EPA10 DD PLATFORM OPERATORS MANUAL

To the Operator

This manual contains instructionson the safe operation and preventivemaintenance of your Detroit Dieselengine used in vehicle applications.Maintenance instructions coverroutine engine services such aslubricating oil and filter changes inenough detail to permit self-servicing,if desired.

The operator should become familiarwith the contents of this manual beforeoperating the engine or carrying outmaintenance procedures.

Power-driven equipment is onlyas safe as the person operating thecontrols. You are urged, as theoperator of this diesel engine, to keepfingers and clothing away from therevolving belts, drive shafts, pulleys,etc. on the engine installation.

Throughout this manual CAUTIONSand WARNINGS regarding personalsafety and NOTICES regardingengine performance or service lifewill appear. To avoid personal injuryand ensure long engine service life,always heed these instructions.

Whenever possible, it will benefityou to rely on an authorized DetroitDiesel service outlet for all yourservice needs from maintenance tomajor parts replacement. Authorizedservice outlets worldwide stockfactory-original parts.

The information and specificationsin this publication are based on theinformation in effect at the time ofapproval for printing. Contact anauthorized Detroit Diesel serviceoutlet for information on the latestrevision. The right is reserved tomake changes at any time withoutobligation.

Detroit Diesel engines are built inaccordance with sound technologicalprinciples and based on state-of-the-arttechnology.

Despite this, the engine may constitutea risk of damage to property or injuryto persons if it is not used for itsintended purpose.

The engine should not be modified orconverted in an incorrect manner orthe safety instructions included in thismanual disregarded.

All information subject to change without notice. iDDC-SVC-MAN-0075 Copyright 2010 DETROIT DIESEL CORPORATION

NOTICE:Coolant must be inhibited withthe recommended SupplementalCoolant Additives (SCA) listed inthe How-To Procedures sectionof this engine Operator Manual.In addition, the engine can beequipped with a coolant filter as aninstalled option or as an after-saleitem. Failure to check andmaintain SCA levels at requiredconcentrations will result insevere damage (corrosion) tothe engine cooling system andrelated components.

WARRANTYThe applicable engine warranty iscontained in the booklet WarrantyInformation for Detroit DieselEngines, available from authorizedDetroit Diesel service outlets.

Keep this Operator Manualwith the engine installation atall times. It contains importantoperating, maintenance, and safetyinstructions.

Trademark Information

DDC, Detroit Diesel, DDEC,Optimized Idle, Diagnostic Link,BlueTec, POWER Trac, POWERCOOL, and POWER GUARDare registered trademarks of DetroitDiesel Corporation. All othertrademarks used are the property oftheir respective owners.

ii All information subject to change without notice.DDC-SVC-MAN-0075 Copyright 2010 DETROIT DIESEL CORPORATION

EPA10 DD PLATFORM OPERATORS MANUAL

TABLE OF CONTENTS

INTRODUCTION .................................................................................. 1NON-GENUINE AND REBUILT COMPONENT QUALITY ALERT .. 1PERSONNEL REQUIREMENTS ..................................................... 2ENGINE CONVERSIONS AND MODIFICATIONS .......................... 2

CAUTION SUMMARY .......................................................................... 3ENGINE OPERATION ..................................................................... 3PREVENTIVE MAINTENANCE ....................................................... 5COMPRESSED AIR ......................................................................... 7COOLING SYSTEM ......................................................................... 7ELECTRICAL SYSTEM ................................................................... 8AIR INTAKE SYSTEM ...................................................................... 8LUBRICATING OIL AND FILTERS .................................................. 9FUEL SYSTEM ................................................................................ 9AFTERTREATMENT SYSTEM ........................................................ 10

DD PLATFORM ENGINE COMPONENTS .......................................... 12DD13 ENGINE COMPONENTS ...................................................... 12DD15 ENGINE COMPONENTS ...................................................... 14DD16 ENGINE COMPONENTS ...................................................... 16

ENGINE MODEL AND SERIAL NUMBER DESIGNATION ................ 18ENGINE MODEL AND SERIAL NUMBER ....................................... 18ENGINE SERIAL NUMBER ............................................................. 18ENGINE CERTIFICATION LABEL ................................................... 18

INSTRUCTIONS FOR STARTING THE ENGINE ................................ 21FIRST TIME START RECOMMENDATIONS ................................... 21SYSTEM CHECKS .......................................................................... 21CHECKING THE COOLING SYSTEM ........................................ 21LUBRICATION SYSTEM CHECKS ............................................. 22PRE-LUBRICATING THE ENGINE ......................................... 22CHECKING THE OIL LEVEL .................................................. 22AFTER AN EXTENDED STORAGE ........................................ 23

FUEL SYSTEM CHECKS ............................................................ 24

All information subject to change without notice. iiiDDC-SVC-MAN-0075 Copyright 2010 DETROIT DIESEL CORPORATION

TABLE OF CONTENTS

ADDING FUEL ........................................................................ 24PRIMING THE FUEL SYSTEM ............................................... 25

CHECKING OTHER ENGINE AND ATS RELATED PARTS ....... 26FIRST TIME START OF THE ENGINE ............................................ 27STARTING AN ENGINE WITH AN ELECTRIC STARTER .......... 28

RUNNING THE ENGINE ................................................................. 29CHECKING THE OIL PRESSURE .............................................. 29WARMING UP THE ENGINE ...................................................... 29INSPECTION DURING IDLING ................................................... 29CHECKING THE TRANSMISSION ............................................. 29CHECKING FOR FLUID LEAKS ................................................. 29CHECKING THE CRANKCASE .................................................. 30CHECKING THE TURBOCHARGER .......................................... 30AXIAL POWER TURBINE ........................................................... 30AVOID UNNECESSARY IDLING ................................................. 30

STOPPING THE ENGINE ................................................................ 31EMERGENCY JUMP STARTING .................................................... 31ROUTINE ENGINE START .............................................................. 32STARTING THE ENGINE ROUTINELY ....................................... 33CHECKING THE COOLANT LEVEL (COLD CHECK) ................ 34CHECKING THE COOLANT LEVEL (HOT CHECK) .................. 34

MONITORING ENGINE OPERATION ............................................. 35MONITORING THE BATTERY CHARGING SYSTEM ................ 35MONITORING THE OIL PRESSURE .......................................... 35EXCESSIVE IDLING ................................................................... 36

CHANGING THE IDLE SPEED ....................................................... 36SHUTTING DOWN THE ENGINE AFTER HIGH LOADOPERATION .................................................................................... 36EMERGENCY RUNNING MODE .................................................... 36STOP ENGINE OVERRIDE OPTION .............................................. 37MOMENTARY OVERRIDE .......................................................... 37

COLD WEATHER OPERATION ...................................................... 37WINTER FRONTS ....................................................................... 38

ELECTRONIC ENGINE CONTROL SYSTEM (DDEC 10) .................. 39ELECTRONIC ENGINE CONTROL SYSTEM (DDEC 10)FEATURES ...................................................................................... 40CRUISE CONTROL ..................................................................... 40DATA RECORDING CAPABILITY ............................................... 42

iv All information subject to change without notice.DDC-SVC-MAN-0075 Copyright 2010 DETROIT DIESEL CORPORATION

EPA10 DD PLATFORM OPERATORS MANUAL

ENGINE BRAKE .......................................................................... 43ENGINE PROTECTION .............................................................. 44CALIFORNIA ENGINE IDLE LIMITING ....................................... 45IDLE SHUTDOWN TIMER .......................................................... 45

ELECTRONIC ENGINE CONTROL SYSTEM (DDEC 10)OPERATION .................................................................................... 46STOP ENGINE OVERRIDE SWITCH ......................................... 46IMMEDIATE SPEED REDUCTION ............................................. 47RED STOP LAMP ........................................................................ 47DIAGNOSTIC TOOL .................................................................... 47FLASHING MALFUNCTION CODES ...................................... 48READING FAULT CODES ...................................................... 49ACTIVE CODES ...................................................................... 4