EPA07 Series 60 Operatorâ€™s Manual

EPA07 SERIES 60 ENGINE OPERATOR'S MANUAL

To the Operator

This guide contains instructions onthe safe operation and preventivemaintenance of your Detroit DieselSeries 60® engine used in vehicle, orfire fighting apparatus applications.Maintenance instructions coverroutine engine services such as lubeoil and filter changes in enough detailto permit self-servicing, if desired.

The operator should become familiarwith the contents of this guide beforeoperating the engine or carrying outmaintenance procedures.

Power-driven equipment is onlyas safe as the person operating thecontrols. You are urged, as theoperator of this diesel engine, to keepfingers and clothing away from therevolving belts, drive shafts, pulleys,etc. on the engine installation.

Throughout this guide CAUTIONSregarding personal safety andNOTICES regarding engineperformance or service life willappear. To avoid personal injury andensure long engine service life, alwaysheed these instructions.

Whenever possible, it will benefityou to rely on an authorized DetroitDiesel service outlet for all yourservice needs from maintenance tomajor parts replacement. Authorizedservice outlets worldwide stockfactory-original parts and havethe specialized equipment andexperienced, trained personnelto provide prompt preventivemaintenance and skilled enginerepairs.

The information and specificationsin this publication are based on theinformation in effect at the time ofapproval for printing. Contact anauthorized Detroit Diesel serviceoutlet for information on the latestrevision. The right is reserved tomake changes at any time withoutobligation.

The Series 60 engine is built inaccordance with sound technologicalprinciples and based on state-of-the-arttechnology.

Despite this, the engine may constitutea risk of damage to property or injuryto persons if it is not used for itsintended purpose.

The engine should not be modified orconverted in an incorrect manner orthe safety instructions included in thismanual disregarded.

All information subject to change without notice. iDDC-SVC-MAN-0006 Copyright © 2009 DETROIT DIESEL CORPORATION

NOTICE:Coolant must be inhibited with therecommended SCAs (supplementalcoolant additives) listed in theHow To section of this engineoperator's guide. In addition, theengine can be equipped with acoolant filter/inhibitor system as aninstalled option or as an after-saleitem. Failure to check andmaintain SCA levels at requiredconcentrations will result insevere damage (corrosion) tothe engine cooling system andrelated components.

WARRANTYThe applicable engine warranty iscontained in the booklet “WarrantyInformation for Series 60 Engines,”available from authorized DetroitDiesel service outlets.

Keep this Operator's Guidewith the engine installation atall times. It contains importantoperating, maintenance, and safetyinstructions.

Trademark Information

DDC®, Detroit Diesel®, DDEC®,Series 60®, Optimized Idle®,Diagnostic Link®, reliabilt®,POWER Trac®, POWER COOL®,and POWER GUARD® are registeredtrademarks of Detroit DieselCorporation. Delco Remy® is aregistered trademark of Delco RemyAmerica, Inc. Bosch® is a registeredtrademark of Robert Bosch CompanyN.A. Fuel Pro®, and Mega Filter®are registered trademarks of DavcoManufacturing, L.L.C. Nexiq™ isa trademark of Nexiq Technologies,Inc. PowerBand® is a registeredtrademark of Gates Rubber Company.Tectyl® is a registered trademark ofDaubert Chemical Company, Inc.Biobor® is a registered trademark ofUnited States Borax and ChemicalCorporation. DuPont® is a registeredtrademark of E.I. DuPont de Nemoursand Company, Inc. All othertrademarks used are the property oftheir respective owners.

ii All information subject to change without notice.DDC-SVC-MAN-0006 Copyright © 2009 DETROIT DIESEL CORPORATION


TABLE OF CONTENTS

INTRODUCTION .................................................................................. 1NON-GENUINE AND REBUILT COMPONENT QUALITY ALERT .. 1PERSONNEL REQUIREMENTS ..................................................... 2ENGINE CONVERSIONS AND MODIFICATIONS .......................... 2

CAUTION SUMMARY .......................................................................... 3ENGINE OPERATION ..................................................................... 3PREVENTIVE MAINTENANCE ....................................................... 5ELECTRICAL SYSTEM ................................................................... 8COOLING SYSTEM ......................................................................... 8AIR INTAKE SYSTEM ...................................................................... 9FUEL SYSTEM ................................................................................ 9COMPRESSED AIR ......................................................................... 10STARTING AIDS .............................................................................. 11LUBRICATING OIL AND FILTERS .................................................. 12AFTERTREATMENT SYSTEM ........................................................ 12

ENGINE IDENTIFICATION .................................................................. 14ENGINE COMPONENTS ................................................................. 14ENGINE MODEL AND SERIAL NUMBER DESIGINATON ............. 16CERTIFICATION LABEL .................................................................. 17

OPERATING INSTRUCTIONS FOR STARTING THE ENGINE .......... 18FIRST TIME START PREPARATION .............................................. 18SYSTEM CHECKS .......................................................................... 18

COOLING SYSTEM CHECKS .................................................... 18LUBRICATION SYSTEM CHECKS ............................................. 19

CHECKING THE OIL LEVEL .................................................. 19EXTENDED STORAGE .......................................................... 20

FUEL SYSTEM CHECKS ............................................................ 20ADDING FUEL ........................................................................ 21PRIMING THE FUEL SYSTEM ............................................... 21

OTHER CHECKS ........................................................................ 22STARTING THE ENGINE FOR THE FIRST TIME ...................... 22

ELECTRIC STARTER ............................................................. 24

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RUNNING THE ENGINE ................................................................. 24OIL PRESSURE .......................................................................... 24WARM-UP ................................................................................... 25INSPECTION ............................................................................... 25

TRANSMISSION ..................................................................... 25FLUID LEAKS ......................................................................... 25CRANKCASE .......................................................................... 25TURBOCHARGER .................................................................. 25

AVOID UNNECESSARY IDLING ................................................. 25STOPPING THE ENGINE ................................................................ 26EMERGENCY JUMP STARTING .................................................... 26ROUTINE ENGINE START .............................................................. 27

STARTING THE ENGINE-ROUTINE ........................................... 27CHECKING THE COOLANT LEVEL (COLD CHECK) ................ 28CHECKING THE COOLANT LEVEL (HOT CHECK) .................. 29

MONITORING ENGINE OPERATION ............................................. 29BATTERY CHARGE .................................................................... 29OIL PRESSURE .......................................................................... 30EXCESSIVE IDLING ................................................................... 30

CHANGING THE IDLE SPEED ....................................................... 30SHUTTING DOWN THE ENGINE ................................................... 30

SHUTTING DOWN AFTER HIGH LOAD OPERATION ............... 31EMERGENCY RUNNING MODE .................................................... 31STOP ENGINE OVERRIDE OPTION .............................................. 31COLD WEATHER OPERATION ...................................................... 32

WINTER FRONTS ....................................................................... 32

DDEC VI SYSTEM ............................................................................... 33MOTOR CONTROL MODULE ......................................................... 33COMMON POWERTRAIN CONTROLLER ..................................... 34DDEC FEATURES ........................................................................... 35

CRUISE CONTROL ..................................................................... 35DATA RECORDING CAPABILITY ............................................... 37ENGINE BRAKES ....................................................................... 37ENGINE PROTECTION .............................................................. 38CALIFORNIA ENGINE IDLE LIMITING ....................................... 38IDLE SHUTDOWN TIMER .......................................................... 39

DDEC VI OPERATION ..................................................................... 39STOP ENGINE OVERRIDE SWITCH ......................................... 40

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IMMEDIATE SPEED REDUCTION ............................................. 41RED STOP LAMP ........................................................................ 41DIAGNOSTIC TOOL .................................................................... 41

FLASHING MALFUNCTION CODES ...................................... 41ACTIVE CODES ...................................................................... 43INACTIVE CODES .................................................................. 43

DDEC VI ENGINE DRIVING TIPS ....................................................... 44ACCELERATING THE VEHICLE ..................................................... 44CRUISE CONTROL ......................................................................... 44ENGINE BRAKES AND CRUISE CONTROL .................................. 46SHIFTING ........................................................................................ 46IDLING ............................................................................................. 47

ENGINE BRAKE SYSTEM .................................................................. 48DRIVER CONTROL SWITCHES ..................................................... 48

LOW/HIGH SWITCH ................................................................... 48LOW/MED/HIGH SWITCH .......................................................... 48

CLUTCH PEDAL AND THROTTLE POSITION CONTROLS .......... 48ENGINE BRAKE OPERATION ........................................................ 48ANTI-LOCK BRAKING SYSTEMS ................................................... 49DRIVING ON FLAT, DRY PAVEMENT ............................................. 50DESCENDING A LONG, STEEP GRADE ....................................... 50DRIVING ON WET OR SLIPPERY PAVEMENT .............................. 52

ENGINE SYSTEMS ............................................................................. 53FUEL SYSTEM ................................................................................ 53LUBRICATION SYSTEM ................................................................. 53AIR SYSTEM ................................................................................... 53COOLING SYSTEM ......................................................................... 53ELECTRICAL SYSTEM ................................................................... 53EXHAUST SYSTEM ........................................................................ 53EXHAUST GAS RECIRCULATION SYSTEM .................................. 53

AFTERTREATMENT SYSTEM ............................................................ 54OPERATING REQUIREMENTS ...................................................... 55MAINTENANCE ............................................................................... 55PARKED REGENERATION PROCEDURE ..................................... 56

HAZARDOUS APPLICATIONS ................................................... 57DPF STATIONARY REGEN ONLY = 0-DISABLED ................ 58

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DPF STATIONARY REGEN ONLY = 1-ENABLED ................. 58SERVICE RECORD ......................................................................... 58

DRIVER ACTIONS ............................................................................... 59

INSTRUMENT PANEL LAMPS ........................................................... 61

MAINTENANCE ................................................................................... 63SCHEDULED INTERVALS .............................................................. 63PREVENTIVE MAINTENANCE INTERVALS .................................. 73

ITEM 1 – LUBRICATING OIL ...................................................... 73ITEM 2 – FUEL AND FUEL TANK ............................................... 75ITEM 3 – FUEL LINES, FLEXIBLE HOSES ................................ 76

LEAKS ..................................................................................... 76HOSES AND FITTINGS .......................................................... 76HOSE SERVICE LIFE ............................................................. 76

ITEM 4 – COOLING SYSTEM ..................................................... 77COOLANT LEVEL ................................................................... 77COOLANT INHIBITORS .......................................................... 77COOLANT DRAIN INTERVAL ................................................. 77

ITEM 5 – TURBOCHARGER, AIR-TO-AIR CHARGE COOLER . 79WASTEGATED TURBOCHARGERS ...................................... 79

ITEM 6 – BATTERY ..................................................................... 79ITEM 7 – AFTERTREATMENT SYSTEM .................................... 80ITEM 8 – DRIVE BELTS .............................................................. 80

V-BELTS .................................................................................. 812-GROOVE POWERBAND ..................................................... 8212–RIB POLY-V BELT ............................................................. 82BELT REPLACEMENT ............................................................ 82

ITEM 9 – AIR COMPRESSOR .................................................... 83ITEM 10 – AIR CLEANER ........................................................... 83

AIR CLEANER REPLACEMENT ............................................. 83ITEM 11 – LUBRICATING OIL FILTERS ..................................... 83ITEM 12 – FUEL FILTERS .......................................................... 84

FUEL PRO® 382 FILTERS ..................................................... 84SPIN-ON FILTERS .................................................................. 85

ITEM 13 – WATER PUMP AND COOLANT INHIBITORELEMENT .................................................................................... 85

WATER PUMP DRAIN HOLE ................................................. 85

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COOLANT INHIBITOR ELEMENT .......................................... 85ITEM 14 – CRANKING MOTOR .................................................. 86ITEM 15 – AIR SYSTEM ............................................................. 86ITEM 16 – EXHAUST SYSTEM .................................................. 86ITEM 17 – ENGINE (STEAM CLEAN) ......................................... 86ITEM 18 – RADIATOR ................................................................. 86ITEM 19 – OIL PRESSURE ......................................................... 87ITEM 20 – BATTERY-CHARGING ALTERNATOR ...................... 87

BOSCH® T1 ALTERNATOR SERVICE REQUIREMENTS ..... 88GENERAL SERVICE REQUIREMENTS – BOSCH® ANDDELCO REMY® ALTERNATORS ........................................... 88

ITEM 21 – ENGINE AND TRANSMISSION MOUNTS ................ 88ITEM 22 – CRANKCASE PRESSURE ........................................ 88ITEM 23 – FAN HUB .................................................................... 88ITEM 24 – THERMOSTATS AND SEALS ................................... 88ITEM 25 – CRANKCASE BREATHER ........................................ 89ITEM 26 – ENGINE TUNE-UP .................................................... 89ITEM 27 – VIBRATION DAMPER ................................................ 90

HOW-TO SECTION .............................................................................. 91HOW TO SELECT LUBRICATING OIL ............................................ 91

LUBRICANT REQUIREMENTS .................................................. 91COLD WEATHER STARTING ..................................................... 91SYNTHETIC OILS ....................................................................... 92THE USE OF SUPPLEMENTAL ADDITIVES .............................. 92

WHEN TO CHANGE OIL ................................................................. 92DISPOSING OF WASTE OIL ...................................................... 93

HOW TO REPLACE THE LUBE OIL FILTERS ................................ 94REPLACE SPIN-ON TYPE OIL FILTER ...................................... 94

HOW TO SELECT DIESEL FUEL ................................................... 95QUALITY ..................................................................................... 96FUEL CONTAMINATION ............................................................. 96

BIODIESEL ............................................................................. 96PROHIBITED ADDITIVES ........................................................... 97

USED LUBRICATING OIL ....................................................... 97FUEL ADDITIVES WITH SULFUR OR SULFATED ASH ........ 97GASOLINE .............................................................................. 97

HOW TO REPLACE THE FUEL FILTERS ....................................... 98

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REPLACE SPIN-ON TYPE PRIMARY OR SECONDARY FUELFILTER ELEMENTS .................................................................... 98REPLACE FUEL/WATER SEPARATOR ELEMENT .................... 100REPLACE FUEL PRO® 382/382E FUEL FILTER ELEMENT ..... 100

ENGINE OUT OF FUEL — HOW TO RESTART ............................. 103ENGINES WITH SPIN-ON FILTERS ........................................... 103ENGINES WITH FUEL PRO FILTERS ........................................ 103

HOW TO CLEAN THE ENGINE ...................................................... 104HIGH-PRESSURE CLEANING EQUIPMENT ............................. 104

HOW TO CLEAN THE COOLING SYSTEM .................................... 105DEGREASING ............................................................................. 105

HOW TO SELECT COOLANT ......................................................... 106DEFINITIONS .............................................................................. 106APPROVED COOLANTS ............................................................ 107

EG & WATER PLUS SCA INHIBITOR OR P G & WATERPLUS SCA INHIBITOR ............................................................ 108MIXING EG OR PG ANTIFREEZE AND WATER ................... 109RECYCLED ANTIFREEZE .................................................... 109EG/WATER + OAT INHIBITOR OR PG/WATER + OATINHIBITOR .............................................................................. 110WATER ONLY + SCA OR WATER ONLY + OAT INHIBITOR 110WATER REQUIREMENTS ..................................................... 111

COOLANTS NOT RECOMMENDED .......................................... 112ALL ANTIFREEZES AND COOLANTS CONTAININGPHOSPHATE ........................................................................... 112AUTOMOTIVE TYPE COOLANTS .......................................... 112METHYL ALCOHOL-BASED ANTIFREEZE ........................... 112GLYCOL-BASED COOLANTS FORMULATED FOR HVAC ... 112

ADDITIVES NOT RECOMMENDED ........................................... 112SOLUBLE OIL ADDITIVES ..................................................... 112CHROMATE ADDITIVES ........................................................ 112

COOLANT INHIBITOR TEST INTERVALS ................................. 113SUPPLEMENTAL COOLANT ADDITIVES FOR FULLYFORMULATED COOLANT ..................................................... 113MAINTENANCE INTERVALS .................................................. 114

SCA TEST PROCEDURES ......................................................... 115COOLANT FILTERS (NON-OAT SYSTEMS) .............................. 116DROPOUT ................................................................................... 117

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COOLANT EXTENDER INHIBITOR ADDITIVE FOR “OAT”COOLANT ................................................................................... 117

OAT COOLANT DRAIN INTERVAL ........................................ 118CHRONIC COOLANT SYSTEM PROBLEMS ............................. 118DETROIT DIESEL COOLING SYSTEM MAINTENANCEPRODUCTS ................................................................................. 118

POWER COOL SCAS ............................................................. 118POWER COOL COOLANT FILTER ELEMENTS .................... 118POWER COOL CLEANERS ................................................... 119

SUMMARY OF COOLANT RECOMMENDATIONS .................... 119COOLANT LIFE OF GLYCOL COOLANT ............................... 120COOLANT LIFE OF OAT COOLANT ...................................... 120COOLANT LIFE OF OTHER COOLANTS .............................. 120

HOW TO DRAIN AND FLUSH THE COOLING SYSTEM ............... 121HOSES ........................................................................................ 122

WHEN TO SERVICE THE DRY TYPE AIR CLEANER ................... 122

TROUBLESHOOTING ......................................................................... 123ABNORMAL COOLANT TEMPERATURE ....................................... 123HARD STARTING ............................................................................ 124AFTERTREATMENT SYSTEM ........................................................ 125ABNORMAL ENGINE OPERATION ................................................ 126ABNORMAL OPERATING CONDITIONS ....................................... 127

ENGINE STORAGE ............................................................................. 128PREPARING ENGINE FOR STORAGE .......................................... 128

TEMPORARY STORAGE (30 DAYS OR LESS) ......................... 128EXTENDED STORAGE (MORE THAN 30 DAYS) ...................... 129PROCEDURE FOR RESTORING TO SERVICE AN ENGINETHAT HAS BEEN IN EXTENDED STORAGE ............................. 132

CUSTOMER ASSISTANCE ................................................................. 134ROAD SERVICE IN THE U.S. OR CANADA ................................... 136WORKING WITH DETROIT DIESEL SERVICE OUTLETS ............ 136

STEP ONE ................................................................................... 137STEP TWO .................................................................................. 137STEP THREE .............................................................................. 137

SPECIFICATIONS ................................................................................ 138FUEL AND LUBRICATING OIL REQUIREMENTS .......................... 138

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OIL PAN CAPACITY .................................................................... 138POWER COOL ENGINE PRODUCTS ............................................ 138

POWER COOL FULLY FORMULATED IEG COOLANT ............. 1382000 SUPPLEMENTAL COOLANT ADDITIVE ........................... 1393000 SUPPLEMENTAL ADDITIVE FILTERS .............................. 139NEED RELEASE COOLANT FILTERS ....................................... 140PLUS EXTENDED LIFE OAT COOLANT .................................... 140PLUS EXTENDER FOR POWER COOL PLUS OAT COOLANT 140COOLING SYSTEM CLEANERS ................................................ 141COOLANT TESTING AND ANALYSIS PRODUCTS ................... 141

x All information subject to change without notice.DDC-SVC-MAN-0006 Copyright © 2009 DETROIT DIESEL CORPORATION


INTRODUCTION

This guide is intended for use bythe operator of a Detroit DieselSeries 60 engine used in the followingapplications:

□ On-Highway Vehicles

□ Fire Truck or Crash/RescueVehicles

Non-Genuine and RebuiltComponent Quality AlertElectronic engine controls havebeen instrumental in aiding enginemanufacturers in meeting the stringentemission requirements of the U.S.Environmental Protection Agency(U.S. EPA) and the California AirResources Board (CARB) andalso in meeting the ever-increasingperformance demands of the customer.

Maintenance procedures mustbe followed in order to continuesatisfactory performance anddurability and to ensure coverage ofthe engine under the manufacturer'swarranty. Many of these maintenanceprocedures also ensure that theengine continues to comply withapplicable emissions standards.Proper maintenance procedures, usingspecific components engineered tocomply with emissions regulations,may be performed by an authorizedDetroit Diesel distributor or dealer,an independent outlet or the operator

or owner. The owner is responsiblefor determining the suitability ofcomponents to maintain emissionscompliance during the engine's usefulemission life.

Detroit Diesel cautions that theindiscriminate rebuilding of precisioncomponents, without the benefit ofspecifications, specialized equipment,and knowledge of the electronicoperating system, will jeopardizeperformance or lead to more seriousproblems, and can take the engineoutside of compliance with U.S. EPAor CARB emissions standards.

There are other components inan engine, such as turbocharger,camshaft, piston, etc., whichare specifically designed andmanufactured to exacting standardsfor emissions compliance. It isimportant that these components, ifreplaced, modified or substituted, canbe verified to ensure that the engineremains in compliance with emissionsstandards. The use of inadequatelyengineered, manufactured or testedcomponents in repair or rebuild ofthe engine may be in violation of thefederal Clean Air Act and applicableU.S. EPA or CARB regulations.

All information subject to change without notice. 1DDC-SVC-MAN-0006 Copyright © 2009 DETROIT DIESEL CORPORATION

INTRODUCTION

Furthermore, modern engines exhibitoperating parameters which requirethe use of proper fluids, such asfuel, coolant and lubricating oil, tomaintain long engine life. The use offluids that do not meet Detroit Dieselspecifications may result in early wearout or engine failure.

Personnel RequirementsWork on the engine should be carriedout only by skilled technicians whohave been instructed in the specificskills necessary for the type of workbeing performed.

Engine Conversions andModificationsThe function and safety of the enginecould be affected if unauthorizedmodifications are made to it. DetroitDiesel will not accept responsibilityfor any resulting damage.

Tampering with the fuel injectionsystem and engine electronics couldalso affect the engine's power output orexhaust emission levels. Compliancewith the manufacturer's settingsand with statutory environmentalprotection regulations cannot then beguaranteed.

2 All information subject to change without notice.DDC-SVC-MAN-0006 Copyright © 2009 DETROIT DIESEL CORPORATION


CAUTION SUMMARY

The following cautions must beobserved by the operator of thevehicle or equipment in which thisengine is installed and/or by thoseperforming basic engine preventivemaintenance. Failure to read andheed these cautions and exercisereasonable care for personal safetyand the safety of others whenoperating the vehicle/equipmentor performing basic enginepreventive maintenance may resultin personal injury and engineand/or vehicle/equipment damage.

Engine OperationObserve the following cautions whenoperating the engine.

PERSONAL INJURY

To avoid injury from loss ofvehicle/vessel control, theoperator of a DDEC equippedengine must not use or readany diagnostic tool while thevehicle/vessel is moving.

HOT EXHAUST

During parked regeneration theexhaust gases will be extremelyHOT and could cause a fireif directed at combustiblematerials. The vehicle must beparked outside.

PERSONAL INJURY

To avoid injury from engineshutdown in an unsafe situation,ensure the operator knows howto override the stop enginecondition on a DDEC-equippedunit.


CAUTION SUMMARY

PERSONAL INJURY

Diesel engine exhaust and someof its constituents are known tothe State of California to causecancer, birth defects, and otherreproductive harm.

□ Always start and operate anengine in a well ventilatedarea.

□ If operating an engine inan enclosed area, vent theexhaust to the outside.

□ Do not modify or tamperwith the exhaust system oremission control system.

LOSS OF VEHICLE CONTROL

To avoid injury from loss ofvehicle control, do not activatethe Engine Brake system underthe following conditions:

□ On wet or slippery pavement,unless the vehicle is equippedwith ABS (anti-lock brakingsystem) and you have hadprior experience drivingunder these conditions.

□ When driving without a trailer(bobtailing) or pulling anempty trailer.

□ If the tractor drive wheelsbegin to lock or there isfishtail motion after theEngine Brake is activated,deactivate the brake systemimmediately if this occurs.




To avoid injury from the loss ofvehicle control, do not use cruisecontrol under these conditions:

□ When it is not possible tokeep the vehicle at a constantspeed (on winding roads, inheavy traffic, in traffic thatvaries in speed, etc.).

□ On slippery roads(wet pavement, ice-orsnow-covered roads, loosegravel, etc.).

Preventive MaintenanceObserve the following cautions whenperforming preventative maintenance.

PERSONAL INJURY

To avoid injury when workingnear or on an operating engine,remove loose items of clothingand jewelry. Tie back or containlong hair that could be caught inany moving part causing injury.

PERSONAL INJURY

To avoid injury when workingon or near an operating engine,wear protective clothing,eye protection, and hearingprotection.

HOT OIL

To avoid injury from hot oil, donot operate the engine with therocker cover(s) removed.

FIRE

To avoid injury from fire, containand eliminate leaks of flammablefluids as they occur. Failure toeliminate leaks could result infire.


CAUTION SUMMARY

USED ENGINE OIL

To avoid injury to skin fromcontact with the contaminants inused engine oil, wear protectivegloves and apron.

PERSONAL INJURY

To avoid injury when usingcaustic cleaning agents, followthe chemical manufacturersusage, disposal, and safetyinstructions.

PERSONAL INJURY

To avoid injury from hot surfaces,wear protective gloves, or allowengine to cool before removingany component.

PERSONAL INJURY

To avoid injury, use care whenworking around moving belts androtating parts on the engine.

FIRE

To avoid injury from combustionof heated lubricating-oil vapors,stop the engine immediately if anoil leak is detected.

PERSONAL INJURY

To avoid injury from contactwith rotating parts when anengine is operating with the airinlet piping removed, install anair inlet screen shield over theturbocharger air inlet. The shieldprevents contact with rotatingparts.



HOT COOLANT

To avoid scalding from theexpulsion of hot coolant, neverremove the cooling systempressure cap while the engine isat operating temperature. Wearadequate protective clothing(face shield, rubber gloves,apron, and boots). Remove thecap slowly to relieve pressure.

FIRE

To avoid injury from fire, do notsmoke or allow open flames whenworking on an operating engine.

FIRE

To avoid injury from fire from abuildup of volatile vapors, keepthe engine area well ventilatedduring operation.

PERSONAL INJURY

To avoid injury from rotating beltsand fans, do not remove anddiscard safety guards.

PERSONAL INJURY

To avoid injury from slipping andfalling, immediately clean up anyspilled liquids.


CAUTION SUMMARY

Electrical SystemObserve the following cautions whenjump starting an engine, charginga battery, or working with thevehicle/application electrical system.

ELECTRICAL SHOCK

To avoid injury from electricalshock, do not touch batteryterminals, alternator terminals, orwiring cables while the engine isoperating.

Battery Explosion and Acid Burn

To avoid injury from batteryexplosion or contact with batteryacid, work in a well ventilatedarea, wear protective clothing,and avoid sparks or flames nearthe battery. If you come in contactwith battery acid:

□ Flush your skin with water.

□ Apply baking soda or lime tohelp neutralize the acid.

□ Flush your eyes with water.

□ Get medical attentionimmediately.

PERSONAL INJURY

To avoid injury from accidentalengine startup while servicingthe engine, disconnect/disablethe starting system.

Cooling SystemObserve the following cautions whenservicing the cooling system.

HOT COOLANT




PERSONAL INJURY


Air Intake SystemObserve the following cautions whenworking on the air intake system.

PERSONAL INJURY


PERSONAL INJURY

To avoid injury from contactwith rotating parts when anengine is operating with the airinlet piping removed, install anair inlet screen shield over theturbocharger air inlet. The shieldprevents contact with rotatingparts.

Fuel SystemObserve the following cautions whenfueling the vehicle or working withthe fuel system.

FIRE

To avoid injury from fire, keep allpotential ignition sources awayfrom diesel fuel, including openflames, sparks, and electricalresistance heating elements. Donot smoke when refueling.

FIRE

To avoid increased risk of a fuelfire, do not mix gasoline anddiesel fuel.


CAUTION SUMMARY

FIRE

To avoid injury from fire causedby heated diesel-fuel vapors:

□ Keep those people who are notdirectly involved in servicingaway from the engine.

□ Stop the engine immediately ifa fuel leak is detected.

□ Do not smoke or allow openflames when working on anoperating engine.

□ Wear adequate protectiveclothing (face shield,insulated gloves and apron,etc.).

□ To prevent a buildup ofpotentially volatile vapors,keep the engine area wellventilated during operation.

Compressed AirObserve the following cautions whenusing compressed air.

EYE INJURY

To avoid injury from flying debriswhen using compressed air, wearadequate eye protection (faceshield or safety goggles) and donot exceed 276 kPa (40 psi) airpressure.



Starting AidsObserve the following cautions whenusing starting aids.

FLAMES, EXPLOSION ANDTOXICITY

To avoid injury from flames,explosion, and toxicants whenusing ether, the followingprecautions must be taken:

□ Do not smoke when servicingether system.

□ Work in well ventilated area.

□ Do not work near open flames,pilot flames (gas or oilheaters), or sparks.

□ Do not weld or carry an openflame near the ether system ifyou smell ether or otherwisesuspect a leak.



□ Always wear goggles whentesting.

□ If fluid enters the eyes or iffumes irritate the eyes, washeyes with large quantities ofclean water for 15 minutes.A physician, preferably aneye specialist, should becontacted.

□ Contents of cylinder are underpressure. Store cylindersin a cool dry area. Do notincinerate, puncture orattempt to remove cores fromcylinders.


CAUTION SUMMARY

Lubricating Oil and FiltersObserve the following cautions whenreplacing the engine lubricating oiland filters.

PERSONAL INJURY


FIRE

To avoid injury from combustionof heated lubricating-oil vapors,stop the engine immediately if anoil leak is detected.

FIRE

To avoid injury from fire, do notsmoke or allow open flames whenworking on an operating engine.

FIRE

To avoid injury from fire from abuildup of volatile vapors, keepthe engine area well ventilatedduring operation.

Aftertreatment SystemObserve the following cautions whenservicing the Aftertreatment System(ATS). Be advised that these two labelsare attached to the AftertreatmentDevice (ATD).



Figure 1 Hot Surfaces External and Internal Caution

Figure 2 Heavy Aftertreatment Device Caution


ENGINE IDENTIFICATION


The Series 60 engine has a certificationlabel, model number and engine serialnumber for identification.

Engine ComponentsFor a general view of the Series60 engine, showing majorcomponents,see Figure 3 andFigure 4

1. Delivery Pipe 5. EGR Cooler

2. Delta P Sensor 6. Oil Filters

3. Engine Mounted Radiator Bracket 7. Turbocharger

4. Oil Pan 8. Actuator

Figure 3 Major Engine Components, Right Side



1. Venturi 6. Primary Fuel Filter/Water Separator

2. EGR Valve 7. Intake Throttle Valve

3. Intake Manifold 8. Adaptor

4. Doser Block Assembly 9. Motor Control Module (MCM)

5. Mixer 10. Secondary Fuel Filter

Figure 4 Major Engine Components, Left Side



Engine Model And SerialNumber DesiginatonThe engine serial number and modelnumber are laser etched on thecylinder block in the left side just

below the intake manifold and abovethe cast-in Detroit Diesel logo (asviewed from the flywheel end).

See Figure 5

Figure 5 Location of Engine Serial and Model Numbers



Certification LabelIf required, a certification label isattached to the valve rocker cover.This label certifies that the engineconforms to federal and certain state

emissions regulations for its particularapplication. It also gives the operatingconditions under which certificationwas made. See Figure 6.

Figure 6 Typical Engine Certification Label


OPERATING INSTRUCTIONS FOR STARTING THE ENGINE

OPERATING INSTRUCTIONS FOR STARTING THEENGINE

Following are instructions for startingthe engine.

First Time StartPreparationWhen preparing to start a new ornewly overhauled engine which hasbeen in storage, perform all of theoperations listed below. Also refer tothe “ENGINE STORAGE” section.Failure to follow these instructionsmay result in serious engine damage.

Be sure you are familiar with all ofthe instruments, gauges and controlswhich are needed to operate theengine.

Note especially the location andfunction of the following:

□ Oil pressure gauge

□ Low oil pressure warning light

□ Coolant temperature gauge

□ High coolant temperature warninglight

□ Water in fuel warning light

□ Air restriction indicator

Watch for any signs of engineproblems when starting or driving. Ifthe engine overheats, uses excessivefuel or lubricating oil, vibrates,

misfires, makes unusual noises, orshows an unusual loss of power, turnthe engine off as soon as possible anddetermine the cause of the problem.Engine damage may be avoided by aquick response to early indications ofproblems.

When starting the engine in coldweather, refer to “How to SelectCoolant” in the HOW-TO SECTION.

System ChecksPerform the following system checksbefore starting for the first time.

Cooling System Checks

Check the cooling system as follows:

1. Make sure all drain cocks inthe cooling system are installed(drain cocks are often removedfor shipping) and are closedtightly.

2. Remove the radiator pressurecontrol cap and fill with genuineDetroit Diesel POWER COOL®antifreeze or an equivalent qualityethylene glycol or propyleneglycol-base antifreeze solutionin the required concentration.In extremely hot environments,properly inhibited water maybe used in the summer. Keep the



coolant level at the bottom of thefiller neck to allow for expansionof the coolant. For more detailedrecommendations, refer to Howto Select Coolant in the HOW-TOSECTION.

3. Entrapped air must be purgedafter filling the cooling system.To do this, allow the engine towarm up with the pressure capremoved. With the transmissionin neutral, increase engine speedabove 1,000 rpm and add coolantto the radiator as required.

4. Check to make sure the frontof the radiator and air-to-aircharge cooler (if equipped) areunblocked and free of debris.

Lubrication System Checks

The lubricating oil film on the rotatingparts and bearings of a new or newlyoverhauled engine, or one which hasbeen in storage for six months ormore, may be insufficient when theengine is started for the first time.

NOTICE:Insufficient lubrication at startup cancause serious damage to enginecomponents.

To insure an immediate flow ofoil to all bearing surfaces at initialengine startup, the engine lubrication

system should be charged with acommercially available pressurepre-lubricator. If this is impractical,rocker covers should be removed andclean lubricating oil should be pouredover the rocker arms. The oil shouldbe the same weight and viscosityas that used in the crankcase. Afterpre-lubricating, add additional oil tobring the level to the proper mark onthe dipstick.

For lubricant recommendation, refer toHow to Select Lubricating Oil in theHOW-TO SECTION.

Checking the Oil Level — Checkthe oil level as follows:

1. Check the oil level using the oildipstick. The dipstick has anoperating range identified by acrosshatch. If the oil meniscusis within this crosshatch rangethen the oil range is adequate forengine operation. (See Figure 7).

Figure 7 Check Lube Oil Level



PERSONAL INJURY


2. If necessary, top off by fillingengine oil through the oil fillcap to the satisfactory fillrange on the oil dipstick. Fordetailed procedures, refer to the“MAINTENANCE” section. Donot overfill.

Extended Storage — An enginein storage for an extended periodof time (over winter, for example)may accumulate water in the oilpan through normal condensation ofmoisture (always present in the air)on the cold, internal surfaces of theengine.

NOTICE:Failure to eliminate water-dilutedlubricating oil may lead to seriousengine damage at startup.

Lube oil diluted by water cannotprovide adequate bearing protectionat engine startup. For this reason,Detroit Diesel recommends replacingthe engine lubricating oil and filtersafter extended storage.

Fuel System Checks

Fill the tanks with the recommendedfuel. Keeping tanks full reduces watercondensation and helps keep fuelcool, which is important to engineperformance. Full tanks also reducethe chance for microbe (black slime)growth. For fuel recommendations,refer to How to Select Diesel Fuel inthe HOW-TO SECTION of this guide.Make sure the fuel shutoff valve (ifused) is open.

NOTICE:Prolonged use of the starting motorand engine fuel pump to prime thefuel system can result in damage tothe starter, fuel pump and injectors.

This may cause erratic engineoperation due to the amount of airin the lines and filters from the fuelsupply tank to the cylinder head

NOTICE:NEVER use a starting aid such asether to run the engine until thefuel system is primed. Doing sowill result in injector damage.



If an external starting aid is used, theheat generated by the external fuelsource will cause the injector tips tobe damaged when the fuel cools them.The injector plunger and bushingcan be scored from running withoutlubrication.

NOTICE:Engines equipped with startingdevices dependent on compressedair or gas reservoirs should alwaysbe primed before initial startup.Otherwise, reserve pressure canbe exhausted and injectors may bedamaged from lack of lubricationand cooling.

To insure prompt starting and evenrunning, the fuel system mustbe primed if air has entered the fuelsystem. Priming is done by connectinga manual or electric priming pump tothe secondary fuel filter adaptor.

Authorized Detroit Diesel serviceoutlets are properly equipped and havethe trained technicians to perform thisservice.

Priming is not normally required ifthe filter elements are filled with cleanfuel when installed and the manifoldsare not drained of fuel.

If the engine is equipped with afuel/water separator, drain off anywater that has accumulated. Waterin fuel can seriously affect engine

performance and may cause enginedamage. Detroit Diesel recommendsinstallation of a fuel/water separatorwherever water contamination is aconcern.

Adding Fuel — When adding fuel,pay attention to the following:

□ Add winter or summer grade fuelaccording to the season of theyear.

□ Work in the cleanest conditionspossible.

□ Prevent water from entering thefuel tank.

For further information, refer to DieselFuels in the “HOW-TO SECTION”of this guide.

Priming the Fuel System —Prime the fuel system as follows:

1. If equipped with a hand pumpon the fuel filter or fuel/waterseparator, work the hand pumpuntil resistance is felt.

2. Crank the engine for 30 secondsat a time, but no longer. Beforecranking the engine again, waitat least two minutes. The engineshould start within six 30-secondattempts.



Other Checks

Make sure the transmission isfilled to the proper level with thefluid recommended by the gearmanufacturer. Do not overfill.







Make sure cable connections tothe storage batteries are clean andtight. Check the hydrometer “eye” ofmaintenance-free batteries for charge.See Figure 8.

If lead-acid or low-maintenancebatteries are used, make sure batteryelectrolyte level is normal.

Use only batteries that have beencorrectly filled and serviced. To

provide corrosion protection, applydielectric grease liberally to theterminal pads.

Check the turbocharger for signs ofoil or exhaust leaks. Leaks should becorrected before starting the engine.Check engine mounting bolts fortightness. Bolts should be retightened,if necessary.

Figure 8 Maintenance-FreeBattery “Eye”

Starting the Engine For The FirstTime

Before starting the engine the firsttime, perform the operations listed inthe System Checks section.



NOTICE:The turbocharger may be seriouslydamaged if the engine is crankedwith the air shutdown in the closedposition.

An emergency manual or automaticshutdown system, must be set in theopen position before starting.



□ Do not smoke when servicingether system.

□ Work in well ventilated area.

□ Do not work near open flames,pilot flames (gas or oilheaters), or sparks.

□ Do not weld or carry an openflame near the ether system ifyou smell ether or otherwisesuspect a leak.

The engine may require the use of acold weather starting aid if the ambienttemperature is below 40°F (4°C).

To start a Series 60 engine, make surethe transmission is in neutral and turnthe ignition key on.

ENGINE EXHAUST

To avoid injury from inhalingengine exhaust, always operatethe engine in a well-ventilatedarea. Engine exhaust is toxic.

PERSONAL INJURY


You will notice that both the AmberWarning Lamp and the Red Stop Lampwill come on. This is the result ofthe Detroit Diesel Electronic Control(DDEC®) computer diagnosingthe system to ensure everything isfunctional, including the light bulbsfor the warning lights. If everythingis OK, both lights will go out inapproximately five seconds.

Start the engine after the lights goout. If starting a vehicle, start theengine with foot off the foot pedal.



NOTICE:If the warning lights stay on, ordo not come on momentarily afterturning on the ignition, contactthe Detroit Diesel CustomerSupport Center at 313–592–5800.Operating the engine under thesecircumstances may result in enginedamage.

Electric Starter — Start an engineequipped with an electric startingmotor as follows:

NOTICE:To prevent serious starting motordamage, do not press the starterswitch again after the engine hasstarted.

1. Chock the tires, place thetransmission in neutral, and setthe parking brake.

2. With foot OFF the foot pedal,turn on the ignition switch andstart the engine

3. If the engine doesn't start after20 seconds, stop. Try again afterwaiting about one minute.

NOTICE:Do not rev the engine if the oilpressure gauge indicates no oilpressure. Shut down the enginewithin approximately ten secondsto avoid engine damage. Check todetermine the cause of the problem.

4. Monitor the oil pressure gaugeimmediately after starting theengine.

NOTE:Do not place the engine under full loaduntil it reaches operating temperature.

Running the EngineWhile the engine is operating, monitorthe battery charge indicator light,the oil pressure and avoid excessiveidling.

Oil Pressure

Observe the oil pressure gageimmediately after starting the engine.A good indicator that all moving partsare getting lubrication is when the oilpressure gage registers pressure 35kPa or 5 psi at idle speed.

If no pressure is indicated within 10 to15 seconds, stop the engine and checkthe lubrication system.



The pressure should not drop below193 kPa or 28 psi at 1800 rpm, andnormal operating pressure should behigher. If oil pressure does not fallwithin these guidelines, it should bechecked with a manual gage.

HOT OIL

To avoid injury from hot oil, donot operate the engine with therocker cover(s) removed.

Warm-up

Run the engine at part throttle forabout five minutes to allow it to warmup before applying a load.

Inspection

While the engine is idling, inspect thetransmission, check for fluid leaks,check the crankcase and turbocharger.

Transmission — While theengine is idling, check the automatictransmission (if equipped) for properoil level and add oil as required.

Fluid Leaks — Look for coolant,fuel or lubricating oil leaks. If anyare found, shut down the engineimmediately and have the leaksrepaired after the engine has cooled.

Crankcase — If the engine oilwas replaced, stop the engine afternormal operating temperature hasbeen reached. Allow the oil to drainback into the crankcase for abouttwenty minutes, then check the oillevel. If necessary, add oil to bringthe level to the proper mark on thedipstick. Use only the heavy-duty oilsrecommended. Refer to How to SelectLubricating Oil in this guide.

Turbocharger — Make a visualinspection of the turbocharger foroil leaks, exhaust leaks, excessivenoise or vibration. Stop the engineimmediately if a leak or unusual noiseor vibration is noted. Do not restartthe engine until the cause of theconcern has been investigated andcorrected. Authorized Detroit Dieselservice outlets are properly equippedto perform this service.

Avoid Unnecessary Idling

Whenever possible, avoid unnecessaryidling.

During long engine idling periodswith the transmission in neutral, theengine coolant temperature may fallbelow the normal operating range.



The incomplete combustion of fuelin a cold engine will cause crankcaseoil dilution, formation of lacquer orgummy deposits on the valves, pistons,and rings, and rapid accumulation ofsludge in the engine. When prolongedidling is necessary, maintain at least850 rpm spring/summer and 1200 rpmfall/winter.

Stopping the EngineStop an engine under normal operatingconditions as follows:

1. Reduce engine speed to idle andput all shift levers in the neutralposition.

NOTICE:Do not stop a turbocharged engineimmediately after a high-speedoperation. Allow a sufficientcool-down period to prevent theturbo from continuing to turn withoutan oil supply to the bearings.

2. Allow the engine to run betweenidle and 1000 rpm with no loadfor four or five minutes. Thisallows the engine to cool andpermits the turbocharger to slowdown. After four or five minutes,shut down the engine.

Emergency Jump StartingThe DDEC VI system operates on 12volts DC. If a DDEC VI engine withan electric starting motor requiresemergency jump starting, do notexceed 16 volts DC.

BATTERY EXPLOSION

To avoid injury from batteryexplosion when jump starting theengine, do not attach the cableend to the negative terminal ofthe disabled battery.

NOTICE:Jump starting with voltages greaterthan those indicated or reversingbattery polarity may damage theMotor Control Module.

NOTICE:Failure to connect jumper cablesin the proper sequence can resultin alternator and/or equipmentdamage.



Before attempting to jump start theengine, make sure the jumper cablesare connected properly (positive topositive, negative to negative ground)and in the proper sequence (negativeto negative ground last).







Routine Engine StartFollowing are procedures for a routineeveryday engine start.

ENGINE EXHAUST


PERSONAL INJURY


Starting the Engine-Routine

Before a routine start, refer to theMAINTENANCE section and see thedaily checks for your engine.



Important: Before starting theengine, carefully read all operatinginstructions in this manual and do allthe recommended pretrip inspectionsand daily maintenance. Check theengine oil and fuel levels, and draincontaminants from the fuel/waterseparator (optional).

NOTE:If you drain the fuel/water separatorcompletely, you may have to prime thefuel system.

NOTE:As a safety function, the electronicengine control system may be wired tostart the engine only If the transmissionis in neutral. This is vehicle applicationspecific.

1. Turn on the ignition switch.

2. With the accelerator pedal in theidle position, start the engine.

3. Check the engine for leaks.

[a] Check all hoses, hose clamps,and pipe unions on the enginefor tightness. Shut down theengine and tighten them ifnecessary.

[b] Check the oil feed and returnlines at the turbocharger fortightness. Shut down theengine and tighten them ifnecessary.

4. Shut down the engine.

5. Approximately five minutes aftershutdown, check the engine oillevel. If necessary, add oil up tothe satisfactory fill range on theoil dipstick (see Figure 9). Do notoverfill.

Figure 9 Oil Dipstick

6. Check all the mounting fastenerson the engine for tightness.

Checking the Coolant Level(Cold Check)

Check coolant level as follows:

1. Ensure that all coolant plugs inthe bottom of the radiator and onthe radiator outlet pipe are secureand tight.

2. Check the coolant level. Thecooling system is correctly filledwhen the coolant is between the



maximum and minimum markson the surge tank.

NOTE:For more information, refer to the“MAINTENANCE” section.

Checking the Coolant Level (HotCheck)

Check the coolant levels as follows:

1. Allow the engine to run forapproximately five minutes at amoderate speed.

HOT COOLANT


2. Then, with the coolanttemperature above 50°C (122°F),recheck the coolant level.

3. Add more coolant if necessary.Open the heater valves beforeadding coolant.

4. Do not close the heater valvesuntil the engine has been run

briefly and the coolant levelagain checked and corrected asnecessary.

Monitoring EngineOperationWhile the engine is operating, monitorthe battery charge indicator light,the oil pressure and avoid excessiveidling.

Battery Charge

The battery charge indicator lightmust go out once the enginestarts. See Figure 10

Figure 10 Battery Charge IndicatorLight

If the indicator light comes onwhile the engine is running, do thefollowing:



FIRE

To avoid injury from fire, keep allpotential ignition sources awayfrom diesel fuel, including openflames, sparks, and electricalresistance heating elements. Donot smoke when refueling.

1. Shut down the engine.

2. Check the poly-V belt fortightness.

3. Charge or replace the batteries asneeded.

4. If necessary, visit the nearestauthorized dealer to have thealternator voltage and outputchecked. Do a load test on thebatteries.

Oil Pressure

When the engine has reached itsnormal operating temperature, theengine oil pressure must not dropbelow the following values:

□ 193 kPa (28 psi) at rated speed

□ 35 kPa (5 psi) at idling speed

If oil pressure drops below thesevalues, stop the engine and determinethe cause.

Excessive Idling

Never allow the engine to idle formore than 30 minutes. Excessiveidling can cause oil to leak from theturbocharger.

Changing the Idle SpeedThe rpm range of the Series 60 engineis 600 to 850 rpm if the parameters inthe Common Powertrain Controller(CPC) are set to the default range.

Change the idle speed as follows:

1. Turn the cruise control switch tothe ON position.

2. To increase the idle speed, pushthe RSM/ACL switch until theidle is fast enough.

3. To decrease the idle speed, pushthe SET/CST switch until the idleis slow enough.

Shutting Down the EngineIf the engine has been running at fulloutput or the coolant temperature hasbeen high, allow the engine to idlefor four or five minutes without load.Then turn off the ignition key switch.

If any of the following occur, shutdown the engine immediately.

□ The oil pressure swings back andforth or falls sharply.



□ Engine power and rpm fall, eventhough the accelerator pedalremains steady.

□ The exhaust pipe gives off heavysmoke.

□ The coolant and/or oil temperatureclimb abnormally.

□ Abnormal sounds suddenly occurin the engine or turbocharger.

Shutting Down After High LoadOperation

After high load operation, do thefollowing:

NOTICE:An engine running at full output orwith high coolant temperature aftera high load operation, should idlefor one or two minutes without load.Shutting down without idling maycause damage to the turbocharger.

Turn off the ignition switch and shutdown the engine.

Emergency Running ModeThe engine is equipped with DDECVI which monitors the engine as it isrunning.

As soon as a fault is detected, it isevaluated and one of the followingmeasures is initiated.

NOTICE:

To prevent possible serious enginedamage, have any faults correctedwithout delay by an authorizeddealer.

□ In conjunction with any dashboardor instrument panel display, thecode for the electronic controlunit reporting the fault can be readimmediately on the display.

□ If the fault is serious enough toimpair normal operation, DDECVI switches over to limp homemode. The limp home speed isdependent on MCM parametersand could be idle speed or 1000rpm. This allows you to move thevehicle to a service location.

Stop Engine OverrideOptionThe Stop Engine Override Optionis used for a momentary override.The Motor Control Module (MCM)will record the number of times theoverride is activated after a faultoccurs.



Momentary Override – A StopEngine Override (SEO) switchis used to override the shutdownsequence (see Figure 11). Thisoverride resets the 60 second (30seconds for oil pressure) shutdowntimer, restoring power to the levelwhen the Red Stop Lamp (RSL)/StopEnginewas illuminated. The switchmust be recycled after five seconds toobtain a subsequent override.

Figure 11 SEO Switch andWarning Lamps

NOTE:The operator has the responsibility totake action to avoid engine damage.

Cold Weather OperationSpecial precautions must be takenduring cold weather. To protectyour engine, special cold weatherhandling is required for fuel, engineoil, coolant, and batteries. For detailedinformation, refer to the servicemanual.

Winter Fronts

A winter front may be used to improvecab heating while idling. At least 25%of the grill opening should remainopen in sectioned stripes that runperpendicular to the charge air coolertube flow direction. This assures evencooling across each tube and reducesheader to tube stress and possiblefailure. Winter fronts should only beused when the ambient temperatureremains below -12.2° C (10° F).



DDEC VI SYSTEM

Detroit Diesel Series 60 enginesequipped with DDEC are identifiedby the letter “G” in the sixth positionof the model number. Example:6067HG6E. The Series 60 engine for2007 is equipped with DDEC VI.

DDEC VI regulates the fuelinjection quantity and timing usingsolenoid valves, allowing extremelylow-emission operation. Besides theengine and its related sensors, thesystem has two control modules:

□ The Motor Control Module(MCM)

□ The Common PowertrainController (CPC) located underthe right-hand dash panel

The two control units are connected bya proprietary datalink through whichall necessary data and information canbe exchanged.

The CPC broadcasts all informationon the J1587 and J1939 datalinks,where it can be read by the diagnostictool.

The MCM monitors both the engineand the datalink. When a malfunctionor other problem is detected, thesystem selects an appropriateresponse; for example, the emergencyrunning mode may be activated.

The Accelerator Pedal Assembly(AP) eliminates the need for anythrottle linkage.

Motor Control ModuleThe MCM (see Figure 12) is typicallylocated on the left-hand side of theengine.

The MCM processes the data receivedfrom the CPC, for example theposition of the accelerator pedal,engine brake, etc.

Figure 12 MCM

These data are evaluated togetherwith the data from the sensors onthe engine, such as coolant andfuel temperature and oil and chargepressure. The data is then compared tothe characteristic maps or lines storedin the MCM.


DDEC VI SYSTEM

From these data, quantity and timingof injection are calculated.

NOTE:To obtain a replacement MCM, allthe data given on the MCM label arerequired.

The MCM data label has the 10 digitengine serial number (see Figure 13).

Figure 13 MCM Label

Common PowertrainControllerThe CPC communicates with anyother MCM unit installed on thevehicle over the J1939 data link.See Figure 14.

Data for specific applications is storedin the CPC. These include idle speed,maximum running speed, and speedlimitation.

Figure 14 CPC

The CPC receives data from thefollowing sources:

□ The operator (accelerator pedalposition, engine brake switch)

□ Other electronic control units(for example, the anti-lock brakesystem)

□ The MCM (oil pressure andcoolant temperature)

From these data, instructions arecomputed for controlling the engineand transmitted to the CPC via theproprietary datalink.



DDEC FeaturesDDEC offers a variety of features andoptions designed to warn the operatorof an engine malfunction.

Options can range from warning panellights to automatic reduction in enginepower followed by automatic engineshutdown.

DDEC has the ability to performdiagnostics for self-checks andcontinuous monitoring of othersystem components.

Depending on the application,DDEC can monitor oil temperature,coolant temperature, oil pressure, fuelpressure, coolant level and remotesensors (if used).

DDEC connects to the AmberWarningLamp (AWL)/Check Engine and theRed Stop Lamp (RSL)/Stop Engine toprovide a visual warning of a systemmalfunction.

Cruise Control

Cruise Control is available with anyDDEC engine. Cruise Control willoperate in either Engine or VehicleSpeed Mode and maintain a targetedspeed (MPH or RPM) by increasing ordecreasing fueling. The targeted speedcan be selected and adjusted withdash-mounted switches. See Figure 15

Figure 15 Typical Cruise ControlSwitches

Cruise Control may also beprogrammed to permit fast idleusing the Cruise Control switches.

With the engine at normal idle,transmission in neutral and servicebrakes on, press the SPD CNTLSwitch, and use the RSM/ACCSwitch. The engine rpm shouldincrease to a pre-defined speed. Theengine rpm can be raised or loweredfrom this point using the SET/CSTand RSM/ACC switches.

Cruise Control will maintain the setspeed under normal road and loadconditions.


DDEC VI SYSTEM


To avoid injury from the loss ofvehicle control, do not use cruisecontrol under these conditions:

□ When it is not possible tokeep the vehicle at a constantspeed (on winding roads, inheavy traffic, in traffic thatvaries in speed, etc.).

□ On slippery roads(wet pavement, ice-orsnow-covered roads, loosegravel, etc.).

NOTICE:When descending a hill with CruiseControl OFF, do not allow theengine to exceed 2,500 rpm.Failure to observe this can result inover speeding and serious enginedamage.

It cannot limit vehicle speeds ondown grades if available enginebraking effort is exceeded, nor can itmaintain speed on upgrades if powerrequirements exceed engine powercapability.

Engine speed and power are variedunder Cruise Control to maintain the

set vehicle speed. The vehicle speedmust be above Min Cruise Set Speedand below Max Cruise Set Speed. Itis recommended that Max Cruise SetSpeed be set to the default to allowproper operation of other featuressuch as Fuel Economy Incentive andPasSmart. The Vehicle Speed Limitshould be used to limit vehicle throttlespeed.

When the SPD CNTL is in the ONposition, Cruise Control is engaged bymomentarily contacting the SET/CSTSwitch. As a check after each enginestart, DDEC looks for a one timeactivation of the clutch (if equipped)and service brake before DDECallows Cruise Control to be enabled.The MCM must also recognize thatthe Cruise Enable Switch has changed.If the Cruise Enable Switch is off, itneeds to be turned on. If the CruiseEnable Switch is on, it must be turnedoff then on for cruise to operate.

Holding the switch in the SET/CSTposition allows the vehicle to slow to alower speed. Toggling the switch willresult in a one mile-per-hour (1.6 kph)decrease in vehicle speed. If CruiseControl has been disabled, togglingthe RSM/ACC Switch restores thevehicle to the previously set cruisespeed.



Cruise Control can be overridden atany time with the throttle pedal ifthe vehicle is operating at less thanthe programmed Max Road Speed.Additionally, using either the brake orthe clutch will disable Cruise Control.

Data Recording Capability

DDEC VI contains the ability toextract detailed data on the engine’suse and performance using DDECReports software. This data, knownas DDEC Data, is stored in the CPCand contains information on engineperformance (such as fuel economy,idle time, time in top gear) and criticalincidents (such as detailed diagnosticdata records and hard braking events).DDEC Data can be downloaded usingDDEC Reports software to producereports.

DDEC Reports software is part ofthe Detroit Diesel Diagnostic Link®7.0 (DDDL 7.0) software package.DDDL 7.0 requires at least a PentiumII computer with at least 256 MB ofRAM.

Engine Brakes

Engine brakes are enabled by adash-mounted On/Off switch with aseparate intensity switch to select low,medium or high braking power.






The engine brakes will only operatewhen the Accelerator Pedal is fullyreleased. Disengaging the clutchwill prevent the engine brakes fromoperating.


DDEC VI SYSTEM

Engine brakes will supply brakingpower even when in Cruise Control.The MCM will control the amountof engine braking with respect tothe Cruise Control set speed. Themaximum amount of braking (low,medium, high) is selected with thedash switches.

Engine Protection

The DDEC engine protectionsystem monitors all engine sensorsand electronic components, andrecognizes system malfunctions. Ifa critical fault is detected, the AWL(Check Engine) and RSL (StopEngine) illuminate. The malfunctioncodes are logged into the MCM'smemory.

The standard parameters which aremonitored for engine protectionare: low coolant level, high coolanttemperature, low oil pressure, andhigh oil temperature.

This system features a 30-second,stepped-power shutdown sequenceor an immediate speed reductionwithout shutdown in the event a majorengine malfunction occurs, such aslow oil pressure, high oil or coolanttemperature, or low coolant level.

PERSONAL INJURY

To avoid injury from engineshutdown in an unsafe situation,ensure the operator knows howto override the stop enginecondition on a DDEC-equippedunit.

NOTICE:Engines equipped with thepower-down/shutdown option havea system override button or switchto allow engine operation for ashort period of time. Using theoverride button so the engine doesnot shutdown in 30 seconds butoperates for an extended periodmay result in engine damage.

California Engine Idle Limiting

In order to meet the California EngineIdle Limiting Standard, an engineidle shutdown feature has been builtinto the DDEC VI Engine ControlStrategy. When the California EngineIdle Limiting feature is enabled, theengine will generally shut down afterfive minutes of continuous idlingwhen the transmission is in neutralor park and the parking brake is setor after fifteen minutes when thetransmission is in neutral or park andthe parking brake is not set.



Activating or momentarily changingthe position of the service brakepedal, the clutch pedal, Stop EngineOverride, the accelerator pedal, orpark brake status during the final 30seconds before a shutdown wouldotherwise occur will prevent theengine from shutting down and willreset the shutdown timer. After anautomatic shutdown, the engine maybe restarted and operated normally.

The automatic shutdown featureis generally disabled on enginescertified by the US EPA for useoutside California but is required tobe enabled for all California certifiedengines with the exception of enginesused in specific vehicle types whichthe state of California has determinedto be exempt from the idle shutdownrequirement. These include buses,school buses, recreational vehicles,medium duty vehicles, military tacticalvehicles, and authorized emergencyvehicles as they are defined by thestate of California. Owners of thesevehicle types that wish to have theshutdown feature disabled shouldconsult with California authorities todetermine if their vehicles qualify forthe exemption.

Idle Shutdown Timer

This feature is an optional 1 –100 minute idle shutdown system.Its purpose is to conserve fuel byeliminating excessive idling and

allowing a turbocharger cool-downperiod. To activate the shutdown, thetransmission must be in neutral withthe vehicle parking brakes set and theengine in idle or fast-idle mode.

DDEC VI Operation

NOTE:This engine is equipped with DDECsoftware. This software generallyassures optimal engine performance.The installation of software upgradesmay cause minor changes in featuresand engine performance.

Since the DDEC system is electronic,a battery is required to operate thecomputer. The system operates at12 volts. However, in the event ofa power supply malfunction, thesystem will continue to operate atreduced voltage. When this occurs,the AWL (Check Engine) will comeon. See Figure 16.

Figure 16 Warning Lamps andSEO Switch


DDEC VI SYSTEM

The engine will only operate atreduced rpm until the battery voltagereaches a point where the MCM willno longer function and the engineshuts down.

Should the AWL (Check Engine)come on for any reason, the vehiclecan still be operated and the driver canproceed to the required destination.This condition should be reportedto an authorized Detroit Dieseldistributor or dealer.

NOTICE:When the RSL (Stop Engine) comeson, the computer has detected amajor malfunction in the enginethat requires immediate attention.It is the operator responsibilityto shut down the engine to avoidserious damage.

The engine can be configured togive a warning only, to ramp down(reduce power) or to shut down.Ramp down will reduce engine rpmto a pre-determined speed, but willnot shut down the engine. Withthe 30-second shutdown option, theengine will begin a 30-second, steppedpower-down sequence until it shutsdown completely.

A “Stop Engine Override” can beprocured in case the vehicle is tooperate in a critical location.

Stop Engine Override Switch

This feature allows the operator tooverride the automatic stop enginesequence.

This is done by pressing the StopEngine Override Switch every 15 to 20seconds to prevent engine shutdownfrom occurring.

NOTE:The Stop Engine Override Switch andthe Diagnostic Request Switch are thesame.

NOTE:Holding down the Stop EngineOverride Switch will not prevent theengine shutdown sequence. Youmust continue to reset the automaticshutdown system by pressing the StopEngine Override Switch at intervals ofapproximately 15 to 20 seconds.

It takes 30 seconds from the time theautomatic shutdown sequence beginsuntil engine shutdown. Therefore,the operator must press the overrideswitch just prior to engine shutdownand continue to do so until the vehiclecan be brought to a stop in a safelocation.



Immediate Speed Reduction

The immediate speed reduction optionwill bring engine rpm back to apredetermined speed, but will not shutdown the engine.

The engine should not be restartedafter it has been shut down by theengine protection system, unlessthe problem has been located andcorrected.

Red Stop Lamp

The conditions that will cause the RSL(Stop Engine) to come on are:

□ High coolant temperature

□ Loss of coolant

□ High oil temperature

□ Low oil pressure

□ Auxiliary shutdown

Whenever the AWL (Check Engine)or the RSL (Stop Engine) come on,the DDEC computer will determinewhere the problem is and will thenstore this information in its memory.

If the malfunction is intermittent, thelights will come on and go off as thecomputer senses the changing enginecondition.

Diagnostic Tool

The diagnostic tool for DDEC VI isDDDL 7.0. DDDL 7.0 requires at

least a Pentium II computer with atleast 256 MB of RAM.

Once the malfunction has beencorrected, the DDEC system willreturn the engine to normal operation.

The temperature of air in the intakesystem is increased with the additionof an EGR. DDEC is programmed toreduce fueling (power) for a short timeto reduce air and coolant temperatureswhen necessary.

DDEC will store an informationcode that this event occurred, butno corrective action is required asthis action is designed to maintainoperation without a noticeable affecton vehicle performance.

Flashing Malfunction Codes —All malfunction codes are four digits.The malfunction code recorded in thecomputer memory will remain until itis erased by a technician.

The flashing malfunction code canalso be obtained by the operator.To support flashing codes, a StopEngine Override/Diagnostic RequestSwitch must be configured and theAWL (Check Engine) and RSL (StopEngine) must be hard-wired. The CPCcannot flash these lamps if they arenot hard-wired.

The flashing code feature may beactivated by satisfying one of thefollowing conditions:


DDEC VI SYSTEM

□ Engine speed is <100 rpm andthe SEO switch is put in the ONposition.

□ Idle Governor is active and theSEO switch is put in the ONposition.

□ Vehicle speed is <3 mph and ParkBrake is activated and the SEOswitch is put in the ON position.

The flashing code feature isdeactivated once the SEO switchis returned to the OFF position orthe listed conditions are no longersatisfied.

Only one light will be flashing codesat any time. All codes will be flashedtwice. The inter-digit pause is 1.5

seconds. The pause between codesis 3.5 seconds. The same 3.5 secondpause occurs as the switch is madefrom RSL (Stop Engine) to AWL(Check Engine). See Figure 17.

When code flashing is initiated,the active codes will be flashed onthe RSL (Stop Engine). Then theinactive codes will be flashed on theAWL (Check Engine). When all theinactive codes have been flashed, theprocess of flashing all the active codesfollowed by all the inactive codes willrepeat until the conditions for codeflashing are no longer satisfied.

If there are no active or inactive faultsthe number 3 is flashed once followedby an inter-code gap of 3 seconds.

Figure 17 RSL (Stop Engine) Flashing Code Example



To Read Codes: Press and hold theSEO/Diagnostic Request Switch.Active codes will be flashed on theRSL (Stop Engine) first, followed byinactive codes being flashed on theAWL (Check Engine).

The codes will continue to flashand repeat as long as the DiagnosticRequest Switch is held in the ONposition. Both CPC and MCM faultsare included.

Active Codes — The active codeswill be flashed on the RSL (StopEngine) in the order of most recentto least recent occurrence based onengine hours.

Inactive Codes — The inactivecodes will be flashed on the AWL(Check Engine) in the order of mostrecent to least recent occurrence basedon engine hours.


DDEC VI ENGINE DRIVING TIPS


Driving with an electronicallycontrolled engine feels different fromdriving with a mechanically governedengine.

Accelerating the VehicleEngine response versus pedalmovement may feel different fromthe mechanical-governed engine youwere driving. The Accelerator Pedal(AP) was designed to communicate“percentage” foot pedal travel tothe engine's Motor Control Module(MCM). The engine will respondaccordingly to the driver's demand.

Another throttle or governorcharacteristic you may need time toget used to is the DDEC LimitingSpeed Governor. This allows thedriver to command total engineresponse between idle and rated speed,such as accelerating at half throttle– an advantage when driving underslippery conditions.

If you require wide-open throttleengine response, either accelerating orjust plain pulling hard, the throttle APwill have to be held to the floor. Toobtain 100% fueling at any speed, theAP will have to be maintained at thefully pressed position.

Cruise ControlFor added driver convenience andcomfort, DDEC VI also features aCruise Control option that works justlike the system in your car. It canbe operated in any gear above 1000rpm or road speed faster than 20mph (32 kph), up to the rated enginespeed. And it can be programmed tohold your road speed at or below themaximum vehicle speed. The switchto energize Cruise Control is usuallymounted on the instrument panel.See Figure 18

Figure 18 Typical Cruise ControlSwitches



Turn the switch ON to energize thesystem. Remember as a check aftereach engine start, DDEC VI looks fora one time activation of the clutch (ifequipped) and service brake beforeDDEC VI allows Cruise Control to beenabled.

DDEC VI must also see or recognizethat the Cruise Enable Switch haschanged. If the Cruise Enable Switchis OFF it needs to be turned ON. If theCruise Enable Switch is left in the ONposition at key OFF, the switch mustbe cycled OFF then ON for DDECVI to see a status change to allowCruise Control activation. The statusof DDEC VI inputs to activate CruiseControl at key ON is listed in Table 1.

Once Cruise Control is enabledand you reach your road speed,press the Set Switch to activateCruise Control. The cruise lightwill come on. To increase road

speed in one mile-per-hour (1.6kilometer-per-hour) increments, pressthe RSM/ACL Switch. To reduce roadspeed, press and hold the SET/CSTSwitch until the lower speed isreached.

Cruise Control is deactivated byslightly pressing the service brakes,clutch pedal, or trailer brake. TheOn/Off Switch will also deactivateCruise Control.

Cruise Control will maintain vehiclespeed even on up grades, unless powerrequirements demand a downshift.And, of course, Cruise Control doesnot limit your speed on down grades.Most likely, Cruise Control will feelstronger than driving with the footpedal because of the instantaneousand wide-open throttle response.That's why Cruise Control use is notsuggested during slippery drivingconditions.

Input Status of Input atKey ON

Status of InputBefore Cruise

Control ActivatesService Brake Switch ON OFF

Clutch Release Switch(Manual Trans only) ON OFF

Cruise Control EnableSwitch OFF ON

Table 1 Input Status to Activate Cruise Control



Use Cruise Control after down shiftingon a hill to pull the hill. Hitting theRSM/ACL Switch (not the Set Switch)will keep the truck accelerating in thelower gears up to the rated enginespeed.

Cruise Control will disengage below1000 rpm or 20 mph (32 kph) roadspeed. When using Cruise Control,if you want to pull the engine below1000 rpm, remember to hold thethrottle pedal to the floor to keep theengine pulling at wide-open throttle.The engine will pull to about 1050rpm.

Remember: The electronic dataprogrammed into the DDEC VIsystem will not allow you to hurt oroverfuel the engine at low or “lug”engine speeds. There is enough oilpressure to withstand hard pulls at lowengine speeds.

Engine Brakes and CruiseControlIf your engine is equipped with bothCruise Control and engine brakeretarders, the engine retarders canoperate automatically while youare in Cruise Control. If the CruiseControl/Engine Brake function isturned ON in the DDEC systemprogramming, the engine retarderswill come on “low” when yourset road speed increases a fewmiles-per-hour (kilometers per hour)

above your cruise set speed. Ifyour speed continues to increase,the DDEC system will increase theengine retarders' braking powerprogressively. When the vehiclereturns to the set cruise speed, theengine retarders will turn off until youneed them.

For safety reasons, don't use CruiseControl when it is not possible to keepthe vehicle at constant speed due to:

□ Winding roads

□ Heavy traffic

□ Slippery pavement

□ Descending grades that call forengine brake assistance.

For an explanation of the engine brakeretarder system and recommendationsfor proper operation, refer to ENGINEBRAKE SYSTEM.

ShiftingDepending on your transmissionmodel, the gear split may vary from500 to 300 rpm. The electronicgovernor provides almost no overruncapability; and, if the transmissionis downshifted too early, you willexperience a temporary loss of pullingpower until the engine speed fallsbelow rated speed.



In general, when using a 7- or 9-speedtransmission, you should alwaysdownshift between 1250 and 1300rpm. This is true even on steep gradeswith heavy loads. When using an18-, 15- or 13-speed transmission,you will need to downshift at an rpmthat allows “less than rated” rpmbefore throttle application in the nextgear down. You may want to limitengine speed to 1900 rpm in all gears.The Series 60 provides horsepowerthrough 2100 rpm, but fuel economyis not as efficient above 1800 rpm.

Low rpm operation should feel greatlyenhanced due to the characteristicsof the variable nozzle turbocharger.Engine response should be almostinstantaneous below peak torqueengine speeds. This should encourageprogressive shifting especially duringslow vehicle speed operation.

If you decide to drive at lower rpm'sfor improved fuel economy, don't letdifferent engine noises throw you offguard. The Series 60 sounds quietat 1400 rpm, almost as if it had quitpulling. If you had a boost gage tolook at while driving, you wouldnotice the turbocharger maintainingsteady intake manifold pressure, evenas rpm falls. Depending on the airintake arrangement, you may alsoexperience a “chuffing” sound as theengine starts to pull hard at lowerrpm's. This is caused by the velocitychanges of the air flow within the air

intake plumbing. Electronic enginescan actually deliver more fuel at lowerengine speeds than at rated speed.

One difference you may notice withthe EGR equipped engine is underhood noise. The gear train has beenredesigned for quieter operation,and the EGR gas flow may benoticeable to the tuned attentive ear.The turbocharger operates at higherboost pressure forcing EGR gas flowthrough the EGR plumbing. In somesituations the driver may believehe/she has experienced a charge aircooler system leak. Even connectingtrailer light and air hoses, the drivermay hear a different tone (exhaust andunder hood with the engine idling.) Ifequipped with a turbo boost gage, thedriver may occasionally note intakemanifold pressure exceeds 35 psi.

IdlingThe common belief that idling a dieselengine causes no engine damage iswrong. Idling produces sulfuric acid,which breaks down the oil and eatsinto bearings, rings, valve stems andengine surfaces. If you must idlethe engine for cab heat or cooling,the high idle function of the CruiseControl switches should be used.An idle speed of 900 rpm should beenough to provide cab heat in above32°F (0°C) ambients.


ENGINE BRAKE SYSTEM

ENGINE BRAKE SYSTEM

Certain Series 60 vehicle enginesare equipped with engine brakes,commonly referred to as retarders.Before operating the vehicle, youmust familiarize yourself with theretarder system to obtain optimumbenefit from it. Engine brake controlsystems may vary slightly, dependingon the engine brake configuration andcab design. However, basic operatorcontrols are similar for all models.

Driver Control SwitchesVehicles with manual transmissionsallow the driver to turn the enginebrake on and off and select a low,medium or high level of braking. Twotypes of switches are available.

Low/High Switch

The “Low” setting on this switchactivates three (3) brake cylinders,supplying approximately 50% ofnormal engine braking horsepower.The “High” setting activates all six(6) cylinders, providing full enginebraking horsepower.

Low/Med/High Switch

The “Low” setting on this switchactivates two (2) brake cylinders,yielding about one-third enginebraking horsepower. The “Medium”activates four (4) cylinders, supplying

about two-thirds engine brakinghorsepower. The “High” settingactivates all six (6) cylinders,providing full engine brakinghorsepower.

Clutch Pedal and ThrottlePosition ControlsEngine brakes have two additionalcontrols, one activated by the positionof the clutch pedal and the otheractivated by the position of thethrottle. These controls permit fullyautomatic operation of the enginebraking system.

Engine Brake OperationThe engine brake retarder systemdepends on a full-pressure flow ofwarm engine lubricating oil for properlubrication of moving parts andoptimum performance. .

NOTICE:Always allow the engine to reachfull normal operating temperaturebefore activating the engine brakesystem to ensure positive enginebrake engagement.








Under normal driving conditions theengine brake system is left in the ONposition. However, this should changeif roads become wet or slippery.

After it is switched on, the enginebrake system is automaticallyactivated each time you removeyour feet completely from the clutchpedal and throttle. The engine brakeautomatically deactivates itself when

you press the clutch pedal whileshifting gears.

NOTICE:Do not attempt to “double clutch”the transmission while the enginebrake system is turned on. Shiftinggears without pressing the clutch orusing the engine brake to reduceengine rpm may result in seriouspowertrain damage.

NOTE:Some systems may be programmedto activate themselves only when thebrake pedal is pressed, so read yourvehicle owner's manual thoroughly tofind out if you have this option.

Anti-Lock BrakingSystemsVehicles equipped with ABS(anti-lock braking systems) havethe ability to turn the engine brakeretarder OFF if a wheel-slip conditionis detected. The engine brake willautomatically turn itself ON once thewheel slip is no longer detected.


ENGINE BRAKE SYSTEM

The DDEC system will deactivatethe engine brake system when theengine speed falls below 1000 rpmor when the vehicle slows down to apre-set speed, depending on DDECprogramming. This prevents stallingthe engine. Engine brakes can alsobe used with vehicle Cruise ControlTURNED ON.

Driving on Flat, DryPavementUse the following guidelines whendriving on flat, dry pavement:

1. If driving on flat, dry, openstretches with a light load andgreater slowing power is notrequired, place the progressivebraking switch in the LOWposition.

2. If you find you are still using theservice brakes, move the switchto a higher position until you donot need to use the service brakesto slow the vehicle down.

3. If you are carrying a heavier loadand road traction is good, movethe progressive braking switch tothe “High” position.

4. Check your progressive brakingswitch often for proper position,since road conditions can changequickly. Never skip a step whenoperating the progressive brakingswitch. Always go from OFF

to LOW, and then to a higherposition.

Descending a Long, SteepGradeAn explanation of “control speed”may be helpful in understanding howto use the engine brake system whiledescending a grade. Control Speedis the constant speed at which theforces pushing the vehicle forward ona grade are equal to the forces holdingit back, without using the vehicleservice brakes. In other words, thisis the speed the vehicle will maintainwithout using the service brakes orfueling.

Use the following guidelines whendescending a long, steep grade:

1. Before beginning the descent,determine if your engine brakesystem is operating properly bylifting your foot briefly off thethrottle. You should feel thesystem activate.



BRAKE FADE

To avoid injury, do not overapply the vehicle service brakeswhen descending a long, steepgrade. Excessive use of thevehicle brakes will cause themto heat up, reducing theirstopping ability. This condition,referred to as “brake fade”, mayresult in loss of braking, whichcould lead to personal injury orvehicle/property damage or both.

2. Ensure the progressive brakingswitch is in the appropriate powerposition.

PERSONAL INJURY

Failure to keep the vehicle withinsafe control speed limits whiledescending a grade may resultin loss of vehicle control, whichcould cause personal injury.

NOTICE:Failure to keep the vehicle withinsafe control speed limits whiledescending a grade may result invehicle or property damage or both.

3. Do not exceed the safe controlspeed of your vehicle. Example:You could descend a 6% grade,under control only at 10 mph (16kph) without an engine brake, butat 25 mph (40 kph) with an enginebrake. You could not descendthat same hill at 50 mph (80 kph)and still expect to remain undercontrol. Get to know how muchslowing power your engine brakecan provide. So get to knowyour engine brake system beforeclimbing hills and do not exceeda safe control speed.

4. Check your progressive brakingswitch often for proper position,since road conditions can changequickly. Never skip a step whenoperating the progressive brakingswitch. Always go from OFFto LOW and then to a higherposition when on slippery roads.


ENGINE BRAKE SYSTEM

Driving on Wet or SlipperyPavementDo not attempt to use the engine brakesystem on wet or slippery roads untilyou have some experience with it ondry pavement.






NOTE:On single trailers or combinations,a light air application of the trailerbrakes may be desirable to help

keep the trailer stretched out. Followthe manufacturer's recommendedoperating procedure when using yourtrailer brakes.

On wet or slippery pavement, startwith the master switch in the OFFposition and use the gear you wouldnormally use under these conditions.

If the vehicle is maintaining traction,place the selective braking switch inthe LOW position and turn ON theengine brake system. If the drivewheels are maintaining traction andyou desire greater slowing power,move the braking switch to the nexthighest position.

However, if the tractor drive wheelsbegin to lock or there is a fishtailmotion, turn the engine brake systemOFF immediately and do not activateit until road conditions improve.

Check your progressive brakingswitch often for proper position, sinceroad conditions can change quickly.Never skip a step when operating theprogressive braking system. Alwaysgo from OFF to LOW and then to ahigher position.



ENGINE SYSTEMS

The engine systems are the following:

Fuel SystemThe fuel system consists of DDEC,fuel injectors, fuel manifolds (integralwith the cylinder head), fuel pump,a cooling plate for the MotorControl Module (MCM), primaryand secondary fuel filters, and thenecessary connecting fuel lines.

Lubrication SystemThe lubricating oil system consists ofan oil pump, oil cooler, two full-flowoil filters, bypass valves at the oilpump and oil filter adaptor, andoil pressure regulator valve in thecylinder block vertical oil gallery.

Air SystemThe outside air drawn into theengine passes through the air filterand is pulled into the turbochargerand compressed. It then moves tothe air-to-air charge cooler (heatexchanger) and is cooled. Next itflows to the intake manifold and intothe cylinders, where it mixes withatomized fuel from the injectors.

For optimum protection of theengine from dust and other airbornecontaminants, service the dry typeair cleaners used when the maximum

allowable air restriction has beenreached, or annually, whicheveroccurs first.

Cooling SystemA radiator/thermo-modulated fancooling system is used on Series 60engines. This system has a centrifugaltype fresh water pump to circulatecoolant within the engine. Twofull-blocking type thermostats locatedin a housing attached to the right sideof the cylinder head control the flowof coolant.

Electrical SystemThe electrical system consists ofa starting motor, starting switch,battery-charging alternator, storagebatteries, and the necessary wiring.

Exhaust SystemHot exhaust gas flowing from theexhaust manifold into the exhaust riseris used to drive the turbocharger.

Exhaust Gas RecirculationSystemThe purpose of the Exhaust GasRecirculation System (EGR) is toreduce engine exhaust gas emissionsin accordance with EPA regulations.


AFTERTREATMENT SYSTEM


In order to meet current emissionsregulations, the traditional muffler hasbeen replaced by a new AftertreatmentDevice (ATD). This device consistsof a Diesel Oxidation Catalyst (DOC)and a Diesel Particulate Filter (DPF).Together these two components burnoff collected particulate matter in aprocess called “regeneration.” The

key to successful regeneration is highexhaust temperature for an extendedperiod of time. Without adequatetemperatures for regeneration, thefilter will continue to trap particulatesand eventually plug. In order to avoidplugging, Detroit Diesel has designedan actively regenerated AftertreatmentSystem (ATS). See Figure 19.

Figure 19 Aftertreatment System



Operating RequirementsOxidation of the particulate matteris the key to filter performance.This requires that the catalyzingagent (platinum coated passages)are providing optimum enhancementto the oxidation process. Thefollowing requirements must be met,otherwise the ATD warranty may becompromised:

NOTICE:Do not use kerosene or fuel blendedwith used lube oil.

□ Use Ultra-Low Sulfur Fuel (ULSF)with 15 ppm (0.0015 wt%) sulfurcontent or less, based on ASTMD2622 test procedure

□ Lube oil must have a sulfated ashlevel less than 1.0 wt %; currentlyreferred to as CJ-4 oil.

NOTICE:

Not following the operatingrequirements may result in damageto the ATD or accelerated ashplugging of the diesel particulatefilter.

MaintenanceA high amount of black smokeemitting from the vehicle orillumination of the Amber WarningLamp or Red Stop Lamp areindications of a system problem.Should this occur, refer to theAftertreatment System Technician'sGuide (7SE63), or contact the DetroitDiesel Customer Support Center at313–592–5800.

Illumination of the Diesel ParticulateFilter (DPF) Regeneration Lampindicates that a parked regeneration isrequired.

There is a need to periodically removeaccumulated ash, derived from enginelube oil, from the filter. This ashdoes not oxidize in the filter duringthe regeneration process and mustbe removed through a cleaningprocedure. All Detroit Diesel ATDequipped engines will illuminate adashboard warning lamp indicating theneed for ash cleaning. For informationon this cleaning procedure, refer to theAftertreatment System Technician'sGuide (7SE63), or contact the DetroitDiesel Customer Support Center at313–592–5800.



Parked RegenerationProcedureRegeneration of the ATS isfundamental for the oxidation ofsoot. This process happens duringthe normal operation cycle of thevehicle; it can occur both passivelyand actively. Regardless of this,the operator will see no differencein vehicle performance or vehiclecontrol. If the ATS is not capableof completing an over-the-roadregeneration due to duty cycleconstraints or other restrictions, aparked regeneration may need tooccur.

The driver will be notified of theneed for a DPF regeneration byillumination of the DPF RegenerationLamp. Refer to section DRIVERACTIONS .

NOTE:If the DDEC VI electronics have notrequested the initiation of a parkedregeneration (the DPF RegenerationLamp is not illuminated), the Regenrequest switch is disabled.

NOTE:The driver MUST stay with the vehiclethroughout the regeneration process.

NOTE:Not all vehicles may be equippedwith a Regen request switch due toapplication or user specification.

NOTE:The procedure will take up to40 minutes (depends on engine typeand the amount of soot accumulatedin the filter).



To initiate a parked regeneration,perform the following:

1. Keep engine at slow idle (cannotbe in PTO mode).

2. Transmission is in neutral withparking brake ON.

3. Cycle the parking brake fromOFF to ON.

NOTE:Air tank pressure must be high enoughfor the parking brake switch to hold inthe OFF position.

4. Press and release clutch pedal (ifequipped with clutch pedal).

5. Cycle transmission to DRIVEand back to NEUTRAL (if notequipped with clutch pedal).

6. Hold DPF Switch in the ONposition for five seconds andthen release (engine speed willincrease and DPF Lamp will goout).

The regeneration will take up to 40minutes.

The regeneration is completed whenthe engine returns to low idle and theDPF Lamp remains off. The HighExhaust System Temperature (HEST)Lamp will remain on but the vehiclecan be driven.

If the Parked Regeneration exits andthe DPF Lamp remains on, repeat theprocedure. If the second try also fails,contact the Detroit Diesel CustomerSupport Center at (313) 592-5800.

NOTE:A Parked Regeneration will stop if thekey is turned to the OFF position, thevehicle is put into gear, or the parkingbrake is released.

Hazardous Applications

The MCM should be configured tonot allow automatically triggeredover-the-road regenerations (DPFManual Regen Only Enable =Enabled).

NOTE:This is for hazardous applications only.

There are two CPC options:

□ DPF Stationary Regen Only =0-Disabled

□ DPF Stationary Regen Only =1-Enabled



DPF Stationary Regen Only =0-Disabled — This option allowsthe DPF Regen Switch to requesta parked regeneration if the parkedregeneration entry conditions are met.This option also allowsMCM-initiatedover-the-road regenerations to occur.

DPF Stationary Regen Only =1-Enabled — This option onlyallows a parked regeneration tooccur by using the DPF RegenerationSwitch. The MCM will be unableto initiate an active over-the-roadregeneration when this option isenabled.

Service RecordIt is mandatory that customers ordistributors maintain a proper recordof the particulate filter servicing andcleaning. This record is an agent towarranty considerations. The recordmust include information such as:

□ Date of cleaning or replacement

□ Vehicle mileage at the time ofcleaning or replacement

□ Particulate filter part number andserial number



DRIVER ACTIONS

Name IndicatorLamp Description Driver Action

SOLID: Exhaust is athigh temperature andvehicle is at low speedor parked.

High ExhaustSystem

Temperature(HEST) Lamp

FLASHING: A ParkedRegeneration is inprocess and the systemis not up to temperature.

No change in drivingstyle is required.

MalfunctionIndicator

Lamp (MIL)

Indicates a failure ofan Emission ControlDevice. The MIL mayilluminate at the sametime as the CheckEngine Lamp.

Vehicle can bedriven to end ofthe shift. If the MILremains on afterthree drive cycles,call for service.

DPFRegeneration

Lamp

SOLID: Indicates thata Regeneration may beneeded.

FLASHING: Indicatesthat a Regeneration isrequired as soon aspossible.

Perform a ParkedRegeneration ORbring vehicle tohighway speedsto allow foran AutomaticRegeneration.

DPFRegeneration

Lamp+

CheckEngine Lamp

FLASHING+

Indicates that a ParkedRegeneration MUST beperformed.

A ParkedRegeneration mustbe performed.

ENGINE DERATE


DRIVER ACTIONS

Name IndicatorLamp Description Driver Action

DPFRegeneration

Lamp+

CheckEngine Lamp

+Red Stop

Lamp (RSL)

FLASHING+

+

Indicates that a ParkedRegeneration MUST beperformed.

A ParkedRegeneration mustbe performed.

ENGINE DERATE

Table 2 Driver Actions



INSTRUMENT PANEL LAMPS

Lamp LampName Description Results

AmberWarning

Lamp (AWL)

Indicates a fault with theengine controls.

Vehicle can bedriven to endof shift. Call forservice.

Red StopLamp (RSL)

Indicates a major enginefault that may result inengine damage. Enginederate and/or shutdownsequence will be initiated.

Move the vehicleto the nearestsafe location andshutdown theengine. Call forservice

DPF Regen-eration Lamp

Solid yellow indicates aparked regeneration isrequired. Blinking yellow,derate, and/or shutdownare possible as soot loadcontinues to increase.Lamp will shut off duringparked regeneration.

Lamp Solid- parkedregenerationrequiredLamp Flashing- parkedregenerationrequiredimmediately.

High ExhaustSystem

TemperatureLamp

(HEST)

Indicates exhausttemperature is abovea preset limit and the unitis operating at low vehiclespeed. Lamp flashes onceevery ten seconds duringa parked regen. Lamp isyellow.

Vehicle can bedriven.

MalfunctionIndicator

Lamp (MIL)

Yellow lamp Indicates afailure of an EmissionControl device. Mayilluminate at the same timeas the Amber WarningLamp

Vehicle can bedriven to end ofthe shift. Call forservice

Table 3 Instrument Panel Lamps


INSTRUMENT PANEL LAMPS

The activation conditions arelisted in Table 4.

Lamp Lamp Solid Lamp Flashing

□ At the start of every ignitioncycle (a bulb check).

□ When an electronic systemfault occurs (problemshould be diagnosed assoon as possible).

□ Diagnostic Request Switchis used to activate the AWLto flash inactive codes.

□ Last 90 seconds before idleshutdown if programmedfor override.

□ Idle shutdown or theOptimized Idle shutdownoccurs.


□ A potential enginedamaging fault isdetected.

□ When Engine ProtectionShutdown occurs.

□ Diagnostic Request Switchis used to activate the RSLto flash active codes.

□ Parked regeneration isrequired.


When a parked regenerationis required immediately (Ifthe lamp flashing is ignored,derate and/or shutdown couldoccur.


□ Vehicle speed is less than5 mph and the DPF outlettemperature is greaterthan 977°F (525°C).

Flashes every 10 secondsduring a parked regen


□ For any emission relatedfault (light out when thefault is inactive)

Never flashes

Table 4 Lamp Activation Conditions



MAINTENANCE

The following is intended as aguide for establishing preventivemaintenance intervals. Therecommendations given shouldbe followed as closely as possibleto obtain long life and optimumperformance from your engine.Maintenance intervals indicated aretime (hours) of actual operation.

The intervals shown apply only tothe maintenance functions described.These functions should be coordinatedwith other regularly scheduledmaintenance.

Scheduled IntervalsA description of the maintenance tobe performed for each item in thefollowing tables can be found in thePreventive Maintenance Intervalssection.

Recommended maintenance intervalsfor Series 60 on-highway truckand parlor coach engines arelisted in Table 5, Table 6 and Table7. Recommended maintenanceintervals for Series 60 fire fighting,crash/rescue, and emergency vehicleengines are listed in Table 8, Table9, and Table 10. Recommendedmaintenance intervals for Series 60crane engines are listed in Table 11,Table 12, and Table 13.

NOTICE:Failure to check and maintainSCA (supplemental coolantadditive) levels at requiredconcentrations will result insevere damage (corrosion) tothe engine cooling system andrelated components. Coolant mustbe inhibited with the recommendedSCAs listed in this guide. Refer to“How to Select Coolant”. In addition,the engine can be equipped with acoolant filter/inhibitor system as aninstalled option or as an after-saleitem.


MAINTENANCE

Item DailyChecks

7,500 Miles(12,000 Km)

30,000 Miles(48,280 Km)

1. Lubricating Oil I R

2. Fuel Tank I

3. Fuel Lines & Flex Hoses I

4. Cooling System I

5. Turbocharger I I

6. Battery I

7. Aftertreatment Device Inspect every 6 months or 15,000miles (24,000 Km)

8. Drive Belts I

9. Air Compressor I

10. Air Cleaner I

11. Lube Oil Filters R

12. Fuel Filters R

13. Coolant/Inhibitor Level I

All items are described in Preventive Maintenance Intervals.I – Inspect, service, correct or replace as necessary.R – Replace.

Table 5 On-Highway Truck and Parlor Coach Daily, 7,500 Mile, and15,000 Mile Checks



Months 6 12 18 24 30 36 42 48 54 60Miles/Km( X 1000)

15/24

30/48

45/72

60/96

75/120

90/144

105/168

120/192

135/216

150/240

Item Procedure

1. Lubricating Oil Replace every 30,000 miles (48,280 km).

2. Fuel Tank I I I I I

4. CoolingSystem I I

5. Turbocharger I I I I I I I I I I7. Aftertreatment

DeviceInspect every 6 months or 15,000 miles (24,000 Km)Severe Duty: ash removal at 550,000 miles (893,185 Km)Short-Haul: ash removal at 550,000 miles (893,185 Km)Long-Haul: ash removal at 550,000 miles (893,185 Km)

8. Drive Belts I I I I I I I R I I

9. AirCompressor I I I I I I I I I I

11. Lube Oil Filter Replace when lubricating oil is changed.

12. Fuel Filters R R R R R R R R R R13. Water Pump/

Inhibitor Level I I I I I I I I I I

14. Cranking Motor Follow manufacturer's recommendations.

15. Air System I I I I I I I I I I

16. ExhaustSystem I I I I I I I I I I


Table 6 On-Highway Truck and Parlor Coach Regular MaintenanceIntervals


MAINTENANCE

Months 6 12 18 24 30 36 42 48 54 60Miles/Km( X 1000)

15/24

30/48

45/72

60/96

75/120

90/144

105/168

120/192

135/216

150/240

Item Procedures17. Engine

(Steam Clean) I I

18. Radiator & A/ACharge Cooler I I I I I

19. Oil Pressure I I20. Battery Charging

Alternator I I I I I I I I I I

21. Engine &Transmission Mounts I I

22. Crankcase Pressure I I

23. Fan Hub I

24. Thermostats & Seals I

25. Crankcase Breather I

26. Engine Tune-Up I

27. Vibration Damper Replace at major engine overhaul or earlierif dented or leaking.


Table 7 On-Highway Truck and Parlor Coach Regular MaintenanceIntervals (continued)



Item DailyChecks

100 Hours or3,000 Miles( 4,800 Km)

300 Hours or6,000 Miles( 9,600 Km)

1. Lubricating Oil I R

2. Fuel Tank I

3. Fuel Lines & Flexible Hoses I

4. Cooling System I

5. Turbocharger I

6. Battery I

7. Aftertreatment Device Inspect every 6 months or 15,000miles (24,000 Km)

8. Drive Belts I

9. Air Compressor I

10. Air Cleaner I

11. Lube Oil Filter R

12. Fuel Filters R

13. Coolant/ Inhibitor Level I

18. Radiator I

20. Battery Charging Alternator I


Table 8 Fire Fighting, Crash/Rescue and Emergency VehicleEngine Daily, 100 Hour and 300 Hour Checks


MAINTENANCE

Hours 300 600 900 1,200 1,500Miles/Km(X 1000)

6/9.6

12/19.6

18/28.8

24/38.4

30/48

Item Procedures

1. Lubricating Oil Change every 300 hours or 6,000 miles (1,600km), whichever comes first.

2. Fuel Tank I I I I I

4. CoolingSystem I I

5. Turbocharger7. Aftertreatment

DeviceInspect every 6 months or 15,000 miles (24,000 Km)Severe Duty: ash removal at 400,000 miles (643,720 Km)Short-Haul: ash removal at 500,000 miles (804,650 Km)Long-Haul: ash removal at 600,000 miles (965580 Km)

9. AirCompressor I I I I I

11. Lube OilFilters Replace when lubricating oil is changed.

12. Fuel Filters R R R R R13. Water Pump/

Inhibitor Level I I I I I

14. CrankingMotor Follow manufacturer's recommendations.

15. Air System I I I I I

16. ExhaustSystem I I I I I


Table 9 Fire Fighting, Crash/Rescue and Emergency VehicleEngine Regular Maintenance Intervals



Hours 300 600 900 1,200 1,500Miles/Km(X 1000) 6/9.6 12/19.3 18/28.8 24/38.4 30/48

Item Procedures

17. Engine (Steam Clean)18. Radiator & A/A Charge

Cooler I I I I I

19. Oil Pressure I I20. Battery Charging

Alternator I I I I I

21. Engine & TransmissionMounts I I

22. Crankcase Pressure I I

23. Fan Hub I

24. Thermostats & Seals

25. Crankcase Breather I

26. Engine Tune-Up I

27. Vibration Damper Replace at major engine overhaul orearlier if dented or leaking.

All items are describled in Preventive Maintenance Intervals.I – Inspect, service, correct or replace as necessary.R – Replace.

Table 10 Fire Fighting, Crash/Rescue and Emergency VehicleEngine Regular Maintenance Intervals (continued)


MAINTENANCE

Item DailyChecks

100 Hror

3,000 Mi

150 Hror

4,500 Mi

200 Hror

6,000 Mi

300 Hror

9,000 Mi1. Lubricating Oil I

2. Fuel Tank I I3. Fuel Lines &

Flexible Hoses I

4. Cooling System I

5. Turbocharger I

6. Battery I

7. Tachometer Drive I

8. Drive Belts I

9. Air Compressor I

10. Air Cleaner I

11. Lube Oil Filters —

12. Fuel Filters R13. Coolant/ Inhibitor

Level I

18. Radiator I20. Battery Charging

Alternator I


Table 11 Crane Engine Daily, 100 Hour, 150 Hour, 200 Hour, and300 Hour Checks



Hours 150 300 450 600 750 900 1050 1200 1350 1500Miles/Km( X 1000)

4.5/7.2

9.0/14.4

13.5/21.6

18/28.8

22.5/36

27/43.2

31.5/50.4

36/57.6

40.5/64.6

45/72

Item Procedures

1. Lubricating Oil Change lubricating oil every 250 hours or 1year, whichever comes first.

2. Fuel Tank I I I I I4. Cooling

System I I

5. Turbocharger I I I I I I I I I I7. Tachometer

Drive I I I I I I I I I I

8. Drive Belts I I I I I I I R I I9. Air

Compressor I I I I I I I I I I

11. Lube Oil Filters Replace when lubricating oil is changed.

12. Fuel Filters R R R R R R R R R R13. Coolant Pump/

Inhibitor Level I I I I I I I I I I

14. CrankingMotor Follow manufacturer's recommendations.

15. Air System I I I I I I I I I I


Table 12 Crane Regular Maintenance Intervals


MAINTENANCE

Hours 150 300 450 600 750 900 1050 1200 1350 1500Miles/Km( X 1000)

4.5/7.2

9.0/14.4

13.5/21.6

18/28.8

22.5/36

27/43.2

31.5/50.4

36/57.6

40.5/64.6

45/72

Item Procedures

16. Exhaust System I I I I I I I I I I17. Engine

(Steam Clean)18. Radiator & A/A

Charge Cooler I I I I I

19. Oil Pressure I I20. Battery

ChargingAlternator

I I I I I

21. Engine &TransmissionMounts

I I

22. CrankcasePressure I I

23. Fan Hub I24. Thermostats &

Seals25. Crankcase

Breather I

26. Engine Tune-Up I27. Vibration

DamperReplace at major engine overhaul or earlier

if dented or leaking.All items are described in Preventive Maintenance Intervals.I – Inspect, service, correct or replace as necessary.R – Replace.

Table 13 Crane Regular Maintenance Intervals (continued)



Preventive MaintenanceIntervalsThis section describes the items listedin the maintenance interval tables.

The “Daily” instructions apply toroutine or daily starting of the engine.They do not apply to a new engineor one that has been operated for aconsiderable period of time.

For new or stored engines, refer to theSeries 60 Service Manual (6SE483).Follow instructions in Section 13.1under Preparations for Starting theEngine the First Time.

Preventive maintenance other than the“Daily” checks should be performedby authorized Detroit Diesel serviceoutlets. These outlets have the trainedpersonnel and special tools to properlyperform all services.

Item 1 – Lubricating Oil

Check the oil level daily with theengine stopped. If the engine hasjust been stopped and is warm, waitapproximately 20 minutes to allowthe oil to drain back into the oil panbefore checking. The dipstick hasan operating range identified by acrosshatch. If the oil meniscus iswithin this crosshatch range thenthe oil range is adequate for engineoperation.

Add the proper grade of oil to maintainthe satisfactory range on the dipstick.See Figure 20.

Figure 20 Check Oil Level Daily

NOTICE:When adding lubricating oil, donot overfill. Oil may be blown outthrough the crankcase breather ifthe crankcase is overfilled.

All diesel engines are designed touse some oil, so the periodic additionof oil is normal. See Figure 21 todetermine the degree of oil usage.


MAINTENANCE

Figure 21 Engine Oil Consumption Guidelines

NOTICE:If the oil level is constantly abovenormal and excess oil has not beenadded to the crankcase, consultwith an authorized Detroit Dieselservice outlet for the cause. Fuel orcoolant dilution of lubricating oil canresult in serious engine damage.

Before adding lubricating oil, refer toHow to Select Lubricating Oil in thisguide. Change lubricating oil andfilters at the intervals listed in Table 14when using fuel with a sulfur contentof less than 0.05 mass percent. Whenusing fuel with a higher sulfur content,refer to When to Change Oil in thisguide.

Service Application Lube Oil and Filter Change Interval*30,000 Miles (48,280 Kilometers) —Long Haul20,000 Miles (32,000 Kilometers) —Short HaulHighway Truck & Motor Coach

15,000 Miles (24,000 Kilometers) —Severe

Fire Fighting, Crash/Rescue, &Emergency Vehicles

6,000 Miles (9,600 Kilometers), 300 Hoursor 1 Year, whichever comes first

* Change both full-flow filters when lube oil is changed.

Table 14 Recommended Engine Oil Drain and Filter ChangeIntervals (Diesel Fuel Sulfur Content Less Than0.05 Mass % (0.0015 wt%))



Item 2 – Fuel and Fuel Tank

Keep the fuel tank filled to reducecondensation. See Figure 22.

Figure 22 Filled Fuel Tank

Before adding fuel, refer to How toSelect Diesel Fuel in the HOW-TOSECTION of this guide.

Refill the tank at the end of each day'soperation to prevent condensationfrom contaminating the fuel.Condensation formed in a partiallyfilled tank promotes the growth ofmicroorganisms that can clog fuelfilters and restrict fuel flow.

To prevent microbe growth,add a biocide to the fuel tankor primary fuel supply. Wateraccumulation can be controlled byusing additives containing methylcarbitol or butyl cellusolve. Followmanufacturer's usage, handling andsafety precautions.

PERSONAL INJURY

To avoid injury from improper useof chemicals, follow the chemicalmanufacturer’s usage, handling,and disposal instructions.Observe all manufacturer’scautions.

NOTICE:Never use galvanized steel fueltanks, fittings, pipes or supply lines.The fuel reacts chemically with thezinc coating to form powdery flakesthat can quickly clog the fuel filtersand damage the fuel pump andinjectors.

Open the drain at the bottom of thefuel tank every 30,000 miles (48,280kilometers) to drain off any waterand/or sediment.

Every 120,000 miles (192,000kilometers) or 12 months tighten allfuel tank mountings and brackets. Atthe same time, check the seal in thefuel tank cap, the breather hole in thecap and the condition of the flexiblefuel lines. Repair or replace the parts,as necessary.


MAINTENANCE

Item 3 – Fuel Lines, FlexibleHoses

A pre-start inspection of hoses andfuel lines is recommended.

Leaks — Make a visual check forfuel leaks at all engine-mounted fuellines and connections, and at thefuel tank suction and return lines.Since fuel tanks are susceptible toroad hazards, leaks in this area maybest be detected by checking for anaccumulation of fuel under the tank.

FIRE

To avoid injury from fire, containand eliminate leaks of flammablefluids as they occur. Failure toeliminate leaks could result infire.

Leaks are not only detrimental tomachine operation, but they can alsoresult in added expense caused by theneed to replace lost fluids.

Hoses and Fittings — Checkhoses daily as part of the pre-startinspection. Examine hoses for leaks,and check all fittings, clamps andties carefully. Make sure hoses arenot resting on or touching shafts,couplings, heated surfaces includingexhaust manifolds, any sharp edges,

or other obviously hazardous areas.Since all machinery vibrates andmoves to a certain extent, clamps andties can fatigue with age. To ensurecontinued proper support, inspectfasteners frequently and tighten orreplace them as necessary. If fittingshave loosened or cracked or if hoseshave ruptured or worn through, takecorrective action immediately.

Hose Service Life — A hose hasa finite service life. With this inmind, all hoses should be thoroughlyinspected at least every 500 operatinghours (1,000 hours for fire-resistantfuel and lubricating oil hoses) and/orannually. Look for cover damageand/or indications of twisted, worn,crimped, brittle, cracked or leakinglines. Hoses with their outer coverworn through or with damaged metalreinforcements should be consideredunfit for further service.

All hoses in and out of machineryshould be replaced during majoroverhaul and/or after a maximum offive (5) years of service.

NOTE:Fire-resistant fuel and lube oil hoseassemblies do not require automaticreplacement after five years of serviceor at major overhaul, but should beinspected carefully before being putback into service.



Item 4 – Cooling System

The cooling system must be full forproper operation of the engine.

HOT COOLANT


Check the coolant level daily andmaintain it near the bottom of thefiller neck on the radiator. On someinstallations this is done by checkingan overflow bottle or sight glass. Addcoolant as required, but do not overfill.Before adding coolant, refer to How toSelect Coolant in this guide.

Coolant Level — Make a dailyvisual check for cooling system leaks.Look for an accumulation of coolantwhen the engine is running and whenit is stopped. Coolant leaks may bemore apparent on a engine when it iscold.

Coolant Inhibitors — Theinhibitors in antifreeze solutions mustbe replenished with a non-chromatecorrosion inhibitor supplement whenindicated by testing the coolant.Refer to How to Select Coolant in thisguide.for required test intervals andinhibitor levels.

NOTICE:Coolant must be inhibited withthe recommended SCAs listed inthis guide. Failure to check andmaintain SCA levels at requiredconcentrations will result insevere damage (corrosion) tothe engine cooling system andrelated components.

The cooling system is protected by asupplemental coolant additive (SCA)element In addition, the engine can beequipped with a coolant filter/inhibitorsystem as an installed option or as anafter-sale item.

Coolant Drain Interval — Acoolant system properly maintainedand protected with supplementalcoolant inhibitors can be operatedup to the intervals listed. Atthese intervals the coolant mustbe drained and disposed of in anenvironmentally responsible manneraccording to state and/or federal(EPA) recommendations.


MAINTENANCE

Detroit Diesel recommendsreplacing coolant at the intervalslisted in Table 15.

Coolant Type Coolant Replacement Interval

A 50/50 mix of POWER COOL® fullyformulated, inhibited ethylene glycolantifreeze and water or a 50/50 mix offully formulated, inhibited propyleneglycol antifreeze and water

With proper maintenance1 coolantcan be operated 2 years, 300,000miles (480,000 km), or 4,000 hours,whichever comes first. At this time thecooling system must be completelydrained and cleaned before refill.

A 50/50 mix of phosphate-free TMCRP-329 “Type A“ (propylene glycol)antifreeze and water.

With proper maintenance1 coolant canbe operated for the life of the engineuntil overhaul.2 For life to overhaul,pre-charged coolant in combinationwith a need-release filter must beused. At this time the cooling systemmust be completely drained andcleaned before refill.

A 50/50 mix of OAT (organic acidtechnology) coolant and water.

With proper maintenance coolant canbe operated 4 years, 600,000 miles(960,000 km), or 10,000 operatinghours, whichever comes first. 3 Atthis time the cooling system mustbe completely drained and cleanedbefore refill.

1 Proper maintenance involves periodic evaluation using PowerTrac®3-Way Coolant Test Strips and the addition of required SCA, asindicated by the test strip.

2 To verify coolant acceptability, submit a sample to Detroit Diesel forcoolant analysis every 3 years, 300,000 miles (480,000 km) or6,000 operating hours, whichever comes first. Submit sample usingPowerTrac coolant analysis kit, part number 23516921 (IEG/IPGcoolant) or 23523398 (organic coolant).

3 OAT coolants require the addition of an extender every 2 years,300,000 miles (480,000 km), or 5,000 hours, whichever comes first.Use 1 pint to 20 gallons of OAT coolant.

Table 15 Coolant Drain Intervals



Item 5 – Turbocharger, Air-to-AirCharge Cooler

Visually inspect the turbochargermountings, intake and exhaust ductingand connections for leaks daily.

PERSONAL INJURY


Check the lube oil inlet and outletlines for leaks or restrictions to oilflow. Check for unusual noise orvibration and, if excessive, stop theengine and do not operate until thecause is determined.

Periodically inspect the air-to-aircharge cooler (if used) for buildup ofdirt, mud, etc. and wash off. Checkthe charge cooler, ductwork, andflexible connections for leaks andhave repaired or replaced, as required.

Check turbocharger heat-insulatingexhaust system blankets (if used) fordamage on a daily basis. Torn, matted,crushed, oil-soaked or otherwisedamaged insulation blankets must bereplaced immediately.

Wastegated Turbochargers —The turbocharger wastegate actuator

is factory-calibrated and is notadjustable. Check actuator operationat the intervals shown in themaintenance schedule.

EYE INJURY


Item 6 – Battery

Check the hydrometer “eye” ofmaintenance-free batteries for charge.See Figure 23.

Figure 23 Maintenance-FreeBattery “Eye”


MAINTENANCE

PERSONAL INJURY

To avoid injury from accidentalengine startup while servicingthe engine, disconnect/disablethe starting system.

If lead-acid or low-maintenancebatteries are used, check the specificgravity of each cell every 150operating hours. Check morefrequently in warm weather due tothe more rapid loss of water throughevaporation.

Maintain the electrolyte levelaccording to the battery manufacturer'srecommendations, but do not overfill.Overfilling can cause poor batteryperformance or early failure.

Keep the terminal side of the batteryclean. When necessary, wash witha solution of baking soda and water.Rinse with fresh water. Do not allowthe soda solution to enter the cells.

Inspect the cables, clamps andhold-down brackets regularly. Cleanand reapply a light coating ofpetroleum jelly when needed. Havecorroded or damaged parts replaced.

If the engine is to be out of servicefor more than 30 days, remove thebatteries and store in a cool, dryplace. Keep batteries fully charged,

if possible. Replace any battery thatfails to hold a charge.

Periodically check battery connectionsfor corrosion and tightness. Ifnecessary, remove connectionsand wire brush any corrosion fromterminals and cable ends. Replacedamaged wiring.

Item 7 – Aftertreatment System

There is a need to periodically removeaccumulated ash, derived from enginelube oil, from the filter. This ashdoes not oxidize in the filter duringthe regeneration process and mustbe removed through a cleaningprocedure. All Detroit Diesel ATDequipped engines will illuminate adashboard warning lamp indicatingthe need for ash cleaning. Also inspectthe ATD for wiring concerns (chaffingor melted) and loose connections.

Item 8 – Drive Belts

Belts should be neither too tight nortoo loose. Belts that are too tightimpose extra loads on the crankshaft,fan and/or alternator bearings,shortening both belt and bearing life.Excessively overtightened belts canresult in crankshaft breakage. A loosebelt will slip and may cause damageto accessory components.



PERSONAL INJURY

To avoid injury from rotating beltsand fans, do not remove anddiscard safety guards.

Use a belt tension gage, such asKent-Moore® tool J 23586–B(V-belt), J 23600–B (poly-V belt),J 41251 (PowerBand® and 12–ribpoly-V belt), or equivalent, whentensioning drive belts. Tension beltsto the values listed in Table 16.

V-Belts — New standard V-beltswill stretch after the first few hours

of operation. Tighten V-belts aslisted in Table 16.

Run the engine for 10 to 15 minutesto seat the belts, then readjust tension.Check and retension belts after 1/2hour and again after 8 hours or250 miles (400 km) of operation.Thereafter, check the tension of thedrive belts every 100 hours or 6,000miles (10,000 km) and adjust, ifnecessary.

If a belt tension gage is not available,adjust the belt tension so that a firmpush with the thumb, at a pointmidway between the two pulleys, willpress the belt .50 in. – .75 in. (13 –19 mm).

Fan DriveSingle Belt 2 or 3 Belts

80 – 100 lbs (356 – 445 N) 60 – 80 lbs (267 – 356 N)

Alternator DriveBelt New Used

Two 1/2–in. V-Groove 125 lbs (556 N) 100 lbs (445 N)

2–Groove PowerBand® 200 lbs (890 N) 150 lbs (667 N)

12–Rib Poly-V (50 DN Alternator) 350 lbs (1,557 N) 250 lbs (1,112 N)

Table 16 Drive Belt Tensioning


MAINTENANCE

2-Groove PowerBand — A 8-ribbelt is used with the 50 DN alternatorfor motorcoach applications. Toprovide proper running tension for thebelt, current Series 60 engines use anauto belt tensioner, which requires noadjustment. See Figure 24.

Figure 24 Auto Belt TensionerAssembly with 50 DNAlternator

Tighten a new drive belt to 200 lbs(890 N), then run the engine for 10minutes at 1200 rpm. Stop the engineand allow a 10 – 15 minute cool downperiod. Check tension. If less than150 lbs (667 N), retension to 150 lbs(667 N). Following initial tensioning,measure belt tension every monthor every 7,500 miles (12,000 km),whichever comes first. Retension beltto 150 lbs (667 N) at these intervals.

12–Rib Poly-V Belt — Tighten an12–rib poly-V belt to 350 lbs (1,557N), then run the engine at high idle for30 minutes. Stop the engine and allow

a 10 – 15 minute cool down period.Check tension with tool J 41251–Bor equivalent. If tension is 250 lbs(1,112 N) or more, no retensioning isrequired. If tension is less than 250 lbs(1,112 N), retension to 250 lbs (1,112N). Measure belt tension every monthor every 7,500 miles (12,000 km),whichever comes first. Retension to250 lbs (1,112 N) as required.

Belt Replacement — Drive belts(V and poly-V) should be replacedevery 2,000 hours or 100,000 miles(160,000 km).

Replace all belts in a set when oneis worn. Single belts of similar sizeshould not be used as a substitute for amatched belt set.

Premature belt wear can result becauseof belt length variation. All beltswithin a matched set are within .032in. (0.8 mm) of their specified centerdistances.

When installing or adjusting anaccessory drive belt, be sure the boltat the accessory adjusting pivot pointis properly tightened, as well as thebolt in the adjusting slot. In addition,check the torque on the alternator andbracket mounting bolts. Retighten asrequired.



Item 9 – Air Compressor

All air compressor intake parts shouldbe removed and cleaned at 7,500 miles(12,000 km).

To clean either the hair type or thepolyurethane type compressor airstrainer element, saturate it andsqueeze it in fuel oil or any othercleaning agent that is not detrimentalto the element until it is dirt-free. Thensaturate the element in lubricating oiland squeeze it dry before placing itback into the air strainer.

For air strainer replacement,contact the nearest servicing dealer.Replace hair type elements with thepolyurethane type, if available.

The air compressor mounting boltsshould be tightened every 12 monthsor 30,000 miles (48,280 km).

Item 10 – Air Cleaner

The air cleaner element should beinspected every 15,000 miles (24,000km) or more often if the engine isoperated under severe dust conditions.

Replace the element, if necessary.Check the gaskets for deteriorationand replace, if necessary. If the drytype air cleaner is equipped with anaspirator, check for aspirator damageor clogging. Clean, repair or replace,as necessary.

NOTICE:Do not allow the air inlet restriction toexceed 20 in. H2O (5.0 kPa) underany engine operating conditions.A clogged air cleaner element willcause excessive intake restrictionand reduced air supply to theengine resulting in increased fuelconsumption, inefficient engineoperation and reduced engine life.

Inspect the entire air system for leaksdaily. Look especially for torn air inletpiping or boots and loose or damagedclamps. Have worn or damaged partsrepaired or replaced, as required.Retighten loose connections.

Air Cleaner Replacement —Dry type air cleaner elements shouldbe replaced after one year of serviceor when the maximum allowable airintake restriction has been reached,whichever comes first. Refer to Whento Service the Dry Type Air Cleaner inthis guide for additional information.

Item 11 – Lubricating Oil Filters

Install new spin-on oil filters at amaximum of 30,000 miles (48,280km). For city transit coach engines,install filters at a maximum of 6,000miles (9,600 km).


MAINTENANCE

Install the new filters, turning themuntil they contact the gasket fully withno side movement. Turn full-flowfilters an additional 2/3 turn byhand, or as indicated on the filter.See Figure 25.

PERSONAL INJURY


Make a visual check of all lubricatingoil lines for wear and/or chafing. Ifany indication of wear is evident,replace the oil lines and correct thecause.

Check for oil leaks after starting theengine.

Figure 25 Lubricating Oil Filters

Item 12 – Fuel Filters

One method of determining whenfilters are plugged to the extent thatthey need replacing is based on thefuel pressure at the cylinder head fuelinlet fitting and the inlet restriction atthe fuel pump.

In a clean system the maximum pumpinlet restriction should not exceed 6inches of mercury (20.3 kPa). In adirty system it must not exceed 12inches of mercury (41 kPa).

At normal operating speed and withthe standard fuel pressure regulator,the fuel pressure is 55 – 70 psi (375– 483 kPa).

Change the fuel filters whenever theinlet restriction at the pump reaches 12inches of mercury (41 kPa) at normaloperating speeds and whenever thefuel pressure at the inlet fitting falls tothe minimum fuel pressure of 6 inchesof mercury (20.3 kPa).

NOTE:Filter change intervals may beshortened to conform with establishedpreventive maintenance schedules,but should never be extended.

Fuel Pro® 382 Filters — Installnew Fuel Pro® 382 primary fuel filterelements when the fuel level in thesee-thru cover reaches the top of theelement or after one year of service,whichever comes first.



Spin-On Filters — Install newspin-on primary and secondary fuelfilter elements on vehicle enginesevery 15,000 miles (24,000 km) orevery six months, whichever comesfirst. See Figure 26.

Replace spin-on filter elementsimmediately if plugging is indicated,regardless of mileage or hour intervals.

Item 13 – Water Pump andCoolant Inhibitor Element

Check the water pump and the coolantinhibitor element.

Figure 26 Spin-On Fuel FilterLocations

Water Pump Drain Hole — Thewater pump drain hole should beinspected every 6 months to make sureit is open. A small chemical build-upor streaking at the drain hole mayoccur. This is not an indication of adefective water pump or seal.

Remove the build-up with a milddetergent cleaner and a brush. If

coolant does not leak from the drainhole under normal conditions, do notreplace the water pump.

Coolant Inhibitor Element — Ifthe cooling system is protected by asupplemental coolant additive (SCA)element, the coolant must be testedat required intervals and the elementreplaced, if required. See Figure 27.

Figure 27 Coolant InhibitorElement

Required test intervals arelisted in Table 24.


MAINTENANCE

For SCA test procedures refer toHow to Select Coolant and SCA TestProcedures in this guide. Use thecoolant filter element required. Thevalves mounted on the filter adaptorhead must be opened after the elementis replaced.

Item 14 – Cranking Motor

For cranking motor (starter)information, contact an authorizedDelco Remy® or Bosch® servicecenter, depending on manufacturer.

Item 15 – Air System

All the connections in the air systemshould be checked to make surethey are tight and leak free. Checkall hoses and ducting for punctures,deterioration or other damage andreplace, if necessary.

Item 16 – Exhaust System

Have the exhaust manifold retainingbolts and other connections checkedfor tightness. Have the exhaust piperain cap checked for proper operation,if so equipped.

Item 17 – Engine (Steam Clean)

Steam clean the engine and enginecompartment every 60,000 miles(96,000 km) or 2,000 hours,whichever comes first.

NOTICE:Do not apply steam or solventdirectly to the battery-chargingalternator, starting motor, DDECcomponents, sensors or otherelectrical components, as damagemay result.

Item 18 – Radiator

The exterior of the radiator coreshould be inspected every 30,000miles (48,280 km), 12 months, or 300hours (industrial applications) andcleaned, if necessary.

EYE INJURY


Use a quality grease solvent, suchas mineral spirits, and dry withcompressed air. Fuel oil, kerosene orgasoline should not be used.

It may be necessary to clean theradiator more frequently if the engineis being operated in extremely dustyor dirty areas.



If the low coolant level sensor isinstalled in the top tank of the radiator,it should be tested for proper operationevery 100,000 miles (160,000 km)or 12 months, whichever comes first.Authorized Detroit Diesel distributorsare properly equipped to perform thisservice.

Item 19 – Oil Pressure

Under normal operation, oil pressureis noted each time the engine isstarted. In the event the equipmenthas warning lights rather than pressureindicators, the pressure should bechecked and recorded every 60,000miles (96,000 km).

Item 20 – Battery-ChargingAlternator

Precautions must be taken whenworking on or around the alternator.The diodes and transistors in thealternator circuit are very sensitiveand can be easily destroyed.

To avoid equipment damage, payattention to the following:







□ Avoid grounding the outputterminal. Grounding analternator's output wire or terminal(which is always “hot,” regardlessof whether or not the engineis running) and accidentallyreversing the battery polarity willresult in equipment damage.

□ Do not reverse battery connections.

□ Never disconnect the batterywhile the alternator is operating.Disconnecting the battery canresult in damage to the batterydiodes. In applications whichhave two (2) sets of batteries,switching from one set to theother while the engine is running


MAINTENANCE

will momentarily disconnect thebatteries.

□ If a booster battery is to be used,batteries must be connectedcorrectly (negative to negative,positive to positive).

□ Never use a fast charger with thebatteries connected or as a boosterfor battery output.

For information on the alternatorassembly, contact an authorizedDelco Remy® or Bosch® distributor,depending on manufacturer.

Bosch® T1 Alternator ServiceRequirements — The transistorregulator must be replaced every100,000 miles (160,000 km) usingkit part number 23524613 (includesregulator assembly and brushes).Front and rear bearings must bereplaced every 200,000 miles(320,000 km) using kit 23524614(includes bearings, seals and spacerring). Authorized Bosch distributorshave the parts, tools and trainedpersonnel to perform these services.

General Service Requirements– Bosch® and Delco Remy®Alternators — Terminals shouldbe checked for corrosion and looseconnections and wiring inspectedfor damage and frayed insulation.Have wiring repaired or replaced, asrequired.

Check torque on alternator mountingbolts and bracketing every 15,000miles (24,000 km). Retighten, ifnecessary.

Item 21 – Engine andTransmission Mounts

The engine and transmission mountingbolts and the condition of the mountingpads should be checked every 60,000miles (96,000 km) or 600 hours.Tighten and/or repair as necessary.

Item 22 – Crankcase Pressure

The crankcase pressure should bechecked and recorded every 60,000miles (96,000 km) or 600 hours.

Item 23 – Fan Hub

If the fan bearing hub assembly has agrease fitting, use a hand grease gunto lubricate the bearings with one shotof quality lithium-base, multi-purposegrease every 100,000 miles (160,000km).

Care should be taken not to overfillthe bearing housing.

Item 24 – Thermostats and Seals

Replace the thermostats and sealsevery 240,000 miles (384,000 km) or24 months, whichever comes first.



Item 25 – Crankcase Breather

The internally mounted (in the enginerocker cover) crankcase breatherassembly (see Figure 28) shouldbe removed and the steel mesh padwashed in clean fuel oil every 250,000miles (402,300 km).

Figure 28 Internal Breather (inRocker Cover)

Item 26 – Engine Tune-Up

There is no scheduled interval forperforming an engine tune-up.However, the valve lash and injectorheights must be measured and, ifnecessary, adjusted at the initialinterval listed in Table 17.

Once the initial measurements/ad-justments have been made, anyadjustments beyond this point shouldbe made only as required to maintainsatisfactory engine performance.

Engine Application Measurement/Adjustment Period

Vehicle Engines 60,000 Miles (96,000 km) or24 Months, whichever comes first

Table 17 Initial Valve Lash and Injector Height Adjustment


MAINTENANCE

Item 27 – Vibration Damper

The viscous vibration damper shouldbe inspected periodically and replacedif dented or leaking. See Figure 29.

Figure 29 Viscous VibrationDamper

Heat from normal engine operationmay, over a period of time, cause thefluid within the damper to break downand lose its dampening properties.For this reason the viscous vibrationdamper must be replaced at timeof normal major engine overhaul,regardless of apparent condition.



HOW-TO SECTION

This section covers Detroit Diesel'srecommendations on how to selectlubricating oil, diesel fuel, and coolantand includes basic engine maintenanceprocedures which can be performedby the operator.

NOTICE:The manufacturer's warrantyapplicable to Series 60 enginesprovides in part that the provisionsof such warranty shall not applyto any engine unit that has beensubject to misuse, negligence oraccident. Accordingly, malfunctionsattributable to neglect or failure tofollow the manufacturer's fuel orlubricating recommendations maynot be within the coverage of thewarranty.

How to Select LubricatingOilThe selection of the proper lubricatingoil is important to achieve the longand trouble-free service which DetroitDiesel engines are designed toprovide. The proper lubricating oil formodel year 2007 Series 60 enginesis selected based on SAE viscositygrade and API (American PetroleumInstitute) service designation. Onlyoils licensed to display the API symbolshould be used. See Figure 30.

NOTICE:Lubricating oil must have a sulfatedash level less than 1.0 wt %;currently referred to as CJ-4 oil.

Figure 30 API Lubricant Symbol

Lubricant Requirements

API CJ-4 oils must be used inengines meeting January 2007,and later build, exhaust emissionregulations.

Cold Weather Starting

At ambient temperatures below–20°C (–4°F) when sufficient starterspeed cannot be achieved with SAE15W-40 oils, the use of 5W-XX oilsand 10W-XX oils (XX =30 or 40) isallowed to improve starting.


HOW-TO SECTION

NOTICE:

Monograde oils should notbe used in Series 60 engines,regardless of API serviceclassification. Monograde oilsgel at lower ambient temperatures,reducing lubricant flow, and do notprovide adequate lubricity at higherengine operating temperaturesresulting in severe engine damage.

The oils must be API CJ-4 that havedemonstrated field performance inDetroit Diesel engines. These oilsmust possess a High Temperature /High Shear (HT/HS) of 3.7 minimum.For further information, refer topublication Engine Requirements –Lubricating Oil, Fuel and Filters,7SE270, available from authorizedDetroit Diesel distributors.

Synthetic Oils

Synthetic oils may be used in DetroitDiesel engines, provided they are APIlicensed and meet the performanceand chemical requirements ofnon-synthetic oils outlined in thispublication. Synthetic oils offerimproved low-temperature flowproperties and high-temperatureoxidation resistance. However,they are generally more costly thannon-synthetic oils.

Product information about syntheticoils should be reviewed carefully.Performance additive systems oftenrespond differently in synthetic oils.

Their use does not permit extension ofrecommended oil drain intervals.

The Use of SupplementalAdditives

Lubricants meeting the DetroitDiesel specifications outlined in thispublication already contain a balancedadditive treatment. Supplementaladditives are generally not necessaryand can even be harmful. Theseadditives may be marketed as eitheroil treatments or engine treatments andare discouraged from use in DetroitDiesel engines.

Engine damage resulting from theuse of such materials is not coveredby your Detroit Diesel warranty.Detroit Diesel will not providestatements beyond this publicationrelative to their use.

When to Change OilThe length of time an engine mayoperate before an oil change dependsupon the lubricant and fuel used,engine oil consumption, and theoperating cycle.



USED ENGINE OIL

To avoid injury to skin fromcontact with the contaminants inused engine oil, wear protectivegloves and apron.

The maximum interval at whichthe engine may operate before theoil and filters must be changed islisted in Table 18.

Oil analysis may be used to determinewhether this interval should beshortened, but it should not be used tolengthen the interval.

The use of fuels with sulfur contentabove 0.05 mass percent will require ashortening of drain intervals and/or the

use of a higher TBN oil. For detailedinformation refer to publicationEngine Requirements – LubricatingOil, Fuel and Filters (7SE270),available from authorized DetroitDiesel distributors.

Disposing of Waste Oil

Dispose of used lubricating oiland filters in an environmentallyresponsible manner, accordingto federal (EPA) and/or staterecommendations. The disposal ofwaste oil may be best addressed by theengine oil supplier, who may acceptresponsibility for proper disposal ofthis material as part of the business ofproviding lubricant.

Engine Application Drain IntervalHighway Truck & Motor Coach 30,000 Miles (48,280 km)

Fire Truck or Crash/Rescue Vehicle 6,000 Miles (9,600 km), 300 Hours or1 Year, whichever comes first

Table 18 Maximum Oil Drain and Filter Change Interval (Fuel Sulfur15 ppm Weight Percent or Less)


HOW-TO SECTION

How to Replace the LubeOil FiltersFilters are an integral part of thelubricating oil system. Properfilter selection and maintenanceare important to satisfactory engineperformance and service life.

Filters should be used to maintaina clean system, not to clean up acontaminated system.

Replace Spin-On Type Oil Filter

Replace spin-on type filters(see Figure 31) as follows:

Figure 31 Spin-On Oil Filters

PERSONAL INJURY


1. Place a suitable container underthe engine oil pan, remove drainplug and drain the lubricatingoil. Replace the drain plug andtighten securely.

2. Remove spin-on filters usingtool J–29917 or equivalent and a1/2-in. drive socket wrench andextension.

3. Dispose of used oil andfilters in an environmentallyresponsible manner, accordingto federal (EPA) and/or staterecommendations.

4. Clean the filter gasket-contactsurface of the adaptor head with aclean, lint-free cloth.

5. Fill the new filters with cleanlubricating oil and lightly coat thefilter gaskets with the same oil.

NOTICE:Overtightening the filter may crackor distort the filter adaptor.

6. Start the new filters on the adaptorhead and tighten by hand until



the gaskets touch the mountingadaptor head. Tighten filters anadditional two-thirds turn byhand, or as indicated on thefilter.

7. Add oil as required to bring thelevel within the satisfactory rangeon the dipstick. See Figure 32.

Figure 32 Check Oil Level

ENGINE EXHAUST


8. Start and run the engine for ashort period and check for leaksThen shut down the engine.

9. After any leaks have beencorrected, stop the engine longenough for oil from various partsof the engine to drain back tothe crankcase (approximately 20

minutes). Add oil as requiredto bring the level within thesatisfactory range on the dipstick.See Figure 32.

NOTICE:If the engine oil level is constantlyabove normal and excess lubeoil has not been added to thecrankcase, consult with anauthorized Detroit Diesel serviceoutlet for the cause. Fuel or coolantdilution of lube oil can result inserious engine damage.

How to Select Diesel FuelAll 2007 diesel engines in 2007 aredesigned to operate on Ultra-LowSulfur Diesel (ULSD) fuel, see Figure33

Figure 33 ULSD Sticker


HOW-TO SECTION

Quality

Fuel quality is an important factorin obtaining satisfactory engineperformance, long engine life, andacceptable exhaust emission levels.

In general, fuels meeting theproperties of ASTM designationD 975 (grades 1-D and 2-D) haveprovided satisfactory performance.

The fuels used must be clean,completely distilled, stable, andnon-corrosive. For more informationregarding the significance of theseproperties and selection of the properfuel, refer to publication, EngineRequirements – Lubricating Oil, Fueland Filters (7SE270), available fromauthorized Detroit Diesel distributors.

NOTICE:Use only Ultra-Low Sulfur Diesel(ULSD) fuel (15 ppm sulfur contentmaximum), based on ASTMD2622 test procedure. Using fuelother than ULSD will damage theAftertreatment Device.

Fuel Contamination

Generally, fuel contaminationoccurs as the result of improper fuelhandling. The most common typesof contamination are water, dirt, andmicrobial growth (“black slime”).The formation of varnishes andgums resulting from poor stability or

extended storage (“stale fuel”) alsoaffects fuel quality. The best treatmentfor contamination is prevention bymaintaining a clean storage systemand choosing a reputable fuel supplier.

Supplemental additives are notrecommended due to potentialinjector system or engine damage.Our experience has been that suchadditives increase operating costswithout providing benefit.

The use of supplemental fuel additivesdoes not necessarily void the enginewarranty. However, repair expenseswhich result from fuel system orengine component malfunctions ordamage attributed to their use willnot be covered.

These products should beaccompanied by performancedata supporting their merit. It is notthe policy of Detroit Diesel to test,evaluate, approve or endorse suchproducts.

Biodiesel — Biodiesel fuels meetingASTM D 6751 specification, priorto blending can be mixed up to 5%maximum by volume in petroleumdiesel fuel. Detroit Diesel highlyrecommends biodiesel fuels madefrom soybean or rapeseed oil throughthe proper transesterification reactionprocess. Other feedstock sourceof biodiesel fuels such as animalfat and used cooking oils are not



recommended by Detroit Diesel. Theresulting mixture must meet ASTM D975 specification. More informationis available in the Detroit Dieselpublication Lubricating Oil, Fuel, andFilters (7SE270).

Failures attributed to the use ofbiodiesel fuel will not be coveredby Detroit Diesel product warranty.Also, any engine performanceproblem related to the use of biodieselfuel would not be recognizednor considered Detroit Diesel'sresponsibility.

Prohibited Additives

The following fuel additives are notallowed and MUST NOT be mixedwith diesel fuel:

Used Lubricating Oil — Do not usefuel blended with used lubricating oil.Detroit Diesel specifically prohibitsthe use of used lubricating oil in dieselfuel.

NOTICE:Do not burn used lubricating oilin fuel. It will cause the dieselparticulate filter to prematurely plugwith ash.

Used lubricating oil containscombustion acids and particulatematerials which can severely erodefuel injector components, resulting in

loss of power and increased exhaustemissions. In addition, the use ofdrained lubricating oil will increasemaintenance requirements due to filterplugging and combustion deposits.

Fuel Additives with Sulfuror Sulfated Ash — Do notuse non-approved fuel additivescontaining sulfur or sulfated ash.

Gasoline — The addition ofgasoline to diesel fuel will create aserious fire hazard. The presenceof gasoline in diesel fuel will reducefuel cetane number and increasecombustion temperatures.

FIRE

To avoid increased risk of a fuelfire, do not mix gasoline anddiesel fuel.

Tanks which contain a mixture ofgasoline and diesel fuel should bedrained and cleaned as soon aspossible.

Detroit Diesel will not be responsiblefor any detrimental effects itdetermines resulted from addingdrained lubricating oil or gasoline tothe diesel fuel.


HOW-TO SECTION

How to Replace the FuelFiltersFilters are an integral part of thefuel system. Proper filter selectionand maintenance are important tosatisfactory engine operation andservice life. Filters should be used tomaintain a clean system, not to cleanup a contaminated system. Referto the Specifications section of thisguide for proper filter selection.

Spin-on type primary and secondaryfuel filters are used on Series 60engines.

The primary filter (marked “P”) orcombination filter and fuel/waterseparator removes large impuritiesfrom the fuel. The secondary filter(marked “S”) removes the smallerparticles.

The spin-on type filter consists of ashell, element and gasket unitized intoa single cartridge and a filter adaptorwhich includes threaded insertsto accept the spin-on cartridges.See Figure 34.

An optional fuel/water separator maybe installed in place of the standardprimary filter.

Figure 34 Typical Spin-On TypeFuel Filter

Replace Spin-On Type Primaryor Secondary Fuel FilterElements

Replace spin-on fuel filter elements asfollows:

1. Shut down the engine and allowit to cool.

2. With the engine at ambienttemperature and cool to the touch,place a suitable container underthe filter.

3. If a fuel shutoff valve is installedon the discharge side of thesecondary fuel filter, turn the



handle on the shutoff valve to theclosed position (perpendicular tothe valve).

NOTICE:Have replacement filters filled withfuel and ready to install immediately.This prevents possible siphoningand fuel system aeration.

4. Using a suitable band type filterwrench, remove the primary andsecondary fuel filters. Dispose ofthe filters in an environmentallyresponsible manner, accordingto federal (EPA) and/or staterecommendations.

5. If not previously filled, fill newreplacement filters with cleandiesel fuel and coat the gasketslightly with the fuel.

6. Thread the new filters onto theadaptor inserts until the gasketsmake full contact with the adaptorhead and no side movement isevident.

NOTICE:Overtightening the filter may crackor distort the adaptors.

7. Tighten filters an additionalone-half turn by hand, or asindicated on the filter.

8. Turn the handle on the shutoffvalve to the Open position (inline with the valve).

ENGINE EXHAUST


9. Start the engine and check forleaks. Shut down the engine.Correct any leaks with the engineoff.

NOTICE:Never use the starting motor andfuel pump to prime the fuel filters.Prolonged used of both to prime thefuel system can result in damage tothe starter, fuel pump and injector.

If the engine fails to start after filterreplacement, the fuel system willrequire priming with tool J 5956 (orequivalent). Authorized Detroit Dieseldistributors are properly equipped toperform this service.


HOW-TO SECTION

Replace Fuel/Water SeparatorElement

If an optional primary filter/waterseparator is installed, replace theelement as follows:



3. If a fuel shutoff valve is installedon the discharge side of thefuel/water separator, turn thehandle on the shutoff valve to theclosed position (perpendicular tothe valve).

4. Drain off some fuel by openingthe drain valve.

5. Using a strap wrench, removethe element and bowl together,then remove the bowl from theelement. The filter and bowlhave right-hand threads, so turncounter-clockwise to remove.

6. Clean the bowl and the O-ringseal.

7. Apply a light coating or cleanfuel or grease to the O-ring seal,thread the bowl onto the new filterand tighten by hand.

NOTICE:To avoid damaging the bowl orthe filter, do not use tools whentightening.

8. Apply a light coating of clean fuelor grease to the new O-ring sealon the top of the filter. Thread thefilter and bowl assembly onto thefilter head and tighten by handuntil snug.

9. To eliminate air from the filter,operate the primer pump on thefilter head (if equipped) until thefuel purges at the filter assembly.

10. Start the engine and check forleaks. Shut down the engine.Correct any leaks with the engineoff.

Replace Fuel Pro® 382/382EFuel Filter Element

The Fuel Pro 382/383E diesel fuelfilter system consists of a permanentlymounted fuel processor, a replaceablefilter element and sealing grommetassembly, a filter spring, a see-thrucover and seal, a cover collar, and avent cap and seal. See Figure 35.



Figure 35 Fuel Pro 382E FuelProcessor Assembly

The system also includes a fuel heaterelement, thermostatic switch andwiring harness.

Replace the element as follows:



3. A fuel shutoff valve may beinstalled on the discharge side ofthe fuel filter. If installed, turn thehandle on the shutoff valve to theclosed position (perpendicular tothe valve).

4. Open the drain valve at the baseof the fuel processor and drain thefuel until it is below the bottomof the filter in the see-thru cover.Close the drain valve. The fuelmay be returned to the tank.

5. Using filter collar/vent capwrench P/N: 38202 or equivalent,remove the collar by turningcounter-clockwise. Remove thecover, filter spring and cover sealring by lifting straight up and overthe filter element.

6. Remove the element from thecenter stud (fuel outlet pipe)by pulling upward and twistingslightly.

NOTE:Current filter elements include anintegral sealing grommet. If a formerelement is replaced, make sure theseparate sealing grommet is removedfrom the center stud before installingthe new element.

7. Dispose of the used element andgrommet in an environmentallyresponsible manner, accordingto federal (EPA) and/or staterecommendations.


HOW-TO SECTION

8. Check to make sure the sealinggrommet is included in the baseof the replacement filter element,then install the element onto thecenter stud by pushing down andtwisting slightly.

9. Check to make sure the spring isinstalled at the top of the cover.If missing, this spring must bereplaced to insure proper filteroperation. Wipe the cover lip andcover seal clean.

NOTICE:Do not use a wrench of any kind totighten the collar. This may lead toovertightening, which can damagethe collar and/or the cover.

10. After making sure the seal isproperly positioned at the base ofthe cover, install the cover andcollar onto the fuel processor.Tighten the collar by hand untilsecure.

11. Using filter collar/vent capwrench 232002 or equivalent,remove the vent cap from the topof the cover by turning the capcounter-clockwise. Fill the coverfull of clean fuel. After makingsure the O-ring seal is installed onthe vent cap, reinstall the cap andtighten by hand.

NOTICE:To avoid cover or vent cap damage,do not use tools to tighten the ventcap.

12. Open the fuel shutoff valve (ifinstalled) and start the engine.When the lubrication systemreaches its normal operatingpressure, increase engine speed tohigh idle for 2 to 3 minutes.

NOTICE:Do not allow the fuel level in thesee-thru cover to fall below the topof the collar, since this may leadto interruption of the fuel flow andengine stalling.

13. After the air is purged and withthe engine still running, loosenthe vent cap. The fuel level inthe cover will start falling. Whenthe fuel level falls to the top ofthe collar, tighten the vent capquickly by hand.

14. Shut down the engine and tightenthe collar again by hand . Restartthe engine and check for leaks.

NOTE:The filter cover will not fill completelyduring engine operation. It willgradually fill over time, and the fuellevel will rise as the filter medium



becomes clogged. The filter elementdoes not require changing untilthe fuel level has risen to the topof the element, or after one year ofservice, whichever comes first.

Engine Out of Fuel — Howto RestartWhen an engine has run out of fuel,there is a definite procedure to followwhen restarting it.

NOTICE:Never use the starting motor andfuel pump to prime the fuel filters.Prolonged use of the starting motorand fuel pump to prime the fuelsystem can result in damage to thestarter, fuel pump and injectors.

Priming the engine with the startingmotor and fuel pump causes erraticengine running due to the amount ofair in the fuel lines and filters

Engines with Spin-On Filters

Use the following procedure for anengine with spin-on filters.

1. Fill the fuel tank with therecommended grade of fuel. Ifonly partial filling is possible,add a minimum of 10 gallons (38liters) of fuel to the tank.

2. Close the fuel shutoff valve (ifinstalled) on the secondary filter

head and remove the spin-on fuelfilters. Fill with clean fuel throughthe fuel inlet holes (the outer ringof small holes on the element) toinsure the fuel is filtered.

3. Thread the elements onto theadaptor inserts until the gasketsmake full contact with the adaptorhead and no side movementis evident. Tighten filters anadditional one-half turn by hand,or as indicated on the filter.

4. Open the fuel shutoff valve (ifinstalled), start the engine andcheck for leaks. Shut down theengine before correcting leaks.

NOTE:If the engine fails to start afterreplacement of fuel filters, the fuelsystem will require priming with toolJ 5956 or equivalent. AuthorizedDetroit Diesel distributors are properlyequipped to perform this service.

Engines with Fuel Pro Filters

Use the following procedure for anengine with Fuel Pro filters.

1. Remove the vent cap fromthe top of the filter by turningcounter-clockwise. Fill the coverfull of clean fuel.


HOW-TO SECTION

NOTICE:To avoid cover or vent dap damage,do not use tools to tighten the ventcap.

2. After making sure the O-ringseal is installed on the vent plug,reinstall the plug and tighten byhand only.

NOTICE:Do not allow the fuel level in thesee-thru cover to fall below the topof the collar, since this may leadto interruption of the fuel flow andengine stalling.

3. Start the engine and allow thelubrication system to reach itsnormal operating pressure, thenincrease engine speed to high idlefor 2 to 3 minutes.

4. After the air is purged and withthe engine still running, loosenthe vent cap on the filter cover.The fuel level in the cover willstart falling. When the fuel levelfalls to the top of the collar on theFuel Pro cover, tighten the ventcap quickly by hand.

NOTE:If the engine fails to start afterreplacement of fuel filters, the fuelsystem will require priming with tool

J 5956 or equivalent. AuthorizedDetroit Diesel distributors are properlyequipped to perform this service.

How to Clean the EngineImportant: Observe all environmentalprotection regulations.

High-Pressure CleaningEquipment

Information on suitable cleaningand protective products is availablefrom any authorized dealer. Note theequipment manufacturer's operatinginstructions.

NOTICE:To prevent damage to enginecomponents, keep the watermoving at all times while cleaning.Never direct water onto electricalcomponents, plug connectors, sealsor flexible hoses.

To avoid injury, wear a face shieldor goggles.

Comply with the minimum workingdistance between the high-pressurenozzle and the surface being cleaned:



□ Approximately 28 inches (700mm) for circular pattern jets

□ Approximately 12 inches (300mm) for 25-degree flat jets anddirt cutters

How to Clean the CoolingSystemImportant: Collect the used coolant,cleaning solutions, and washingliquids and dispose of them in anenvironmentally responsible manner.

Clean as follows:

NOTICE:Clean at moderate pressures onlyto avoid damaging the radiator grillefins.

EYE INJURY


1. First remove debris (dust, insects,etc.) from the fins of the radiatorgrille.

2. Remove the debris by blowingthem through with compressed airor spraying them out with water.Work from the rear of the radiator(in the opposite direction of thenormal cooling air flow).

3. Drain the coolant when the engineis cold. For detailed procedures,see the vehicle/chassismaintenance manual. Fortypes of coolant, refer to the“How to Select Coolant” section.

4. If the HVAC unit is connectedto the cooling system, open theregulating valves all the way.

Degreasing

Degrease as follows:

1. Fill the cooling system with a 5%solution (1.6 ounces per quart ofwater—50 grams per liter) of amildly alkaline cleaning agent,such as sodium carbonate.

2. Run the engine at moderate speeduntil the thermostat starts to open,at an operating temperature ofapproximately 80°C (176°F).Then run it for about five minuteslonger. Shut down the engine andallow it to cool to approximately50°C (112°F).


HOW-TO SECTION

HOT COOLANT


3. Drain all the cleaning solution.

4. Flush the cleaning solution fromthe cooling system.

[a] Immediately after drainingthe cleaning solution, flushthe system with clean water.

[b] Once the clean water hasdrained, fill the system againwith clean water.

[c] Run the engine. Allowthe engine to warm up toapproximately 80°C (176°F),and then run it about fiveminutes longer.

[d] Drain the hot water.

5. Fill the cooling system with newcoolant. For detailed procedures,see the vehicle/chassismaintenance manual. Fortypes of coolant, refer to the“How to Select Coolant” section.

How to Select CoolantThis section covers selection of therequired coolant for Series 60 engines.

Definitions

To help ensure completeunderstanding of the information, thedefinitions of the following terms arelisted in Table 19.



Term Definition

Antifreeze

Ethylene glycol (EG) or propylene glycol (PG)containing a corrosion inhibitor package and whichmeets an appropriate heavy-duty specification (i.e.,TMC RP-329 “Type A” for ethylene glycol or TMCRP-330 “Type A” for propylene glycol).

CoolantThe fluid mixture circulating in the engine coolingsystem, typically a mixture of 50% water and 50%antifreeze.

Drop–Out Precipitated sludge or deposit formation on coolingsystem components.

Fully FormulatedAntifreeze

Contains all the necessary inhibitors to protect a dieselengine, and does not, therefore, require a pre-chargeof SCA before its first use.

Initial–Fill CoolantThe coolant that is used in a new or rebuilt engine, orany time the cooling system is emptied and then refilledwith coolant.

OATOrganic Acid Technology. An inhibitor system basedon organic acid inhibitors, instead of traditional NorthAmerican inhibitor formulations.

SCASupplemental Coolant Additive. SCAs are used in apreventive maintenance program to prevent corrosion,cavitation, and the formation of deposits.

Table 19 Coolant Terms

Approved Coolants

Required specifications for water,ethylene glycol, propylene glycol,inhibitor packages and inhibitorconcentration are included in thissection.

NOTICE:To avoid engine damage frominadequate or over concentratedcoolant, the required specificationsmust be adhered to before thecoolant is replaced.


HOW-TO SECTION

The approved and preferredcoolants for Series 60 enginesare listed in Table 20.

Once installed, these coolantsshould be maintained accordingto the procedures discussed underMaintenance in this section.

Coolant Fill Option ProductEthylene Glycol & Water + CorrosionInhibitors 1 DDC Power Cool

Commercial Equivalent of DDC PowerCool

Fully Formulated TMC RP-329 Type AAntifreeze & Water

Propylene Glycol & Water + CorrosionInhibitors 1 DDC Power Cool Plus

Ethylene Glycol & Water + OATInhibitors DDC Power Cool Plus

Water Only + Corrosion Inhibitors 2 Water + DDC Power Cool 3000

Water Only + OAT Inhibitors 2 Water + DDC Power Cool Plus 60001 Preferred Coolant2 Water-only coolant systems offer no freeze protection and should not

be used where ambient temperatures can fall to 32° F (0° C).

Table 20 Initial Fill Coolant Options

EG & Water Plus SCA Inhibitoror P G & Water Plus SCAInhibitor — These products areavailable as fully formulated,phosphate-free, extended serviceinterval (ESI) coolants. They arecommercially available from DetroitDiesel (recommended) and othermanufacturers as either a concentratedantifreeze or as a pre-mixed antifreeze.The pre-mixed antifreeze is ready foruse, while the concentrated coolantmust be mixed with water prior to use.

Detroit Diesel Power Cool enginecoolant (P/N: 23512138) is thepreferred ethylene glycol (EG)

coolant. If other commercial brands ofethylene glycol are used, they must beequivalent to the Power Cool. DetroitDiesel does not market a propyleneglycol (PG) coolant. If a propyleneglycol coolant is used, it must alsomeet the following requirements:

□ Fully formulated ethyleneglycol-based, low silicateantifreeze or coolant mustmeet TMC RP-329 “Type A”requirements.

□ Fully formulated propyleneglycol-based antifreeze or coolant



must meet TMC RP-330 “TypeA” requirements.

Fully formulated antifreeze does notrequire a dosage of SCA prior toinitial use.

Mixing EG or PG Antifreezeand Water — If a concentratedethylene glycol (EG) or propyleneglycol (PG) antifreeze is purchased,mix the antifreeze with water meetingthe required quality standardslisted in Table 23 and fill the coolingsystem.

If a pre-diluted, fully formulatedcoolant is purchased, fill thecooling system. For best overallperformance, a coolant consistingof 50% concentration of antifreeze(50% antifreeze, 50% water) isrecommended.

An antifreeze concentration over67% (67% antifreeze, 33% water) isnot recommended due to poor heat

transfer, reduced freeze protection(IEG only), and possible silicatedropout. An antifreeze concentrationbelow 33% (33% antifreeze, 67%water) offers too little freeze and/orcorrosion protection and is notrecommended.

Always verify that the freeze pointand nitrite concentration of theantifreeze/water mixture are correctby using a POWER Trac® 3–WayCoolant Test Strip. If chemicalanalysis is used, elements in thecoolant must fall within the limitslisted in Table 21.

Recycled Antifreeze — Antifreezeor coolant recycled by reverseosmosis, distillation, and ionexchange, properly re-inhibited tomeet TMC RP-329 Type A or TMCRP-330 Type A requirements, hasbeen demonstrated to provide serviceequivalent to virgin antifreeze.

Fully Formulated Glycol Coolant Concentration LimitsBoron 125 – 500 PPM

Nitrite 900 – 3200 PPM

Nitrate 200 – 1000 PPM

Silicon 50 – 250 PPM

Phosphorous 0 PPM

pH 8.0 – 11.0

Table 21 Fully Formulated Glycol Coolant Limits with TMC RP-329,TMC RP-330 Chemistry Type A (50/50 Coolant/WaterMixture)


HOW-TO SECTION

Recycled antifreeze or coolants ofthese types are preferred. Otherrecycled coolants, especially coolantsrecycled through filtration processes,are not recommended.

EG/Water + OAT Inhibitor orPG/Water + OAT Inhibitor —Ethylene glycol and propyleneglycol are also available with a OATcorrosion package. These coolantsrequire less maintenance over theuseful life of the engine. OATcoolants, maintained as detailed inthe Maintenance section of thisguide, may be operated up to 4 years,600,000 miles (960,000 km), or10,000 operating hours, whichevercomes first. Refer to Coolant InhibitorTest Intervals in this guide. Thecooling system should either beequipped with a blank coolant filter,or the coolant filter and piping may beomitted from the system.

OAT fully formulated antifreezesare available as concentrated andpre-mixed. Concentrated antifreezesshould be mixed 50% (50% antifreeze,50% water).

OAT coolants should not be mixedwith conventional coolants. If theyare mixed, no damage will result, butthe long-life advantages of the OATcoolant will be lost. In this event,the coolant should be maintained as afully formulated IEG coolant, not as

an OAT (Organic Acid Technology)coolant.

Detroit Diesel markets a OAT-inhibited ethylene glycol coolant,DDC Power Cool Plus, whichcontains all the required additives.If a non-DDC OAT antifreeze isused, it must conform to TMC 338specification. Do not add extender tonew OAT antifreeze or coolant.

Water Only + SCA or WaterOnly + OAT Inhibitor — Inwarm climates a coolant basedon water with corrosion inhibitorsis approved for use. Water-onlysystems need to be treated with theproper dosage of corrosion inhibitors.Detroit Diesel-approved SCAs orOAT corrosion inhibitors must beadded to the water to provide requiredcorrosion and cavitation erosionprotection. OAT inhibitors such asPower Cool Plus 6000 are availablefor water-only systems. Inhibitorshould be mixed at 7.5% – 10% byvolume with water. For a list ofPower Cool products, refer to sectionSPECIFICATIONS in this guide.Traditional SCA (Power Cool 3000)can also be used to protect the engine.Power Cool 3000 concentration limitsare listed in Table 22.

NOTE:Do not use Power Trac 3–Way TestStrips to test OAT coolant.



Power Cool 3000 Coolant Concentration LimitsBoron 125 – 500 PPM

Nitrite 900 – 3200 PPM

Nitrate 200 – 1000 PPM

Silicon 50 – 250 PPM

Phosphorous 0 PPM

pH 8.0 – 11.0

Table 22 Power Cool 3000 Concentration Limits (5% Power Cool3000/ 95% Water)

POWER COOL® 3000 SCA inhibitorsshould be mixed at 5% by volumewith water. This is 1 quart per 5gallons of water. These additionscan be made by adding liquid SCAsavailable in a variety of sizes. Coolantfilters are also available for differentcooling system capacities. Thesefilters release the proper amount ofSCA at initial fill.

Water Requirements —Distilled, reverse osmosis-purified,

or de-ionized water which eliminatesthe adverse effects of minerals in tapwater is preferred.

High levels of dissolved chlorides,sulfates, magnesium, and calcium insome tap water causes scale depositsand/or corrosion resulting in waterpump failures and poor heat transfer,leading to overheating. If tap wateris used, the mineral content in thewater must be below the maximumallowable limits listed in Table 23.

Maximum AllowableParts per Million Grains per Gallon

Chlorides 40 2.5

Sulfates 100 5.8

Total Dissolved Solids 340 20Total Hardness –Magnesium and Calcium 170 10

Table 23 Satisfactory Water Limits – Make-Up Water Only


HOW-TO SECTION

NOTICE:Do not add additional SCA tonew, fully formulated antifreeze orcoolant. This can result in dropoutand/or the formation of deposits.

Coolants Not Recommended

The following coolants are notrecommended for use in Detroit Dieselengines.

All Antifreezes And CoolantsContaining Phosphate — Thesecoolants are not recommended. Dropout, overheating and water pump sealfailures can result from the use ofcoolant or inhibitor packages based onphosphate.

Automotive Type Coolants —These coolants generally contain highlevels of phosphate and silicate, offerno liner pitting protection, and arenot suitable for use in Detroit Dieselengines.

Methyl Alcohol-BasedAntifreeze — This must not beused because of its effect on thenon-metallic components of thecooling system and its low boilingpoint.

Glycol-based CoolantsFormulated For HVAC —These coolants formulated forHeating/Ventilation/Air Conditioning(HVAC) should not be used. Thesecoolants generally contain high levelsof phosphates, which can depositon hot internal engine surfaces andreduce heat transfer.

Additives Not Recommended

The following additives are notrecommended for use in Series 60engines.

Soluble Oil Additives — Theseadditives are not approved for use inDetroit Diesel engine cooling systems.A small amount of oil adverselyaffects heat transfer. For example, a1.25% concentration of soluble oilincreases fire deck temperature 6%.A 2.50% concentration increases firedeck temperature 15%. The use ofsoluble oil additives may result inengine overheating and/or failure.

Chromate Additives — Theseadditives are not approved for usein Detroit Diesel engine coolingsystems. Chromate additives canform chromium hydroxide, commonlycalled “green slime.” This, in turn,can result in engine damage due topoor heat transfer. Cooling systemsoperated with chromium-inhibitedcoolant must be chemically cleaned



with Power Cool dry chemicalcooling system cleaner/conditionerlisted in Table 33 (or equivalentsulfamic acid/sodium carbonatecleaner) and flushed.

Coolant Inhibitor Test Intervals

The coolant inhibitor level should bechecked at the intervals listed in Table24.

HOT COOLANT


If topping off is needed, add coolantwhich is identical to the initial fillcoolant.

Supplemental Coolant Additivesfor Fully Formulated Coolant— The concentrations of someinhibitors will gradually depleteduring normal engine operation.SCAs replenish the protection forcooling system components. Thecoolant must be maintained with theproper concentration of SCA. DetroitDiesel Power Coolmaintenance SCAsare recommended.

The proper application of SCA willprovide:

□ pH control.

□ Restored inhibitor levels to preventcorrosion.

□ Water softening to deter formationof mineral deposits.

□ Cavitation protection to protectwet sleeve cylinder liners.

Service Application Inhibitor Test IntervalOn-Highway Trucks and Motor Coaches 20,000 Miles (32,000 Kilometers)Pick-Up and Delivery, Short Trip, andEmergency Vehicles

6,000 Miles (9,600 Kilometers) or 3Months, whichever comes first

Table 24 Required Coolant Inhibitor Test Intervals


HOW-TO SECTION

Maintenance Intervals — Checkthe nitrite concentration at the regular

intervals listed in Table 25 with aPower Trac 3–Way Test Strip.

Coolant Interval 1 Action

20,000 Miles (32,000 km)or 3 Months*

Test nitrite concentrationwith test strip. Add SCA ordilute coolant as needed.

Antifreeze / Water +SCA Inhibitor (DDCPower Cool) 300,000 Miles

(480,000 km)Drain and clean system.Refill with new coolant.


Test nitrite concentrationwith test strip. Add SCA ordilute coolant as needed.

Ethylene Glycol/ Water + SCAInhibitororPropylene Glycol/ Water + SCAInhibitor

300,000 Miles(480,000 km)

Drain and clean system.Refill with new coolant.

Test at 1 Year. —300,000 Miles(480,000 km) or 2 Years*

Add Power Cool PlusExtender

Ethylene Glycol/ Water + OATInhibitororPropylene Glycol/ Water + OATInhibitor

600,000 Miles(960,000 km)

Drain and clean system.Replace with new coolant.


Test nitrite concentrationwith test strip. Add SCA ordilute coolant as needed.Water Only + SCA

Inhibitor 300,000 Miles(480,000 km)

Drain and clean system.Replace with new coolant.

300,000 Miles(480,000 km) or 2 Years*

Add Power Cool PlusExtenderWater Only + OAT

Coolant 600,000 Miles(960,000 km)

Clean and drain. Replacewith new coolant.

1 Maintenance interval based on application. Drain interval dependenton proper maintenance.

Table 25 Coolant Maintenance Intervals

Nitrite levels must be within theranges listed in Table 21.



NOTICE:Always maintain concentrationsof SCA at recommended levels.Failure to properly maintain coolantwith SCA can result in damage tothe cooling system and its relatedcomponents, over-concentration ofSCA inhibitor can result in poor heattransfer and engine damage.Donot use traditional SCAs with OATcoolant.

Additional SCA must be added to thecoolant when it becomes depleted, asindicated by a nitrite concentrationof 900 PPM or less. If the nitriteconcentration is greater than 900PPM, do not add additional SCA. Ifthe nitrite concentration is above 3200PPM, the system is over-inhibited andshould be partially drained and filledwith a 50/50 mix of water and EG orPG.

In this case the EG or PG shouldcontain no inhibitors and shouldconform to ASTM D4985. Thiswill dilute the over-concentratedinhibitors.

NOTE:In non-OAT systems, nitriteconcentration of 5000 PPM orhigher on a Series 60 enginesuggests problematic additiveover-concentration. This conditionmust be corrected by immediatedraining and flushing of the coolingsystem. Refill the system with new fullyformulated or pre-charged coolant.Check the nitrite concentration level atthe next maintenance interval with aPower Trac 3–Way Test Strip.

SCA Test Procedures

Detroit Diesel Power Trac 3–WayCoolant Test Strips should beused to measure nitrite andglycol concentrations. Partnumbers are listed in Table 34.Cavitation/corrosion is indicatedon the strip by the level of nitriteconcentration. Freeze/boil overprotection is determined by glycolconcentration.


HOW-TO SECTION

HOT COOLANT


For best results make the test whilethe coolant is between 50° – 140° F(10.0° – 60° C). Wait at least 60, butnot longer than 75, seconds beforereading the nitrite level. Use the teststrips as follows:

1. Dip the strip into coolant forone second. Remove and shakebriskly to eliminate excess fluid.

2. Immediately compare the pad end(% glycol) to the color chart onthe container.

3. Sixty seconds (one minute) afterdipping, compare the nitrite padto the color chart.

4. Color change of the additiveindicator (middle pad) indicatesthe presence of inhibitor that isnot approved by Detroit Diesel.

Promptly replace and tighten the teststrip container cap after each use.

Discard unused strips if they haveturned light pink or tan.

A factory coolant analysis programis available through authorizedDetroit Diesel service outlets. Partnumbers are listed in Table 34 in theSpecifications section. To verifycoolant acceptability, submit a samplefor coolant analysis every two (2)years, 300,000 miles (480,000 km),or 10,000 operating hours, whichevercomes first.

Coolant Filters (Non-OATSystems)

Spin-on coolant filters are available forDetroit Diesel engines. Membranesin the filters release SCAs beforethe coolant approaches a corrosivecondition, protecting the engine fromcorrosion. The elements release theSCA charge as needed, as opposed tothe maintenance SCA elements, whichinstantaneously release the SCAcharge. Coolant filter elements shouldbe replaced after one (1) year, 120,000miles (192,000 km) or 2,000 operatinghours, whichever comes first.



Dropout

Excessive amounts of some inhibitorsin the coolant can cause a gel orcrystalline deposit that reduces heattransfer and coolant flow. The deposit,called “dropout,” takes the color ofthe coolant when wet, but appears as awhite or gray powder when dry. It canpick up solid particles in the coolantand become gritty, causing excessivewear of water pump seals and othercooling system components.

PERSONAL INJURY

To avoid injury when usingcaustic cleaning agents, followthe chemical manufacturersusage, disposal, and safetyinstructions.

The wet gel can be removed by usinga non-acid (alkali) type heavy-dutycleaner, such as Detroit Diesel PowerCool On-Line Cleaner (sodiumnitrite/sodium tetraborate). Partnumbers are listed in Table 33.

NOTE:If the gel is allowed to dry, it isnecessary to disassemble theengine and clean it with a causticsolution or physically clean individualcomponents.

Coolant Extender InhibitorAdditive for “OAT” Coolant

The inhibitors in OAT coolant mustalso be maintained, but less oftenthan traditional SCA-type coolants.A portable test is available to test thelevels of OAT inhibitors in coolant.Where this is not used, fleet testinghas determined that a OAT coolantextender package should be added tothe coolant at 300,000 miles (480,000km), two (2) years, or 5,000 hours,whichever comes first. The propermaintenance dosages for all OATcoolants are listed in Table 25 ,reflecting 0.6% by volume extender.This dosage should be added to thewater-only and the glycol systems atthe same interval.

The proper application of extender toOAT coolant will provide:

□ pH Control

□ Restored inhibitor levels to preventcorrosion

□ Cavitation protection to protectwet sleeve cylinder liners

NOTE:Do not use traditional SCAs inOAT coolant, and do not useOAT extender in traditional coolant.


HOW-TO SECTION

OAT Coolant Drain Interval —A properly maintained OAT-inhibitedcoolant will last 600,000 miles(960,000 km), four (4) years, or10,000 operating hours, whichevercomes first. At this time the coolantshould be drained, and the coolingsystem should be thoroughly cleaned,flushed, and filled with new, properlyinhibited OAT coolant.

Chronic Coolant SystemProblems

The most commonly seen coolantsystem problems result frommaintenance and formulation factorssuch as:

□ Hard water

□ Dilution of the coolant by theaddition of untreated water

□ Over dosage or under dosage ofcorrosion inhibitors

□ Improper corrosion inhibitor (mostoften phosphated)

□ Mixing SCAs

□ Improper testing

Detroit Diesel Cooling SystemMaintenance Products

The following products are availableto do maintenance on the coolingsystem.

Power Cool SCAs — Power CoolSCAs are water-soluble chemicalcompounds. These products areavailable in coolant filter elements,liquid packages, and in fullyformulated Power Cool antifreeze.

NOTE:Power Cool 3000 liquid SCA is morecompatible with hard water thanPower Cool 2000 SCA.

Power Cool Coolant FilterElements — Power Cool coolantfilter elements (spin-on canisters) areavailable in various sizes suitable forcooling systems of varying capacities.Selection of the proper element sizeis vital when pre-charging non-fullyformulated coolant at initial fill andat maintenance intervals. A fullyformulated antifreeze must nothave SCA added at initial fill. Donot use SCA-containing filterswith OAT antifreeze or coolant.The need for maintenance elementsis determined by the results of thenitrite concentration test performedat each cooling system interval. Donot automatically install maintenanceelements at maintenance intervals,unless the nitrite concentration fallsbelow 900 parts per million.



Power Cool Cleaners — PowerCool Liquid On-Line Cleaner is usedfor light deposits. Power Cool DryChemical Cleaner/Conditioner is usedfor heavy deposits or scale.

Summary of CoolantRecommendations

HOT COOLANT


1. Always maintain the enginecoolant to meet Detroit Dieselspecifications.

2. Only use water that meets thespecifications listed in Table 23.Distilled, de-mineralized (reverseosmosis) or de-ionized water ispreferred.

3. The proper dosage of inhibitorsmust be included in the coolantat initial fill for all Detroit Dieselengines. This dosage is usuallyincluded in the fully formulatedantifreeze used, or it may need to

be added if water alone or if lessthan 50% antifreeze is used. Theuser is urged to refer to the fulltext of this section to determinethe proper dosage. Mixingof different manufacturers'technologies (brands) could causecooling system problems.

4. Maintain the inhibitor at theprescribed concentration. Testthe nitrite concentration by usinga titration kit or Detroit DieselPower Trac 3-Way Coolant TestStrips. Add SCA only if the nitriteconcentration is below 900 PPM.Do not use SCA in OAT coolant,and do not use Power Trac 3-WayCoolant Test Strips to test OATcoolant.

NOTE:If the nitrite concentration exceeds3,200 PPM, the coolant must bedrained and replaced with newcoolant. A thorough cleaning of thecooling system may be required.

5. Do not use another manufacturer'stest kit to measure the SCAconcentration of Detroit Dieselmaintenance products.

6. Pre-mix coolant makeup solutionsto the proper concentration beforeadding to the cooling system.

7. Do not mix OAT and othercoolants in the same engine.


HOW-TO SECTION

8. Do not use automotive coolants.

9. Where antifreeze/boil overprotection is required, use onlyantifreeze that meets TMCRP-329 “Type A” (EG) orTMC RP-330 “Type A” (PG)specifications. Always maintaincoolant at the proper level.

10. Do not use the following inDetroit Diesel engine coolingsystems:

□ Soluble oil

□ High silicate, automotive-typeantifreeze

□ Chromate SCAs

□ Methoxy propanol-basecoolant

□ Methyl alcohol-base coolant

□ Sealer additives or coolantcontaining sealer additives.

□ HVAC coolant

□ Phosphated coolants

Coolant life of Glycol Coolant —A properly maintained coolingsystem, filled with phosphate-freecoolant consisting of a 50/50 mix ofantifreeze and water per TMC RP-329“Type A” (EG) or TMC RP-330“Type A” (PG) specifications can beoperated to the limits recommended.The proper maintenance involvesperiodic evaluation using Power Trac

3-Way Coolant Test Strips and theaddition of SCA as needed, indicatedby the strip test. To verify coolantacceptability, submit a sample forcoolant analysis every 300,000 miles(480,000 km), three (3) years, or5,000 operating hours, whichevercomes first. Submit the sample ina DDC Power Trac Coolant TestBottle. Required part numbers arelisted in Table 34.

Coolant Life of OAT Coolant — Aproperly maintained OAT coolant maybe operated 600,000 miles (960,000km), four (4) years, or until overhaul,whichever comes first. At this time thesystem must be completely drained,thoroughly cleaned, and refilled. OATCoolants require the addition of anextender at 300,000 miles (480,000km), two (2) years, or 5,000 hours,whichever comes first. Use 1 pintof extender for every 20 gallons ofcoolant.

Coolant Life of Other Coolants—Other properly maintained coolantsmay be operated up to 250,000 miles(480,000 km), two (2) years, or 4,000operating hours, whichever comesfirst. At this time the system mustbe completely drained, thoroughlycleaned, and refilled.



How to Drain and Flush theCooling SystemDrain and flush the cooling system asfollows:

HOT COOLANT


1. With the engine cool, drain theprevious solution from the engineand radiator. Dispose of thecoolant in an environmentallyfriendly manner, accordingto state and/or federal (EPA)recommendations.

2. Refill the cooling systemwith clean, soft water and agood cooling system cleaningcompound, such as thoselisted in Table 33 in theSpecifications section. Ifthe engine is warm, fill slowlyto prevent the rapid cooling anddistortion of the metal castings.

3. Start the engine and operate it forfifteen minutes to circulate thesolution thoroughly.

4. Stop the engine and allow it tocool.

5. With the engine cool, drain thecooling system completely.

6. Refill the cooling system withclean, soft water and operate it forfifteen minutes.

7. Stop the engine and allow it tocool.

8. With the engine cool, drain thecleaner residue from the coolingsystem.

9. Refill the system with the requiredcoolant. Refer to section How toSelect Coolant.

10. Entrapped air must be purgedafter filling the cooling system.To do this, allow the engine towarm up without the pressure capinstalled. With the transmissionin neutral, increase engine speedabove 1000 RPM and add coolantas required. Install the pressurecap after the coolant level hasstabilized at the bottom of theradiator filler neck.


HOW-TO SECTION

NOTICE:If the engine overheats andthe coolant level is satisfactory,the cooling system may requirecleaning with a descaling solventand backflushing. AuthorizedDetroit Diesel service outlets areproperly equipped to perform theseservices.

In addition to the cleaning procedure,other components of the coolingsystem should be checked periodicallyto keep the engine operating at peakefficiency.

Hoses

Cooling system hoses should beinspected and any hose that showsobvious signs of damage or feelsabnormally soft or hard should bereplaced. Damaged clamps shouldalso be replaced. All external leaksshould be corrected as soon asdetected.

NOTE:If Detroit Diesel Power Coolantifreeze/coolant (or equivalent fullyformulated, precharged antifreezeis used, a precharge element is notrequired. Coolant inhibitor levelsmust be checked at the intervalslisted in Table 24.

When to Service the DryType Air CleanerReplace dry type air cleaner elementswhen the maximum allowable aircleaner restriction (20 inches ofwater or 5.0 kPa) has been reachedor annually, whichever comes first.Some air cleaners are equipped witha restriction indicator which aids indetermining the servicing interval.

Cleaning and/or reusing dry papertype air cleaner elements is notrecommended unless the cleaningmethod used removes cloggingwithout damaging the element.Inspection and cleaning of elementsmust be done in accordance withthe air cleaner manufacturer'srecommendations, if any.



TROUBLESHOOTING

This section covers basictroubleshooting of engine operationor performance malfunctions andtheir probable causes. In addition tooperating the engine carefully and

maintaining it properly make sure tocorrect any malfunction promptly.

Abnormal CoolantTemperature

Abnormal Coolant Temperature Symptoms and Probable Causes

Probable Causes AboveNormal

BelowNormal

Restricted cooling system passages X —

Restricted radiator core passages X —

Slipping fan drive belts X —

Faulty temperature-controlled fan X —

Obstruction in front of radiator or intercooler X

Low coolant level X —

Damaged hoses X —

Faulty thermostats X —

Faulty water pump X —

Faulty radiator pressure cap X —

Air in coolant X —

Thermostats not fully closed — X

Leakage around thermostat seals — X

Faulty temperature-controlled fan — X


TROUBLESHOOTING

Hard Starting

Hard Starting Symptoms and Probable Causes

Probable Causes Engine WillNot Rotate

LowCrankingSpeed

EngineCranks ButWill NotStart

Low Battery Voltage X X —Loose cranking motorconnections X — —

Faulty cranking motor X X —

Faulty cranking motor switch X X X

Internal seizure X — —

Improper lube oil — X —Circuit breaker/electronic controlmalfunction — — X

Fuse blown or missing — — XInsufficient Fuel SupplyAir in fuel — — X

Out of fuel — — X

Loose fuel connections — — X

Cracked fuel lines — — X

Obstructed fuel filters/lines — — XFaulty fuel pump — — XFaulty injector operation — — XRestricted fuel fitting missing — — X

DDEC Malfunction — — XInstallation/operation of fuelcheck valve or shutoff valve — — X

Low CompressionWorn intake and exhaust valves — — X

Worn piston rings/liners — — X



Hard Starting Symptoms and Probable Causes

Probable Causes Engine WillNot Rotate

LowCrankingSpeed

EngineCranks ButWill NotStart

Leaking cylinder head gasket — — XImproper intake or exhaust valveadjustments — — X

Aftertreatment SystemEngines that meet the EPA 2007emissions standards are equipedwith an a Aftertreatment System thatprevents 95% of the particulate matter(soot) from leaving the exhaust. Thiswill eliminate the use of visible smokediagnostics unless there is a systemfailure issue. White smoke or steamat start up or during cold weatheroperation is still a characteristic ofengine operation. Abnormal amountsof black/blue smoke may merit furtherinvestigation.


TROUBLESHOOTING

Abnormal EngineOperation

Abnormal Engine Operation Symptoms and Probable Causes

Probable Causes

RoughRunning orFrequentStalling

Low Power Detonation

Misfiring cylinder X X —

Insufficient fuel X X —

High return fuel temperature X X —

Low compression X X —

DDEC malfunction X X —High air inlet restriction/ex-haust back pressure — X —

Engine application — X —

High air inlet temperature — X —

High altitude operation — X —Incorrect engine gear traintiming — X —

Low coolant temperature — — X

Oil picked up by inlet airstream — — X

Faulty injector operation — — XIncorrect injector heightsetting — X X



Abnormal OperatingConditionsAbnormal Operating Condition Symptoms and Probable Causes

Probable Causes High Lube OilConsumption

Low OilPressure

Loose connections X —

Cracked lines X —

Damaged gaskets or seal rings X —

* Lube oil loss at breather tube X —

* Lube oil loss at dipstick tube X —

Leaking oil cooler X —

Leaking valve stem seals X —

Worn/broken oil control rings X

Scored liner and/or piston X —

Excessive engine installation angle X —

Crankcase overfilled X —Oil in air tanks (air compressormalfunction) X —

Plugged crankcase breather X —

Oil level low — XImproper engine oil viscosity (fuel in theoil) — X

Faulty oil pressure regulator valve — XWorn crankshaft, camshaft orconnecting rod bearings — X

Missing cup plugs in rocker arm shafts — X

Faulty oil pressure relief valve — X

Air leaks in oil pump (suction side) — XWorn or damaged oil pump — XFaulty oil pressure gage — X

Faulty electrical components (for gage) — X

Plugged oil line or orifice — X

* Indicates high crankcase pressure


ENGINE STORAGE

ENGINE STORAGE

When an engine is to be stored orremoved from operation for a periodof time, special precautions shouldbe taken to protect the interior andexterior of the engine, transmissionand other parts from rust accumulationand corrosion. The parts requiringattention and the recommendedpreparations are given below.

Preparing Engine forStorageIt will be necessary to remove allrust or corrosion completely fromany exposed part before applying rustpreventive compound. Therefore,it is recommended that the enginebe processed for storage as soon aspossible after removal from operation.

The engine should be stored ina building that is dry and can beheated during the winter months.Moisture-absorbing chemicals areavailable commercially for use whenexcessive dampness prevails in thestorage area.

Temporary Storage (30 Days orLess)

To protect the engine for a temporaryperiod of time (30 days or less), followthis procedure:

1. With the engine at ambienttemperature and cool to the touch,drain engine crankcase oil into asuitable container. Dispose of theoil in an environmentally friendlymanner, according to state and/orfederal (EPA) recommendations.

2. Fill the crankcase to the properlevel with the recommendedviscosity and grade of oil.

3. Fill the fuel tank with therecommended grade of fuel oil.Operate the engine for two (2)minutes at 1200 rpm and no load.Do not drain the fuel system orthe crankcase after this run.

4. Check the air cleaner and serviceit, if necessary.

5. If freezing weather is expectedduring the storage period,check the antifreeze/coolant forrequired freeze and inhibitorprotection. Add antifreezesolution to the cooling system inaccordance with Detroit Diesel's



recommendations. Refer to Howto Select Coolant in this guide.

NOTE:If an antifreeze solution is not requiredduring storage, flush the coolingsystem with a good soluble oil (3% –5% by volume) rust inhibitor to preventrusting of the outside diameter of thecylinder liners.

EYE INJURY


6. Clean the exterior of the engine(except electrical parts) with fueloil and dry with compressed air.

7. Seal all engine openings. Thematerial used must be waterproof,vaporproof and possess sufficientphysical strength to resistpuncture and damage from theexpansion of entrapped air.

An engine prepared in this manner canbe returned to service in a short timeby removing the seals at the engineopenings and by checking the enginecoolant, fuel oil, lubricating oil andtransmission oil levels.

Extended Storage (More than 30Days)

To prepare an engine for extendedstorage (more than 30 days), followthis procedure:

1. Drain the cooling system andflush with clean, soft water. Refillwith clean, soft water and adda rust inhibitor to the coolingsystem.

2. Circulate the coolant by operatingthe engine until normal operatingtemperature is reached.

3. Stop the engine.

4. With the engine at ambienttemperature and cool to the touch,drain the engine crankcase oilinto a suitable container. Removethe oil filters. Dispose of the oiland filters in an environmentallyfriendly manner, accordingto state and/or federal (EPA)recommendations. Replace thedrain plug and tighten to 45 –50 N·m (33 – 37 lb-ft) torque.

5. Install new lubricating oilfilters. Fill the crankcase tothe proper level with Tectyl®930A preservative lubricatingoil or an equivalent 30–weightpreservative lubricating oilmeeting Mil-L-21260C, Grade 2Specification.

6. Drain the fuel tank. Refill withenough clean No. 1 diesel fuel to


ENGINE STORAGE

permit the engine to operate forabout ten (10) minutes. If drainingthe fuel tank is not convenient,use a separate, portable supply ofrecommended fuel.

NOTE:If engines are stored wherecondensation of water in the fueltank may be a problem, additivescontaining methyl carbitol or butylcellusolve may be added to the fuel.Follow manufacturer's instructionsfor treatment. Where biologicalcontamination of fuel may be aproblem, add a biocide such asBiobor® JF (or equivalent) to thefuel. When using a biocide, followthe manufacturer's concentrationrecommendations and observe allcautions and warnings.

7. Drain the fuel system and removethe fuel filters. Dispose of usedfilters in an environmentallyresponsible manner, accordingto state and/or federal (EPA)recommendations. Fill the newfilters with No. 1 diesel fuel orpure kerosene and install on theengine.

8. Operate the engine for five (5)minutes to circulate the clean fuelthroughout the engine. Be surethe engine fuel system is full.

9. Stop the engine and allow tocool. Then disconnect the fuel

return line and the inlet line atthe primary filter and securelyplug both to retain the fuel in theengine.

10. Transmission: Follow themanufacturer's recommendationsfor prolonged storage.

11. Power Take-Off: If equipped,follow manufacturer'srecommendations for prolongedstorage.

NOTICE:Failure to properly seal off theturbocharger air inlet and exhaustoutlet openings before enginestorage may permit air drafts tocirculate through the turbochargerand rotate the turbine/compressorshaft without an adequate flow oflubricating oil to the center housingbearings resulting in severe bearingdamage.

12. Turbocharger: Sinceturbocharger bearings arepressure lubricated through theexternal oil line leading fromthe oil filter adaptor while theengine is operating, no furtherattention is required. However,the turbocharger air inlet andturbine exhaust outlet connectionshould be sealed off withmoisture-resistant tape.



13. Apply a non-friction rustpreventive compound to allexposed engine parts. Ifconvenient, apply the rustpreventive compound to theengine flywheel. If not, disengagethe clutch mechanism to preventthe clutch disc from sticking tothe flywheel.

NOTE:Do not apply oil, grease or anywax-base compound to the flywheel.The cast iron will absorb thesesubstances, which can “sweat” outduring operation and cause the clutchto slip.

14. Drain the engine cooling system.If the engine will be exposedto freezing temperatures, installgenuine Detroit Diesel PowerCool antifreeze or an equivalentethylene glycol-base or propyleneglycol-base antifreeze solutionthat provides the required freeze,boil over and inhibitor protection.Refer to How to Select Coolant inthis guide.

15. Drain the preservative oil fromthe engine crankcase. Reinstalland torque the 3/4” – 14 square,magnetic drain plug to 45 –50 N·m (33 – 37 lb-ft).

16. Remove and clean the batteryand battery cables with a bakingsoda-water solution and rinse

with fresh water. Do not allowthe soda solution to enter thebattery. Add distilled water tothe electrolyte (if necessary) andfully charge the battery. Store thebattery in a cool (never below 0°C or 32° F) dry place. Keep thebattery fully charged and checkthe level and specific gravity ofthe electrolyte regularly.

17. Insert heavy paper strips betweenthe pulleys and drive belts toprevent sticking.

18. Seal all engine openings,including the exhaust outlet,with moisture-resistant tape. Usecardboard, plywood or metalcovers where practical.

19. Clean and dry the exterior paintedsurfaces of the engine and spraywith a suitable liquid automobilebody wax, a synthetic resinvarnish, or a rust preventivecompound.

20. Protect the engine with a goodweather-resistant tarpaulin andstore it under cover, preferablyin a dry building which can beheated during the winter months.


ENGINE STORAGE

Outdoor storage of the engine is notrecommended. If units must be keptout of doors, follow the preparationand storage instructions alreadygiven. Protect units with quality,weather-resistant tarpaulins (or othersuitable covers) arranged to providefor air circulation.

NOTICE:Do not use plastic sheeting foroutdoor storage. Enough moisturecan condense on the inside of theplastic to rust ferrous metal surfacesand pit aluminum surfaces. If a unitis stored outside for any extendedperiod of time, severe corrosiondamage can result.

NOTE:Plastic is fine for indoor storage.

The stored engine should be inspectedperiodically. If there are anyindications of rust or corrosion,corrective steps must be taken toprevent damage to the engine parts.Perform a complete inspection at theend of one year and apply additionaltreatment as required.

Procedure for Restoring toService an Engine that Has Beenin Extended Storage

If an engine has been in extendedstorage, prepare it for service asfollows:

1. Remove the covers and tape fromall the openings of the engine, fueltank and electrical equipment. Donot overlook the exhaust outlet.

2. Remove the plugs from the inletand outlet fuel lines and reconnectthe lines to their proper positions.

3. Wash the exterior of the enginewith fuel oil to remove therust preventive. Do not washelectrical components.

4. Remove the rust preventive fromthe flywheel. Flush any solubleoil rust inhibitor (if used) in thecooling system.

5. Remove the paper strips frombetween the pulleys and drivebelts.

6. Fill the crankcase to the properlevel with the required grade oflubricating oil. Use a pressurelubricator to insure all bearingsand rocker shafts are lubricated.

7. Fill the fuel tank with the requiredfuel.

8. Close all drain cocks and fill theengine cooling system with clean,



soft water and required inhibitors.If the engine is to be exposedto freezing temperatures, installgenuine Detroit Diesel PowerCool antifreeze or an equivalentethylene glycol-base or propyleneglycol-base antifreeze solutionwhich provides required freeze,boil over, and inhibitor protection.Refer to section How to SelectCoolant.

9. Install and connect the battery.Make sure the average specificgravity of the battery is 1.260or higher. Charge the battery, ifnecessary.

10. Service the air cleaner, if required.

11. Transmission: Follow themanufacturer's recommendationscovering the return of thetransmission to service.

12. Power Take-Off: If equipped,follow the manufacturer'srecommendations covering thereturn of the power take-off toservice.

13. Turbocharger: Remove thecovers from the turbochargerair inlet and turbine outletconnections. Reconnectpiping as required. Prelubethe turbocharger centerbearing housing. Refer toLubrication System Checks in theOPERATING INSTRUCTIONS

FOR STARTING THE ENGINEsection of this guide.

ENGINE EXHAUST


14. After all preparations arecompleted, start the engine.

NOTE:The small amount of rust preventivewhich remains in the fuel systemwill cause smoky exhaust for a fewminutes.

NOTE:Before subjecting the engine to a loador high speed, allow it to reach normaloperating temperature.

15. Check for trouble codes.

[a] If there are no codes, performa parked regeneration.

[b] If there are codes, repair whatis necessary then perform aparked regeneration.


CUSTOMER ASSISTANCE

CUSTOMER ASSISTANCE

The satisfaction and goodwill of theowners of Detroit Diesel engines are ofprimary concern to Detroit Diesel and

its distributor/dealer organizations.See Figure 36 for Detroit DieselNAFTA On-Highway service regions.

Figure 36 Detroit Diesel NAFTA On-Highway Service Regions



NAFTA ON-HIGHWAY SERVICE REGIONSDETROIT DIESEL REGIONALSALES OFFICES

DETROIT DIESEL REGIONALSERVICE OFFICES

NORTHEAST REGIONDetroit Diesel CorporationPowder Miss Plaza, Suite 3A51 Gibralter DriveMorris Plains, NJ 07950-1274Phone: 973-492-6555Fax: 973-267-5922

NORTH EASTERN REGIONDetroit Diesel Corporation13400 Outer Drive WestDetroit, MI 48239-4001Telephone: 313-592-5420Fax: 311-592-5887

CENTRAL REGIONDetroit Diesel Corporation9255 Indian Creek Parkway, Suite 850Overland Park, KS 66210Phone: 678-570-2389

NORTH CENTRAL & WESTERNREGIONSDetroit Diesel Corporation7700 Irvine Center, Suite 275Irvine CA 92618Phone: 949-753-7710Fax: 949-753-7711

SOUTHERN REGIONDetroit Diesel Corporation3325 Paddocks Parkway, Suite 230Suwanne, GA 30024Phone: 678-341-6100Fax: 678-341-6150

SOUTHERN REGIONDetroit Diesel Corporation3325 Paddocks Parkway, Suite 230Suwanne, GA 30024Phone: 678-341-6100Fax: 678-341-6150

WESTERN REGIONDetroit Diesel Corporation7700 Irvine Center, Suite 275Irvine CA 92618Phone: 949-753-7710Fax: 949-753-7711

CANADA REGIONDetroit Diesel of Canada, Ltd.150 Dufferin Ave., Suite 701London ON N5A 5N6Phone: 519-661-0149Fax: 519-661-0171

CANADA REGIONDetroit Diesel of Canada, Ltd.150 Dufferin Ave., Suite 701London ON N5A 5N6Phone: 519-661-0149Fax: 519-661-0171

MEXICO REGIONDetroit Diesel Allison de Mexico, S.A.Av. Santa Rosa 58Col. Ampliacion NorteSan Juan Ixtacala, TlanepantlaC.P. 54160, Edo de MexicoPhone: 525-333-1802Fax: 525-333-1870


CUSTOMER ASSISTANCE

Road Service in the U.S. orCanadaIf you require road service for anyreason in the U.S. or Canada, you maycall the 1–800–445–1980 customerassistance phone number. An operatorwill assist you in determining whattype of service is required. Not allproblems are engine related and notall problems are covered by engineor vehicle warranties. YOU MAYBE RESPONSIBLE FOR REPAIREXPENSES.

Before calling Customer Assistance,please do the following:

□ Check coolant level

□ Check fuel level

□ Check DDEC fuses

□ Check for fuel leaks

□ Make sure manual shutoff valve (ifinstalled) on the fuel filter adaptor,fuel processor body or fuel supplyline is open.

□ Check the oil level on the dipstick.

□ Check diagnostic codes.

If you call, have the followinginformation available:

□ Engine serial number

□ Vehicle make and model

□ Odometer mileage (kilometers) orhourmeter hours

□ Vehicle owner/company name

Working with Detroit DieselService OutletsAs the owner of a Detroit Dieselproduct you have a complete networkof Detroit Diesel service outlets in theU.S. and Canada, plus many outletsworldwide that are prepared to meetyour parts and service needs:

□ Service by trained personnel.

□ Sales team to help determine yourspecific power requirements.

□ In many areas, emergency service24 hours a day.

□ Complete parts support, includingreliabilt® remanufacturedcomponents.

□ Product information and literature.

We recognize however, that despitethe best intentions of everyoneconcerned, misunderstandings mayoccur. Normally, any situationthat arises in connection with thesale, operation or service of yourproduct will be handled by theauthorized service outlet in your area(in the U.S. and Canada, check theYellow Pages or service locator atwww.detroitdiesel.com for DetroitDiesel service outlet nearest you).



Detroit Diesel has established athree-step procedure that customersshould follow when experiencinga problem with any Detroit DieselProduct or Part. Detroit Diesel fullyrealizes that ultimately the customer'sconcerns will be resolved at theDistributor/Dealer level and thereforeencourages customers to follow theprocedure outlined below:

Step One

Customers should discuss the problemwith a member of managementfrom the authorized service outlet.Frequently, complaints are the resultof a breakdown in communicationand can quickly be resolved by amember of management. If they havealready discussed the problem withthe Distributor or Dealer Sales orService Manager, they should contactthe General Manager.

Step Two

When it appears that the problemcannot readily be resolved at theDistributor/Dealer level withoutadditional assistance, the DetroitDiesel Customer Support Center(CSC) should be contacted at313–592–5800.

The information provided to the CSCwill be forwarded to the appropriateRegional Product Support Manager.The customer will then be assisted

be a member of the Regional ProductSupport Managers staff, depending onthe nature of his/her problem.

Prior to this contacting the CSC, thecustomer should have the followinginformation available:

□ Name and location of authorizedservice outlet

□ Type, make and vehicleidentification number ofequipment

□ Engine model and serial number

□ Engine delivery date andaccumulated miles/kilometers orhours of operation

□ Nature of problem

□ Chronological summary ofengine's repair history

Step Three

If the customer is still not satisfied,he/she should present the entire matterin writing or by phone to:

Director of Technical Service orManager, Service Operations BX5Detroit Diesel Corporation13400 Outer Drive, WestDetroit, Michigan 48239–4001Phone: 313–592–5000Fax: 313–592–5888


SPECIFICATIONS

SPECIFICATIONS

This section lists the various POWERCOOL engine products.

Fuel and Lubricating OilFiltersConsult with a Detroit DieselDistributor to obtain the proper fuelfilters and lubricating oil filters.

OIL PAN CAPACITY

Engine oil capacity can vary,depending on the oil pan used andthe engine application. Contact theDetroit Diesel Customer Support

Center (313–592–5800) if you needthis specific information.

POWER COOL ENGINEPRODUCTSMaintenance of the cooling systemrequires the chemical make-up of thesystem to be balanced.

POWER COOL Fully FormulatedIEG Coolant

The part numbers and sizes ofconcentrated POWER COOL andpre-blended 50:50 POWER COOL arelisted in Table 26.

Coolant Type Part Number Description23512138 1 Gallon Jug – 6 Per Case

23512139 55 Gallon Drum

23529295 330 Gallon ToteConcentrated

23512140 Bulk Delivery – 1,000 Gallon Min.

23528203 1 Gallon Jug – 6 Per Case


23528544 330 Gallon TotePre-Blended

50:50


Table 26 POWER COOL Fully Formulated IEG Coolant



POWER COOL 2000 and 3000Supplemental Coolant Additive

Coolant Type Part Number Description23507858 Pint Bottle – 12 Per case

23507859 Half Gallon Jug – 6 Per Case

23507860 5 Gallon PailFor Power Cool IEG

Coolant


Table 27 POWER COOL 2000 Supplemental Coolant Additive

Coolant Type Part Number Description23507854 Pint Bottle – 12 Per Case

23507855 Half Gallon Jug – 6 Per Case

23507856 5 Gallon PailFor POWER COOL

IEG Coolant


Table 28 POWER COOL 3000 Supplemental Coolant Additive

POWER COOL 3000Supplemental Additive CoolantFilters

Coolant Type Part Number Description23507545 4 Ounce (1 Pint Equivalent)

23508425 8 Ounce (2 Pint Equivalent)




For POWER COOLIEG Coolant


Table 29 POWER COOL 3000 Supplemental Additive Coolant Filters


SPECIFICATIONS

POWER COOL SupplementalAdditive Need Release CoolantFilters

Coolant Type Part Number DescriptionNF2091 For 0 – 8 Gallon SystemsFor POWER COOL

IEG Coolant 23516489 For 8 – 20 Gallon Systems

Table 30 POWER COOL Supplemental Additive Need ReleaseCoolant Filters

POWER COOL Plus ExtendedLife OAT Coolant

Coolant Type Part Number Description23519397 1 Gallon Jug – 6 Per Case

23519394 55 Gallon DrumConcentrated


23519396 One Gallon Jug – 6 Per Case

23519398 55 Gallon DrumPre-Blended 50:50


Table 31 POWER COOL Plus Extended Life OAT Coolant

POWER COOL Plus ExtenderFor Use With POWER COOLPlus OAT Coolant

Coolant Type Part Number Description

For Power Cool Plus 23519400 Quart Bottle – 6 Per Case

Table 32 POWER COOL Plus Extender for Use with POWER COOLPlus OAT Coolant



POWER COOL Cooling SystemCleaners

Coolant Type Part Number Description200164 On-Half Gallon Jug – 6 Per Case

200105 5 Gallon PailOn-Line Cleaner


Twin Pack 201549 Twin Pack – 2 Per Case

Table 33 POWER COOL Cooling System Cleaners

POWER TRAC Coolant TestingAnd Analysis Products

Application PartNumber Description

Indicates Nitrite,Molybdate & Glycol

Levels23519401 3-Way Coolant Test Strips

(Single Foil Packs)



(Bottle of 50)



(Bottle of 10)

Complete IEG/IPGCoolant Analysis 23516921 Coolant Analysis Bottle

(Carton of 6)Organic Coolant

Analysis 23523398 Laboratory Coolant Analysis Bottle(Carton of 6)

Table 34 Power Trac Coolant Testing and Analysis Products


EPA07 Series 60 Operatorâ€™s Manual

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Transcript of EPA07 Series 60 Operatorâ€™s Manual