DDC-SVC-MAN-0057
SERIES 40 ENGINE OPERATOR'S GUIDE
To the Operator
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 operator should become familiar
with the contents of this guide before
operating the engine or carrying out
maintenance procedures.
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.
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.
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)
DDC-SVC-MAN-0057 0305 Copyright © 2003 DETROIT DIESEL CORPORATION
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NOTICE:
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.
Trademark Information
Detroit Diesel®, DDC®, DDEC®,
reliabilt®, POWER COOL®, POWER
Trac® and POWER GUARD® are
registered trademarks of Detroit
Diesel Corporation. Series 40™
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.
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All information subject to change without notice. (Rev. May 2004)
DDC-SVC-MAN-0057 0305 Copyright © 2003 DETROIT DIESEL CORPORATION
SERIES 40 ENGINE OPERATOR'S GUIDE
TABLE OF CONTENTS
INTRODUCTION ..................................................................................
NON-GENUINE AND REBUILT COMPONENT QUALITY ALERT ..
1
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 ............................................................
PREPARATIONS FOR FIRST TIME ENGINE START .....................
COOLING SYSTEM CHECKS ....................................................
LUBRICATION SYSTEM CHECKS .............................................
FUEL SYSTEM CHECKS ............................................................
OTHER CHECKS ........................................................................
STARTING THE ENGINE ................................................................
ENGINE DIAGNOSTIC BUTTON ................................................
INITIAL ENGINE START .............................................................
EMERGENCY JUMP STARTING ....................................................
RUNNING THE ENGINE .................................................................
OIL PRESSURE ..........................................................................
WARM-UP ...................................................................................
INSPECTION ...............................................................................
AVOID UNNECESSARY IDLING .................................................
STOPPING THE ENGINE ................................................................
NORMAL STOPPING ..................................................................
SHUTDOWN WARNING LIGHT AND BUZZER ..............................
ROAD OPERATION .........................................................................
COLD WEATHER OPERATION ......................................................
HOT WEATHER OPERATION .........................................................
EXTENDED IDLING PERIODS .......................................................
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SERIES 40 ELECTRONIC CONTROL SYSTEM ................................ 31
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TABLE OF CONTENTS
SERIES 40 ENGINE SYSTEMS ..........................................................
FUEL SYSTEM ................................................................................
LUBRICATION SYSTEM .................................................................
COOLING SYSTEM .........................................................................
ELECTRICAL SYSTEM ...................................................................
AIR INDUCTION SYSTEM ..............................................................
EXHAUST SYSTEM ........................................................................
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36
36
36
MAINTENANCE SCHEDULES ............................................................ 37
MAINTENANCE INTERVALS .......................................................... 37
LUBRICATION AND PREVENTIVE MAINTENANCE INTERVALS ....
ITEM 1 – LUBRICATING OIL ...........................................................
ITEM 2 – FUEL AND FUEL TANK ...................................................
ITEM 3 – FUEL LINES, FLEXIBLE HOSES .....................................
PRE-START INSPECTION ..........................................................
HOSE SERVICE LIFE .................................................................
ITEM 4 – COOLING SYSTEM .........................................................
COOLANT LEVEL .......................................................................
COOLANT INHIBITORS ..............................................................
COOLANT DRAIN INTERVAL .....................................................
ITEM 5 – TURBOCHARGER, AIR-TO-AIR CHARGE COOLER .....
ITEM 6 – BATTERY .........................................................................
ITEM 7– DRIVE BELTS ...................................................................
ITEM 8 – AIR COMPRESSOR .........................................................
ITEM 9 – AIR CLEANER ..................................................................
AIR CLEANER REPLACEMENT .................................................
ITEM 10 – LUBRICATING OIL FILTERS .........................................
ITEM 11 – FUEL FILTERS ...............................................................
FUEL FILTER AND STRAINER ..................................................
FUEL PRO® 382 FILTERS ..........................................................
ITEM 12 – WATER PUMP, COOLANT INHIBITOR ELEMENT .......
WATER PUMP ............................................................................
COOLANT INHIBITOR ELEMENT ..............................................
ITEM 13 – CRANKING MOTOR ......................................................
ITEM 14 – AIR SYSTEM ..................................................................
ITEM 15 – EXHAUST SYSTEM .......................................................
ITEM 16 – ENGINE (STEAM CLEAN) .............................................
ITEM 17 – RADIATOR .....................................................................
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DDC-SVC-MAN-0057 0305 Copyright © 2003 DETROIT DIESEL CORPORATION
SERIES 40 ENGINE OPERATOR'S GUIDE
ITEM 18 – OIL PRESSURE .............................................................
ITEM 19 – BATTERY-CHARGING ALTERNATOR ..........................
BOSCH & DELCO-REMY SERVICE REQUIREMENTS .............
ALTERNATOR PRECAUTIONS ..................................................
ITEM 20 – ENGINE AND TRANSMISSION MOUNTS ....................
ITEM 21 – CRANKCASE PRESSURE ............................................
ITEM 22 – FAN HUB ........................................................................
ITEM 23 – THERMOSTAT AND SEAL ............................................
ITEM 24 – CRANKCASE BREATHER .............................................
ITEM 25 – ENGINE TUNE-UP .........................................................
ITEM 26 – IDLER PULLEY ..............................................................
ITEM 27 – VIBRATION DAMPER ....................................................
WELDING PRECAUTION ...........................................................
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HOW-TO SECTION ..............................................................................
A. HOW TO SELECT LUBRICATING OIL .......................................
LUBRICANT SELECTION IN NORTH AMERICA .......................
LUBRICANT REQUIREMENTS ..................................................
THE USE OF SUPPLEMENTAL ADDITIVES ..............................
B. WHEN TO CHANGE OIL .............................................................
OIL DRAIN INTERVALS ..............................................................
DISPOSING OF WASTE OIL ......................................................
C. HOW TO REPLACE THE LUBE OIL FILTER .............................
REPLACE SPIN-ON TYPE OIL FILTER ......................................
D. HOW TO SELECT FUEL OIL ......................................................
QUALITY .....................................................................................
FUEL CONTAMINATION .............................................................
PROHIBITED ADDITIVES ...........................................................
USED LUBRICATING OIL .......................................................
GASOLINE .............................................................................
E. HOW TO REPLACE THE FUEL FILTER .....................................
REPLACE FUEL FILTER AND STRAINER .................................
PRIME THE FUEL SYSTEM .......................................................
REPLACE FUEL/WATER SEPARATOR ELEMENT ....................
REPLACE FUEL PRO FILTER ELEMENT ..................................
F. ENGINE OUT OF FUEL — HOW TO RESTART .........................
G. HOW TO SELECT COOLANT ....................................................
DEFINITIONS ..............................................................................
APPROVED COOLANTS ............................................................
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TABLE OF CONTENTS
EG OR PG & WATER + SCA INHIBITOR ...............................
MIXING EG OR PG ANTIFREEZE AND WATER ...................
RECYCLED ANTIFREEZE ....................................................
EG OR PG & WATER + OAT INHIBITOR ...............................
WATER ONLY + SCA OR WATER ONLY + OAT INHIBITOR
WATER REQUIREMENTS .....................................................
COOLANTS NOT RECOMMENDED ..........................................
ADDITIVES NOT RECOMMENDED ...........................................
MAINTENANCE ...........................................................................
COOLANT INHIBITOR TEST INTERVALS ............................
SUPPLEMENTAL ADDITIVES ................................................
MAINTENANCE INTERVALS ..................................................
SCA TEST PROCEDURES .........................................................
NEED-RELEASE FILTERS (NON-OAT SYSTEMS) ....................
DROPOUT ...................................................................................
EXTENDER ADDITIVE FOR OAT COOLANT ............................
OAT COOLANT DRAIN INTERVAL ........................................
CHRONIC COOLANT SYSTEM PROBLEMS .............................
MAINTENANCE PRODUCTS .....................................................
POWER COOL SCAS .............................................................
POWER COOL COOLANT FILTER ELEMENTS ....................
POWER COOL CLEANERS ...................................................
SUMMARY OF COOLANT RECOMMENDATIONS ....................
H. HOW TO REPLACE THE COOLANT FILTER ............................
I. HOW TO DRAIN AND FLUSH THE COOLING SYSTEM ............
J. WHEN TO SERVICE THE DRY TYPE AIR CLEANER ................
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BASIC TROUBLESHOOTING ............................................................. 109
ENGINE STORAGE .............................................................................
PREPARING ENGINE FOR STORAGE ..........................................
TEMPORARY STORAGE (30 DAYS OR LESS) .........................
EXTENDED STORAGE (MORE THAN 30 DAYS) ......................
RESTORING ENGINE TO SERVICE ..........................................
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SERVICE PUBLICATIONS .................................................................. 122
DETROIT DIESEL CUSTOMER ASSISTANCE .................................. 123
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All information subject to change without notice. (Rev. May 2004)
DDC-SVC-MAN-0057 0305 Copyright © 2003 DETROIT DIESEL CORPORATION
SERIES 40 ENGINE OPERATOR'S GUIDE
MOTOR COACH, MOTOR HOME AND TRANSIT BUS ENGINE
WARRANTY ......................................................................................... 129
FIRE TRUCK OR CRASH VEHICLE ENGINE WARRANTY .............. 132
CONSTRUCTION/INDUSTRIAL ENGINE WARRANTY ..................... 135
PRIME AND STAND-BY POWER GENERATOR SET ENGINE
WARRANTY ......................................................................................... 139
SPECIFICATIONS ................................................................................
FUEL AND LUBRICATING OIL FILTER REQUIREMENTS ............
ENGINE OIL CAPACITY ..................................................................
POWER COOL ENGINE PRODUCTS ............................................
FULLY FORMULATED IEG COOLANT .......................................
LATIN AMERICAN COOLANT ....................................................
2000 SUPPLEMENTAL COOLANT ADDITIVE ...........................
3000 SUPPLEMENTAL COOLANT ADDITIVE ...........................
3000 SUPPLEMENTAL ADDITIVE COOLANT FILTERS ............
SUPPLEMENTAL ADDITIVE NEED-RELEASE FILTERS ..........
PLUS EXTENDED LIFE OAT COOLANT ....................................
PLUS EXTENDER FOR POWER COOL PLUS OAT COOLANT
PLUS OAT INHIBITOR FOR WATER-ONLY SYSTEMS .............
COOLING SYSTEM CLEANERS ................................................
COOLANT TESTING AND ANALYSIS PRODUCTS ...................
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TABLE OF CONTENTS
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DDC-SVC-MAN-0057 0305 Copyright © 2003 DETROIT DIESEL CORPORATION
SERIES 40 ENGINE OPERATOR'S GUIDE
INTRODUCTION
This guide is intended for use by the
operator of a Detroit Diesel Series
40™ engine used in one of the
following applications:
□ Transit Coaches
□ Construction/Industrial
□ Generator Set
Non-Genuine and Rebuilt
Component Quality Alert
In recent years, electronic engine
controls have been instrumental
in aiding engine manufacturers in
meeting the stringent emission
requirements of the U.S.
Environmental Protection Agency
(U.S. EPA) and the California Air
Resources Board (CARB) and
also in meeting the ever-increasing
performance demands of the customer.
Maintenance procedures are to
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. The U.S.
EPA specifically defines an engine's
“useful emission life” — currently
established as 290,000 miles (464,000
kilometers) for on-highway engines.
Proper maintenance procedures, using
specific components engineered to
comply with emissions regulations,
may be performed by an authorized
Detroit Diesel 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.
Electronic controls and components
have significantly increased in
sophistication, but the fundamental
objective remains the same — precise
timing and delivery of fuel. The very
heart of the Detroit Diesel electronic
controls is the electronic unit injector
(EUI). The proper functioning of the
EUI is absolutely paramount if the
benefits of electronic controls are to be
realized. Detroit Diesel Corporation
has built over 650,000 engines with
electronic unit injectors — more than
anyone else in the business.
Detroit Diesel 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.
All information subject to change without notice. (Rev. May 2004)
DDC-SVC-MAN-0057 0305 Copyright © 2003 DETROIT DIESEL CORPORATION
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INTRODUCTION
There are other components in
an engine, such as turbocharger,
camshaft, piston, etc., 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 (Environmental Protection
Agency) or CARB (California Air
Resources Board) 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 Diesel
Corporation specifications may result
in 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
SERIES 40 ENGINE OPERATOR'S GUIDE
CAUTION SUMMARY
The following cautions must be
observed by the operator of the
vehicle or equipment in which this
engine is installed and/or by those
performing basic engine preventive
maintenance. Failure to read and
heed these cautions and exercise
reasonable care for personal safety
and the safety of others when
operating the vehicle/equipment
or performing basic engine
preventive maintenance may result
in personal injury and engine
and/or vehicle/equipment damage.
1. Observe the following cautions
when operating the engine:
To avoid injury from the loss of
vehicle control, do not use cruise
control under these conditions:
□ When it is not possible to
keep the vehicle at a constant
speed (on winding roads, in
heavy traffic, in traffic that
varies in speed, etc.).
To avoid injury from loss of
vehicle control, do not activate
the Engine Brake system under
the following conditions:
□ On wet or slippery pavement,
unless the vehicle is equipped
with ABS (anti-lock braking
system) and you have had
prior experience driving
under these conditions.
□ When driving without a trailer
(bobtailing) or pulling and
empty trailer.
□ If the tractor drive wheels
begin to lock or there is
fishtail motion after the
Engine Brake is activated.
Deactivate the brake system
immediately, if this occurs.
Failure to observe these
precautions may result in
loss of vehicle control and/or
personal injury.
□ On slippery roads
(wet pavement, ice-or
snow-covered roads, loose
gravel, etc.).
All information subject to change without notice. (Rev. May 2004)
DDC-SVC-MAN-0057 0305 Copyright © 2003 DETROIT DIESEL CORPORATION
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CAUTION SUMMARY
Diesel engine exhaust and some
of its constituents are known to
the State of California to cause
cancer, birth defects, and other
reproductive harm.
To avoid injury when working
on or near an operating engine,
wear protective clothing,
eye protection, and hearing
protection.
□ Always start and operate an
engine in a well ventilated
area.
□ If operating an engine in
an enclosed area, vent the
exhaust to the outside.
□ Do not modify or tamper
with the exhaust system or
emission control system.
2. Observe the following cautions
when performing basic
preventive maintenance on
the engine:
To avoid injury from hot oil, do
not operate the engine with the
rocker cover(s) removed.
To avoid injury from fire, contain
and eliminate leaks of flammable
fluids as they occur. Failure to
eliminate leaks could result in
fire.
To avoid injury when working
near or on an operating engine,
remove loose items of clothing,
jewelry, tie back or contain long
hair that could be caught in any
moving part causing injury.
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All information subject to change without notice. (Rev. May 2004)
DDC-SVC-MAN-0057 0305 Copyright © 2003 DETROIT DIESEL CORPORATION
SERIES 40 ENGINE OPERATOR'S GUIDE
To avoid injury from contact with
the contaminants in used engine
oil, wear protective gloves and
apron.
To avoid injury from hot surfaces,
allow engine to cool before
removing any component. Wear
protective gloves.
To avoid injury from slipping and
falling, immediately clean up any
spilled liquids.
To avoid injury, use care when
working around moving belts and
rotating parts on the engine.
To avoid injury from the expulsion
of hot coolant, never remove the
cooling system pressure cap
while the engine is at operating
temperature. Remove the cap
slowly to relieve pressure. Wear
adequate protective clothing
(face shield or safety goggles,
rubber gloves, apron, and boots).
To avoid injury from contact
with rotating parts when an
engine is operating with the air
inlet piping removed, install an
air inlet screen shield over the
turbocharger air inlet. The shield
prevents contact with rotating
parts.
All information subject to change without notice. (Rev. May 2004)
DDC-SVC-MAN-0057 0305 Copyright © 2003 DETROIT DIESEL CORPORATION
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CAUTION SUMMARY
To avoid injury from fire caused
by heated lubricating-oil vapors:
□ Keep those people who are not
directly involved in servicing
away from the engine.
□ Stop the engine immediately if
an oil leak is detected.
□ Do not allow open flames or
smoke when working on an
operating engine.
□ Wear adequate protective
clothing (face shield,
insulated gloves, apron,
etc.) to avoid burns.
□ To prevent a buildup of
potentially volatile vapors,
keep the engine area well
ventilated during operation.
Lubricating oil is relatively
harmless at ambient
temperatures.
To avoid injury when using
caustic cleaning agents, follow
the chemical manufacturers
usage, disposal, and safety
instructions.
3. Observe the following cautions
when using compressed air:
To avoid injury from flying debris
when using compressed air, wear
adequate eye protection (face
shield or safety goggles) and do
not exceed 40 psi (276 kPa) air
pressure.
4. Observe the following cautions
when using starting aids:
To avoid injury from rotating belts
and fans, do not remove and
discard safety guards.
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All information subject to change without notice. (Rev. May 2004)
DDC-SVC-MAN-0057 0305 Copyright © 2003 DETROIT DIESEL CORPORATION
SERIES 40 ENGINE OPERATOR'S GUIDE
To avoid injury from flames,
explosion, and toxicants when
using ether, the following
precautions must be taken:
To avoid injury from flames,
explosion, and toxicants when
using ether, the following
precautions must be taken:
□ Always wear goggles when
testing.
□ Do not smoke when servicing
ether system.
□ If fluid enters the eyes or if
fumes irritate the eyes, wash
eyes with large quantities of
clean water for 15 minutes.
A physician, preferably an
eye specialist, should be
contacted.
□ Work in well-ventilated area.
□ Contents of cylinder are under
pressure. Store cylinders
in a cool dry area. Do not
incinerate, puncture or
attempt to remove cores from
cylinders.
□ Do not work near open flames,
pilot flames (gas or oil
heaters), or sparks.
□ Do not weld or carry an open
flame near the ether system if
you smell ether or otherwise
suspect a leak.
5. Observe the following cautions
when jump starting an engine,
charging a battery, or working
with the vehicle/application
electrical system:
To avoid injury from accidental
engine startup while servicing
the engine, disconnect/disable
the starting system.
All information subject to change without notice. (Rev. May 2004)
DDC-SVC-MAN-0057 0305 Copyright © 2003 DETROIT DIESEL CORPORATION
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CAUTION SUMMARY
To avoid injury from battery
explosion or contact with battery
acid, work in a well-ventilated
area, wear protective clothing,
and avoid sparks or flames
near the battery. Always
establish correct polarity before
connecting cables to the battery
or battery circuit. If you come in
contact with battery acid:
□ Flush your skin with water.
□ Apply baking soda or lime to
help neutralize the acid.
□ Flush your eyes with water.
To avoid increased risk of a fuel
fire, do not mix gasoline and
diesel fuel.
To avoid injury from fire, keep all
potential ignition sources away
from diesel fuel, open flames,
sparks, and electrical resistance
heating elements. Do not smoke
when refueling.
□ Get medical attention
immediately.
To avoid injury from electrical
shock, do not touch battery
terminals, alternator terminals, or
wiring cables while the engine is
operating.
To avoid injury from fire, contain
and eliminate leaks of flammable
fluids as they occur. Failure to
eliminate leaks could result in
fire.
6. Observe the following cautions
when fueling the vehicle,
replacing fuel filters or working
with the engine fuel system.
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All information subject to change without notice. (Rev. May 2004)
DDC-SVC-MAN-0057 0305 Copyright © 2003 DETROIT DIESEL CORPORATION
SERIES 40 ENGINE OPERATOR'S GUIDE
To avoid injury from fire caused
by heated diesel-fuel vapors:
□ Keep those people who are not
directly involved in servicing
away from the engine.
□ Stop the engine immediately if
a fuel leak is detected.
□ Do not allow open flames or
smoke when working on an
operating engine.
□ Wear adequate protective
clothing (face shield,
insulated gloves and apron,
etc.).
□ To prevent a buildup of
potentially volatile vapors,
keep the engine area well
ventilated during operation.
Diesel fuel is relatively harmless
at ambient temperatures.
To avoid injury from the expulsion
of hot coolant, never remove the
cooling system pressure cap
while the engine is at operating
temperature. Remove the cap
slowly to relieve pressure. Wear
adequate protective clothing
(face shield or safety goggles,
rubber gloves, apron, and boots).
To avoid injury from slipping and
falling, immediately clean up any
spilled liquids.
8. Observe the following cautions
when working on the engine air
intake system:
7. Observe the following cautions
when servicing the cooling
system:
To avoid injury from hot surfaces,
allow engine to cool before
removing any component. Wear
protective gloves.
All information subject to change without notice. (Rev. May 2004)
DDC-SVC-MAN-0057 0305 Copyright © 2003 DETROIT DIESEL CORPORATION
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CAUTION SUMMARY
To avoid injury from contact
with rotating parts when an
engine is operating with the air
inlet piping removed, install an
air inlet screen shield over the
turbocharger air inlet. The shield
prevents contact with rotating
parts.
9. Observe the following cautions
when replacing the engine
lubricating oil and filters:
To avoid injury from fire caused
by heated lubricating-oil vapors:
□ Keep those people who are not
directly involved in servicing
away from the engine.
□ Stop the engine immediately if
an oil leak is detected.
□ Do not allow open flames or
smoke when working on an
operating engine.
□ Wear adequate protective
clothing (face shield,
insulated gloves, apron,
etc.) to avoid burns.
□ To prevent a buildup of
potentially volatile vapors,
keep the engine area well
ventilated during operation.
Lubricating oil is relatively
harmless at ambient
temperatures.
To avoid injury from slipping and
falling, immediately clean up any
spilled liquids.
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All information subject to change without notice. (Rev. May 2004)
DDC-SVC-MAN-0057 0305 Copyright © 2003 DETROIT DIESEL CORPORATION
SERIES 40 ENGINE OPERATOR'S GUIDE
GENERAL INFORMATION
Engine Features
The Series 40 is a family of
inline six-cylinder, 4-stroke cycle,
water-cooled, turbocharged engines
which may be equipped with a
chassis-mounted, air-to-air charge
cooler system.
Engines built prior to 1998 used
a mechanical, high-pressure fuel
pump and individual injector nozzles.
Operators of these engines should refer
to Series 40 Engine Operators Guide
6SE516 for preventive maintenance
information.
Engines built from 1998 – present are
direct fuel injected with hydraulically
actuated, electronically controlled unit
injectors. This operator's guide covers
these current engines.
Component Locations
The following figures show the
locations of major engine components.
All information subject to change without notice. (Rev. May 2004)
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11
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
12
Major Component Locations, Front View
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SERIES 40 ENGINE OPERATOR'S GUIDE
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 Regulating
Valve
Figure 2
Major Component Locations, Left Side View
All information subject to change without notice. (Rev. May 2004)
DDC-SVC-MAN-0057 0305 Copyright © 2003 DETROIT DIESEL CORPORATION
13
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
14
Major Component Locations, Right Side View
All information subject to change without notice. (Rev. May 2004)
DDC-SVC-MAN-0057 0305 Copyright © 2003 DETROIT DIESEL CORPORATION
SERIES 40 ENGINE OPERATOR'S GUIDE
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
All information subject to change without notice. (Rev. May 2004)
DDC-SVC-MAN-0057 0305 Copyright © 2003 DETROIT DIESEL CORPORATION
15
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
16
All information subject to change without notice. (Rev. May 2004)
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SERIES 40 ENGINE OPERATOR'S GUIDE
The engine model and serial numbers
were previously laser etched on the
left side, center of the cylinder block.
See Figure 5. Beginning in late year
2000, these numbers were relocated
to a machined pad on the right side of
the block, and directly above the oil
cooler. See Figure 6.
Figure 7
Turbocharger
Identification
The turbocharger identification plate
is located on the flat, inboard face of
the compressor housing. See Figure 7.
Turbocharger Identification (non-wastegate turbo shown)
All information subject to change without notice. (Rev. May 2004)
DDC-SVC-MAN-0057 0305 Copyright © 2003 DETROIT DIESEL CORPORATION
17
OPERATING INSTRUCTIONS
OPERATING INSTRUCTIONS
Preparations for Starting
the Engine the First Time
When preparing to start a new or
newly overhauled engine which has
been in storage, perform all of the
operations listed below. Failure to
follow these instructions may result
in serious engine damage. Before a
routine start, see the “Daily” checks
for your engine. Refer to section
MAINTENANCE SCHEDULES.
Diesel engine exhaust and some
of its constituents are known to
the State of California to cause
cancer, birth defects, and other
reproductive harm.
□ Always start and operate an
engine in a well ventilated
area.
□ If operating an engine in
an enclosed area, vent the
exhaust to the outside.
□ Do not modify or tamper
with the exhaust system or
emission control system.
18
To avoid injury when working
near or on an operating engine,
remove loose items of clothing,
jewelry, tie back or contain long
hair that could be caught in any
moving part causing injury.
Cooling System Checks
1. Make sure all drain cocks in
the cooling system are installed
(drain cocks are often removed
for shipping) and are closed
tightly.
2. Remove the radiator pressure
control cap and fill with genuine
Detroit Diesel Power Cool
antifreeze or an equivalent quality
ethylene glycol or propylene
glycol-base antifreeze solution
in the required concentration.
In extremely hot environments,
properly inhibited water may
be used in the summer. Keep
the coolant level at the bottom
of the filler neck to allow for
expansion of the coolant. For
more detailed recommendations,
All information subject to change without notice. (Rev. May 2004)
DDC-SVC-MAN-0057 0305 Copyright © 2003 DETROIT DIESEL CORPORATION
SERIES 40 ENGINE OPERATOR'S GUIDE
refer to section G. How to Select
Coolant in this guide.
NOTE:
Entrapped air must be purged after
filling the cooling system. To do this,
allow the engine to warm up with
the pressure cap removed. With
the transmission in neutral, increase
engine speed above 1,000 rpm and
add coolant to the radiator as required.
rocker cover should be removed
and clean lubricating oil should be
poured over the rocker arms. The
oil should be the same weight and
viscosity as that used in the crankcase.
After pre-lubricating, replace rocker
cover and add additional oil to bring
the level to the proper mark on the
dipstick. See Figure 8.
3. Check to make sure the front of
the radiator and air-to-air charge
cooler are unblocked and free of
debris.
Lubrication System Checks
The lubricating oil film on the rotating
parts and bearings of a new or newly
overhauled engine, or one which has
been in storage for six months or
more, may be insufficient when the
engine is started for the first time.
NOTICE:
Insufficient lubrication at startup can
cause serious damage to engine
components.
To insure an immediate flow of
oil to all bearing surfaces at initial
engine startup, the engine lubrication
system should be charged with a
commercially available pressure
pre-lubricator. If this is impractical,
Figure 8
Check Lube Oil Level
Before Starting
NOTE:
The current oil level gage is identified
by the words “Operating Range” and
“Add” separated by a cross-hatched
area. When using this dipstick, keep
the oil level within the cross-hatched
area.
NOTE:
The former oil level gage has the word
“Full” above the upper gage line and
the word “Add” below the lower gage
line. When using this dipstick, maintain
the oil level between the “Full” and
“Add” gage lines.
All information subject to change without notice. (Rev. May 2004)
DDC-SVC-MAN-0057 0305 Copyright © 2003 DETROIT DIESEL CORPORATION
19
OPERATING INSTRUCTIONS
condensation and helps keep fuel
cool, which is important to engine
performance. Full tanks also reduce
the chance for microbe (black slime)
growth. For fuel recommendations,
refer to section D. How to Select Fuel
Oil in the How To section of this
guide. Make sure the fuel shutoff
valve (if used) is open.
NOTICE:
To avoid engine damage, never
operate the engine when the oil level
is outside the cross-hatched area
on the current dipstick or outside the
area between the “Add” and “Full”
gage lines on the former dipstick.
For lubricant recommendation,
refer to section A. How to Select
Lubricating Oil in the How To section
of this guide.
Extended Storage – An engine
in storage for an extended period
of time (over winter, for example)
may accumulate water in the oil
pan through normal condensation of
moisture (always present in the air)
on the cold, internal surfaces of the
engine. Lube oil diluted by water
cannot provide adequate bearing
protection at engine startup. For this
reason, Detroit Diesel recommends
replacing the engine lubricating oil
and filters after extended storage.
NOTICE:
Failure to eliminate water-diluted
lubricating oil may lead to serious
engine damage at startup.
Fuel System Checks
NOTICE:
Do not use the engine starting
system to prime the fuel system
before initial engine start. This can
result in damage to the starter, fuel
pump and injectors tips and may
cause erratic engine operation due
to the amount of air in the lines and
filters from the fuel supply tank to
the cylinder head.
Engines equipped with starting
devices dependent on compressed
air or gas reservoirs should always
be primed before initial startup.
Otherwise, reserve pressure can
be exhausted and injectors may be
damaged from lack of lubrication
and cooling.
Under no circumstances should
a starting aid such as ether be
used to run the engine until the
fuel system is primed. Injector tip
damage will result if this method
is used.
Fill the tanks with the recommended
fuel. Keeping tanks full reduces water
20
All information subject to change without notice. (Rev. May 2004)
DDC-SVC-MAN-0057 0305 Copyright © 2003 DETROIT DIESEL CORPORATION
SERIES 40 ENGINE OPERATOR'S GUIDE
NOTICE:
NOTICE:
Starting an engine taken out of
storage or one recently overhauled
without first priming the fuel system
will result in an overload condition
that can damage the injector tips.
To avoid injector tip damage, the
fuel system must be primed before
initial engine startup.
Failure to disconnect the CMP
(camshaft position sensor) before
priming the engine may allow the
engine to start during priming,
which could result in severe engine
damage.
1. Disconnect the CMP (camshaft
position sensor) to prevent the
engine from starting.
If the engine is equipped with a
fuel/water separator, drain off any
water that has accumulated. Water
in fuel can seriously affect engine
performance and may cause engine
damage. Detroit Diesel recommends
installation of a fuel/water separator
wherever water contamination is a
concern.
2. Using the manual priming pump
on the fuel filter header, fill the
system with clean fuel until the
primer pump is hard to depress.
3. Crank the engine three times for
15 seconds each. Reapply the
primer pump after each crank
cycle.
If previously disconnected, reconnect
charge air cooler piping to valve
cover/intake manifold.
To insure prompt starting, even
running and avoid injector tip damage,
the fuel system must be primed before
initial engine start. Use this procedure:
NOTE:
Authorized Detroit Diesel service
outlets are properly equipped and
have the trained technicians to perform
this service.
4. Once the primer pump is hard to
depress (usually three crank and
hand prime cycles), reconnect the
CMP.
Other Checks
Check the hydrometer “eye” of
maintenance-free batteries for charge.
See Figure 9.
All information subject to change without notice. (Rev. May 2004)
DDC-SVC-MAN-0057 0305 Copyright © 2003 DETROIT DIESEL CORPORATION
21
OPERATING INSTRUCTIONS
Starting the Engine
Before starting the engine the first
time, refer to section Preparations for
Starting the Engine the First Time in
the Operating Instructions section
and perform the operations listed.
Figure 9
To avoid injury from flames,
explosion, and toxicants when
using ether, the following
precautions must be taken:
Check “Eye” of
Maintenance-Free
Batteries
□ Do not smoke when servicing
ether system.
If lead-acid or low-maintenance
batteries are used, make sure battery
electrolyte level is normal.
□ Work in well-ventilated area.
□ Do not work near open flames,
pilot flames (gas or oil
heaters), or sparks.
Make sure cable connections to the
storage batteries are clean and tight.
Check the turbocharger for signs of
oil or exhaust leaks. Leaks should be
corrected before starting the engine.
Check engine mounting bolts for
tightness. Bolts should be retightened,
if necessary.
Make sure the transmission is
filled to the proper level with the
fluid recommended by the gear
manufacturer. Do not overfill.
□ Do not weld or carry an open
flame near the ether system if
you smell ether or otherwise
suspect a leak.
The engine may require the use of a
cold weather starting aid if the ambient
temperature is below 40 °F (4 °C).
Check drive belts to make sure they
are in good condition (not cracked,
torn, worn or glazed).
22
All information subject to change without notice. (Rev. May 2004)
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SERIES 40 ENGINE OPERATOR'S GUIDE
Engine Diagnostic Button
Initial Engine Start
The engine diagnostic button, located
on the vehicle dashboard, is used
to read faults detected by the ECM
(electronic control module). The
ECM will flash the CEL (check engine
light) to warn of problems with the
engine, oil, or coolant and indicates
which faults have been detected.
Depress and hold the engine diagnostic
button. Turn the ignition switch to
the ON position and then release
the engine diagnostic button. DO
NOT START THE ENGINE. The
ECM will begin the self-test to
check the sensor output circuits. If a
fault is detected, the CEL will flash
repeatedly, signaling the action fault
code. Additional information on the
engine diagnostic button is available
in the Series 40 Troubleshooting
Manual, 6SE241, available from
authorized Detroit Diesel distributors.
Diesel engine exhaust and some
of its constituents are known to
the State of California to cause
cancer, birth defects, and other
reproductive harm.
□ Always start and operate an
engine in a well ventilated
area.
□ If operating an engine in
an enclosed area, vent the
exhaust to the outside.
□ Do not modify or tamper
with the exhaust system or
emission control system.
Electric Starter – Start an engine
equipped with an electric starting
motor as follows:
1. Set the parking brake and place
the transmission in NEUTRAL. If
an automatic transmission, place
it in PARK or NEUTRAL.
2. Depress the clutch pedal, if
equipped. Do not depress the
accelerator pedal.
All information subject to change without notice. (Rev. May 2004)
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23
OPERATING INSTRUCTIONS
to bring the pressure up to at least
the recommended minimum for
starting.
NOTICE:
To prevent serious starting motor
damage, do not press the starter
switch again after the engine has
started.
2. With foot OFF the foot pedal,
turn the ignition key to the start
position and press and hold the
starter button until the engine
starts.
3. With foot off of the accelerator
pedal, turn the ignition key to
the START position and crank
the engine. If the vehicle has
push button starting, PRESS and
HOLD the starter button.
NOTE:
If the engine fails to start after four
attempts or if it starts and stops
immediately, an inspection should be
made to determine the cause.
4. As soon as the engine starts,
release the key or starter button,
if applicable.
Emergency Jump Starting
NOTE:
If the engine fails to start within 15
seconds, release the starter switch and
allow the starter to cool for 15 seconds
before trying again. If the engine
fails to start after four attempts or if
it starts and then stops immediately,
an inspection should be made to
determine the cause.
Air Starter – Because of the limited
volume of most compressed air
storage tanks and the relatively short
duration of the cranking cycle, it is
important to make sure the engine is
ready to start before activating the air
starter. Start an engine equipped with
an air starter as follows:
To avoid injury from battery
explosion when jump starting the
engine, do not attach the cable
end to the negative terminal of
the disabled battery.
The Series 40 engine ECM (electronic
control module) operates on either
12 or 24 volts. When jump starting
an engine, do not exceed 18 volts for
a 12–volt system or 32 volts for a
24–volt system.
1. Check the pressure in the air
storage tank. If necessary, add air
24
All information subject to change without notice. (Rev. May 2004)
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SERIES 40 ENGINE OPERATOR'S GUIDE
2. Place the transmission in
NEUTRAL and set the parking
brake.
NOTICE:
Jump starting with voltages greater
than those indicated or reversing
battery polarity may damage the
ECM (electronic control module).
3. Bring the assisting vehicle close
to the disabled vehicle, but do not
allow vehicles to touch. Stop the
engine on the assisting vehicle.
Perform the following operations for
emergency jump starting:
4. Shut off all lights, heater, air
conditioner and any other
electrical loads in both vehicles.
5. Connect the first jumper cable to
the positive (+) terminal of the
dead battery and the positive (+)
terminal of the booster battery.
Connect the second jumper cable
to the negative (-) terminal of the
booster battery and an engine bolt
head, metal support bracket or
other good metallic contact on the
disabled vehicle.
To avoid injury from battery
explosion or contact with battery
acid, work in a well-ventilated
area, wear protective clothing,
and avoid sparks or flames
near the battery. Always
establish correct polarity before
connecting cables to the battery
or battery circuit. If you come in
contact with battery acid:
6. Start the engine on the assisting
vehicle and allow it to charge the
battery on the disabled vehicle for
at least one minute.
□ Flush your skin with water.
□ Apply baking soda or lime to
help neutralize the acid.
7. With foot OFF the foot pedal,
turn the ignition key to the start
position and press and hold the
starter button until the engine
starts.
□ Flush your eyes with water.
□ Get medical attention
immediately.
1. To prevent possible shorting,
remove metal rings and watches
and do not allow metal tools to
contact the positive terminal of
the battery.
NOTE:
If the engine fails to start after four
attempts or if it starts and stops
immediately, an inspection should be
made to determine the cause.
All information subject to change without notice. (Rev. May 2004)
DDC-SVC-MAN-0057 0305 Copyright © 2003 DETROIT DIESEL CORPORATION
25
OPERATING INSTRUCTIONS
Inspection
8. After the engine starts, remove
jumper cables in reverse order of
attachment.
Transmission – While the engine
is idling, check the automatic
transmission (if equipped) for proper
oil level and add oil as required.
Running the Engine
Oil Pressure
Observe the oil pressure gage
immediately after starting the engine.
A good indicator that all moving parts
are getting lubrication is when the oil
pressure gage exceeds 137 kPa (20
psi) after starting. If oil pressure is
less than this or if no oil pressure is
indicated, stop the engine, check for
the cause and correct the condition.
After the engine has reached operating
temperature, the oil pressure should
be 276 kPa (40 psi) minimum. If oil
pressure does not meet this minimum,
stop the engine, check for the cause
and correct the condition.
To avoid injury from hot oil, do
not operate the engine with the
rocker cover(s) removed.
Warm-up
Run the engine at part throttle for
about five minutes to allow it to warm
up before applying a load.
26
Fluid Leaks – Look for coolant,
fuel or lubricating oil leaks. If any
are found, shut down the engine
immediately and have the leaks
repaired after the engine has cooled.
Crankcase – If the engine oil was
replaced, stop the engine after normal
operating temperature has been
reached. Allow the oil to drain
back into the crankcase for about
twenty minutes, then check the oil
level. If necessary, add oil to bring
the level to the proper mark on the
dipstick. Use only the heavy-duty oils
recommended. Refer to section A.
How to Select Lubricating Oil in this
guide.
Turbocharger – Make a visual
inspection of the turbocharger for
oil leaks, exhaust leaks, excessive
noise or vibration. Stop the engine
immediately if a leak or unusual noise
or vibration is noted. Do not restart
the engine until the cause of the
concern has been investigated and
corrected. Authorized Detroit Diesel
service outlets are properly equipped
to perform this service.
All information subject to change without notice. (Rev. May 2004)
DDC-SVC-MAN-0057 0305 Copyright © 2003 DETROIT DIESEL CORPORATION
SERIES 40 ENGINE OPERATOR'S GUIDE
Avoid Unnecessary Idling
2. Allow the engine to run between
idle and 1000 rpm with no load
for four or five minutes. This
allows the engine to cool and
permits the turbocharger to slow
down. After four or five minutes,
shut down the engine.
Whenever possible, avoid unnecessary
idling.
During long engine idling periods
with the transmission in neutral, the
engine coolant temperature may fall
below the normal operating range.
The incomplete combustion of fuel
in a cold engine will cause crankcase
oil dilution, formation of lacquer or
gummy deposits on the valves, pistons,
and rings, and rapid accumulation of
sludge in the engine. When prolonged
idling is necessary, maintain at least
850 rpm spring/summer and 1200 rpm
fall/winter.
Stopping the Engine
Normal Stopping
Stop an engine under normal operating
conditions as follows:
1. Reduce engine speed to idle and
put all shift levers in the neutral
position.
Shutdown Warning Light
and Buzzer
Vehicles may be equipped with an
automatic engine shutdown system
that will stop the engine in the event of
high coolant temperature, low coolant
level, or low engine oil pressure. The
SEL (stop engine light) and alarm
buzzer and light on the instrument
panel alert the operator of high coolant
temperature, low coolant level, or
low oil pressure conditions. Should
temperature or pressure continue to
change beyond the warning point to a
predetermined level, the engine will
automatically shut down.
NOTICE:
Stopping a turbocharged engine
immediately after high-speed
operation without allowing a
sufficient cool-down period may
cause damage to the turbocharger,
as it will continue to turn without an
oil supply to the bearings.
All information subject to change without notice. (Rev. May 2004)
NOTICE:
To avoid engine damage when the
override feature is selected, the
engine should be run no longer than
is absolutely necessary.
DDC-SVC-MAN-0057 0305 Copyright © 2003 DETROIT DIESEL CORPORATION
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OPERATING INSTRUCTIONS
Road Operation
To receive satisfactory engine
performance with maximum fuel
economy, the following general
guidelines should be followed when
operating the vehicle:
□ Start the vehicle in motion by
using the highest gear speed in the
transmission that will move the
load without slipping the clutch.
□ Once in motion, accelerate
smoothly and evenly to
engine rated speed. Rapid
acceleration will result in high
fuel consumption with no increase
in performance.
□ To avoid “lugging,” do not allow
engine speed to drop below peak
torque when pulling at full throttle.
□ When approaching a hill, depress
the accelerator smoothly to start
the climb at full power, then
shift down as needed to maintain
maximum permitted vehicle
speed, depending on conditions.
NOTICE:
Do not allow the engine to
overspeed when descending a
grade with a load. Operating the
engine beyond high idle speed can
cause severe damage.
28
□ Prevent overspeeding of the engine
when descending a long and steep
grade. The electronic governor
has no control over engine speed
when it is being pushed by the
loaded vehicle. Operate in a gear
that will permit an engine speed
not in excess of high idle rpm.
Cold Weather Operation
Observe the following instructions
before operating the engine in
temperatures of 32 °F (0 °C):
1. Ensure batteries are of sufficient
size and are fully charged. Check
that all other electrical equipment
is in optimum condition.
2. Fill the cooling system with
required coolant. Periodically
check level and top off, if
necessary. Refer to section G.
How to Select Coolant in this
guide.
3. At the end of each day's operation,
allow the engine to cool and
then drain the water from the
fuel/water separator, if equipped.
Fill the fuel tank with required
fuel to prevent condensation.
Refer to section D. How to Select
Fuel Oil in this guide.
4. Use the proper lubricating oil
for the ambient temperatures
encountered. Refer to section A.
How to Select Lubricating Oil
All information subject to change without notice. (Rev. May 2004)
DDC-SVC-MAN-0057 0305 Copyright © 2003 DETROIT DIESEL CORPORATION
SERIES 40 ENGINE OPERATOR'S GUIDE
fuel/water separator, if equipped.
Fill the fuel tank with required
fuel to prevent condensation.
Refer to section D. How to Select
Fuel Oil in this guide.
in this guide. Check the lube oil
level at the start of each day and
top off, if necessary.
5. At temperatures between 10 °F
(–12 °C ) and 20 °F (–7 °C), DDC
recommends using an ether-start
kit and block heater. An on/off
fan is also recommended.
6. At temperatures below 20 °F (–7
°C), an ether-start kit, coolant
heater and oil pan heater are
required. Contact an authorized
Detroit Diesel distributor about
special cold weather equipment
and precautions.
Hot Weather Operation
Observe the following instructions
before operating the engine in hot
weather.
1. Ensure the battery has the proper
amount of electrolyte in each
cell, if not a maintenance–free
battery. Top off cells with distilled
water, or as per manufacturer's
instructions.
4. Keep the external surfaces of the
engine, radiator and accessories
clean to avoid dirt buildup, which
could lead to engine overheating.
Extended Idling Periods
Avoid extended idling, especially
at low engine speeds. The low idle
speed for Series 40 vehicle engines
is 700 rpm, while the low idle for
construction/industrial engines is
normally 800 rpm. If idling for long
periods is necessary, use the optional
electronic fast idle feature. Diesel
engine efficiency is improved when
cylinder temperatures remain high.
If cylinder temperatures are too low,
the following may occur:
2. Fill the cooling system with
required coolant. Periodically
check level and top off, if
necessary. Refer to section G.
How to Select Coolant in this
guide.
3. At the end of each day's operation,
allow the engine to cool and
then drain the water from the
All information subject to change without notice. (Rev. May 2004)
1. Unburned fuel, which has the
dark-colored appearance of
lubricating oil, may seep from
the exhaust manifold gaskets
and vehicle exhaust system
connections. This seepage
is commonly called exhaust
“slobber.”
2. Cylinder temperature will be
too low to allow complete
combustion and unburned fuel
will wash lubricating oil from the
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29
OPERATING INSTRUCTIONS
cylinder liners. The unburned fuel
will be carried into the lubricating
oil, causing fuel dilution.
3. Carbon deposits will form on
fuel injector tips, causing nozzle
plugging.
□ Engine load is greater than 25%.
□ Brake pedal is applied or brake
switch fault is detected.
4. Carbon deposits will form on the
turbine wheel of the turbocharger,
reducing turbocharger efficiency.
A CAP (cold ambient protection)
system has been added to the ECMs
used on vehicles. This software aids
in engine warm-up and helps maintain
optimum engine heat during extended
idling periods.
After five (5) minutes of idle time
with the intake air temperature below
32 °F (0 °C), the CAP will slowly
ramp up the engine idle speed to
900 rpm (engines with automatic
transmissions) or 1400 rpm (engines
with manual transmissions). Engine
speed will increase or decrease to
an rpm that will maintain a coolant
temperature of 160 °F (71 °C).
□ Clutch pedal is depressed or clutch
pedal switch fault is detected
(manual transmission).
□ Shift selector is moved from
neutral to forward or reverse range
(automatic transmission).
□ PTO switch, also used for
electronic hand throttle, is turned
on.
□ Accelerator pedal is depressed or
accelerator pedal sensor fault is
detected.
□ Timed idle shutdown is enabled.
□ CTO (coolant temperature sensor)
fault is detected.
NOTE:
The lower CAP rpm limit for engines
with automatic transmissions
minimizes the possibility of vehicle
lurch, should the operator place the
shift lever in gear without first applying
the service brakes to lower the idle
speed to 700 rpm.
30
The cycle described above will
continue until one or a combination of
any of the following occurs:
□ AIT (ambient air intake
temperature) sensor fault is
detected.
All information subject to change without notice. (Rev. May 2004)
DDC-SVC-MAN-0057 0305 Copyright © 2003 DETROIT DIESEL CORPORATION
SERIES 40 ENGINE OPERATOR'S GUIDE
SERIES 40 ELECTRONIC CONTROL SYSTEM
Series 40 engines use a consolidated
engine controller (CEC) and diagnosis
Figure 10
system with its own ECM (electronic
control module). See Figure 10.
Typical Series 40 Engine-Mounted ECM
This system functions much like
the DDEC system, but is configured
differently and uses its own unique
diagnostic codes. The diagnostic
codes for Series 40 engines are
listed in Table 1, Table 2 , Table 3, and
Table 4.
All information subject to change without notice. (Rev. May 2004)
DDC-SVC-MAN-0057 0305 Copyright © 2003 DETROIT DIESEL CORPORATION
31
SERIES 40 ELECTRONIC CONTROL SYSTEM
Flash
Code
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*
MAP
Intake 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 Transitions
for Cam Rev
CMP Signal Noise Deleted
144
CMP
* Indicates WARN Lamp on When Fault Set
Table 1
32
Series 40 Diagnostic Flash Codes
All information subject to change without notice. (Rev. May 2004)
DDC-SVC-MAN-0057 0305 Copyright © 2003 DETROIT DIESEL CORPORATION
SERIES 40 ENGINE OPERATOR'S GUIDE
Flash
Code
Circuit
Description
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
244
EDL
Injection Control Press. Regulator OCC
Self Test Failed
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
Engine Warning Light OCC Fault
266
WEL
* Indicates WARN Lamp on When Fault Set
Table 2
Series 40 Diagnostic Flash Codes (continued)
All information subject to change without notice. (Rev. May 2004)
DDC-SVC-MAN-0057 0305 Copyright © 2003 DETROIT DIESEL CORPORATION
33
SERIES 40 ELECTRONIC CONTROL SYSTEM
Flash
Code
Circuit
Description
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
—
321
ECT**
Engine Coolant Temp. Unable to Reach
Commanded Set Point
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*
IPR
Injection 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
INJ
High Side to Low Side Open (Cyl.
Number Indicated)
431 – 436
INJ
High Side Shorted to Low Side
(Cyl. Number Indicated)
451 – 456
INJ
High Side Shorted to Ground or V Bat.
(Cyl. Number Indicated)
* Indicates WARN Lamp on When Fault Set
Table 3
34
Series 40 Diagnostic Flash Codes (continued)
All information subject to change without notice. (Rev. May 2004)
DDC-SVC-MAN-0057 0305 Copyright © 2003 DETROIT DIESEL CORPORATION
SERIES 40 ENGINE OPERATOR'S GUIDE
Flash
Code
Circuit
Description
461 – 466
Perf. Diag.
Cylinder Contrib. Test Failed (Cyl
Number 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
Programmable Parameter Memory Content Corrupt
665
ECM
* Indicates WARN Lamp on When Fault Set
Table 4
Series 40 Diagnostic Flash Codes
All information subject to change without notice. (Rev. May 2004)
DDC-SVC-MAN-0057 0305 Copyright © 2003 DETROIT DIESEL CORPORATION
35
SERIES 40 ENGINE SYSTEMS
SERIES 40 ENGINE SYSTEMS
Fuel System
The fuel system consists of
the fuel pump, hydraulically
activated/electronically controlled
unit injector assemblies, fuel pipes,
fuel strainer and filter, and fuel lines.
Lubrication System
The lubrication system consists of the
oil pump, oil cooler, oil strainer and
filter, bypass and pressure regulator
valves, oil temperature control valve,
and lubricating oil lines.
Cooling System
The cooling system consists of
a centrifugal-type fresh water
pump, full-blocking thermostat,
charge air cooler, radiator, and
thermo-modulated fan. The fresh
water pump circulates coolant within
the engine and through the oil cooler,
radiator and air-to-air charge cooler.
The thermostat installed in a recess
in the left-front corner of the cylinder
head controls the flow of coolant,
while the thermo-modulated fan
controls the flow of air through the
radiator and charge cooler.
battery-charging alternator, storage
batteries and necessary wiring.
Air Induction System
The air induction system consists of
the air cleaner, air-to-air charge cooler
(some applications), compressor side
of the turbocharger, valve cover/intake
manifold and intake valves. Outside
air is drawn through the air cleaner
and into the turbocharger where it is
compressed. It then flows through the
air-to-air charge cooler, into the intake
manifold and into the cylinders where
it mixes with atomized fuel from the
injector nozzles.
Exhaust System
The exhaust system consists of the
exhaust valves, exhaust manifold,
turbine side of the turbocharger,
exhaust piping and muffler. Hot
exhaust gases flowing from the
exhaust manifold into the exhaust riser
drive the turbocharger. Exhaust gases
then pass through the muffler and out
to atmosphere.
Electrical System
The electrical system consists of
the starting motor, starting switch,
36
All information subject to change without notice. (Rev. May 2004)
DDC-SVC-MAN-0057 0305 Copyright © 2003 DETROIT DIESEL CORPORATION
SERIES 40 ENGINE OPERATOR'S GUIDE
MAINTENANCE SCHEDULES
Maintenance Intervals
Recommended maintenance intervals
for Series 40 motor coach engines
are listed in Table 5, Table 6 and
Table 7. Recommended maintenance
intervals for Series 40 transit coach
engines are listed in Table 8, Table
9, and Table 10. Recommended
maintenance intervals for Series 40
construction/industrial and stationary
engines are listed in Table 11, Table
12, and Table 13. Recommended
maintenance intervals for Series
40 fire fighting, crash/rescue, and
emergency vehicle engines are
listed in Table 14, Table 15, and Table
16. Recommended maintenance
intervals for Series 40 generator drive
engines are listed in Table 17, Table
18, and Table 19.
All information subject to change without notice. (Rev. May 2004)
NOTICE:
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.
DDC-SVC-MAN-0057 0305 Copyright © 2003 DETROIT DIESEL CORPORATION
37
MAINTENANCE SCHEDULES
Item
Daily
Checks
1 – Lubricating Oil*
I
2 – Fuel Tank*
I
3 – Fuel Lines & Flex
Hoses*
4 – Cooling System*
5 – Turbocharger, A/A
Charge Cooler*
8 – Air Compressor*
12,000
Miles
(19,200
Km)
18,000
Miles
( 28,800
Km)
R
24,000
Miles
( 28,800
Km)
R
I
I
I
I
I
6 – Battery*
7– Drive Belt*
6,000
Miles
(9,600
Km)
I
I
I
I
I
I
I
I
I
9 – Air Cleaner*
10 – Lube Oil Filters*
R
R
11 – Fuel Filters*
12 – Water Pump/
Inhibitor Level*
14 – Air System*
R
I
I
I
I
I
* – See item in text.
I – Inspect, service, correct or replace as necessary.
R – Replace.
Table 5
38
Motor Coach Daily, 6,000 Mile, 12,000 Mile and 18,000
Mile Checks
All information subject to change without notice. (Rev. May 2004)
DDC-SVC-MAN-0057 0305 Copyright © 2003 DETROIT DIESEL CORPORATION
SERIES 40 ENGINE OPERATOR'S GUIDE
Item
Months
6
12
18
24
30
36
42
48
54
Miles/Km
( X 1000)
12/
19
24/
38
36/
58
48/
77
60/
96
72/
115
84/
134
96/
154
108/ 124/
173 198
1- Lubricating
Oil*
Replace lubricating oil every 12,000 miles (19,200 km).
2- Fuel Tank*
I
I
4- Cooling
System*
I
I
I
5 Turbocharger,
A/A Charge
Cooler*
6 - Battery*
60
I
I
I
I
I
I
I
I
I
I
I
I
Inspect at each oil change.
Replace every 100,000 miles (160,000 km).
7- Drive Belt*
8- Air
Compressor*
I
I
I
I
I
I
I
I
I
I
9 - Air Cleaner*
I
I
I
I
I
I
I
I
I
I
I
I
10 - Lube Oil
Filter*
Replace when lubricating oil is changed.
11 - Fuel Filters*
12 - Water
Pump/ Inhibitor
Level*
13 - Cranking
Motor*
14 - Air System*
R
I
I
I
I
R
I
I
I
Follow manufacturer's recommendations.
I
I
I
I
I
I
15 - Exhaust
I
I
I
I
I
I
System*
* – See item in text.
I – Inspect, service, correct or replace as necessary.
R – Replace.
Table 6
I
I
I
I
I
I
I
I
I
Motor Coach Regular Maintenance Intervals
All information subject to change without notice. (Rev. May 2004)
DDC-SVC-MAN-0057 0305 Copyright © 2003 DETROIT DIESEL CORPORATION
39
MAINTENANCE SCHEDULES
Months
Item Miles/Km
( X 1000)
6
12
18
24
30
36
42
48
54
12/
19
24/
38
36/
58
48/
77
60/
96
72/
115
84/
134
96/
154
108/ 124/
173 198
16 - Engine
(Steam Clean)*
I
17 - Radiator*
18 - Oil
Pressure*
19 - Battery
Charging
Alternator*
20 - Engine &
Transmission
Mounts*
21 - Crankcase
Pressure*
22 - Fan Hub*
23 Thermostats
& Seals*
24 - Crankcase
Breather*
25 - Engine
Tune-Up*
26 - Idler Pulley*
I
I
I
I
I
I
I
I
I
I
60
I
I
I
I
I
I
I
I
I
I
I
I
Inspect every 15,000 miles or every oil change.
Replace every 60,000 miles.
I
I
I
Inspect every 45,000 miles (72,000 km).
Replace every 60,000 miles (96,000 km).
27 - Vibration
Inspect once a year. Replace at major engine overhaul
or earlier if dented or damaged.
Damper*
* – See item in text.
I – Inspect, service, correct or replace as necessary.
R – Replace.
Table 7
40
Motor Coach Regular Maintenance Intervals (continued)
All information subject to change without notice. (Rev. May 2004)
DDC-SVC-MAN-0057 0305 Copyright © 2003 DETROIT DIESEL CORPORATION
SERIES 40 ENGINE OPERATOR'S GUIDE
Daily
Checks
6,000
Miles
(9,600
Km)
12,000
Miles
(19,200
Km)
18,000
Miles
(28,800
Km)
24,000
Miles
(38,400
Km)
1 - Lubricating Oil*
I
R
R
R
R
2 - Fuel Tank*
I
Item
3 - Fuel Lines & Flexible
Hoses*
4 - Cooling System*
I
I
5 - Turbocharger, A/A
Charge Cooler*
I
I
6 - Battery*
I
I
I
I
7 - Drive Belt*
I
8 - Air Compressor*
9 - Air Cleaner*
10 - Lube Oil Filters*
I
I
I
I
I
I
R
R
R
R
11 - Fuel Filters*
R
12 - Water Pump/
I
Inhibitor Level*
* – See item in text.
I – Inspect, service, correct or replace as necessary.
R – Replace.
Table 8
R
I
Transit Coach Daily, 6,000 Mile, 12,000 Mile, and 18,000
Mile and 24,000 Mile Checks
All information subject to change without notice. (Rev. May 2004)
DDC-SVC-MAN-0057 0305 Copyright © 2003 DETROIT DIESEL CORPORATION
41
MAINTENANCE SCHEDULES
Item
Months
6
12
18
24
30
36
42
Miles/Km
( X 1000)
15/
24
30/
48
45/
72
60/
96
75/
120
90/
144
105/ 120/ 135/ 150/
168 192 216 240
1 - Lubricating
Oil*
54
60
Replace lubricating oil every 12,000 miles (19,200 km).
2 - Fuel Tank*
I
I
4 - Cooling
System*
5 Turbocharger,
A/A Charge
Cooler*
6 - Battery*
48
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
Inspect at each oil change.
Replace every 100,000 miles (160,000 km).
7 - Drive Belt*
8 - Air
Compressor*
I
I
I
I
I
I
I
I
I
I
9 - Air Cleaner*
I
I
I
I
I
I
I
I
I
I
10 - Lube Oil
Filters*
Replace when lubricating oil is changed.
11 - Fuel Filters*
12 - Water
Pump/ Inhibitor
Level*
13 - Cranking
Motor*
14 - Air System*
R
I
I
R
I
I
R
I
I
42
I
I
R
I
I
I
I
Follow manufacturer's recommendations.
I
I
I
I
I
I
* – See item in text.
I – Inspect, service, correct or replace as necessary.
R – Replace.
Table 9
R
I
I
Transit Coach Regular Maintenance Intervals
All information subject to change without notice. (Rev. May 2004)
DDC-SVC-MAN-0057 0305 Copyright © 2003 DETROIT DIESEL CORPORATION
SERIES 40 ENGINE OPERATOR'S GUIDE
Item
Months
6
12
18
24
30
36
42
Miles/Km
( X 1000)
15/
24
30/
48
45/
72
60/
96
75/
120
90/
144
105/ 120/ 135/ 150/
168 192 216 240
I
I
I
I
I
I
15 - Exhaust
System*
16 - Engine
(Steam Clean)*
I
17 - Radiator*
18 - Oil
Pressure*
19 - Battery
Charging
Alternator*
20 - Engine &
Transmission
Mounts*
21 - Crankcase
Pressure*
22 - Fan Hub*
23 Thermostats
& Seals*
24 - Crankcase
Breather*
25 - Engine
Tune-Up*
26 - Idler Pulley*
I
I
I
I
I
I
54
I
60
I
I
I
I
I
I
I
48
I
I
I
I
I
I
I
I
I
I
I
I
Inspect every 6,000 miles or every oil change.
Replace every 60,000 miles.
I
I
I
I
I
I
I
I
I
Inspect every 45,000 miles (72,000 km).
Replace every 60,000 miles (96,000 km).
Inspect once a year. Replace at major engine overhaul
27 - Vibration
or earlier if dented or damaged.
Damper*
* – See item in text.
I – Inspect, service, correct or replace as necessary.
R – Replace.
Table 10
Transit Coach Regular Maintenance Intervals (continued)
All information subject to change without notice. (Rev. May 2004)
DDC-SVC-MAN-0057 0305 Copyright © 2003 DETROIT DIESEL CORPORATION
43
MAINTENANCE SCHEDULES
Item
Daily
Checks
1 - Lubricating
Oil*
I
2 - Fuel Tank*
I
3 - Fuel Lines
& Flexible
Hoses*
4 - Cooling
System*
5 Turbocharger,
A/A Charge
Cooler*
6 - Battery*
7 - Drive Belt*
8 - Air
Compressor*
9 - Air
Cleaner*
10 - Lube Oil
Filters*
11 - Fuel
Filters*
12 - Water
Pump/
Inhibitor
Level*
100
Hours
150
Hours
200
Hours
I
I
I
I
I
I
I
I
R
R
I
I
19 - Battery
Charging
Alternator*
* – See item in text.
I – Inspect, service, correct or replace as necessary.
R – Replace.
44
450
Hours
R
17 - Radiator*
Table 11
300
Hours
I
Stationary or Construction/Industrial Engine Daily, 100
Hour, 150 Hour, 200 Hour, and 300 Hour Checks
All information subject to change without notice. (Rev. May 2004)
DDC-SVC-MAN-0057 0305 Copyright © 2003 DETROIT DIESEL CORPORATION
SERIES 40 ENGINE OPERATOR'S GUIDE
Item
Hours
150
1 - Lubricating
Oil*
300
450
750
900
1,050 1,200 1,350 1,500
Change lubricating oil every 450 hours or 1 year,
whichever comes first.
2 - Fuel Tank*
I
I
4 - Cooling
System*
5 Turbocharger,
A/A Charge
Cooler*
6 - Battery*
600
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
Inspect at each oil change.
Replace every 2,000 hours.
7 - Drive Belt*
8 - Air
Compressor*
I
I
I
I
I
I
I
I
I
I
9 - Air Cleaner*
I
I
I
I
I
I
I
I
I
I
10 - Lube Oil
Filters*
Replace when lubricating oil is changed.
11 - Fuel Filters*
12 - Water
Pump/ Inhibitor
Level*
13 - Cranking
Motor*
14 - Air System*
R
I
I
R
I
I
R
I
I
I
I
R
I
I
I
I
Follow manufacturer's recommendations.
I
I
I
I
I
I
* – See item in text.
I – Inspect, service, correct or replace as necessary.
R – Replace.
Table 12
R
I
I
Stationary or Construction/Industrial Regular Maintenance
Intervals
All information subject to change without notice. (Rev. May 2004)
DDC-SVC-MAN-0057 0305 Copyright © 2003 DETROIT DIESEL CORPORATION
45
MAINTENANCE SCHEDULES
Item
Hours
15 - Exhaust
System*
150
300
450
600
750
900
I
I
I
I
I
I
1,050 1,200 1,350 1,500
I
I
I
I
16 - Engine
(Steam Clean)*
17 - Radiator*
18 - Oil
Pressure*
19 - Battery
Charging
Alternator*
20 - Engine &
Transmission
Mounts*
21 - Crankcase
Pressure*
22 - Fan Hub*
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
Inspect every 150 hours.
Replace every 1,000 hours.
23 Thermostats
& Seals*
24 - Crankcase
Breather*
25 - Engine
Tune-Up*
26 - Idler Pulley*
I
I
I
Inspect every 1,500 hours.
Replace every 2,000 hours.
27 - Vibration
Inspect once a year. Replace at major engine overhaul
or earlier if dented or damaged.
Damper*
* – See item in text.
I – Inspect, service, correct or replace as necessary.
R – Replace.
Table 13
46
Stationary or Construction/Industrial Regular Maintenance
Intervals (continued)
All information subject to change without notice. (Rev. May 2004)
DDC-SVC-MAN-0057 0305 Copyright © 2003 DETROIT DIESEL CORPORATION
SERIES 40 ENGINE OPERATOR'S GUIDE
Item
Daily
Checks
1 - Lubricating Oil*
I
2 - Fuel Tank*
I
3 - Fuel Lines & Flexible Hoses*
I
4 - Cooling System*
I
5 - Turbocharger, A/A Charge
Cooler*
6 - Battery*
100 Hours or
3,000 Miles
( 4,800 Km)
300 Hours
or 6,000
Miles
( 9,600 Km)
R
I
I
7 - Drive Belt*
I
8 - 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*
I
19 - 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 Vehicle
Engine Daily, 100 Hour and 300 Hour Checks
All information subject to change without notice. (Rev. May 2004)
DDC-SVC-MAN-0057 0305 Copyright © 2003 DETROIT DIESEL CORPORATION
47
MAINTENANCE SCHEDULES
Hours
Item
Miles/Km
(X 1000)
1 - Lubricating Oil*
2 - Fuel Tank*
300
600
900
1,200
1,500
6/
12/
18/
24/
30/
1.6
9.6
28.8
38.4
48
Change lubricating oil every 300 hours or 6,000
miles (9,600 km), whichever comes first.
I
4 - Cooling System*
I
I
I
I
I
I
5 - Turbocharger, A/A
Charge Cooler*
6 - Battery*
I
I
I
I
Inspect at each oil change.
Replace every 2,000 hours.
7 - Drive Belt*
8 - Air Compressor*
I
I
I
I
I
I
9 - Air Cleaner*
10 - Lube Oil Filters*
Replace when lubricating oil is changed.
11 - Fuel Filters*
12 - Water Pump/ Inhibitor
Level*
13 - Cranking Motor*
R
I
I
R
I
I
I
Follow manufacturer's recommendations.
14 - Air System*
I
I
I
I
I
15 - Exhaust System*
I
I
I
I
I
* – See item in text.
I – Inspect, service, correct or replace as necessary.
R – Replace.
Table 15
48
Fire Fighting, Crash/Rescue and Emergency Vehicle
Engine Regular Maintenance Intervals
All information subject to change without notice. (Rev. May 2004)
DDC-SVC-MAN-0057 0305 Copyright © 2003 DETROIT DIESEL CORPORATION
SERIES 40 ENGINE OPERATOR'S GUIDE
Item
Hours
300
600
900
1,200
1,500
Miles/Km
(X 1000)
6/
1.6
12/
9.6
18/
28.8
24/
38.4
30/
48
I
I
I
I
I
16 - Engine (Steam Clean)*
17 - Radiator*
18 - Oil Pressure*
19 - Battery Charging
Alternator*
20 - Engine & Transmission
Mounts*
I
I
21 - Crankcase Pressure*
22 - Fan Hub*
I
I
I
I
I
I
I
I
I
Inspect every 6,000 miles or every oil change.
Replace every 60,000 miles.
23 - Thermostats & Seals*
24 - Crankcase Breather*
I
25 - Engine Tune-Up*
26 - Idler Pulley*
27 - Vibration Damper*
I
Inspect every 45,000 miles (72,000 km)
or 1,500 hours.
Replace every 60,000 miles (96,000
km) or 2,000 hours.
Inspect once a year. Replace at major engine
overhaul or earlier if dented or damaged.
* – See item in text.
I – Inspect, service, correct or replace as necessary.
R – Replace.
Table 16
Fire Fighting, Crash/Rescue and Emergency Vehicle
Engine Regular Maintenance Intervals (continued)
All information subject to change without notice. (Rev. May 2004)
DDC-SVC-MAN-0057 0305 Copyright © 2003 DETROIT DIESEL CORPORATION
49
MAINTENANCE SCHEDULES
Prime
Daily
Standby
Monthly
1 - Lubricating Oil*
I
I #
2 - Fuel Tank*
I
I
3 - Fuel Lines & Flexible Hoses*
I
4 - Cooling System*
I
5 - Turbocharger, A/A Charge Cooler*
I
Item
6 - Battery*
I #
I
7 - Drive Belt*
I
9 - Cleaner*
I
I
11 - Fuel Filter, Water Separator*
I
I #
18 - Oil Pressure*
I
I #
Load Test
* 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 set
manufacturer's instructions.
Table 17
50
I
P
Generator Set Engine Prime Daily and Standby Monthly
Maintenance Intervals
All information subject to change without notice. (Rev. May 2004)
DDC-SVC-MAN-0057 0305 Copyright © 2003 DETROIT DIESEL CORPORATION
SERIES 40 ENGINE OPERATOR'S GUIDE
Hours
Item
150
300
2 - Fuel Tank*
I
11 - Fuel
Filters*
1,500
1,800
2,100
R
R
I
I
Inspect at each oil change.
Replace every 2,000 hours.
7 - Drive Belt*
10 - Lube Oil
Filters*
1,200
I
3 - Fuel Lines
& Flexible
Hoses*
4 - Cooling
System*
9 - Air Cleaner*
900
Prime: Replace every 300 hours or 3 months,
whichever comes first.
Standby: Replace every 450 hours or 1 year,
whichever comes first.
1 - Lubricating
Oil*
5 Turbocharger,
A/A Charge
Cooler*
6 - Battery*
600
I
I
I
I
I
I
I
I
Replace when lubricating oil is changed.
Prime: Replace every 500 hours or 6 months,
whichever comes first.
Standby: Replace every 300 hours or 1 year,
whichever comes first.
12 - Water
Pump/ Inhibitor
I
Level*
13 - Cranking
Follow manufacturer's recommendations.
Motor*
* See item in text.
I – Inspect, service, correct or replace as necessary.
R – Replace
Table 18
Generator Set Engine Regular Maintenance Intervals
All information subject to change without notice. (Rev. May 2004)
DDC-SVC-MAN-0057 0305 Copyright © 2003 DETROIT DIESEL CORPORATION
51
MAINTENANCE SCHEDULES
Hours
Item
150
300
600
14 - Air System*
I
15 - Exhaust
System*
I
900
1,200 1,500
1,800
2,100
16 - Engine
(Steam Clean)*
17 - Radiator*
18 - Oil
Pressure*
19 - Battery
Charging
Alternator*
20 - Engine
& Generator
Mounts*
21 - Crankcase
Pressure*
22 - Fan Hub*
I
I
I
I
I
I
Inspect every 150 hours.
Replace every 1,000 hours.
23 - Thermostat
& Seals*
24 - Crankcase
Breather*
25 - Engine
Tune-Up*
26 - Idler Pulley*
27 - Vibration
Damper*
R
I
I
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
52
Generator Set Engine Regular Maintenance Intervals
(continued)
All information subject to change without notice. (Rev. May 2004)
DDC-SVC-MAN-0057 0305 Copyright © 2003 DETROIT DIESEL CORPORATION
SERIES 40 ENGINE OPERATOR'S GUIDE
LUBRICATION AND PREVENTIVE MAINTENANCE
INTERVALS
The following is intended as a
guide for establishing preventive
maintenance intervals. The
recommendations given should
be followed as closely as possible
to obtain long life and optimum
performance from your engine.
Maintenance intervals indicated are
time (hours) of actual operation.
The intervals shown apply only to
the maintenance functions described.
These functions should be coordinated
with other regularly scheduled
maintenance.
just been stopped and is warm, wait
approximately 20 minutes to allow the
oil to drain back into the oil pan before
checking. Add the proper grade of oil
to maintain the correct level on the
dipstick.
See Figure 11 for the current oil level
gage. When using this dipstick, keep
the oil level within the cross-hatched
area.
The “Daily” instructions apply to
routine or daily starting of the engine.
They do not apply to a new engine
or one that has been operated for a
considerable period of time.
For new or stored engines, refer to
Restoring an Engine to Service after
Extended Storage in this guide.
Preventive maintenance other than the
“Daily” checks should be performed
by authorized Detroit Diesel service
outlets. These outlets have the trained
personnel and special tools to properly
perform all services.
Figure 11
Current Oil Level Gage
See Figure 12 for the former oil level
gage. When using this dipstick, keep
the oil level between the “Full” and
“Add” lines.
Item 1 – Lubricating Oil
Check the oil level daily with the
engine stopped. If the engine has
All information subject to change without notice. (Rev. May 2004)
DDC-SVC-MAN-0057 0305 Copyright © 2003 DETROIT DIESEL CORPORATION
53
LUBRICATION AND PREVENTIVE MAINTENANCE INTERVALS
lubricating oil and filters at the
intervals listed in Table 20 when
using fuel with a sulfur content of
less than 0.05 mass percent. When
using fuel with a higher sulfur content,
refer to section B. When to Change
Oil.
Figure 12
Former Oil Level Gage
NOTICE:
When adding lubricating oil, do
not overfill. Oil may be blown out
through the crankcase breather if
the crankcase is overfilled. For total
engine oil capacity, refer to section
Engine Oil Capacity.
All diesel engines are designed to use
some oil, so the periodic addition of
oil is normal.
NOTICE:
If the oil level is constantly above
normal and excess oil has not been
added to the crankcase, consult
with an authorized Detroit Diesel
service outlet for the cause. Fuel or
coolant dilution of lubricating oil can
result in serious engine damage.
Before adding lubricating oil,
refer to section A. How to Select
Lubricating Oil in this guide. Change
54
All information subject to change without notice. (Rev. May 2004)
DDC-SVC-MAN-0057 0305 Copyright © 2003 DETROIT DIESEL CORPORATION
SERIES 40 ENGINE OPERATOR'S GUIDE
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), 300
Hours or 1 Year, whichever comes first
Stationary or Construction/ Industrial
& Agricultural
450 Hours or 1 Year, whichever comes
first
300 Hours or 3 Months, whichever
comes first
450 Hours or 1 Year, whichever comes
first
* Change both full-flow filters when lube oil is changed.
Stationary Generator – Prime Power
or Continuous
Stationary Generator – Standby
Table 20
Recommended Maximum Oil Drain/Filter Change Intervals
(Diesel Fuel Sulfur Content Less Than 0.05 Mass %)
The length of time an engine may
operate before an oil change depends
upon the lubricant and fuel used,
engine oil consumption, and the
operating cycle. The maximum
interval at which the engine may
operate before the oil and filters
must be changed is listed in Table
20. Oil analysis may be used to
determine whether this interval should
be shortened, but it should not be used
to lengthen the interval.
Item 2 – Fuel and Fuel Tank
Figure 13
Keep Fuel Tank Filled to
Reduce Condensation
Keep the fuel tank filled to reduce
condensation. Before adding fuel,
refer to section D. How to Select Fuel
Oil in this guide. See Figure 13.
All information subject to change without notice. (Rev. May 2004)
DDC-SVC-MAN-0057 0305 Copyright © 2003 DETROIT DIESEL CORPORATION
55
LUBRICATION AND PREVENTIVE MAINTENANCE INTERVALS
Refill the tank at the end of each day's
operation to prevent condensation
from contaminating the fuel.
Condensation formed in a partially
filled tank promotes the growth of
microorganisms that can clog fuel
filters and restrict fuel flow.
time, check the seal in the fuel tank
cap, the breather hole in the cap and
the condition of the flexible fuel
lines. Repair or replace the parts, as
necessary.
NOTICE:
Galvanized steel fuel tanks, fittings,
pipes or supply lines should never
be used, because the fuel reacts
chemically with the zinc coating to
form powdery flakes that can quickly
clog the fuel filters and damage the
fuel pump and injectors.
To avoid injury from improper use
of chemicals, follow the chemical
manufacturer’s usage, handling,
and disposal instructions.
Observe all manufacturer’s
cautions.
Item 3 – Fuel Lines,
Flexible Hoses
To prevent microbe growth,
add a biocide to the fuel tank
or primary fuel supply. Water
accumulation can be controlled by
using additives containing methyl
carbitol or butyl cellusolve. Follow
manufacturer's usage, handling and
safety precautions.
Pre-Start Inspection
Open the drain at the bottom of the
fuel tank every 30,000 miles (48,000
kilometers) or 300 hours for stationary
and industrial engines to drain off any
water and/or sediment.
Leaks – Make a visual check for fuel
leaks at all engine-mounted fuel lines
and connections, and at the fuel tank
suction and return lines. Since fuel
tanks are susceptible to road hazards,
leaks in this area may best be detected
by checking for an accumulation of
fuel under the tank.
Every 120,000 miles (192,000
kilometers), 12 months, or 600
hours for construction/industrial
applications tighten all fuel tank
mountings and brackets. At the same
56
All information subject to change without notice. (Rev. May 2004)
DDC-SVC-MAN-0057 0305 Copyright © 2003 DETROIT DIESEL CORPORATION
SERIES 40 ENGINE OPERATOR'S GUIDE
To avoid injury from fire, contain
and eliminate leaks of flammable
fluids as they occur. Failure to
eliminate leaks could result in
fire.
Leaks are not only detrimental to
machine operation, but they can also
result in added expense caused by the
need to replace lost fluids.
Hoses and Fittings– Check hoses
daily as part of the pre-start inspection.
Examine hoses for leaks, and check
all fittings, clamps and ties carefully.
Make sure hoses are not resting
on or touching shafts, couplings,
heated surfaces including exhaust
manifolds, any sharp edges, or other
obviously hazardous areas. Since all
machinery vibrates and moves to a
certain extent, clamps and ties can
fatigue with age. To ensure continued
proper support, inspect fasteners
frequently and tighten or replace them
as necessary. If fittings have loosened
or cracked or if hoses have ruptured or
worn through, take corrective action
immediately.
500 operating hours (1,000 hours
for fire-resistant fuel and lubricating
oil hoses) and/or annually. Look
for cover damage and/or indications
of twisted, worn, crimped, brittle,
cracked or leaking lines. Hoses with
their outer cover worn through or with
damaged metal reinforcements should
be considered unfit for further service.
All hoses in and out of machinery
should be replaced during major
overhaul and/or after a maximum of
five (5) years of service.
NOTE:
Fire-resistant fuel and lube oil hose
assemblies do not require automatic
replacement after five years of service
or at major overhaul, but should be
inspected carefully before being put
back into service.
Hose Service Life
A hose has a finite service life. With
this in mind, all hoses should be
thoroughly inspected at least every
All information subject to change without notice. (Rev. May 2004)
DDC-SVC-MAN-0057 0305 Copyright © 2003 DETROIT DIESEL CORPORATION
57
LUBRICATION AND PREVENTIVE MAINTENANCE INTERVALS
Item 4 – Cooling System
Coolant Inhibitors
NOTICE:
To avoid injury from the expulsion
of hot coolant, never remove the
cooling system pressure cap
while the engine is at operating
temperature. Remove the cap
slowly to relieve pressure. Wear
adequate protective clothing
(face shield or safety goggles,
rubber gloves, apron, and boots).
Coolant Level
The cooling system must be full for
proper operation of the engine.
With the engine stopped, check the
coolant level daily and maintain it
near the bottom of the filler neck on
the radiator. On some installations
this is done by checking an overflow
bottle or sight glass. Add coolant as
required, but do not overfill. Before
adding coolant, refer to section G.
How to Select Coolant in this guide.
Make a daily visual check for
cooling system leaks. Look for an
accumulation of coolant when the
engine is running and when it is
stopped. Coolant leaks may be more
apparent on a engine when it is cold.
58
Coolant must be inhibited with the
recommended SCA's (supplemental
coolant additives) listed in this
guide. In addition, the engine
can be equipped with a coolant
filter/inhibitor system as an
installed option or as an after-sale
item. Failure to check and
maintain SCA levels at required
concentrations will result in
severe damage (corrosion) to
the engine cooling system and
related components.
Check the coolant SCA (supplemental
coolant inhibitors) at the intervals
listed in Table 28. The inhibitors
in antifreeze solutions must be
replenished with a non-chromate
corrosion inhibitor supplement when
indicated. Refer to section G. How to
Select Coolant for required inhibitor
levels.
Coolant Drain Interval
Detroit Diesel recommends
replacing coolant at the intervals
listed in Table 21.
All information subject to change without notice. (Rev. May 2004)
DDC-SVC-MAN-0057 0305 Copyright © 2003 DETROIT DIESEL CORPORATION
SERIES 40 ENGINE OPERATOR'S GUIDE
A coolant system properly maintained
and protected with supplemental
coolant inhibitors can be operated
up to the intervals listed. At
these intervals the coolant must
be drained and disposed of in an
environmentally responsible manner
according to state and/or federal
(EPA) recommendations.
Coolant Type
Coolant Replacement Interval
With proper maintenance1 coolant
can be operated 2 years, 300,000
miles (480,000 km), or 4,000 hours,
whichever comes first. At this time the
cooling system must be completely
drained and cleaned before refill.
With proper maintenance1 coolant can
A 50/50 mix of phosphate-free TMC
be operated for the life of the engine
RP-329 “Type A“ (propylene glycol)
until overhaul.2 For life to overhaul,
antifreeze and water.
pre-charged coolant in combination
with a need-release filter must be
used. At this time the cooling system
must be completely drained and
cleaned before refill.
With proper maintenance coolant can
A 50/50 mix of OAT (organic acid
be operated 4 years, 600,000 miles
technology) coolant and water.
(960,000 km), or 10,000 operating
hours, whichever comes first. 3 At
this time the cooling system must
be completely drained and cleaned
before refill.
1
Proper maintenance involves periodic evaluation using PowerTrac®
3-Way Coolant Test Strips and the addition of required SCA, as
indicated by the test strip.
2
To verify coolant acceptability, submit a sample to DDC for coolant
analysis every 3 years, 300,000 miles (480,000 km) or 6,000
operating hours, whichever comes first. Submit sample using
PowerTrac coolant analysis kit, part number 23516921 (IEG/IPG
coolant) 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.
A 50/50 mix of Power Cool® fully
formulated, inhibited ethylene glycol
antifreeze and water or a 50/50 mix of
fully formulated, inhibited propylene
glycol antifreeze and water
Table 21
Coolant Drain Intervals
All information subject to change without notice. (Rev. May 2004)
DDC-SVC-MAN-0057 0305 Copyright © 2003 DETROIT DIESEL CORPORATION
59
LUBRICATION AND PREVENTIVE MAINTENANCE INTERVALS
Item 5 – Turbocharger,
Air-to-Air Charge Cooler
NOTE:
If lack of engine performance is
noted after high-mileage operation,
the turbocharger wastegate should
be checked for proper operation.
Authorized Detroit Diesel distributors
have the trained personnel and are
properly equipped to perform this
service.
To avoid injury from hot surfaces,
allow engine to cool before
removing any component. Wear
protective gloves.
Item 6 – Battery
Visually inspect the turbocharger
mountings, intake and exhaust ducting
and connections for leaks daily. Check
the lube oil inlet and outlet lines for
leaks or restrictions to oil flow. Check
for unusual noise or vibration and, if
excessive, stop the engine and do not
operate until the cause is determined.
Periodically inspect the charge air
cooler (if used) for buildup of dirt,
mud, etc. and wash off. Check
the charge cooler, ductwork, and
flexible connections for leaks and
have repaired or replaced, as required.
Check turbocharger heat-insulating
exhaust system blankets (if used) for
damage on a daily basis. Torn, matted,
crushed, oil-soaked or otherwise
damaged insulation blankets must be
replaced immediately.
To avoid injury from accidental
engine startup while servicing
the engine, disconnect/disable
the starting system.
Check the hydrometer “eye” of
maintenance-free batteries for charge.
See Figure 14. If lead-acid or
low-maintenance batteries are used,
check the specific gravity of each cell
every 150 operating hours. Check
more frequently in warm weather due
to the more rapid loss of water through
evaporation.
Wastegated Turbochargers – The
turbocharger wastegate actuator
is factory-calibrated and is not
adjustable.
60
All information subject to change without notice. (Rev. May 2004)
DDC-SVC-MAN-0057 0305 Copyright © 2003 DETROIT DIESEL CORPORATION
SERIES 40 ENGINE OPERATOR'S GUIDE
if possible. Replace any battery that
fails to hold a charge.
Periodically check battery connections
for corrosion and tightness. If
necessary, remove connections
and wire brush any corrosion from
terminals and cable ends. Replace
damaged wiring.
Item 7– Drive Belt
Figure 14
Check “Eye” of
Maintenance-Free
Batteries
Maintain the electrolyte level
according to the battery manufacturer's
recommendations, but do not overfill.
Overfilling can cause poor battery
performance or early failure.
Keep the terminal side of the battery
clean. When necessary, wash with
a solution of baking soda and water.
Rinse with fresh water. Do not allow
the soda solution to enter the cells.
Inspect the cables, clamps and
hold-down brackets regularly. Clean
and reapply a light coating of
petroleum jelly when needed. Have
corroded or damaged parts replaced.
If the engine is to be out of service
for more than 30 days, remove the
batteries and store in a cool, dry
place. Keep batteries fully charged,
Inspect the serpentine drive belt
after every oil change. Replace belt
every 100,000 miles (160,000 km)
on vehicle engines or every 2,000
hours on construction/industrial and
stationary engines. Replace earlier if
belt shows signs of excessive wear or
damage.
Always replace the drive belt with the
quality belt specified for your engine
to ensure the belt will be neither too
tight nor too loose. A belt that is
too tight imposes extra loads on the
crankshaft, water pump, alternator and
fan hub bearings, shortening both belt
and bearing life. A loose belt will slip
and may cause damage to accessory
components.
Before installing the drive belt, check
the torque on the alternator and
bracket mounting bolts. Retighten as
required. The drive belt idler pulley
should also be inspected whenever the
belt is removed. Refer to Item 26 –
Idler Pulley.
All information subject to change without notice. (Rev. May 2004)
DDC-SVC-MAN-0057 0305 Copyright © 2003 DETROIT DIESEL CORPORATION
61
LUBRICATION AND PREVENTIVE MAINTENANCE INTERVALS
150 Hours or 4,500 miles (7,200
km)
To avoid injury from rotating belts
and fans, do not remove and
discard safety guards.
Item 8 – Air Compressor
To clean either the hair type or the
polyurethane type compressor air
strainer element, saturate it and
squeeze it in fuel oil or any other
cleaning agent that is not detrimental
to the element until it is dirt-free. Then
saturate the element in lubricating oil
and squeeze it dry before placing it
back into the air strainer.
For air strainer replacement,
contact the nearest servicing dealer.
Replace hair type elements with the
polyurethane type, if available.
The air compressor mounting bolts
should be tightened every 12 months
or 30,000 miles (48,000 km) for
vehicle engines or every 300 hours for
stationary and industrial engines.
Item 9 – Air Cleaner
Figure 15
Typical Air Compressor
Assembly
All air compressor intake parts
should be removed and cleaned at the
following intervals:
□ Motor Coach, Transit Coach,
Crash/Rescue, Pick-Up and
Delivery Vehicle Engines – 6,000
miles (9,600 km)
□ Construction/Industrial
Engines/Stationary Engines–
62
Check the air cleaner restriction
indicator daily and service, if required.
Inspect the air cleaner element every
12,000 miles (19,200 km) for vehicle
engines, or 150 hours for stationary
and industrial engines. Inspect more
often if the engine is operated under
severe dust conditions. Replace the
element, if necessary. Check the
gaskets for deterioration and replace,
if necessary. If the dry type air cleaner
is equipped with an aspirator, check
for aspirator damage or clogging.
Clean, repair or replace, as necessary.
All information subject to change without notice. (Rev. May 2004)
DDC-SVC-MAN-0057 0305 Copyright © 2003 DETROIT DIESEL CORPORATION
SERIES 40 ENGINE OPERATOR'S GUIDE
NOTICE:
Do not allow the air inlet restriction
to exceed 20 inches of water (5.0
kPa) under any engine operating
conditions. A clogged air cleaner
element will cause excessive
intake restriction and a reduced
air supply to the engine. This, in
turn, can result in increased fuel
consumption, inefficient engine
operation and reduced engine life.
Inspect the entire air system for leaks
daily. Look especially for torn air inlet
piping or boots and loose or damaged
clamps. Have worn or damaged parts
repaired or replaced, as required.
Retighten loose connections.
Item 10 – Lubricating Oil
Filter
To avoid injury from slipping and
falling, immediately clean up any
spilled liquids.
Install new spin-on oil filters whenever
the engine oil is changed. Oil change
intervals are listed in Table 20.
Refer to section C. How to Replace
the Lube Oil Filter for procedure.
See Figure 16 for typical filter
installation.
Air Cleaner Replacement
Dry type air cleaner elements
should be replaced after one year
of service or when the maximum
allowable air intake restriction has
been reached, whichever comes first.
Refer to section J. When to Service
the Dry Type Air Cleaner in this guide
for additional information.
1. Oil Cooler
Assembly
3. Oil Filter
Header
2. Oil Filter
Figure 16
All information subject to change without notice. (Rev. May 2004)
Typical Oil Filter
Installation
DDC-SVC-MAN-0057 0305 Copyright © 2003 DETROIT DIESEL CORPORATION
63
LUBRICATION AND PREVENTIVE MAINTENANCE INTERVALS
Make a visual check of all lubricating
oil lines for wear and/or chafing. If
any indication of wear is evident,
replace the oil lines and correct the
cause.
Check for oil leaks after starting the
engine.
Item 11 – Fuel Filter
Fuel Filter and Strainer
If equipped, drain the fuel/water
separator daily.
See Figure 17 for a typical fuel filter
and strainer installation. Replace the
fuel filter and clean the strainer at the
intervals listed in the maintenance
tables or every other oil change. For
change intervals, refer to Maintenance
Intervals. For change procedure,
refer to section Replace Fuel Filter
and Strainer.
64
All information subject to change without notice. (Rev. May 2004)
DDC-SVC-MAN-0057 0305 Copyright © 2003 DETROIT DIESEL CORPORATION
SERIES 40 ENGINE OPERATOR'S GUIDE
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 be
shortened to conform with established
preventive maintenance schedules,
but should never be extended.
no less than 60 psi (414 kPa) at normal
operating speed.
Change the fuel filters whenever the
fuel pressure at the inlet fitting falls
below this level.
One method of determining when
filters are plugged to the extent that
they need replacing is based on the
fuel pressure at the cylinder head fuel
inlet fitting. Fuel pressure should be
All information subject to change without notice. (Rev. May 2004)
DDC-SVC-MAN-0057 0305 Copyright © 2003 DETROIT DIESEL CORPORATION
65
LUBRICATION AND PREVENTIVE MAINTENANCE INTERVALS
Fuel Pro® 382 Filters
Install new Fuel Pro® 382 primary
fuel filter elements when the fuel
level in the see-thru cover reaches the
top of the element or after one year
of service, whichever comes first.
Refer to section Replace “Fuel Pro®
382/382E” Fuel Filter Element.
Item 12 – Water Pump and
Coolant Inhibitor Element
Water Pump
Water Pump Drain Hole – The water
pump drain hole should be inspected
every 6 months to make sure it is
open. A small chemical build-up
or streaking at the drain hole may
occur. This is not an indication of
a defective water pump or seal.
Remove the build-up with a mild
detergent cleaner and a brush. If
coolant does not leak from the drain
hole under normal conditions, do not
replace the water pump.
Coolant Inhibitor Element
The coolant must be tested at required
intervals and the coolant inhibitor
element replaced, if required.
1. Spin-on
Inhibitor
Element
Figure 18
2.
Filter
Adaptor
Installing Coolant
Inhibitor Element
Required test intervals are
listed in Table 28 . For SCA
test procedures refer to section G.
How to Select Coolant and then
refer to section SCA Test Procedures
in this guide. Use the coolant filter
element required. Refer to section
Power Cool Engine Products for
element part number listing. The
valves mounted on the filter adaptor
head must be opened after the element
is replaced.
Item 13 – Cranking Motor
For cranking motor (starter) assembly
information, contact an authorized
Delco Remy® distributor.
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All information subject to change without notice. (Rev. May 2004)
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SERIES 40 ENGINE OPERATOR'S GUIDE
Item 14 – Air System
Item 17 – Radiator
All the connections in the air system
should be checked to make sure
they are tight and leak free. Check
all hoses and ducting for punctures,
deterioration or other damage and
replace, if necessary.
The exterior of the radiator core
should be inspected every 30,000
miles (48,000 km), 12 months, or
300 hours (stationary and industrial
engines) and cleaned, if necessary.
Item 15 – Exhaust System
Have the exhaust manifold retaining
bolts and other connections checked
for tightness. Have the exhaust pipe
rain cap checked for proper operation,
if so equipped.
To avoid injury from flying debris
when using compressed air, wear
adequate eye protection (face
shield or safety goggles) and do
not exceed 40 psi (276 kPa) air
pressure.
Item 16 – Engine (Steam
Clean)
Steam clean the engine and engine
compartment every 60,000 miles
(96,000 km) or 2,100 hours,
whichever comes first. Steam clean
more frequently, if operating in dusty
or dirty environments.
NOTICE:
Do not apply steam or solvent
directly to the battery-charging
alternator, starting motor, electronic
engine control components, sensors
or other electrical components, as
damage to electrical equipment may
result.
Use a quality grease solvent, such
as mineral spirits, and dry with
compressed air. Fuel oil, kerosene or
gasoline should not be used.
It may be necessary to clean the
radiator more frequently if the engine
is being operated in extremely dusty
or dirty areas.
If the low coolant level sensor is
installed in the top tank of the radiator,
it should be tested for proper operation
every 100,000 miles (160,000 km)
or 12 months, whichever comes first.
Authorized Detroit Diesel distributors
are properly equipped to perform this
service.
All information subject to change without notice. (Rev. May 2004)
DDC-SVC-MAN-0057 0305 Copyright © 2003 DETROIT DIESEL CORPORATION
67
LUBRICATION AND PREVENTIVE MAINTENANCE INTERVALS
Item 18 – Oil Pressure
Under normal operation, oil pressure
is noted each time the engine is
started. In the event the equipment
has warning lights rather than pressure
indicators, the pressure should be
checked and recorded every 60,000
miles (96,000 km) for vehicle engines
or every 600 hours for stationary and
industrial engines.
Item 19 – Battery-Charging
Alternator
General Service Requirements
□ Flush your eyes with water.
□ Get medical attention
immediately.
Check torque on alternator mounting
bolts and bracketing every 15,000
miles (24,000 km) on coach engines or
every 300 hours on all other engines.
Retighten, if necessary.
Precautions must be taken when
working on or around the alternator.
The diodes and transistors in the
alternator circuit are very sensitive
and can be easily destroyed.
□ Flush your skin with water.
□ Apply baking soda or lime to
help neutralize the acid.
Terminals should be checked for
corrosion and loose connections
and wiring inspected for damage
and frayed insulation. Have wiring
repaired or replaced, as required.
Alternator Precautions
To avoid injury from battery
explosion or contact with battery
acid, work in a well-ventilated
area, wear protective clothing,
and avoid sparks or flames
near the battery. Always
establish correct polarity before
connecting cables to the battery
or battery circuit. If you come in
contact with battery acid:
1. Avoid grounding the output
terminal. Grounding an
alternator's output wire or
terminal (which is always “hot,”
regardless of whether or not
the engine is running) and
accidentally reversing the battery
polarity will result in equipment
damage.
2. Do not reverse battery
connections. This can also
cause damage.
3. Never disconnect the battery
while the alternator is operating.
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All information subject to change without notice. (Rev. May 2004)
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SERIES 40 ENGINE OPERATOR'S GUIDE
Disconnecting the battery can
result in damage to the battery
diodes. In applications which
have two (2) sets of batteries,
switching from one set to the
other while the engine is running
will momentarily disconnect
the batteries. This can result in
equipment damage.
4. If a booster battery is to be used,
batteries must be connected
correctly (negative to negative,
positive to positive) to avoid
equipment damage.
5. Never use a fast charger with the
batteries connected or as a booster
for battery output.
For information on the alternator
assembly, contact an authorized Delco
Remy® distributor.
Item 20 – Engine and
Transmission Mounts
higher than 6 in. water (1.5 kPa) at
maximum no-load speed with the
breather restrictor tool installed.
Item 22 – Fan Hub
The fan hub assembly includes
a sealed bearing which is not
serviceable.
□ Inspection Interval: Inspect the
fan hub for free bearing rotation at
the interval shown in the regular
maintenance interval table for
your engine. If the hub does not
spin freely or is noisy (indicating
bearings are “dry” or worn),
replace the fan hub.
□ Replacement Interval: Replace
the fan hub at the interval shown
in the regular maintenance interval
table for your engine, regardless
of apparent condition.
The engine and transmission mounting
bolts and the condition of the mounting
pads should be checked every 60,000
miles (96,000 km) or 600 hours.
Tighten and/or repair as necessary.
Item 21 – Crankcase
Pressure
The crankcase pressure should be
checked and recorded at the intervals
in the maintenance schedules.
Crankcase pressure should be no
All information subject to change without notice. (Rev. May 2004)
DDC-SVC-MAN-0057 0305 Copyright © 2003 DETROIT DIESEL CORPORATION
69
LUBRICATION AND PREVENTIVE MAINTENANCE INTERVALS
Item 23 – Thermostat and
Seal
on vehicle engines. On non-vehicle
engines, replace the thermostat and
seal every 4,000 hours or 24 months,
whichever comes first.
Item 24 – Crankcase
Breather
The steel mesh breather pad in the
valve cover/intake manifold should
be removed and washed in clean
fuel oil when the valve cover is
removed for valve lash measurement
and adjustment. These intervals are
listed in Table 22.
1. Thermostat
3. Cylinder Head
Item 25 – Engine Tune-Up
2. Seal
Figure 19
There is no scheduled interval for
performing an engine tune-up.
However, the valve lash must be
measured and, if necessary, adjusted at
the regular intervals listed in Table 22.
Typical Thermostat
Installation
Replace the thermostat and seal
every 240,000 miles (384,000 km)
Valve Lash Measurement/
Adjustment Interval
Engine Application
Motor Coach
Transit Coach
Stationary, Construction/Industrial,
Agricultural, or Generator Set Engines
* Whichever comes first.
Table 22
70
Every 60,000 Miles (96,000 km)
or 24 Months*
Every 45,000 Miles (72,000 km)
or 18 Months*
Every 1,500 Hours or 45,000
Miles (72,000 km)*
Valve Lash Measurement/Adjustment Schedule
All information subject to change without notice. (Rev. May 2004)
DDC-SVC-MAN-0057 0305 Copyright © 2003 DETROIT DIESEL CORPORATION
SERIES 40 ENGINE OPERATOR'S GUIDE
Item 26 – Idler Pulley
The fan belt idler pulley requires
periodic inspection and replacement.
□ Inspection Interval: Inspect
the idler pulley for free bearing
rotation at 45,000 miles (72,000
km) on vehicle engines and at 450
hours on non-vehicle engines, or
whenever the serpentine belt is
removed. If the pulley does not
spin freely or is noisy (indicating
bearings are “dry” or worn),
replace the pulley.
□ Replacement Interval: Replace
the idler pulley every 60,000
miles (72,000 km) of operation
on vehicle engines or every 9,000
hours of operation on non-vehicle
engines, regardless of apparent
condition.
Item 27 – Vibration Damper
All Series 40 engines use
rubber-bushed vibration dampers,
except generator sets, which use
viscous dampers.
Figure 20
Typical Rubber-Bushed
Vibration Damper
□ Rubber-Bushed Damper:
Inspect damper (see Figure 20)
once a year. Replace if rubber
“streaking” on the damper face
exceeds guidelines (contact a
DDC distributor for guidelines)
or if deep splits appear in the
rubber member. Deep splits
can allow chunks of rubber
to break off from the damper
(“chunking”), affecting its balance
and dampening efficiency.
All information subject to change without notice. (Rev. May 2004)
Heat from normal engine
operation will, over a period of
time, cause the rubber member in
the vibration damper to become
brittle as it ages. For this reason
the vibration damper must be
replaced at time of normal major
engine overhaul, regardless of
apparent condition.
DDC-SVC-MAN-0057 0305 Copyright © 2003 DETROIT DIESEL CORPORATION
71
LUBRICATION AND PREVENTIVE MAINTENANCE INTERVALS
Welding Precaution
NOTICE:
Figure 21
Typical Viscous
Vibration Damper
□ Viscous Damper: Inspect damper
( see Figure 21) once a year.
Replace if dented or leaking. Heat
from normal engine operation
may, over a period of time,
cause the fluid within the damper
to break down and lose its
dampening properties. For this
reason the viscous damper must be
replaced at time of normal major
engine overhaul, regardless of
apparent condition.
72
Failure to isolate the electronic
engine control system
components from high current
flow can result in severe ECM
(electronic control module)
damage. To avoid damage to
vehicle electronic components,
disconnect both the positive (+)
and the negative (-) battery cables
prior to electric welding. Attach the
welder's ground cable as close as
possible to the joint being welded.
If it is necessary to weld close
to an electronic component, the
component should be temporarily
removed.
Whenever welding is done on any
part of the vehicle, the batteries
must be disconnected, both power
and ground, which must include all
electronic power feeds. The electronic
components may easily be damaged
by the high voltage used and the RF
(radio frequency) energy present in
the arc.
All information subject to change without notice. (Rev. May 2004)
DDC-SVC-MAN-0057 0305 Copyright © 2003 DETROIT DIESEL CORPORATION
SERIES 40 ENGINE OPERATOR'S GUIDE
HOW-TO SECTION
This section covers Detroit Diesel's
recommendations on how to select
lubricating oil, fuel oil, and coolant
and includes basic engine maintenance
procedures which can be performed
by the operator.
service designation. Only oils licensed
to display the API service mark should
be used. See Figure 22.
Lubricant Requirements
NOTICE:
The manufacturer's warranty
applicable to Series 40 engines
provides in part that the provisions
of such warranty shall not apply
to any engine unit that has been
subject to misuse, negligence or
accident. Accordingly, malfunctions
attributable to neglect or failure to
follow the manufacturer's fuel or
lubricating recommendations may
not be within the coverage of the
warranty.
A. How to Select
Lubricating Oil
Lubricant Selection in North
America
The selection of the proper lubricating
oil is important to achieve the long
and trouble-free service which Detroit
Diesel engines are designed to
provide. The proper lubricating oil for
all Detroit Diesel engines is selected
based on SAE viscosity grade and
API (American Petroleum Institute)
Figure 22
API Lubricant Service
Mark
API CI-4 or CH-4 oils are
recommended for use in all engines.
Engines Built Prior to 1998
Lubricants meeting API Service
Category CG-4 may be used in
engines built prior to 1998 when API
CI-4 or CH-4 oils are not available.
NOTE:
The use of CG-4 oils in these
engines may require a reduction in
oil drain interval, depending upon the
application and the fuel sulfur level.
All information subject to change without notice. (Rev. May 2004)
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HOW-TO SECTION
Cold Weather Starting
At ambient temperatures below –4
°F (–20 °C) when sufficient starter
speed cannot be achieved with SAE
15W-40 oils, the use of 5W-XX oils
and 10W-XX oils, where XX is 30 or
40, is allowed to improve startability,
provided they are API CI-4 or API
CI-4 or CH-4 and have demonstrated
field performance in DDC engines.
These oils must possess a HT/HS of
3.7 minimum.
NOTICE:
Monograde oils should not
be used in Series 40 engines,
regardless of API service
classification. Monograde oils
gel at lower ambient temperatures,
reducing lubricant flow, and
they do not provide adequate
lubricity at higher engine operating
temperatures. These factors can
result in severe engine damage.
available from authorized Detroit
Diesel distributors.
The Use of Supplemental
Additives
Lubricants meeting the Detroit
Diesel specifications outlined in this
publication already contain a balanced
additive treatment. Supplemental
additives are generally not necessary
and can even be harmful. These
additives may be marketed as either
oil treatments or engine treatments
and are discouraged from use in
Detroit Diesel engines. Engine
damage resulting from the use of
such materials is not covered by
your Detroit Diesel Corporation
warranty. Detroit Diesel will not
provide statements beyond this
publication relative to their use.
When the use of high sulfur fuel
(greater than 0.05% mass sulfur) is
unavoidable, high alkalinity (TBN)
lubricants are recommended. High
sulfur fuels require modification
to oil drain intervals. For further
information, refer to publication
Engine Requirements – Lubricating
Oil, Fuel and Filters, 7SE270,
74
All information subject to change without notice. (Rev. May 2004)
DDC-SVC-MAN-0057 0305 Copyright © 2003 DETROIT DIESEL CORPORATION
SERIES 40 ENGINE OPERATOR'S GUIDE
B. When to Change Oil
Oil Drain Intervals
To avoid injury from contact with
the contaminants in used engine
oil, wear protective gloves and
apron.
The length of time an engine may
operate before an oil change depends
upon the lubricant and fuel used,
engine oil consumption, and the
operating cycle. The maximum
interval at which the engine may
operate before the oil and filters
must be changed is listed in Table
23. Oil analysis may be used to
determine whether this interval should
be shortened, but it should not be used
to lengthen the interval.
The use of fuels with sulfur content
above 0.05 mass percent will require
a shortening of drain intervals and/or
the use of a higher TBN oil. See
the information listed in Table 23.
For detailed information refer to
publication Engine Requirements –
Lubricating Oil, Fuel and Filters
(7SE270), available from authorized
Detroit Diesel distributors.
Engine Application
Drain Interval
Motor Coach, City Transit Coach
12,000 Miles (19,200 km)
Fire Truck or Crash/Rescue Vehicle
6,000 Miles (9,600 km), 300 Hours or
1 Year, whichever comes first
150 Hours, 4,500 Miles (7,200 km) or
1 year, whichever comes first
Construction, Industrial or Agriculture
Stationary Generator Set, Prime
Power or Continuous
Stationary Generator Set, Standby
Table 23
250 Hours or 3 Months, whichever
comes first
150 Hours or 1 Year, whichever comes
first
Maximum Oil Drain and Filter Change Interval (Fuel Sulfur
0.05 Weight Percent or Less)
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HOW-TO SECTION
Disposing of Waste Oil
Dispose of used lubricating oil
and filters in an environmentally
responsible manner, according
to federal (EPA) and/or state
recommendations. The disposal of
waste oil may be best addressed by the
engine oil supplier, who may accept
responsibility for proper disposal of
this material as part of the business of
providing lubricant.
1. Oil Cooler Assembly
C. How to Replace the
Lube Oil Filter
Filters are an integral part of the
lubricating oil system. Proper
filter selection and maintenance
are important to satisfactory engine
performance and service life.
Filters should be used to maintain
a clean system, not to clean up a
contaminated system. Filter part
numbers arelisted in Table 43 in the
Specifications section of this guide.
3. Oil Filter Header (part of oil cooler
assembly)
2. Oil Filter
Figure 23
76
Typical Oil Filter Installation
All information subject to change without notice. (Rev. May 2004)
DDC-SVC-MAN-0057 0305 Copyright © 2003 DETROIT DIESEL CORPORATION
SERIES 40 ENGINE OPERATOR'S GUIDE
Replace Spin-On Type Oil Filter
To avoid injury from slipping and
falling, immediately clean up any
spilled liquids.
Replace spin-on type filter as follows:
1. Place a suitable container under
the engine oil pan, remove
the drain plug and drain the
lubricating oil. Replace the drain
plug and tighten securely.
2. Remove spin-on filter using tool
J 29917 or equivalent and a
1/2-in. drive socket wrench and
extension. See Figure 24.
3. Dispose of used oil and
filter in an environmentally
responsible manner, according
to federal (EPA) and/or state
recommendations.
4. Clean the filter gasket-contact
surface of the adaptor head with a
clean, lint-free cloth.
5. Fill the new filter with clean
lubricating oil and lightly coat the
filter gasket with the same oil.
NOTICE:
Do not overtighten filters.
Overtightening may crack or
distort the filter adaptor.
6. Start the new filter on the adaptor
head and tighten by hand until
the gasket touches the mounting
adaptor head. Tighten filter
an additional one full turn by
hand, or as indicated on the
filter.
7. Add oil as required to bring the
level to the “Full” or “Operating
Range” mark on the dipstick.
Refer to Item 1 – Lubricating Oil.
1. Oil Filter
Figure 24
2. Oil Filter
Header
Removing Oil Filter
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HOW-TO SECTION
NOTICE:
If the engine oil level is constantly
above normal and excess lube
oil has not been added to the
crankcase, consult with an
authorized Detroit Diesel service
outlet for the cause. Fuel or coolant
dilution of lube oil can result in
severe engine damage.
Diesel engine exhaust and some
of its constituents are known to
the State of California to cause
cancer, birth defects, and other
reproductive harm.
□ Always start and operate an
engine in a well ventilated
area.
D. How to Select Fuel Oil
□ If operating an engine in
an enclosed area, vent the
exhaust to the outside.
Quality
□ Do not modify or tamper
with the exhaust system or
emission control system.
8. Start and run the engine for a short
period and check for leaks. After
leaks have been corrected, stop
the engine long enough for oil
from various parts of the engine
to drain back to the crankcase
(approximately 20 minutes). Add
oil as required to bring the level to
the “Full” or “Operating Range”
mark on the dipstick.
78
Fuel quality is an important factor
in obtaining satisfactory engine
performance, long engine life, and
acceptable exhaust emission levels.
Detroit Diesel engines are designed to
operate on most diesel fuels marketed
today.
In general, fuels meeting the
properties of ASTM designation
D 975 (grades 1-D and 2-D) have
provided satisfactory performance.
The fuels used must be clean,
completely distilled, stable, and
non-corrosive. For more information
regarding the significance of these
properties and selection of the proper
fuel, refer to publication, Engine
Requirements – Lubricating Oil, Fuel
and Filters (7SE270), available from
authorized Detroit Diesel distributors.
All information subject to change without notice. (Rev. May 2004)
DDC-SVC-MAN-0057 0305 Copyright © 2003 DETROIT DIESEL CORPORATION
SERIES 40 ENGINE OPERATOR'S GUIDE
Fuel Contamination
Prohibited Additives
Generally, fuel contamination
occurs as the result of improper fuel
handling. The most common types
of contamination are water, dirt, and
microbial growth (“black slime”).
The formation of varnishes and
gums resulting from poor stability or
extended storage (“stale fuel”) also
affects fuel quality. The best treatment
for contamination is prevention by
maintaining a clean fuel storage
system and choosing a reputable fuel
supplier.
The following fuel additives are not
allowed and MUST NOT be mixed
with diesel fuel:
Supplemental additives are not
recommended due to potential
injector system or engine damage.
Our experience has been that such
additives increase operating costs
without providing benefit.
The use of supplemental fuel additives
does not necessarily void the engine
warranty. However, repair expenses
which result from fuel system or
engine component malfunctions
or damage attributed to their
use will not be covered. These
products should be accompanied by
performance data supporting their
merit. It is not the policy of Detroit
Diesel Corporation to test, evaluate,
approve or endorse such products.
Used Lubricating Oil — Detroit
Diesel specifically prohibits the
use of used lubricating oil in diesel
fuel. Used lubricating oil contains
combustion acids and particulate
materials which can severely erode
fuel injector components, resulting in
loss of power and increased exhaust
emissions. In addition, the use of
drained lubricating oil will increase
maintenance requirements due to filter
plugging and combustion deposits.
Gasoline —
To avoid increased risk of a fuel
fire, do not mix gasoline and
diesel fuel.
The addition of gasoline to diesel
fuel will create a serious fire hazard.
The presence of gasoline in diesel fuel
will reduce fuel cetane number and
increase combustion temperatures.
Tanks which contain such mixtures
should be drained and cleaned as soon
as possible.
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HOW-TO SECTION
Detroit Diesel Corporation will not be
responsible for any detrimental effects
it determines resulted from adding
drained lubricating oil or gasoline to
the diesel fuel.
NOTE:
An optional fuel/water separator may
be installed in the system piping ahead
of the fuel strainer.
Replace Fuel Filter and Strainer
E. How to Replace the Fuel
Filter
Filters are an integral part of the
fuel system. Proper filter selection
and maintenance are important to
satisfactory engine operation and
service life. Filters should be used to
maintain a clean system, not to clean
up a contaminated system. Refer
to the Specifications section of this
guide for proper filter selection.
To avoid injury from hot surfaces,
allow engine to cool before
removing any component. Wear
protective gloves.
Replace spin-on fuel filter element
and strainer as follows:
A reusable, cylindrical, woven nylon
primary fuel strainer element and
replaceable spin-on type secondary
fuel filter element are used on Series
40 engines. The strainer consists of
a cylindrical, woven nylon element
that installs onto the strainer header
and is protected by a screw-on plastic
body with a replaceable seal ring.
See Figure 25.
1. Shut down the engine and allow
it to cool.
2. With the engine at ambient
temperature and cool to the touch,
place a suitable container under
the filter.
The spin-on secondary filter consists
of a shell, element and gasket unitized
into a single cartridge and a filter
adaptor header which includes
threaded inserts to accept the spin-on
cartridge. The header also includes a
fuel priming pump and air bleed screw
for manual priming of the system after
filter replacement.See Figure 25.
80
3. A fuel shutoff valve may be
installed on the discharge side
of the fuel filter adaptor head.
If installed, turn the handle on
the shutoff valve to the closed
position (perpendicular to the
valve).
4. Using a suitable band type
filter wrench, remove the
fuel filter. Dispose of the
filter in an environmentally
responsible manner, according
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DDC-SVC-MAN-0057 0305 Copyright © 2003 DETROIT DIESEL CORPORATION
SERIES 40 ENGINE OPERATOR'S GUIDE
to federal (EPA) and/or state
recommendations. See Figure .
5. Using a 29 mm or 1 1/8–in. deep
socket, carefully remove the
plastic 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 damage
or plugging and clean or replace,
as required. Clean the cover.
Replace the O-ring, if damaged.
NOTE:
Install the strainer into the cover with
the open end toward the filter header.
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HOW-TO SECTION
NOTICE:
NOTICE:
Do not use tools to install the
strainer and do not overtighten,
since this could distort or crack
the plastic cover, resulting in fuel
leakage during engine operation.
Failure to disconnect the CMP
(camshaft position sensor) before
priming the engine may allow the
engine to start during priming,
which could result in severe engine
damage.
7. Insert the strainer into the cover
with the open end facing UP. With
the O-ring in place, install the
strainer onto the header. Tighten
securely by hand.
12. Refer to Prime the Fuel System
and Start the Engine below before
starting the engine.
8. Wipe the filter adaptor header
with a clean, lint-free cloth.
Prime the Fuel System and Start
the Engine
9. Fill the new replacement filter
with clean diesel fuel and coat the
gasket lightly with the fuel.
10. Thread the new filter onto the
adaptor insert until the gasket
makes full contact with the
adaptor header and no side
movement is evident. Tighten
filter an additional one-half turn
by hand, or as indicated on the
filter.
NOTICE:
Failure to disconnect the CMP
(camshaft position sensor) before
priming the engine may allow the
engine to start during priming,
which could result in severe engine
damage.
Prime the fuel system as follows:
NOTICE:
Do not overtighten the filter.
Overtightening may crack or distort
the adaptor head.
11. If previously closed, open the fuel
shutoff valve.
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DDC-SVC-MAN-0057 0305 Copyright © 2003 DETROIT DIESEL CORPORATION
SERIES 40 ENGINE OPERATOR'S GUIDE
NOTICE:
Under no circumstances should
the starting motor and fuel pump
be used to prime the fuel filter.
Prolonged used of the starting motor
and fuel pump to prime the fuel
system can result in damage to the
starter, fuel pump and injectors and
cause erratic running of the engine
due to the amount of air in the fuel
lines and filter.
1. Disconnect the CMP (camshaft
position sensor) to prevent the
engine from starting. The CMP
is installed on the front cover
of the engine between the water
pump pulley and the fan pulley.
See Figure 1.
2. Operate the manual primer pump
on the filter header until the
primer pump is hard to depress.
See Figure 25.
3. Crank the engine three times for
15 seconds each. Reapply the
primer pump after each crank
cycle.
4. Once the primer pump is hard to
depress (usually three crank and
hand prime cycles), reconnect the
CMP.
All information subject to change without notice. (Rev. May 2004)
Diesel engine exhaust and some
of its constituents are known to
the State of California to cause
cancer, birth defects, and other
reproductive harm.
□ Always start and operate an
engine in a well ventilated
area.
□ If operating an engine in
an enclosed area, vent the
exhaust to the outside.
□ Do not modify or tamper
with the exhaust system or
emission control system.
NOTICE:
To avoid starter damage, do not
crank the engine longer than
15 seconds at a time. Allow a
15-second starter cool down interval
between starting attempts.
5. Start the engine and check for
leaks. Shut down the engine.
Correct any leaks with the engine
off.
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83
HOW-TO SECTION
Replace Fuel/Water Separator
Element
NOTICE:
If an optional primary filter/water
separator is installed in the fuel system
piping, replace the element as follows:
1. Shut down the engine and allow
it to cool.
2. With the engine at ambient
temperature and cool to the touch,
place a suitable container under
the filter.
3. A fuel shutoff valve may be
installed on the discharge side
of the fuel/water separator. If
installed, turn the handle on
the shutoff valve to the closed
position (perpendicular to the
valve).
8. Apply a light coating of clean fuel
oil or grease to the new O-ring
seal on the top of the replacement
filter. Thread the filter and bowl
assembly onto the filter header
and tighten by hand until snug.
9. To eliminate air from the filter,
operate the primer pump on the
filter header until the fuel purges
at the filter assembly.
10. Refer to section Prime the Fuel
System and Start the Engine
before starting the engine.
4. Drain off some fuel by opening
the drain valve.
11. Shut down the engine. Correct
any leaks with the engine off.
5. Using a strap wrench, remove
the element and bowl together,
then remove the bowl from the
element. The filter and bowl
have right-hand threads, so turn
counter-clockwise to remove.
Replace “Fuel Pro® 382/382E”
Fuel Filter Element
6. Clean the bowl and the O-ring
seal.
7. Apply a light coating of clean
fuel or grease to the O-ring seal,
thread the bowl onto the new filter
and tighten by hand.
84
To avoid damaging the bowl or
the filter, do not use tools when
tightening.
The Fuel Pro 382/383E diesel fuel
filter system consists of a permanently
mounted fuel processor, a replaceable
filter element and sealing grommet
assembly, a filter spring, a see-thru
cover and seal, a cover collar, and a
vent cap and seal. The Fuel Pro 382E
system also includes a fuel heater
element, thermostatic switch and
wiring harness. See Figure 26.
All information subject to change without notice. (Rev. May 2004)
DDC-SVC-MAN-0057 0305 Copyright © 2003 DETROIT DIESEL CORPORATION
SERIES 40 ENGINE OPERATOR'S GUIDE
closed position (perpendicular to
the valve).
4. Open the drain valve at the base
of the fuel processor and drain the
fuel until it is below the bottom
of the filter in the see-thru cover.
Close the drain valve. The fuel
may be returned to the tank.
5. Using filter collar/vent cap
wrench part number 232002 or
equivalent, remove the collar
by turning counter-clockwise.
Remove the cover, filter spring
and cover seal ring by lifting
straight up and over the filter
element.
6. Remove the element from the
center stud (fuel outlet pipe)
by pulling upward and twisting
slightly.
Figure 26
Fuel Pro 382E Fuel
Processor Assembly
Replace the element as follows:
1. Shut down the engine and allow
it to cool.
2. With the engine at ambient
temperature and cool to the touch,
place a suitable container under
the filter.
NOTE:
Current filter elements include an
integral sealing grommet. If a former
element is replaced, make sure the
separate sealing grommet is removed
from the center stud before installing
the new element.
3. A fuel shutoff valve may be
installed on the discharge side of
the fuel filter. If installed, turn the
handle on the shutoff valve to the
All information subject to change without notice. (Rev. May 2004)
7. Dispose of the used element and
grommet in an environmentally
responsible manner, according
to federal (EPA) and/or state
recommendations.
8. Check to make sure the sealing
grommet is included in the base
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85
HOW-TO SECTION
of the replacement filter element,
then install the element onto the
center stud by pushing down and
twisting slightly.
NOTICE:
9. Check to make sure the spring is
installed at the top of the cover.
If missing, this spring must be
replaced to insure proper filter
operation. Wipe the cover lip and
cover seal clean.
NOTICE:
To avoid cover or vent cap damage,
do not use tools to tighten the vent
cap.
12. Open the fuel shutoff valve (if
equipped).
13. The fuel system must be primed
before starting the engine.
Refer to section Prime the Fuel
System and Start the Engine.
14. After starting the engine, allow
the lubrication system to reach its
normal operating pressure, then
increase engine speed to high idle
for 2 to 3 minutes.
Do not use a wrench of any kind
to tighten the collar, since this may
lead to overtightening, which can
damage the collar and/or the cover.
10. After making sure the seal is
properly positioned at the base of
the cover, install the cover and
collar onto the fuel processor.
Tighten the collar by hand until
secure.
NOTICE:
11. Using filter collar/vent cap
wrench 232002 or equivalent,
remove the vent cap from the top
of the cover by turning the cap
counter-clockwise. Fill the cover
full of clean fuel. After making
sure the O-ring seal is installed on
the vent cap, reinstall the cap and
tighten by hand.
Do not allow the fuel level in the
see-thru cover to fall below the top
of the collar, since this may lead
to interruption of the fuel flow and
engine stalling.
15. After the air is purged and with
the engine still running, loosen
the vent cap. The fuel level in
the cover will start falling. When
the fuel level falls to the top of
the collar, tighten the vent cap
quickly by hand.
16. Shut down the engine and tighten
the collar again by hand .
86
All information subject to change without notice. (Rev. May 2004)
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SERIES 40 ENGINE OPERATOR'S GUIDE
17. Restart the engine and check for
leaks. Shut down the engine.
Correct any leaks with the engine
off.
Spin-On Filter — Use the following
procedure for an engine with a spin-on
filter.
NOTE:
The filter cover will not fill completely
during engine operation. It will
gradually fill over time, and the fuel
level will rise as the filter medium
becomes clogged. The filter element
does not require changing until
the fuel level has risen to the top
of the element, or after one year of
service, whichever comes first.
F. Engine Out of Fuel —
How to Restart
NOTICE:
Under no circumstances should
the starting motor and fuel pump
be used to prime the fuel filters.
Prolonged used of the starting motor
and fuel pump to prime the fuel
system can result in damage to the
starter, fuel pump and injectors and
cause erratic running of the engine
due to the amount of air in the fuel
lines and filters.
When an engine has run out of fuel,
there is a definite procedure to follow
when restarting it.
1. Fill the fuel tank with the
recommended grade of fuel. If
only partial filling is possible,
add a minimum of 10 gallons (38
liters) of fuel to the tank.
2. Close the fuel shutoff valve (if
installed) on the filter header and
remove the spin-on fuel filter. Fill
with clean fuel through the fuel
inlet holes (the outer ring of small
holes on the element) to insure
the fuel is filtered. Thread the
element onto the filter header until
the gasket makes full contact with
the header and no side movement
is evident. Tighten filter an
additional one-half turn by hand,
or as indicated on the filter.
3. Open the fuel shutoff valve (if
installed).
NOTICE:
Failure to disconnect the CMP
(camshaft position sensor) before
priming the engine may allow the
engine to start during priming,
which could result in severe engine
damage.
4. Prime the fuel system as follows:
[a] Disconnect the CMP
(camshaft position sensor)
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87
HOW-TO SECTION
to prevent the engine from
starting.
NOTICE:
[b] Operate the manual primer
pump on the filter header until
the primer pump is hard to
depress. See Figure 25.
[c] Crank the engine three times
for 15 seconds each. Reapply
the primer pump after each
crank cycle.
[d] Once the primer pump is
hard to depress (usually three
crank and hand prime cycles),
reconnect the CMP.
NOTICE:
To avoid starter damage, do not
crank the engine longer than
15 seconds at a time. Allow a
15-second starter cool down interval
between starting attempts.
5. Start the engine and check for
leaks.
Fuel Pro Filters — Use the following
procedure for an engine with Fuel Pro
filters.
1. Remove the vent cap from
the top of the filter by turning
counter-clockwise. Fill the cover
full of clean fuel. After making
sure the O-ring seal is installed on
the vent plug, reinstall the plug
and tighten by hand only.
88
To avoid cover or vent cap damage,
do not use tools to tighten the vent
cap.
NOTICE:
Do not allow the fuel level in the
see-thru cover to fall below the top
of the collar, since this may lead
to interruption of the fuel flow and
engine stalling.
2. Start the engine and allow the
lubrication system to reach its
normal operating pressure, then
increase engine speed to high idle
for 2 to 3 minutes. After the air is
purged and with the engine still
running, loosen the vent cap on
the filter cover. the fuel level in
the cover will start falling. When
the fuel level falls to the top of
the collar on the Fuel Pro cover,
tighten the vent cap quickly by
hand.
NOTE:
If the engine fails to start after
replacement of fuel filters, the fuel
system will require priming with tool
J 5956 or equivalent. Authorized
Detroit Diesel distributors are properly
equipped to perform this service.
All information subject to change without notice. (Rev. May 2004)
DDC-SVC-MAN-0057 0305 Copyright © 2003 DETROIT DIESEL CORPORATION
SERIES 40 ENGINE OPERATOR'S GUIDE
G. How to Select Coolant
Definitions
This section covers selection of
the required coolant for Series 40
engines. To help ensure complete
understanding of the information, the
definitions of the following terms are
provided:
Antifreeze — Ethylene glycol
or propylene glycol containing a
corrosion inhibitor package and which
meets an appropriate heavy-duty
specification (i.e., TMC RP-329 for
ethylene glycol or TMC RP-330 for
propylene glycol).
organic acid inhibitors, instead of
traditional North American inhibitor
formulations.
SCA — Supplemental Coolant
Additive. SCAs are used in a
preventive maintenance program to
prevent corrosion, cavitation, and the
formation of deposits.
Approved Coolants
NOTICE:
Required specifications for water,
ethylene glycol, propylene glycol,
inhibitor packages and inhibitor
concentration are included in
this section. To avoid possible
engine damage from inadequate
or overconcentrated coolant,
this information should be read
thoroughly before the coolant is
replaced.
Coolant — The fluid mixture
circulating in the engine cooling
system, typically a mixture of 50%
water and 50% antifreeze.
Drop–Out — Precipitated sludge or
deposit formation on cooling system
components.
Fully Formulated Antifreeze —
Contains all the necessary inhibitors
to protect a diesel engine, and does
not, therefore, require a pre-charge of
SCA before its first use.
Initial–Fill Coolant — The coolant
that is used in a new or rebuilt engine,
or any time the cooling system is
emptied and then refilled with coolant.
The approved and preferred
coolants for Series 40 engines
are listed in Table 24. Once installed,
these coolants should be maintained
according to the procedures discussed
under Maintenance in this section.
OAT — Organic Acid Technology.
An inhibitor system based on
All information subject to change without notice. (Rev. May 2004)
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89
HOW-TO SECTION
Product
Coolant Fill Option
Ethylene Glycol & Water + Corrosion
Inhibitors 1
Commercial Equivalent of DDC Power
Cool
Propylene Glycol & Water + Corrosion
Inhibitors 1
Ethylene Glycol & Water + OAT
Inhibitors
Water Only + Corrosion Inhibitors 2
Water Only + OAT Inhibitors
1
2
2
DDC Power Cool
Fully Formulated TMC RP-329 Type A
Antifreeze & Water
Fully Formulated TMC RP-330 Type A
Antifreeze & Water
DDC Power Cool Plus
Water + DDC Power Cool 3000
Water + DDC Power Cool Plus 6000
Preferred coolant.
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 Plus
SCA Inhibitor or Propylene
Glycol & Water Plus SCA
Inhibitor — These products are
available as fully formulated,
phosphate-free, extended service
interval (ESI) coolants. They are
commercially available from Detroit
Diesel (recommended) and other
manufacturers as either a concentrated
antifreeze or as a pre-mixed antifreeze.
The pre-mixed antifreeze is ready for
use, while the concentrated coolant
must be mixed with water prior to use.
Detroit Diesel Power Cool engine
coolant (part number 23512138)
is the preferred ethylene glycol
coolant. If other commercial brands
of ethylene glycol are used, they
must be equivalent to the Power Cool
90
(see following paragraph). Detroit
Diesel does not market a propylene
glycol coolant. If a propylene glycol
coolant is used, it must also meet the
requirements listed in the following
paragraph.
Fully formulated ethylene
glycol-based, low silicate antifreeze
or coolant must meet TMC RP-329
“Type A” requirements. Fully
formulated propylene glycol-based
antifreeze or coolant must meet TMC
RP-330 “Type A” requirements. Fully
formulated antifreeze does not require
a dosage of SCA (supplemental
coolant additive) prior to initial use.
Mixing EG or PG Antifreeze
and Water — If a concentrated
ethylene glycol (EG) or propylene
All information subject to change without notice. (Rev. May 2004)
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SERIES 40 ENGINE OPERATOR'S GUIDE
glycol (PG) antifreeze is purchased,
mix the antifreeze with water meeting
the required quality standards
listed in Table 27 and fill the cooling
system.
Figure 27
Coolant Freezing and
Boiling Temperatures
Versus Inhibited
Ethylene Glycol (IEG)
Concentration (Sea
Level)
Figure 28
Coolant Freezing and
Boiling Temperatures
Versus Inhibited
Propylene Glycol (IPG)
Concentration (Sea
Level)
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91
HOW-TO SECTION
corrosion protection and is not
recommended.
If a pre-diluted, fully formulated
coolant is purchased, simply fill the
cooling system. For best overall
performance, a coolant consisting
of 50% concentration of antifreeze
(50% antifreeze, 50% water) is
recommended.
See Figure 27 for ethylene glycol-base
coolant concentration versus freezing
and boiling temperatures. See Figure
28 for propylene glycol-base coolant
concentration versus freezing and
boiling temperatures.
An antifreeze concentration over
67% (67% antifreeze, 33% water) is
not recommended due to poor heat
transfer, reduced freeze protection
(IEG only), and possible silicate
dropout. An antifreeze concentration
below 33% (33% antifreeze, 67%
water) offers too little freeze and/or
Always verify that the freeze point
and nitrite concentration of the
antifreeze/water mixture are correct
by using a POWER Trac® 3–Way
Coolant Test Strip. If chemical
analysis is used, elements in the
coolant must fall within the limits
listed in Table 25.
Fully Formulated Glycol Coolant Concentration Limits
Table 25
Boron
125 – 500 PPM
Nitrite
900 – 3200 PPM
Nitrate
200 – 3200 PPM
Silicon
50 – 250 PPM
Phosphorous
0 PPM
pH
8.0 – 11.0
Fully Formulated Glycol Coolant Limits with TMC RP-329,
TMC RP-330 Chemistry Type A (50/50 Coolant/Water
Mixture)
Recycled Antifreeze — Antifreeze
or coolant recycled by reverse
osmosis, distillation, and ion
exchange, properly re-inhibited
to meet TMC RP-329 Type A or
TMC RP-330 Type A requirements,
has been demonstrated to provide
92
service equivalent to virgin antifreeze.
Recycled antifreeze or coolants of
these types are preferred. Other
recycled coolants, especially coolants
recycled through filtration processes,
are not recommended.
All information subject to change without notice. (Rev. May 2004)
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SERIES 40 ENGINE OPERATOR'S GUIDE
Ethylene Glycol/Water +
OAT Inhibitor or Propylene
Glycol/Water + OAT Inhibitor —
Ethylene glycol and propylene
glycol are also available with a
(Organic Acid Technology) corrosion
package. These coolants require less
maintenance over the useful life of the
engine. OAT coolants, maintained as
detailed in the Maintenance section
of this guide, may be operated up to
4 years, 600,000 miles (960,000 km),
or 10,000 operating hours, whichever
comes first. Refer to section
Maintenance. The cooling system
should either be equipped with a
“blank” coolant filter, or the coolant
filter and piping may be omitted from
the system.
OAT fully formulated antifreezes
are available as concentrated and
pre-mixed. Concentrated antifreezes
should be mixed 50% (50% antifreeze,
50% water).
OAT coolants should not be mixed
with conventional coolants. If they
are mixed, no damage will result, but
the long-life advantages of the OAT
coolant will be lost. In this event,
the coolant should be maintained as a
fully formulated IEG coolant, not as
an OAT (Organic Acid Technology)
coolant.
If a non-DDC OAT antifreeze is
used, it must conform to TMC 338
specification. Do not add extender to
new OAT antifreeze or coolant.
Water Only + SCA or Water
Only + OAT Inhibitor — In
warm climates a coolant based
on water with corrosion inhibitors
is approved for use. Water-only
systems need to be treated with the
proper dosage of corrosion inhibitors.
Detroit Diesel-approved SCAs or
OAT corrosion inhibitors must be
added to the water to provide required
corrosion and cavitation erosion
protection. OAT inhibitors such as
Power Cool Plus 6000 are available
for water-only systems. Inhibitor
should be mixed at 7.5% – 10% by
volume with water. For a list of Power
Cool products, refer to section Power
Cool Engine Products in this guide.
Traditional SCA (Power Cool 3000)
can also be used to protect the engine.
Power Cool 3000 concentration limits
are listed in Table 26.
NOTE:
Do not use Power Trac 3–Way Test
Strips to test OAT coolant.
Detroit Diesel markets a OATinhibited ethylene glycol coolant,
DDC Power Cool Plus, which
contains all the required additives.
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HOW-TO SECTION
Power Cool 3000 Coolant Concentration Limits
Table 26
Boron
125 – 500 PPM
Nitrite
900 – 3200 PPM
Nitrate
0 – 1000 PPM
Silicon
50 – 250 PPM
Phosphorous
0 PPM
pH
8.0 – 11.0
Power Cool 3000 Concentration Limits (5% Power Cool
3000/ 95% Water)
or de-ionized water which eliminates
the adverse effects of minerals in
tap water is preferred. High levels
of dissolved chlorides, sulfates,
magnesium, and calcium in some tap
water causes scale deposits and/or
corrosion. These deposits have been
shown to result in water pump failures
and poor heat transfer, resulting in
overheating. If tap water is used, the
mineral content in the water must be
below the maximum allowable limits
listed in Table 27.
Power Cool 3000 SCA inhibitors
should be mixed at 5% by volume
with water. This is 1 quart per 5
gallons of water. These additions
can be made by adding liquid SCAs
available in a variety of sizes. Coolant
filters are also available for different
cooling system capacities. These
filters release the proper amount of
SCA at initial fill.
Water Requirements —
Distilled, reverse osmosis-purified,
Maximum Allowable
Parts 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
94
Satisfactory Water Limits – Make-Up Water Only
All information subject to change without notice. (Rev. May 2004)
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SERIES 40 ENGINE OPERATOR'S GUIDE
5. Glycol-based coolants formulated for heating/ventilation/air
conditioning (HVAC) should not
be used. These coolants generally
contain high levels of phosphates,
which can deposit on hot internal
engine surfaces and reduce heat
transfer.
NOTICE:
Do not add additional SCA to
new, fully formulated antifreeze or
coolant. This can result in dropout
and/or the formation of deposits.
Coolants Not Recommended
The following coolants are not
recommended for use in Detroit Diesel
engines:
1. All antifreezes and coolants
containing phosphate are
not recommended. Drop out,
overheating and water pump seal
failures can result from the use
of coolant or inhibitor packages
based on phosphate.
Additives Not Recommended
The following additives are not
recommended for use in Series 40
engines:
2. Automotive type coolants
generally contain high levels of
phosphate and silicate, offer no
liner pitting protection, and are
not suitable for use in Detroit
Diesel engines.
3. Methyl alcohol-based antifreeze
must not be used because of
its effect on the non-metallic
components of the cooling system
and its low boiling point.
4. Methoxy propanol-based
antifreeze must not be used
because it is not compatible with
the fluoroelastomer seals found in
the cooling system.
All information subject to change without notice. (Rev. May 2004)
1. Soluble oil additives are not
approved for use in Detroit Diesel
engine cooling systems. A small
amount of oil adversely affects
heat transfer. For example, a
1.25% concentration of soluble
oil increases fire deck temperature
6%. A 2.50% concentration
increases fire deck temperature
15%. The use of soluble oil
additives may result in engine
overheating and/or failure.
2. Chromate additives are not
approved for use in Detroit
Diesel engine cooling systems.
Chromate additives can form
chromium hydroxide, commonly
called “green slime.” This,
in turn, can result in engine
damage due to poor heat transfer.
Cooling systems operated with
chromium-inhibited coolant must
be chemically cleaned with Power
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HOW-TO SECTION
Cool dry chemical cooling system
cleaner/conditioner (or equivalent
sulfamic acid/sodium carbonate
cleaner) and flushed.
Coolant Inhibitor Test Intervals
— The coolant inhibitor level
should be checked at the intervals
listed in Table 28.
Maintenance
This section describes the procedures
for maintaining the coolant inhibitor
level and proper concentration.
Inhibitor Test Interval
Service Application
Motor Coaches
18,000 Miles (32,000 Kilometers)
City Transit Coaches, Pick-Up and
Delivery, Short Trip, and Emergency
Vehicles
Industrial, Continuous– Duty Generator
Set and All Other Applications, except
Standby Generator Set
6,000 Miles (9,600 Kilometers) or 3
Months, whichever comes first
Stand-By Generator Set
200 Hours or Yearly, whichever
comes first
Table 28
500 Hours or 3 Months, whichever
comes first
Required Coolant Inhibitor Test Intervals
If topping off is needed, add coolant
which is identical to the initial fill
coolant.
To avoid injury from the expulsion
of hot coolant, never remove the
cooling system pressure cap
while the engine is at operating
temperature. Remove the cap
slowly to relieve pressure. Wear
adequate protective clothing
(face shield or safety goggles,
rubber gloves, apron, and boots).
96
Supplemental Coolant Additives
for Fully Formulated Coolant
— The concentrations of some
inhibitors will gradually deplete
during normal engine operation.
SCAs replenish the protection for
cooling system components. The
coolant must be maintained with the
proper concentration of SCA. Detroit
Diesel Power Cool maintenance SCAs
are recommended.
All information subject to change without notice. (Rev. May 2004)
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SERIES 40 ENGINE OPERATOR'S GUIDE
The proper application of SCA will
provide:
□ pH control.
□ Restored inhibitor levels to prevent
corrosion.
□ Water softening to deter formation
of mineral deposits.
□ Cavitation protection to protect
wet sleeve cylinder liners.
Maintenance Intervals — Check
the nitrite concentration at the regular
intervals listed in Table 29 with a
Power Trac 3–Way Test Strip.
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HOW-TO SECTION
Coolant
Interval 1
Action
Antifreeze / Water +
SCA Inhibitor (DDC
Power Cool)
A. 20,000 Miles (32,000
km) or 3 Months*
B. 500 Hours or 3 Months*
A. 300,000 Miles (480,000
km)
B. 2 Years or 4,000 Hours*
A. 20,000 Miles (32,000
km) or 3 Months*
B. 500 Hours or 3 Months*
A. 300,000 Miles (480,000
km)
B. 2 Years or 4,000 Hours*
Test nitrite concentration
with test strip. Add SCA or
dilute coolant as needed.
Drain and clean system.
Refill with new coolant.
Test at 1 Year.
—
Ethylene Glycol
/ Water + SCA
Inhibitor
or
Propylene Glycol
/ Water + SCA
Inhibitor
Ethylene Glycol
/ Water + OAT
Inhibitor
or
Propylene Glycol
/ Water + OAT
Inhibitor
Test nitrite concentration
with test strip. Add SCA or
dilute coolant as needed.
Drain and clean system.
Refill with new coolant.
A. 300,000 Miles (480,000 Add Power Cool Plus
km) or 2 Years*
Extender
B. 5,000 Hours
A. 600,000 Miles (960,000 Drain and clean system.
Replace with new coolant.
km)
B.4 Years or 10,000
Hours*
Test nitrite concentration
Water Only + SCA
A. 20,000 Miles (32,000
with test strip. Add SCA or
Inhibitor
km) or 3 Months*
B. 500 Hours or 3 Months* dilute coolant as needed.
A. 300,000 Miles (480,000 Drain and clean system.
Replace with new coolant.
km)
B. 2 Years or 4,000 Hours
Water Only + OAT
A. 300,000 Miles (480,000 Add Power Cool Plus
Coolant
km) or 2 Years*
Extender
B. 5,000 Hours
A. 600,000 Miles (960,000 Clean and drain. Replace
km)
with new coolant.
B. 4 Years or 10,000 Hours
1
Maintenance interval based on application. Drain interval dependent
on proper maintenance.
A. Motor Coaches, City Transit Coaches, Pick-Up and Delivery, Short
Trip and Emergency Vehicles
B. Industrial, Generator Set and Other Applications
Table 29
98
Coolant Maintenance Intervals
All information subject to change without notice. (Rev. May 2004)
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SERIES 40 ENGINE OPERATOR'S GUIDE
Nitrite levels must be within the
ranges listed in Table 25.
NOTICE:
Failure to properly maintain coolant
with SCA can result in damage
to the cooling system and its
related components. Conversely,
over-concentration of SCA inhibitor
can result in poor heat transfer,
leading to engine damage.
Always maintain concentrations at
recommended levels. Do not use
traditional SCAs with OAT coolant.
Additional SCA must be added to the
coolant when it becomes depleted, as
indicated by a nitrite concentration
of 900 PPM or less. If the nitrite
concentration is greater than 900
PPM, do not add additional SCA. If
the nitrite concentration is above 3200
PPM, the system is over-inhibited and
should be partially drained and filled
with a 50/50 mix of water and EG or
PG.
over-concentration. This condition
must be corrected by immediate
draining and flushing of the cooling
system. Refill the system with new fully
formulated or pre-charged coolant.
Check the nitrite concentration level at
the next maintenance interval with a
Power Trac 3–Way Test Strip.
SCA Test Procedures
Detroit Diesel Power Trac 3–Way
Coolant Test Strips should be
used to measure nitrite and
glycol concentrations. Part
numbers are listed in Table 55.
Cavitation/corrosion is indicated
on the strip by the level of nitrite
concentration. Freeze/boil over
protection is determined by glycol
concentration.
In this case the EG or PG should
contain no inhibitors and should
conform to ASTM D4985. This
will dilute the over-concentrated
inhibitors.
NOTE:
In non-OAT systems, nitrite
concentration of 5000 PPM or
higher on a Series 40 engine
suggests problematic additive
All information subject to change without notice. (Rev. May 2004)
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HOW-TO SECTION
Discard unused strips if they have
turned light pink or tan.
A factory coolant analysis program
is available through authorized
Detroit Diesel service outlets. Part
numbers are listed in Table 55 in the
Specifications section. To verify
coolant acceptability, submit a sample
for coolant analysis every two (2)
years, 300,000 miles (480,000 km),
or 10,000 operating hours, whichever
comes first.
To avoid injury from the expulsion
of hot coolant, never remove the
cooling system pressure cap
while the engine is at operating
temperature. Remove the cap
slowly to relieve pressure. Wear
adequate protective clothing
(face shield or safety goggles,
rubber gloves, apron, and boots).
Need Release Coolant Filters
(Non-OAT Systems)
For best results make the test while
the coolant is between 50° – 140 °F
(10.0° – 60 °C). Wait at least 60, but
not longer than 75, seconds before
reading the nitrite level. Use the test
strips as follows:
1. Dip the strip into coolant for
one second. Remove and shake
briskly to eliminate excess fluid.
2. Immediately compare the pad end
(% glycol) to the color chart on
the container.
3. Sixty seconds (one minute) after
dipping, compare the nitrite pad
to the color chart.
Spin-on coolant filters are available for
Detroit Diesel engines. Membranes
in the filters release SCAs before
the coolant approaches a corrosive
condition, protecting the engine from
corrosion. The elements release the
SCA charge as needed, as opposed to
the maintenance SCA elements, which
instantaneously release the SCA
charge. Coolant filter elements should
be replaced after one (1) year, 120,000
miles (192,000 km) or 2,000 operating
hours, whichever comes first.
4. Color change of the additive
indicator (middle pad) indicates
the presence of inhibitor that is
not approved by Detroit Diesel.
Promptly replace and tighten the test
strip container cap after each use.
100
All information subject to change without notice. (Rev. May 2004)
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SERIES 40 ENGINE OPERATOR'S GUIDE
Dropout
Excessive amounts of some inhibitors
in the coolant can cause a gel or
crystalline deposit that reduces heat
transfer and coolant flow. The deposit,
called “dropout,” takes the color of
the coolant when wet, but appears as a
white or gray powder when dry. It can
pick up solid particles in the coolant
and become gritty, causing excessive
wear of water pump seals and other
cooling system components.
To avoid injury when using
caustic cleaning agents, follow
the chemical manufacturers
usage, disposal, and safety
instructions.
Coolant Extender Inhibitor
Additive for “OAT” Coolant
The inhibitors in OAT coolant must
also be maintained, but less often
than traditional SCA-type coolants.
A portable test is available to test the
levels of OAT inhibitors in coolant.
Where this is not used, fleet testing
has determined that a OAT coolant
extender package should be added to
the coolant at 300,000 miles (480,000
km), two (2) years, or 5,000 hours,
whichever comes first. The proper
maintenance dosages for all OAT
coolants are listed in Table 29 ,
reflecting 0.6% by volume extender.
This dosage should be added to the
water-only and the glycol systems at
the same interval.
The proper application of extender to
OAT coolant will provide:
□ pH Control
The wet gel can be removed by
using a non-acid (alkali) type
heavy-duty cleaner, such as Detroit
Diesel Power Cool On-Line Cleaner
(sodium nitrite/sodium tetraborate).
Refer to section POWER COOL
COOLING SYSTEM CLEANERS
for part numbers.
NOTE:
If the gel is allowed to dry, it is
necessary to disassemble the
engine and clean it with a caustic
solution or physically clean individual
components.
□ Restored inhibitor levels to prevent
corrosion
□ Cavitation protection to protect
wet sleeve cylinder liners
NOTE:
Do not use traditional SCAs in
OAT coolant, and do not use
OAT extender in traditional coolant.
OAT Coolant Drain Interval —
A properly maintained OAT-inhibited
coolant will last 600,000 miles
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101
HOW-TO SECTION
(960,000 km), four (4) years, or
10,000 operating hours, whichever
comes first. At this time the coolant
should be drained, and the cooling
system should be thoroughly cleaned,
flushed, and filled with new, properly
inhibited OAT coolant.
NOTE:
Power Cool 3000 liquid SCA is more
compatible with hard water than
Power Cool 2000 SCA.
Chronic Coolant System
Problems
The most commonly seen coolant
system problems result from
maintenance and formulation factors
such as:
□ Hard water
□ Dilution of the coolant by the
addition of untreated water
□ Over dosage or under dosage of
corrosion inhibitors
□ Improper corrosion inhibitor (most
often phosphated)
□ Mixing SCAs
□ Improper testing
Detroit Diesel Cooling System
Maintenance Products
Power Cool SCAs — Power Cool
SCAs are water-soluble chemical
compounds. These products are
available in coolant filter elements,
liquid packages, and in fully
formulated Power Cool antifreeze.
102
Power Cool Coolant Filter
Elements — Power Cool coolant
filter elements (spin-on canisters) are
available in various sizes suitable for
cooling systems of varying capacities.
Selection of the proper element size
is vital when pre-charging non-fully
formulated coolant at initial fill and
at maintenance intervals. A fully
formulated antifreeze must not
have SCA added at initial fill. Do
not use SCA-containing filters
with OAT antifreeze or coolant.
The need for maintenance elements
is determined by the results of the
nitrite concentration test performed
at each cooling system interval. Do
not automatically install maintenance
elements at maintenance intervals,
unless the nitrite concentration falls
below 900 parts per million.
Power Cool Cleaners — Power
Cool Liquid On-Line Cleaner is used
for light deposits. Power Cool Dry
Chemical Cleaner/Conditioner is used
for heavy deposits or scale.
All information subject to change without notice. (Rev. May 2004)
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SERIES 40 ENGINE OPERATOR'S GUIDE
Summary of Coolant
Recommendations
To avoid injury from the expulsion
of hot coolant, never remove the
cooling system pressure cap
while the engine is at operating
temperature. Remove the cap
slowly to relieve pressure. Wear
adequate protective clothing
(face shield or safety goggles,
rubber gloves, apron, and boots).
1. Always maintain the engine
coolant to meet Detroit Diesel
specifications.
technologies (brands) could cause
cooling system problems.
4. Maintain the inhibitor at the
prescribed concentration. Test
the nitrite concentration by using
a titration kit or Detroit Diesel
Power Trac 3-Way Coolant Test
Strips. Add SCA only if the nitrite
concentration is below 900 PPM.
Do not use SCA in OAT coolant,
and do not use Power Trac 3-Way
Coolant Test Strips to test OAT
coolant.
NOTE:
If the nitrite concentration exceeds
3,200 PPM, the coolant must be
drained and replaced with new
coolant. A thorough cleaning of the
cooling system may be required.
2. Only use water that meets the
specifications listed in Table 27.
Distilled, de-mineralized (reverse
osmosis) or de-ionized water is
preferred.
3. The proper dosage of inhibitors
must be included in the coolant
at initial fill for all Detroit Diesel
engines. This dosage is usually
included in the fully formulated
antifreeze used, or it may need to
be added if water alone or if less
than 50% antifreeze is used. The
user is urged to refer to the full
text of this section to determine
the proper dosage. Mixing
of different manufacturers'
All information subject to change without notice. (Rev. May 2004)
5. Do not use another manufacturer's
test kit to measure the SCA
concentration of Detroit Diesel
maintenance products.
6. Pre-mix coolant makeup solutions
to the proper concentration before
adding to the cooling system.
7. Do not mix OAT and other
coolants in the same engine.
8. Do not use automotive coolants.
9. Where antifreeze/boil over
protection is required, use only
antifreeze that meets TMC
RP-329 “Type A” (EG) or
TMC RP-330 “Type A” (PG)
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103
HOW-TO SECTION
drained, thoroughly cleaned,
and refilled.
specifications. Always maintain
coolant at the proper level.
10. Coolant Life:
□ Glycol Coolant. A properly
maintained cooling system,
filled with phosphate-free
coolant consisting of a 50/50
mix of antifreeze and water
per TMC RP-329 “Type
A” (EG) or TMC RP-330
“Type A” (PG) specifications
can be operated to the
limits recommended. The
proper maintenance involves
periodic evaluation using
Power Trac 3-Way Coolant
Test Strips and the addition
of SCA as needed, indicated
by the strip test. To verify
coolant acceptability, submit
a sample for coolant analysis
every 300,000 miles (480,000
km), three (3) years, or 5,000
operating hours, whichever
comes first. Submit the
sample in a DDC Power
Trac Coolant Test Bottle.
Required part numbers are
listed in Table 55.
□ OAT Coolant. A properly
maintained OAT coolant may
be operated 600,000 miles
(960,000 km), four (4) years,
or until overhaul, whichever
comes first. At this time the
system must be completely
104
□ OAT Coolants require the
addition of an extender at
300,000 miles (480,000 km),
two (2) years, or 5,000 hours,
whichever comes first. Use 1
pint of extender for every 20
gallons of coolant.
□ Other Coolants. Other
properly maintained coolants
may be operated up to
250,000 miles (480,000
km), two (2) years, or 4,000
operating hours, whichever
comes first. At this time the
system must be completely
drained, thoroughly cleaned,
and refilled.
11. Do not use the following in
engine cooling systems:
□ Soluble oil
□ High silicate, automotive-type
antifreeze
□ Chromate SCAs
□ Methoxy propanol-base
coolant
□ Methyl alcohol-base coolant
□ Sealer additives or coolant
containing sealer additives.
□ HVAC coolant
□ Phosphated coolants
All information subject to change without notice. (Rev. May 2004)
DDC-SVC-MAN-0057 0305 Copyright © 2003 DETROIT DIESEL CORPORATION
SERIES 40 ENGINE OPERATOR'S GUIDE
H. How to Replace the
Coolant Filter
filter/strap wrench. See Figure 29.
The coolant filter is installed on a
header mounted at the rear of the
gear case just above the oil cooler .
Replace the coolant filter as follows:
To avoid injury from the expulsion
of hot coolant, never remove the
cooling system pressure cap
while the engine is at operating
temperature. Remove the cap
slowly to relieve pressure. Wear
adequate protective clothing
(face shield or safety goggles,
rubber gloves, apron, and boots).
1. Coolant
Filter
Figure 29
2. Coolant
Filter
Header
Removing Coolant Filter
4. Lubricate the new coolant filter
gasket (1) with clean engine oil
and install onto the header (2).
See Figure 30.
1. With the engine at ambient
temperature and cool to the touch,
carefully remove the radiator or
deaeration tank pressure cap to
relieve pressure in the cooling
system.
2. Close the manual shutoff valve
on the coolant filter header by
turning handle clockwise. In the
closed position, the handle will
be pointing straight up.
3. Loosen and remove the
coolant filter by turning
counter-clockwise using a
All information subject to change without notice. (Rev. May 2004)
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105
HOW-TO SECTION
I. How to Drain and Flush
the Cooling System
1. Coolant
Filter
Gasket
2.
3. Oil Cooler
Filter
Header
Figure 30
Installing Coolant Filter
5. Tighten filter until gasket makes
full contact with the header, then
tighten one additional full turn.
6. Inspect the coolant level in the
radiator or deaeration tank and
top off with required coolant, if
necessary. Replace the pressure
cap and tighten securely.
7. Open the manual shutoff valve
by turning counter-clockwise.
In the open position, the handle
will be parallel with the filter and
pointing rearward.
106
To avoid injury from the expulsion
of hot coolant, never remove the
cooling system pressure cap
while the engine is at operating
temperature. Remove the cap
slowly to relieve pressure. Wear
adequate protective clothing
(face shield or safety goggles,
rubber gloves, apron, and boots).
1. With the engine cool, slowly
loosen and remove the pressure
cap from the radiator or deaeration
tank. Place a suitable container
under the radiator and drain the
previous solution from the engine
and radiator. Dispose of the
coolant in an environmentally
friendly manner, according
to state and/or federal (EPA)
recommendations.
2. Refill the cooling system
with clean, soft water and a
good cooling system cleaning
compound, such as those
listed in Table 54 in the
Specifications section. If
the engine is warm, fill slowly
to prevent the rapid cooling and
distortion of the metal castings.
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SERIES 40 ENGINE OPERATOR'S GUIDE
3. Start the engine and operate it for
fifteen minutes to circulate the
solution thoroughly.
NOTICE:
If the engine overheats and
the coolant level is satisfactory,
the cooling system may require
cleaning with a descaling solvent
and backflushing. Authorized
Detroit Diesel service outlets are
properly equipped to perform these
services.
4. Stop the engine and allow it to
cool.
5. With the engine cool, drain the
cooling system completely.
6. Refill the cooling system with
clean, soft water and operate it for
fifteen minutes.
7. Stop the engine and allow it to
cool.
8. With the engine cool, drain the
cleaner residue from the cooling
system.
9. Refill the system with the required
coolant. Refer to section G. How
to Select Coolant.
10. Entrapped air must be purged
after filling the cooling system.
To do this, start the engine and
allow it to warm up without the
pressure cap installed. With the
transmission in neutral, increase
engine speed above 1000 RPM
and add coolant as required.
Install the pressure cap after the
coolant level has stabilized at
the bottom of the radiator filler
neck or the level indicated on the
deaeration tank .
In addition to the cleaning procedure,
other components of the cooling
system should be checked periodically
to keep the engine operating at peak
efficiency.
Hoses. Cooling system hoses should
be inspected and any hose that shows
obvious signs of damage or feels
abnormally soft or hard should be
replaced. Damaged clamps should
also be replaced. All external leaks
should be corrected as soon as
detected.
NOTE:
If Detroit Diesel Power Cool
antifreeze/coolant (or equivalent fully
formulated, precharged antifreeze
is used, a precharge element is not
required. Coolant inhibitor levels
must be checked at the intervals
listed in Table 28.
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107
HOW-TO SECTION
J. When to Service the Dry
Type Air Cleaner
Replace dry type air cleaner elements
when the maximum allowable air
cleaner restriction (20 inches of water
or 5.0 kPa) has been reached or
annually, whichever comes first.
Exception: On engines equipped with
boreless turbochargers, such as certain
transit bus applications, replace the
element when the maximum allowable
air cleaner restriction of 15 inches of
water (3.7 kPa) has been reached, or
annually, whichever comes first.
Some air cleaners are equipped with
a restriction indicator which aids in
determining the servicing interval.
Cleaning and/or reusing dry paper
type air cleaner elements is not
recommended unless the cleaning
method used removes clogging
without damaging the element.
Inspection and cleaning of elements
must be done in accordance with the
air cleaner element manufacturer's
recommendations, if any.
108
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DDC-SVC-MAN-0057 0305 Copyright © 2003 DETROIT DIESEL CORPORATION
SERIES 40 ENGINE OPERATOR'S GUIDE
BASIC TROUBLESHOOTING
This section covers basic
troubleshooting of engine operation
or performance malfunctions and
their probable causes. Hard starting
symptoms are listed in Table 30.
Objectionable exhaust symptoms are
listed in Table 31. Abnormal engine
operation symptoms are listed in Table
32. Abnormal operating condition
symptoms are listed in Table 33.
Abnormal coolant temperature
symptoms are listed in Table 34.
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BASIC TROUBLESHOOTING
Probable Causes
Low Battery Voltage
Engine Will
Not Rotate
Low
Cranking
Speed
X
X
Loose cranking motor
connections
Faulty cranking motor
X
X
Faulty cranking motor switch
X
X
Internal seizure
X
Improper lube oil
Circuit breaker/electronic control
malfunction
Fuse blown or missing
Engine
Cranks But
Will Not
Start
X
X
X
X
X
Insufficient Fuel Supply
Air 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 system
malfunction
Installation/operation of fuel
check valve or shutoff valve
Low Compression
X
Worn intake and exhaust valves
X
Worn piston rings/liners
X
110
X
All information subject to change without notice. (Rev. May 2004)
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SERIES 40 ENGINE OPERATOR'S GUIDE
Engine Will
Not Rotate
Probable Causes
Leaking cylinder head gasket
Low
Cranking
Speed
Engine
Cranks But
Will Not
Start
X
Improper intake or exhaust valve
adjustments
Table 30
X
Hard Starting Symptoms and Probable Causes
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BASIC TROUBLESHOOTING
Probable Causes
Black
or Gray
Smoke
Damaged or dirty air cleaner
X
Improper grade of fuel
X
Excessive exhaust back pressure
X
Blue
Smoke
X
Misfiring cylinders
Lubricating oil not burned in
cylinder (being burned in exhaust
manifold or turbocharger)
Faulty injector timing
White
Smoke
X
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
112
Objectionable Exhaust Symptoms and Probable Causes
All information subject to change without notice. (Rev. May 2004)
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SERIES 40 ENGINE OPERATOR'S GUIDE
Rough
Running or
Frequent
Stalling
Low Power
Misfiring cylinder
X
X
Insufficient fuel
X
X
High return fuel temperature
X
X
Low compression
X
X
X
X
Probable Causes
Electronic control system
malfunction
High air inlet restriction/exhaust back pressure
Detonation
X
Engine application
X
High air inlet temperature
X
High altitude operation
X
Incorrect engine gear train
timing
X
Low coolant temperature
X
Oil picked up by inlet airstream
X
Faulty injector operation
X
Incorrect injector height
setting
Table 32
X
X
Abnormal Engine Operation Symptoms and Probable
Causes
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BASIC TROUBLESHOOTING
High Lube Oil
Consumption
Probable Causes
Loose connections
X
Cracked, leaking oil lines
X
Damaged gaskets or seal rings
X
Lube oil loss at breather tube *
X
Lube oil loss at dipstick tube *
X
Leaking oil cooler
X
Leaking valve stem seals
X
Worn/broken oil control rings
X
Scored liner and/or piston
X
Excessive engine installation angle
X
Crankcase overfilled
X
Oil in air tanks (air compressor
malfunction)
X
Plugged crankcase breather
X
Low Oil
Pressure
Oil level low
X
Improper engine oil viscosity (fuel in the
oil)
X
Faulty oil pressure regulator valve
X
Worn crankshaft, camshaft or
connecting rod bearings
X
Missing cup plugs in rocker arm shaft
X
Faulty oil pressure relief valve
X
Air leaks in oil pump (suction side)
X
Worn or damaged oil pump
X
Faulty oil pressure gage
X
Faulty electrical components (for gage)
X
Plugged oil line or orifice
X
* Indicates high crankcase pressure
Table 33
114
Abnormal Operating Condition Symptoms and Probable
Causes
All information subject to change without notice. (Rev. May 2004)
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SERIES 40 ENGINE OPERATOR'S GUIDE
Probable Causes
Above
Normal
Restricted cooling system passages
X
Restricted radiator core passages
X
Slipping fan drive belt
X
Faulty thermo-modulated fan (failure to engage
fan)
X
Below
Normal
Faulty thermo-modulated fan (failure to
disengage fan)
X
Obstruction in front of radiator
X
Low coolant level
X
Damaged hoses
X
Faulty thermostat
X
Faulty water pump
X
Faulty radiator pressure cap
X
Air in coolant
X
Thermostat not fully closed
X
Leakage around thermostat seal
X
Table 34
Abnormal Coolant Temperature Symptoms and Probable
Causes
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115
ENGINE STORAGE
ENGINE STORAGE
Preparing Engine for
Storage
When an engine is to be stored or
removed from operation for a period
of time, special precautions should
be taken to protect the interior and
exterior of the engine, transmission
and other parts from rust accumulation
and corrosion. The parts requiring
attention and the recommended
preparations are given below.
All rust or corrosion should be
removed completely from any
exposed part before applying rust
preventive compound. Therefore,
DDC recommends processing the
engine for storage as soon as possible
after removing it from service.
2. Fill the crankcase to the proper
level with the recommended
viscosity and grade of oil.
3. Fill the fuel tank with the
recommended grade of fuel oil.
Operate the engine for two (2)
minutes at 1200 rpm and no load.
Do not drain the fuel system or
the crankcase after this run.
4. Check the air cleaner and service
it, if necessary.
5. If freezing weather is expected
during the storage period, check
the antifreeze/coolant for required
freeze and inhibitor protection.
Add antifreeze solution to the
cooling system in accordance
with DDC's recommendations.
Refer to section G. How to Select
Coolant.
The engine should be stored in
a building that is dry and can be
heated during the winter months.
Moisture-absorbing chemicals are
available commercially for use when
excessive dampness prevails in the
storage area.
Temporary Storage (30 Days or
Less)
To protect the engine for a temporary
period of time (30 days or less), follow
this procedure:
1. With the engine at ambient
temperature and cool to the touch,
116
drain engine crankcase oil into a
suitable container. Dispose of the
oil in an environmentally friendly
manner, according to state and/or
federal (EPA) recommendations.
NOTE:
If an antifreeze solution is not required
during storage, flush the cooling
system with a good, soluble oil (3% –
5% by volume) rust inhibitor to prevent
rusting of the outside diameter of the
cylinder liners.
All information subject to change without notice. (Rev. May 2004)
DDC-SVC-MAN-0057 0305 Copyright © 2003 DETROIT DIESEL CORPORATION
SERIES 40 ENGINE OPERATOR'S GUIDE
Extended Storage (More than 30
Days)
To avoid injury from flying debris
when using compressed air, wear
adequate eye protection (face
shield or safety goggles) and do
not exceed 40 psi (276 kPa) air
pressure.
To prepare an engine for extended
storage (more than 30 days), follow
this procedure:
1. Drain the cooling system and
flush with clean, soft water. Refill
with clean, soft water and add
a rust inhibitor to the cooling
system.
6. Clean the exterior of the engine
(except electrical parts) with fuel
oil and dry with compressed air.
2. Circulate the coolant by operating
the engine until normal operating
temperature is reached.
7. Seal all engine openings,
including the turbocharger air
and exhaust outlets and the
valve cover/intake manifold
opening. The material used
must be waterproof, vaporproof
and possess sufficient physical
strength to resist puncture and
damage from the expansion of
entrapped air.
3. Stop the engine.
An engine prepared in this manner can
be returned to service in a short time
by removing the seals at the engine
openings and reconnecting piping; by
checking the engine coolant, fuel oil,
lubricating oil and transmission oil
levels; and by priming the fuel system
before starting.
4. With the engine at ambient
temperature and cool to the touch,
drain the engine crankcase oil
into a suitable container. Remove
the oil filter. Dispose of the oil
and filter in an environmentally
friendly manner, according
to state and/or federal (EPA)
recommendations. Replace the
oil drain plug and tighten to 45 –
50 N·m (33 – 37 lb-ft) torque.
5. Install a new lubricating oil
filter. Fill the crankcase to
the proper level with Tectyl®
930A preservative lubricating
oil or an equivalent 30–weight
preservative lubricating oil
meeting Mil-L-21260C, Grade 2
Specification.
6. Drain the fuel tank. Refill with
enough clean No. 1 diesel fuel
All information subject to change without notice. (Rev. May 2004)
DDC-SVC-MAN-0057 0305 Copyright © 2003 DETROIT DIESEL CORPORATION
117
ENGINE STORAGE
9. Stop the engine and allow to cool.
Then disconnect the fuel return
line and the inlet line at the fuel
filter and securely plug both to
retain the fuel in the engine.
or pure kerosene to permit the
engine to operate for about ten
(10) minutes. If draining the
fuel tank is not convenient, use
a separate, portable supply of
recommended fuel.
10. Transmission: Follow the
manufacturer's recommendations
for prolonged storage.
NOTE:
If engines are stored where
condensation of water in the fuel
tank may be a problem, additives
containing methyl carbitol or butyl
cellusolve may be added to the fuel.
Follow manufacturer's instructions
for treatment. Where biological
contamination of fuel may be a
problem, add a biocide such as
Biobor® JF (or equivalent) to the
fuel. When using a biocide, follow
the manufacturer's concentration
recommendations and observe all
cautions and warnings.
11. Power Take-Off: If equipped,
follow manufacturer's
recommendations for prolonged
storage.
12. Apply a non-friction rust
preventive compound to all
exposed engine parts. If
convenient, apply the rust
preventive compound to the
engine flywheel. If not, disengage
the clutch mechanism to prevent
the clutch disc from sticking to
the flywheel.
7. Drain the fuel system and remove
the fuel filters. Dispose of used
filters in an environmentally
responsible manner, according
to state and/or federal (EPA)
recommendations. Fill the new
filters with No. 1 diesel fuel or
pure kerosene and install on the
engine. Prime the fuel system.
8. Start and operate the engine for
five (5) minutes to circulate the
clean fuel throughout the system
and ensure the system is full.
118
NOTE:
Do not apply oil, grease or any
wax-base compound to the flywheel.
The cast iron will absorb these
substances, which can “sweat” out
during engine operation and cause the
clutch to slip.
13. Drain the engine cooling system.
14. Drain the preservative oil from
the engine crankcase. Reinstall
and tighten the oil drain plug.
All information subject to change without notice. (Rev. May 2004)
DDC-SVC-MAN-0057 0305 Copyright © 2003 DETROIT DIESEL CORPORATION
SERIES 40 ENGINE OPERATOR'S GUIDE
15. Remove and clean the battery
and battery cables with a baking
soda-water solution and rinse
with fresh water. Do not allow
the soda solution to enter the
battery. Add distilled water to
the electrolyte (if necessary) and
fully charge the battery. Store the
battery in a cool (never below 0
°C or 32 °F) dry place. Keep the
battery fully charged and check
the level and specific gravity of
the electrolyte regularly.
16. Insert heavy paper strips between
the pulleys and serpentine drive
belt to prevent sticking or remove
the drive belt and store separately.
NOTICE:
18. Clean and dry the exterior painted
surfaces of the engine and spray
with a suitable liquid automobile
body wax, a synthetic resin
varnish, or a rust preventive
compound.
19. Protect the engine with a good
weather-resistant tarpaulin and
store it under cover, preferably
in a dry building which can be
heated during the winter months.
Outdoor storage of the engine is not
recommended. If units must be kept
out of doors, follow the preparation
and storage instructions already
given. Protect units with quality,
weather-resistant tarpaulins (or other
suitable covers) arranged to provide
for air circulation.
Failure to properly seal off the
turbocharger air inlet and exhaust
outlet openings before engine
storage may permit air drafts to
circulate through the turbocharger
and rotate the turbine/compressor
shaft without an adequate flow of
lubricating oil to the center housing
bearings. This can result in severe
bearing damage.
17. Seal all engine openings,
including the turbocharger air
and exhaust outlets and the valve
cover/intake manifold opening.
Use moisture-resistant tape and
cardboard, plywood or metal
covers where practical.
All information subject to change without notice. (Rev. May 2004)
DDC-SVC-MAN-0057 0305 Copyright © 2003 DETROIT DIESEL CORPORATION
119
ENGINE STORAGE
3. Wash or steam clean the exterior
of the engine to remove the rust
preventive, if previously applied.
Do not wash or apply steam to
electrical components.
NOTICE:
Do not use plastic sheeting for
outdoor storage. Plastic is fine
for indoor storage. When used
outdoors, however, enough moisture
can condense on the inside of the
plastic to rust ferrous metal surfaces
and pit aluminum surfaces. If a unit
is stored outside for any extended
period of time, severe corrosion
damage can result.
4. Remove the rust preventive from
the flywheel. Flush any soluble
oil rust inhibitor (if used) in the
cooling system.
The stored engine should be inspected
periodically. If there are any
indications of rust or corrosion,
corrective steps must be taken to
prevent damage to the engine parts.
Perform a complete inspection at the
end of one year and apply additional
treatment as required.
Restoring an Engine to Service
after Extended Storage
If an engine has been in extended
storage, prepare it for service as
follows:
1. Remove the covers and tape from
all the openings of the engine, fuel
tank and electrical equipment. Do
not overlook the turbocharger air
and exhaust outlets and the valve
cover/intake manifold openings.
2. Remove the plugs from the inlet
and outlet fuel lines and reconnect
the lines to their proper positions.
120
5. Remove the paper strips
from between the pulleys and
serpentine drive belt or reinstall
the drive belt, if previously
removed.
6. Fill the crankcase to the proper
level with the required grade of
lubricating oil. Use a pressure
lubricator to insure all bearings
and rocker shafts are lubricated.
7. Fill the fuel tank with the required
fuel. Prime the fuel system.
8. Close all drain cocks and fill the
engine cooling system with clean,
soft water and required inhibitors.
If the engine is to be exposed
to freezing temperatures, install
genuine Detroit Diesel Power
Cool antifreeze or an equivalent
ethylene glycol-base or propylene
glycol-base antifreeze solution
which provides required freeze,
boil over, and inhibitor protection.
Refer to section G. How to Select
Coolant.
All information subject to change without notice. (Rev. May 2004)
DDC-SVC-MAN-0057 0305 Copyright © 2003 DETROIT DIESEL CORPORATION
SERIES 40 ENGINE OPERATOR'S GUIDE
9. Install and connect the battery.
Make sure the average specific
gravity of the battery is 1.260
or higher. Charge the battery, if
necessary.
Preparations for Starting the
Engine the First Time.
10. Service the air cleaner, if required.
Diesel engine exhaust and some
of its constituents are known to
the State of California to cause
cancer, birth defects, and other
reproductive harm.
11. Transmission: Follow the
manufacturer's recommendations
covering the return of the
transmission to service.
12. Power Take-Off: If equipped,
follow the manufacturer's
recommendations covering the
return of the power take-off to
service.
□ Always start and operate an
engine in a well ventilated
area.
□ If operating an engine in
an enclosed area, vent the
exhaust to the outside.
13. Turbocharger:
[a] Remove the tape or covers
from the turbocharger air and
exhaust outlet connections
and the valve cover/intake
manifold opening. Reconnect
piping as required.
[b] Remove the oil inlet
tube assembly from the
turbocharger center bearing
housing. Prelube bearings by
pouring approximately five
(5) ounces of clean lubricating
oil into the opening. Reinstall
the oil inlet pipe using a new
gasket, and torque inlet pipe
flange bolts to specifications.
14. Refer to section Lubrication
System Checks in section
□ Do not modify or tamper
with the exhaust system or
emission control system.
15. After all preparations are
completed, start the engine.
NOTE:
The small amount of rust preventive
which remains in the fuel system
will cause smoky exhaust for a few
minutes.
NOTE:
Before subjecting the engine to a
load or high speed, allow it to reach
normal operating temperature. Then
monitor the electronic control system
diagnostic data link for trouble codes.
All information subject to change without notice. (Rev. May 2004)
DDC-SVC-MAN-0057 0305 Copyright © 2003 DETROIT DIESEL CORPORATION
121
SERVICE PUBLICATIONS
SERVICE PUBLICATIONS
Detroit Diesel distributor in the U.S.
or Canada. Check the Yellow Pages
under “Engine, Diesel” or refer to the
Distributor and Dealer Directory listed
below for the distributor or service
outlet nearest you.
The service manual covering Detroit
Diesel Series 40 engines and various
reference works which may be of
interest to the owner/operator are
listed in Table 35.
To purchase a copy of any of these
publications, contact an authorize
Description
Form No.
Series 40 Service Manual
6SE410
Series 40 Troubleshooting Manual
6SE241
U.S. and Canada Distributor/Dealer Directory
6SE280
International Distributor/Dealer Directory
6SE281
Lube Oil, Fuel and Filter Requirements
7SE270
Coolant Requirements for Engine Cooling Systems
7SE298
Technician's Guide – Used Lubricating Oil Analysis
7SE398
Technician's Guide – Turbocharger
7SE374
Technician's Guide – Cooling System
7SE390
Table 35
122
Service Publications
All information subject to change without notice. (Rev. May 2004)
DDC-SVC-MAN-0057 0305 Copyright © 2003 DETROIT DIESEL CORPORATION
SERIES 40 ENGINE OPERATOR'S GUIDE
DETROIT DIESEL CUSTOMER ASSISTANCE
U.S. and Canada
1–800–445–1980
If you require service for any reason in
the U.S. or Canada, you may call the
1–800–445–1980 customer assistance
phone number. An operator will
assist you in determining what type of
service is required. Not all problems
are engine related and not all problems
are covered by engine warranties.
YOU MAY BE RESPONSIBLE FOR
REPAIR EXPENSES.
Before calling Customer Assistance,
please do the following:
□ Check coolant level.
□ Check fuel level.
□ Check for fuel leaks
□ Make sure manual shutoff valve (if
installed) on the fuel filter adaptor,
fuel processor body or fuel supply
line is open.
□ Check the oil level on the dipstick.
□ Check diagnostic codes against
those listed in section SERIES
40 ELECTRONIC CONTROL
SYSTEM.
If you call, have the following
information available:
□ Engine serial and model numbers.
Refer to section ENGINE
MODEL AND SERIAL
NUMBER LOCATIONS for
location.
□ Vehicle, equipment or generator
set make and model
□ Accumulated miles/kilometers or
hours of operation.
□ Vehicle, equipment or generator
set owner/company name
Customer Assistance
The satisfaction and goodwill of the
owners of Detroit Diesel engines are
of primary concern to Detroit Diesel
Corporation and its distributor/dealer
organizations. As the owner of a
Detroit Diesel product you have
a complete network of over 2,000
Detroit Diesel service outlets in the
U.S. and Canada, plus many outlets
worldwide that are prepared to meet
your parts and service needs:
□ Service by trained personnel.
□ Sales team to help determine your
specific power requirements.
□ In many areas, emergency service
24 hours a day.
□ Complete parts support, including
reliabilt® remanufactured
components.
□ Product information and literature.
All information subject to change without notice. (Rev. May 2004)
DDC-SVC-MAN-0057 0305 Copyright © 2003 DETROIT DIESEL CORPORATION
123
DETROIT DIESEL CUSTOMER ASSISTANCE
We recognize, however, that despite
the best intentions of everyone
concerned, misunderstandings may
occur. Normally, any situation that
arises in connection with the sale,
operation or service of your product
will be handled by the authorized
service outlet in your area. In the U.S.
and Canada, check the Yellow Pages
for the Detroit Diesel service outlet
nearest you.
To further assure your complete
satisfaction, we have developed the
following procedure to be followed in
the event you have a problem that has
not been handled satisfactorily.
Step One
Discuss your problem with a member
of management from the authorized
service outlet. Frequently, complaints
are the result of a breakdown in
communication and can quickly be
resolved by a member of management.
If you have already discussed the
problem with the Sales or Service
Manager, contact the General
Manager. If your complaint originates
with a dealer, explain the matter
to a management member of the
distributorship with whom the dealer
has a service agreement.
Step Two
When it appears that your problem
cannot be readily resolved at the
distributor level without additional
124
assistance, contact the Detroit Diesel
Regional Product Support Manager
or Operations Manager responsible
for your local distributor. You will be
assisted by a member of the manager's
staff, depending upon the nature of
your problem.
Prior to this contact, have the
following information available:
□ Engine model number*
____________________________.
□ Engine serial number*
____________________________
.
□ Type and make of equipment.
□ Engine delivery date and
accumulated miles or hours
of operation.
□ Nature of problem.
□ Chronological summary of
engine's history.
□ Name and location of authorized
service outlet.
*Important: Write your engine
model number and serial number
on the lines provided. They
will identify your engine and
all service parts, plus provide
warranty and extended coverage
information. Refer to section
ENGINE MODEL AND SERIAL
NUMBER LOCATIONS for location
of engine model and serial numbers.
All information subject to change without notice. (Rev. May 2004)
DDC-SVC-MAN-0057 0305 Copyright © 2003 DETROIT DIESEL CORPORATION
SERIES 40 ENGINE OPERATOR'S GUIDE
Step Three
If you are still not satisfied, present the
entire matter in writing or by phone to:
Vice President, Customer Assurance
Detroit Diesel Corporation
13400 Outer Drive, West
Detroit, MI 48239–4001
Phone: 313–592–7357
FAX: 313–592–7888
When contacting the Detroit Diesel
regional offices or the DDC/MTU
Off-Highway Customer Assurance
Center, please keep in mind that
ultimately your problem will likely
be resolved at the distributorship or
dealership, utilizing their facilities,
equipment, and personnel. Therefore,
Figure 31
it is suggested that you follow
the above steps in sequence when
experiencing a problem.
See Figure 31 for the Detroit Diesel
NAFTA On-Highway Regions.
See Figure 32 for the Detroit
Diesel-MTU Off-Highway Sales and
Customer Assurance Center.
The addresses and phone/fax numbers
for the on-highway regional offices
are listed in Table 36. The addresses
and phone/fax numbers for the Detroit
Diesel-MTU Off-Highway Sales and
Customer Assurance Center offices
are listed in Table 37. The addresses
and phone/fax numbers for Detroit
Diesel international regional offices
are listed in Table 38.
Detroit Diesel NAFTA On-Highway Regions
All information subject to change without notice. (Rev. May 2004)
DDC-SVC-MAN-0057 0305 Copyright © 2003 DETROIT DIESEL CORPORATION
125
DETROIT DIESEL CUSTOMER ASSISTANCE
Figure 32
DDC-MTU Off-Highway Sales and Customer Assurance Center
WESTERN REGION
Irvine, California
7700 Irvine Center, Suite 275
Irvine, CA 92618
Phone: 949-753-7710
Fax: 949-753-7711
CANADIAN REGION
London, Ontario
Detroit Diesel of Canada, Ltd.
150 Dufferin Ave., Suite 701
London, ON N5A 5N6
Phone: 519-661-0149
Fax: 519-661-0171
Table 36
126
EASTERN REGION
Piscataway, New Jersey
169 Old New Brunswick Road
Piscataway, NJ 08854
Phone: 732-926-9622
Fax: 732-926-8522
Detroit Diesel North American NAFTA On-Highway Offices
All information subject to change without notice. (Rev. May 2004)
DDC-SVC-MAN-0057 0305 Copyright © 2003 DETROIT DIESEL CORPORATION
SERIES 40 ENGINE OPERATOR'S GUIDE
Construction, Industrial and Mining
Sales (BX7)
13400 Outer Drive, West
Detroit, MI 48239-4001
Telephone: 313-592-5608
Fax: 313-592-5625
Powergen and Oilfield Sales (BX11)
13400 Outer Drive, West
Detroit, MI 48239-4001
Telephone: 313-592-7459
Fax: 313-592-5158
Customer Assurance (M24)
13400 Outer Drive, West
Detroit, MI 48239-4001
Telephone: 313-592-5550
Fax: 313-592-5717
Table 37
Marine Sales (BX6)
13400 Outer Drive, West
Detroit, MI 48239-4001
Telephone: 313-592-5124
Fax: 313-592-5137
Government Sales (BX11)
13400 Outer Drive, West
Detroit, MI 48239-4001
Telephone: 313-592-5708
Fax: 313-592-5158
DDC-MTU Off-Highway Sales and Customer Assurance
Center Offices
All information subject to change without notice. (Rev. May 2004)
DDC-SVC-MAN-0057 0305 Copyright © 2003 DETROIT DIESEL CORPORATION
127
DETROIT DIESEL CUSTOMER ASSISTANCE
EUROPE, MIDDLE EAST, AFRICA
(EMA) REGION (On/Off-Highway)
The Netherlands
Ridderpoort 9
2984 Ridderkerk
The Netherlands
Phone: (31) 180-442-900
Fax: (31) 180-419-544
LATIN AMERICAN REGION
(Off-Highway)Miami, Florida
2277 N.W. 14th Street
Latin America Building
Miami, Florida 33125-0068
Phone: 305-637-1555
Fax: 305-637-1580
ASIAN REGION (On-Highway)
13400 Outer Drive, West
Detroit, Michigan
Phone: 313-592-5990
Fax: 313-592-5887
ASIA/PACIFIC REGION
(Off-Highway)
Singapore
No. 16 Benoi Crescent
Singapore 629979
Phone: (65) 686-15922
Fax: (65) 686-11550
PACIFIC REGION (Off-Highway)
Australia
11–13 Garling Road
Kings Park, NSW 2148
Beaumaris, Victoria 3193
Australia
Phone: (612) 8822-7000
Fax: (612) 8822-7083
AUSTRALIAN REGION
(On-Highway)
P.O. Box 1472
Canterbury, Victoria 3124
Australia
Phone: (61) 39-836-0775
Fax: (61) 39-836-0770
MEXICO (On/Off-Highway)
Detroit Diesel Allison de Mexico, S.A.
Av. Santa Rosa 58
Col. Ampliacion Norte
San Juan Ixtacala, Tlanepantla
C.P. 54160, Edo de Mexico
Phone: 525-333-1802
Fax: 525-333-1870
Table 38
128
Detroit Diesel International Off-Highway Regional Offices
All information subject to change without notice. (Rev. May 2004)
DDC-SVC-MAN-0057 0305 Copyright © 2003 DETROIT DIESEL CORPORATION
SERIES 40 ENGINE OPERATOR'S GUIDE
LIMITED WARRANTY ON ENGINES USED IN
MOTOR COACH, MOTOR HOME AND TRANSIT BUS
APPLICATIONS
TERMS OF COVERAGE
Uses
This warranty applies to the first retail
purchaser and subsequent owners
during the WARRANTY PERIOD
of new Detroit Diesel Series 40®
Engines (referred to as Engine)
and attached starting motor, air
compressor and alternator (referred
to as Accessories) manufactured
by Detroit Diesel Corporation
and/or supplied by Detroit Diesel
Corporation, Detroit Diesel of Canada
Limited, or Detroit Diesel Overseas
Distribution Corporation (all which
are collectively referred to as DDC)
which are used in on-highway vehicle
applications, including motor coaches,
motor homes and transit busses.
parts or components supplied or
approved by DDC will be used. DDC
may, at its discretion, replace rather
than repair components. A reasonable
time must be allowed to perform
the warranty repair after taking the
engine to the authorized service outlet.
Repairs will be performed during
normal business hours.
The owner is responsible for the
percentage of repair costs shown in the
WARRANTY PERIOD chart below.
Warranty Period
The WARRANTY PERIOD begins
on the date the engine is delivered to
the first retail purchaser or put in use
prior to sale at retail, whichever date
occurs first, and ends at the time or
hour limits listed in Table 39.
Defects
This warranty covers Engine
REPAIRS to correct any malfunction
occurring during the WARRANTY
PERIOD resulting from defects in
material or workmanship.
Repairs
To obtain warranty repairs, you must
request the needed repairs within
the WARRANTY PERIOD from an
authorized DDC service outlet. Only
new genuine parts or remanufactured
All information subject to change without notice. (Rev. May 2004)
DDC-SVC-MAN-0057 0305 Copyright © 2003 DETROIT DIESEL CORPORATION
129
LIMITED WARRANTY ON ENGINES USED IN MOTOR COACH, MOTOR
HOME AND TRANSIT BUS APPLICATIONS
WARRANTY PERIOD
Warranty Limitations
(Whichever Occurs First)
Item
MONTHS
Engine
Table 39
0 – 12
MILES/KILOMETERS
0 – 50,000
Miles
0 – 80,000
Kilometers
Repair Charges to Be
Paid by Owner
PARTS
LABOR
No Charge
No Charge
Warranty Period – Motor Coach, Motor Home and Transit
Coach Applications
Like Replacement Engine
Engine(s) supplied by DDC as a
replacement for an Engine still under
warranty will assume the identity of
the Engine being replaced and be
entitled to the remaining warranty
coverage.
Service Supplies
The cost of service supplies such as
coolant, oil and filters which are not
reusable due to warranted repairs is
covered by this warranty.
Engine Removal and Reinstallation
Reasonable labor costs for Engine
removal and reinstallation, when
necessary to make a warranty repair,
are covered by this warranty.
Repairs Due to Accidents, Misuse,
Alteration, Storage Damage,
Negligence or Certain Modifications
Repairs due to an accident, misuse,
alteration, misapplication, storage
damage, negligence or modification
exceeding DDC specifications are not
covered by this warranty.
Braking Devices
DDC is not responsible for the repair
of mechanical braking devices that are
not factory-installed or not installed
by DDC distributors. Such devices are
warranted by the brake manufacturer.
Maintenance
THIS WARRANTY DOES NOT
COVER:
130
All information subject to change without notice. (Rev. May 2004)
DDC-SVC-MAN-0057 0305 Copyright © 2003 DETROIT DIESEL CORPORATION
SERIES 40 ENGINE OPERATOR'S GUIDE
DDC is not responsible for the cost of
maintenance or repairs due to lack of
performance of required maintenance
services as recommended by DDC, or
the failure to use fuel, oil, lubricants, or
coolant meeting DDC-recommended
specifications. Performance of
the required maintenance and use of
proper fuel, oil, lubricants, and coolant
are the responsibility of the owner.
Refer to section MAINTENANCE
SCHEDULES in this guide for details.
Incidental or Consequential
Damages
DDC is not responsible for incidental
or consequential costs or expenses
which the owner may incur as a result
of malfunction or failure covered by
this warranty, such as communication
expenses, meals, lodging, overtime,
towing, loss of use of the Engine or
vehicle (“downtime”), loss of time,
inconvenience, cargo loss or damage
and other similar costs and expenses.
AND ACCESSORIES AS USED
IN MOTOR COACH, MOTOR
HOME AND TRANSIT COACH
APPLICATIONS. DETROIT DIESEL
CORPORATION MAKES NO
OTHER WARRANTIES EXPRESS
OR IMPLIED, INCLUDING
ANY IMPLIED WARRANTY
OF MERCHANTABILITY OR
FITNESS FOR A PARTICULAR
PURPOSE. DETROIT DIESEL
CORPORATION SHALL NOT BE
LIABLE FOR ANY INCIDENTAL
OR CONSEQUENTIAL DAMAGES
AS DESCRIBED ABOVE.
Some states do not allow the limitation
of how long this warranty may last
or the limitation or exclusion of
incidental or consequential damages,
so the above may not apply to you.
This warranty gives you specific legal
rights, and you may also have other
rights which may vary from state to
state.
Other Limitations
The performance of REPAIRS is the
exclusive Owner's remedy under this
warranty. DDC does not authorize
any person to assume or create for
it any other obligation or liability in
connection with the Engine or the
Accessories.
THIS LIMITED WARRANTY AND
THE EMISSIONS WARRANTY
ARE THE ONLY WARRANTIES
APPLICABLE TO THE ENGINE
All information subject to change without notice. (Rev. May 2004)
DDC-SVC-MAN-0057 0305 Copyright © 2003 DETROIT DIESEL CORPORATION
131
LIMITED WARRANTY ON ENGINES USED IN FIRE TRUCK OR CRASH
VEHICLE APPLICATIONS
LIMITED WARRANTY ON ENGINES USED IN FIRE TRUCK
OR CRASH VEHICLE APPLICATIONS
TERMS OF COVERAGE
Uses
This warranty applies to the first retail
purchaser and subsequent owners
during the WARRANTY PERIOD of
new Detroit Diesel Series 40® Engines
(referred to as Engine) manufactured
by Detroit Diesel Corporation
and/or supplied by Detroit Diesel
Corporation, Detroit Diesel of Canada
Limited, or Detroit Diesel Overseas
Distribution Corporation (all which
are collectively referred to as DDC)
which are used in fire truck or crash
vehicle applications.
the warranty repair after taking the
engine to the authorized service outlet.
Repairs will be performed during
normal business hours.
Warranty Period
The WARRANTY PERIOD begins
on the date the engine is delivered
to the first retail purchaser or put in
use prior to sale at retail, whichever
date occurs first, and ends at the
time or mileage/kilometer limits
listed in Table 40.
Defects
This warranty covers Engine
REPAIRS to correct any malfunction
occurring during the WARRANTY
PERIOD resulting from defects in
material or workmanship.
Repairs
To obtain warranty repairs, you must
request the needed repairs within
the WARRANTY PERIOD from an
authorized DDC service outlet. Only
new genuine parts or remanufactured
parts or components supplied or
approved by DDC will be used. DDC
may, at its discretion, replace rather
than repair components. A reasonable
time must be allowed to perform
132
All information subject to change without notice. (Rev. May 2004)
DDC-SVC-MAN-0057 0305 Copyright © 2003 DETROIT DIESEL CORPORATION
SERIES 40 ENGINE OPERATOR'S GUIDE
WARRANTY PERIOD
Warranty Limitations
(Whichever Occurs First)
Item
MONTHS
Engine
0 – 60
Accessories
0 – 24
Table 40
MILES/KILOMETERS
0 – 50,000
Miles
0 – 80,000
Kilometers
0 – 50,000
Miles
0 – 80,000
Kilometers
Repair Charges to Be
Paid by Owner
PARTS
LABOR
No Charge
No Charge
No Charge
No Charge
Warranty Period – Fire Truck or Crash Vehicle Applications
Like Replacement Engine
Engine(s) supplied by DDC as a
replacement for an Engine still under
warranty will assume the identity of
the Engine being replaced and be
entitled to the remaining warranty
coverage.
Service Supplies
The cost of service supplies such as
coolant, oil and filters which are not
reusable due to warranted repairs is
covered by this warranty.
Engine Removal and Reinstallation
Reasonable labor costs for Engine
removal and reinstallation, when
necessary to make a warranty repair,
are covered by this warranty.
THIS WARRANTY DOES NOT
COVER:
Repairs Due to Accidents, Misuse,
Alteration, Storage Damage,
Negligence or Certain Modifications
Repairs due to an accident, misuse,
alteration, misapplication, storage
damage, negligence or modification
exceeding DDC specifications are not
covered by this warranty.
Maintenance
DDC is not responsible for the cost of
maintenance or repairs due to lack of
performance of required maintenance
services as recommended by DDC, or
the failure to use fuel, oil, lubricants, or
coolant meeting DDC-recommended
specifications. Performance of
the required maintenance and use of
proper fuel, oil, lubricants, and coolant
are the responsibility of the owner.
Refer to section MAINTENANCE
SCHEDULES in this guide for details.
All information subject to change without notice. (Rev. May 2004)
DDC-SVC-MAN-0057 0305 Copyright © 2003 DETROIT DIESEL CORPORATION
133
LIMITED WARRANTY ON ENGINES USED IN FIRE TRUCK OR CRASH
VEHICLE APPLICATIONS
Incidental or Consequential
Damages
OR CONSEQUENTIAL DAMAGES
AS DESCRIBED ABOVE.
DDC is not responsible for incidental
or consequential costs or expenses
which the owner may incur as a result
of malfunction or failure covered by
this warranty, such as communication
expenses, meals, lodging, overtime,
towing, loss of use of the Engine or
vehicle (“downtime”), loss of time,
inconvenience, cargo loss or damage
and other similar costs and expenses.
Some states do not allow the limitation
of how long this warranty may last
or the limitation or exclusion of
incidental or consequential damages,
so the above may not apply to you.
This warranty gives you specific legal
rights, and you may also have other
rights which may vary from state to
state.
Other Limitations
The performance of REPAIRS is the
exclusive Owner's remedy under this
warranty. DDC does not authorize
any person to assume or create for
it any other obligation or liability in
connection with the Engine or the
Accessories.
THIS LIMITED WARRANTY AND
THE EMISSIONS WARRANTY
ARE THE ONLY WARRANTIES
APPLICABLE TO THE ENGINE
AND ACCESSORIES AS USED IN
FIRE TRUCK OR CRASH VEHICLE
APPLICATIONS. DETROIT DIESEL
CORPORATION MAKES NO
OTHER WARRANTIES EXPRESS
OR IMPLIED, INCLUDING
ANY IMPLIED WARRANTY
OF MERCHANTABILITY OR
FITNESS FOR A PARTICULAR
PURPOSE. DETROIT DIESEL
CORPORATION SHALL NOT BE
LIABLE FOR ANY INCIDENTAL
134
All information subject to change without notice. (Rev. May 2004)
DDC-SVC-MAN-0057 0305 Copyright © 2003 DETROIT DIESEL CORPORATION
SERIES 40 ENGINE OPERATOR'S GUIDE
LIMITED WARRANTY ON ENGINES USED IN
CONSTRUCTION/INDUSTRIAL APPLICATIONS
TERMS OF COVERAGE
Uses
This warranty applies to the first retail
purchaser and subsequent owners
during the WARRANTY PERIOD
of new Detroit Diesel Series 40®
Engines (referred to as Engine)
manufactured by Detroit Diesel
Corporation and/or supplied by
Detroit Diesel Corporation, Detroit
Diesel of Canada Limited, or
Detroit Diesel Overseas Distribution
Corporation (all which are collectively
referred to as DDC) which are used in
construction/industrial applications.
the warranty repair after taking the
engine to the authorized service outlet.
Repairs will be performed during
normal business hours.
The owner is responsible for the
percentage of repair costs shown in the
WARRANTY PERIOD chart below.
Warranty Period
The WARRANTY PERIOD begins
on the date the engine is delivered to
the first retail purchaser or put in use
prior to sale at retail, whichever date
occurs first, and ends at the time or
hour limits listed in Table 41.
Defects
This warranty covers Engine
REPAIRS to correct any malfunction
occurring during the WARRANTY
PERIOD resulting from defects in
material or workmanship.
Repairs
To obtain warranty repairs, you must
request the needed repairs within
the WARRANTY PERIOD from an
authorized DDC service outlet. Only
new genuine parts or remanufactured
parts or components supplied or
approved by DDC will be used. DDC
may, at its discretion, replace rather
than repair components. A reasonable
time must be allowed to perform
All information subject to change without notice. (Rev. May 2004)
DDC-SVC-MAN-0057 0305 Copyright © 2003 DETROIT DIESEL CORPORATION
135
LIMITED WARRANTY ON ENGINES USED IN CONSTRUCTION/INDUSTRIAL
APPLICATIONS
WARRANTY PERIOD
Engine
Application
Warranty Limitations
(Whichever Occurs First)
Repair Charges to Be
Paid by Owner
MONTHS
ENGINE
HOURS
PARTS
LABOR**
Engine
0 – 12
Unlimited
No Charge
No Charge
Accessories
0 – 12
0 – 2,000
No Charge
No Charge
Upon expiration of the twelve (12) month warranty coverage, but within
12,000 hours of use, the warranty continues to apply as follows:
Major
No Charge
No Charge
Components
0 – 12,000
13 – 36
†
† Cylinder block casting, cylinder head casting, crankshaft, camshaft
and connecting rods.
Table 41
Warranty Period Chart – Construction/Industrial
Applications
Like Replacement Engine
Engine(s) supplied by DDC as a
replacement for an Engine still under
warranty will assume the identity of
the Engine being replaced and be
entitled to the remaining warranty
coverage.
Service Supplies
The cost of service supplies such as
coolant, oil and filters which are not
reusable due to warranted repairs is
covered by this warranty.
Mechanic's Travel Expenses
Engine Removal and Reinstallation
– Construction/Industrial
Applications
Reasonable labor costs for Engine
removal and reinstallation, when
necessary to make a warranty repair,
are covered by this warranty during
the first twelve (12) months of service.
THIS WARRANTY DOES NOT
COVER:
Repairs Due to Accidents, Misuse,
Alteration, Storage Damage,
Negligence or Certain Modifications
DDC will pay reasonable travel
expenses for the repairing mechanic
to travel to and from the repair site.
136
All information subject to change without notice. (Rev. May 2004)
DDC-SVC-MAN-0057 0305 Copyright © 2003 DETROIT DIESEL CORPORATION
SERIES 40 ENGINE OPERATOR'S GUIDE
Repairs due to an accident, misuse,
alteration, misapplication, storage
damage, negligence or modification
exceeding DDC specifications are not
covered by this warranty.
Non-DDC Supplied/Manufactured
Components
of malfunction or failure covered by
this warranty, such as communication
expenses, meals, lodging, overtime,
towing, loss of use of the Engine or
vehicle (“downtime”), loss of time,
inconvenience, cargo loss or damage
and other similar costs and expenses.
DDC is not responsible for repair
of components and/or assemblies
which are manufactured or supplied
by another manufacturer, such as
non-DDC power take-offs, intake
and exhaust systems and fuel storage
tanks. Such items are covered by the
equipment manufacturer.
Other Limitations
Maintenance
THIS LIMITED WARRANTY AND
THE EMISSIONS WARRANTY
ARE THE ONLY WARRANTIES
APPLICABLE TO THE ENGINE
AND ACCESSORIES AS USED IN
CONSTRUCTION/INDUSTRIAL
APPLICATIONS. DETROIT DIESEL
CORPORATION MAKES NO
OTHER WARRANTIES EXPRESS
OR IMPLIED, INCLUDING
ANY IMPLIED WARRANTY
OF MERCHANTABILITY OR
FITNESS FOR A PARTICULAR
PURPOSE. DETROIT DIESEL
CORPORATION SHALL NOT BE
LIABLE FOR ANY INCIDENTAL
OR CONSEQUENTIAL DAMAGES
AS DESCRIBED ABOVE.
DDC is not responsible for the
cost of maintenance or repairs
due to lack of performance of
required maintenance services as
recommended by DDC, or the
failure to use fuel, oil, lubricants and
coolant meeting DDC-recommended
specifications. Performance of
the required maintenance and use of
proper fuel, oil, lubricants, and coolant
are the responsibility of the owner.
Refer to section MAINTENANCE
SCHEDULES in this guide for details.
Incidental or Consequential
Damages
The performance of REPAIRS is the
exclusive Owner's remedy under this
warranty. DDC does not authorize
any person to assume or create for
it any other obligation or liability in
connection with the Engine or the
Accessories.
DDC is not responsible for incidental
or consequential costs or expenses
which the owner may incur as a result
All information subject to change without notice. (Rev. May 2004)
DDC-SVC-MAN-0057 0305 Copyright © 2003 DETROIT DIESEL CORPORATION
137
LIMITED WARRANTY ON ENGINES USED IN CONSTRUCTION/INDUSTRIAL
APPLICATIONS
Some states do not allow the limitation
of how long this warranty may last
or the limitation or exclusion of
incidental or consequential damages,
so the above may not apply to you.
This warranty gives you specific legal
rights, and you may also have other
rights which may vary from state to
state.
138
All information subject to change without notice. (Rev. May 2004)
DDC-SVC-MAN-0057 0305 Copyright © 2003 DETROIT DIESEL CORPORATION
SERIES 40 ENGINE OPERATOR'S GUIDE
LIMITED WARRANTY ON ENGINES USED IN PRIME AND
STAND-BY POWER GENERATOR SETS
TERMS OF COVERAGE
Uses
This warranty applies to the first retail
purchaser and subsequent owners
during the WARRANTY PERIOD of
new Detroit Diesel Series 40® Engines
(referred to as Engine) manufactured
by Detroit Diesel Corporation
and/or supplied by Detroit Diesel
Corporation, Detroit Diesel of Canada
Limited, or Detroit Diesel Overseas
Distribution Corporation (all which
are collectively referred to as DDC)
which are used in prime or stand-by
power generators delivered in the U.S.
or Canada.
time must be allowed to perform
the warranty repair after taking the
engine to the authorized service outlet.
Repairs will be performed during
normal business hours.
The owner is responsible for the
percentage of repair costs shown in the
WARRANTY PERIOD chart below.
Warranty Period
The WARRANTY PERIOD begins
on the date the engine is delivered to
the first retail purchaser or put in use
prior to sale at retail, whichever date
occurs first, and ends at the time or
hour limits listed in Table 42.
Defects
This warranty covers Engine
REPAIRS to correct any malfunction
occurring during the WARRANTY
PERIOD resulting from defects in
material or workmanship.
Repairs
To obtain warranty repairs, you must
request the needed repairs within
the WARRANTY PERIOD from an
authorized DDC service outlet. Only
new genuine parts or remanufactured
parts or components supplied or
approved by DDC will be used. DDC
may, at its discretion, replace rather
than repair components. A reasonable
All information subject to change without notice. (Rev. May 2004)
DDC-SVC-MAN-0057 0305 Copyright © 2003 DETROIT DIESEL CORPORATION
139
LIMITED WARRANTY ON ENGINES USED IN PRIME AND STAND-BY
POWER GENERATOR SETS
WARRANTY PERIOD
Engine
Application
Warranty Limitations
(Whichever Occurs First)
MONTHS
ENGINE
HOURS
Repair Charges to Be
Paid by Owner
PARTS
LABOR**
Prime Power
No Charge
No Charge
0 – 12
Unlimited
Generator
Upon expiration of the 12 month warranty coverage, but within 24 months
of delivery date, the warranty continues to apply as follows:
Major
Components
†
13 – 24
No Limit
No Charge
100%
Stand-by
No Charge
No Charge
0 – 12
0 – 400
Power
Generator
** 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
Like Replacement Engine
Engine(s) supplied by DDC as a
replacement for an Engine still under
warranty will assume the identity of
the Engine being replaced and be
entitled to the remaining warranty
coverage.
Service Supplies
The cost of service supplies such as
coolant, oil and filters which are not
reusable due to warranted repairs is
covered by this warranty.
Mechanic's Travel Expenses
140
DDC will pay reasonable travel
expenses for the repairing mechanic
to travel to and from the repair site.
THIS WARRANTY DOES NOT
COVER:
Repairs Due to Accidents, Misuse,
Storage Damage, Negligence or
Certain Modifications
Repairs due to an accident, misuse,
misapplication, storage damage,
negligence or modification exceeding
DDC specifications are not covered by
this warranty.
All information subject to change without notice. (Rev. May 2004)
DDC-SVC-MAN-0057 0305 Copyright © 2003 DETROIT DIESEL CORPORATION
SERIES 40 ENGINE OPERATOR'S GUIDE
Engine Removal and Reinstallation
Labor costs to gain access or replace
the Engine, including removal and
reinstallation of items/materials or
components in which the Engine
is installed, are not covered by this
warranty.
Non-DDC Supplied/Manufactured
Components
DDC is not responsible for repair of
components and/or assemblies which
are manufactured or supplied by
another manufacturer, such as intake
and exhaust systems and fuel storage
tanks. Such items are covered by the
equipment manufacturer.
Maintenance
DDC is not responsible for the cost of
maintenance or repairs due to lack of
performance of required maintenance
services as recommended by DDC, or
the failure to use fuel, oil, lubricants,
coolant, cooling air and ventilation
meeting DDC-recommended
specifications. Performance of the
required maintenance and use of
proper fuel, oil, lubricants, coolant
cooling air and ventilation are
the responsibility of the owner.
Refer to section MAINTENANCE
SCHEDULES in this guide for details.
Incidental or Consequential
Damage
This warranty does not cover any
economic loss, including without
limitation, communication expenses,
meals, lodging, loss of use of the
Engine, loss of time, inconvenience,
overtime, transportation of the Engine
or any other cost or expense resulting
from a defect covered by this warranty.
Other Limitations
THIS LIMITED WARRANTY
IS THE ONLY WARRANTY
APPLICABLE TO THE ENGINE
AND ACCESSORIES AS
USED IN PRIME POWER
AND STAND-BY POWER
GENERATORS. DETROIT DIESEL
CORPORATION MAKES NO
OTHER WARRANTIES EXPRESS
OR IMPLIED, INCLUDING
ANY IMPLIED WARRANTY
OF MERCHANTABILITY OR
FITNESS FOR A PARTICULAR
PURPOSE. DETROIT DIESEL
CORPORATION SHALL NOT BE
LIABLE FOR ANY INCIDENTAL
OR CONSEQUENTIAL DAMAGES
AS DESCRIBED ABOVE.
Some states do not allow the limitation
of how long this warranty may last
or the limitation or exclusion of
incidental or consequential damages,
so the above may not apply to you.
This warranty gives you specific legal
rights, and you may also have other
rights which may vary from state to
state.
All information subject to change without notice. (Rev. May 2004)
DDC-SVC-MAN-0057 0305 Copyright © 2003 DETROIT DIESEL CORPORATION
141
SPECIFICATIONS
SPECIFICATIONS
Fuel and Lubricating Oil
Filter Requirements
FUEL FILTER REQUIREMENTS – Series 40 Regular Service
Filter Type
Detroit Diesel Part No.
Secondary — Spin-On
1 820 479 C1 (6 In.)
Secondary — Spin-On
23523907
Primary — Fuel Pro 232 Element
23528565
LUBRICATING OIL FILTER REQUIREMENTS
Table 43
Filter Type
Detroit Diesel Part No.
Full Flow
23529744
Series 40 Fuel and Lubricating Oil Filter Requirements
Engine Oil Capacity
OIL PAN CAPACITY
All 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 filter
24 quarts to the FULL mark .......Without oil filter
TOTAL OIL CAPACITY OF THE ENGINE
28 quarts to the FULL mark with filter installed and filter and oil galleries charged
Table 44
142
Series 40 Engine Oil Capacity
All information subject to change without notice. (Rev. May 2004)
DDC-SVC-MAN-0057 0305 Copyright © 2003 DETROIT DIESEL CORPORATION
SERIES 40 ENGINE OPERATOR'S GUIDE
Power Cool Engine
Products
POWER COOL FULLY
FORMULATED IEG COOLANT
Coolant Type
Concentrated
Part Number
Description
23512138
1 Gallon Jug – 6
Per Case
23512139
55 Gallon Drum
23529295
23512140
23528203
Pre-Blended 50:50
Table 45
330 Gallon Tote
Bulk Delivery – 1,000
Gallon Min.
1 Gallon Jug – 6
Per Case
23518918
55 Gallon Drum
23528544
330 Gallon Tote
23513503
Bulk Delivery – 1,000
Gallon Min.
POWER COOL Fully Formulated IEG Coolant
POWER COOL LATIN
AMERICAN COOLANT
Coolant Type
Pre-Blended 67:33
Table 46
Part Number
Description
23524737
1 Gallon Jug – 6
Per Case
23524923
55 Gallon Drum
23524924
Bulk Delivery – 1,000
Gallon Minimum
POWER COOL Latin American Coolant
All information subject to change without notice. (Rev. May 2004)
DDC-SVC-MAN-0057 0305 Copyright © 2003 DETROIT DIESEL CORPORATION
143
SPECIFICATIONS
POWER COOL 2000
SUPPLEMENTAL COOLANT
ADDITIVE
Coolant Type
For Power Cool IEG
Coolant
Table 47
Part Number
Description
23507858
Pint Bottle – 12 Per case
23507859
Half Gallon Jug – 6
Per Case
23507860
5 Gallon Pail
23507861
55 Gallon Drum
POWER COOL 2000 Supplemental Coolant Additive
POWER COOL 3000
SUPPLEMENTAL COOLANT
ADDITIVE
Coolant Type
For POWER COOL
IEG Coolant
Table 48
144
Part Number
Description
23507854
Pint Bottle – 12 Per Case
23507855
Half Gallon Jug – 6
Per Case
23507856
5 Gallon Pail
23507857
55 Gallon Drum
POWER COOL 3000 Supplemental Coolant Additive
All information subject to change without notice. (Rev. May 2004)
DDC-SVC-MAN-0057 0305 Copyright © 2003 DETROIT DIESEL CORPORATION
SERIES 40 ENGINE OPERATOR'S GUIDE
POWER COOL 3000
SUPPLEMENTAL ADDITIVE
COOLANT FILTERS
Coolant Type
For POWER COOL
IEG Coolant
Table 49
Part Number
Description
23507545
4 Ounce (1 Pint
Equivalent)
23508425
8 Ounce (2 Pint
Equivalent)
23508426
12 Ounce (3 Pint
Equivalent)
23507189
16 Ounce (4 Pint
Equivalent)
23508427
32 Ounce (8 Pint
Equivalent)
23508428
53 Ounce (13 Pint
Equivalent)
POWER COOL 3000 Supplemental Additive Coolant Filters
POWER COOL SUPPLEMENTAL
ADDITIVE NEED RELEASE
COOLANT FILTERS
Coolant Type
For POWER COOL
IEG Coolant
Table 50
Part Number
Description
23516488
For 0 – 8 Gallon Systems
23516489
For 8 – 20 Gallon
Systems
POWER COOL SUPPLEMENTAL ADDITIVE NEED
RELEASE COOLANT FILTERS
All information subject to change without notice. (Rev. May 2004)
DDC-SVC-MAN-0057 0305 Copyright © 2003 DETROIT DIESEL CORPORATION
145
SPECIFICATIONS
POWER COOL PLUS EXTENDED
LIFE OAT COOLANT
Coolant Type
Concentrated
Part Number
Description
23519397
1 Gallon Jug – 6
Per Case
23519394
23519395
23519396
Pre-Blended 50:50
Table 51
55 Gallon Drum
Bulk Delivery – 1,000
Gallon Min.
One Gallon Jug – 6
Per Case
23519398
55 Gallon Drum
23519399
Bulk Delivery – 1,000
Gallon Min.
POWER COOL Plus Extended Life OAT Coolant
POWER COOL PLUS EXTENDER
FOR USE WITH POWER COOL
PLUS OAT COOLANT
Coolant Type
For Power Cool Plus
Table 52
146
Part Number
23519400
Description
Quart Bottle – 6 Per
Case
POWER COOL Plus Extender for Use with POWER COOL
Plus OAT Coolant
All information subject to change without notice. (Rev. May 2004)
DDC-SVC-MAN-0057 0305 Copyright © 2003 DETROIT DIESEL CORPORATION
SERIES 40 ENGINE OPERATOR'S GUIDE
POWER COOL PLUS 6000 OAT
INHIBITOR FOR WATER-ONLY
SYSTEMS
Coolant Type
Water Only
Table 53
Description
Part Number
23522127
1 Gallon Jug – 6 Per
Case
23522128
5 Gallon Pail
POWER COOL Plus 6000 OAT Inhibitor for Water-Only
Systems
POWER COOL COOLING
SYSTEM CLEANERS
Coolant Type
Description
Part Number
200164
On-Half Gallon Jug – 6
Per Case
On-Line Cleaner
200105
5 Gallon Pail
200155
55 Gallon Drum
Twin Pack
201549
Twin Pack – 2 Per Case
Table 54
Power Cool Cooling System Cleaners
All information subject to change without notice. (Rev. May 2004)
DDC-SVC-MAN-0057 0305 Copyright © 2003 DETROIT DIESEL CORPORATION
147
SPECIFICATIONS
POWER TRAC COOLANT
TESTING AND ANALYSIS
PRODUCTS
Application
Part Number
Description
Indicates Nitrite,
Molybdate & Glycol
Levels
23519401
3-Way Coolant Test
Strips
(Single Foil Packs)
Indicates Nitrite,
Molybdate & Glycol
Levels
23519402
3-Way Coolant Test
Strips
(Bottle of 50)
23522774
3-Way Coolant Test
Strips
(Bottle of 10)
23516921
Coolant Analysis Bottle
(Carton of 6)
23523398
Laboratory Coolant
Analysis Bottle
(Carton of 6)
Indicates Nitrite,
Molybdate & Glycol
Levels
Complete IEG/IPG
Coolant Analysis
Organic Coolant
Analysis
Table 55
148
Power Trac Coolant Testing and Analysis Products
All information subject to change without notice. (Rev. May 2004)
DDC-SVC-MAN-0057 0305 Copyright © 2003 DETROIT DIESEL CORPORATION
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