Detroit Diesel EPA04 Series 40 Manual de usuario

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.

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

youtorelyonanauthorized Detroit

Diesel service outlet for all your

service needs from maintenance to

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.

All information subject to change without notice. (Rev. May 2004) i

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

recommendedSCAslistedinthis

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.

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.

Trademark Information

Detroit Diesel®, DDC®, DDEC®,

reliabilt®, POWER COOL®, POWER

Trac®andPOWER 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.

ii All information subject to change without notice. (Rev. May 2004)

SERIES 40 ENGINE OPERATOR'S GUIDE

TABLE OF CONTENTS

INTRODUCTION .................................................................................. 1

NON-GENUINE AND REBUILT COMPONENT QUALITY ALERT .. 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 ............................................................ 18

PREPARATIONS FOR FIRST TIME ENGINE START ..................... 18

COOLING SYSTEM CHECKS .................................................... 18

LUBRICATION SYSTEM CHECKS ............................................. 19

FUEL SYSTEM CHECKS ............................................................ 20

OTHER CHECKS ........................................................................ 21

STARTING THE ENGINE ................................................................ 22

ENGINE DIAGNOSTIC BUTTON ................................................ 23

INITIAL ENGINE START ............................................................. 23

EMERGENCY JUMP STARTING .................................................... 24

RUNNING THE ENGINE ................................................................. 26

OIL PRESSURE .......................................................................... 26

WARM-UP ................................................................................... 26

INSPECTION ............................................................................... 26

AVOID UNNECESSARY IDLING ................................................. 27

STOPPING THE ENGINE ................................................................ 27

NORMAL STOPPING .................................................................. 27

SHUTDOWN WARNING LIGHT AND BUZZER .............................. 27

ROAD OPERATION ......................................................................... 28

COLD WEATHER OPERATION ...................................................... 28

HOT WEATHER OPERATION ......................................................... 29

EXTENDED IDLING PERIODS ....................................................... 29

SERIES 40 ELECTRONIC CONTROL SYSTEM ................................ 31

All information subject to change without notice. (Rev. May 2004) iii

TABLEOFCONTENTS

SERIES 40 ENGINE SYSTEMS .......................................................... 36

FUEL SYSTEM ................................................................................ 36

LUBRICATION SYSTEM ................................................................. 36

COOLING SYSTEM ......................................................................... 36

ELECTRICAL SYSTEM ................................................................... 36

AIR INDUCTION SYSTEM .............................................................. 36

EXHAUST SYSTEM ........................................................................ 36

MAINTENANCE SCHEDULES ............................................................ 37

MAINTENANCE INTERVALS .......................................................... 37

LUBRICATION AND PREVENTIVE MAINTENANCE INTERVALS .... 53

ITEM 1 – LUBRICATING OIL ........................................................... 53

ITEM 2 – FUEL AND FUEL TANK ................................................... 55

ITEM 3 – FUEL LINES, FLEXIBLE HOSES ..................................... 56

PRE-START INSPECTION .......................................................... 56

HOSE SERVICE LIFE ................................................................. 57

ITEM 4 – COOLING SYSTEM ......................................................... 58

COOLANT LEVEL ....................................................................... 58

COOLANT INHIBITORS .............................................................. 58

COOLANT DRAIN INTERVAL ..................................................... 58

ITEM 5 – TURBOCHARGER, AIR-TO-AIR CHARGE COOLER ..... 60

ITEM 6 – BATTERY ......................................................................... 60

ITEM 7– DRIVE BELTS ................................................................... 61

ITEM 8 – AIR COMPRESSOR ......................................................... 62

ITEM 9 – AIR CLEANER .................................................................. 62

AIR CLEANER REPLACEMENT ................................................. 63

ITEM 10 – LUBRICATING OIL FILTERS ......................................... 63

ITEM 11 – FUEL FILTERS ............................................................... 64

FUEL FILTER AND STRAINER .................................................. 64

FUEL PRO® 382 FILTERS .......................................................... 66

ITEM 12 – WATER PUMP, COOLANT INHIBITOR ELEMENT ....... 66

WATER PUMP ............................................................................ 66

COOLANT INHIBITOR ELEMENT .............................................. 66

ITEM 13 – CRANKING MOTOR ...................................................... 66

ITEM 14 – AIR SYSTEM .................................................................. 67

ITEM 15 – EXHAUST SYSTEM ....................................................... 67

ITEM 16 – ENGINE (STEAM CLEAN) ............................................. 67

ITEM 17 – RADIATOR ..................................................................... 67

iv All information subject to change without notice. (Rev. May 2004)

SERIES 40 ENGINE OPERATOR'S GUIDE

ITEM 18 – OIL PRESSURE ............................................................. 68

ITEM 19 – BATTERY-CHARGING ALTERNATOR .......................... 68

BOSCH & DELCO-REMY SERVICE REQUIREMENTS ............. 68

ALTERNATOR PRECAUTIONS .................................................. 68

ITEM 20 – ENGINE AND TRANSMISSION MOUNTS .................... 69

ITEM 21 – CRANKCASE PRESSURE ............................................ 69

ITEM 22 – FAN HUB ........................................................................ 69

ITEM 23 – THERMOSTAT AND SEAL ............................................ 70

ITEM 24 – CRANKCASE BREATHER ............................................. 70

ITEM 25 – ENGINE TUNE-UP ......................................................... 70

ITEM 26 – IDLER PULLEY .............................................................. 71

ITEM 27 – VIBRATION DAMPER .................................................... 71

WELDING PRECAUTION ........................................................... 72

HOW-TO SECTION .............................................................................. 73

A. HOW TO SELECT LUBRICATING OIL ....................................... 73

LUBRICANT SELECTION IN NORTH AMERICA ....................... 73

LUBRICANT REQUIREMENTS .................................................. 73

THE USE OF SUPPLEMENTAL ADDITIVES .............................. 74

B. WHEN TO CHANGE OIL ............................................................. 75

OIL DRAIN INTERVALS .............................................................. 75

DISPOSING OF WASTE OIL ...................................................... 76

C. HOW TO REPLACE THE LUBE OIL FILTER ............................. 76

REPLACE SPIN-ON TYPE OIL FILTER ...................................... 77

D. HOW TO SELECT FUEL OIL ...................................................... 78

QUALITY ..................................................................................... 78

FUEL CONTAMINATION ............................................................. 79

PROHIBITED ADDITIVES ........................................................... 79

USED LUBRICATING OIL ....................................................... 79

GASOLINE ............................................................................. 79

E. HOW TO REPLACE THE FUEL FILTER ..................................... 80

REPLACE FUEL FILTER AND STRAINER ................................. 80

PRIME THE FUEL SYSTEM ....................................................... 82

REPLACE FUEL/WATER SEPARATOR ELEMENT .................... 84

REPLACE FUEL PRO FILTER ELEMENT .................................. 84

F. ENGINE OUT OF FUEL — HOW TO RESTART ......................... 87

G. HOW TO SELECT COOLANT .................................................... 89

DEFINITIONS .............................................................................. 89

APPROVED COOLANTS ............................................................ 89

All information subject to change without notice. (Rev. May 2004) v

TABLEOFCONTENTS

EG OR PG & WATER + SCA INHIBITOR ............................... 90

MIXING EG OR PG ANTIFREEZE AND WATER ................... 90

RECYCLED ANTIFREEZE .................................................... 92

EG OR PG & WATER + OAT INHIBITOR ............................... 93

WATER ONLY + SCA OR WATER ONLY + OAT INHIBITOR 93

WATER REQUIREMENTS ..................................................... 94

COOLANTS NOT RECOMMENDED .......................................... 95

ADDITIVES NOT RECOMMENDED ........................................... 95

MAINTENANCE ........................................................................... 96

COOLANT INHIBITOR TEST INTERVALS ............................ 96

SUPPLEMENTAL ADDITIVES ................................................ 96

MAINTENANCE INTERVALS .................................................. 97

SCA TEST PROCEDURES ......................................................... 99

NEED-RELEASE FILTERS (NON-OAT SYSTEMS) .................... 100

DROPOUT ................................................................................... 101

EXTENDER ADDITIVE FOR OAT COOLANT ............................ 101

OAT COOLANT DRAIN INTERVAL ........................................ 101

CHRONIC COOLANT SYSTEM PROBLEMS ............................. 102

MAINTENANCE PRODUCTS ..................................................... 102

POWER COOL SCAS ............................................................. 102

POWER COOL COOLANT FILTER ELEMENTS .................... 102

POWER COOL CLEANERS ................................................... 102

SUMMARY OF COOLANT RECOMMENDATIONS .................... 103

H. HOW TO REPLACE THE COOLANT FILTER ............................ 105

I. HOW TO DRAIN AND FLUSH THE COOLING SYSTEM ............ 106

J. WHEN TO SERVICE THE DRY TYPE AIR CLEANER ................ 108

BASIC TROUBLESHOOTING ............................................................. 109

ENGINE STORAGE ............................................................................. 116

PREPARING ENGINE FOR STORAGE .......................................... 116

TEMPORARY STORAGE (30 DAYS OR LESS) ......................... 116

EXTENDED STORAGE (MORE THAN 30 DAYS) ...................... 117

RESTORING ENGINE TO SERVICE .......................................... 120

SERVICE PUBLICATIONS .................................................................. 122

DETROIT DIESEL CUSTOMER ASSISTANCE .................................. 123

vi All information subject to change without notice. (Rev. May 2004)

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 ................................................................................ 142

FUEL AND LUBRICATING OIL FILTER REQUIREMENTS ............ 142

ENGINE OIL CAPACITY .................................................................. 142

POWER COOL ENGINE PRODUCTS ............................................ 143

FULLY FORMULATED IEG COOLANT ....................................... 143

LATIN AMERICAN COOLANT .................................................... 143

2000 SUPPLEMENTAL COOLANT ADDITIVE ........................... 144

3000 SUPPLEMENTAL COOLANT ADDITIVE ........................... 144

3000 SUPPLEMENTAL ADDITIVE COOLANT FILTERS ............ 145

SUPPLEMENTAL ADDITIVE NEED-RELEASE FILTERS .......... 145

PLUS EXTENDED LIFE OAT COOLANT .................................... 146

PLUS EXTENDER FOR POWER COOL PLUS OAT COOLANT 146

PLUS OAT INHIBITOR FOR WATER-ONLY SYSTEMS ............. 147

COOLING SYSTEM CLEANERS ................................................ 147

COOLANT TESTING AND ANALYSIS PRODUCTS ................... 148

All information subject to change without notice. (Rev. May 2004) vii

TABLEOFCONTENTS

viii All information subject to change without notice. (Rev. May 2004)

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