Detroit Diesel EPA07 MBE 4000 User manual

EPA07 MBE 4000 OPERATOR'S MANUAL
To the Operator
This guide contains instructions on
the safe operation and preventive
maintenance of your Detroit
Diesel EPA07 MBE 4000 engine.
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, etc. on
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
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.
The MBE 4000 engine is built in
accordance with sound technological
principles and based on state-of-the-art
technology.
Despite this, the engine may constitute
a risk of damage to property or injury
to persons if it is not used for its
intended purpose.
The engine should not be modified or
converted in an incorrect manner or
the safety instructions included in this
manual disregarded.
All information subject to change without notice. i
DDC-SVC-MAN-0041 Copyright © 2009 DETROIT DIESEL CORPORATION

NOTICE:
Coolant must be inhibited with the
recommended SCAs (supplemental
coolant additives) listed in the
How To section of this engine
operator's 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.
WARRANTY
The applicable engine warranty is
contained in the booklet “Warranty
Information for MBE 4000 Engines,”
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
DDC®, Detroit Diesel®, DDEC®,
Optimized Idle®, Diagnostic Link®,
reliabilt®, POWER Trac®, POWER
COOL®, and POWER GUARD®
are registered trademarks of Detroit
Diesel Corporation. Delco Remy®
is a registered trademark of Delco
Remy America, Inc. Bosch® is
a registered trademark of Robert
Bosch Company N.A. Fuel Pro®is
a registered trademarks of Davco
Manufacturing, L.L.C. Nexiq™ is
a trademark of Nexiq Technologies,
Inc. PowerBand® is a registered
trademark of Gates Rubber Company.
Tectyl® is a registered trademark of
Daubert Chemical Company, Inc.
Biobor® is a registered trademark of
United States Borax and Chemical
Corporation. DuPont® is a registered
trademark of E.I. DuPont de Nemours
and Company, Inc. All other
trademarks used are the property of
their respective owners.
ii All information subject to change without notice.
DDC-SVC-MAN-0041 Copyright © 2009 DETROIT DIESEL CORPORATION

EPA07 MBE 4000 OPERATOR'S MANUAL
TABLE OF CONTENTS
INTRODUCTION .................................................................................. 1
NON-GENUINE AND REBUILT COMPONENT QUALITY ALERT .. 1
PERSONNEL REQUIREMENTS ..................................................... 2
ENGINE CONVERSIONS AND MODIFICATIONS .......................... 2
CAUTION SUMMARY .......................................................................... 3
ENGINE OPERATION ..................................................................... 3
PREVENTIVE MAINTENANCE ....................................................... 4
ELECTRICAL SYSTEM ................................................................... 6
COOLING SYSTEM ......................................................................... 7
AIR INTAKE SYSTEM ...................................................................... 7
FUEL SYSTEM ................................................................................ 8
STARTING AIDS .............................................................................. 8
COMPRESSED AIR ......................................................................... 9
LUBRICATING OIL AND FILTERS .................................................. 9
AFTERTREATMENT SYSTEM ........................................................ 9
ENGINE IDENTIFICATION .................................................................. 11
ENGINE COMPONENTS ................................................................. 11
ENGINE MODEL AND SERIAL NUMBER DESIGNATION ............. 16
DETAILS ON THE PLATE .......................................................... 16
CERTIFICATION LABELS ............................................................... 17
OPERATING INSTRUCTIONS FOR STARTING THE ENGINE .......... 18
FIRST TIME START PREPARATION .............................................. 18
SYSTEM CHECKS .......................................................................... 18
COOLING SYSTEM CHECKS .................................................... 18
LUBRICATION SYSTEM CHECKS ............................................. 19
CHECKING THE OIL LEVEL .................................................. 19
EXTENDED STORAGE .......................................................... 20
FUEL SYSTEM CHECKS ............................................................ 20
ADDING FUEL ........................................................................ 22
PRIMING THE FUEL SYSTEM ............................................... 22
OTHER CHECKS ........................................................................ 22
STARTING THE ENGINE-FOR THE FIRST TIME ...................... 24
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TABLEOFCONTENTS
ELECTRIC STARTER ............................................................. 25
RUNNING THE ENGINE ................................................................. 26
OIL PRESSURE .......................................................................... 26
WARM-UP ................................................................................... 26
INSPECTION ............................................................................... 26
TRANSMISSION ..................................................................... 26
FLUID LEAKS ......................................................................... 26
CRANKCASE .......................................................................... 26
TURBOCHARGER .................................................................. 26
AVOID UNNECESSARY IDLING ................................................. 27
STOPPING THE ENGINE ................................................................ 27
EMERGENCY JUMP STARTING .................................................... 27
ROUTINE ENGINE START .............................................................. 28
STARTING THE ENGINE-ROUTINE ........................................... 29
CHECKING THE COOLANT LEVEL (COLD CHECK) ................ 30
CHECKING THE COOLANT LEVEL (HOT CHECK) .................. 30
MONITORING ENGINE OPERATION ............................................. 31
BATTERY CHARGE .................................................................... 31
OIL PRESSURE .......................................................................... 32
EXCESSIVE IDLING ................................................................... 32
CHANGING THE IDLE SPEED ....................................................... 32
SHUTTING DOWN THE ENGINE ................................................... 32
SHUTTING DOWN AFTER HIGH LOAD OPERATION ............... 33
EMERGENCY RUNNING MODE .................................................... 34
STOP ENGINE OVERRIDE OPTION .............................................. 34
COLD WEATHER OPERATION ...................................................... 35
WINTER FRONTS ....................................................................... 35
DDEC VI SYSTEM ............................................................................... 36
MOTOR CONTROL MODULE ......................................................... 36
COMMON POWERTRAIN CONTROLLER ..................................... 37
DDEC FEATURES ........................................................................... 38
CRUISE CONTROL ..................................................................... 38
DATA RECORDING CAPABILITY ............................................... 40
ENGINE BRAKES ....................................................................... 40
ENGINE PROTECTION .............................................................. 41
CALIFORNIA ENGINE IDLE LIMITING ....................................... 41
IDLE SHUTDOWN TIMER .......................................................... 42
DDEC VI OPERATION ..................................................................... 42
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EPA07 MBE 4000 OPERATOR'S MANUAL
STOP ENGINE OVERRIDE SWITCH ......................................... 43
IMMEDIATE SPEED REDUCTION ............................................. 44
RED STOP LAMP ........................................................................ 44
DIAGNOSTIC TOOL .................................................................... 44
FLASHING MALFUNCTION CODES ...................................... 44
DDEC VI ENGINE DRIVING TIPS ....................................................... 47
ACCELERATING THE VEHICLE ..................................................... 47
CRUISE CONTROL ......................................................................... 47
ENGINE BRAKES AND CRUISE CONTROL .................................. 49
SHIFTING ........................................................................................ 49
IDLING ............................................................................................. 50
ENGINE BRAKE SYSTEM .................................................................. 51
EXHAUST BRAKE/CONSTANT-THROTTLE VALVES .................... 51
ANTI-LOCK BRAKING SYSTEMS ................................................... 53
DRIVING ON FLAT, DRY PAVEMENT ............................................. 53
DESCENDING A LONG, STEEP GRADE ....................................... 54
DRIVING ON WET OR SLIPPERY PAVEMENT .............................. 55
ENGINE SYSTEMS ............................................................................. 57
FUEL SYSTEM ................................................................................ 57
LUBRICATION SYSTEM ................................................................. 57
AIR SYSTEM ................................................................................... 57
COOLING SYSTEM ......................................................................... 57
ELECTRICAL SYSTEM ................................................................... 58
EXHAUST SYSTEM ........................................................................ 58
EXHAUST GAS RECIRCULATION SYSTEM .................................. 58
AFTERTREATMENT SYSTEM ............................................................ 59
OPERATING REQUIREMENTS ...................................................... 60
PARKED REGENERATION PROCEDURE ..................................... 60
HAZARDOUS APPLICATIONS ................................................... 61
DPF STATIONARY REGEN ONLY = 0-DISABLED ................ 62
DPF STATIONARY REGEN ONLY = 1-ENABLED ................. 62
SERVICE RECORD ......................................................................... 62
MAINTENANCE ............................................................................... 62
DRIVER ACTIONS ............................................................................... 63
INSTRUMENT PANEL LAMPS ........................................................... 65
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TABLEOFCONTENTS
MAINTENANCE ................................................................................... 67
SCHEDULED INTERVALS .............................................................. 67
MAINTENANCE SCHEDULE TYPES ......................................... 67
SEVERE SERVICE ................................................................. 67
SHORT-HAUL ......................................................................... 68
LONG-HAUL ........................................................................... 68
MAINTENANCE INTERVALS .................................................. 68
SCHEDULE USE ......................................................................... 68
MAINTENANCE TABLES ................................................................ 69
PREVENTIVE MAINTENANCE INTERVALS .................................. 73
ITEM 1 – LUBRICATING OIL FILTER ......................................... 73
ITEM 2 – COOLING SYSTEM ..................................................... 74
ITEM 3 – VALVE LASH CHECKING AND ADJUSTMENT .......... 75
ITEM 4 – DRIVE BELTS .............................................................. 75
ITEM 5 – FUEL/WATER SEPARATOR ........................................ 76
ITEM 6 – FUEL FILTERS ............................................................ 76
ITEM 7– AIR SYSTEM ................................................................ 77
ITEM 8– EXHAUST SYSTEM ..................................................... 78
ITEM 9 – AIR COMPRESSOR .................................................... 78
ITEM 10 – AFTERTREATMENT SYSTEM (ATS) ........................ 78
ITEM 11 – VIBRATION DAMPER ................................................ 78
ITEM 12 – REPTO TORSIONAL DAMPER CHECKING ............. 79
REPTO TORSIONAL DAMPER INSPECTION ....................... 79
REPTO TORSIONAL DAMPER CLEANING ........................... 79
REQUIRED MAINTENANCE OPERATIONS ................................... 80
ENGINE INSPECTING ................................................................ 80
HOW-TO SECTION .............................................................................. 81
HOW TO SELECT LUBRICATING OIL ............................................ 81
LUBRICANT REQUIREMENTS .................................................. 81
COLD WEATHER STARTING ..................................................... 81
SYNTHETIC OILS ....................................................................... 82
THE USE OF SUPPLEMENTAL ADDITIVES .............................. 83
WHEN TO CHANGE OIL ............................................................. 83
DISPOSING OF WASTE OIL .................................................. 84
HOW TO REPLACE THE LUBE OIL AND FILTER ......................... 84
REPLACE LUBRICATING OIL AND FILTER ............................... 84
HOW TO SELECT DIESEL FUEL ................................................... 87
QUALITY ..................................................................................... 87
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EPA07 MBE 4000 OPERATOR'S MANUAL
FUEL CONTAMINATION ............................................................. 87
BIODIESEL ............................................................................. 88
PROHIBITED ADDITIVES ........................................................... 88
USED LUBRICATING OIL ....................................................... 88
FUEL ADDITIVES WITH SULFUR OR SULFATED ASH ........ 88
GASOLINE .............................................................................. 89
HOW TO REPLACE THE FUEL FILTERS ....................................... 89
REPLACE MAIN FUEL FILTER ELEMENT ................................. 89
FUEL/WATER SEPARATOR PREFILTER ELEMENT
CLEANING .................................................................................. 91
REPLACE DAVCO 382 FUEL PRO®FUEL/WATER SEPARATOR
ELEMENT .................................................................................... 92
REPLACE DAVCO 382/382E FUEL PRO® FUEL FILTER
ELEMENT .................................................................................... 93
ENGINE OUT OF FUEL — HOW TO RESTART ............................. 96
ENGINES WITH FUEL PRO FILTERS ........................................ 96
ENGINE MOUNTED FUEL FILTER ............................................ 96
HOW TO CLEAN THE ENGINE ...................................................... 97
HIGH-PRESSURE CLEANING EQUIPMENT ............................. 97
HOW TO CLEAN THE COOLING SYSTEM .................................... 97
DEGREASING ............................................................................. 98
HOW TO SELECT COOLANT ......................................................... 99
DEFINITIONS .............................................................................. 99
APPROVED COOLANTS ............................................................ 100
ETHYLENE GLYCOL / WATER + CONVENTIONAL
CORROSION INHIBITOR, PROPYLENE GLYCOL / WATER
+ CONVENTIONAL CORROSION INHIBITOR ....................... 101
MIXING EG OR PG ANTIFREEZE AND WATER ................... 102
RECYCLED ANTIFREEZE .................................................... 103
ETHYLENE GLYCOL / WATER + OAT INHIBITOR,
PROPYLENE GLYCOL / WATER + OAT INHIBITOR ............. 103
WATER ONLY + SCA, WATER ONLY + OAT INHIBITOR ..... 104
WATER REQUIREMENTS ...................................................... 105
COOLANTS NOT RECOMMENDED .......................................... 105
ALL ANTIFREEZES AND COOLANTS CONTAINING
PHOSPHATE ........................................................................... 105
AUTOMOTIVE TYPE COOLANTS .......................................... 106
METHYL ALCOHOL-BASED ANTIFREEZE ........................... 106
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TABLEOFCONTENTS
GLYCOL-BASED COOLANTS FORMULATED FOR HVAC ... 106
ADDITIVES NOT RECOMMENDED ........................................... 106
SOLUBLE OILS ....................................................................... 106
CHROMATES .......................................................................... 106
COOLANT INHIBITOR TEST INTERVALS ................................. 107
SUPPLEMENTAL COOLANT ADDITIVES FOR FULLY
FORMULATED COOLANT ...................................................... 107
MAINTENANCE INTERVALS .................................................. 108
SCA TEST PROCEDURES ......................................................... 110
NEED RELEASE COOLANT FILTERS (NON-OAT SYSTEMS) . 111
DROPOUT ................................................................................... 112
COOLANT EXTENDER INHIBITOR ADDITIVE FOR “OAT”
COOLANT ................................................................................... 112
OAT COOLANT DRAIN INTERVAL ........................................ 113
CHRONIC COOLANT SYSTEM PROBLEMS ............................. 113
DETROIT DIESEL COOLING SYSTEM MAINTENANCE
PRODUCTS ................................................................................. 113
POWER COOL SCAS ............................................................. 113
POWER COOL COOLANT FILTER ELEMENTS .................... 113
POWER COOL CLEANERS ................................................... 113
SUMMARY OF COOLANT RECOMMENDATIONS .................... 114
COOLANT LIFE OF GLYCOL COOLANT ............................... 115
COOLANT LIFE OF OAT COOLANT ...................................... 115
COOLANT LIFE OF OTHER COOLANTS .............................. 115
COOLANT FLUSHING AND CHANGING ................................... 116
COOLING SYSTEM INSPECTING ............................................. 117
TROUBLESHOOTING ......................................................................... 118
ENGINE STORAGE ............................................................................. 131
PREPARING ENGINE FOR STORAGE .......................................... 131
TEMPORARY STORAGE (30 DAYS OR LESS) ......................... 131
EXTENDED STORAGE (MORE THAN 30 DAYS) ...................... 132
PROCEDURE FOR RESTORING TO SERVICE AN ENGINE
THAT HAS BEEN IN EXTENDED STORAGE ............................. 135
CUSTOMER ASSISTANCE ................................................................. 137
ROAD SERVICE IN THE U.S. OR CANADA ................................... 139
WORKING WITH DETROIT DIESEL SERVICE OUTLETS ............ 139
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EPA07 MBE 4000 OPERATOR'S MANUAL
STEP ONE ................................................................................... 140
STEP TWO .................................................................................. 140
STEP THREE .............................................................................. 140
SPECIFICATIONS ................................................................................ 141
FUEL AND LUBRICATING OIL FILTERS ........................................ 141
OIL PAN CAPACITY .................................................................... 141
POWER COOL ENGINE PRODUCTS ............................................ 141
POWER COOL FULLY FORMULATED IEG COOLANT ............. 141
POWER COOL 2000 AND 3000 SUPPLEMENTAL COOLANT
ADDITIVE .................................................................................... 142
POWER COOL 3000 SUPPLEMENTAL ADDITIVE COOLANT
FILTERS ...................................................................................... 143
POWER COOL SUPPLEMENTAL ADDITIVE NEED RELEASE
COOLANT FILTERS .................................................................... 143
POWER COOL PLUS EXTENDED LIFE OAT COOLANT .......... 144
POWER COOL PLUS EXTENDER FOR USE WITH POWER
COOL PLUS OAT COOLANT ...................................................... 144
POWER COOL COOLING SYSTEM CLEANERS ...................... 144
POWER TRAC COOLANT TESTING AND ANALYSIS
PRODUCTS ................................................................................. 145
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TABLEOFCONTENTS
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EPA07 MBE 4000 OPERATOR'S MANUAL
INTRODUCTION
This guide is intended for use
by the operator of an MBE 4000
diesel engine used in the following
applications:
□On-Highway Vehicles
□Fire Truck or Crash/Rescue
Vehicles
Non-Genuine and Rebuilt
Component Quality Alert
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 must
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.
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.
Detroit Diesel cautions that the
indiscriminate rebuilding of precision
components, without the benefitof
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.
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 or CARB regulations.
All information subject to change without notice. 1
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INTRODUCTION
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
specifications may result in early wear
out or engine failure.
Personnel Requirements
Work on the engine should be carried
out only by skilled technicians who
have been instructed in the specific
skills necessary for the type of work
being performed.
Engine Conversions and
Modifications
The function and safety of the engine
could be affected if unauthorized
modifications are made to it. Detroit
Diesel will not accept responsibility
for any resulting damage.
Tampering with the fuel injection
system and engine electronics could
also affect the engine's power output or
exhaust emission levels. Compliance
with the manufacturer's settings
and with statutory environmental
protection regulations cannot then be
guaranteed.
2All information subject to change without notice.
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EPA07 MBE 4000 OPERATOR'S MANUAL
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..
Engine Operation
Observe the following cautions when
operating the engine.
FIRE
To avoid injury from fire, keep all
potential ignition sources away
from diesel fuel, including open
flames, sparks, and electrical
resistance heating elements. Do
not smoke when refueling.
HOT EXHAUST
During parked regeneration the
exhaust gases will be extremely
HOT and could cause a fire
if directed at combustible
materials. The vehicle must be
parked outside.
PERSONAL INJURY
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.
All information subject to change without notice. 3
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CAUTION SUMMARY
Preventive Maintenance
Observe the following cautions when
performing preventative maintenance.
HOT OIL
To avoid injury from hot oil, do
not operate the engine with the
rocker cover(s) removed.
PERSONAL INJURY
To avoid injury from slipping and
falling, immediately clean up any
spilled liquids.
USED ENGINE OIL
To avoid injury to skin from
contact with the contaminants in
used engine oil, wear protective
gloves and apron.
PERSONAL INJURY
To avoid injury when working
near or on an operating engine
equipped with an hydraulic
clutch fan, remove loose items
of clothing and jewelry. Tie back
or contain long hair that could
be caught in any moving part
causing injury. The hydraulic fan
may start without warning.
HOT COOLANT
To avoid scalding from the
expulsion of hot coolant, never
remove the cooling system
pressure cap while the engine is
at operating temperature. Wear
adequate protective clothing
(face shield, rubber gloves,
apron, and boots). Remove the
cap slowly to relieve pressure.
4All information subject to change without notice.
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EPA07 MBE 4000 OPERATOR'S MANUAL
PERSONAL INJURY
To avoid injury from the
projection of tools or other
objects that may fall on or behind
the vibration damper of an
engine, always check and remove
these items before starting the
engine.
PERSONAL INJURY
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.
PERSONAL INJURY
To avoid injury when using
caustic cleaning agents, follow
the chemical manufacturers
usage, disposal, and safety
instructions.
FIRE
To avoid injury from combustion
of heated lubricating-oil vapors,
stop the engine immediately if an
oilleakisdetected.
FIRE
To avoid injury from fire, do not
smoke or allow open flames when
workingonanoperatingengine.
FIRE
To avoid injury from fire from a
buildup of volatile vapors, keep
the engine area well ventilated
during operation.
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CAUTION SUMMARY
Electrical System
Observe the following cautions when
jump starting an engine, charging a
battery, or working with the vehicle
electrical system.
PERSONAL INJURY
To avoid injury from accidental
engine startup while servicing
the engine, disconnect/disable
the starting system.
Electrical Shock
To avoid injury from electrical
shock, use care when connecting
battery cables. The magnetic
switch studs are at battery
voltage.
Battery Explosion and Acid Burn
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. If you come in contact
with battery acid:
□Flush your skin with water.
□Applybakingsodaorlimeto
help neutralize the acid.
□Flush your eyes with water.
□Get medical attention
immediately.
ELECTRICAL SHOCK
To avoid injury from electrical
shock, do not touch battery
terminals, alternator terminals, or
wiring cables while the engine is
operating.
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EPA07 MBE 4000 OPERATOR'S MANUAL
Cooling System
Observe the following cautions when
servicing the cooling system.
HOT COOLANT
To avoid scalding from the
expulsion of hot coolant, never
remove the cooling system
pressure cap while the engine is
at operating temperature. Wear
adequate protective clothing
(face shield, rubber gloves,
apron, and boots). Remove the
cap slowly to relieve pressure.
PERSONAL INJURY
To avoid injury from slipping and
falling, immediately clean up any
spilled liquids.
Air Intake System
Observe the following cautions when
working on the air intake system.
PERSONAL INJURY
To avoid injury from hot surfaces,
wear protective gloves, or allow
engine to cool before removing
any component.
PERSONAL INJURY
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.
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CAUTION SUMMARY
Fuel System
Observe the following cautions when
fueling the vehicle or working with
the fuel system.
PERSONAL INJURY
To avoid injury from fuel spills,
do not overfill the fuel tank.
FIRE
To avoid injury from fire, contain
and eliminate leaks of flammable
fluids as they occur. Failure to
eliminate leaks could result in
fire.
FIRE
To avoid injury from fire, keep all
potential ignition sources away
from diesel fuel, including open
flames, sparks, and electrical
resistance heating elements. Do
not smoke when refueling.
FIRE
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
afuelleakisdetected.
□Do not smoke or allow open
flames 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.
Starting Aids
8All information subject to change without notice.
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