Detroit Engine Ddc Svc Man 0039

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DDC-SVC-MAN-0039

EPA04 Series 60®

Operator’s Manual

13400 Outer Drive, West, Detroit, Michigan 48239-4001

Telephone: 313-592-5000
www.detroitdiesel.com

Specifications are subject to change without notice. Detroit Diesel Corporation

is registered to ISO 9001:2001. Copyright © Detroit Diesel Corporation.
All rights reserved. Detroit Diesel Corporation is a Daimler company.
Printed in U.S.A.

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 SERIES 60 ON-HIGHWAY ENGINE OPERATOR'S GUIDE

To the Operator Whenever possible, it will benefit

you to rely on an authorized Detroit
This guide contains instructions on Diesel service outlet for all your
the safe operation and preventive service needs from maintenance to
maintenance of your Detroit Diesel major parts replacement. Authorized
Series 60® engine used in vehicle or service outlets worldwide stock
fire fighting apparatus applications. factory-original parts and have
Maintenance instructions cover the specialized equipment and
routine engine services such as lube experienced, trained personnel
oil and filter changes in enough detail to provide prompt preventive
to permit self-servicing, if desired. maintenance and skilled engine
repairs.
The operator should become familiar
with the contents of this guide before The information and specifications
operating the engine or carrying out in this publication are based on the
maintenance procedures. information in effect at the time of
approval for printing. Contact an
Power-driven equipment is only
authorized Detroit Diesel service
as safe as the person operating the
outlet for information on the latest
controls. You are urged, as the
revision. The right is reserved to
operator of this diesel engine, to keep
make changes at any time without
fingers and clothing away from the
obligation.
revolving belts, drive shafts, pulleys,
etc. on the engine installation.
Throughout this guide CAUTIONS
regarding personal safety and
NOTICES regarding engine
performance or service life will
appear. To avoid personal injury and
ensure long engine service life, always
heed these instructions.

All information subject to change without notice. i

DDC-SVC-MAN-0039 Copyright © 2009 DETROIT DIESEL CORPORATION
 NOTICE: Trademark Information
Coolant must be inhibited with the DDC®, Detroit Diesel®, DDEC®,
recommended SCAs (supplemental Series 60®, Optimized Idle®,
coolant additives) listed in the Diagnostic Link®, reliabilt®,
How To section of this engine POWER Trac®, POWER COOL®,
operator's guide. In addition, the and POWER GUARD® are registered
engine can be equipped with a trademarks of Detroit Diesel
coolant filter/inhibitor system as an Corporation. Delco Remy® is a
installed option or as an after-sale registered trademark of Delco Remy
item. Failure to check and America, Inc. Bosch® is a registered
maintain SCA levels at required trademark of Robert Bosch Company
concentrations will result in N.A. Fuel Pro®, and Mega Filter®
severe damage (corrosion) to are registered trademarks of Davco
the engine cooling system and Manufacturing, L.L.C. PowerBand®
related components. is a registered trademark of Gates
Rubber Company. Tectyl® is a
registered trademark of Daubert
Chemical Company, Inc. Biobor® is a
WARRANTY registered trademark of United States
Borax and Chemical Corporation.
The applicable engine warranty is
DuPont® is a registered trademark
contained in the booklet “Warranty
of E.I. DuPont de Nemours and
Information for Series 60 Engines,”
Company, Inc. All other trademarks
available from authorized Detroit
used are the property of their
Diesel service outlets.
respective owners.

Keep this Operator's Guide

with the engine installation at
all times. It contains important
operating, maintenance, and safety
instructions.

ii All information subject to change without notice.

DDC-SVC-MAN-0039 Copyright © 2009 DETROIT DIESEL CORPORATION
 SERIES 60 ON-HIGHWAY ENGINE OPERATOR'S GUIDE

TABLE OF CONTENTS

INTRODUCTION .................................................................................. 1
NON-GENUINE AND REBUILT COMPONENT QUALITY ALERT .. 1

CAUTION SUMMARY .......................................................................... 3

ENGINE OPERATION ..................................................................... 3
PREVENTIVE MAINTENANCE ....................................................... 4
ELECTRICAL SYSTEM ................................................................... 7
COOLING SYSTEM ......................................................................... 8
AIR INTAKE SYSTEM ...................................................................... 8
FUEL SYSTEM ................................................................................ 9
STARTING AIDS .............................................................................. 9
COMPRESSED AIR ......................................................................... 11
LUBRICATING OIL AND FILTERS .................................................. 11

ENGINE MODEL AND SERIAL NUMBER DESIGNATION ................ 12

CERTIFICATION LABELS ............................................................... 13

OPERATING INSTRUCTIONS FOR A FIRST TIME START .............. 14

SYSTEM CHECKS .......................................................................... 14
COOLING SYSTEM CHECKS .................................................... 14
LUBRICATION SYSTEM CHECKS ............................................. 15
EXTENDED STORAGE .......................................................... 15
FUEL SYSTEM CHECKS ............................................................ 16
OTHER CHECKS ........................................................................ 17
STARTING THE ENGINE ................................................................ 17
INITIAL ENGINE START ............................................................. 18
ELECTRIC STARTER ............................................................. 18
AIR STARTER ......................................................................... 19
RUNNING THE ENGINE ................................................................. 19
OIL PRESSURE .......................................................................... 19
WARM-UP ................................................................................... 19
INSPECTION ............................................................................... 19
TRANSMISSION ..................................................................... 19
FLUID LEAKS ......................................................................... 19
CRANKCASE .......................................................................... 20

All information subject to change without notice. iii

DDC-SVC-MAN-0039 Copyright © 2009 DETROIT DIESEL CORPORATION
TABLE OF CONTENTS

TURBOCHARGER .................................................................. 20
AVOID UNNECESSARY IDLING ................................................. 20
STOPPING THE ENGINE ................................................................ 20
EMERGENCY JUMP STARTING .................................................... 21

DDEC V SYSTEM ................................................................................ 22

DDEC FEATURES ........................................................................... 22
ENGINE PROTECTION .............................................................. 23
IDLE SHUTDOWN TIMER .......................................................... 23
CRUISE CONTROL ..................................................................... 23
ENGINE BRAKES ....................................................................... 25
DATA RECORDING CAPABILITY ............................................... 26
DDEC V OPERATION ...................................................................... 26
STOP ENGINE OVERRIDE SWITCH ......................................... 27
IMMEDIATE SPEED REDUCTION ............................................. 27
RED STOP LAMP ........................................................................ 27
DIAGNOSTIC DATA READER .................................................... 28
DDEC V ENGINE DRIVING TIPS ........................................................ 35
ACCELERATING THE VEHICLE ..................................................... 35
CRUISE CONTROL ......................................................................... 35
ENGINE BRAKES AND CRUISE CONTROL .................................. 37
SHIFTING ........................................................................................ 37
IDLING ............................................................................................. 39
WINTER FRONTS ....................................................................... 39
ENGINE BRAKE SYSTEM .................................................................. 40
DRIVER CONTROL SWITCHES ..................................................... 40
LOW/HIGH SWITCH ................................................................... 40
LOW/MED/HIGH SWITCH .......................................................... 40
CLUTCH PEDAL AND THROTTLE POSITION CONTROLS .......... 40
ENGINE BRAKE OPERATION ........................................................ 40
ANTI-LOCK BRAKING SYSTEMS ................................................... 42
DRIVING ON FLAT, DRY PAVEMENT ............................................. 42
DESCENDING A LONG, STEEP GRADE ....................................... 42
DRIVING ON WET OR SLIPPERY PAVEMENT .............................. 44
ENGINE SYSTEMS ............................................................................. 45
FUEL SYSTEM ................................................................................ 45
LUBRICATION SYSTEM ................................................................. 45

iv All information subject to change without notice.

DDC-SVC-MAN-0039 Copyright © 2009 DETROIT DIESEL CORPORATION
 SERIES 60 ON-HIGHWAY ENGINE OPERATOR'S GUIDE

AIR SYSTEM ................................................................................... 45

COOLING SYSTEM ......................................................................... 45
ELECTRICAL SYSTEM ................................................................... 45
EXHAUST SYSTEM ........................................................................ 45
EXHAUST GAS RECIRCULATION SYSTEM .................................. 45
MAINTENANCE ................................................................................... 46
MAINTENANCE INTERVALS .......................................................... 46
PREVENTIVE MAINTENANCE INTERVALS .................................. 56
ITEM 1 – LUBRICATING OIL ...................................................... 56
ITEM 2 – FUEL AND FUEL TANK ............................................... 57
ITEM 3 – FUEL LINES, FLEXIBLE HOSES ................................ 59
LEAKS ..................................................................................... 59
HOSES AND FITTINGS .......................................................... 59
HOSE SERVICE LIFE ............................................................. 59
ITEM 4 – COOLING SYSTEM ..................................................... 60
COOLANT LEVEL ................................................................... 60
COOLANT INHIBITORS .......................................................... 60
COOLANT DRAIN INTERVAL ................................................. 60
ITEM 5 – TURBOCHARGER, AIR-TO-AIR CHARGE COOLER . 62
WASTEGATED TURBOCHARGERS ...................................... 62
ITEM 6 – BATTERY ..................................................................... 63
ITEM 7 – TACHOMETER DRIVE ................................................ 64
ITEM 8 – DRIVE BELTS .............................................................. 64
V-BELTS .................................................................................. 64
2-GROOVE POWERBAND ..................................................... 65
12–RIB POLY-V BELT ............................................................. 65
BELT REPLACEMENT ............................................................ 66
ITEM 9 – AIR COMPRESSOR .................................................... 66
ITEM 10 – AIR CLEANER ........................................................... 66
AIR CLEANER REPLACEMENT ............................................. 67
ITEM 11 – LUBRICATING OIL FILTERS ..................................... 67
ITEM 12 – FUEL FILTERS .......................................................... 68
FUEL PRO® 382 FILTERS ..................................................... 68
SPIN-ON FILTERS .................................................................. 68
ITEM 13 – WATER PUMP AND COOLANT INHIBITOR
ELEMENT .................................................................................... 68
WATER PUMP DRAIN HOLE ................................................. 68
COOLANT INHIBITOR ELEMENT .......................................... 69

All information subject to change without notice. v

DDC-SVC-MAN-0039 Copyright © 2009 DETROIT DIESEL CORPORATION
TABLE OF CONTENTS

ITEM 14 – CRANKING MOTOR .................................................. 69

ITEM 15 – AIR SYSTEM ............................................................. 69
ITEM 16 – EXHAUST SYSTEM .................................................. 70
ITEM 17 – ENGINE (STEAM CLEAN) ......................................... 70
ITEM 18 – RADIATOR ................................................................. 70
ITEM 19 – OIL PRESSURE ......................................................... 71
ITEM 20 – BATTERY-CHARGING ALTERNATOR ...................... 71
BOSCH® T1 ALTERNATOR SERVICE REQUIREMENTS ..... 72
GENERAL SERVICE REQUIREMENTS – BOSCH® AND
DELCO REMY® ALTERNATORS ........................................... 72
ITEM 21 – ENGINE AND TRANSMISSION MOUNTS ................ 72
ITEM 22 – CRANKCASE PRESSURE ........................................ 72
ITEM 23 – FAN HUB .................................................................... 72
ITEM 24 – THERMOSTATS AND SEALS ................................... 72
ITEM 25 – CRANKCASE BREATHER ........................................ 73
ITEM 26 – ENGINE TUNE-UP .................................................... 73
ITEM 27 – VIBRATION DAMPER ................................................ 74
HOW-TO SECTION .............................................................................. 75
HOW TO SELECT LUBRICATING OIL ............................................ 75
LUBRICANT REQUIREMENTS .................................................. 75
EGR-EQUIPPED ENGINES .................................................... 75
NON-EGR ENGINES .............................................................. 75
ENGINES BUILT PRIOR TO 1998 .......................................... 75
COLD WEATHER STARTING ..................................................... 76
SYNTHETIC OILS ....................................................................... 76
THE USE OF SUPPLEMENTAL ADDITIVES .............................. 77
WHEN TO CHANGE OIL ................................................................. 77
DISPOSING OF WASTE OIL ...................................................... 78
HOW TO REPLACE THE LUBE OIL FILTERS ................................ 78
REPLACE SPIN-ON TYPE OIL FILTER ...................................... 78
HOW TO SELECT FUEL OIL .......................................................... 80
QUALITY ..................................................................................... 80
FUEL CONTAMINATION ............................................................. 80
PROHIBITED ADDITIVES ........................................................... 81
USED LUBRICATING OIL ....................................................... 81
GASOLINE ............................................................................. 81
HOW TO REPLACE THE FUEL FILTERS ....................................... 81
REPLACE SPIN-ON PRIMARY OR SECONDARY ELEMENTS 82

vi All information subject to change without notice.

DDC-SVC-MAN-0039 Copyright © 2009 DETROIT DIESEL CORPORATION
 SERIES 60 ON-HIGHWAY ENGINE OPERATOR'S GUIDE

REPLACE FUEL/WATER SEPARATOR ELEMENT .................... 84

REPLACE FUEL PRO ELEMENT ............................................... 85
ENGINE OUT OF FUEL — HOW TO RESTART ............................. 87
ENGINES WITH SPIN-ON FILTERS ........................................... 87
ENGINES WITH FUEL PRO FILTERS ........................................ 88
HOW TO SELECT COOLANT ......................................................... 89
DEFINITIONS .............................................................................. 89
APPROVED COOLANTS ............................................................ 90
EG & WATER OR PG & WATER PLUS SCA INHIBITOR ....... 91
MIXING EG OR PG ANTIFREEZE AND WATER ................... 91
RECYCLED ANTIFREEZE .................................................... 94
EG/WATER + OAT INHIBITOR OR PG/WATER + OAT
INHIBITOR .............................................................................. 94
WATER ONLY + SCA OR WATER ONLY + OAT INHIBITOR 95
WATER REQUIREMENTS ..................................................... 96
COOLANTS NOT RECOMMENDED .......................................... 96
ALL ANTIFREEZES AND COOLANTS CONTAINING
PHOSPHATE ........................................................................... 96
AUTOMOTIVE TYPE COOLANTS .......................................... 96
METHYL ALCOHOL-BASED ANTIFREEZE ........................... 96
GLYCOL-BASED COOLANTS FORMULATED FOR HVAC ... 97
ADDITIVES NOT RECOMMENDED ........................................... 97
SOLUBLE OIL ADDITIVES ..................................................... 97
CHROMATE ADDITIVES ........................................................ 97
COOLANT INHIBITOR TEST INTERVALS ................................. 97
SUPPLEMENTAL COOLANT ADDITIVES FOR FULLY
FORMULATED COOLANT ..................................................... 98
MAINTENANCE INTERVALS .................................................. 98
SCA TEST PROCEDURES ......................................................... 100
NEED RELEASE COOLANT FILTERS (NON-OAT SYSTEMS) . 101
DROPOUT ................................................................................... 102
EXTENDER INHIBITOR ADDITIVE FOR “OAT” COOLANT ....... 102
OAT COOLANT DRAIN INTERVAL ........................................ 103
CHRONIC COOLANT SYSTEM PROBLEMS ............................. 103
COOLING SYSTEM MAINTENANCE PRODUCTS .................... 103
POWER COOL SCAS ............................................................. 103
POWER COOL COOLANT FILTER ELEMENTS .................... 103
POWER COOL CLEANERS ................................................... 103

All information subject to change without notice. vii

DDC-SVC-MAN-0039 Copyright © 2009 DETROIT DIESEL CORPORATION
Detroit Engine Ddc Svc Man 0039
Full download: http://manualplace.com/download/detroit-engine-ddc-svc-man-0039
TABLE OF CONTENTS

SUMMARY OF COOLANT RECOMMENDATIONS .................... 104

COOLANT LIFE OF GLYCOL COOLANT ............................... 105
COOLANT LIFE OF OAT COOLANT ...................................... 105
COOLANT LIFE OF OTHER COOLANTS .............................. 105
HOW TO DRAIN AND FLUSH THE COOLING SYSTEM ............... 106
HOSES ........................................................................................ 107
WHEN TO SERVICE THE DRY TYPE AIR CLEANER ................... 107

BASIC TROUBLESHOOTING ............................................................. 108

ENGINE STORAGE ............................................................................. 113

PREPARING ENGINE FOR STORAGE .......................................... 113
TEMPORARY STORAGE (30 DAYS OR LESS) ......................... 113
EXTENDED STORAGE (MORE THAN 30 DAYS) ...................... 114
RESTORING AN ENGINE AFTER EXTENDED STORAGE ....... 117

SERIES 60 SERVICE PUBLICATIONS ............................................... 119

CUSTOMER ASSISTANCE ................................................................. 120

ROAD SERVICE IN THE U.S. OR CANADA ................................... 123
WORKING WITH DDC SERVICE OUTLETS .................................. 123

LIMITED WARRANTY ON HIGHWAY VEHICLE ENGINES ............... 126

TERMS OF COVERAGE ................................................................. 126
USES ........................................................................................... 126
DEFECTS .................................................................................... 126
REPAIRS ..................................................................................... 126
WARRANTY PERIOD .................................................................. 126
LIKE REPLACEMENT ENGINE .................................................. 126
SERVICE SUPPLIES .................................................................. 127
ENGINE REMOVAL AND REINSTALLATION ............................. 127
THIS WARRANTY DOES NOT COVER: ......................................... 127
REPAIRS DUE TO ACCIDENTS, MISUSE, STORAGE DAMAGE,
NEGLIGENCE OR CERTAIN MODIFICATIONS ......................... 127
BRAKING DEVICES .................................................................... 128
FUEL INJECTORS AFTER 200,000 MILES/320,000
KILOMETERS .............................................................................. 128
MAINTENANCE ........................................................................... 128
INCIDENTAL OR CONSEQUENTIAL DAMAGE ......................... 128
OTHER LIMITATIONS ................................................................. 128

viii All information subject to change without notice.

DDC-SVC-MAN-0039 Copyright © 2009 DETROIT DIESEL CORPORATION

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