MAN DD Platform Manual (EN)

DDC-SVC-MAN-0175 DD Platform EuroIV Operators Manual Specifications are subject to change without notice. Detroit Diesel Corporation is registered to ISO 9001:2001. Copyright © Detroit Diesel Corporation. All rights reserved. Detroit Diesel Corporation is a Daimler company. Printed in U.S.A.

Стр. 1

Table of Contents Table of Contents Forward ............................................................................................................. 4 Introduction.................................................................................................... 4 Non-Genuine and Rebuilt Component Quality Alert.................................... 4 Personnel Requirements................................................................................ 4 Engine Conversions and Modifications......................................................... 5 To the Operator ................................................................................................

6 Caution Summary ............................................................................................. 8 Engine Identification ...................................................................................... 15 Engine Components - DD Platform............................................................. 15 Engine Model and Serial Number Designation........................................... 16 Operating Instructions for Starting the Engine ........................................... 20 First Time Start Preparations....................................................................... 20 Detroit Diesel Electronic Controls (DDEC) System ....................................

38 DDEC VI System........................................................................................ 38 Detroit Diesel Electronic Control System Operation.................................. 40 Detroit Diesel Electronic Control System Features..................................... 44 Accelerating the Vehicle.............................................................................. 46 Cruise Control.............................................................................................. 47 Engine Brake and Cruise Control................................................................

49 DD Platform Shifting................................................................................... 50 Idling............................................................................................................ 50 Engine Brake System ...................................................................................... 51 Driver Control Switches.............................................................................. 51 Clutch Pedal and Throttle Position Controls............................................... 51 Engine Brake Activation Conditions...........................................................

51 Engine Brake Operation............................................................................... 51 Anti-Lock Braking Systems........................................................................ 52 Operating on Flat, Dry Pavement................................................................ 53 Operating Down a Long, Steep Grade......................................................... 53 Operating on Wet or Slippery Pavement..................................................... 54 Engine Systems ...............................................................................................

56 Preventive Maintenance Intervals ................................................................ 58 Preventive Maintenance Intervals................................................................ 58 Preventive Maintenance Tables................................................................... 62 Routine Preventive Maintenance .................................................................. 64 Monitoring the Lubricating Oil................................................................... 64 Monitoring the Lubricating Oil Filter..........................................................

65 Monitoring the Cooling System................................................................... 66 Inspection of the Radiator............................................................................ 67 Monitoring the Cooling System Filter......................................................... 68 Monitoring the Fuel Filters.......................................................................... 68 Adjusting the Valve Lash............................................................................ 68 Monitoring the Belt Tensioner..................................................................... 69 2 All information subject to change without notice.

Copyright © 2014 DETROIT DIESEL CORPORATION DDC-SVC-MAN-0175

Стр. 2

DD Platform EuroIV Operators Manual Monitoring the Serpentine Belts.................................................................. 69 Inspection of the Air Intake System............................................................ 70 Monitoring the Air Cleaner.......................................................................... 70 Monitoring the Exhaust System................................................................... 71 Inspection of the Air Compressor................................................................ 71 Monitoring the Fuel and Fuel Tank.............................................................

71 Inspection of Hoses and Fittings for Fuel Leaks......................................... 72 Inspection of the Turbocharger and Charge Air Cooler.............................. 73 Inspection of the Battery.............................................................................. 73 Steam Cleaning the Engine.......................................................................... 74 Inspection of the Battery-Charging Alternator............................................ 74 Lubricating the Fan Hub.............................................................................. 75 Checking the Vibration Damper..................................................................

75 How to Procedures .......................................................................................... 77 How to Select Lubricating Oil..................................................................... 77 When to Change Oil.................................................................................... 78 How to Replace the Lubricating Oil and Oil Filter..................................... 79 How to Select Diesel Fuel........................................................................... 81 How to Replace the Fuel Filters..................................................................

83 Engine Out of Fuel – How to Restart.......................................................... 89 How to Clean an Engine.............................................................................. 90 How to Clean the Cooling System............................................................... 91 Degreasing the Cooling System................................................................... 92 How to Select Coolant................................................................................. 92 How to Replace the Coolant Filter............................................................

100 Checking the Hoses................................................................................... 101 How to Service the Dry Type Air Cleaner................................................ 101 Troubleshooting ............................................................................................ 103 Abnormal Coolant Temperature................................................................ 103 Hard Starting.............................................................................................. 103 Abnormal Engine Operation......................................................................

104 Abnormal Operating Conditions................................................................ 105 Engine Storage .............................................................................................. 107 Preparing Engine for Storage..................................................................... 107 Procedure for Restoring to Service an Engine that Has Been in Extended Storage....................................................................................................... 110 Customer Assistance .....................................................................................

112 Customer Assistance.................................................................................. 112 Detroit Genuine Coolant Engine Products ................................................. 114 Engine Oil Capacities ................................................................................... 116 All information subject to change without notice. 3 DDC-SVC-MAN-0175 Copyright © 2014 DETROIT DIESEL CORPORATION

Стр. 3

Personnel Requirements

Forward Forward Introduction This manual is intended for use by the operator of a Detroit™ engine used in On- Highway Vehicle applications. Non-Genuine and Rebuilt Component Quality Alert Electronic engine controls have been instrumental in aiding engine manufacturers in meeting the stringent emission requirements of the U.S. Environmental Protection Agency (EPA) and the California Air Resources Board (CARB) and also in meeting the ever-increasing performance demands of the customer. Maintenance procedures must be followed in order to continue satisfactory performance and durability and to ensure coverage of the engine under the manufacturer’s warranty.

Many of these maintenance procedures also ensure that the engine continues to comply with applicable emissions standards. Proper maintenance procedures, using specific components engineered to comply with emissions regulations, may be performed by an authorized Detroit™ distributor or dealer, an independent outlet or the operator or owner. The owner is responsible for determining the suitability of components to maintain emissions compliance during the engine’s useful emission life.

Detroit™ cautions that the indiscriminate rebuilding of precision components, without the benefit of specifications, specialized equipment, and knowledge of the electronic operating system, will jeopardize performance or lead to more serious problems, and can take the engine outside of compliance with U.S. EPA or CARB emissions standards. There are several other components in an engine, such as turbocharger, camshaft, piston, which are specifically designed and manufactured to exacting standards for emissions compliance. It is important that these components, if replaced, modified or substituted, can be verified to ensure that the engine remains in compliance with emissions standards.

The use of inadequately engineered, manufactured or tested components in repair or rebuild of the engine may be in violation of the federal Clean Air Act and applicable U.S. EPA or CARB regulations. Furthermore, modern engines exhibit operating parameters which require the use of proper fluids, such as fuel, coolant and lubricating oil, to maintain long engine life. The use of fluids that do not meet Detroit™ specifications may result in premature wear or engine failure. 4 All information subject to change without notice. Copyright © 2014 DETROIT DIESEL CORPORATION DDC-SVC-MAN-0175

Стр. 4