WARRANTYARE THE ONLY WARRANTIESAPPLICABLE TO THE ENGINE

AND ACCESSORIES AS USEDIN MOTOR COACH, MOTORHOME AND TRANSIT COACHAPPLICATIONS. DETROIT DIESELCORPORATION MAKES NOOTHER WARRANTIES EXPRESSOR IMPLIED, INCLUDINGANY IMPLIED WARRANTYOF MERCHANTABILITY ORFITNESS FOR A PARTICULARPURPOSE. DETROIT DIESELCORPORATION SHALL NOT BELIABLE FOR ANY INCIDENTALOR CONSEQUENTIAL DAMAGESAS DESCRIBED ABOVE.

Some states do not allow the limitationof how long this warranty may lastor the limitation or exclusion ofincidental or consequential damages,so the above may not apply to you.This warranty gives you specific legalrights, and you may also have otherrights which may vary from state tostate.


LIMITED WARRANTY ON ENGINES USED IN FIRE TRUCK OR CRASHVEHICLE APPLICATIONS

LIMITED WARRANTY ON ENGINES USED IN FIRE TRUCKOR CRASH VEHICLE APPLICATIONS

TERMS OF COVERAGE

Uses

This warranty applies to the first retailpurchaser and subsequent ownersduring the WARRANTY PERIOD ofnew Detroit Diesel Series 40® Engines(referred to as Engine) manufacturedby Detroit Diesel Corporationand/or supplied by Detroit DieselCorporation, Detroit Diesel of CanadaLimited, or Detroit Diesel OverseasDistribution Corporation (all whichare collectively referred to as DDC)which are used in fire truck or crashvehicle applications.

Defects


Repairs

To obtain warranty repairs, you mustrequest the needed repairs withinthe WARRANTY PERIOD from anauthorized DDC service outlet. Onlynew genuine parts or remanufacturedparts or components supplied orapproved by DDC will be used. DDCmay, at its discretion, replace ratherthan repair components. A reasonabletime must be allowed to perform

the warranty repair after taking theengine to the authorized service outlet.Repairs will be performed duringnormal business hours.

Warranty Period

The WARRANTY PERIOD beginson the date the engine is deliveredto the first retail purchaser or put inuse prior to sale at retail, whicheverdate occurs first, and ends at thetime or mileage/kilometer limitslisted in Table 40.





Paid by OwnerItem

MONTHS MILES/KILO-METERS PARTS LABOR

Engine 0 – 60

0 – 50,000Miles


No Charge No Charge

Accessories 0 – 24

0 – 50,000Miles


No Charge No Charge

Table 40 Warranty Period – Fire Truck or Crash Vehicle Applications



Service Supplies



Reasonable labor costs for Engineremoval and reinstallation, whennecessary to make a warranty repair,are covered by this warranty.




Maintenance

DDC is not responsible for the cost ofmaintenance or repairs due to lack ofperformance of required maintenanceservices as recommended by DDC, orthe failure to use fuel, oil, lubricants, orcoolant meeting DDC-recommendedspecifications. Performance ofthe required maintenance and use ofproper fuel, oil, lubricants, and coolantare the responsibility of the owner.Refer to section MAINTENANCESCHEDULES in this guide for details.


LIMITED WARRANTY ON ENGINES USED IN FIRE TRUCK OR CRASHVEHICLE APPLICATIONS


DDC is not responsible for incidentalor consequential costs or expenseswhich the owner may incur as a resultof malfunction or failure covered bythis warranty, such as communicationexpenses, meals, lodging, overtime,towing, loss of use of the Engine orvehicle (“downtime”), loss of time,inconvenience, cargo loss or damageand other similar costs and expenses.

Other Limitations


THIS LIMITED WARRANTY ANDTHE EMISSIONS WARRANTYARE THE ONLY WARRANTIESAPPLICABLE TO THE ENGINEAND ACCESSORIES AS USED INFIRE TRUCKOR CRASH VEHICLEAPPLICATIONS. DETROIT DIESELCORPORATION MAKES NOOTHER WARRANTIES EXPRESSOR IMPLIED, INCLUDINGANY IMPLIED WARRANTYOF MERCHANTABILITY ORFITNESS FOR A PARTICULARPURPOSE. DETROIT DIESELCORPORATION SHALL NOT BELIABLE FOR ANY INCIDENTAL

OR CONSEQUENTIAL DAMAGESAS DESCRIBED ABOVE.




LIMITED WARRANTY ON ENGINES USED INCONSTRUCTION/INDUSTRIAL APPLICATIONS

TERMS OF COVERAGE

Uses

This warranty applies to the first retailpurchaser and subsequent ownersduring the WARRANTY PERIODof new Detroit Diesel Series 40®Engines (referred to as Engine)manufactured by Detroit DieselCorporation and/or supplied byDetroit Diesel Corporation, DetroitDiesel of Canada Limited, orDetroit Diesel Overseas DistributionCorporation (all which are collectivelyreferred to as DDC) which are used inconstruction/industrial applications.

Defects


Repairs

To obtain warranty repairs, you mustrequest the needed repairs withinthe WARRANTY PERIOD from anauthorized DDC service outlet. Onlynew genuine parts or remanufacturedparts or components supplied orapproved by DDC will be used. DDCmay, at its discretion, replace ratherthan repair components. A reasonabletime must be allowed to perform

the warranty repair after taking theengine to the authorized service outlet.Repairs will be performed duringnormal business hours.


Warranty Period



LIMITED WARRANTY ON ENGINES USED IN CONSTRUCTION/INDUSTRIALAPPLICATIONS



Paid by OwnerEngineApplication

MONTHS ENGINEHOURS PARTS LABOR**

Engine 0 – 12 Unlimited No Charge No Charge

Accessories 0 – 12 0 – 2,000 No Charge No ChargeUpon expiration of the twelve (12) month warranty coverage, but within

12,000 hours of use, the warranty continues to apply as follows:Major

Components†

13 – 36 0 – 12,000 No Charge No Charge

† Cylinder block casting, cylinder head casting, crankshaft, camshaftand connecting rods.

Table 41 Warranty Period Chart – Construction/IndustrialApplications



Service Supplies


Mechanic's Travel Expenses

DDC will pay reasonable travelexpenses for the repairing mechanicto travel to and from the repair site.

Engine Removal and Reinstallation– Construction/IndustrialApplications

Reasonable labor costs for Engineremoval and reinstallation, whennecessary to make a warranty repair,are covered by this warranty duringthe first twelve (12) months of service.






Non-DDC Supplied/ManufacturedComponents

DDC is not responsible for repairof components and/or assemblieswhich are manufactured or suppliedby another manufacturer, such asnon-DDC power take-offs, intakeand exhaust systems and fuel storagetanks. Such items are covered by theequipment manufacturer.

Maintenance

DDC is not responsible for thecost of maintenance or repairsdue to lack of performance ofrequired maintenance services asrecommended by DDC, or thefailure to use fuel, oil, lubricants andcoolant meeting DDC-recommendedspecifications. Performance ofthe required maintenance and use ofproper fuel, oil, lubricants, and coolantare the responsibility of the owner.Refer to section MAINTENANCESCHEDULES in this guide for details.


DDC is not responsible for incidentalor consequential costs or expenseswhich the owner may incur as a result

of malfunction or failure covered bythis warranty, such as communicationexpenses, meals, lodging, overtime,towing, loss of use of the Engine orvehicle (“downtime”), loss of time,inconvenience, cargo loss or damageand other similar costs and expenses.

Other Limitations


THIS LIMITED WARRANTY ANDTHE EMISSIONS WARRANTYARE THE ONLY WARRANTIESAPPLICABLE TO THE ENGINEAND ACCESSORIES AS USED INCONSTRUCTION/INDUSTRIALAPPLICATIONS. DETROIT DIESELCORPORATION MAKES NOOTHER WARRANTIES EXPRESSOR IMPLIED, INCLUDINGANY IMPLIED WARRANTYOF MERCHANTABILITY ORFITNESS FOR A PARTICULARPURPOSE. DETROIT DIESELCORPORATION SHALL NOT BELIABLE FOR ANY INCIDENTALOR CONSEQUENTIAL DAMAGESAS DESCRIBED ABOVE.


LIMITED WARRANTY ON ENGINES USED IN CONSTRUCTION/INDUSTRIALAPPLICATIONS




LIMITED WARRANTY ON ENGINES USED IN PRIME ANDSTAND-BY POWER GENERATOR SETS

TERMS OF COVERAGE

Uses

This warranty applies to the first retailpurchaser and subsequent ownersduring the WARRANTY PERIOD ofnew Detroit Diesel Series 40® Engines(referred to as Engine) manufacturedby Detroit Diesel Corporationand/or supplied by Detroit DieselCorporation, Detroit Diesel of CanadaLimited, or Detroit Diesel OverseasDistribution Corporation (all whichare collectively referred to as DDC)which are used in prime or stand-bypower generators delivered in the U.S.or Canada.

Defects


Repairs

To obtain warranty repairs, you mustrequest the needed repairs withinthe WARRANTY PERIOD from anauthorized DDC service outlet. Onlynew genuine parts or remanufacturedparts or components supplied orapproved by DDC will be used. DDCmay, at its discretion, replace ratherthan repair components. A reasonable

time must be allowed to performthe warranty repair after taking theengine to the authorized service outlet.Repairs will be performed duringnormal business hours.


Warranty Period



LIMITED WARRANTY ON ENGINES USED IN PRIME AND STAND-BYPOWER GENERATOR SETS



Paid by OwnerEngineApplication

MONTHS ENGINEHOURS PARTS LABOR**

Prime PowerGenerator 0 – 12 Unlimited No Charge No Charge

Upon expiration of the 12 month warranty coverage, but within 24 monthsof delivery date, the warranty continues to apply as follows:

MajorComponents

†13 – 24 No Limit No Charge 100%

Stand-byPower

Generator0 – 12 0 – 400 No Charge No Charge

** 100% of engine removal and reinstallation labor charge to be paid by owner.† Cylinder block casting, cylinder head casting, crankshaft, camshaft

and connecting rods.

Table 42 Warranty Period Chart – Prime Power Generator Set



Service Supplies


Mechanic's Travel Expenses

DDC will pay reasonable travelexpenses for the repairing mechanicto travel to and from the repair site.


Repairs Due to Accidents, Misuse,Storage Damage, Negligence orCertain Modifications

Repairs due to an accident, misuse,misapplication, storage damage,negligence or modification exceedingDDC specifications are not covered bythis warranty.




Labor costs to gain access or replacethe Engine, including removal andreinstallation of items/materials orcomponents in which the Engineis installed, are not covered by thiswarranty.

Non-DDC Supplied/ManufacturedComponents

DDC is not responsible for repair ofcomponents and/or assemblies whichare manufactured or supplied byanother manufacturer, such as intakeand exhaust systems and fuel storagetanks. Such items are covered by theequipment manufacturer.

Maintenance

DDC is not responsible for the cost ofmaintenance or repairs due to lack ofperformance of required maintenanceservices as recommended by DDC, orthe failure to use fuel, oil, lubricants,coolant, cooling air and ventilationmeeting DDC-recommendedspecifications. Performance of therequired maintenance and use ofproper fuel, oil, lubricants, coolantcooling air and ventilation arethe responsibility of the owner.Refer to section MAINTENANCESCHEDULES in this guide for details.

Incidental or ConsequentialDamage

This warranty does not cover anyeconomic loss, including withoutlimitation, communication expenses,meals, lodging, loss of use of theEngine, loss of time, inconvenience,overtime, transportation of the Engineor any other cost or expense resultingfrom a defect covered by this warranty.

Other Limitations

THIS LIMITED WARRANTYIS THE ONLY WARRANTYAPPLICABLE TO THE ENGINEAND ACCESSORIES ASUSED IN PRIME POWERAND STAND-BY POWERGENERATORS. DETROIT DIESELCORPORATION MAKES NOOTHER WARRANTIES EXPRESSOR IMPLIED, INCLUDINGANY IMPLIED WARRANTYOF MERCHANTABILITY ORFITNESS FOR A PARTICULARPURPOSE. DETROIT DIESELCORPORATION SHALL NOT BELIABLE FOR ANY INCIDENTALOR CONSEQUENTIAL DAMAGESAS DESCRIBED ABOVE.



SPECIFICATIONS

SPECIFICATIONS

Fuel and Lubricating OilFilter Requirements

FUEL FILTER REQUIREMENTS – Series 40 Regular ServiceFilter Type Detroit Diesel Part No.

Secondary — Spin-On 1 820 479 C1 (6 In.)

Secondary — Spin-On 23523907Primary — Fuel Pro 232 Element 23528565

LUBRICATING OIL FILTER REQUIREMENTSFilter Type Detroit Diesel Part No.Full Flow 23529744

Table 43 Series 40 Fuel and Lubricating Oil Filter Requirements

Engine Oil Capacity

OIL PAN CAPACITYAll Series 40 off-highway oil pans (front sump and rear sump)

require the same amount of engine oil:22 quarts to the ADD mark ....... Without oil filter24 quarts to the FULL mark .......Without oil filterTOTAL OIL CAPACITY OF THE ENGINE

28 quarts to the FULL mark with filter installed and filter and oil galleries charged

Table 44 Series 40 Engine Oil Capacity



Power Cool EngineProducts

POWER COOL FULLYFORMULATED IEG COOLANT

Coolant Type Part Number Description

23512138 1 Gallon Jug – 6Per Case

23512139 55 Gallon Drum

23529295 330 Gallon ToteConcentrated

23512140 Bulk Delivery – 1,000Gallon Min.



23528544 330 Gallon TotePre-Blended 50:50


Table 45 POWER COOL Fully Formulated IEG Coolant

POWER COOL LATINAMERICAN COOLANT



23524923 55 Gallon DrumPre-Blended 67:33

23524924 Bulk Delivery – 1,000Gallon Minimum

Table 46 POWER COOL Latin American Coolant


SPECIFICATIONS

POWER COOL 2000SUPPLEMENTAL COOLANTADDITIVE


23507858 Pint Bottle – 12 Per case

23507859 Half Gallon Jug – 6Per Case

23507860 5 Gallon Pail

For Power Cool IEGCoolant


Table 47 POWER COOL 2000 Supplemental Coolant Additive

POWER COOL 3000SUPPLEMENTAL COOLANTADDITIVE


23507854 Pint Bottle – 12 Per Case

23507855 Half Gallon Jug – 6Per Case


For POWER COOLIEG Coolant


Table 48 POWER COOL 3000 Supplemental Coolant Additive



POWER COOL 3000SUPPLEMENTAL ADDITIVECOOLANT FILTERS


235075454 Ounce (1 Pint

Equivalent)

235084258 Ounce (2 Pint

Equivalent)

2350842612 Ounce (3 Pint

Equivalent)

2350718916 Ounce (4 Pint

Equivalent)

2350842732 Ounce (8 Pint

Equivalent)

For POWER COOLIEG Coolant

2350842853 Ounce (13 Pint

Equivalent)

Table 49 POWER COOL 3000 Supplemental Additive Coolant Filters

POWER COOL SUPPLEMENTALADDITIVE NEED RELEASECOOLANT FILTERS


23516488 For 0 – 8 Gallon SystemsFor POWER COOL

IEG Coolant 23516489For 8 – 20 Gallon

Systems

Table 50 POWER COOL SUPPLEMENTAL ADDITIVE NEEDRELEASE COOLANT FILTERS


SPECIFICATIONS

POWER COOL PLUSEXTENDEDLIFE OAT COOLANT



23519394 55 Gallon DrumConcentrated


23519396 One Gallon Jug – 6Per Case

23519398 55 Gallon DrumPre-Blended 50:50


Table 51 POWER COOL Plus Extended Life OAT Coolant

POWER COOL PLUSEXTENDERFOR USE WITH POWER COOLPLUS OAT COOLANT


For Power Cool Plus 23519400 Quart Bottle – 6 PerCase

Table 52 POWER COOL Plus Extender for Use with POWER COOLPlus OAT Coolant



POWER COOL PLUS 6000 OATINHIBITOR FOR WATER-ONLYSYSTEMS


23522127 1 Gallon Jug – 6 PerCaseWater Only


Table 53 POWER COOL Plus 6000 OAT Inhibitor for Water-OnlySystems

POWER COOL COOLINGSYSTEM CLEANERS


200164 On-Half Gallon Jug – 6Per Case

200105 5 Gallon PailOn-Line Cleaner


Twin Pack 201549 Twin Pack – 2 Per Case

Table 54 Power Cool Cooling System Cleaners


SPECIFICATIONS

POWER TRAC COOLANTTESTING AND ANALYSISPRODUCTS

Application Part Number DescriptionIndicates Nitrite,Molybdate & GlycolLevels

235194013-Way Coolant TestStrips(Single Foil Packs)

Indicates Nitrite,Molybdate & GlycolLevels

235194023-Way Coolant TestStrips(Bottle of 50)

Indicates Nitrite,Molybdate & GlycolLevels

235227743-Way Coolant TestStrips(Bottle of 10)

Complete IEG/IPGCoolant Analysis 23516921

Coolant Analysis Bottle(Carton of 6)

Organic CoolantAnalysis 23523398

Laboratory CoolantAnalysis Bottle(Carton of 6)

Table 55 Power Trac Coolant Testing and Analysis Products


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