Detroit Diesel 60 Manuel

SERIES 60 ENGINE OPERATOR'S GUIDE

To the Operator

This guide contains instructions on

the safe operation and preventive

maintenance of your Detroit Diesel

Series 60®engine used in vehicle,

stationary, construction/industrial,

agricultural, generator set or fire

fighting apparatus applications.

Maintenance instructions cover

routine engine services such as lube

oil and filter changes in enough detail

to permit self-servicing, if desired.

The operator should become familiar

with the contents of this guide before

operating the engine or carrying out

maintenance procedures.

Power-driven equipment is only

as safe as the person operating the

controls. You are urged, as the

operator of this diesel engine, to keep

fingers and clothing away from the

revolving belts, drive shafts, 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.

Whenever possible, it will benefit

youtorelyonanauthorized Detroit

Diesel service outlet for all your

service needs from maintenance to

major parts replacement. Authorized

service outlets worldwide stock

factory-original parts and have

the specialized equipment and

experienced, trained personnel

to provide prompt preventive

maintenance and skilled engine

repairs.

The information and specifications

in this publication are based on the

information in effect at the time of

approval for printing. Contact an

authorized Detroit Diesel service

outlet for information on the latest

revision. The right is reserved to

make changes at any time without

obligation.

All information subject to change without notice. (Rev. 01/04) i

NOTICE:

Coolant must be inhibited with the

recommended SCAs (supplemental

coolant additives) listed in the

How To section of this engine

operator's guide. In addition, the

engine can be equipped with a

coolant filter/inhibitor system as an

installedoptionorasanafter-sale

item. Failure to check and

maintain SCA levels at required

concentrations will result in

severe damage (corrosion) to

the engine cooling system and

related components.

WARRANTY

The applicable engine warranty is

contained in the booklet “Warranty

Information for Series 60 Engines,”

available from authorized Detroit

Diesel service outlets.

Keep this Operator's Guide

withtheengineinstallationat

all times. It contains important

operating, maintenance, and safety

instructions.

Trademark Information

DDC®, Detroit Diesel®,DDEC

®,

Series 60®, Optimized Idle®,

Diagnostic Link®, reliabilt®,Power

Trac®,Power Cool®,andPower

Guard®are registered trademarks of

Detroit Diesel Corporation. Delco

Remy®is a registered trademark of

Delco Remy America, Inc. Bosch®

is a registered trademark of Robert

Bosch Company N.A. Fuel Pro®,Sea

Pro®and Mega Filter®are registered

trademarks of Davco Manufacturing,

L.L.C. PowerBand®is a registered

trademark of Gates Rubber Company.

Tectyl®is a registered trademark of

Daubert Chemical Company, Inc.

Biobor®is a registered trademark of

United States Borax and Chemical

Corporation. DuPont®is a registered

trademark of E.I. DuPont de Nemours

and Company, Inc. All other

trademarks used are the property of

their respective owners.

ii All information subject to change without notice. (Rev. 01/04)

SERIES 60 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 .............................................................................. 10

COMPRESSED AIR ......................................................................... 11

LUBRICATING OIL AND FILTERS ................................................... 11

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

OPTION LABELS ............................................................................. 13

CERTIFICATION LABELS ............................................................... 14

OPERATING INSTRUCTIONS FOR A FIRST TIME START .............. 15

SYSTEM CHECKS .......................................................................... 15

COOLING SYSTEM CHECKS .................................................... 15

LUBRICATION SYSTEM CHECKS ............................................. 16

EXTENDED STORAGE ........................................................... 16

FUEL SYSTEM CHECKS ............................................................ 17

OTHER CHECKS ........................................................................ 18

STARTING THE ENGINE ................................................................ 18

INITIAL ENGINE START .............................................................. 19

ELECTRIC STARTER ............................................................. 19

AIR STARTER ......................................................................... 20

RUNNING THE ENGINE ................................................................. 20

OIL PRESSURE .......................................................................... 20

WARM-UP ................................................................................... 20

INSPECTION ............................................................................... 20

TRANSMISSION ..................................................................... 20

FLUID LEAKS ......................................................................... 20

All information subject to change without notice. (Rev. 01/04) iii

TABLEOFCONTENTS

CRANKCASE .......................................................................... 21

TURBOCHARGER .................................................................. 21

AVOID UNNECESSARY IDLING ................................................. 21

STOPPING THE ENGINE ................................................................ 21

EMERGENCY JUMP STARTING .................................................... 22

DDEC V SYSTEM ................................................................................ 23

DDEC FEATURES ........................................................................... 23

ENGINE PROTECTION ............................................................... 24

IDLE SHUTDOWN TIMER ........................................................... 24

CRUISE CONTROL ..................................................................... 24

ENGINE BRAKES ....................................................................... 26

DATA RECORDING CAPABILITY ................................................ 27

DDEC V OPERATION ...................................................................... 27

STOP ENGINE OVERRIDE SWITCH .......................................... 28

IMMEDIATE SPEED REDUCTION .............................................. 28

RED STOP LAMP ........................................................................ 28

DIAGNOSTIC DATA READER ..................................................... 29

DDEC V ENGINE DRIVING TIPS ........................................................ 36

ACCELERATING THE VEHICLE ..................................................... 36

CRUISE CONTROL ......................................................................... 36

ENGINE BRAKES AND CRUISE CONTROL .................................. 38

SHIFTING ........................................................................................ 38

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 ........................................................ 41

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

iv All information subject to change without notice. (Rev. 01/04)

SERIES 60 ENGINE OPERATOR'S GUIDE

LUBRICATION SYSTEM .................................................................. 45

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 ................................... 62

ITEM 1 – LUBRICATING OIL ....................................................... 62

ITEM 2 – FUEL AND FUEL TANK ............................................... 64

ITEM 3 – FUEL LINES, FLEXIBLE HOSES ................................ 65

LEAKS ..................................................................................... 65

HOSES AND FITTINGS .......................................................... 65

HOSE SERVICE LIFE ............................................................. 65

ITEM 4 – COOLING SYSTEM ..................................................... 66

COOLANT LEVEL ................................................................... 66

COOLANT INHIBITORS .......................................................... 66

COOLANT DRAIN INTERVAL ................................................. 66

ITEM 5 – TURBOCHARGER, AIR-TO-AIR CHARGE COOLER . 68

WASTEGATED TURBOCHARGERS ...................................... 68

ITEM 6 – BATTERY ..................................................................... 69

ITEM 7 – TACHOMETER DRIVE ................................................. 70

ITEM 8 – DRIVE BELTS .............................................................. 70

V-BELTS .................................................................................. 70

2-GROOVE POWERBAND ..................................................... 71

12–RIB POLY-V BELT ............................................................. 71

BELT REPLACEMENT ............................................................ 72

ITEM 9 – AIR COMPRESSOR .................................................... 72

ITEM 10 – AIR CLEANER ........................................................... 72

AIR CLEANER REPLACEMENT ............................................. 73

ITEM 11 – LUBRICATING OIL FILTERS ..................................... 73

ITEM 12 – FUEL FILTERS ........................................................... 74

FUEL PRO®382 FILTERS ...................................................... 74

SPIN-ON FILTERS .................................................................. 74

ITEM 13 – WATER PUMP AND COOLANT INHIBITOR

ELEMENT .................................................................................... 75

WATER PUMP DRAIN HOLE .................................................. 75

All information subject to change without notice. (Rev. 01/04) v

TABLEOFCONTENTS

COOLANT INHIBITOR ELEMENT .......................................... 75

ITEM 14 – CRANKING MOTOR .................................................. 75

ITEM 15 – AIR SYSTEM ............................................................. 76

ITEM 16 – EXHAUST SYSTEM ................................................... 76

ITEM 17 – ENGINE (STEAM CLEAN) ......................................... 76

ITEM 18 – RADIATOR ................................................................. 76

ITEM 19 – OIL PRESSURE ......................................................... 77

ITEM 20 – BATTERY-CHARGING ALTERNATOR ...................... 77

BOSCH®T1 ALTERNATOR SERVICE REQUIREMENTS ...... 78

GENERAL SERVICE REQUIREMENTS – BOSCH®AND

DELCO REMY®ALTERNATORS ............................................ 78

ITEM 21 – ENGINE AND TRANSMISSION MOUNTS ................ 78

ITEM 22 – CRANKCASE PRESSURE ........................................ 78

ITEM 23 – FAN HUB .................................................................... 78

ITEM 24 – THERMOSTATS AND SEALS .................................... 79

ITEM 25 – CRANKCASE BREATHER ......................................... 79

ITEM 26 – ENGINE TUNE-UP .................................................... 79

ITEM 27 – VIBRATION DAMPER ................................................ 80

HOW-TO SECTION .............................................................................. 81

HOW TO SELECT LUBRICATING OIL ............................................ 81

LUBRICANT REQUIREMENTS .................................................. 81

EGR-EQUIPPED ENGINES .................................................... 81

NON-EGR ENGINES .............................................................. 81

ENGINES BUILT PRIOR TO 1998 .......................................... 81

COLD WEATHER STARTING ...................................................... 82

SYNTHETIC OILS ....................................................................... 82

THE USE OF SUPPLEMENTAL ADDITIVES .............................. 83

WHEN TO CHANGE OIL ................................................................. 83

DISPOSING OF WASTE OIL ...................................................... 84

HOW TO REPLACE THE LUBE OIL FILTERS ................................ 84

REPLACE SPIN-ON TYPE OIL FILTER ...................................... 84

HOW TO SELECT FUEL OIL ........................................................... 86

QUALITY ...................................................................................... 86

FUEL CONTAMINATION ............................................................. 86

PROHIBITED ADDITIVES ........................................................... 87

USED LUBRICATING OIL ....................................................... 87

GASOLINE ............................................................................. 87

HOW TO REPLACE THE FUEL FILTERS ....................................... 87

vi All information subject to change without notice. (Rev. 01/04)

SERIES 60 ENGINE OPERATOR'S GUIDE

REPLACE SPIN-ON PRIMARY OR SECONDARY ELEMENTS . 88

REPLACE FUEL/WATER SEPARATOR ELEMENT .................... 89

REPLACE FUEL PRO ELEMENT ............................................... 90

ENGINE OUT OF FUEL — HOW TO RESTART ............................. 93

ENGINES WITH SPIN-ON FILTERS ........................................... 93

ENGINES WITH FUEL PRO FILTERS ........................................ 93

HOW TO SELECT COOLANT ......................................................... 94

DEFINITIONS .............................................................................. 94

APPROVED COOLANTS ............................................................ 95

EG & WATER OR PG & WATER PLUS SCA INHIBITOR ....... 96

MIXING EG OR PG ANTIFREEZE AND WATER .................... 96

RECYCLED ANTIFREEZE .................................................... 98

EG/WATER+OATINHIBITORORPG/WATER+OAT

INHIBITOR .............................................................................. 98

WATERONLY+SCAORWATERONLY+OATINHIBITOR . 99

WATER REQUIREMENTS ..................................................... 100

COOLANTS NOT RECOMMENDED ........................................... 100

ALL ANTIFREEZES AND COOLANTS CONTAINING

PHOSPHATE ........................................................................... 100

AUTOMOTIVE TYPE COOLANTS .......................................... 100

METHYL ALCOHOL-BASED ANTIFREEZE ........................... 100

GLYCOL-BASED COOLANTS FORMULATED FOR HVAC .... 101

ADDITIVES NOT RECOMMENDED ........................................... 101

SOLUBLE OIL ADDITIVES ..................................................... 101

CHROMATE ADDITIVES ........................................................ 101

MAINTENANCE ........................................................................... 101

SUPPLEMENTAL COOLANT ADDITIVES FOR FULLY

FORMULATED COOLANT ..................................................... 102

MAINTENANCE INTERVALS .................................................. 102

SCA TEST PROCEDURES ......................................................... 104

NEED RELEASE COOLANT FILTERS (NON-OAT SYSTEMS) .. 105

DROPOUT ................................................................................... 106

EXTENDER INHIBITOR ADDITIVE FOR “OAT” COOLANT ....... 106

OAT COOLANT DRAIN INTERVAL ......................................... 107

CHRONIC COOLANT SYSTEM PROBLEMS ............................. 107

COOLING SYSTEM MAINTENANCE PRODUCTS .................... 107

POWER COOL SCAS ............................................................. 107

POWER COOL COOLANT FILTER ELEMENTS .................... 107

All information subject to change without notice. (Rev. 01/04) vii

TABLEOFCONTENTS

POWER COOL CLEANERS ................................................... 107

SUMMARY OF COOLANT RECOMMENDATIONS .................... 108

HOW TO DRAIN AND FLUSH THE COOLING SYSTEM ............... 110

HOSES ........................................................................................ 111

WHEN TO SERVICE THE DRY TYPE AIR CLEANER .................... 111

BASIC TROUBLESHOOTING ............................................................. 112

ENGINE STORAGE ............................................................................. 117

PREPARING ENGINE FOR STORAGE ........................................... 117

TEMPORARY STORAGE (30 DAYS OR LESS) .......................... 117

EXTENDED STORAGE (MORE THAN 30 DAYS) ....................... 118

RESTORING AN ENGINE AFTER EXTENDED STORAGE ....... 121

SERIES 60 SERVICE PUBLICATIONS ............................................... 123

CUSTOMER ASSISTANCE ................................................................. 124

ROAD SERVICE IN THE U.S. OR CANADA ................................... 127

WORKING WITH DDC SERVICE OUTLETS .................................. 127

LIMITED WARRANTY ON HIGHWAY VEHICLE ENGINES ............... 129

TERMS OF COVERAGE ................................................................. 129

USES ........................................................................................... 129

DEFECTS .................................................................................... 129

REPAIRS ..................................................................................... 129

WARRANTY PERIOD .................................................................. 129

LIKE REPLACEMENT ENGINE .................................................. 129

SERVICE SUPPLIES ................................................................... 130

ENGINE REMOVAL AND REINSTALLATION .............................. 130

THIS WARRANTY DOES NOT COVER: ......................................... 130

REPAIRS DUE TO ACCIDENTS, MISUSE, STORAGE DAMAGE,

NEGLIGENCE OR CERTAIN MODIFICATIONS ......................... 130

BRAKING DEVICES .................................................................... 131

FUEL INJECTORS AFTER 200,000 MILES/320,000

KILOMETERS .............................................................................. 131

MAINTENANCE ........................................................................... 131

INCIDENTAL OR CONSEQUENTIAL DAMAGE ......................... 131

OTHER LIMITATIONS .................................................................. 131

LIMITED WARRANTY ON URBAN BUS, MOTOR COACH OR

MOTOR HOME ENGINES ................................................................... 133

viii All information subject to change without notice. (Rev. 01/04)

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