Shifting a Manual Transmission..............30 Vehicle Emergency Operation..............30 Detroit Diesel Electronic Controls System........... 32 Detroit Diesel Electronic Controls System..........32 Detroit Diesel Electronic Control System Operation........32 Detroit Diesel Electronic Control System Features........37 Engine Systems....................40 Engine Systems.................... 40 Aftertreatment System.................
Gen 5 DD Platform Operators Manual Forward Introduction This manual is intended to be used by the operator of Detroit™ Gen 5 Heavy Duty engines. The manual covers basic information on engine components, engine operation, Detroit Diesel Electronic Controls (DDEC®) system, engine systems, aftertreatment system, instrument panel indicators, preventative maintenance, how to procedures, and engine storage.
Engine Conversions and Modifications The function and safety of the engine could be affected if unauthorized modifications are made to it. Detroit™ will not accept responsibility for any resulting damage. Tampering with the fuel injection system and engine electronics could also affect engine power output or exhaust emission levels.
Whenever possible, it will benefit to rely on an authorized Detroit™ service outlet for any service needs from maintenance to major parts replacement. Authorized service outlets worldwide stock factory-original parts.
• DD13 Engine Components • DD15 Engine Components • Engine Model and Serial Number DD13 Engine Components Detroit™ Gen 5 Heavy Duty DD13 major engine components are shown below: 1. Water Pump 7. High Pressure Fuel Pump 2. Oil Coolant Module 8.
Using 472912S0608850 as an example: • 472 = engine type (DD15) • 912 = model • S = assembly plant (Detroit™) • 0608850 = serial number Engine Model Breakdown All information subject to change without notice.
Engine Operation Engine Operation Engine Operation This chapter will discuss how to properly operate a Detroit™ Gen 5 Heavy Duty engine. This chapter is broken down into sections that discuss various conditions of engine operation. The following sections will be covered in this chapter: •...
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Detroit™ service outlet for further instructions. Engine damage may be avoided by a quick response to early indications of problems.
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Priming the fuel system includes the use of special tools. Authorized Detroit™ service outlets are properly equipped for this type of service. Never use the starting motor and fuel pump to prime the fuel system. Prolonged use of the starting motor and fuel pump to prime the fuel system can result in damage to the starter, fuel pump, and injectors.
ON position. At the start of every ignition cycle, the instrument panel indicator lights will come on. This is the result of the electronic engine control system, called Detroit Diesel Electronic Control® (DDEC®), diagnosing the system to ensure everything is functional, including the cluster for the warning indicators.
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8. Check the engine for leaks. If any leaks are found, shut down the engine immediately and have the leaks repaired by an authorized Detroit™ service outlet. • Check all hoses, hose clamps, and pipe unions on the engine for tightness.
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For more information on high idle using the cruise control switches, Refer to section "Detroit Diesel Electronic Control System Features". An idle speed of 900 rpm should be enough to provide cab heat in above 0°C (32°F) temperatures. Never allow the engine to idle for more than 30 minutes.
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• The coolant and/or oil temperature climb abnormally. • Abnormal sounds suddenly occur in the engine or turbocharger. Contact an authorized Detroit™ service outlet if any of the above conditions is present. Stop an engine under normal operating conditions as follows: 1.
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Winter Fronts Winter fronts on Detroit™ Gen 5 Heavy Duty engines are seldom necessary due to the modern design of the engine cooling system. The coolant thermostat is mounted on the inlet side of the cooling system and regulates coolant flow from the radiator into the engine.
If oil pressure drops below the normal operating range or if an oil pressure warning indicator becomes active, stop the engine and determine the cause. It may be necessary to take the vehicle to an authorized Detroit™ service outlet. Monitoring the Instrument Panel During engine operation, monitor the instrument panel and instrument panel indicators for any warnings or messages concerning the vehicle's operating status.
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Detroit™ service outlet. Emergency Jump Starting The engine's electronic system operates on 12 volts DC. If a Detroit™ Gen 5 Heavy Duty engine requires emergency jump starting, do not exceed 16 volts DC as this may damage the MCM and or other electrical equipment.
Detroit Diesel Electronic Controls System Detroit Diesel Electronic Controls System All Detroit™ Gen 5 Heavy Duty engines are equipped with an electronic control system called Detroit Diesel Electronic Control® (DDEC®). The DDEC ® system monitors the functions that regulates the Detroit™ powertrain.
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ACM. Transmission Control Module Vehicles equipped with a Detroit Transmission will also be equipped with a TCM. The TCM will be mounted on the left side of the transmission (see graphic below).
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Should the Check Engine Indicator come on for any reason, the vehicle can still be operated and the driver can proceed to the required destination. This condition should be reported to an authorized Detroit™ service outlet . Depending on the fault, DDEC® can give a warning only, ramp down engine power or initiate a shut down.
Detroit Diesel Electronic Control System Features Detroit Diesel Electronic Control System Features The electronic control system called Detroit Diesel Electronic Control® (DDEC®) offers a variety of features and options designed to alert the operator of any engine, aftertreatment, and transmission (if equipped with DT12) malfunctions. Options All information subject to change without notice.
Aftertreatment System Aftertreatment Systems Detroit™ Gen 5 Heavy Duty engines are equipped with the second generation of the Global Aftertreatment System (GATS 2.0). The function of the Aftertreatment System (ATS) is to reduce emisson levels in the engine exhaust. Mounted onto the ATS are eight sensors, a Diesel Exhaust Fluid (DEF) doser, and an Aftertreatment Control Module (ACM).
Air System Air System On Detroit™ Gen 5 Heavy Duty engines, outside air enters the engine through the air filter and is drawn into the turbocharger where it is compressed. The compressed air is then forced through the charge air cooler (heat exchanger) where it is cooled.
"How to Select Coolants". Electrical System Electrical System The electrical system used in Detroit™ Gen 5 Heavy Duty engines consists of a starting motor, starting switch, battery-charging alternator, storage batteries, and necessary wiring. For information on the Detroit Diesel Electronic Control (DDEC®) system Refer to section "Detroit Diesel Electronic Controls System".
Lubrication System Lubrication System The lubrication system of a Detroit™ Gen 5 Heavy Duty engine consists of an oil coolant module, oil filter, oil cooler, oil pan, oil pump, oil suction manifold, oil pressure regulator valve, oil thermostat, and oil pressure sensor. Clean, pressurized oil is fed to all components via passages in the engine block and cylinder head.
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For instructions on checking the lubricating oil level, Refer to section "How to Check the Lubricating Oil Level". The engine oil capacities for the Detroit™ Gen 5 Heavy Duty engine are listed in the table below. Contact a Detroit™ service outlet if more specific information is needed.
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Aftertreatment System (ATS) There is a need to periodically remove accumulated ash, from the Diesel Particulate Filter (DPF). Detroit™ Gen 5 Heavy Duty engines will illuminate a dashboard warning indicator indicating the need for ash cleaning. Once the DPF has reached maximum ash volume, the recommended service for the DPF is to remove the DPF and replace with a Reliabilt®...
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Failure to maintain the cooling system at required concentrations or using coolants that do not meet Detroit™ specifications will result in severe damage to the engine cooling system and related components. The cooling system should be maintained per the maintenance intervals, Refer to section "Preventive Maintenance Tables".
Refer to section "How to Drain the Fuel Coalescer". Lubricating Oil and Filter Detroit™ Gen 5 Heavy Duty engines are equipped with a single cartridge-style oil filter that is part of the oil coolant module. Incorporated into the module is a drain back port which allows residual oil to be returned to the oil pan when the filter is removed.
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-** Check per section "Poly-V-Belt Inspection". - ***Fuel Economy represents overall fuel economy (including idle time) - ‡Currently, only Detroit™ Fuel Filter/Water Separator & Davco 385/482/485/487 are the only frame-mounted filtration systems compatible for Detroit™ Engines. - §Maintenance System can be enabled for this component.
Diesel Exhaust Fluid Filter Replacement The Diesel Exhaust Fluid (DEF) pump is a chassis-mounted filter, which filters out debris from the DEF. If the DEF is contaminated, contact an authorized Detroit™ service outlet for further instructions. Replacing the DEF filter requires the use of special diagnostic tools to prime the DEF system.
Inspect the turbocharger and charge air cooler as follows: NOTE: If any of the following conditions exist, it may be necessary to take the vehicle to an authorized Detroit™ service outlet. 1. Inspect the turbocharger mounting, intake and exhaust ducting, and connections for leaks daily.
Once the engine is turned off, the belt will re-center itself. Do not use any type of cleaning solvent on the rubber parts of the tensioner or on belts. Detroit does not approve the use of belt dressing or other like products as this may result in premature belt wear.
If misalignment is occurring, the belt may be riding off-centered on the pulley. In these scenarios, it may be necessary to take the vehicle to an authorized Detroit™ service outlet. Inspection of the Cooling System All information subject to change without notice.
At these intervals the coolant must be drained and disposed of in an environmentally responsible manner according to state and/or federal recommendations. Authorized Detroit™ service outlets are properly equipped for this type of service. Inspect the cooling system as follows: Checking for Coolant Leaks Perform daily visual checks for cooling system leaks.
After replacing the fuel filters, the fuel system will require priming. Priming the fuel system includes the use of special tools. Authorized Detroit™ service outlets are properly equipped for this type of service. Never use the starting motor and fuel pump to prime the fuel system.
Inspection of the Lubricating System Inspection of the Lubrication System Detroit™ Gen 5 Heavy Duty engines are equipped with a single cartridge-style oil filter that is part of the oil coolant module. Incorporated into the module is a drain back port, which allows residual oil to be returned to the oil pan when the filter is removed.
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The oil filter is an integral part of the lubrication system. Proper filter selection and maintenance are important to satisfactory engine performance and service life. Authorized Detroit™ service outlets are properly equipped for this type of service. Oil filter replacement should be used to maintain a clean system, but is not sufficient to clean a contaminated system.
- Checking the Coolant Level (Hot Check) • How to Select Coolants - Extended Life Coolants - Standard Life Coolants - Detroit™ Genuine Coolant Engine Products - Water Requirements - Recycle Coolants - Coolants Not Permitted - Non-Formulated Additives Not Permitted.
Diesel Exhaust Fluid Availability Diesel Exhaust Fluid (DEF) is available in various container sizes at authorized Detroit™ service outlets, truck stops and many truck service outlets. DEF is available in container sizes as small as 2.5 gallons for convenient, in-vehicle storage in case of emergency use.
Concentrated coolants should be mixed at 50% (50% coolant/50% water). All ELCs used must also meet DFS 93K217 specification. Detroit™ requires that these types of coolants be free of nitrite and phosphate. Detroit™ has found that ELC's containing nitrite may lead to a breakdown of the coolant and subsequent damage to the cooling system.
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These coolants require interval testing to maintain inhibitor concentration. SLC antifreeze coolants are commercially available from Detroit™ service outlets and other manufacturers as either concentrated or as pre-mixed coolant. Concentrated coolants should be mixed at 50% (50% coolant/50% water). All fully formulated coolants used must also meet DFS 93K217 specification.
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Coolants Not Permitted The following coolants are not to be used in Detroit™ Gen 5 Heavy Duty engines : • Automotive/Passenger car-type coolants must not be used because they offer no liner pitting protection. Also, these types of coolants generally contain high levels of phosphates and silicates.
Cooling systems operated with a chromate-inhibited coolant must be chemically cleaned with specially formulate cleaning agents available through authorized Detroit™ service outlets. Only use Detroit™ approved cleaning agents. • Phosphate Inhibitors: Phosphate has tendency to form deposits on surfaces transferring high heat which ultimately affect cooling capabilities.
The use of supplemental fuel additives does not necessarily void the engine warranty. However, warranty and repair expenses which are determined, by Detroit™ or its representative, to have resulted from a fuel additive will not be covered by Detroit™ warranty.
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Restarting an engine that has run out of fuel includes the use of special tools to prime the fuel system. Authorized Detroit™ service outlets are properly equipped for this type of service. Never use the starting motor and fuel pump to prime the fuel system.
6. If the engine does not start, allow for a 60-second cool down and repeat previous steps two through five. The starting cycle can be repeated up to three times. If engine still fails to start, contact an authorized Detroit™ service outlet.
4. If necessary, top off the engine oil by filling no more than 5.0 L (5.2 qt) at a time. Use only Detroit™ approved oil, Refer to section "Synthetic Oils and Additives". Do not overfill as overfilling the oil pan can cause engine damage.
Synthetic Oils and Additives Synthetic Oils Synthetic oils may be used in Detroit™ Gen 5 Heavy Duty engines provided they are approved by DFS. The use of synthetic oils does not necessarily ensure the extension of the recommended oil drain intervals beyond the limits.
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• The clutch pedal is depressed. • The accelerator pedal is at zero percent activation. The Detroit Diesel Electronic Control® (DDEC®) system will deactivate the engine brake system when the engine speed falls below a preset rpm or when the vehicle slows down to a preset speed.
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(vehicle speed over 0 MPH) is considered to be an operator-induced engine overspeed. Any mechanical engine failure within 3218 km (2000 mi) of an operator-induced engine overspeed event will not be eligible for Detroit warranty coverage. Operate the engine brakes when descending a long, steep grade as follows: 1.
Detroit™ recognizes 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 a Detroit™ product will be handled by the authorized Detroit™ service outlet. The service locator at www.demanddetroit.com can be used for help in finding an authorized Detroit™...
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