PREVOST H3-45 Owner's manual

Type
Owner's manual

This manual is also suitable for

00-1
SECTION 00:
GENERAL INFORMATION
CONTENTS
1. FOREWORD.................................................................................................................................00-2
2. UPDATES, SERVICE BULLETINS AND SERVICE INFORMATION DOCUMENT.........................00-2
3. SCHEMATICS...............................................................................................................................00-2
4. SAFETY NOTICE..........................................................................................................................00-2
5. DATA PLATES CERTIFICATIONS................................................................................................00-3
5.1 Engine...........................................................................................................................00-3
5.2 Transmission ................................................................................................................00-3
5.3 Drive Axle .....................................................................................................................00-3
5.4 Front Axle .....................................................................................................................00-3
5.5 Power Steering Pump...................................................................................................00-3
5.6 Coach Final Record......................................................................................................00-4
5.7 Safety Certification........................................................................................................00-4
5.8 Dot Certification Label ..................................................................................................00-4
5.9 EPA Engine Label.........................................................................................................00-4
5.10 Fuel Tank Label............................................................................................................00-4
5.11 Vehicle Identification Number (VIN)..............................................................................00-4
6. FASTENER STRENGTH IDENTIFICATION..................................................................................00-6
6.1 Prevailing Torque Fasteners...........................................................................................00-7
6.2 Recommendations For Reuse ........................................................................................00-7
6.3 Six Lobed Socket Head..................................................................................................00-7
7. MAINTENANCE MANUAL - TABLE OF CONTENTS...................................................................00-10
LIST OF ILLUSTRATIONS
FIG. 1: SERIAL AND MODEL NUMBERS ........................................................................................00-3
FIG. 2: LABEL..................................................................................................................................00-3
FIG. 3: TYPICAL SERIAL AND MODEL NUMBERS.........................................................................00-3
FIG. 4: TYPICAL SERIAL AND MODEL NUMBERS.........................................................................00-3
FIG. 5: POWER STEERING PUMP NAMEPLATE............................................................................00-3
FIG. 6. DOT CERTIFICATION LABEL..............................................................................................00-4
FIG. 7: ENGINE COMPARTMENT ...................................................................................................00-4
FIG. 8: FUEL TANK ACCESS PANEL..............................................................................................00-4
FIG. 9: VEHICLE I.D. .......................................................................................................................00-5
FIG. 10: VEHICLE IDENTIFICATION NUMBER.................................................................................00-5
FIG. 11: THREAD NOTATION............................................................................................................00-6
FIG. 12: BOLT STRENGTH MARKINGS............................................................................................00-6
FIG. 13: PREVAILING TORQUE FASTENERS..................................................................................00-7
FIG. 14: TORQUE CHART.................................................................................................................00-7
FIG. 15: METRIC - ENGLISH CONVERSION TABLE.........................................................................00-8
FIG. 16: CONVERSION CHART - CUSTOMARY AND METRIC.........................................................00-9
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Section 00: GENERAL INFORMATION
00-2
1. FOREWORD
This manual includes procedures for diagnosis, service, maintenance and repair for components of
the coach model listed on the front cover page.
This manual should be kept in a handy place for ready reference by the technician. If properly used, it
will meet the needs of the technician and vehicle owner.
Information provided in Section 1 through 24 pertains to standard equipment items, systems and com-
ponents and the most commonly used optional equipment and special equipment offered on the
coach models covered by this manual.
At the beginning of each section : a Table of Contents and a list of illustrations give the page number
on which each subject begins and where each figure is located.
Coach operating information is provided in a separate Operator's Manual. Audio/Video system opera-
tor instructions are also included in a separate manual.
More specific information on engine and transmission operating, maintenance, and overhaul informa-
tion is contained in the applicable engine or transmission service manual published by the engine or
transmission manufacturer. Engine and transmission parts information is contained in the applicable
engine or transmission parts catalog published by the engine or transmission manufacturer.
All information, illustrations and specifications contained in this manual are based on the latest prod-
uct information available at the time of publication approval. The right is reserved to make product
changes at any time without notice.
Note: Typical illustrations may be used, therefore minor illustration difference may exist when com-
pared to actual parts or other publications.
2. UPDATES, SERVICE BULLETINS AND SERVICE INFORMATION
DOCUMENTS
They are issued, when required, to supplement or supersede information in this manual. Update sheet
and bulletins should be noted and filed at the end of the proper section for future use.
3. SCHEMATICS
Vehicle AIR SCHEMATICS are provided at the end of Section 12, "Brake". SUSPENSION AIR SCHE-
MATICS are provided at the end of Section 16, "Suspension". Moreover, ELECTRICAL SCHEMATICS
are provided in the technical publication box. Refer to those schematics for detailed circuit informa-
tion or during diagnosis.
4. SAFETY NOTICE
This maintenance manual has been prepared in order to assist skilled mechanics in the efficient repair
and maintenance of PRÉVOST vehicles.
This manual covers only the procedures as of the manufacturing date.
Safety features may be impaired if other than genuine PRÉVOST parts are installed.
Torque wrench tightening specifications must be strictly observed. Locking devices must be installed
or replaced by new ones, where specified. If the efficiency of a locking device is impaired, It must be
replaced.
This manual emphasizes particular information outlined by the wording and symbols:
Warning: Identifies an instruction which, if not followed, could cause personal injuries.
Caution: Outlined an instruction which, if not followed, could severely damage vehicle components.
Note: Indicates supplementary information needed to fully complete an instruction.Although, the mere
reading of such information does not eliminate the hazard, your understanding of the information will
promote its correct use.
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Section 00: GENERAL INFORMATION
00-3
5. DATA PLATES
CERTIFICATIONS
Delay and confusion can be avoided by placing the
complete vehicle identification number of the coach
and the serial numbers of the engine on parts orders
and correspondence. Also, the transmission, axles,
power steering pump chassis and other major
components are identified by serial numbers.
5.1 Engine
The engine serial and model number are stamped
on the cylinder block (as viewed from the flywheel
end) on the left side just below the fire deck and
above the cast-in Detroit Diesel logo (Fig. 1).
FIGURE 1: SERIAL AND MODEL NUMBERS OEH3B802
In addition, option plates made of laminated
paper are located on the rocker cover (starter
side). The engine serial and model number
and a list of the optional engine equipment is
written on the option plate. Refer to this
information when ordering replacement parts
(Fig. 2).
FIGURE 2: LABEL
5.2 Transmission
The transmission identification plate is located on
the right-rear side of the transmission.The
identification plate shows the transmission serial
number, part number (assembly number), and
model number. Use all three numbers when ordering
parts.
5.3 Drive Axle
OEH3B812
FIGURE 3: TYPICAL SERIAL AND MODEL NUMBERS
5.4 Front Axle
OEH3B814
FIGURE 4: TYPICAL SERIAL AND MODEL NUMBERS
5.5 Power Steering Pump
Power steering pump serial number is located on a
tag on the pump (Fig. 5). The pump is mounted on
the engine beside the crankshaft pulley.
00001
FIGURE 5: POWER STEERING PUMP NAMEPLATE
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Section 00: GENERAL INFORMATION
00-4
5.6 Coach Final Record
The Coach Final Record is a record of all data
pertaining to the assembly of the coach. This
record is included in the technical publication
package supplied with the coach. Retain this
record in the company records office for
reference and safe-keeping.
5.7 Safety Certification
Coach components meet specifications and
standards as follows:
− Material and parts conform to ASTM and/or
SAE standards in effect at the time of
manufacture.
− All factory-installed interior materials meet
FMVSS 302 for fire resistance.
− Certified according to Provincial, State and
Federal Safety standards (Canadian and
US) BMCSS, FMVSS, and CMVSS.
Other applicable certification labels are affixed
to the component.
5.8 DOT Certification Label
This certifies that coaches manufactured by
Prevost Car Inc., comply with all Federal Motor
Vehicle Safety Standards at the time of
manufacture. The DOT Certification label is
affixed on the wall, at the L.H. side of the
driver's seat under the L.H. side control panel
(Fig. 6).
FIGURE 6: DOT CERTIFICATION LABEL OEH3B818
5.9 EPA Engine Label
The exhaust emission certification label affixed to
the oil reserve tank certifies that the engine
conforms to federal and any state exhaust emission
regulations (Fig. 7). It gives the operating conditions
under which certification was made.
FIGURE 7: ENGINE COMPARTMENT OEH3B820
5.10 Fuel Tank Label
The fuel tank label is affixed to the R.H. side of
the fuel tank (Fig. 8). To read this label,
unscrew the fuel tank access panel nuts
located at the left in the condenser
compartment.
FIGURE 8: FUEL TANK ACCESS PANEL OEH3B822
5.11 Vehicle Identification
Number (VIN)
The seventeen-digit vehicle identification
number (VIN) is located on a plate (Fig. 9 & 10)
located on the windshield frame pillar (driver's
side). The VIN is visible from the outside of
the coach. Make sure the correct vehicle
identification number is given when ordering
replacement parts. Using the VIN when
ordering parts will facilitate processing.
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Section 00: GENERAL INFORMATION
00-5
FIGURE 9: VEHICLE I.D. OEH3B816
Note: Record the VIN in the coach
documentation and keep with company
records. The VIN will normally be used for
vehicle registration and for obtaining vehicle
insurance coverage.
FIGURE 10: VEHICLE IDENTIFICATION NUMBER VIN
* TABLE - CHARACTERS USED FOR DESIGNATING THE MODEL YEAR
YEAR
CODE
YEAR
CODE
1996
T
1998
W
1997
V
1999
X
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Section 00: GENERAL INFORMATION
00-6
6. FASTENER STRENGTH IDENTIFICATION
Most commonly used metric fastener strength property classes are 9.8 and 10.9 with the class identi-
fication embossed on the head of each bolt. Customary (inch) strength classes range from grade 2 to
8 with radial line identification embossed on each bolt head actual grade (i.e., a grade 7 bolt will have
5 embossed radial lines on the bolt head). Some metric nuts will be marked with single digit strength
identification numbers on the nut face. Fig. 12 shows the different strength markings. When replacing
metric fasteners, be careful to use fasteners of the same or greater strength than the original fasten-
ers (the same number marking or higher). It is also important to select replacement fastener of the cor-
rect size. Correct replacement fasteners are available through the parts division. Some metric fasten-
ers available in after-market parts sources were designed to metric standards of countries other the
United States and may be of a lower strength, may not have the numbered head marking system, and
may be of a different thread pitch.
FIGURE 11: THREAD NOTATION 00002
FIGURE 12: BOLT STRENGTH MARKINGS 00003
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Section 00: GENERAL INFORMATION
00-7
The metric fasteners used on the coach are
designed to new standards and may not yet be
manufactured by some nondomestic fastener
suppliers. In general, except for special appli-
cations, the common sizes and pitches are :
♦ M 8 X 1.25
♦ M 10 X 1.5
♦ M 12 X 1.75
♦ M 14 X 2
6.1 Prevailing Torque Fasteners
A prevailing torque nut is designed with an in-
terference fit between the nut and bolt threads.
This is most often accomplished by distortion
of the top of an all-metal nut or by using a ny-
lon patch on the threads. A nylon insert may
also be used as a method of interference be-
tween nut and bolt threads (Fig. 13).
A prevailing torque bolt is designed to develop
an interference fit bolt and nut threads, or the
threads of a tapped hole. This is accomplished
by distorting some of the threads or by using a
nylon patch or adhesive (Fig. 13).
6.2 Recommendations For Reuse
1. Clean, unrusted prevailing torque fastener
may be reused as follows :
a) Clean dirt and other foreign material from
the fastener.
b) Inspect the fastener to ensure there is no
crack, elongation, or other sign of fatigue
or overtightening. If there is any doubt, re-
place with a new prevailing torque fastener
of equal or greater strength.
c) Assemble parts and hand start fastener.
d) Observe that , before the fastener seats, it
develops torque per the chart in figure 14.
If there is any doubt, replace with a new
prevailing torque fastener of equal or
greater strength.
e) Tighten the fastener to torque specified in
the applicable section of this manual.
2. Fasteners which are rusty or damaged
should be replaced with new parts of equal
or greater strength.
FIGURE 13: PREVAILING TORQUE FASTENERS 00004
6.3 Six Lobed Socket Head
Six lobed socket head (Torx) fastener are used
in some applications on vehicles covered in
this manual. The tools designed for these fas-
teners are available commercially. However, in
some cases, if the correct tool is not available,
a hex socket head wrench may be used.
FIGURE 14: TORQUE CHART
METRIC SIZES
6 & 6.3
8
12
14
20
NUT AND ALL
N
•
m
0.4
0.8
2.2
3.0
7.0
METAL BOLTS
lbf
•
in
4.0
7.0
18
25
57
ADHESIVE OR NY-
LON
N
•
m
0.4
0.6
1.6
2.4
5.6
COATED BOLTS
lbf
•
in
4.0
5.0
14
20
46
SIZES
.250
.312
.375
.500
.562
.750
NUT AND ALL
N
•
m
0.4
0.6
1.4
2.4
3.2
6.2
METAL BOLTS
lbf
•
in
4.0
5.0
12
20
27
51
ADHESIVE OR NY-
LON
N
•
m
0.4
0.6
1.0
1.8
2.6
5.2
COATED BOLTS
lbf
•
in
4.0
5.0
9.0
15
22
43
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Section 00: GENERAL INFORMATION
00-8
FIGURE 15: METRIC - ENGLISH CONVERSION TABLE 00005
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Section 00: GENERAL INFORMATION
00-9
FIGURE 16: CONVERSION CHART - CUSTOMARY AND METRIC 00006
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Section 00: GENERAL INFORMATION
00-10
7. MAINTENANCE MANUAL - TABLE OF CONTENTS
The Table of Contents on this page indicates the sections covered in this manual. At the beginning of
each section is a Table of Contents which gives the page number on which each subject begins.
ENGINE 01
CLUTCH 02
FUEL SYSTEM 03
EXHAUST SYSTEM 04
COOLING SYSTEM 05
ELECTRICAL SYSTEM 06
TRANSMISSION 07
PROPELLER SHAFT 09
FRONT AXLE 10
REAR AXLE 11
BRAKE AND AIR SYSTEM 12
WHEELS, HUBS AND TIRES 13
STEERING 14
SUSPENSION 16
BODY 18
HEATING AND A/C SYSTEMS 22
ACCESSORIES 23
LUBRICATION 24
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01-1
SECTION 01: ENGINE
CONTENTS
1. ENGINE ...............................................................................................................................................01-3
1.1 Description.............................................................................................................................01-3
2. ENGINE-MOUNTED COMPONENTS...................................................................................................01-3
2.1 Electronic Control Module....................................................................................................01-4
2.2 Electronic Unit Injector.........................................................................................................01-4
2.3 Synchronous Reference Sensor ..........................................................................................01-5
2.4 Timing Reference Sensor.....................................................................................................01-6
2.5 Turbo Boost Pressure Sensor..............................................................................................01-6
2.6 Coolant Temperature Sensor...............................................................................................01-6
2.7 Fuel Temperature Sensor.....................................................................................................01-6
2.8 Air Temperature Sensor.......................................................................................................01-7
2.9 Oil Pressure Sensor.............................................................................................................01-7
2.10 Oil Temperature Sensor.......................................................................................................01-7
3. ENGINE-RELATED COMPONENTS....................................................................................................01-7
3.1 Coolant Level System (CLS)..................................................................................................01-8
3.2 Electronic Foot Pedal Assembly (EFPA) & Throttle Position Sensor .....................................01-8
3.3 Cruise Control Switch.............................................................................................................01-8
3.4 Diagnostic System Accessories.............................................................................................01-9
4. DDEC III Diagnostic Codes..................................................................................................................01-10
4.1 Reading Diagnostic Codes - Flash Method...........................................................................01-10
4.2 DDEC III Diagnostic Codes List.............................................................................................01-11
5. ENGINE OIL LEVEL.............................................................................................................................01-14
6. ENGINE OIL AND FILTER CHANGE ...................................................................................................01-14
7. RECOMMENDED ENGINE OIL TYPE..................................................................................................01-15
8. WELDING PRECAUTION.....................................................................................................................01-15
9. POWER PLANT ASSEMBLY REMOVAL (Automatic and Manual).......................................................01-16
10. POWER PLANT ASSEMBLY INSTALLATION (Automatic and Manual)..............................................01-19
11. ENGINE MOUNTS ..............................................................................................................................01-20
12. JAKE BRAKE......................................................................................................................................01-20
13. SPECIFICATIONS...............................................................................................................................01-21
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Section 01: Engine
01-2
LIST OF ILLUSTRATIONS
FIG. 1: DETROIT DIESEL SERIES 60 ENGINE......................................................................................01-3
FIG. 2: ELECTRONIC CONTROL MODULE (ECM).................................................................................01-4
FIG. 3: ELECTRONIC UNIT INJECTOR CROSS-SECTION....................................................................01-5
FIG. 4: SRS LOCATION..........................................................................................................................01-5
FIG. 5: BULL GEAR................................................................................................................................01-5
FIG. 6: TIMING REFERENCE SENSOR AND RELATED PARTS ...........................................................01-6
FIG. 7: TURBO BOOST PRESSURE SENSOR.......................................................................................01-6
FIG. 8: ENGINE FUEL TEMPERATURE SENSOR..................................................................................01-7
FIG. 9: ENGINE OIL PRESSURE AND OIL TEMPERATURE SENSOR..................................................01-7
FIG. 10: ELECTRONIC FOOT PEDAL ASSEMBLY ..................................................................................01-8
FIG. 11: ENGINE OIL LEVEL DIPSTICK ..................................................................................................01-14
FIG. 12: ENGINE COMPARTMENT ..........................................................................................................01-14
FIG. 13: UNDER VEHICLE VIEW..............................................................................................................01-15
FIG. 14: ENGINE COMPARTMENT ..........................................................................................................01-16
FIG. 15: ENGINE COMPARTMENT ..........................................................................................................01-17
FIG. 16: ENGINE COMPARTMENT ..........................................................................................................01-17
FIG. 17: RUBBER DAMPER TOLERANCE...............................................................................................01-19
FIG. 18: POWER PLANT CRADLE INSTALLATION.................................................................................01-21
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Section 01: Engine
01-3
1. ENGINE
1.1 Description
This vehicle is powered by a 6-cylinder, four-cycle, Detroit Diesel series 60 engine, equipped with an
electronic control system (DDEC III). Two volumes of charge are used in the engine: 11 liters or 12.7
liters. Summary information on the Electronic Control System is given in this section. Complete
maintenance and repair information on the engine will be found in the current DDEC III Service
Manual #6SE483. Engine controls, accessories and related components are covered in the
applicable sections of this maintenance manual. Engine removal and installation procedures are given
at the end of this section. The DDEC system is self-diagnostic. It can identify faulty components and
other engine-related problems by providing the technician with a diagnostic code. Refer to DDEC
Troubleshooting Guide # 6SE492 for more complete information on diagnosis of components and
system problems published by Detroit Diesel.
DDEC III (Detroit Diesel Electronic Control) controls the timing and amount of fuel injection by the
electronic unit injectors (EUI). The system also monitors several engine functions using electrical
sensors which send electrical signals to the Electronic Control Module (ECM). The ECM computes the
electrical signals and determines the correct fuel output and timing for optimum power, fuel economy
and emissions. The ECM also has the ability to display warnings or shut down the engine completely
(depending on option selection) in the event of damaging engine conditions, such as low oil pressure,
low coolant, or high oil temperature.
The system components are divided in two categories: engine-mounted components and
engine-related components.
2. ENGINE-MOUNTED COMPONENTS
FIGURE 1: DETROIT DIESEL SERIES 60 ENGINE 01015
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Section 01: Engine
01-4
Engine-mounted components are as follows:
• Electronic Control Module
• Electronic Unit Injector
• Synchronous Reference Sensor
• Timing Reference Sensor
• Turbo Boost Pressure Sensor
• Coolant Temperature Sensor
• Fuel Temperature Sensor
• Air Temperature Sensor
• Oil Pressure Sensor
• Oil Temperature Sensor
2.1 Electronic Control Module
The Electronic Control Module is mounted, on
the starter side of the engine (Fig. 2). It is
considered the "Brain" of the DDEC III system
because it provides overall monitoring and
control of the engine by comparing input data
from the various sensors to a set of calibration
data stored in the EEPROM (Electrically
Erasable, Programmable, Read-Only Memory)
within the Electronic Control Module. After
comparing the input data with the calibrations
data, the ECM sends high current command
pulses to the Electronic Unit Injectors (EUI) to
initiate fuel injection. The ECM also receives
feedback regarding the start and end of
injection for a given cylinder.
The EEPROM within the Electronic Control
Module is factory programmed by Detroit
Diesel. Reprogramming must be done at a
Detroit Diesel authorized service center.
However, some changes may be performed to
the cruise control and road speed limit using a
diagnostic data reader (see paragraph "4.
DDEC III Diagnostic Codes" in this section).
01018
FIGURE 2: ELECTRONIC CONTROL MODULE (ECM)
2.2 Electronic Unit Injector
The Electronic Unit Injector is a compact unit
that injects diesel fuel directly into the
combustion chamber (Fig. 3). The amount of
fuel injected and beginning of injection timing
is determined by the Electronic Control Module
(ECM). The ECM sends a command pulse
which activates the injector solenoid. The EUI
performs four functions:
• Creates the high-fuel pressure required for
efficient injection
• Meters and injects the exact amount of fuel
required to handle the load
• Atomizes the fuel for mixing with the air in
the combustion chamber
• Permits continuous fuel flow for component
cooling
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Section 01: Engine
01-5
01019
FIGURE 3: ELECTRONIC UNIT INJECTOR CROSS-
SECTION
2.3 Synchronous Reference
Sensor
The Synchronous Reference Sensor (SRS) is
an electronic component that is mounted to the
rear of the gear case (Fig. 4). The SRS sensor
extends through a hole in the gear case and is
positioned near the rear of the bull gear. A bolt,
inserted through a hole in the SRS bracket,
secures the SRS assembly to the gear case.
The SRS connector is black. The SRS sends a
signal to the ECM. This signal is generated by
a raised metal pin on the rear of the bull gear
(Fig. 5).
FIGURE 4: SRS LOCATION 01020
FIGURE 5: BULL GEAR 01021
The bull gear pin passes by the SRS as the
number one piston reaches 45° before Top-
Dead-Center. This information is used by the
ECM to determine engine speed.
The SRS is non-serviceable and must be
replaced as a unit. No adjustment is required.
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Section 01: Engine
01-6
2.4 Timing Reference Sensor
The Timing Reference Sensor (TRS) is an
electronic component that is mounted on the
left side of the gear case, near the crankshaft
center line (Fig. 6).
01022
FIGURE 6: TIMING REFERENCE SENSOR AND
RELATED PARTS
The TRS sensor extends through an opening
in the gear case and is positioned near the
timing wheel gear teeth. A bolt, inserted
through a hole in the TRS bracket, secures the
TRS assembly to the gear case. The TRS
connector is gray.
The TRS sensor sends a signal to the ECM.
This is generated by a series of evenly spaced
teeth on the timing wheel, rotating by the
crankshaft. A tooth passes by the TRS as
each cylinder reaches 10o before Top-Dead-
Center. These signals are used by the ECM to
determine injector solenoid operation time. The
TRS is non-serviceable and must be replaced
as a unit. No adjustment is required.
2.5 Turbo Boost Pressure
Sensor
The Turbo Boost Pressure Sensor is mounted
to the intake manifold with two bolts. A rubber
O-ring is used to seal the sensor to the
manifold (Fig. 7). This device is a pressure
sensor that sends an electrical signal to the
ECM. The ECM uses this information to
compute the amount of air entering the engine.
Fuel supply is regulated by the turbo boost
sensor information to control engine exhaust.
The turbo boost sensor is non-serviceable and
must be replaced as an assembly. No
adjustment is required.
FIGURE 7: TURBO BOOST PRESSURE SENSOR 01023
2.6 Coolant Temperature Sensor
The coolant temperature sensor is mounted on
the engine, on the radiator side of the engine
(Fig. 1). The sensor protects the engine in
case of overheating by sensing coolant
temperature.
2.7 Fuel Temperature Sensor
The Fuel Temperature Sensor (FTS) is
installed on the secondary fuel filter (Fig. 8).
The FTS sends an electrical signal to the ECM
indicating fuel inlet temperature. The ECM
uses this information to calculate fuel
consumption.
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Section 01: Engine
01-7
The FTS is non-serviceable and must be
replaced as a unit. No adjustment is required.
01024
FIGURE 8: ENGINE FUEL TEMPERATURE SENSOR
2.8 Air Temperature Sensor
The Air Temperature Sensor (Fig. 1) located on
the engine (starter side) near the intake
manifold provides input data to vary hot idle
speed and injection timing. This helps to
improve cold starts and reduces white exhaust.
2.9 Oil Pressure Sensor
The Oil Pressure Sensor (OPS) is installed in
the main engine oil gallery. A typical location is
the left rear corner of the cylinder block (Fig.
9).
The OPS sends an electrical signal to the ECM
indicating the engine oil pressure at any given
speed. A low oil pressure signal exceeding
seven seconds is used by the ECM to begin
the stop engine or warning function. The OPS
is non-serviceable and must be replaced as a
unit. No adjustment is required.
01025
FIGURE 9: ENGINE OIL PRESSURE AND OIL
TEMPERATURE SENSOR
2.10 Oil Temperature Sensor
The Oil Temperature Sensor (OTS) is installed
on the main engine oil gallery. A typical
location is the left rear corner of the cylinder
block as shown in Figure 9. The OTS sends an
electrical signal to the ECM indicating engine
oil temperature. The ECM uses this information
to modify engine speed for better cold weather
starts and faster warm-ups. Oil temperatures
exceeding engine specifications for two
seconds or more will illuminate the Check
Engine Light. The OTS is non-serviceable and
must be replaced as a unit. No adjustment is
required.
3. ENGINE-RELATED
COMPONENTS
Engine-related components:
• Coolant Level System (CLS)
• Electronic Foot Pedal Assembly (EFPA)
and Throttle Position Sensor
• Cruise Control Switch (CCS)
• Diagnostic System Accessories (DSA)
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Section 01: Engine
01-8
3.1 Coolant Level System (CLS)
The coolant level system consists of a conductivity
probe mounted in the surge tank and an electronic
interface module located, inside the rear junction
box. Coolant level is determined by the change in
impedance of the probe and its brass mount when it
is immersed in coolant. The electronic device in the
module conditions the signal to levels compatible
with DDEC. Low coolant level will trigger the
warning engine functions. The probe and the
electronic interface module are non-serviceable
items and if found defective, they should be
replaced as units. No adjustment is required.
3.2 Electronic Foot Pedal
Assembly (EFPA) & Throttle
Position Sensor
The Electronic Foot Pedal Assembly (EFPA)
connects the accelerator pedal to a Throttle
Position Sensor (TPS). The (TPS) is a device
that sends an electrical signal to the Electronic
Control Module (ECM) that varies in voltage,
depending on how low the pedal is depressed.
The system is installed in the space normally
occupied by the mechanical foot pedal. The
(EFPA) has maximum and minimum stops that
are built into the unit during manufacturing
(Fig. 10).
The (TPS) converts the operator's foot pedal
input into a signal for the ECM. The (EFPA) is
shown in Figure 10.
When installed by the equipment manufacturer,
the TPS should not require adjustment. If the
TPS is suspected of being misadjusted,
confirm that the sensor is installed in
accordance with the manufacturer's
specifications. It is recommended that the idle
count be at 50 or higher with a full throttle
count of up to 200.
The TPS is self-calibrating and therefore has
no optimum closed throttle or wide open
throttle count value. If the counts are within the
50 to 200 range, the sensor is properly set.
01026
FIGURE 10: ELECTRONIC FOOT PEDAL ASSEMBLY
Monitor the (TPS) as the controls move it
through its full stroke. Be sure there is no
misalignment or obstruction preventing the
smooth movement of the TPS through the full
stroke. Using a diagnostic data reader, check
that the idle and full throttle position counts do
not fall within the error zones. The error zones
occur when the idle position is less than 14
counts, or when the full throttle position is more
than 233 counts. Should these conditions
occur, the ECU will signal diagnostic codes of
21-12 for idle error and 21-23 for wide open
throttle error.
3.3 Cruise Control Switches
(CCS)
The four cruise control switches are located in
the driver's area on the L.H. side control
panel.
1. Cruise On/Off: This is the main switch that
actuates the ECM memory in order to use the
speed regulating mode.
2. Cruise Set: This switch is used to set the
cruise control speed or to decrease the set
speed by 2 MPH at each application.
BACK / RETOUR
Section 01: Engine
01-9
Note: Cruise control system will not accept
speed settings, nor will the "Resume" switch
operate below 20 mph (32 km/h) and the
engine speed must be above 1100 RPM.
3. Cruise Resume: Each time this switch is
actuated, the speed will be increased by 2 mph
(3,5 km/h). This switch allows the driver return
to the last regulated speed following a brake or
"DECEL" switch application.
Note: On-off switch must be in the "ON"
position in order to return to the last regulated
speed.
4. Cruise Decel: Will cancel the cruise
temporarily like a brake application but without
actuating brake light. Set speed is still in
memory for resume.
For additional information, see your "Operator's
Manual"
3.4 Diagnostic System
Accessories (DSA)
The DDEC III engine Diagnostic System
Accessories include the following:
• Check Engine warning light;
• Stop Engine warning light;
• Stop Engine Override switch; and
• Diagnostic Data Link (DDL) connectors.
1. Check Engine Warning Light: This
light, mounted on the central
dashboard panel, illuminates to
indicate that a problem is currently
being detected and that a code has
been stored in the ECM memory. This
light also has a 5-second bulb check
when the ignition is first turned on. The
Check Engine Light illuminates when
the temperature at coolant sensors
exceeds 217°F (103°C) and the
temperature at oil sensors exceeds
260°F (127°C). When sensors reach
those temperatures, engine power
starts to decrease linearly.
2. Stop Engine Warning Light: This
light, also mounted on the central
dashboard panel, illuminates to indica-
te that a major engine problem is
occurring (with the exception of a 5-
second bulb check when the ignition is
first turned on). The Stop Engine Light
illuminates when temperature at coo-
lant sensors exceeds 222°F (106°C)
and the temperature at oil sensors
exceeds 239°F (115°C). When sensors
reach those temperatures, the engine
will shut down after 30 seconds. This
30-second delay period may be
repeated using the OVERRIDE switch.
Note: Once engine is stopped, it can not be
restarted until the malfunction is corrected.
3. Stop Engine OVERRIDE Switch: This
switch, mounted on the L.H. lower
control panel, is used when the Stop
engine warning light is illuminated.
Push down the switch to allow a 30-
second delay period (non cumulative)
in the shutdown procedure. This swicth
can be repeatedly depressed, i.e. one
(1) pulse is sufficient for each 30
second period, in order to move the
vehicle out of traffic.
Note: The stop engine override switch will be
operative only if it has been depressed before the
end of the 30 second delay period.
Caution: The OVERRIDE switch must be used
only in emergency cases, such as to move the
vehicle out of traffic. Excessive use of this switch
could cause serious damage to the engine.
4. Diagnostic Data Link (DDL)
Connectors: A connector is mounted
on the L.H. Lower Control Panel.
Another connector is located in the
rear electric compartment. They allow
to connect the Diagnostic Data Reader
(DDR) and to read the codes or to
access pertinent data on the engine
condition. This enables a more
complete analysis of any defect found
in the DDEC system operation. For
more information, see Detroit Diesel
Troubleshooting Guide #6SE492.
BACK / RETOUR
Section 01: Engine
01-10
4. DDEC III DIAGNOSTIC CODES
4.1 Reading Diagnostic Codes -
Flash Method:
DDEC III makes use of two types of codes:
Active and inactive. The difference between
the two types of codes are as follows:
1. Active Codes: These are the codes which
are currently keeping the Check Engine or
Stop Engine light illuminated. Active codes
are flashed via the Stop Engine Light when
check with override switch.
2. Inactive Codes: These are all the codes
logged in the ECM (whether or not they are
currently turning on the Stop or Check
Engine Light). Inactive codes are flashed
via the Check Engine light when checked
with override switch.
In most instances, only the DDR can provide
the information necessary for a quick diagnosis
of the problem. If you just need to read out
codes, however, and do not have a DDR
available, the following procedure will let you
read out codes. Make sure the rear starting
switch (located in the engine compartment) is
in the normal position. Momentarily depress
the Stop Engine Override switch (located on
the L.H. lower control panel) with the ignition
ON, the engine idling or engine shut-off. Active
codes will be flashed on the stop engine
telltale (located on the central dashboard),
followed by the inactive codes being flashed
on the check engine telltale (located on the
central dashboard). The cycle repeats itself
until the operator depresses the Stop Engine
Override Switch. A code "43" consists of four
flashes, followed by a short pause, then three
flashes in quick succession.
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