DDC-SVC-MAN-0039.PDF - SERIES 60 ON-HIGHWAY ...SERIES 60 ON-HIGHWAY ENGINE OPERATOR'S GUIDE INTRODUCTION This guide is intended for use by the operator of a Detroit Diesel Series 60®

SERIES 60 ON-HIGHWAY ENGINE OPERATOR'S GUIDE

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.

All information subject to change without notice. (Rev. 06/06) iDDC-SVC-MAN-0039 Copyright © 2006 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. PowerBand®is a registered trademark of GatesRubber Company. Tectyl® is aregistered trademark of DaubertChemical Company, Inc. Biobor® is aregistered trademark of United StatesBorax and Chemical Corporation.DuPont® is a registered trademarkof E.I. DuPont de Nemours andCompany, Inc. All other trademarksused are the property of theirrespective owners.

ii All information subject to change without notice. (Rev. 06/06)DDC-SVC-MAN-0039 Copyright © 2006 DETROIT DIESEL CORPORATION


TABLE OF CONTENTS

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

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

ENGINE MODEL AND SERIAL NUMBER DESIGNATION ................ 12CERTIFICATION LABELS ............................................................... 13

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

COOLING SYSTEM CHECKS .................................................... 14LUBRICATION SYSTEM CHECKS ............................................. 15

EXTENDED STORAGE .......................................................... 15FUEL SYSTEM CHECKS ............................................................ 16OTHER CHECKS ........................................................................ 17

STARTING THE ENGINE ................................................................ 17INITIAL ENGINE START ............................................................. 18

ELECTRIC STARTER ............................................................. 18AIR STARTER ......................................................................... 19

RUNNING THE ENGINE ................................................................. 19OIL PRESSURE .......................................................................... 19WARM-UP ................................................................................... 19INSPECTION ............................................................................... 19

TRANSMISSION ..................................................................... 19FLUID LEAKS ......................................................................... 19CRANKCASE .......................................................................... 20

All information subject to change without notice. (Rev. 06/06) iiiDDC-SVC-MAN-0039 Copyright © 2006 DETROIT DIESEL CORPORATION

TABLE OF CONTENTS

TURBOCHARGER .................................................................. 20AVOID UNNECESSARY IDLING ................................................. 20

STOPPING THE ENGINE ................................................................ 20EMERGENCY JUMP STARTING .................................................... 21

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

ENGINE PROTECTION .............................................................. 23IDLE SHUTDOWN TIMER .......................................................... 23CRUISE CONTROL ..................................................................... 23ENGINE BRAKES ....................................................................... 25DATA RECORDING CAPABILITY ............................................... 26

DDEC V OPERATION ...................................................................... 26STOP ENGINE OVERRIDE SWITCH ......................................... 27IMMEDIATE SPEED REDUCTION ............................................. 27RED STOP LAMP ........................................................................ 27DIAGNOSTIC DATA READER .................................................... 28

DDEC V ENGINE DRIVING TIPS ........................................................ 35ACCELERATING THE VEHICLE ..................................................... 35CRUISE CONTROL ......................................................................... 35ENGINE BRAKES AND CRUISE CONTROL .................................. 37SHIFTING ........................................................................................ 37IDLING ............................................................................................. 39

WINTER FRONTS ....................................................................... 39

ENGINE BRAKE SYSTEM .................................................................. 40DRIVER CONTROL SWITCHES ..................................................... 40

LOW/HIGH SWITCH ................................................................... 40LOW/MED/HIGH SWITCH .......................................................... 40

CLUTCH PEDAL AND THROTTLE POSITION CONTROLS .......... 40ENGINE BRAKE OPERATION ........................................................ 40ANTI-LOCK BRAKING SYSTEMS ................................................... 42DRIVING ON FLAT, DRY PAVEMENT ............................................. 42DESCENDING A LONG, STEEP GRADE ....................................... 42DRIVING ON WET OR SLIPPERY PAVEMENT .............................. 44

ENGINE SYSTEMS ............................................................................. 45FUEL SYSTEM ................................................................................ 45LUBRICATION SYSTEM ................................................................. 45

iv All information subject to change without notice. (Rev. 06/06)DDC-SVC-MAN-0039 Copyright © 2006 DETROIT DIESEL CORPORATION


AIR SYSTEM ................................................................................... 45COOLING SYSTEM ......................................................................... 45ELECTRICAL SYSTEM ................................................................... 45EXHAUST SYSTEM ........................................................................ 45EXHAUST GAS RECIRCULATION SYSTEM .................................. 45

MAINTENANCE ................................................................................... 46SCHEDULED INTERVALS .............................................................. 46PREVENTIVE MAINTENANCE INTERVALS .................................. 56

ITEM 1 – LUBRICATING OIL ...................................................... 56ITEM 2 – FUEL AND FUEL TANK ............................................... 57ITEM 3 – FUEL LINES, FLEXIBLE HOSES ................................ 59

LEAKS ..................................................................................... 59HOSES AND FITTINGS .......................................................... 59HOSE SERVICE LIFE ............................................................. 59

ITEM 4 – COOLING SYSTEM ..................................................... 60COOLANT LEVEL ................................................................... 60COOLANT INHIBITORS .......................................................... 60COOLANT DRAIN INTERVAL ................................................. 60

ITEM 5 – TURBOCHARGER, AIR-TO-AIR CHARGE COOLER . 62WASTEGATED TURBOCHARGERS ...................................... 62

ITEM 6 – BATTERY ..................................................................... 63ITEM 7 – TACHOMETER DRIVE ................................................ 64ITEM 8 – DRIVE BELTS .............................................................. 64

V-BELTS .................................................................................. 642-GROOVE POWERBAND ..................................................... 6512–RIB POLY-V BELT ............................................................. 65BELT REPLACEMENT ............................................................ 66

ITEM 9 – AIR COMPRESSOR .................................................... 66ITEM 10 – AIR CLEANER ........................................................... 66

AIR CLEANER REPLACEMENT ............................................. 67ITEM 11 – LUBRICATING OIL FILTERS ..................................... 67ITEM 12 – FUEL FILTERS .......................................................... 68

FUEL PRO® 382 FILTERS ..................................................... 68SPIN-ON FILTERS .................................................................. 68

ITEM 13 – WATER PUMP AND COOLANT INHIBITORELEMENT .................................................................................... 68

WATER PUMP DRAIN HOLE ................................................. 68COOLANT INHIBITOR ELEMENT .......................................... 69

All information subject to change without notice. (Rev. 06/06) vDDC-SVC-MAN-0039 Copyright © 2006 DETROIT DIESEL CORPORATION

TABLE OF CONTENTS

ITEM 14 – CRANKING MOTOR .................................................. 69ITEM 15 – AIR SYSTEM ............................................................. 69ITEM 16 – EXHAUST SYSTEM .................................................. 70ITEM 17 – ENGINE (STEAM CLEAN) ......................................... 70ITEM 18 – RADIATOR ................................................................. 70ITEM 19 – OIL PRESSURE ......................................................... 71ITEM 20 – BATTERY-CHARGING ALTERNATOR ...................... 71

BOSCH® T1 ALTERNATOR SERVICE REQUIREMENTS ..... 72GENERAL SERVICE REQUIREMENTS – BOSCH® ANDDELCO REMY® ALTERNATORS ........................................... 72

ITEM 21 – ENGINE AND TRANSMISSION MOUNTS ................ 72ITEM 22 – CRANKCASE PRESSURE ........................................ 72ITEM 23 – FAN HUB .................................................................... 72ITEM 24 – THERMOSTATS AND SEALS ................................... 72ITEM 25 – CRANKCASE BREATHER ........................................ 73ITEM 26 – ENGINE TUNE-UP .................................................... 73ITEM 27 – VIBRATION DAMPER ................................................ 74

HOW-TO SECTION .............................................................................. 75HOW TO SELECT LUBRICATING OIL ............................................ 75

LUBRICANT REQUIREMENTS .................................................. 75EGR-EQUIPPED ENGINES .................................................... 75NON-EGR ENGINES .............................................................. 75ENGINES BUILT PRIOR TO 1998 .......................................... 75

COLD WEATHER STARTING ..................................................... 76SYNTHETIC OILS ....................................................................... 76THE USE OF SUPPLEMENTAL ADDITIVES .............................. 77

WHEN TO CHANGE OIL ................................................................. 77DISPOSING OF WASTE OIL ...................................................... 78

HOW TO REPLACE THE LUBE OIL FILTERS ................................ 78REPLACE SPIN-ON TYPE OIL FILTER ...................................... 78

HOW TO SELECT FUEL OIL .......................................................... 80QUALITY ..................................................................................... 80FUEL CONTAMINATION ............................................................. 80PROHIBITED ADDITIVES ........................................................... 81

USED LUBRICATING OIL ....................................................... 81GASOLINE ............................................................................. 81

HOW TO REPLACE THE FUEL FILTERS ....................................... 81

vi All information subject to change without notice. (Rev. 06/06)DDC-SVC-MAN-0039 Copyright © 2006 DETROIT DIESEL CORPORATION


REPLACE SPIN-ON TYPE PRIMARY OR SECONDARY FUELFILTER ELEMENTS .................................................................... 82REPLACE FUEL/WATER SEPARATOR ELEMENT .................... 84REPLACE FUEL PRO® 382/382E FUEL FILTER ELEMENT ..... 85

ENGINE OUT OF FUEL — HOW TO RESTART ............................. 87ENGINES WITH SPIN-ON FILTERS ........................................... 87ENGINES WITH FUEL PRO FILTERS ........................................ 88

HOW TO SELECT COOLANT ......................................................... 89DEFINITIONS .............................................................................. 89APPROVED COOLANTS ............................................................ 90

EG & WATER PLUS SCA INHIBITOR OR P G & WATERPLUS SCA INHIBITOR ............................................................ 91MIXING EG OR PG ANTIFREEZE AND WATER ................... 91RECYCLED ANTIFREEZE .................................................... 94EG/WATER + OAT INHIBITOR OR PG/WATER + OATINHIBITOR .............................................................................. 94WATER ONLY + SCA OR WATER ONLY + OAT INHIBITOR 95WATER REQUIREMENTS ..................................................... 96

COOLANTS NOT RECOMMENDED .......................................... 96ALL ANTIFREEZES AND COOLANTS CONTAININGPHOSPHATE ........................................................................... 96AUTOMOTIVE TYPE COOLANTS .......................................... 96METHYL ALCOHOL-BASED ANTIFREEZE ........................... 96GLYCOL-BASED COOLANTS FORMULATED FOR HVAC ... 97

ADDITIVES NOT RECOMMENDED ........................................... 97SOLUBLE OIL ADDITIVES ..................................................... 97CHROMATE ADDITIVES ........................................................ 97

COOLANT INHIBITOR TEST INTERVALS ................................. 97SUPPLEMENTAL COOLANT ADDITIVES FOR FULLYFORMULATED COOLANT ..................................................... 98MAINTENANCE INTERVALS .................................................. 98

SCA TEST PROCEDURES ......................................................... 100NEED RELEASE COOLANT FILTERS (NON-OAT SYSTEMS) . 101DROPOUT ................................................................................... 102COOLANT EXTENDER INHIBITOR ADDITIVE FOR “OAT”COOLANT ................................................................................... 102

OAT COOLANT DRAIN INTERVAL ........................................ 103CHRONIC COOLANT SYSTEM PROBLEMS ............................. 103

All information subject to change without notice. (Rev. 06/06) viiDDC-SVC-MAN-0039 Copyright © 2006 DETROIT DIESEL CORPORATION

TABLE OF CONTENTS

DETROIT DIESEL COOLING SYSTEM MAINTENANCEPRODUCTS ................................................................................. 103

POWER COOL SCAS ............................................................. 103POWER COOL COOLANT FILTER ELEMENTS .................... 103POWER COOL CLEANERS ................................................... 103

SUMMARY OF COOLANT RECOMMENDATIONS .................... 104COOLANT LIFE OF GLYCOL COOLANT ............................... 105COOLANT LIFE OF OAT COOLANT ...................................... 105COOLANT LIFE OF OTHER COOLANTS .............................. 105

HOW TO DRAIN AND FLUSH THE COOLING SYSTEM ............... 106HOSES ........................................................................................ 107

WHEN TO SERVICE THE DRY TYPE AIR CLEANER ................... 107

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

ENGINE STORAGE ............................................................................. 113PREPARING ENGINE FOR STORAGE .......................................... 113

TEMPORARY STORAGE (30 DAYS OR LESS) ......................... 113EXTENDED STORAGE (MORE THAN 30 DAYS) ...................... 114PROCEDURE FOR RESTORING TO SERVICE AN ENGINETHAT HAS BEEN IN EXTENDED STORAGE ............................. 117

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

CUSTOMER ASSISTANCE ................................................................. 120ROAD SERVICE IN THE U.S. OR CANADA ................................... 123WORKING WITH DDC SERVICE OUTLETS .................................. 123

LIMITED WARRANTY ON SERIES 60 DDEC V EGR ENGINESUSED IN ON-HIGHWAY VEHICLE APPLICATIONS .......................... 126

TERMS OF COVERAGE ................................................................. 126USES ........................................................................................... 126DEFECTS .................................................................................... 126REPAIRS ..................................................................................... 126WARRANTY PERIOD .................................................................. 126LIKE REPLACEMENT ENGINE .................................................. 126SERVICE SUPPLIES .................................................................. 127ENGINE REMOVAL AND REINSTALLATION ............................. 127

THIS WARRANTY DOES NOT COVER: ......................................... 127

viii All information subject to change without notice. (Rev. 06/06)DDC-SVC-MAN-0039 Copyright © 2006 DETROIT DIESEL CORPORATION


REPAIRS DUE TO ACCIDENTS, MISUSE, STORAGE DAMAGE,NEGLIGENCE OR CERTAIN MODIFICATIONS ......................... 127BRAKING DEVICES .................................................................... 128FUEL INJECTORS AFTER 200,000 MILES/320,000KILOMETERS .............................................................................. 128MAINTENANCE ........................................................................... 128INCIDENTAL OR CONSEQUENTIAL DAMAGE ......................... 128OTHER LIMITATIONS ................................................................. 128

LIMITED WARRANTY ON ENGINES POWERING URBAN BUS,MOTOR COACH OR MOTOR HOME APPLICATIONS ...................... 130

TERMS OF COVERAGE ................................................................. 130USES ........................................................................................... 130DEFECTS .................................................................................... 130REPAIRS ..................................................................................... 130WARRANTY PERIOD .................................................................. 130SERVICE SUPPLIES .................................................................. 130LIKE REPLACEMENT ENGINE .................................................. 131ENGINE REMOVAL AND REINSTALLATION ............................. 131

THIS WARRANTY DOES NOT COVER: ......................................... 131REPAIRS DUE TO ACCIDENTS, MISUSE, ALTERATION,STORAGE DAMAGE, NEGLIGENCE OR CERTAINMODIFICATIONS ........................................................................ 131BRAKING DEVICES .................................................................... 132FUEL INJECTORS AFTER 200,000 MILES/320,000KILOMETERS .............................................................................. 132MAINTENANCE ........................................................................... 132INCIDENTAL OR CONSEQUENTIAL DAMAGE ......................... 132OTHER LIMITATIONS ................................................................. 132

LIMITED WARRANTY ON ENGINES USED IN FIRE TRUCK ORCRASH RESCUE VEHICLE APPLICATIONS ..................................... 134

TERMS OF COVERAGE ................................................................. 134USES ........................................................................................... 134DEFECTS .................................................................................... 134REPAIRS ..................................................................................... 134WARRANTY PERIOD .................................................................. 134LIKE REPLACEMENT ENGINE .................................................. 134SERVICE SUPPLIES .................................................................. 134

All information subject to change without notice. (Rev. 06/06) ixDDC-SVC-MAN-0039 Copyright © 2006 DETROIT DIESEL CORPORATION

TABLE OF CONTENTS

ENGINE REMOVAL AND REINSTALLATION ............................. 135THIS WARRANTY DOES NOT COVER: ......................................... 135

REPAIRS DUE TO ACCIDENTS, MISUSE, ALTERATION,STORAGE DAMAGE, NEGLIGENCE OR CERTAINMODIFICATIONS ........................................................................ 135MAINTENANCE ........................................................................... 135INCIDENTAL OR CONSEQUENTIAL DAMAGE ......................... 136OTHER LIMITATIONS ................................................................. 136

SPECIFICATIONS ................................................................................ 137FUEL AND LUBRICATING OIL REQUIREMENTS .......................... 137

OIL PAN CAPACITY .................................................................... 137OIL PAN CAPACITY ................................................................ 137TOTAL OIL CAPACITY OF THE ENGINE ............................... 137

POWER COOL ENGINE PRODUCTS ............................................ 138POWER COOL FULLY FORMULATED IEG COOLANT ............. 138POWER COOL LATIN AMERICAN COOLANT ........................... 138POWER COOL 2000 AND 3000 SUPPLEMENTAL COOLANTADDITIVE .................................................................................... 139POWER COOL 3000 SUPPLEMENTAL ADDITIVE COOLANTFILTERS ...................................................................................... 139POWER COOL SUPPLEMENTAL ADDITIVE NEED RELEASECOOLANT FILTERS .................................................................... 140POWER COOL PLUS EXTENDED LIFE OAT COOLANT .......... 140POWER COOL PLUS EXTENDER FOR USE WITH POWERCOOL PLUS OAT COOLANT ...................................................... 140POWER COOL PLUS 6000 OAT INHIBITOR FOR WATER-ONLYSYSTEMS .................................................................................... 141POWER COOL COOLING SYSTEM CLEANERS ...................... 141POWER TRAC COOLANT TESTING AND ANALYSISPRODUCTS ................................................................................. 142

x All information subject to change without notice. (Rev. 06/06)DDC-SVC-MAN-0039 Copyright © 2006 DETROIT DIESEL CORPORATION


INTRODUCTION

This guide is intended for use by theoperator of a Detroit Diesel Series60® engine used in the followingapplications:

□ On-Highway Vehicles

□ Fire Truck or Crash/RescueVehicles

Non-Genuine and RebuiltComponent Quality AlertIn recent years, electronic enginecontrols have been instrumentalin aiding engine manufacturers inmeeting the stringent emissionrequirements 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 are tobe followed in order to continuesatisfactory performance anddurability and to ensure coverage ofthe engine under the manufacturer'swarranty. Many of these maintenanceprocedures also ensure that the enginecontinues to comply with applicableemissions standards. The U.S.EPA specifically defines an engine's“useful emission life” — currentlyestablished as 435,000 miles (700,000kilometers) for on-highway engines.Proper maintenance procedures, using

specific components engineered tocomply with emissions regulations,may be performed by an authorizedDetroit Diesel distributor or dealer,an independent outlet or the operatoror owner. The owner is responsiblefor determining the suitability ofcomponents to maintain emissionscompliance during the engine's usefulemission life.

Electronic controls and componentshave significantly increased insophistication, but the fundamentalobjective remains the same — precisetiming and delivery of fuel. The veryheart of the Detroit Diesel ElectronicControls (DDEC®) is the electronicunit injector (EUI). The properfunctioning of the EUI is absolutelyparamount if the benefits of electroniccontrols are to be realized. DetroitDiesel Corporation has built over650,000 engines with electronic unitinjectors — more than anyone else inthe business.

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.

All information subject to change without notice. (Rev. 06/06) 1DDC-SVC-MAN-0039 Copyright © 2006 DETROIT DIESEL CORPORATION

INTRODUCTION

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.

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 DieselCorporation specifications may resultin early wear out or engine failure.

2 All information subject to change without notice. (Rev. 06/06)DDC-SVC-MAN-0039 Copyright © 2006 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.

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.

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

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.

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.


CAUTION SUMMARY

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.

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.


CAUTION SUMMARY

Cooling SystemObserve the following cautions whenservicing the cooling system.

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.

PERSONAL INJURY


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

PERSONAL INJURY

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

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

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.

FIRE

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

Starting AidsObserve the following cautions whenusing starting aids.


CAUTION SUMMARY

FLAMES, EXPLOSION ANDTOXICITY

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

□ 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.



□ 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.



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.

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.


ENGINE MODEL AND SERIAL NUMBER DESIGNATION

ENGINE MODEL AND SERIAL NUMBER DESIGNATION

The engine serial number and modelnumber are laser etched on thecylinder block in the left side justbelow the intake manifold and above

the cast-in Detroit Diesel logo (asviewed from the flywheel end).

See Figure 1

Figure 1 Location of Engine Serial and Model Numbers



Certification LabelsIf 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 2.

Figure 2 Typical Engine Certification Labels


OPERATING INSTRUCTIONS FOR A FIRST TIME START


When preparing to start a new ornewly overhauled engine whichhas been in storage, perform all ofthe operations listed below. Failureto follow these instructions mayresult in serious engine damage.Before a routine start, refer to theMAINTENANCE section and see thedaily checks for your engine.

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.

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.

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 thecoolant level at the bottom of the



filler neck to allow for expansionof the coolant. For more detailedrecommendations, refer to Howto Select Coolant in the HOW-TOSECTION of this guide.

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 lubricationsystem should be charged with a

commercially 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. See Figure 3.

Figure 3 Check Lube Oil LevelBefore Starting

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

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 Fuel Oil in theHOW-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:Under no circumstances shoulda starting aid such as ether beused to run the engine until thefuel system is primed. Injectordamage will result if this methodis used.

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

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 4.

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

Check the turbocharger for signs ofoil or exhaust leaks. Leaks should becorrected before starting the engine.Check engine mounting bolts for

tightness. Bolts should be retightened,if necessary.

Figure 4 Maintenance-FreeBattery “Eye”

Starting the EngineBefore 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.



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



□ 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.

Initial Engine Start

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

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 bulbs

for 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, contact DDCTechnical Service. Operating theengine under these circumstancesmay result in engine damage.

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

1. With foot OFF the foot pedal,press the starter switch firmly.

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

2. If the engine fails to start within15 seconds, release the starterswitch and allow the starter tocool for 15 seconds before tryingagain. If the engine fails to startafter four attempts, an inspection



should be made to determine thecause.

Air Starter — Because of the limitedvolume of most compressed airstorage tanks and the relatively shortduration of the cranking cycle, it isimportant to make sure the engine isready to start before activating the airstarter. Start an engine equipped withan air starter as follows:

1. Check the pressure in the airstorage tank. If necessary, add airto bring the pressure up to at leastthe recommended minimum forstarting.

2. With foot OFF the foot pedal,press the starter button firmly andhold until the engine starts.

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 theoil pressure gage registers pressure(5 psi or 35 kPa at idle speed). Ifno pressure is indicated within 10to 15 seconds, stop the engine and

check the lubrication system. Thepressure should not drop below 28 psior 193 kPa at 1800 rpm, and normaloperating pressure should be higher. Ifoil pressure does not fall within theseguidelines, it should be checked witha 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 of

sludge 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:Stopping a turbocharged engineimmediately after high-speedoperation without allowing asufficient cool-down period maycause damage to the turbocharger,as it will continue to turn without anoil 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 V system operates on12 or 24 volts DC. If a DDEC Vengine with an electric starting motorrequires emergency jump starting, donot exceed 32 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 theElectronic Control Unit.

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).

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.


DDEC V SYSTEM

DDEC V SYSTEM

The DDEC system's engine-mountedElectronic Control Unit (ECU)includes control logic to provideoverall engine management.The ECU continuously performsself-diagnostic checks and monitorsother system components. Systemdiagnostic checks are made atignition-on and continue throughoutall engine-operating modes.

Detroit Diesel Series 60 enginesequipped with DDEC are identifiedby the letter “V” in the sixth positionof the model number. Example:6067MV6E. The Series 60 engine for2004 is equipped with DDEC V.

The DDEC engine is equippedwith an electronically controlledfuel injection system. There are nocontrol racks or mechanical linkagesto adjust. This system improves fueleconomy and vehicle performance.It also helps to reduce cold startingtime and increase initial idle speedfor fast engine warm-up and virtualelimination of cold smoke.

The DDEC engine has nomechanical governor. Enginehorsepower, torque, idle, and enginespeed are contained in the internalelectronics. Therefore, there areno mechanical governor springadjustments for idle and high-speedcontrol.

There is no need for a throttle delay.Emission control is performed throughthe ECU.

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

DDEC FeaturesDDEC offers a variety of featuresand options designed to warn theoperator of 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 connectsto theAmber Warning Lamp (AWL)and the Red Stop Lamp (RSL) toprovide a visual warning of a systemmalfunction.



Engine Protection

The DDEC engine protectionsystem monitors all engine sensorsand electronic components, andrecognizes system malfunctions. Ifa critical fault is detected, the AWLand RSL illuminate. The malfunctioncodes are logged into the ECU'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.

Idle Shutdown Timer

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

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 5.


DDEC V SYSTEM

Figure 5 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, turn on the Cruise ControlOn/Off Switch, and use the ResumeSwitch. The engine rpm shouldincrease to a pre-defined speed. Theengine rpm can be raised or loweredfrom this point using the Set andResume switches.

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


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 withCruise Control OFF, do not allowthe engine to exceed 2,500 rpmunder any conditions. Failure toobserve this precaution can resultin overspeeding 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.



When the Cruise Control Switchis in the ON position, CruiseControl is engaged by momentarilycontacting the Set/Coast Switch tothe ON position. As a check aftereach engine start, DDEC looks for aone time activation of the clutch (ifequipped) and service brake beforeDDEC allows Cruise Control tobe enabled. The ECU must alsorecognize that the Cruise EnableSwitch has changed. If the CruiseEnable Switch is off, it needs to beturned on. If the Cruise Enable Switchis on, it must be turned off then on forcruise to operate.

Holding the switch in the ON positionallows the vehicle to slow to a lowerspeed. Toggling the switch will resultin a one mile-per-hour (1.6 kph)decrease in vehicle speed. If CruiseControl has been disabled, togglingthe Resume/Accel Switch restores thevehicle to the previously set cruisespeed.

Using either the brake or the clutchwill disable Cruise Control.

Engine Brakes

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


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.

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


DDEC V SYSTEM

Engine brakes will supply brakingpower even when in Cruise Control.The ECU 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.

Data Recording Capability

DDEC Reports is a data recordingcapability that is standard on all DDECV engines. DDEC Reports containsinformation on driver activities,engine performance and criticalincidence reporting. The informationcan be extracted with Detroit DieselDiagnostic Link® 6.0 (DDDL 6.0)software. To perform the extraction,at least a 486 computer with a 16-MBRAM is required.

DDEC V 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 at 12or 24 volts. However, in the event of apower supply malfunction, the system

will continue to operate at reducedvoltage. When this occurs, the AWLwill come on. See Figure 6.

Figure 6 Typical ShutdownOverride Switch andEngine Lamps

The engine will only operate atreduced rpm until the battery voltagereaches a point where the ECU will nolonger function and the engine shutsdown.

Should the AWL come on for anyreason, the vehicle can still beoperated and the driver can proceedto the required destination. Thiscondition should be reported to anauthorized Detroit Diesel distributoror dealer.



NOTICE:When the RSL comes on, thecomputer has detected a majormalfunction in the engine thatrequires immediate attention. It isthe operator's responsibility toshut 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 besupplied in case the vehicle is tooperate in a critical location.

Stop Engine Override Switch

This feature allows the operator tooverride the automatic stop enginesequence by pressing the Stop EngineOverride 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 RSLto come on are:

□ High coolant temperature

□ Loss of coolant

□ High oil temperature


DDEC V SYSTEM

□ Low oil pressure

□ Auxiliary shutdown

It is important to point out thatwhenever the AWL or the RSLcome on, the DDEC computer willdetermine where the problem is andwill then store this information in itsmemory.

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

Diagnostic Data Reader

The Diagnostic Data Reader (DDR)is a special diagnostic tool that canbe plugged into the engine computermemory to extract informationrelated to the cause of the problem.See Figure 7.

Figure 7 Diagnostic Data ReaderJ 38500

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

The DDR can distinguish betweencodes now active and those stored inthe ECU memory (inactive).

The temperature of air in the intakesystem is increased with the additionof an EGR. DDEC is programmedto reduce fueling (power) for ashort time to reduce air and coolanttemperatures when necessary. DDECwill store an information code thatthis event occurred, but no correctiveaction is required as this actionis designed to maintain operationwithout a noticeable affect on vehicleperformance.

The malfunction code recorded in thecomputer memory will remain until itis erased by a technician.

The malfunction code can also beobtained by the operator. A DiagnosticTest Mode Switch is provided which,when pressed, will cause the AWLto flash a code number. It will, forexample, flash twice. . . pause . . .flash once. . . pause. In other words, acode 21. Code 21 indicates the throttleposition sensor input voltage is high.See Figure 8.

NOTE:A code 25 (two flashes followed by5 flashes) indicates all systems areworking satisfactorily.



Figure 8 RSL/AWL Flashing Code Examples

Active Codes – The active codes willbe flashed on the RSL in the order ofmost recent to least recent occurrencebased on engine hours. If there are noactive codes, a code 25 will be flashed.

Inactive Codes – The inactive codeswill be flashed on the AWL in theorder of most recent to least recentoccurrence based on engine hours. Ifthere are no inactive codes, a code 25will be flashed.

Only One Light Flashes at a Time –Only one light will be flashing codesat any time. When code flashing isinitiated, the active codes (or code25) will be flashed on the RSL. Thenthe inactive codes (or code 25) willbe flashed on the AWL. When all theinactive codes (or code 25) have beenflashed, the process of flashing allthe active codes followed by all theinactive codes will repeat until the

conditions for code flashing are nolonger satisfied.

To Read Codes: Use the DDR orpress and hold the Diagnostic TestMode Switch with the ignition ONand the engine AT IDLE or NOTRUNNING. Press and hold the switch.Active codes will be flashed on theRSL first, followed by inactive codesbeing flashed on the AWL.

The codes will continue to flash andrepeat as long as the diagnostic requestswitch is held in the ON position withthe ignition on. Diagnostic codes arelisted on the following pages.


DDEC V SYSTEM

FlashCode Description

11 VSG Sensor Voltage Low

11 VSG Switch System Not Responding

12 VSG Sensor Voltage High

13 Coolant Level or Add Coolant Level Sensor Input Voltage Lowor EGR Valve Current too High

14 Intercooler Coolant, Coolant, or Oil Temp Sensor Input VoltageHigh

15 Intercooler Coolant, Coolant, or Oil Temp Sensor Input VoltageLow16 Coolant Level or Add Coolant Level Sensor Input Voltage High

17 Throttle Plate Position or Relative Humidity Sensor or BlowerBypass Position Input Voltage High

18 Throttle Plate Position or Relative Humidity Sensor or BlowerBypass Position Input Voltage Low21 Throttle Position Sensor Input Voltage High

22 Throttle Position Sensor Input Voltage Low

23 Fuel Temp Sensor Input Voltage High

23 Oxygen Content Circuit Input Voltage High

24 Fuel Temp Sensor Input Voltage Low

24 Oxygen Content Circuit Input Voltage Low

25 Reserved for “No Codes"

26 Aux. Shutdown #1 or #2 Active

27 Intake Manifold Temp or Ambient Air Temp or Air Temp SensorInput Voltage High

28 Intake Manifold Temp or Ambient Air Temp or Air Temp SensorInput Voltage Low29 TCI Temp Circuit Failed Low

29 Turbo Compressor Temp Out Sensor Input Voltage Low

31 Aux. Output #3, #4, #12, #13, #14, #15 or #16 Open Circuit (HiSide), Short To Ground (Hi Side), or Mechanical System Failure32 RSL or AWL Short to Battery (+) or Open Circuit

33 Turbo Boost Pressure Sensor Input Voltage High




34 Turbo Boost Pressure Sensor Input Voltage Low

35 High Range Oil Pressure Sensor Input Voltage or Oil PressureSensor Input Voltage High

36 High Range Oil Pressure Sensor Input Voltage or Oil PressureSensor Input Voltage Low37 High Range Fuel Pressure Sensor Input Voltage High

37 Fuel Pressure or Fuel Restriction Sensor Input Voltage High

38 High Range Fuel Press Sensor Input Voltage Low

38 Fuel Pressure Sensor Input Voltage Low

38 Fuel Restriction Sensor Input Voltage Low

39 EGR Leak — Boost Power or Boost Jake

39 EGR Valve Not Responding

39 VNT Vanes Not Responding — Boost Power

39 VNT Vanes at Max — Jake

39 VNT Vanes Not Responding — Boost Jake

39 EGR Flow too Low

39 VNT Vanes Not Responding — EGR

41 Too Many CKP Sensor (missing CMP Sensor)

42 Too few CKP Sensor (missing CKP Sensor)

43 Coolant Level Low

44 Intercooler Coolant, Coolant, Intake Manifold, Air Inlet or Oil TempHigh

44 Engine Power Derate Due to Intake Manifold Temp, Oil Temp, orCoolant Temp45 High Range Oil Pressure or Oil Pressure Low

46 ECU Battery Voltage Low

46 RTC Backup Battery or Sensor Supply Voltage Low

46 Injector V (reg), Injector V (slope) or Injector I (pull-in) VoltageFailed Low

47 High Range Fuel Pressure, Fuel Pressure, Turbo Boost Pressure,Air Inlet Pressure or Injection Control Pressure High


DDEC V SYSTEM


47 Engine Power Derate Due to Turbo Boost Pressure

48 High Range Fuel Pressure, Fuel Pressure, Air Inlet Pressure,Injection Control Pressure or EGR Delta Pressure Low48 TCI Temp, Turbo Compressor Temp Out, or EGR Temp Low

49 TCI Temp or Turbo Compressor Out Temp High

49 Engine Power Derate Due to Turbo Compressor Out Temp

51 TCI Temp Circuit Failed High

51 Turbo Compressor Out Temp Sensor Input Voltage High

52 A/D Conversion Fail or ADC Reference Voltage Low or High

53 Nonvolatile Checksum Incorrect

53 EEPROM Write Error

53 Out of Calibration

54 Vehicle Speed Sensor Fault

55 Other ECU Fault (Logged in conjunction with another fault)

55 J1939 Data Link Fault, Proprietary Data Link Fault (Master), orProprietary Data Link Fault (Receiver)56 J1587 Data Link Fault or J1922 Data Link Fault

58 Torque Overload or Two-speed Axle Switch Status not Respondingor Failed61 Injector xxx Response Time Long

62 Aux. Output #1, #2, #5, #6, #7, #8, #9, #10, or #11 Short toBattery (+)62 Aux. Output #1, #2, #5, #6, #7, #8, #9, #10, or #11 Open Circuit

62 Aux. Output #1, #2, #5, #6, #7, #8, #9,10 or #11 MechanicalSystem Failure or Not Responding Properly63 PWM #1, #2 #3, #4, #5 or #6 Above or Below Normal Range

63 PWM #1, #2 #3, #4, #5 or #6 Short to Battery (+) or Open Circuit

63 PWM #5 or #6 Mechanical System Failed

64 Turbo Overspeed

64 Turbo Speed Sensor Input Failure — Abnormal Period




65 Throttle Plate Position Above Normal Range, Below NormalRange, Erratic or Not Responding65 Air Filter Restriction and Oil Filter Restriction Sensor Voltage High

65 Air Filter Restriction and Oil Filter Restriction Sensor Voltage Low

66 Engine Knock Level Above Normal Range

66 Engine Knock Level Sensor Input Voltage High or Low

66 Engine Knock Level Sensor Not Responding

67 High Range Coolant Pressure, Air Inlet Pressure or CoolantPressure Sensor Input Voltage High

67 High Range Coolant Pressure, Air Inlet Pressure or CoolantPressure Sensor Input Voltage Low68 TPS Idle Validation Circuit Fault (open circuit or short to ground)

71 Injector xxx Response Time Short

72 Vehicle Overspeed or Vehicle Overspeed (Absolute)

72 Oxygen Content Too High or Too Low

73 Air Filter Restriction High

73 Gas Valve Position Above or Below Normal Range

73 Gas Valve Position Input Voltage High or Low

73 Gas Metering Valve Not Responding

74 Optimized Idle® Safety Loop Short to Ground

74 Oil Filter Restriction High

75 Injector V (reg), Injector V (slope) or Injector I (pull-in) VoltageFailed High75 ECU Battery Voltage High

75 RTC Backup Battery or Sensor Supply Voltage High

76 Engine Overspeed With Engine Brake

77 Miscellaneous Faults — refer to BASIC TROUBLESHOOTING.

78 Cruise Control/Adaptive Cruise Control Fault

81 Oil Level, Crankcase Pressure, Injection Control Pressure orExhaust Temp Sensor Input Voltage High81 Extended Crankcase Pressure Input Voltage High


DDEC V SYSTEM


81 EGR Delta Pressure Sensor Circuit, Engine Oil Life Circuit, orEGR Temp Circuit Failed High81 Timing Actuator Failed High or Low

81 Exhaust Port Temp #1–17 Sensor Voltage High

81 EGR Rate Sensor or EGR Temperature Network Sensor notResponding

82Oil Level, Crankcase Pressure ,Extended Crankcase Pressure,Injection Control Pressure or Exhaust Temp Sensor Input VoltageLow

82 EGR Rate Network Sensor or EGR Temperature Network SensorFailed

82 EGR Delta Pressure Sensor Circuit, Engine Oil Life Circuit, orEGR Temp Circuit Failed Low82 Exhaust Port Temp #1–16 Sensor Voltage Low

82 EGR Temperature Smart Sensor not Responding or Failed

83Pump Pressure, Oil Level, Crankcase Pressure, ExtendedCrankcase Pressure, Exhaust Temp, EGR Delta Pressure or EGRTemp High

83 Exhaust Port Temperature #1–17 High

83 Coolant Ingress Fault Detected

83 Change Oil Now

84 Oil Level, Crankcase Pressure or Extended Crankcase PressureLow84 Change Oil Soon

85 Engine Overspeed or Engine Overspeed Signal

86 Pump Pressure or Barometric Pressure Sensor Input Voltage High

87 Pump Pressure or Barometric Pressure Sensor Input Voltage Low

88 High Range Coolant Pressure or Coolant Pressure Low

89 Fuel Restriction High

89 Maintenance Alert Coolant Level Fault



DDEC V ENGINE DRIVING TIPS

Driving with an electronciallycontrolled engine feels differentfrom driving with a mechanciallygoverened engine.

Accelerating the VehicleEngine response versus pedalmovement may feel different fromthe mechanical-governed engineyou were driving. The AcceleratorPedal was designed to communicate“percentage” foot pedal travel tothe engine's Electronic Control Unit(ECU). 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 acceleratingor just plain pulling hard, the throttle(AP) will have to be held to the floor.To obtain 100% fueling at any speed,the Accelerator Pedal will have tobe maintained at the fully pressedposition.

Cruise ControlFor added driver convenience andcomfort, DDEC V 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 9.

Figure 9 Typical Cruise ControlSwitches



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

The ECU 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 DDECV to see a status change to allowCruise Control activation. The statusof DDEC V 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,press the Resume/Accel Switch. Toreduce road speed, press and hold theSet/Coast Switch until the lower speedis reached.

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 theResume 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.Realistically, the engine will pull toabout 1050 rpm.

Remember: The electronic dataprogrammed into the ECU will notallow you to hurt or overfuel theengine at low or “lug” engine speeds.There is enough oil pressure towithstand hard pulls at low enginespeeds.

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 ECU programming,the engine retarders will come on“low” when your set road speedincreases a few miles-per-hour(kilometers per hour) above your

cruise set speed. If your speedcontinues to increase, the ECU willincrease the engine retarders' brakingpower progressively. When thevehicle returns to the set cruise speed,the engine retarders will turn off untilyou need 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 youoff guard. The Series 60 soundsquiet at 1400 rpm, almost as if ithad quit pulling. Don't believe it!If you had a boost gage to look atwhile driving, you would noticethe turbocharger maintaining steadyintake manifold pressure, even asrpm's fall. 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 velocity

changes of the air flow within the airintake plumbing. Electronic enginescan actually deliver more fuel at lowerengine speeds than at rated speed.

One difference you may noticewith the EGR equipped engine isunderhood noise. The gear trainhas been redesigned for quieteroperation, and the EGR gas flow maybe noticeable to the tuned attentiveear. The turbocharger operates athigher boost pressure forcing EGRgas flow through the EGR plumbingwhich is a noticeable change fromnon-EGR equipped engines. 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 andunderhood with the engine idling.) Ifequipped with a turbo boost gage, t

DDC-SVC-MAN-0039.PDF - SERIES 60 ON-HIGHWAY ...SERIES 60 ON-HIGHWAY ENGINE OPERATOR'S GUIDE INTRODUCTION This guide is intended for use by the operator of a Detroit Diesel Series 60®

Documents