DETROIT Gen 5 DD Series User manual

DDC-SVC-MAN-0217
Gen 5 DD Platform 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.

Table of Contents
California Proposition 65 Warning and Engine Idle Notice......................... 4
Forward............................................................................................................. 5
Introduction.................................................................................................... 5
Non-Genuine and Rebuilt Component Quality Alert.................................... 5
Personnel Requirements................................................................................ 5
Engine Conversions and Modifications......................................................... 6
To the Operator................................................................................................. 7
To The Operator............................................................................................. 7
Warranty......................................................................................................... 7
Trademark Information.................................................................................. 7
Caution Summary............................................................................................. 9
Caution Summary.......................................................................................... 9
Engine Components........................................................................................ 17
Engine Components..................................................................................... 17
DD13 Engine Components.......................................................................... 17
DD15 Engine Components.......................................................................... 18
Engine Model and Serial Number Designation........................................... 19
Engine Operation............................................................................................ 22
Engine Operation......................................................................................... 22
First Time Engine Operation....................................................................... 22
Engine Start and Routine Operation............................................................ 25
Shifting a Manual Transmission.................................................................. 30
Vehicle Emergency Operation..................................................................... 30
Detroit Diesel Electronic Controls System................................................... 32
Detroit Diesel Electronic Controls System.................................................. 32
Detroit Diesel Electronic Control System Operation.................................. 32
Detroit Diesel Electronic Control System Features..................................... 37
Engine Systems............................................................................................... 40
Engine Systems............................................................................................ 40
Aftertreatment System................................................................................. 40
Air System................................................................................................... 43
Cooling System............................................................................................ 43
Electrical System......................................................................................... 44
Engine Brake System................................................................................... 44
Exhaust System and Exhaust Gas Recirculation System............................. 44
Fuel System................................................................................................. 45
Lubrication System...................................................................................... 45
Instrument Panel Indicators.......................................................................... 47
Instrument Panel Indicators......................................................................... 47
Preventive Maintenance Intervals................................................................ 48
Preventive Maintenance Intervals................................................................ 48
Scheduled Maintenance Intervals................................................................ 48
Preventive Maintenance Tables................................................................... 51
Table of Contents
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Routine Preventive Maintenance.................................................................. 55
Routine Preventive Maintenance................................................................. 55
Inspection of the Aftertreatment System..................................................... 55
Inspection of the Air Compressor................................................................ 56
Inspection of the Air Intake System............................................................ 56
Inspection of the Turbocharger and Charge Air Cooler.............................. 56
Inspection of the Batteries........................................................................... 57
Inspection of the Belts................................................................................. 58
Inspection of the Cooling System................................................................ 60
Inspection of the Exhaust System................................................................ 61
Inspection of the Fuel System...................................................................... 61
Inspection of Hoses and Fittings for Leaks................................................. 62
Inspection of the Lubricating System.......................................................... 63
How to Procedures.......................................................................................... 65
How To Procedures...................................................................................... 65
How to Perform a Parked Regeneration...................................................... 65
How to Select Diesel Exhaust Fluid............................................................ 67
How to Check the Coolant Level................................................................. 67
How to Select Coolants............................................................................... 68
How to Select Fuel....................................................................................... 71
How to Drain the Fuel Coalescer................................................................. 72
How to Restart an Engine Out of Fuel......................................................... 73
How to Check the Lubricating Oil Level..................................................... 75
How to Select Lubricating Oil..................................................................... 76
How to Clean an Engine.............................................................................. 77
How to Operate the Cruise Control and Fast Idle........................................ 78
How to Operate the Engine Brakes.............................................................. 79
Customer Assistance....................................................................................... 84
Availability of Detroit™ Service Outlets.................................................... 84
Gen 5 DD Platform Operators Manual
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California Proposition 65 Warning and Engine Idle
Notice
California Proposition 65 Warning and Engine Idle Notice
4 All information subject to change without notice.
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Forward
Introduction
This manual is intended to be used by the operator of Detroit™ Gen 5 Heavy Duty
engines. The manual covers basic information on engine components, engine
operation, Detroit Diesel Electronic Controls (DDEC®) system, engine systems,
aftertreatment system, instrument panel indicators, preventative maintenance, how
to procedures, and engine storage.
Non-Genuine and Rebuilt Component Quality Alert
Electronic engine controls have been instrumental in aiding engine manufacturers
meet federal emission requirements and 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™ service outlet,
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™ cautions that the indiscriminate rebuilding of precision components,
without the benefit of 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 emission standards compliance.
There are several other components in an engine, including but not limited to the
turbocharger, fuel injectors, camshaft s, pistons, diesel exhaust fluid pump, 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 thus ensuring that the engine remains in compliance
with emissions standards. The use of inadequately engineered, manufactured or
tested components in the repair or rebuild of the engine may be in violation of
federal regulations.
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™ specifications may result in premature
wear or engine failure.
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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™ will not accept responsibility for any
resulting damage.
Tampering with the fuel injection system and engine electronics could also affect
engine power output or exhaust emission levels. Compliance with the
manufacturer's settings and with statutory environmental protection regulations
cannot then be guaranteed.
Forward
6 All information subject to change without notice.
Copyright © 2020 DETROIT DIESEL CORPORATION DDC-SVC-MAN-0217

To the Operator
To The Operator
This manual contains instructions on the safe operation and preventive maintenance
of Detroit™ Gen 5 Heavy Duty engines. Maintenance instructions cover routine
engine services in enough detail to permit self-servicing, if desired. Keep this
manual at all times. It contains important operating, maintenance, and safety
instructions.
The operator should become familiar with the contents of this manual before
operating the engine or carrying out maintenance procedures.
Power-driven equipment is only as safe as the person operating the controls. The
operator is urged to keep fingers and clothing away from the revolving belts, drive
shafts, pulleys, and other moving parts of the engine.
Throughout this manual CAUTIONS and WARNINGSregarding personal safety
and NOTES regarding engine performance or service life will appear. To avoid
personal injury and ensure long engine service life, always follow these
instructions.
Whenever possible, it will benefit to rely on an authorized Detroit™ service outlet
for any service needs from maintenance to major parts replacement. Authorized
service outlets worldwide stock factory-original parts.
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™
service outlet for information on the latest revision. The right is reserved to make
changes at any time without obligation.
Detroit™ engines are 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, nor should
the safety instructions included in this manual be disregarded.
Warranty
The applicable engine warranty information is contained in the booklet "Warranty
Information for Detroit™ Engines," available from authorized Detroit™ service
outlets.
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Trademark Information
DDC ®, Detroit™, DDEC ®, Optimized Idle®, DiagnosticLink ®, BlueTec ®,
POWER Trac ®, POWER COOL ®, and POWER COOL PLUS ® are registered
trademarks of Detroit Diesel Corporation ® . All other trademarks used are the
property of their respective owners.
To the Operator
8 All information subject to change without notice.
Copyright © 2020 DETROIT DIESEL CORPORATION DDC-SVC-MAN-0217

Caution Summary
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.
WARNING: PERSONAL INJURY
To avoid injury from loss of vehicle/vessel control, the operator of
a DDEC equipped engine must not use or read any diagnostic
tool while the vehicle/vessel is moving.
WARNING: 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.
CAUTION: LOSS OF VEHICLE CONTROL
To avoid injury from the loss of vehicle control, do not use cruise
control under these conditions:
• When it is not possible to keep the vehicle at a constant speed
(on winding roads, in heavy traffic, in traffic that varies in
speed, etc.).
• On slippery roads (wet pavement, ice-or snow-covered roads,
loose gravel, etc.).
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WARNING: 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.
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.
CAUTION: LOSS OF VEHICLE CONTROL
To avoid injury from loss of vehicle control, do not activate the
Engine Brake system under the following conditions:
• On wet or slippery pavement, unless the vehicle is equipped
with ABS (anti-lock braking system) and you have had prior
experience driving under these conditions.
• When driving without a trailer (bobtailing) or pulling an empty
trailer.
• If the tractor drive wheels begin to lock or there is fishtail
motion after the Engine Brake is activated, deactivate the brake
system immediately if this occurs.
WARNING: BODILY INJURY
To avoid injury from an explosion, do not use ether or starting
fluid on engines equipped with a manifold (grid) heater.
Preventive Maintenance
Observe the following cautions when performing preventive maintenance.
WARNING: PERSONAL INJURY
To avoid injury when working near or on an operating engine,
remove loose items of clothing and jewelry. Tie back or contain
long hair that could be caught in any moving part causing injury.
Caution Summary
10 All information subject to change without notice.
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WARNING: PERSONAL INJURY
To avoid injury when working on or near an operating engine,
wear protective clothing, eye protection, and hearing protection.
WARNING: HOT OIL
To avoid injury from hot oil, do not operate the engine with the
rocker cover(s) removed.
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.
CAUTION: USED ENGINE OIL
To avoid injury to skin from contact with the contaminants in used
engine oil, wear protective gloves and apron.
WARNING: PERSONAL INJURY
To avoid injury when using caustic cleaning agents, follow the
chemical manufacturers usage, disposal, and safety instructions.
WARNING: PERSONAL INJURY
To avoid injury from hot surfaces, wear protective gloves, or allow
engine to cool before removing any component.
WARNING: PERSONAL INJURY
To avoid injury, use care when working around moving belts and
rotating parts on the engine.
WARNING: FIRE
To avoid injury from combustion of heated lubricating-oil vapors,
stop the engine immediately if an oil leak is detected.
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WARNING: 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.
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.
WARNING: FIRE
To avoid injury from fire, do not smoke or allow open flames when
working on an operating engine.
WARNING: FIRE
To avoid injury from fire from a buildup of volatile vapors, keep
the engine area well ventilated during operation.
WARNING: PERSONAL INJURY
To avoid injury from rotating belts and fans, do not remove and
discard safety guards.
WARNING: PERSONAL INJURY
To avoid injury from slipping and falling, immediately clean up any
spilled liquids.
Compressed Air
Observe the following cautions when using compressed air.
WARNING: EYE INJURY
To avoid injury from flying debris when using compressed air,
wear adequate eye protection (face shield or safety goggles) and
do not exceed 276 kPa (40 psi) air pressure.
Caution Summary
12 All information subject to change without notice.
Copyright © 2020 DETROIT DIESEL CORPORATION DDC-SVC-MAN-0217

Cooling System
Observe the following cautions when servicing the cooling system.
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.
WARNING: PERSONAL INJURY
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.
WARNING: ELECTRICAL SHOCK
To avoid injury from electrical shock, do not touch battery
terminals, alternator terminals, or wiring cables while the engine
is operating.
WARNING: 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.
• Apply baking soda or lime to help neutralize the acid.
• Flush your eyes with water.
• Get medical attention immediately.
WARNING: PERSONAL INJURY
To avoid injury from accidental engine startup while servicing the
engine, disconnect/disable the starting system.
Air Intake System
Observe the following cautions when working on the air intake system.
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WARNING: PERSONAL INJURY
To avoid injury from hot surfaces, wear protective gloves, or allow
engine to cool before removing any component.
WARNING: 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.
Lubricating Oil and Filters
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.
WARNING: FIRE
To avoid injury from combustion of heated lubricating-oil vapors,
stop the engine immediately if an oil leak is detected.
WARNING: FIRE
To avoid injury from fire, do not smoke or allow open flames when
working on an operating engine.
WARNING: FIRE
To avoid injury from fire from a buildup of volatile vapors, keep
the engine area well ventilated during operation.
Fuel System
Observe the following cautions when fueling the vehicle or working with the fuel
system.
WARNING: 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.
Caution Summary
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Copyright © 2020 DETROIT DIESEL CORPORATION DDC-SVC-MAN-0217

WARNING: PERSONAL INJURY
To prevent the escape of high pressure fuel that can penetrate
skin, ensure the engine has been shut down for a minimum of 10
minutes before servicing any component within the high pressure
circuit. 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.
WARNING: 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 a fuel leak is detected.
• 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.
Aftertreatment System
Observe the following cautions when servicing the Aftertreatment System (ATS).
Be advised that these two labels are attached to the Aftertreatment Device (ATD).
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Caution Summary
16 All information subject to change without notice.
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Engine Components
Engine Components
The following sections will be covered in this chapter:
• DD13 Engine Components
• DD15 Engine Components
• Engine Model and Serial Number
DD13 Engine Components
Detroit™ Gen 5 Heavy Duty DD13 major engine components are shown below:
1. Water Pump
2. Oil Coolant Module
3. Oil Filter
4. High Pressure Fuel Rail
5. Air Intake Manifold
6. Hydrocarbon Fuel Doser Block
7. High Pressure Fuel Pump
8. Air Compressor
9. Fuel Filter Module
10. Motor Control Module (MCM)
11. Coolant Thermostat
12. Engine Serial Number Location
Figure 1. DD13 Left Side View
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1. Crankcase Breather
2. Turbocharger
3. Fuel Doser Injector Valve
4. Exhaust Gas Recirculation (EGR)
Valve Actuator
5. EGR Cooler
6. Exhaust Manifold
Figure 2. DD13 Right Side View
DD15 Engine Components
Detroit™ Gen 5 Heavy Duty DD15 major engine components are shown below:
Engine Components
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Copyright © 2020 DETROIT DIESEL CORPORATION DDC-SVC-MAN-0217

1. Water Pump
2. Oil Coolant Module
3. Oil Filter
4. High Pressure Fuel Rail
5. Air Intake Manifold
6. Hydrocarbon Fuel Doser Block
7. High Pressure Fuel Pump
8. Air Compressor
9. Fuel Filter Module
10. Motor Control Module (MCM)
11. Coolant Thermostat
12. Engine Serial Number Location
Figure 3. DD15 Left Side View
1. Crankcase Breather
2. Turbocharger
3. Fuel Doser Injector Valve
4. Exhaust Gas Recirculation (EGR)
Valve Actuator
5. EGR Cooler
6. Exhaust Manifold
Figure 4. DD15 Right Side View
Engine Model and Serial Number Designation
The section covers engine model number, serial number and the locations of this
information on the engine.
Engine Model and Serial Number
The fourteen-digit engine model and manufacturing serial number is etched on a
pad located on the left front of the engine cylinder block, above the date and time
of manufacture. Using 472912S0608850 as an example:
• 472 = engine type (DD15)
• 912 = model
• S = assembly plant (Detroit™)
• 0608850 = serial number
Engine Model Breakdown
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Table 1.
HEAVY DUTY MODEL BREAKDOWN
DESCRIPTION ENGINE MODEL DISPLACE-MENT
DD15 472912 14.8 L (DD15)
DD13 471952 12.8 L (DD13)
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 (see graphic below).
Figure 5. Motor Control Module Label
Engine Certification Label
An engine certification label is attached to the engine rocker cover. This label
certifies the engine conforms to federal and state emissions regulations for its
application. It gives the operating conditions under which certification was made
(see graphic below).
Engine Components
20 All information subject to change without notice.
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