Detroit Diesel DD15 EuroIV Operator's Manual
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Detroit Diesel DD15 EuroIV Operator's Manual

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

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Anaximandro Leon
February 20, 2025

I need help to know which Euro emissions regulation is my dd15 engine, serial number 472904S0041491, compatible with?

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Summary of Contents for Detroit Diesel DD15 EuroIV

  • Page 1 DDC-SVC-MAN-0175 DD Platform EuroIV Operators Manual Specifications are subject to change without notice. Detroit Diesel Corporation is registered to ISO 9001:2001. Copyright © Detroit Diesel Corporation. All rights reserved. Detroit Diesel Corporation is a Daimler company. Printed in U.S.A.

  • Page 2: Table Of Contents

    Engine Model and Serial Number Designation........... 16 Operating Instructions for Starting the Engine........... 20 First Time Start Preparations............... 20 Detroit Diesel Electronic Controls (DDEC) System........38 DDEC VI System..................38 Detroit Diesel Electronic Control System Operation........40 Detroit Diesel Electronic Control System Features........44 Accelerating the Vehicle................
  • Page 3 Procedure for Restoring to Service an Engine that Has Been in Extended Storage....................... 110 Customer Assistance..................112 Customer Assistance.................. 112 Detroit Genuine Coolant Engine Products..........114 Engine Oil Capacities................... 116 All information subject to change without notice. DDC-SVC-MAN-0175 Copyright © 2014 DETROIT DIESEL CORPORATION...

  • Page 4: Forward

    The use of fluids that do not meet Detroit™ specifications may result in premature wear or engine failure. All information subject to change without notice. Copyright © 2014 DETROIT DIESEL CORPORATION DDC-SVC-MAN-0175...

  • Page 5: Personnel Requirements

    Tampering with the fuel injection system and engine electronics could also affect engine power output or exhaust emission levels. Compliance with the manufacturer's settings and with statutory environmental protection regulations cannot then be guaranteed. All information subject to change without notice. DDC-SVC-MAN-0175 Copyright © 2014 DETROIT DIESEL CORPORATION...

  • Page 6: To The Operator

    Failure to check and maintain SCA levels at required concentrations will result in severe damage (corrosion) to the engine cooling system and related components. All information subject to change without notice. Copyright © 2014 DETROIT DIESEL CORPORATION DDC-SVC-MAN-0175...
  • Page 7 DDC®, Detroit™, DDEC®, Optimized Idle®, Diagnostic Link®, POWER Trac®, POWER COOL®, and POWER GUARD® are registered trademarks of Detroit Diesel Corporation. All other trademarks used are the property of their respective owners. All information subject to change without notice. DDC-SVC-MAN-0175 Copyright © 2014 DETROIT DIESEL CORPORATION...

  • Page 8: Caution Summary

    WARNING: PERSONAL INJURY To avoid injury from engine shutdown in an unsafe situation, ensure the operator knows how to override the stop engine condition on a DDEC-equipped unit. All information subject to change without notice. Copyright © 2014 DETROIT DIESEL CORPORATION DDC-SVC-MAN-0175...
  • Page 9 WARNING: FIRE To avoid injury from fire, contain and eliminate leaks of flammable fluids as they occur. Failure to eliminate leaks could result in fire. All information subject to change without notice. DDC-SVC-MAN-0175 Copyright © 2014 DETROIT DIESEL CORPORATION...
  • Page 10 Remove the cap slowly to relieve pressure. WARNING: FIRE To avoid injury from fire, do not smoke or allow open flames when working on an operating engine. All information subject to change without notice. Copyright © 2014 DETROIT DIESEL CORPORATION DDC-SVC-MAN-0175...
  • Page 11 To avoid injury from slipping and falling, immediately clean up any spilled liquids. Electrical System Observe the following cautions when jump starting an engine, charging a battery, or working with the vehicle/application electrical system. All information subject to change without notice. DDC-SVC-MAN-0175 Copyright © 2014 DETROIT DIESEL CORPORATION...
  • Page 12 Observe the following cautions when replacing the engine lubricating oil and filter. WARNING: PERSONAL INJURY To avoid injury from slipping and falling, immediately clean up any spilled liquids. All information subject to change without notice. Copyright © 2014 DETROIT DIESEL CORPORATION DDC-SVC-MAN-0175...
  • Page 13 Residual high fuel pressure may be present within the circuit. WARNING: FIRE To avoid increased risk of a fuel fire, do not mix gasoline and diesel fuel. All information subject to change without notice. DDC-SVC-MAN-0175 Copyright © 2014 DETROIT DIESEL CORPORATION...
  • Page 14 • 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. All information subject to change without notice. Copyright © 2014 DETROIT DIESEL CORPORATION DDC-SVC-MAN-0175...

  • Page 15: Engine Identification

    2. Exhaust Gas Recirculation (EGR) 5. Crankcase Breather Cooler 6. Fuel Doser Valve 3. Exhaust Gas Recirculation (EGR) Valve / Actuator Figure 1. DD15 Left Side View All information subject to change without notice. DDC-SVC-MAN-0175 Copyright © 2014 DETROIT DIESEL CORPORATION...

  • Page 16: Engine Model And Serial Number Designation

    Using 472908S0005703 as an example: • 472 = engine model (DD15 EuroIV) • 908 = vehicle application (Freightliner EuroIV) • S = assembly plant (Detroit™) •...
  • Page 17 • 472 - DD15 Motor Control Module and Engine Serial Number The Motor Control Module (MCM) part number and Engine Serial Number (ESN) are located on the MCM label. All information subject to change without notice. DDC-SVC-MAN-0175 Copyright © 2014 DETROIT DIESEL CORPORATION...
  • Page 18 It gives the operating conditions under which certification was made. The following illustration is an EPA07 engine certification exemption label. All information subject to change without notice. Copyright © 2014 DETROIT DIESEL CORPORATION DDC-SVC-MAN-0175...
  • Page 19 DD Platform EuroIV Operators Manual Figure 5. EuroIV Engine Certification Exemption Label All information subject to change without notice. DDC-SVC-MAN-0175 Copyright © 2014 DETROIT DIESEL CORPORATION...

  • Page 20: Operating Instructions For Starting The Engine

    4. Check to make sure the front of the radiator and charge air cooler (if equipped) are unblocked and free of debris. All information subject to change without notice. Copyright © 2014 DETROIT DIESEL CORPORATION DDC-SVC-MAN-0175...
  • Page 21 Otherwise, the engine must be brought up to an operating temperature of 60°C (140°F), parked on a level surface and then shut down for five minutes for an accurate oil level reading. All information subject to change without notice. DDC-SVC-MAN-0175 Copyright © 2014 DETROIT DIESEL CORPORATION...
  • Page 22 'minimum' bend, add oil to bring it up the 'maximum' level. Do NOT fill beyond the maximum fill level on the dipstick, since overfilling may result in high oil consumption and possible severe engine damage. All information subject to change without notice. Copyright © 2014 DETROIT DIESEL CORPORATION DDC-SVC-MAN-0175...
  • Page 23 Full tanks also reduce the chance for microbe (black slime) growth. For fuel recommendations, Refer to section "How to Select Diesel Fuel". All information subject to change without notice. DDC-SVC-MAN-0175 Copyright © 2014 DETROIT DIESEL CORPORATION...
  • Page 24 5. If the engine still fails to start, continue as follows: a. Use DDDL to check for fault codes, repair as necessary. b. Repeat step 2 and step 3. All information subject to change without notice. Copyright © 2014 DETROIT DIESEL CORPORATION DDC-SVC-MAN-0175...
  • Page 25 (3). Service or replace as needed. • To provide corrosion protection, apply dielectric grease liberally to the terminal pads. All information subject to change without notice. DDC-SVC-MAN-0175 Copyright © 2014 DETROIT DIESEL CORPORATION...
  • Page 26 Tie back or contain long hair that could be caught in any moving part causing injury. The hydraulic fan may start without warning. All information subject to change without notice. Copyright © 2014 DETROIT DIESEL CORPORATION DDC-SVC-MAN-0175...
  • Page 27 While the engine is operating, monitor the battery charge indicator light, the oil pressure, and avoid excessive idling. Checking the Oil Pressure Monitor the oil pressure as follows: All information subject to change without notice. DDC-SVC-MAN-0175 Copyright © 2014 DETROIT DIESEL CORPORATION...
  • Page 28 1. 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 60 minutes, then check the oil level. All information subject to change without notice. Copyright © 2014 DETROIT DIESEL CORPORATION DDC-SVC-MAN-0175...
  • Page 29 2. If a leak, unusual noise, or vibration is noted, stop the engine immediately. Do not restart the engine until the cause of the concern has been investigated and corrected. All information subject to change without notice. DDC-SVC-MAN-0175 Copyright © 2014 DETROIT DIESEL CORPORATION...
  • Page 30 WARNING: BATTERY EXPLOSION 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. All information subject to change without notice. Copyright © 2014 DETROIT DIESEL CORPORATION DDC-SVC-MAN-0175...
  • Page 31 The hydraulic fan may start without warning. Routinely Starting the Engine Before a routine start, see the daily checks for your engine in the Maintenance section of this manual. All information subject to change without notice. DDC-SVC-MAN-0175 Copyright © 2014 DETROIT DIESEL CORPORATION...
  • Page 32 6. Check the oil level using the oil dipstick. The oil level is measured using the crosshatch area on the dipstick. If the oil reading within the crosshatch area, then the oil is at the proper level for engine operation. All information subject to change without notice. Copyright © 2014 DETROIT DIESEL CORPORATION DDC-SVC-MAN-0175...
  • Page 33 1. Allow the engine to run for approximately five minutes at a moderate speed. 2. After the coolant temperature reaches 50°C (122°F), recheck the coolant level in the surge tank. All information subject to change without notice. DDC-SVC-MAN-0175 Copyright © 2014 DETROIT DIESEL CORPORATION...
  • Page 34 • 55 psi (380 kPa) at rated speed • 14 psi (97 kPa) at idling speed If oil pressure drops below these values, stop the engine and determine the cause. All information subject to change without notice. Copyright © 2014 DETROIT DIESEL CORPORATION DDC-SVC-MAN-0175...
  • Page 35 1000 rpm. This allows you to safely move the vehicle to a service location or a safe stopping area. All information subject to change without notice. DDC-SVC-MAN-0175 Copyright © 2014 DETROIT DIESEL CORPORATION...
  • Page 36 Cold Weather Operation Special precautions must be taken during cold weather. To protect your engine, special cold weather handling is required for fuel, engine oil, coolant, and batteries. All information subject to change without notice. Copyright © 2014 DETROIT DIESEL CORPORATION DDC-SVC-MAN-0175...
  • Page 37 This assures even cooling across each tube and reduces header to tube stress and possible failure. Winter fronts should only be used when the ambient temperature remains below -12°C (10°F). All information subject to change without notice. DDC-SVC-MAN-0175 Copyright © 2014 DETROIT DIESEL CORPORATION...

  • Page 38: Detroit Diesel Electronic Controls (Ddec) System

    Detroit Diesel Electronic Controls (DDEC) System Detroit Diesel Electronic Controls (DDEC) System DDEC VI System The engine is equipped with a fully electronic control system, which regulates the fuel injection quantity and timing using solenoid valves, allowing extremely low- emission operation. Besides the engine and its related sensors, the system is composed of the following: •...
  • Page 39 • The operator (accelerator pedal position, engine brake switch) • Other electronic control units (for example, the anti-lock brake system) • The MCM (oil pressure and coolant temperature) All information subject to change without notice. DDC-SVC-MAN-0175 Copyright © 2014 DETROIT DIESEL CORPORATION...

  • Page 40: Detroit Diesel Electronic Control System Operation

    Detroit Diesel Electronic Controls (DDEC) System 1. Connector 1 3. Connector 3 2. Connector 2 4. Connector 4 Figure 8. Common Powertrain Controller Detroit Diesel Electronic Control System Operation NOTE: This engine is equipped with DDEC software. This software generally assures optimal engine performance. The installation of software upgrades may cause minor changes in features and engine performance.
  • Page 41 This feature allows the operator to override the automatic stop engine sequence. This is done by pressing the Stop Engine Override Switch every 15 to 20 seconds to prevent engine shutdown from occurring. All information subject to change without notice. DDC-SVC-MAN-0175 Copyright © 2014 DETROIT DIESEL CORPORATION...
  • Page 42 If the malfunction is intermittent, the lights will come on and go off as the computer senses the changing engine condition. Diagnostic Tool The diagnostic tool for Detroit Diesel Electronic Control is the Detroit Diesel Diagnostic Link (DDDL 7.X). DDDL 7.X requirements are listed earlier in the manual under Data Recording Capability.
  • Page 43 If there are no active or inactive faults, the number 3 is flashed once followed by a gap of 3 seconds. All information subject to change without notice. DDC-SVC-MAN-0175 Copyright © 2014 DETROIT DIESEL CORPORATION...

  • Page 44: Detroit Diesel Electronic Control System Features

    Detroit Diesel Electronic Controls (DDEC) System Reading Fault Codes To read the fault codes, press and hold the Stop Engine Override / Diagnostic Request Switch. Active codes will be flashed on the RSL (Stop Engine) first, followed by inactive codes being flashed on the AWL (Check Engine). The codes will continue to flash and repeat as long as the Diagnostic Request Switch is held in the ON position.
  • Page 45 The engine brake will only operate when the Accelerator Pedal is fully released. Disengaging the clutch will prevent the engine brake from operating. All information subject to change without notice. DDC-SVC-MAN-0175 Copyright © 2014 DETROIT DIESEL CORPORATION...

  • Page 46: Accelerating The Vehicle

    Detroit Diesel Electronic Controls (DDEC) System The engine brake will supply braking power even when in Cruise Control. The Motor Control Module will control the amount of engine braking with respect to the Cruise Control set speed. The maximum amount of braking (low, medium, high) is selected with the dash or steering wheel switches.

  • Page 47: Cruise Control

    Fuel Economy Incentive and PasSmart. The Vehicle Speed Limit should be used to limit vehicle throttle speed. All information subject to change without notice. DDC-SVC-MAN-0175 Copyright © 2014 DETROIT DIESEL CORPORATION...
  • Page 48 Detroit Diesel Electronic Controls (DDEC) System Turn the switch ON to energize the system. Remember as a check after each engine start, DDEC looks for a one-time activation of the clutch (if equipped) and service brake before DDEC allows Cruise Control to be enabled.

  • Page 49: Engine Brake And Cruise Control

    For safety reasons, don't use Cruise Control when it is not possible to keep the vehicle at constant speed due to: • Winding roads • Heavy traffic • Slippery pavement • Descending grades calling for engine brake assistance All information subject to change without notice. DDC-SVC-MAN-0175 Copyright © 2014 DETROIT DIESEL CORPORATION...

  • Page 50: Dd Platform Shifting

    Detroit Diesel Electronic Controls (DDEC) System For an explanation of the engine brake system and recommendations for proper operation, "Engine Brake System" in this manual. DD Platform Shifting Depending on your transmission model, the gear split may vary from 400 to 500 rpm.

  • Page 51: Engine Brake System

    • An Engine Brake level (Low/Med/High) is selected. • Vehicle meets the programmed minimum speed. • The Clutch Pedal is out. • The Accelerator Pedal is at zero percent activation. All information subject to change without notice. DDC-SVC-MAN-0175 Copyright © 2014 DETROIT DIESEL CORPORATION...

  • Page 52: Anti-Lock Braking Systems

    NOTE: Some systems may be programmed to activate themselves only when the brake pedal is pressed, so read your vehicle owner's manual thoroughly to find out if you have this option. All information subject to change without notice. Copyright © 2014 DETROIT DIESEL CORPORATION DDC-SVC-MAN-0175...

  • Page 53: Operating On Flat, Dry Pavement

    1. Before beginning the descent, determine if your engine brake system is operating properly by lifting your foot briefly off the accelerator pedal. You should feel the system activate. All information subject to change without notice. DDC-SVC-MAN-0175 Copyright © 2014 DETROIT DIESEL CORPORATION...

  • Page 54: Operating On Wet Or Slippery Pavement

    1. On wet or slippery pavement, start with the master switch in the OFF position and use the gear you would normally use under these conditions. All information subject to change without notice. Copyright © 2014 DETROIT DIESEL CORPORATION DDC-SVC-MAN-0175...
  • Page 55 (LOW/MED/HIGH), since road conditions can change quickly. Never skip a step when operating the progressive braking system. Always go from OFF to LOW and then to a higher position. All information subject to change without notice. DDC-SVC-MAN-0175 Copyright © 2014 DETROIT DIESEL CORPORATION...

  • Page 56: Engine Systems

    The EGR actuator opens and closes the EGR valve to allow hot exhaust gas to enter the EGR cooler. Heat is extracted from the exhaust gas, All information subject to change without notice. Copyright © 2014 DETROIT DIESEL CORPORATION DDC-SVC-MAN-0175...
  • Page 57 Lower temperatures result in lower NOx levels without the negative effects of retarding engine timing. The EGR valve has been moved to the top of the engine for improved serviceability. All information subject to change without notice. DDC-SVC-MAN-0175 Copyright © 2014 DETROIT DIESEL CORPORATION...

  • Page 58: Preventive Maintenance Intervals

    Once the additives have been depleted from the coolant, it will only be a matter of time until the engine components suffer. Refer to section "Cooling System Fill Procedure" Cooling System Inspection - Inspect the cooling system as follows: All information subject to change without notice. Copyright © 2014 DETROIT DIESEL CORPORATION DDC-SVC-MAN-0175...
  • Page 59 A concern occurs when the belt ribs exhibit severe multiple cracking or 'chunking'. At this point, the belt should be replaced. All information subject to change without notice. DDC-SVC-MAN-0175 Copyright © 2014 DETROIT DIESEL CORPORATION...
  • Page 60 NOTICE: Do not over-tighten the water drain valve. Failure to properly tighten the water drain valve may cause damage to the water drain valve and housing. All information subject to change without notice. Copyright © 2014 DETROIT DIESEL CORPORATION DDC-SVC-MAN-0175...
  • Page 61 H2O) under any engine operating conditions. A clogged air cleaner element will cause excessive intake restriction and reduced air supply to the engine resulting in increased fuel consumption, inefficient engine operation and reduced engine life. All information subject to change without notice. DDC-SVC-MAN-0175 Copyright © 2014 DETROIT DIESEL CORPORATION...

  • Page 62: Preventive Maintenance Tables

    Service Maintenance Intervals Miles X 1000/ 100/ 125/ 150/ Km X 1000/ 120/ 160/ 200/ 240/ Hours* 1280 1925 2565 3205 3850 Lubricating Oil Lubricating Oil Filter All information subject to change without notice. Copyright © 2014 DETROIT DIESEL CORPORATION DDC-SVC-MAN-0175...
  • Page 63 • Currently, Davco 482 is the only frame-mounted filtration system compatible for Detroit™ Engines. • Refer to "Routine Preventive Maintenance" for a description of all items. • R = Replace • I = Inspect All information subject to change without notice. DDC-SVC-MAN-0175 Copyright © 2014 DETROIT DIESEL CORPORATION...

  • Page 64: Routine Preventive Maintenance

    Detroit service outlet for the cause. Fuel or coolant dilution of lubricating oil can result in serious engine damage. All information subject to change without notice. Copyright © 2014 DETROIT DIESEL CORPORATION DDC-SVC-MAN-0175...

  • Page 65: Monitoring The Lubricating Oil Filter

    This design, including the cartridge style element, allows for a more environmentally-safe oil change. All information subject to change without notice. DDC-SVC-MAN-0175 Copyright © 2014 DETROIT DIESEL CORPORATION...

  • Page 66: Monitoring The Cooling System

    2. Add coolant as required, but do not overfill. Before adding coolant, refer to "How to Select Coolant" for the listing of required intervals using the recommended coolants All information subject to change without notice. Copyright © 2014 DETROIT DIESEL CORPORATION DDC-SVC-MAN-0175...

  • Page 67: Inspection Of The Radiator

    Environmental Protection Agency (EPA) recommendations. Inspection of the Radiator Inspect the radiator as follows: 1. Inspect the exterior of the radiator core every 30,000 miles (50,000 km) or 12 months. All information subject to change without notice. DDC-SVC-MAN-0175 Copyright © 2014 DETROIT DIESEL CORPORATION...

  • Page 68: Monitoring The Cooling System Filter

    NOTE: Filter change intervals may be shortened to conform with established preventive maintenance schedules, but should never be extended. 1. Replace the fuel filters using the Preventative Maintenance Tables. All information subject to change without notice. Copyright © 2014 DETROIT DIESEL CORPORATION DDC-SVC-MAN-0175...

  • Page 69: Adjusting The Valve Lash

    To provide proper running tension, the current engine uses an automatic fan hub belt tensioner (6) and an accessory belt tensioner (2). Automatic belt tensioners require no adjustment. All information subject to change without notice. DDC-SVC-MAN-0175 Copyright © 2014 DETROIT DIESEL CORPORATION...

  • Page 70: Inspection Of The Air Intake System

    4. Inspect the entire air system for leaks daily. All information subject to change without notice. Copyright © 2014 DETROIT DIESEL CORPORATION DDC-SVC-MAN-0175...

  • Page 71: Monitoring The Exhaust System

    WARNING: PERSONAL INJURY To avoid injury from improper use of chemicals, follow the chemical manufacturer's usage, handling, and disposal instructions. Observe all manufacturer's cautions. All information subject to change without notice. DDC-SVC-MAN-0175 Copyright © 2014 DETROIT DIESEL CORPORATION...

  • Page 72: Inspection Of Hoses And Fittings For Fuel Leaks

    NOTE: Fire-resistant fuel and lubricating 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. All information subject to change without notice. Copyright © 2014 DETROIT DIESEL CORPORATION DDC-SVC-MAN-0175...

  • Page 73: Inspection Of The Turbocharger And Charge Air Cooler

    1. Check for cracks in the battery cases (1), for tightness of the cable clamps (2) at the terminals, and for corrosion of the terminals (3). Service or replace as needed. All information subject to change without notice. DDC-SVC-MAN-0175 Copyright © 2014 DETROIT DIESEL CORPORATION...

  • Page 74: Steam Cleaning The Engine

    DDEC components, sensors or other electrical components, as damage may result. The engine and engine compartment should be steam cleaned every 60,000 miles (100,000 km) or 2,000 hours, whichever comes first. All information subject to change without notice. Copyright © 2014 DETROIT DIESEL CORPORATION DDC-SVC-MAN-0175...

  • Page 75: Inspection Of The Battery-Charging Alternator

    If the fan bearing hub assembly has a grease fitting, use a hand grease gun to lubricate the bearings with one shot of quality lithium-based, multipurpose grease every 120,000 miles (200,000 km). Care should be taken not to overfill the bearing housing. All information subject to change without notice. DDC-SVC-MAN-0175 Copyright © 2014 DETROIT DIESEL CORPORATION...

  • Page 76: Checking The Vibration Damper

    For this reason, replace the viscous vibration damper at time of normal major engine overhaul, regardless of apparent condition. All information subject to change without notice. Copyright © 2014 DETROIT DIESEL CORPORATION DDC-SVC-MAN-0175...

  • Page 77: How To Procedures

    These engines meet 2002 to 2006 model year emission requirements. These oils are similar to API CI-4 PLUS. Figure 10. Example SAE Viscosity Grade: 15W-40 API Classification: CI-4 PLUS All information subject to change without notice. DDC-SVC-MAN-0175 Copyright © 2014 DETROIT DIESEL CORPORATION...

  • Page 78: When To Change Oil

    CAUTION: USED ENGINE OIL To avoid injury to skin from contact with the contaminants in used engine oil, wear protective gloves and apron. All information subject to change without notice. Copyright © 2014 DETROIT DIESEL CORPORATION DDC-SVC-MAN-0175...

  • Page 79: How To Replace The Lubricating Oil And Oil Filter

    3. Using a 36-mm socket, unscrew the oil filter cap and filter and allow the oil to drain into the housing. After draining is complete, remove the assembly from the housing. All information subject to change without notice. DDC-SVC-MAN-0175 Copyright © 2014 DETROIT DIESEL CORPORATION...
  • Page 80 Monitor the oil pressure gauge or indicator lamp. Keep the engine running at idling speed (600 rpm) until the oil pressure reading is 10.2 psi (70 kPa) or more for the DD15. All information subject to change without notice. Copyright © 2014 DETROIT DIESEL CORPORATION DDC-SVC-MAN-0175...

  • Page 81: How To Select Diesel Fuel

    All EuroIV DD engines are designed to operate on Low Sulfur Diesel fuel. Quality NOTICE: Use only Low Sulfur Diesel (LSD) fuel (500 PPM sulfur content maximum), based on ASTM Standard D 2622 test procedure. All information subject to change without notice. DDC-SVC-MAN-0175 Copyright © 2014 DETROIT DIESEL CORPORATION...
  • Page 82 Biodiesel blends above 5% are not recommended Prohibited Additives The following fuel additives are not allowed and MUST NOT be mixed with diesel fuel: All information subject to change without notice. Copyright © 2014 DETROIT DIESEL CORPORATION DDC-SVC-MAN-0175...

  • Page 83: How To Replace The Fuel Filters

    The scheduled maintenance intervals for the appropriate duty cycles are listed in this manual. All information subject to change without notice. DDC-SVC-MAN-0175 Copyright © 2014 DETROIT DIESEL CORPORATION...
  • Page 84 (2) at an angle. 4. Discard the prefilter cap seal ring. Installation of the Fuel Prefilter Install the fuel prefilter as follows: All information subject to change without notice. Copyright © 2014 DETROIT DIESEL CORPORATION DDC-SVC-MAN-0175...
  • Page 85 To avoid injury before starting and running the engine, ensure the vehicle is parked on a level surface, parking brake is set, and the wheels are blocked. All information subject to change without notice. DDC-SVC-MAN-0175 Copyright © 2014 DETROIT DIESEL CORPORATION...
  • Page 86 (1) by placing the filter on a solid surface with the drain back plug location at 12 o’clock (3) and apply pressure on the water coalescer/final filter cap at an angle. All information subject to change without notice. Copyright © 2014 DETROIT DIESEL CORPORATION DDC-SVC-MAN-0175...
  • Page 87 (C).Apply a heavy coat of Parker super O-lube or petroleum-based lithium grease to the upper (A) and lower seals (B) on the water coalescer/final filter. All information subject to change without notice. DDC-SVC-MAN-0175 Copyright © 2014 DETROIT DIESEL CORPORATION...
  • Page 88 The illustration below shows the proper amount of lubricant to use on the upper and lower seals. 4. Install the water coalescer/final filter into the fuel filter module. All information subject to change without notice. Copyright © 2014 DETROIT DIESEL CORPORATION DDC-SVC-MAN-0175...

  • Page 89: Engine Out Of Fuel - How To Restart

    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. Use the following procedure to prime the fuel system: All information subject to change without notice. DDC-SVC-MAN-0175 Copyright © 2014 DETROIT DIESEL CORPORATION...

  • Page 90: How To Clean An Engine

    NOTICE: To prevent damage to engine components, keep the water moving at all times while cleaning. Never direct water onto electrical components, plug connectors, seals or flexible hoses. All information subject to change without notice. Copyright © 2014 DETROIT DIESEL CORPORATION DDC-SVC-MAN-0175...

  • Page 91: How To Clean The Cooling System

    (face shield or safety goggles) and do not exceed 276 kPa (40 psi) air pressure. NOTICE: Clean at moderate air pressures only to avoid damaging the radiator grille fins. All information subject to change without notice. DDC-SVC-MAN-0175 Copyright © 2014 DETROIT DIESEL CORPORATION...

  • Page 92: Degreasing The Cooling System

    5. Fill the cooling system with new coolant. For detailed procedures, see the vehicle/chassis maintenance manual. For types of coolant, refer to the How to Select Coolant section for the listing of required intervals using the recommended coolants. All information subject to change without notice. Copyright © 2014 DETROIT DIESEL CORPORATION DDC-SVC-MAN-0175...
  • Page 93 The approved and preferred coolants for the engine are listed in the following table. All information subject to change without notice. DDC-SVC-MAN-0175 Copyright © 2014 DETROIT DIESEL CORPORATION...
  • Page 94 Detroit Genuine Fluid Analysis 3–Way Coolant Test Strip. If chemical analysis is used, elements in the coolant must fall within the following limits. All information subject to change without notice. Copyright © 2014 DETROIT DIESEL CORPORATION DDC-SVC-MAN-0175...
  • Page 95 Coolant Maintenance Intervals Check the nitrite concentration at the regular intervals listed in the following table with a Detroit Genuine Fluid Analysis 3–Way Test Strip. All information subject to change without notice. DDC-SVC-MAN-0175 Copyright © 2014 DETROIT DIESEL CORPORATION...
  • Page 96 2–years, or 10,000 hours 600,000 miles (960,000 Drain and clean system. km), 4–years, or Engine Refill with new coolant. Overhaul *Propylene glycol is an acceptable substitute for ethylene glycol. All information subject to change without notice. Copyright © 2014 DETROIT DIESEL CORPORATION DDC-SVC-MAN-0175...
  • Page 97 Wear adequate protective clothing (face shield, rubber gloves, apron, and boots). Remove the cap slowly to relieve pressure. All information subject to change without notice. DDC-SVC-MAN-0175 Copyright © 2014 DETROIT DIESEL CORPORATION...
  • Page 98 • Dilution of the coolant by the addition of untreated water • Over dosage or under dosage of corrosion inhibitors • Improper corrosion inhibitor (most often phosphate) • Mixing Supplemental Coolant Additives All information subject to change without notice. Copyright © 2014 DETROIT DIESEL CORPORATION DDC-SVC-MAN-0175...
  • Page 99 TMC RP-329 Type A specification or ASTM Standard D 6210 Type A for Ethylene Glycol. Always maintain coolant at the proper level. Do not use the following in Detroit™ engine cooling systems: All information subject to change without notice. DDC-SVC-MAN-0175 Copyright © 2014 DETROIT DIESEL CORPORATION...

  • Page 100: How To Replace The Coolant Filter

    NOTE: Change the coolant filter only after the vehicle has cooled and no residual pressure is present. NOTE: Use care to prevent foreign objects from entering the filter housing. All information subject to change without notice. Copyright © 2014 DETROIT DIESEL CORPORATION DDC-SVC-MAN-0175...

  • Page 101: Checking The Hoses

    4. Check coolant inhibitor levels at the intervals listed in this manual. Refer to section "EPA07 DD Series Preventive Maintenance Tables" Refer to section "EPA10/GHG14 DD Series Preventive Maintenance Tables" All information subject to change without notice. DDC-SVC-MAN-0175 Copyright © 2014 DETROIT DIESEL CORPORATION...

  • Page 102: How To Service The Dry Type Air Cleaner

    2. Do not clean and/or reuse dry paper-type air cleaner elements unless the cleaning method used removes clogging without damaging the element. 3. Inspect and clean the elements in accordance with the air cleaner manufacturer's recommendations, if any. All information subject to change without notice. Copyright © 2014 DETROIT DIESEL CORPORATION DDC-SVC-MAN-0175...

  • Page 103: Troubleshooting

    Faulty radiator pressure cap — Air in coolant — Thermostat not fully closed — Leakage around thermostat seal — Faulty temperature-controlled fan — Hard Starting This section explains hard starting. All information subject to change without notice. DDC-SVC-MAN-0175 Copyright © 2014 DETROIT DIESEL CORPORATION...

  • Page 104: Abnormal Engine Operation

    Leaking cylinder head gasket — — Improper intake or exhaust valve — — adjustments Abnormal Engine Operation This section explains Abnormal Engine Operation Symptoms and Probable Causes All information subject to change without notice. Copyright © 2014 DETROIT DIESEL CORPORATION DDC-SVC-MAN-0175...

  • Page 105: Abnormal Operating Conditions

    Damaged gaskets or seal rings — * Lubrication oil loss at breather tube — * Lubrication oil loss at dipstick tube — Leaking oil cooler — Leaking valve stem seals — All information subject to change without notice. DDC-SVC-MAN-0175 Copyright © 2014 DETROIT DIESEL CORPORATION...
  • Page 106 Worn or damaged oil pump — Faulty oil pressure gauge — Faulty electrical components (for gauge) — Plugged oil line or orifice — * Indicates high crankcase pressure All information subject to change without notice. Copyright © 2014 DETROIT DIESEL CORPORATION DDC-SVC-MAN-0175...

  • Page 107: Engine Storage

    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 Detroit's recommendations. Refer to section "How to Select Coolant" All information subject to change without notice. DDC-SVC-MAN-0175 Copyright © 2014 DETROIT DIESEL CORPORATION...
  • Page 108 (EPA) recommendations. Replace the drain plug and torque to 45-50 N·m (33-77 lb·ft). All information subject to change without notice. Copyright © 2014 DETROIT DIESEL CORPORATION DDC-SVC-MAN-0175...
  • Page 109 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 operation and cause the clutch to slip. All information subject to change without notice. DDC-SVC-MAN-0175 Copyright © 2014 DETROIT DIESEL CORPORATION...

  • Page 110: Procedure For Restoring To Service An Engine That Has Been In Extended Storage

    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. All information subject to change without notice. Copyright © 2014 DETROIT DIESEL CORPORATION DDC-SVC-MAN-0175...
  • Page 111 16. Check for trouble codes. a. If there are no codes, perform a parked regeneration. b. If there are codes, repair what is necessary then perform a parked regeneration. All information subject to change without notice. DDC-SVC-MAN-0175 Copyright © 2014 DETROIT DIESEL CORPORATION...

  • Page 112: Customer Assistance

    • Sales team to help determine your specific power requirements • In many areas, emergency service 24 hours a day • Complete parts support • Product information and literature All information subject to change without notice. Copyright © 2014 DETROIT DIESEL CORPORATION DDC-SVC-MAN-0175...
  • Page 113 (in Latin America, check the service locator at www.demanddetroit.com for Detroit™ service outlet nearest you). All information subject to change without notice. DDC-SVC-MAN-0175 Copyright © 2014 DETROIT DIESEL CORPORATION...

  • Page 114: Detroit Genuine Coolant Engine Products

    For 0 – 8 Gallon Systems Detroit Genuine Inhibited Ethylene Glycol Coolant 23516489 For 8 – 20 Gallon Systems Detroit Genuine Cooling System Cleaners Detroit Genuine Cooling System Cleaners are shown below. All information subject to change without notice. Copyright © 2014 DETROIT DIESEL CORPORATION DDC-SVC-MAN-0175...
  • Page 115 3-Way Coolant Test Strips (Bottle 23522774 Glycol Levels of 10) Complete Inhibited Ethylene Coolant Analysis Bottle (Carton 23516921 Glycol Coolant Analysis of 6) Organic Coolant Analysis 23539088 Laboratory Coolant Analysis All information subject to change without notice. DDC-SVC-MAN-0175 Copyright © 2014 DETROIT DIESEL CORPORATION...

  • Page 116: Engine Oil Capacities

    (Includes Filter Removal) Dip Stick Min. to 5.0 L (5.2 qt) 5.0 L (5.2 qt) Max. Range Sump Oil Volume 42.0 L (44.4 qt) 37.0 L (39.1 qt) All information subject to change without notice. Copyright © 2014 DETROIT DIESEL CORPORATION DDC-SVC-MAN-0175...

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