DETROIT GHG17 DD User manual

DDC-SVC-MAN-0192
GHG17 DD Medium Duty
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......................... 5
Forward............................................................................................................. 6
Introduction.................................................................................................... 6
Non-Genuine and Rebuilt Component Quality Alert.................................... 6
Personnel Requirements................................................................................ 6
Engine Conversions and Modifications......................................................... 7
Acronyms and Abbreviations........................................................................ 7
To the Operator................................................................................................. 9
To the Operator.............................................................................................. 9
Caution Summary........................................................................................... 11
Caution Summary........................................................................................ 11
Engine Indentification.................................................................................... 19
Engine Components - GHG17 Medium Duty Platform.............................. 19
Engine Model and Serial Number Designation........................................... 22
First Time Start Preparations....................................................................... 26
System Checks............................................................................................. 26
Starting the Engine...................................................................................... 29
Cold Weather Operation.............................................................................. 30
Detroit Diesel Electronic Control System Operation.................................. 32
Detroit Diesel Electronic Control System Operation.................................. 32
Detroit Diesel Electronic Control System Features..................................... 35
Changing the Idle Speed.............................................................................. 35
Stop Engine Override Option...................................................................... 35
Engine Brake............................................................................................... 35
Anti-Lock Braking Systems........................................................................ 36
Engine Protection......................................................................................... 36
California Engine Idle Limiting................................................................... 36
Idle Shutdown Timer................................................................................... 37
Engine Systems............................................................................................... 38
Engine Systems............................................................................................ 38
GHG17 Medium Duty Aftertreatment System............................................ 40
GHG17 Medium Duty Aftertreatment System............................................ 40
Diesel Exhaust Fluid Information................................................................. 41
Diesel Exhaust Fluid Information................................................................ 41
Aftertreatment Device Operating Requirements........................................ 42
Aftertreatment Device Operating Requirements......................................... 42
Diesel Exhaust Fluid Tank............................................................................. 43
Diesel Exhaust Fluid Tank........................................................................... 43
Aftertreatment Maintenance......................................................................... 44
Aftertreatment Maintenance........................................................................ 44
Performing a Parked Regeneration - GHG17............................................. 45
Performing a Parked Regeneration - GHG17.............................................. 45
Diesel Particulate Filter Service Record....................................................... 47
Table of Contents
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Service Record............................................................................................. 47
Instrument Panel Lamps................................................................................ 48
Instrument Panel Lamps.............................................................................. 48
Diesel Exhaust Fluid Level Warning Lamps................................................ 52
Diesel Exhaust Fluid Level Warning Lamps............................................... 52
Aftertreatment System Driver Notifications and Actions........................... 53
Aftertreatment System Driver Notifications and Actions............................ 53
Preventive Maintenance Intervals................................................................ 56
Preventive Maintenance Intervals................................................................ 56
GHG17 Medium Duty Preventive Maintenance Tables.............................. 60
DD5 Short Haul........................................................................................... 60
DD5 Long Haul........................................................................................... 61
DD5 Severe Service..................................................................................... 62
DD8 Short Haul........................................................................................... 63
DD8 Long Haul........................................................................................... 64
DD8 Severe Service..................................................................................... 65
Routine Preventive Maintenance.................................................................. 68
Routine Preventive Maintenance................................................................. 68
Monitoring the Lubricating Oil................................................................... 68
Monitoring the Lubricating Oil Filter.......................................................... 69
Monitoring the Cooling System................................................................... 70
Checking for Coolant Leaks........................................................................ 70
Inspection of the Radiator............................................................................ 71
Monitoring the Fuel Filters.......................................................................... 72
Adjusting the Valve Lash............................................................................. 72
Monitoring the Belt Tensioner..................................................................... 73
Poly-V-Belt Inspection................................................................................. 73
Inspection of the Air Intake System............................................................ 75
Monitoring the Air Cleaner.......................................................................... 75
Monitoring the Exhaust System................................................................... 76
Monitoring the Aftertreatment System........................................................ 76
Inspection of the Air Compressor................................................................ 76
Monitoring the Fuel and Fuel Tank............................................................. 76
Inspection of Hoses and Fittings for Fuel Leaks......................................... 77
Inspection of the Turbocharger and Charge Air Cooler.............................. 78
Inspection of the Battery.............................................................................. 78
Steam Cleaning the Engine.......................................................................... 79
Inspection of the Battery-Charging Alternator............................................ 80
Checking the Vibration Damper.................................................................. 80
How to Procedures.......................................................................................... 82
How to Select Lubricating Oil..................................................................... 82
How to Replace the Lubricating Oil and Oil Filter..................................... 83
How to Select Diesel Fuel........................................................................... 85
How to Replace the Fuel Filters.................................................................. 88
Engine Out of Fuel – How to Restart.......................................................... 92
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How to Clean an Engine.............................................................................. 95
Cleaning/Flushing the Cooling System....................................................... 95
Coolant Selections and Maintenance........................................................... 97
Coolant Fill Options.................................................................................... 98
Coolants for Detroit™ Engines................................................................... 98
Maintenance............................................................................................... 100
Appendix A - Definitions.......................................................................... 107
Appendix B - General Coolant Information.............................................. 108
Appendix C - Detroit™ Cooling System Maintenance Products.............. 110
Customer Assistance..................................................................................... 113
Availability of Detroit™ Service Outlets................................................... 113
Detroit Genuine Coolant Engine Products................................................. 114
Detroit Genuine Coolant Engine Products................................................. 114
Engine Oil Capacities................................................................................... 116
Engine Oil Capacities................................................................................ 116
Table of Contents
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California Proposition 65 Warning and Engine Idle
Notice
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Forward
Introduction
This manual is intended for use by the operator of a Detroit™ engine used in On-
Highway Vehicle applications.
Non-Genuine and Rebuilt Component Quality Alert
Electronic engine controls have aided engine manufacturers to meet the stringent
emission requirements of the U.S. Environmental Protection Agency (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 engine
performance and durability and to ensure engine coverage under the manufacturer's
warranty. Many of these maintenance procedures ensure that the engine complies
with applicable emissions standards. Proper maintenance procedures, using specific
components engineered to comply with emissions regulations, may be performed
by an authorized Detroit™ distributor or dealer, an independent outlet or the
operator / 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 compliance with U.S. EPA or CARB
emissions standards.
There are several other components in an engine, such as turbocharger, camshaft,
piston, fuel doser valve, fuel doser block, diesel particulate filter (DPF) and diesel
exhaust fluid pump that 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.
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.
Forward
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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.
Acronyms and Abbreviations
Table 1.
Acronyms and Abbreviations
ACM Aftertreatment Control
Module
kW Kilowatt
API American Petroleum
Institute
LLiter
ATD Aftertreatment Device lb Pound
ATF Automatic Transmission
Fluid
mMeter
ATS Aftertreatment System MCM Motor Control Module
CAC Charge Air Cooler MIL Malfunction Indicator
Lamp
CAN Controller Area
Network
mpg Miles per Gallon
CARB California Air
Resources Board
mph Miles per Hour
CEL Check Engine Light NHTSA National Highway
Traffic Safety
Administration
CPC Common Powertrain
Controller
NOAT Nitrited Organic Acid
Technology
DDC Detroit Diesel
Corporation
NOx Nitrogen Oxide
DDEC Detroit Diesel
Electronic Controls
OAT Organic Acid
Technology
DEF Diesel Exhaust Fluid OBD On Board Diagnostic
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Acronyms and Abbreviations
DOC Diesel Oxidation
Catalyst
OEM Original Equipment
Manufacturer
DPF Diesel Particulate Filter oz Ounce
DTC Diagnostic Trouble
Code
psi Pounds per Square
Inch
ECM Electronic Control
Module
PTO Power Takeoff
ECT Engine Coolant
Temperature
qt Quart
EGR Exhaust Gas
Recirculation
regen Regeneration
ELC Extended Life Coolant rpm Revolutions per Minute
EPA Environmental
Protection Agency
SAE Society of Automotive
Engineers
FMCSA Federal Motor Carrier
Safety Administration
SCA Supplemental Coolant
Additive
GAWR Gross Axle Weight
Rating
SCR Selective Catalyst
Reduction
GHG Greenhouse Gas SEL Stop Engine Light
GHG14 Greenhouse Gas and
Fuel Efficiency
Regulations
SEO Stop Engine Override
GVWR Gross Vehicle Weight
Rating
S/N Serial Number
HEST High Exhaust System
Temperature
SRS Synchronous
Reference Sensor
in. Inch SRT Standard Repair Time
inH2O Inches of Water TCM Transmission Control
Module
inHg Inches of Mercury TDC Top Dead Center
ISO International
Organization for
Standardization
TPS Throttle Position
Sensor
kKilo (1000) TRS Timing Reference
Sensor
kg Kilogram VIN Vehicle Identification
Number
km Kilometer VSG Variable Speed
Governor
km/h Kilometers per Hour VSS Variable Speed Sensor
kPa Kilopascal
Forward
8 All information subject to change without notice.
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To the Operator
To the Operator
This manual contains instructions on the safe operation and preventive maintenance
of your Detroit™ engine used in vehicle applications. Maintenance instructions
cover routine engine services such as lubricating oil and filter changes in enough
detail to permit self-servicing, if desired.
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. You
are urged, as the operator of this diesel engine, to keep fingers and clothing away
from the revolving belts, drive shafts, and pulleys on the engine installation.
Throughout this manual CAUTIONS and WARNINGS 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™ service
outlet for all your 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 or the
safety instructions included in this manual disregarded.
Keep this Operator Manual with the engine installation at all times. It contains
important operating, maintenance, and safety instructions.
NOTICE: Failure to maintain the cooling system at required
concentrations will result in severe damage to the engine cooling
system and related components. Refer to the "Coolant Selections and
Maintenance" section.
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Table 2.
WARRANTY
The applicable engine warranty is contained in the booklet “Warranty Information for
Detroit™ Engines,” available from authorized Detroit™ service outlets.
Trademark Information
DDC®, Detroit™, DDEC®, Optimized Idle®, Diagnostic Link®, BlueTec®,
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.
To the Operator
10 All information subject to change without notice.
Copyright © 2022 DETROIT DIESEL CORPORATION DDC-SVC-MAN-0192

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
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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
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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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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
18 All information subject to change without notice.
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Engine Indentification
Engine Components - GHG17 Medium Duty Platform
GHG17 Medium Duty Platform engine components are shown below:
DD5 Engine Components
For general views of the Detroit™ DD5 engine and major components, see the
following:
Table 3.
DD5 Left Side View
1. Water Pump
2. Coolant Thermostat
3. Fuel Rail
4. Hydrocarbon Doser Block
5. High Pressure Fuel Pump
6. Single-Stage Air Compressor
7. Motor Control Module (MCM)
8. Fuel Filter Module
9. Exhaust Gas Recirculation (EGR) Valve
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Table 4.
DD5 Right Side View
1. Exhaust Manifold
2. Camshaft Phase Actuator
3. Exhaust Gas Recirculation (EGR) Cooler
4. Coolant Outlet Elbow
5. Charge Air Cooler (CAC) Inlet Pipe
6. Coolant Inlet Elbow
7. Oil/Coolant Module
8. Turbocharger
9. Wastegate Actuator Fuel Doser Injector
Valve
DD8 Engine Components
For general views of the Detroit™ DD8 engine and major components, see the
following:
Engine Indentification
20 All information subject to change without notice.
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