Man Series 40 Engine Operator's Guide

SERIES 40 ENGINE OPERATOR'S GUIDE To the Operator major parts replacement. Authorized service outlets worldwide stock factory-original parts and have the specialized equipment and experienced, trained personnel to provide prompt preventive maintenance and skilled engine repairs. This guide contains instructions on the safe operation and preventive maintenance of your Detroit Diesel Series 40™engine used in motor coach, transit coach, construction/industrial, emergency vehicle and power generator set applications. Maintenance instructions cover routine engine services such as lube oil and filter changes in enough detail to permit self-servicing, if desired.

The information and specifications in this publication are based on the information in effect at the time of approval for printing. Contact an authorized Detroit Diesel service outlet for information on the latest revision. The right is reserved to make changes at any time without obligation. The operator should become familiar with the contents of this guide before operating the engine or carrying out maintenance procedures. Power-driven equipment is only as safe as the person operating the controls. You are urged, as the operator of this diesel engine, to keep fingers and clothing away from the revolving belts, drive shafts, pulleys, etc. on the engine installation.

Throughout this guide CAUTIONS regarding personal safety and NOTICES regarding engine performance or service life will appear. To avoid personal injury and ensure long engine service life, always heed these instructions. Whenever possible, it will benefit you to rely on an authorized Detroit Diesel service outlet for all your service needs from maintenance to All information subject to change without notice. (Rev. May 2004) i DDC-SVC-MAN-0057 0305 Copyright © 2003 DETROIT DIESEL CORPORATION

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NOTICE: Trademark Information Failure to check and maintain SCA (supplemental coolant additive) levels at required concentrations will result in severe damage (corrosion) to the engine cooling system and related components. Coolant must be inhibited with the recommended SCAs listed in this guide.Refer to section G. How to Select Coolant. In addition, the engine can be equipped with a coolant filter/inhibitor system as an installed option or as an after-sale item. Detroit Diesel®, DDC®, DDEC®, reliabilt®, POWER COOL ®, POWER Trac ® and POWER GUARD ® are registered trademarks of Detroit Diesel Corporation. Series is a trademark of Detroit Diesel Corporation.

Delco Remy® is a registered trademark of Delco Remy America, Inc.Fuel Pro®, Sea Pro®, and Mega Filter® are registered trademarks of Davco Manufacturing, L.L.C.. PowerBand® is a registered trademark of Gates Rubber Company. Biobor® is a registered trademark of United States Borax and Chemical Corporation. All other trademarks used are the property of their respective owners. WARRANTY The applicable engine warranty for Series 40 engines is contained in the Warranty Information section of this operator's guide. Individual engine warranty information booklets are available from authorized Detroit Diesel service outlets. Keep this Operator's Guide with the engine installation at all times.

It contains important operating, maintenance, and safety instructions. ii All information subject to change without notice. (Rev. May 2004) DDC-SVC-MAN-0057 0305 Copyright © 2003 DETROIT DIESEL CORPORATION

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SERIES 40 ENGINE OPERATOR'S GUIDE TABLE OF CONTENTS INTRODUCTION .................................................................................. 1 NON-GENUINE AND REBUILT COMPONENT QUALITY ALERT .. 1 CAUTION SUMMARY .......................................................................... 3 GENERAL INFORMATION .................................................................. 11 ENGINE FEATURES ....................................................................... 11 COMPONENT LOCATION ............................................................... 11 ENGINE MODEL AND SERIAL NUMBER LOCATIONS ....................

16 TURBOCHARGER IDENTIFICATION ............................................. 17 OPERATING INSTRUCTIONS ............................................................ 18 PREPARATIONS FOR FIRST TIME ENGINE START ..................... 18 COOLING SYSTEM CHECKS .................................................... 18 LUBRICATION SYSTEM CHECKS ............................................. 19 FUEL SYSTEM CHECKS ............................................................ 20 OTHER CHECKS ........................................................................ 21 STARTING THE ENGINE ................................................................

22 ENGINE DIAGNOSTIC BUTTON ................................................ 23 INITIAL ENGINE START ............................................................. 23 EMERGENCY JUMP STARTING .................................................... 24 RUNNING THE ENGINE ................................................................. 26 OIL PRESSURE .......................................................................... 26 WARM-UP ................................................................................... 26 INSPECTION ............................................................................... 26 AVOID UNNECESSARY IDLING .................................................

27 STOPPING THE ENGINE ................................................................ 27 NORMAL STOPPING .................................................................. 27 SHUTDOWN WARNING LIGHT AND BUZZER .............................. 27 ROAD OPERATION ......................................................................... 28 COLD WEATHER OPERATION ...................................................... 28 HOT WEATHER OPERATION ......................................................... 29 EXTENDED IDLING PERIODS ....................................................... 29 SERIES 40 ELECTRONIC CONTROL SYSTEM ................................

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

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

36 MAINTENANCE SCHEDULES ............................................................ 37 MAINTENANCE INTERVALS .......................................................... 37 LUBRICATION AND PREVENTIVE MAINTENANCE INTERVALS .... 53 ITEM 1 – LUBRICATING OIL ........................................................... 53 ITEM 2 – FUEL AND FUEL TANK ................................................... 55 ITEM 3 – FUEL LINES, FLEXIBLE HOSES ..................................... 56 PRE-START INSPECTION .......................................................... 56 HOSE SERVICE LIFE .................................................................

57 ITEM 4 – COOLING SYSTEM ......................................................... 58 COOLANT LEVEL ....................................................................... 58 COOLANT INHIBITORS .............................................................. 58 COOLANT DRAIN INTERVAL ..................................................... 58 ITEM 5 – TURBOCHARGER, AIR-TO-AIR CHARGE COOLER ..... 60 ITEM 6 – BATTERY ......................................................................... 60 ITEM 7– DRIVE BELTS ................................................................... 61 ITEM 8 – AIR COMPRESSOR .........................................................

62 ITEM 9 – AIR CLEANER .................................................................. 62 AIR CLEANER REPLACEMENT ................................................. 63 ITEM 10 – LUBRICATING OIL FILTERS ......................................... 63 ITEM 11 – FUEL FILTERS ............................................................... 64 FUEL FILTER AND STRAINER .................................................. 64 FUEL PRO® 382 FILTERS .......................................................... 66 ITEM 12 – WATER PUMP, COOLANT INHIBITOR ELEMENT ....... 66 WATER PUMP ............................................................................

66 COOLANT INHIBITOR ELEMENT .............................................. 66 ITEM 13 – CRANKING MOTOR ...................................................... 66 ITEM 14 – AIR SYSTEM .................................................................. 67 ITEM 15 – EXHAUST SYSTEM ....................................................... 67 ITEM 16 – ENGINE (STEAM CLEAN) ............................................. 67 ITEM 17 – RADIATOR ..................................................................... 67 iv All information subject to change without notice. (Rev. May 2004) DDC-SVC-MAN-0057 0305 Copyright © 2003 DETROIT DIESEL CORPORATION

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