Detroit Series 60 Operation Manual

DDC-SVC-MAN-0039

Specifications are subject to change without notice. Detroit Diesel Corporationis registered to ISO 9001:2001. Copyright © Detroit Diesel Corporation.All rights reserved. Detroit Diesel Corporation is a Daimler company.Printed in U.S.A.

13400 Outer Drive, West, Detroit, Michigan 48239-4001Telephone: 313-592-5000www.detroitdiesel.com

EPA04 Series 60®

Operator’s Manual

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. iDDC-SVC-MAN-0039 Copyright © 2009 DETROIT DIESEL CORPORATION

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

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

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

Trademark Information

DDC®, Detroit Diesel®, DDEC®,Series 60®, Optimized Idle®,Diagnostic Link®, reliabilt®,POWER Trac®, POWER COOL®,and POWER GUARD® are registeredtrademarks of Detroit DieselCorporation. Delco Remy® is aregistered trademark of Delco RemyAmerica, Inc. Bosch® is a registeredtrademark of Robert Bosch CompanyN.A. Fuel Pro®, and Mega Filter®are registered trademarks of DavcoManufacturing, L.L.C. 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.DDC-SVC-MAN-0039 Copyright © 2009 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

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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

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

MAINTENANCE ................................................................................... 46MAINTENANCE 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

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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 ....................................... 81REPLACE SPIN-ON PRIMARY OR SECONDARY ELEMENTS 82

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REPLACE FUEL/WATER SEPARATOR ELEMENT .................... 84REPLACE FUEL PRO 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 OR PG & WATER PLUS 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 ................................................................................... 102EXTENDER INHIBITOR ADDITIVE FOR “OAT” COOLANT ....... 102

OAT COOLANT DRAIN INTERVAL ........................................ 103CHRONIC COOLANT SYSTEM PROBLEMS ............................. 103COOLING SYSTEM MAINTENANCE PRODUCTS .................... 103

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

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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) ...................... 114RESTORING AN ENGINE AFTER 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 HIGHWAY VEHICLE ENGINES ............... 126TERMS OF COVERAGE ................................................................. 126

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

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

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LIMITED WARRANTY ON URBAN BUS, MOTOR COACH ORMOTOR HOME ENGINES ................................................................... 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 FIRE TRUCK OR CRASH RESCUEVEHICLE ENGINES ............................................................................. 134

TERMS OF COVERAGE ................................................................. 134USES ........................................................................................... 134DEFECTS .................................................................................... 134REPAIRS ..................................................................................... 134WARRANTY PERIOD .................................................................. 134LIKE REPLACEMENT ENGINE .................................................. 134SERVICE SUPPLIES .................................................................. 134ENGINE REMOVAL AND REINSTALLATION ............................. 135

THIS WARRANTY DOES NOT COVER: ......................................... 135REPAIRS DUE TO ACCIDENTS, MISUSE, ALTERATION,STORAGE DAMAGE, NEGLIGENCE OR CERTAINMODIFICATIONS ........................................................................ 135MAINTENANCE ........................................................................... 135INCIDENTAL OR CONSEQUENTIAL DAMAGE ......................... 136OTHER LIMITATIONS ................................................................. 136

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

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

POWER COOL ENGINE PRODUCTS ............................................ 138FULLY FORMULATED IEG COOLANT ....................................... 138LATIN AMERICAN COOLANT .................................................... 1382000 SUPPLEMENTAL COOLANT ADDITIVE ........................... 1393000 SUPPLEMENTAL ADDITIVE FILTERS .............................. 139NEED RELEASE COOLANT FILTERS ....................................... 140PLUS EXTENDED LIFE OAT COOLANT .................................... 140PLUS EXTENDER FOR POWER COOL PLUS OAT COOLANT 140PLUS 6000 OAT INHIBITOR FOR WATER-ONLY SYSTEMS .... 141COOLING SYSTEM CLEANERS ................................................ 141COOLANT TESTING AND ANALYSIS PRODUCTS ................... 142

x All information subject to change without notice.DDC-SVC-MAN-0039 Copyright © 2009 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.

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


CAUTION SUMMARY

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

Engine OperationObserve the following cautions whenoperating the engine.

PERSONAL INJURY

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

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


PERSONAL INJURY


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

PERSONAL INJURY


PERSONAL INJURY

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



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

FIRE

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

FIRE


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





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).








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.






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 VoltageLow

16 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 Low

21 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 Low

29 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 Failure

32 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 Low

37 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 Temp

45 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 Low

48 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 Failed

61 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 Properly

63 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 Responding

65 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 Low

68 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 High

75 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 High

81 Extended Crankcase Pressure Input Voltage High


DDEC V SYSTEM


81 EGR Delta Pressure Sensor Circuit, Engine Oil Life Circuit, orEGR Temp Circuit Failed High

81 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 Low

82 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 PressureLow

84 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, thedriver may occasionally note intakemanifold pressure exceeds 35 psi.



IdlingThe common belief that idling a dieselengine causes no engine damage iswrong. Idling produces sulfuric acid,which breaks down the oil and eatsinto bearings, rings, valve stems andengine surfaces. If you must idlethe engine for cab heat or cooling,the high idle function of the CruiseControl switches should be used. Anidle speed of 1100 rpm should beenough to provide cab heat in above32° F (0° C) ambients.

Winter Fronts

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


ENGINE BRAKE SYSTEM

ENGINE BRAKE SYSTEM

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

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

Low/High Switch

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

Low/Med/High Switch

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

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

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

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

NOTICE:To ensure positive engine brakeengagement when required, alwaysallow the engine to reach full normaloperating temperature beforeactivating the engine brake system.








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

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

you press the clutch pedal whileshifting gears.

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

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


ENGINE BRAKE SYSTEM

Anti-Lock BrakingSystemsVehicles equipped with ABS(anti-lock braking systems) havethe ability to turn the engine brakeretarder OFF if a wheel-slip conditionis detected. The engine brake willautomatically turn itself ON oncethe wheel slip is no longer detected.The DDEC system will deactivatethe engine brake system when theengine speed falls below 1000 rpmor when the vehicle slows down to apre-set speed, depending on DDECprogramming. This prevents stallingthe engine. Engine brakes can alsobe used with vehicle Cruise ControlTURNED ON.

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

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

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

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

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

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



BRAKE FADE

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

Use the following guidelines whendescending a long, steep grade:

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

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

PERSONAL INJURY

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

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

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

4. Check your progressive brakingswitch often for proper position,since road conditions can changequickly. Never skip a step when


ENGINE BRAKE SYSTEM

operating the progressive brakingswitch. Always go from OFFto LOW and then to a higherposition when on slippery roads.

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






NOTE:On single trailers or combinations,a light air application of the trailerbrakes may be desirable to helpkeep the trailer stretched out. Followthe manufacturer's recommendedoperating procedure when using yourtrailer brakes.

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

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

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

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



ENGINE SYSTEMS

The engine systems are the following:

Fuel SystemThe fuel system consists of DDEC,fuel injectors, fuel manifolds (integralwith the cylinder head), fuel pump,a cooling plate for the ECU onnon-automotive engines, primaryand secondary fuel filters, and thenecessary connecting fuel lines.

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

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

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

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

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

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

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

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


MAINTENANCE

MAINTENANCE

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

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

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

Recommended maintenance intervalsfor Series 60 on-highway truckand parlor coach engines arelisted in Table 2, Table 3 and Table 4.Recommended maintenance intervalsfor Series 60 transit coach engines arelisted in Table 5, Table 6, and Table7. Recommended maintenanceintervals for Series 60 fire fighting,crash/rescue, and emergency vehicleengines are listed in Table 8, Table 9,and Table 10.

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



Item DailyChecks

7,500 Miles(12,000 Km)

15,000 Miles(24,000 Km)

1. Lubricating Oil I — R

2. Fuel Tank I — —

3. Fuel Lines & Flex Hoses I — —

4. Cooling System I — —

5. Turbocharger I — I

6. Battery — I —

7. Tachometer Drive — — I

8. Drive Belts — I —

9. Air Compressor — I —

10. Air Cleaner — — I

11. Lube Oil Filters — — R

12. Fuel Filters — — R

13. Coolant/Inhibitor Level — — I

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

Table 2 On-Highway Truck and Parlor Coach Daily, 7,500 Mile, and15,000 Mile Checks


MAINTENANCE

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

15/24

30/48

45/72

60/96

75/120

90/144

105/168

120/192

135/216

150/240

Item Procedure

1. Lubricating Oil Replace every 15,000 miles (24,000 km).

2. Fuel Tank — I — I — I — I — I

4. Cooling System — — — I — — — I — —

5. Turbocharger I I I I I I I I I I

7. Tachometer Drive I I I I I I I I I I

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

9. Air Compressor I I I I I I I I I I

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

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

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

14. Cranking Motor Follow manufacturer's recommendations.

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

16. Exhaust System I I I I I I I I I I


Table 3 On-Highway Truck and Parlor Coach Regular MaintenanceIntervals



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

15/24

30/48

45/72

60/96

75/120

90/144

105/168

120/192

135/216

150/240

Item Procedures17. Engine

(Steam Clean) — — — I — — — I — —

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

19. Oil Pressure — — — I — — — I — —20. Battery Charging

Alternator I I I I I I I I I I

21. Engine &Transmission Mounts — — — I — — — I — —

22. Crankcase Pressure — — — I — — — I — —

23. Fan Hub — — — — — — — I — —

24. Thermostats & Seals — — — — — — — I — —

25. Crankcase Breather — — — — — — — I — —

26. Engine Tune-Up — — — I — — — — — —

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


Table 4 On-Highway Truck and Parlor Coach Regular MaintenanceIntervals (continued)


MAINTENANCE

Item DailyChecks

6,000 Miles(9,600 Km)

7,500 Miles(12,000 Km)

15,000Miles

(24,000 Km)1. Lubricating Oil I R — —

2. Fuel Tank I — — —

3. Fuel Lines &Flexible Hoses I — — —

4. Cooling System I — — —

5. Turbocharger I — — I

6. Battery — — I —

8. Drive Belts — — I —

9. Air Compressor — — I —

10. Air Cleaner — — — I

11. Lube Oil Filters — R — —

12. Fuel Filters — — — R13. Coolant/ Inhibitor

Level — — — I


Table 5 Transit Coach Daily, 6,000 Mile, 7,500 Mile, and 15,000Mile Checks



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

15/24

30/48

45/72

60/96

75/120

90/144

105/168

120/192

135/216

150/240

Item Procedures

1. Lubricating Oil Replace every 6,000 miles (9,600 km).

2. Fuel Tank — I — I — I — I — I

4. Cooling System — — — I — — — I — —

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

Drive I I I I I I I I I I

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

9. Air Compressor I I I I I I I I I I

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

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

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


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


Table 6 Transit Coach Regular Maintenance Intervals


MAINTENANCE

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

15/24

30/48

45/72

60/96

75/120

90/144

105/168

120/192

135/216

150/240

Item Procedures

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

(Steam Clean) — — — I — — — I — —

18. Radiator & A/ACooler — I — I — I — I — I

19. Oil Pressure — — — I — — — I — —20. Battery Charging

Alternator I I I I I I I I I I

21. Engine &TransmissionMounts

— — — I — — — I — —

22. CrankcasePressure — — — I — — — I — —

23. Fan Hub — — — — — — — I — —24. Thermostats &

Seals — — — — — — — I — —

25. CrankcaseBreather — — — — — — — I — —

26. Engine Tune-Up — — — I — — — — — —

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


Table 7 Transit Coach Regular Maintenance Intervals (continued)



Item DailyChecks

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

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

1. Lubricating Oil I — R

2. Fuel Tank I — —

3. Fuel Lines & Flexible Hoses I — —

4. Cooling System I — —

5. Turbocharger I

6. Battery — I —

7. Tachometer Drive — — I

8. Drive Belts — I —

9. Air Compressor — — I

10. Air Cleaner — — I

11. Lube Oil Filter — — R

12. Fuel Filters — — R

13. Coolant/ Inhibitor Level — — I

18. Radiator — — I

20. Battery Charging Alternator — — I


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


MAINTENANCE

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

6/1.6

12/9.6

18/28.8

24/38.4

30/48

Item Procedures

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

2. Fuel Tank I I I I I

4. Cooling System — I — I —

5. Turbocharger — — — — —

7. Tachometer Drive I I I I I

9. Air Compressor I I I I I

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

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

Level I I I I I


15. Air System I I I I I

16. Exhaust System I I I I I


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



Hours 300 600 900 1,200 1,500Miles/Km(X 1000) 6/1.6 12/9.6 18/28.8 24/38.4 30/48

Item Procedures

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

Cooler I I I I I

19. Oil Pressure — I — I —20. Battery Charging

Alternator I I I I I

21. Engine & TransmissionMounts — I — I —

22. Crankcase Pressure — I — I —

23. Fan Hub — — – I —

24. Thermostats & Seals — — — — —

25. Crankcase Breather — — — I —

26. Engine Tune-Up — — — — I

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

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

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


MAINTENANCE

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

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

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

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

Item 1 – Lubricating Oil

Check the oil level daily with theengine stopped. If the engine hasjust been stopped and is warm, waitapproximately 20 minutes to allow theoil to drain back into the oil pan beforechecking. Add the proper grade of oilto maintain the correct level on thedipstick. See Figure 10.

Figure 10 Check Oil Level Daily

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

All diesel engines are designed touse some oil, so the periodic additionof oil is normal. See Figure 11 todetermine the degree of oil usage.



Figure 11 Engine Oil Consumption Guidelines

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

Before adding lubricating oil, refer toHow to Select Lubricating Oil in thisguide. Change lubricating oil andfilters at the intervals listed in Table 11when using fuel with a sulfur contentof less than 0.05 mass percent. Whenusing fuel with a higher sulfur content,refer to When to Change Oil in thisguide.

Service Application Lube Oil and Filter Change Interval*Highway Truck & Motor Coach 15,000 Miles (24,000 Kilometers)

City Transit Coach 6,000 Miles (9,600 Kilometers)Fire Fighting, Crash/Rescue, &Emergency Vehicles

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

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

Table 11 Recommended Engine Oil Drain and Filter ChangeIntervals (Diesel Fuel Sulfur Content Less Than0.05 Mass %)

Item 2 – Fuel and Fuel Tank

Keep the fuel tank filled to reducecondensation. See Figure 12.


MAINTENANCE

Figure 12 Filled Fuel Tank

Before adding fuel, refer to Howto Select Fuel Oil in the HOW-TOSECTION of this guide.

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

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

PERSONAL INJURY

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

NOTICE:Galvanized steel fuel tanks, fittings,pipes or supply lines should neverbe used. The fuel reacts chemicallywith the zinc coating to formpowdery flakes that can quickly clogthe fuel filters and damage the fuelpump and injectors.

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

Every 120,000 miles (192,000kilometers) tighten all fuel tankmountings and brackets. At the sametime, check the seal in the fuel tankcap, the breather hole in the cap andthe condition of the flexible fuellines. Repair or replace the parts, asnecessary.



Item 3 – Fuel Lines, FlexibleHoses

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

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

FIRE


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

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

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

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

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

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


MAINTENANCE

Item 4 – Cooling System

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

HOT COOLANT


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

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

Coolant Inhibitors — Theinhibitors in antifreeze solutions must

be replenished with a non-chromatecorrosion inhibitor supplement whenindicated by testing the coolant.Refer to How to Select Coolant in thisguide for required test intervals andinhibitor levels.

NOTICE:Coolant must be inhibited with therecommended SCA's (supplementalcoolant additives) listed in thisguide. In addition, the enginecan be equipped with a coolantfilter/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.

Coolant Drain Interval —Detroit Diesel recommendsreplacing coolant at the intervalslisted in Table 12.



A coolant system properly maintainedand protected with supplementalcoolant inhibitors can be operatedup to the intervals listed. Atthese intervals the coolant must

be drained and disposed of in anenvironmentally responsible manneraccording to state and/or federal(EPA) recommendations.

Coolant Type Coolant Replacement Interval

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

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

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

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

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

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

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

2 To verify coolant acceptability, submit a sample to DDC for coolantanalysis every 3 years, 300,000 miles (480,000 km) or 6,000operating hours, whichever comes first. Submit sample usingPowerTrac coolant analysis kit, part number 23516921 (IEG/IPGcoolant) or 23523398 (organic coolant).

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

Table 12 Coolant Drain Intervals


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Item 5 – Turbocharger, Air-to-AirCharge Cooler

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

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

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

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

Wastegated Turbochargers —The turbocharger wastegate actuatoris factory-calibrated and is notadjustable. Check actuator operationat the intervals shown in themaintenance schedule.

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NOTICE:Do not exceed 30 psi (207 kPa) airpressure when checking wastegateactuator operation. Excessive airpressure can damage the actuator.

To verify correct wastegate actuatoroperation, apply 30 psi (207 kPa)of regulated shop air and watch foractuator rod movement.



Item 6 – Battery

Check the hydrometer “eye” ofmaintenance-free batteries for charge.See Figure 13.

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

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

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

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

Figure 13 Maintenance-FreeBattery “Eye”

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

If the engine is to be out of servicefor more than 30 days, remove thebatteries and store in a cool, dryplace. Keep batteries fully charged,if possible. Replace any battery thatfails to hold a charge.

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


MAINTENANCE

Item 7 – Tachometer Drive

A typical tachometer drive take-offlocation is the camshaft drive gearaccess cover on the front of the gearcase cover. Lubricate the tachometerdrive (if so equipped) every 150 hoursor 15,000 miles (24,000 km) with anall-purpose grease. At temperaturesabove –1° C (+30° F) use a No. 2grade grease. Use a No. 1 gradegrease below this temperature.

Item 8 – Drive Belts

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

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

Use a belt tension gage, such asKent-Moore® tool J 23586–B(V-belt), J 23600–B (poly-V belt),J 41251 (PowerBand® and 12–ribpoly-V belt), or equivalent, whentensioning drive belts. Tension beltsto the values listed in Table 13.

V-Belts — New standard V-beltswill stretch after the first few hoursof operation. Tighten V-belts aslisted in Table 13.

Fan DriveSingle Belt 2 or 3 Belts

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

Alternator DriveBelt New Used

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

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

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

Table 13 Drive Belt Tensioning



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

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

2-Groove PowerBand — The2-groove PowerBand® is used withthe 50 DN alternator. To provideproper running tension for the belt,current Series 60 engines use an autobelt tensioner, which requires noadjustment. See Figure 14.

Figure 14 Auto Belt TensionerAssembly with 50 DNAlternator

Earlier-built Series 60 engines havea manual belt tensioner assembly.See Figure 15.

Figure 15 Manual TensionerAssembly with 50 DNAlternator

Tighten a new PowerBand® drive beltto 200 lbs (890 N), then run the enginefor 10 minutes at 1200 rpm. Stop theengine and allow a 10 – 15 minutecool down period. Check tension. Ifless than 150 lbs (667 N), retensionto 150 lbs (667 N). Following initialtensioning, measure belt tensionevery month or every 7,500 miles(12,000 km), whichever comes first.Retension belt to 150 lbs (667 N) atthese intervals.

12–Rib Poly-V Belt — Tighten a12–rib poly-V belt to 350 lbs (1,557N), then run the engine at high idle for30 minutes. Stop the engine and allowa 10 – 15 minute cool down period.Check tension with tool J 41251–B


MAINTENANCE

or equivalent. If tension is 250 lbs(1,112 N) or more, no retensioning isrequired. If tension is less than 250 lbs(1,112 N), retension to 250 lbs (1,112N). Measure belt tension every monthor every 7,500 miles (12,000 km),whichever comes first. Retension to250 lbs (1,112 N) as required.

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

Replace all belts in a set when oneis worn. Single belts of similar sizeshould not be used as a substitute fora matched belt set. Premature beltwear can result because of belt lengthvariation. All belts within a matchedset are within .032 in. (0.8 mm) oftheir specified center distances.

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

Item 9 – Air Compressor

All air compressor intake partsshould be removed and cleaned at thefollowing intervals:

□ On Highway Vehicle Engines –7,500 miles (12,000 km)

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

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

The air compressor mounting boltsshould be tightened every 12 monthsor 30,000 miles (48,000 km) foron-highway engines or every 300hours for industrial applications.

Item 10 – Air Cleaner

The air cleaner element should beinspected every 15,000 miles (24,000km) for vehicle engines.

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



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

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

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

Item 11 – Lubricating Oil Filters

For on-highway vehicle engines,install new spin-on oil filters at amaximum of 15,000 miles (24,000km). For city transit coach engines,install filters at a maximum of 6,000miles (9,600 km).

Install the new filters, turning themuntil they contact the gasket fully withno side movement. Turn full-flowfilters an additional 2/3 turn byhand, or as indicated on the filter.See Figure 16.

Figure 16 Lubricating Oil Filters

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

Check for oil leaks after starting theengine.


MAINTENANCE

Item 12 – Fuel Filters

One method of determining whenfilters are plugged to the extent thatthey need replacing is based on thefuel pressure at the cylinder head fuelinlet fitting and the inlet restrictionat the fuel pump. In a clean systemthe maximum pump inlet restrictionshould not exceed 6 inches of mercury(20.3 kPa). In a dirty system it mustnot exceed 12 inches of mercury (41kPa).

At normal operating speed and withthe standard .080 inch restrictionfittings, the fuel pressure is 55 – 70psi (375 – 483 kPa). Change the fuelfilters whenever the inlet restrictionat the pump reaches 12 inches ofmercury (41 kPa) at normal operatingspeeds and whenever the fuel pressureat the inlet fitting falls to the minimumfuel pressure of 6 inches of mercury(20.3 kPa).

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

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

Spin-On Filters — Install newspin-on primary and secondary fuelfilter elements on vehicle enginesevery 15,000 miles (24,000 km) orevery six months, whichever comesfirst. See Figure 17.

Figure 17 Spin-On Fuel FilterLocations

Install new spin-on filter elementson non-vehicle engines every 150hours. Replace spin-on filter elementsimmediately if plugging is indicated,regardless of mileage or hour intervals.

Item 13 – Water Pump andCoolant Inhibitor Element

Check the water pump and the coolantinhibitor element.

Water Pump Drain Hole — Thewater pump drain hole should beinspected every 6 months to makesure it is open. A small chemicalbuild-up or streaking at the drain holemay occur. This is not an indication



of a defective water pump or seal.Remove the build-up with a milddetergent cleaner and a brush. Ifcoolant does not leak from the drainhole under normal conditions, do notreplace the water pump.

Coolant Inhibitor Element — Ifthe cooling system is protected by asupplemental coolant additive (SCA)element, the coolant must be testedat required intervals and the elementreplaced, if required. See Figure 18.

Required test intervals arelisted in Table 20. For SCA testprocedures refer to How to SelectCoolant and SCA Test Proceduresin this guide. Use the coolantfilter element required. Refer toSPECIFICATIONS in this guide forelement part number listing. Thevalves mounted on the filter adaptorhead must be opened after the elementis replaced.

Figure 18 Coolant InhibitorElement

Item 14 – Cranking Motor

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

Item 15 – Air System

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


MAINTENANCE

Item 16 – Exhaust System

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

Item 17 – Engine (Steam Clean)

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

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

Item 18 – Radiator

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

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

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

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



Item 19 – Oil Pressure

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

Item 20 – Battery-ChargingAlternator

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

To avoid equipment damage, payattention to the following:

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

□ Do not reverse battery connections.







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

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

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


MAINTENANCE

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

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

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

Check torque on alternator mountingbolts and bracketing every 15,000miles (24,000 km) on truck and coachengines or every 300 hours on allother engines. Retighten, if necessary.

Item 21 – Engine andTransmission Mounts

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

Item 22 – Crankcase Pressure

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

Item 23 – Fan Hub

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

Care should be taken not to overfillthe bearing housing.

Item 24 – Thermostats and Seals

Replace the thermostats and sealsevery 240,000 miles (384,000 km) onvehicle engines.



Item 25 – Crankcase Breather

The internally mounted (in the enginerocker cover) crankcase breatherassembly (see Figure 19) shouldbe removed and the steel meshpad washed in clean fuel oil every100,000 to 120,000 miles (160,000 to192,000 km) on vehicle engines. Thiscleaning period may be reduced orlengthened according to the severityof service.

Figure 19 Internal Breather (inRocker Cover)

The rocker cover-mounted breatherassembly (part number 23512984)used in the closed crankcase breathersystem should be replaced every 4000operating hours. It is not reusable andno attempt should be made to clean orreuse it.

Item 26 – Engine Tune-Up

There is no scheduled interval forperforming an engine tune-up.However, the valve lash and injectorheights must be measured and, ifnecessary, adjusted at the initialinterval listed in Table 14.

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

Engine Application Measurement/Adjustment Period

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

Table 14 Initial Valve Lash and Injector Height Adjustment


MAINTENANCE

Item 27 – Vibration Damper

The viscous vibration damper shouldbe inspected periodically and replacedif dented or leaking. See Figure 20.

Figure 20 Viscous VibrationDamper

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



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

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

How to Select LubricatingOilThe selection of the proper lubricatingoil is important to achieve the longand trouble-free service which DetroitDiesel engines are designed toprovide. The proper lubricating oil forall Detroit Diesel engines is selectedbased on SAE viscosity grade andAPI (American Petroleum Institute)service designation. Only oils licensedto display the API symbol should beused. See Figure 21.

Figure 21 API Lubricant Symbol

Lubricant Requirements

Lubricant requirements are differentfor the EGR-equipped and non-EGRengines.

EGR-Equipped Engines — APICI-4 oils must be used in October2002 and later–build Series 60engines with cooled EGR (exhaustgas recirculation) devices. APIService Category CI-4 is intended foruse with cooled EGR (exhaust gasrecirculation) engines meeting 2002and later exhaust emission regulations.

Non-EGR Engines — API CI-4 orCH-4 oils are recommended for use inall non-EGR engines.

Engines Built Prior to 1998 —Lubricants meeting API Service


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Category CG-4 may be used inengines built prior to 1998 when APICI-4 or CH-4 oils are not available.

NOTE:The use of CG-4 oils in theseengines may require a reduction inoil drain interval, depending upon theapplication and the fuel sulfur level.

Cold Weather Starting

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

NOTICE:

Monograde oils should notbe used in Series 60 engines,regardless of API serviceclassification. Monograde oilsgel at lower ambient temperatures,reducing lubricant flow, andthey do not provide adequatelubricity at higher engine operatingtemperatures. These factors canresult in severe engine damage.

The oils must be API CI-4 (forEGR-equipped engines) or API CI-4or CH-4 (for non-EGR-equippedengines) and have demonstrated fieldperformance in DDC engines. These

oils must possess a HT/HS of 3.7minimum.

NOTE:Do not use fuel with sulfur contentabove 0.05 mass percent for DetroitDiesel EGR-equipped engines.

When the use of high sulfur fuel(greater than 0.05% mass sulfur) innon-EGR engines is unavoidable,high alkalinity (TBN) lubricantsare recommended. High sulfurfuels require modification tooil drain intervals. For furtherinformation, refer to publicationEngine Requirements – LubricatingOil, Fuel and Filters, 7SE270,available from authorized DetroitDiesel distributors.

Synthetic Oils

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

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



Their use does not permit extension ofrecommended oil drain intervals.

The Use of SupplementalAdditives

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

Engine damage resulting from theuse of such materials is not coveredby your Detroit Diesel Corporationwarranty. Detroit Diesel will notprovide statements beyond thispublication relative to their use.

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

USED ENGINE OIL

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

The maximum interval at whichthe engine may operate before theoil and filters must be changed islisted in Table 15.

Engine Application Drain IntervalHighway Truck & Motor Coach 15,000 Miles (24,000 km)

City Transit Coach# 6,000 Miles (9,600 km)

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

Table 15 Maximum Oil Drain and Filter Change Interval (Fuel Sulfur0.05 Weight Percent or Less)


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

The use of fuels with sulfur contentabove 0.05 mass percent will require ashortening of drain intervals and/or theuse of a higher TBN oil. For detailedinformation refer to publicationEngine Requirements – LubricatingOil, Fuel and Filters (7SE270),available from authorized DetroitDiesel distributors.

Disposing of Waste Oil

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

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

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

Filter part numbers are listed in theSpecifications section of this guide.

Replace Spin-On Type Oil Filter

Replace spin-on type filters(see Figure 22) as follows:

Figure 22 Spin-On Oil Filters



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

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

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

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

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

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

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

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

7. Add oil as required to bring thelevel to the Full mark on thedipstick.

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8. Start and run the engine fora short period and check forleaks. After any leaks have beencorrected, stop the engine longenough for oil from various partsof the engine to drain back tothe crankcase (approximately 20minutes). Add oil as required to


HOW-TO SECTION

bring the level to the Full markon the dipstick.

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

How to Select Fuel OilDetroit Diesel engines are designed tooperate on most diesel fuels marketedtoday.

Quality

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

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

The fuels used must be clean,completely distilled, stable, andnon-corrosive. For more informationregarding the significance of theseproperties and selection of the properfuel, refer to publication, EngineRequirements – Lubricating Oil, Fuel

and Filters (7SE270), available fromauthorized Detroit Diesel distributors.

NOTE:Do not use fuel with sulfur contentabove 0.05 mass percent for DetroitDiesel EGR engines.

Fuel Contamination

Generally, fuel contaminationoccurs as the result of improper fuelhandling. The most common typesof contamination are water, dirt, andmicrobial growth (“black slime”).The formation of varnishes andgums resulting from poor stability orextended storage (“stale fuel”) alsoaffects fuel quality. The best treatmentfor contamination is prevention bymaintaining a clean storage systemand choosing a reputable fuel supplier.

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

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



These products should beaccompanied by performancedata supporting their merit. It isnot the policy of Detroit DieselCorporation to test, evaluate, approveor endorse such products.

Prohibited Additives

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

Used Lubricating Oil — DetroitDiesel specifically prohibits theuse of used lubricating oil in dieselfuel. Used lubricating oil containscombustion acids and particulatematerials which can severely erodefuel injector components, resulting inloss of power and increased exhaustemissions. In addition, the use ofdrained lubricating oil will increasemaintenance requirements due to filterplugging and combustion deposits.

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

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

FIRE

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

Detroit Diesel Corporation will not beresponsible for any detrimental effectsit determines resulted from addingdrained lubricating oil or gasoline tothe diesel fuel.

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

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

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


HOW-TO SECTION

The spin-on type filter consists of ashell, element and gasket unitized intoa single cartridge and a filter adaptorwhich includes threaded insertsto accept the spin-on cartridges.See Figure 23.

Figure 23 Typical Spin-On TypeFuel Filter

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

Replace Spin-On Type Primaryor Secondary Fuel FilterElements

Replace spin-on fuel filter elements asfollows:

1. Shut down the engine and allowit to cool.

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

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

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

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

5. If not previously filled, fill newreplacement filters with clean



diesel fuel and coat the gasketslightly with the fuel oil.

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

NOTICE:Overtightening the filter may crackor distort the adaptors.

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

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

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

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


HOW-TO SECTION

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

Replace Fuel/Water SeparatorElement

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



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

4. Drain off some fuel by openingthe drain valve.

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

6. Clean the bowl and the O-ringseal.

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

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

8. Apply a light coating of clean fueloil or grease to the new O-ringseal on the top of the filter. Threadthe filter and bowl assembly ontothe filter head and tighten byhand until snug.

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

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



Replace Fuel Pro® 382/382EFuel Filter Element

The Fuel Pro 382/383E diesel fuelfilter system consists of a permanentlymounted fuel processor, a replaceablefilter element and sealing grommetassembly, a filter spring, a see-thrucover and seal, a cover collar, and avent cap and seal. See Figure 24.

Figure 24 Fuel Pro 382E FuelProcessor Assembly

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

Replace the element as follows:



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

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

5. Using filter collar/vent capwrench part number 232002 orequivalent, remove the collarby turning counter-clockwise.Remove the cover, filter springand cover seal ring by liftingstraight up and over the filterelement.

6. Remove the element from thecenter stud (fuel outlet pipe)


HOW-TO SECTION

by pulling upward and twistingslightly.

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

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

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

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

NOTICE:Do not use a wrench of any kindto tighten the collar, since this maylead to overtightening, which candamage the collar and/or the cover.

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

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

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

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



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

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

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

NOTE:The filter cover will not fill completelyduring engine operation. It willgradually fill over time, and the fuellevel will rise as the filter mediumbecomes clogged. The filter elementdoes nor require changing untilthe fuel level has risen to the topof the element, or after one year ofservice, whichever comes first.

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

NOTICE:The starting motor and fuel pumpshould never be used to prime thefuel filters. Prolonged used of thestarting motor and fuel pump toprime the fuel system can result indamage to the starter, fuel pumpand injectors and cause erraticrunning of the engine due to theamount of air in the fuel lines andfilters.

Engines with Spin-On Filters

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

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

2. Close the fuel shutoff valve (ifinstalled) on the secondary filterhead and remove the spin-on fuelfilters. Fill with clean fuel throughthe fuel inlet holes (the outer ringof small holes on the element) toinsure the fuel is filtered.

3. Thread the elements onto theadaptor inserts until the gaskets


HOW-TO SECTION

make full contact with the adaptorhead and no side movementis evident. Tighten filters anadditional one-half turn by hand,or as indicated on the filter.

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

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

Engines with Fuel Pro Filters

Use the following procedure for anengine with Fuel Pro filters.

1. Remove the vent cap fromthe top of the filter by turningcounter-clockwise. Fill the coverfull of clean fuel. After makingsure the O-ring seal is installed onthe vent plug, reinstall the plugand tighten by hand only.

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

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

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

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

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



How to Select CoolantThis section covers selection of therequired coolant for Series 60 engines.

Definitions

To help ensure completeunderstanding of the information, thedefinitions of the following terms areprovided:

Antifreeze — Ethylene glycolor propylene glycol containing acorrosion inhibitor package and whichmeets an appropriate heavy-dutyspecification (i.e., TMC RP-329 forethylene glycol or TMC RP-330 forpropylene glycol).

Coolant — The fluid mixturecirculating in the engine coolingsystem, typically a mixture of 50%water and 50% antifreeze.

Drop–Out — Precipitated sludge ordeposit formation on cooling systemcomponents.

Fully Formulated Antifreeze —Contains all the necessary inhibitorsto protect a diesel engine, and doesnot, therefore, require a pre-charge ofSCA before its first use.

Initial–Fill Coolant — The coolantthat is used in a new or rebuilt engine,or any time the cooling system isemptied and then refilled with coolant.

OAT — Organic Acid Technology.An inhibitor system based on

organic acid inhibitors, instead oftraditional North American inhibitorformulations.

SCA — Supplemental CoolantAdditive. SCAs are used in apreventive maintenance program toprevent corrosion, cavitation, and theformation of deposits.


HOW-TO SECTION

Approved Coolants

The approved and preferredcoolants for Series 60 enginesare listed in Table 16.

Once installed, these coolantsshould be maintained accordingto the procedures discussed underMaintenance in this section.

NOTICE:Required specifications for water,ethylene glycol, propylene glycol,inhibitor packages and inhibitorconcentration are included inthis section. To avoid possibleengine damage from inadequateor over concentrated coolant,this information should be readthoroughly before the coolant isreplaced.

Coolant Fill Option ProductEthylene Glycol & Water + CorrosionInhibitors 1 DDC Power Cool

Commercial Equivalent of DDC PowerCool

Fully Formulated TMC RP-329 Type AAntifreeze & Water

Propylene Glycol & Water + CorrosionInhibitors 1 DDC Power Cool Plus

Ethylene Glycol & Water + OATInhibitors DDC Power Cool Plus

Water Only + Corrosion Inhibitors 2 Water + DDC Power Cool 3000

Water Only + OAT Inhibitors 2 Water + DDC Power Cool Plus 60001 Preferred Coolant2 Water-only coolant systems offer no freeze protection and should not

be used where ambient temperatures can fall to 32° F (0° C).

Table 16 Initial Fill Coolant Options



EG & Water Plus SCA Inhibitoror P G & Water Plus SCAInhibitor — These products areavailable as fully formulated,phosphate-free, extended serviceinterval (ESI) coolants. They arecommercially available from DetroitDiesel (recommended) and othermanufacturers as either a concentratedantifreeze or as a pre-mixed antifreeze.The pre-mixed antifreeze is ready foruse, while the concentrated coolantmust be mixed with water prior to use.

Detroit Diesel Power Cool enginecoolant (part number 23512138) isthe preferred ethylene glycol (EG)coolant. If other commercial brands ofethylene glycol are used, they must beequivalent to the Power Cool. DetroitDiesel does not market a propyleneglycol (PG) coolant. If a propyleneglycol coolant is used, it must alsomeet the following requirements:

□ Fully formulated ethyleneglycol-based, low silicateantifreeze or coolant mustmeet TMC RP-329 “Type A”requirements.

□ Fully formulated propyleneglycol-based antifreeze or coolantmust meet TMC RP-330 “TypeA” requirements.

Fully formulated antifreeze does notrequire a dosage of SCA prior toinitial use.

Mixing EG or PG Antifreezeand Water — If a concentratedethylene glycol (EG) or propyleneglycol (PG) antifreeze is purchased,mix the antifreeze with water meetingthe required quality standardslisted in Table 19 and fill the coolingsystem.

If a pre-diluted, fully formulatedcoolant is purchased, fill thecooling system. For best overallperformance, a coolant consistingof 50% concentration of antifreeze(50% antifreeze, 50% water) isrecommended.

An antifreeze concentration over67% (67% antifreeze, 33% water) isnot recommended due to poor heattransfer, reduced freeze protection(IEG only), and possible silicatedropout. An antifreeze concentrationbelow 33% (33% antifreeze, 67%water) offers too little freeze and/orcorrosion protection and is notrecommended.


HOW-TO SECTION

See Figure 25 for ethylene glycol-basecoolant concentration versus freezingand boiling temperatures.

Figure 25 CoolantTemperatures vs IEG Concentration (Sea Level)



See Figure 26 for inhibitedpropylene glycol-base (IPG) coolantconcentration versus freezing andboiling temperatures.

Always verify that the freeze pointand nitrite concentration of the

antifreeze/water mixture are correctby using a POWER Trac® 3–WayCoolant Test Strip. If chemicalanalysis is used, elements in thecoolant must fall within the limitslisted in Table 17.

Figure 26 Coolant Temperatures vs IPG Concentration (Sea Level)


HOW-TO SECTION

Fully Formulated Glycol Coolant Concentration LimitsBoron 125 – 500 PPM

Nitrite 900 – 3200 PPM

Nitrate 200 – 3200 PPM

Silicon 50 – 250 PPM

Phosphorous 0 PPM

pH 8.0 – 11.0

Table 17 Fully Formulated Glycol Coolant Limits with TMC RP-329,TMC RP-330 Chemistry Type A (50/50 Coolant/WaterMixture)

Recycled Antifreeze — Antifreezeor coolant recycled by reverseosmosis, distillation, and ionexchange, properly re-inhibitedto meet TMC RP-329 Type A orTMC RP-330 Type A requirements,has been demonstrated to provideservice equivalent to virgin antifreeze.Recycled antifreeze or coolants ofthese types are preferred. Otherrecycled coolants, especially coolantsrecycled through filtration processes,are not recommended.

EG/Water + OAT Inhibitor orPG/Water + OAT Inhibitor —Ethylene glycol and propyleneglycol are also available with a OATcorrosion package. These coolantsrequire less maintenance over theuseful life of the engine. OATcoolants, maintained as detailed inthe Maintenance section of thisguide, may be operated up to 4 years,

600,000 miles (960,000 km), or10,000 operating hours, whichevercomes first. Refer to Coolant InhibitorTest Intervals in this guide. Thecooling system should either beequipped with a blank coolant filter,or the coolant filter and piping may beomitted from the system.

OAT fully formulated antifreezesare available as concentrated andpre-mixed. Concentrated antifreezesshould be mixed 50% (50% antifreeze,50% water).

OAT coolants should not be mixedwith conventional coolants. If theyare mixed, no damage will result, butthe long-life advantages of the OATcoolant will be lost. In this event,the coolant should be maintained as afully formulated IEG coolant, not asan OAT (Organic Acid Technology)coolant.



Detroit Diesel markets a OAT-inhibited ethylene glycol coolant,DDC Power Cool Plus, whichcontains all the required additives.If a non-DDC OAT antifreeze isused, it must conform to TMC 338specification. Do not add extender tonew OAT antifreeze or coolant.

Water Only + SCA or WaterOnly + OAT Inhibitor — Inwarm climates a coolant basedon water with corrosion inhibitorsis approved for use. Water-onlysystems need to be treated with theproper dosage of corrosion inhibitors.Detroit Diesel-approved SCAs orOAT corrosion inhibitors must beadded to the water to provide requiredcorrosion and cavitation erosionprotection. OAT inhibitors such asPower Cool Plus 6000 are availablefor water-only systems. Inhibitor

should be mixed at 7.5% – 10% byvolume with water. For a list ofPower Cool products, refer to sectionSPECIFICATIONS in this guide.Traditional SCA (Power Cool 3000)can also be used to protect the engine.Power Cool 3000 concentration limitsare listed in Table 18.

NOTE:Do not use Power Trac 3–Way TestStrips to test OAT coolant.

POWER COOL® 3000 SCA inhibitorsshould be mixed at 5% by volumewith water. This is 1 quart per 5gallons of water. These additionscan be made by adding liquid SCAsavailable in a variety of sizes. Coolantfilters are also available for differentcooling system capacities. Thesefilters release the proper amount ofSCA at initial fill.

Power Cool 3000 Coolant Concentration LimitsBoron 125 – 500 PPM

Nitrite 900 – 3200 PPM

Nitrate 0 – 1000 PPM

Silicon 50 – 250 PPM

Phosphorous 0 PPM

pH 8.0 – 11.0

Table 18 Power Cool 3000 Concentration Limits (5% Power Cool3000/ 95% Water)


HOW-TO SECTION

Water Requirements —Distilled, reverse osmosis-purified, orde-ionized water which eliminates theadverse effects of minerals in tap wateris preferred. High levels of dissolvedchlorides, sulfates, magnesium, andcalcium in some tap water causes scaledeposits and/or corrosion resultingin water pump failures and poor heattransfer, leading to overheating. If tapwater is used, the mineral content inthe water must be below the maximumallowable limits listed in Table 19.

NOTICE:Do not add additional SCA tonew, fully formulated antifreeze orcoolant. This can result in dropoutand/or the formation of deposits.

Coolants Not Recommended

The following coolants are notrecommended for use in Detroit Dieselengines.

All Antifreezes And CoolantsContaining Phosphate — Thesecoolants are not recommended. Dropout, overheating and water pump sealfailures can result from the use ofcoolant or inhibitor packages based onphosphate.

Automotive Type Coolants —These coolants generally contain highlevels of phosphate and silicate, offerno liner pitting protection, and arenot suitable for use in Detroit Dieselengines.

Methyl Alcohol-BasedAntifreeze — This must not beused because of its effect on thenon-metallic components of thecooling system and its low boilingpoint.

Maximum AllowableParts per Million Grains per Gallon

Chlorides 40 2.5

Sulfates 100 5.8

Total Dissolved Solids 340 20Total Hardness –Magnesium and Calcium 170 10

Table 19 Satisfactory Water Limits – Make-Up Water Only



Glycol-based CoolantsFormulated For HVAC —These coolants formulated forHeating/Ventilation/Air Conditioning(HVAC) should not be used. Thesecoolants generally contain high levelsof phosphates, which can depositon hot internal engine surfaces andreduce heat transfer.

Additives Not Recommended

The following additives are notrecommended for use in Series 60engines.

Soluble Oil Additives — Theseadditives are not approved for use inDetroit Diesel engine cooling systems.A small amount of oil adverselyaffects heat transfer. For example, a1.25% concentration of soluble oilincreases fire deck temperature 6%.A 2.50% concentration increases firedeck temperature 15%. The use of

soluble oil additives may result inengine overheating and/or failure.

Chromate Additives — Theseadditives are not approved for usein Detroit Diesel engine coolingsystems. Chromate additives canform chromium hydroxide, commonlycalled “green slime.” This, in turn,can result in engine damage due topoor heat transfer. Cooling systemsoperated with chromium-inhibitedcoolant must be chemically cleanedwith Power Cool dry chemicalcooling system cleaner/conditionerlisted in Table 37 (or equivalentsulfamic acid/sodium carbonatecleaner) and flushed.

Coolant Inhibitor Test Intervals

The coolant inhibitor level should bechecked at the intervals listed in Table20.

Service Application Inhibitor Test IntervalOn-Highway Trucks and Motor Coaches 20,000 Miles (32,000 Kilometers)City Transit Coaches, Pick-Up andDelivery, Short Trip, and EmergencyVehicles

6,000 Miles (9,600 Kilometers) or 3Months, whichever comes first

Table 20 Required Coolant Inhibitor Test Intervals


HOW-TO SECTION

HOT COOLANT


If topping off is needed, add coolantwhich is identical to the initial fillcoolant.

Supplemental Coolant Additivesfor Fully Formulated Coolant— The concentrations of someinhibitors will gradually depleteduring normal engine operation.SCAs replenish the protection forcooling system components. Thecoolant must be maintained with theproper concentration of SCA. DetroitDiesel Power Coolmaintenance SCAsare recommended.

The proper application of SCA willprovide:

□ pH control.

□ Restored inhibitor levels to preventcorrosion.

□ Water softening to deter formationof mineral deposits.

□ Cavitation protection to protectwet sleeve cylinder liners.

Maintenance Intervals — Checkthe nitrite concentration at the regularintervals listed in Table 21 with aPower Trac 3–Way Test Strip.



Coolant Interval 1 Action

20,000 Miles (32,000 km)or 3 Months*

Test nitrite concentrationwith test strip. Add SCA ordilute coolant as needed.

Antifreeze / Water +SCA Inhibitor (DDCPower Cool) 300,000 Miles

(480,000 km)Drain and clean system.Refill with new coolant.


Test nitrite concentrationwith test strip. Add SCA ordilute coolant as needed.

Ethylene Glycol/ Water + SCAInhibitororPropylene Glycol/ Water + SCAInhibitor

300,000 Miles(480,000 km)

Drain and clean system.Refill with new coolant.

Test at 1 Year. —300,000 Miles(480,000 km) or 2 Years*

Add Power Cool PlusExtender

Ethylene Glycol/ Water + OATInhibitororPropylene Glycol/ Water + OATInhibitor

600,000 Miles(960,000 km)

Drain and clean system.Replace with new coolant.


Test nitrite concentrationwith test strip. Add SCA ordilute coolant as needed.Water Only + SCA

Inhibitor 300,000 Miles(480,000 km)

Drain and clean system.Replace with new coolant.

300,000 Miles(480,000 km) or 2 Years*

Add Power Cool PlusExtenderWater Only + OAT

Coolant 600,000 Miles(960,000 km)

Clean and drain. Replacewith new coolant.

1 Maintenance interval based on application. Drain interval dependenton proper maintenance.

Table 21 Coolant Maintenance Intervals

Nitrite levels must be within theranges listed in Table 17.


HOW-TO SECTION

NOTICE:Failure to properly maintain coolantwith SCA can result in damageto the cooling system and itsrelated components. Conversely,over-concentration of SCA inhibitorcan result in poor heat transfer,leading to engine damage.Always maintain concentrations atrecommended levels. Do not usetraditional SCAs with OAT coolant.

Additional SCA must be added to thecoolant when it becomes depleted, asindicated by a nitrite concentrationof 900 PPM or less. If the nitriteconcentration is greater than 900PPM, do not add additional SCA. Ifthe nitrite concentration is above 3200PPM, the system is over-inhibited andshould be partially drained and filledwith a 50/50 mix of water and EG orPG.

In this case the EG or PG shouldcontain no inhibitors and shouldconform to ASTM D4985. Thiswill dilute the over-concentratedinhibitors.

NOTE:In non-OAT systems, nitriteconcentration of 5000 PPM orhigher on a Series 60 enginesuggests problematic additiveover-concentration. This conditionmust be corrected by immediatedraining and flushing of the coolingsystem. Refill the system with new fullyformulated or pre-charged coolant.Check the nitrite concentration level atthe next maintenance interval with aPower Trac 3–Way Test Strip.

SCA Test Procedures

Detroit Diesel Power Trac 3–WayCoolant Test Strips should beused to measure nitrite andglycol concentrations. Partnumbers are listed in Table 38.Cavitation/corrosion is indicatedon the strip by the level of nitriteconcentration. Freeze/boil overprotection is determined by glycolconcentration.



HOT COOLANT


For best results make the test whilethe coolant is between 50° – 140° F(10.0° – 60° C). Wait at least 60, butnot longer than 75, seconds beforereading the nitrite level. Use the teststrips as follows:

1. Dip the strip into coolant forone second. Remove and shakebriskly to eliminate excess fluid.

2. Immediately compare the pad end(% glycol) to the color chart onthe container.

3. Sixty seconds (one minute) afterdipping, compare the nitrite padto the color chart.

4. Color change of the additiveindicator (middle pad) indicatesthe presence of inhibitor that isnot approved by Detroit Diesel.

Promptly replace and tighten the teststrip container cap after each use.

Discard unused strips if they haveturned light pink or tan.

A factory coolant analysis programis available through authorizedDetroit Diesel service outlets. Partnumbers are listed in Table 38 in theSpecifications section. To verifycoolant acceptability, submit a samplefor coolant analysis every two (2)years, 300,000 miles (480,000 km),or 10,000 operating hours, whichevercomes first.

Need Release Coolant Filters(Non-OAT Systems)

Spin-on coolant filters are available forDetroit Diesel engines. Membranesin the filters release SCAs beforethe coolant approaches a corrosivecondition, protecting the engine fromcorrosion. The elements release theSCA charge as needed, as opposed tothe maintenance SCA elements, whichinstantaneously release the SCAcharge. Coolant filter elements shouldbe replaced after one (1) year, 120,000miles (192,000 km) or 2,000 operatinghours, whichever comes first.


HOW-TO SECTION

Dropout

Excessive amounts of some inhibitorsin the coolant can cause a gel orcrystalline deposit that reduces heattransfer and coolant flow. The deposit,called “dropout,” takes the color ofthe coolant when wet, but appears as awhite or gray powder when dry. It canpick up solid particles in the coolantand become gritty, causing excessivewear of water pump seals and othercooling system components.

PERSONAL INJURY

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

The wet gel can be removed by usinga non-acid (alkali) type heavy-dutycleaner, such as Detroit Diesel PowerCool On-Line Cleaner (sodiumnitrite/sodium tetraborate). Partnumbers are listed in Table 37.

NOTE:If the gel is allowed to dry, it isnecessary to disassemble theengine and clean it with a causticsolution or physically clean individualcomponents.

Coolant Extender InhibitorAdditive for “OAT” Coolant

The inhibitors in OAT coolant mustalso be maintained, but less oftenthan traditional SCA-type coolants.A portable test is available to test thelevels of OAT inhibitors in coolant.Where this is not used, fleet testinghas determined that a OAT coolantextender package should be added tothe coolant at 300,000 miles (480,000km), two (2) years, or 5,000 hours,whichever comes first. The propermaintenance dosages for all OATcoolants are listed in Table 21 ,reflecting 0.6% by volume extender.This dosage should be added to thewater-only and the glycol systems atthe same interval.

The proper application of extender toOAT coolant will provide:

□ pH Control

□ Restored inhibitor levels to preventcorrosion

□ Cavitation protection to protectwet sleeve cylinder liners

NOTE:Do not use traditional SCAs inOAT coolant, and do not useOAT extender in traditional coolant.



OAT Coolant Drain Interval —A properly maintained OAT-inhibitedcoolant will last 600,000 miles(960,000 km), four (4) years, or10,000 operating hours, whichevercomes first. At this time the coolantshould be drained, and the coolingsystem should be thoroughly cleaned,flushed, and filled with new, properlyinhibited OAT coolant.

Chronic Coolant SystemProblems

The most commonly seen coolantsystem problems result frommaintenance and formulation factorssuch as:

□ Hard water

□ Dilution of the coolant by theaddition of untreated water

□ Over dosage or under dosage ofcorrosion inhibitors

□ Improper corrosion inhibitor (mostoften phosphated)

□ Mixing SCAs

□ Improper testing

Detroit Diesel Cooling SystemMaintenance Products

The following products are availableto do maintenance on the coolingsystem.

Power Cool SCAs — Power CoolSCAs are water-soluble chemicalcompounds. These products areavailable in coolant filter elements,liquid packages, and in fullyformulated Power Cool antifreeze.

NOTE:Power Cool 3000 liquid SCA is morecompatible with hard water thanPower Cool 2000 SCA.

Power Cool Coolant FilterElements — Power Cool coolantfilter elements (spin-on canisters) areavailable in various sizes suitable forcooling systems of varying capacities.Selection of the proper element sizeis vital when pre-charging non-fullyformulated coolant at initial fill andat maintenance intervals. A fullyformulated antifreeze must nothave SCA added at initial fill. Donot use SCA-containing filterswith OAT antifreeze or coolant.The need for maintenance elementsis determined by the results of thenitrite concentration test performedat each cooling system interval. Donot automatically install maintenanceelements at maintenance intervals,unless the nitrite concentration fallsbelow 900 parts per million.

Power Cool Cleaners — PowerCool Liquid On-Line Cleaner is usedfor light deposits. Power Cool Dry


HOW-TO SECTION

Chemical Cleaner/Conditioner is usedfor heavy deposits or scale.

Summary of CoolantRecommendations

HOT COOLANT


1. Always maintain the enginecoolant to meet Detroit Dieselspecifications.

2. Only use water that meets thespecifications listed in Table 19.Distilled, de-mineralized (reverseosmosis) or de-ionized water ispreferred.

3. The proper dosage of inhibitorsmust be included in the coolantat initial fill for all Detroit Dieselengines. This dosage is usuallyincluded in the fully formulatedantifreeze used, or it may need tobe added if water alone or if lessthan 50% antifreeze is used. The

user is urged to refer to the fulltext of this section to determinethe proper dosage. Mixingof different manufacturers'technologies (brands) could causecooling system problems.

4. Maintain the inhibitor at theprescribed concentration. Testthe nitrite concentration by usinga titration kit or Detroit DieselPower Trac 3-Way Coolant TestStrips. Add SCA only if the nitriteconcentration is below 900 PPM.Do not use SCA in OAT coolant,and do not use Power Trac 3-WayCoolant Test Strips to test OATcoolant.

NOTE:If the nitrite concentration exceeds3,200 PPM, the coolant must bedrained and replaced with newcoolant. A thorough cleaning of thecooling system may be required.

5. Do not use another manufacturer'stest kit to measure the SCAconcentration of Detroit Dieselmaintenance products.

6. Pre-mix coolant makeup solutionsto the proper concentration beforeadding to the cooling system.

7. Do not mix OAT and othercoolants in the same engine.

8. Do not use automotive coolants.



9. Where antifreeze/boil overprotection is required, use onlyantifreeze that meets TMCRP-329 “Type A” (EG) orTMC RP-330 “Type A” (PG)specifications. Always maintaincoolant at the proper level.

10. Do not use the following inDetroit Diesel engine coolingsystems:

□ Soluble oil

□ High silicate, automotive-typeantifreeze

□ Chromate SCAs

□ Methoxy propanol-basecoolant

□ Methyl alcohol-base coolant

□ Sealer additives or coolantcontaining sealer additives.

□ HVAC coolant

□ Phosphated coolants

Coolant life of Glycol Coolant —A properly maintained coolingsystem, filled with phosphate-freecoolant consisting of a 50/50 mix ofantifreeze and water per TMC RP-329“Type A” (EG) or TMC RP-330“Type A” (PG) specifications can beoperated to the limits recommended.The proper maintenance involvesperiodic evaluation using Power Trac3-Way Coolant Test Strips and the

addition of SCA as needed, indicatedby the strip test. To verify coolantacceptability, submit a sample forcoolant analysis every 300,000 miles(480,000 km), three (3) years, or5,000 operating hours, whichevercomes first. Submit the sample ina DDC Power Trac Coolant TestBottle. Required part numbers arelisted in Table 38.

Coolant Life of OAT Coolant — Aproperly maintained OAT coolant maybe operated 600,000 miles (960,000km), four (4) years, or until overhaul,whichever comes first. At this time thesystem must be completely drained,thoroughly cleaned, and refilled. OATCoolants require the addition of anextender at 300,000 miles (480,000km), two (2) years, or 5,000 hours,whichever comes first. Use 1 pintof extender for every 20 gallons ofcoolant.

Coolant Life of Other Coolants—Other properly maintained coolantsmay be operated up to 250,000 miles(480,000 km), two (2) years, or 4,000operating hours, whichever comesfirst. At this time the system mustbe completely drained, thoroughlycleaned, and refilled.


HOW-TO SECTION

How to Drain and Flush theCooling SystemDrain and flush the cooling system asfollows:

HOT COOLANT


1. With the engine cool, drain theprevious solution from the engineand radiator. Dispose of thecoolant in an environmentallyfriendly manner, accordingto state and/or federal (EPA)recommendations.

2. Refill the cooling systemwith clean, soft water and agood cooling system cleaningcompound, such as thoselisted in Table 37 in theSpecifications section. Ifthe engine is warm, fill slowlyto prevent the rapid cooling anddistortion of the metal castings.

3. Start the engine and operate it forfifteen minutes to circulate thesolution thoroughly.

4. Stop the engine and allow it tocool.

5. With the engine cool, drain thecooling system completely.

6. Refill the cooling system withclean, soft water and operate it forfifteen minutes.

7. Stop the engine and allow it tocool.

8. With the engine cool, drain thecleaner residue from the coolingsystem.

9. Refill the system with the requiredcoolant. Refer to section How toSelect Coolant.

10. Entrapped air must be purgedafter filling the cooling system.To do this, allow the engine towarm up without the pressure capinstalled. With the transmissionin neutral, increase engine speedabove 1000 RPM and add coolantas required. Install the pressurecap after the coolant level hasstabilized at the bottom of theradiator filler neck.



NOTICE:If the engine overheats andthe coolant level is satisfactory,the cooling system may requirecleaning with a descaling solventand backflushing. AuthorizedDetroit Diesel service outlets areproperly equipped to perform theseservices.

In addition to the cleaning procedure,other components of the coolingsystem should be checked periodicallyto keep the engine operating at peakefficiency.

Hoses

Cooling system hoses should beinspected and any hose that showsobvious signs of damage or feelsabnormally soft or hard should bereplaced. Damaged clamps shouldalso be replaced. All external leaksshould be corrected as soon asdetected.

NOTE:If Detroit Diesel Power Coolantifreeze/coolant (or equivalent fullyformulated, precharged antifreezeis used, a precharge element is notrequired. Coolant inhibitor levelsmust be checked at the intervalslisted in Table 20.

When to Service the DryType Air CleanerReplace dry type air cleaner elementswhen the maximum allowable aircleaner restriction (20 inches ofwater or 5.0 kPa) has been reachedor annually, whichever comes first.Some air cleaners are equipped witha restriction indicator which aids indetermining the servicing interval.

Cleaning and/or reusing dry papertype air cleaner elements is notrecommended unless the cleaningmethod used removes cloggingwithout damaging the element.Inspection and cleaning of elementsmust be done in accordance withthe air cleaner manufacturer'srecommendations, if any.


BASIC TROUBLESHOOTING


This section covers basictroubleshooting of engine operationor performance malfunctions andtheir probable causes. In addition to

operating the engine carefully andmaintaining it properly make sure tocorrect any malfunction promptly.

Objectionable Exhaust Symptoms and Probable Causes

Probable CausesBlackor GraySmoke

BlueSmoke

WhiteSmoke

Damaged or dirty air cleaner X — —

Improper grade of fuel X — —

Excessive exhaust back pressure X — —

Misfiring cylinders — — XLubricating oil not burned incylinder (being burned in exhaustmanifold or turbocharger)

— X —

Faulty injector timing X — —

Faulty oil control rings — X —

Excessive installation angle — X —

Excessive oil in crankcase — X —

High ambient temperature X — —

Thin air (high altitude) X — —

Cetane rating of fuel too low — — X

Air in the fuel system — — X



Hard Starting Symptoms and Probable Causes

Probable Causes Engine WillNot Rotate

LowCrankingSpeed

EngineCranks ButWill NotStart

Low Battery Voltage X X —Loose cranking motorconnections X — —

Faulty cranking motor X X —

Faulty cranking motor switch X X X

Internal seizure X — —

Improper lube oil — X —Circuit breaker/electronic controlmalfunction — — X

Fuse blown or missing — — XInsufficient Fuel SupplyAir in fuel — — X

Out of fuel — — X

Loose fuel connections — — X

Cracked fuel lines — — X

Obstructed fuel filters/lines — — XFaulty fuel pump — — XFaulty injector operation — — XRestricted fuel fitting missing — — X

DDEC Malfunction — — XInstallation/operation of fuelcheck valve or shutoff valve — — X

Low CompressionWorn intake and exhaust valves — — X

Worn piston rings/liners — — XLeaking cylinder head gasket — — XImproper intake or exhaust valveadjustments — — X



Abnormal Engine Operation Symptoms and Probable Causes

Probable Causes

RoughRunning orFrequentStalling

Low Power Detonation

Misfiring cylinder X X —

Insufficient fuel X X —

High return fuel temperature X X —

Low compression X X —

DDEC malfunction X X —High air inlet restriction/ex-haust back pressure — X —

Engine application — X —

High air inlet temperature — X —

High altitude operation — X —Incorrect engine gear traintiming — X —

Low coolant temperature — — X

Oil picked up by inlet airstream — — X

Faulty injector operation — — XIncorrect injector heightsetting — X X



Abnormal Operating Condition Symptoms and Probable Causes

Probable Causes High Lube OilConsumption

Low OilPressure

Loose connections X —

Cracked lines X —

Damaged gaskets or seal rings X —

* Lube oil loss at breather tube X —

* Lube oil loss at dipstick tube X —

Leaking oil cooler X —

Leaking valve stem seals X —

Worn/broken oil control rings X

Scored liner and/or piston X —

Excessive engine installation angle X —

Crankcase overfilled X —Oil in air tanks (air compressormalfunction) X —

Plugged crankcase breather X —

Oil level low — XImproper engine oil viscosity (fuel in theoil) — X

Faulty oil pressure regulator valve — XWorn crankshaft, camshaft orconnecting rod bearings — X

Missing cup plugs in rocker arm shafts — X

Faulty oil pressure relief valve — X

Air leaks in oil pump (suction side) — XWorn or damaged oil pump — XFaulty oil pressure gage — X

Faulty electrical components (for gage) — X

Plugged oil line or orifice — X

* Indicates high crankcase pressure



Abnormal Coolant Temperature Symptoms and Probable Causes

Probable Causes AboveNormal

BelowNormal

Restricted cooling system passages X —

Restricted radiator core passages X —

Slipping fan drive belts X —

Faulty temperature-controlled fan X —

Obstruction in front of radiator or intercooler X

Low coolant level X —

Damaged hoses X —

Faulty thermostats X —

Faulty water pump X —

Faulty radiator pressure cap X —

Air in coolant X —

Thermostats not fully closed — X

Leakage around thermostat seals — X

Faulty temperature-controlled fan — X



ENGINE STORAGE

When an engine is to be stored orremoved from operation for a periodof time, special precautions shouldbe taken to protect the interior andexterior of the engine, transmissionand other parts from rust accumulationand corrosion. The parts requiringattention and the recommendedpreparations are given below.

Preparing Engine forStorageIt will be necessary to remove allrust or corrosion completely fromany exposed part before applying rustpreventive compound. Therefore,it is recommended that the enginebe processed for storage as soon aspossible after removal from operation.

The engine should be stored ina building that is dry and can beheated during the winter months.Moisture-absorbing chemicals areavailable commercially for use whenexcessive dampness prevails in thestorage area.

Temporary Storage (30 Days orLess)

To protect the engine for a temporaryperiod of time (30 days or less), followthis procedure:

1. With the engine at ambienttemperature and cool to the touch,drain engine crankcase oil into asuitable container. Dispose of theoil in an environmentally friendlymanner, according to state and/orfederal (EPA) recommendations.

2. Fill the crankcase to the properlevel with the recommendedviscosity and grade of oil.

3. Fill the fuel tank with therecommended grade of fuel oil.Operate the engine for two (2)minutes at 1200 rpm and no load.Do not drain the fuel system orthe crankcase after this run.

4. Check the air cleaner and serviceit, if necessary.

5. If freezing weather is expectedduring the storage period, checkthe antifreeze/coolant for requiredfreeze and inhibitor protection.Add antifreeze solution to thecooling system in accordancewith DDC's recommendations.


ENGINE STORAGE

Refer to How to Select Coolant inthis guide.

NOTE:If an antifreeze solution is not requiredduring storage, flush the coolingsystem with a good soluble oil (3% –5% by volume) rust inhibitor to preventrusting of the outside diameter of thecylinder liners.

EYE INJURY


6. Clean the exterior of the engine(except electrical parts) with fueloil and dry with compressed air.

7. Seal all engine openings. Thematerial used must be waterproof,vaporproof and possess sufficientphysical strength to resistpuncture and damage from theexpansion of entrapped air.

An engine prepared in this manner canbe returned to service in a short timeby removing the seals at the engineopenings and by checking the enginecoolant, fuel oil, lubricating oil andtransmission oil levels.

Extended Storage (More than 30Days)

To prepare an engine for extendedstorage (more than 30 days), followthis procedure:

1. Drain the cooling system andflush with clean, soft water. Refillwith clean, soft water and adda rust inhibitor to the coolingsystem.

2. Circulate the coolant by operatingthe engine until normal operatingtemperature is reached.

3. Stop the engine.

4. With the engine at ambienttemperature and cool to the touch,drain the engine crankcase oilinto a suitable container. Removethe oil filters. Dispose of the oiland filters in an environmentallyfriendly manner, accordingto state and/or federal (EPA)recommendations. Replace thedrain plug and tighten to 45 –50 N·m (33 – 37 lb-ft) torque.

5. Install new lubricating oilfilters. Fill the crankcase tothe proper level with Tectyl®930A preservative lubricatingoil or an equivalent 30–weightpreservative lubricating oilmeeting Mil-L-21260C, Grade 2Specification.



6. Drain the fuel tank. Refill withenough clean No. 1 diesel fuelor pure kerosene to permit theengine to operate for about ten(10) minutes. If draining thefuel tank is not convenient, usea separate, portable supply ofrecommended fuel.

NOTE:If engines are stored wherecondensation of water in the fueltank may be a problem, additivescontaining methyl carbitol or butylcellusolve may be added to the fuel.Follow manufacturer's instructionsfor treatment. Where biologicalcontamination of fuel may be aproblem, add a biocide such asBiobor® JF (or equivalent) to thefuel. When using a biocide, followthe manufacturer's concentrationrecommendations and observe allcautions and warnings.

7. Drain the fuel system and removethe fuel filters. Dispose of usedfilters in an environmentallyresponsible manner, accordingto state and/or federal (EPA)recommendations. Fill the newfilters with No. 1 diesel fuel orpure kerosene and install on theengine.

8. Operate the engine for five (5)minutes to circulate the clean fuelthroughout the engine. Be surethe engine fuel system is full.

9. Stop the engine and allow tocool. Then disconnect the fuelreturn line and the inlet line atthe primary filter and securelyplug both to retain the fuel in theengine.

10. Transmission: Follow themanufacturer's recommendationsfor prolonged storage.

11. Power Take-Off: If equipped,follow manufacturer'srecommendations for prolongedstorage.

NOTICE:Failure to properly seal off theturbocharger air inlet and exhaustoutlet openings before enginestorage may permit air drafts tocirculate through the turbochargerand rotate the turbine/compressorshaft without an adequate flow oflubricating oil to the center housingbearings. This can result in severebearing damage.

12. Turbocharger: Sinceturbocharger bearings arepressure lubricated through theexternal oil line leading fromthe oil filter adaptor while theengine is operating, no furtherattention is required. However,the turbocharger air inlet andturbine exhaust outlet connection


ENGINE STORAGE

should be sealed off withmoisture-resistant tape.

13. Apply a non-friction rustpreventive compound to allexposed engine parts. Ifconvenient, apply the rustpreventive compound to theengine flywheel. If not, disengagethe clutch mechanism to preventthe clutch disc from sticking tothe flywheel.

NOTE:Do not apply oil, grease or anywax-base compound to the flywheel.The cast iron will absorb thesesubstances, which can “sweat” outduring operation and cause the clutchto slip.

14. Drain the engine cooling system.

15. Drain the preservative oil fromthe engine crankcase. Reinstalland torque the 3/4” – 14 square,magnetic drain plug to 45 –50 N·m (33 – 37 lb-ft).

16. Remove and clean the batteryand battery cables with a bakingsoda-water solution and rinsewith fresh water. Do not allowthe soda solution to enter thebattery. Add distilled water tothe electrolyte (if necessary) andfully charge the battery. Store thebattery in a cool (never below 0°C or 32° F) dry place. Keep the

battery fully charged and checkthe level and specific gravity ofthe electrolyte regularly.

17. Insert heavy paper strips betweenthe pulleys and drive belts toprevent sticking.

18. Seal all engine openings,including the exhaust outlet,with moisture-resistant tape. Usecardboard, plywood or metalcovers where practical.

19. Clean and dry the exterior paintedsurfaces of the engine and spraywith a suitable liquid automobilebody wax, a synthetic resinvarnish, or a rust preventivecompound.

20. Protect the engine with a goodweather-resistant tarpaulin andstore it under cover, preferablyin a dry building which can beheated during the winter months.

Outdoor storage of the engine is notrecommended. If units must be keptout of doors, follow the preparationand storage instructions alreadygiven. Protect units with quality,weather-resistant tarpaulins (or othersuitable covers) arranged to providefor air circulation.



NOTICE:Do not use plastic sheeting foroutdoor storage. Plastic is finefor indoor storage. When usedoutdoors, however, enough moisturecan condense on the inside of theplastic to rust ferrous metal surfacesand pit aluminum surfaces. If a unitis stored outside for any extendedperiod of time, severe corrosiondamage can result.

The stored engine should be inspectedperiodically. If there are anyindications of rust or corrosion,corrective steps must be taken toprevent damage to the engine parts.Perform a complete inspection at theend of one year and apply additionaltreatment as required.

Procedure for Restoring toService an Engine that Has Beenin Extended Storage

If an engine has been in extendedstorage, prepare it for service asfollows:

1. Remove the covers and tape fromall the openings of the engine, fueltank and electrical equipment. Donot overlook the exhaust outlet.

2. Remove the plugs from the inletand outlet fuel lines and reconnectthe lines to their proper positions.

3. Wash the exterior of the enginewith fuel oil to remove therust preventive. Do not washelectrical components.

4. Remove the rust preventive fromthe flywheel. Flush any solubleoil rust inhibitor (if used) in thecooling system.

5. Remove the paper strips frombetween the pulleys and drivebelts.

6. Fill the crankcase to the properlevel with the required grade oflubricating oil. Use a pressurelubricator to insure all bearingsand rocker shafts are lubricated.

7. Fill the fuel tank with the requiredfuel.

8. Close all drain cocks and fill theengine cooling system with clean,soft water and required inhibitors.If the engine is to be exposedto freezing temperatures, installgenuine Detroit Diesel PowerCool antifreeze or an equivalentethylene glycol-base or propyleneglycol-base antifreeze solutionwhich provides required freeze,boil over, and inhibitor protection.Refer to section How to SelectCoolant.

9. Install and connect the battery.Make sure the average specificgravity of the battery is 1.260


ENGINE STORAGE

or higher. Charge the battery, ifnecessary.

10. Service the air cleaner, if required.

11. Transmission: Follow themanufacturer's recommendationscovering the return of thetransmission to service.

12. Power Take-Off: If equipped,follow the manufacturer'srecommendations covering thereturn of the power take-off toservice.

13. Turbocharger: Remove thecovers from the turbochargerair inlet and turbine outletconnections. Reconnectpiping as required. Prelubethe turbocharger centerbearing housing. Refer toLubrication System Checks in theOPERATING INSTRUCTIONSfor a first time start section of thisguide.

PERSONAL INJURY





14. After all preparations arecompleted, start the engine.

NOTE:The small amount of rust preventivewhich remains in the fuel systemwill cause smoky exhaust for a fewminutes.

NOTE:Before subjecting the engine to a loador high speed, allow it to reach normaloperating temperature. Then check fortrouble codes.



SERIES 60 SERVICE PUBLICATIONS

The service manual covering DetroitDiesel Series 60 engines and variousreference works which may be ofinterest to the owner/operator arelisted in Table 22.

To purchase a copy of any of thesepublications, contact an authorize

Detroit Diesel distributor in the U.S.or Canada. Check the Yellow Pagesunder “Engine, Diesel” or refer to theDistributor and Dealer Directory listedbelow for the distributor or serviceoutlet nearest you.

Description Form No.Series 60 Engine Service Manual 6SE483

Series 60 DDEC V Troubleshooting Guide 6SE570

U.S. and Canada Distributor/Dealer Directory 6SE1000

Lube Oil, Fuel and Filter Requirements 7SE270

Coolant Requirements for Engine Cooling Systems 7SE298

Technician's Guide – Used Lubricating Oil Analysis 7SE398

Technician's Guide – Turbocharger 7SE374

Technician's Guide – Cooling System 7SE390

Series 60 EGR Technician's Guide 7SE60

Series 60 Driving Tips –DVD 17SE60

Series 60 Poster 31SA400

Table 22 Service Publications


CUSTOMER ASSISTANCE

CUSTOMER ASSISTANCE

The satisfaction and goodwill of theowners of Detroit Diesel engines areof primary concern to Detroit DieselCorporation and its distributor/dealerorganizations.

Figure 27



DETROIT DIESEL NORTH AMERICAN REGIONALON-HIGHWAY OFFICES

EASTERN REGION 1Suwanne, Georgia3325 Paddocks Parkway, Suite 230Suwanne, GA 30024Telephone: 678-341-6100Fax: 678-341-6150

EASTERN REGION 2Detroit, Michigan13400 Outer Drive WestDetroit, MI 48239-4001Telephone: 313-592-5420Fax:313-592-5887

WESTERN REGION 1Irvine, California7700 Irvine Center, Suite 275Irvine, CA 92618Telephone: 949-753-7710Fax: 949-753-7711

WESTERN REGION 2Irvine, California7700 Irvine Center, Suite 275Irvine, CA 92618Telephone: 949-753-7710Fax: 949-753-7711

CANADIAN REGIONLondon, OntarioDetroit Diesel of Canada, Ltd.150 Dufferin Ave., Suite 701London, ON N5A 5N6Phone: 519-661-0149Fax: 519-661-0171


CUSTOMER ASSISTANCE

DDC INTERNATIONAL REGIONAL OFFICE LOCATIONS

DETROIT DIESEL DISTRIBUTIONCENTER B. V. (On-Highway)The NetherlandsRidderpoort 92984 RidderkerkThe NetherlandsPhone: (31) 180-442-900Fax: (31) 180-419-544

AUSTRALIAN REGION(On-Highway)488 Blackshaws RoadAltona North, Victoria 3025AustraliaPhone: (61) 3 9243-9292Fax: (61) 3 9243-9262

ASIAN REGION (On-Highway)13400 Outer Drive, WestDetroit, Michigan 48239Phone: 313-592-5990Fax: 313-592-5887

MEXICO (On-Highway)Detroit Diesel Allison de Mexico, S.A.Av. Santa Rosa 58Col. Ampliacion Norte54160 TlanepantlaEdo. de MexicoMEXICOPhone: 52 55-5333-1803Fax: 52 55-5333-1875



Road Service in the U.S. orCanadaIf you require road service for anyreason in the U.S. or Canada, you maycall the 1–800–445–1980 customerassistance phone number. An operatorwill assist you in determining whattype of service is required. Not allproblems are engine related and notall problems are covered by engineor vehicle warranties. YOU MAYBE RESPONSIBLE FOR REPAIREXPENSES.

Before calling Customer Assistance,please do the following:

□ Check coolant level

□ Check fuel level

□ Check DDEC fuses

□ Check for fuel leaks

□ Make sure manual shutoff valve (ifinstalled) on the fuel filter adaptor,fuel processor body or fuel supplyline is open.

□ Check the oil level on the dipstick.

□ Check diagnostic codes.

If you call, have the followinginformation available:

□ Engine serial number

□ Truck, bus or equipment make andmodel

□ Odometer mileage (kilometers) orhourmeter hours

□ Truck, bus or equipmentowner/company name

Working with DDC ServiceOutletsAs the owner of a Detroit Dieselproduct you have a complete networkof over 1,000 Detroit Diesel serviceoutlets in the U.S. and Canada, plusmany outlets worldwide that areprepared to meet your parts andservice needs:

□ Service by trained personnel.

□ Sales team to help determine yourspecific power requirements.

□ In many areas, emergency service24 hours a day.

□ Complete parts support, includingreliabilt® remanufacturedcomponents.

□ Product information and literature.

Despite the best intentions of everyoneconcerned, misunderstandings mayoccur. Normally, any situation thatarises in connection with the sale,operation or service of your productwill be handled by the authorizedservice outlet in your area.

In the U.S. and Canada, check theYellow Pages or service locator atwww.detroitdiesel.com for the DetroitDiesel service outlet nearest you.


CUSTOMER ASSISTANCE

To further assure your completesatisfaction, we have developed thefollowing procedure to use if you havea problem that has not been handledsatisfactorily.

Step One

Discuss your problem with a memberof management from the authorizedservice outlet. Frequently, complaintsare the result of a breakdown incommunication and can quickly beresolved by a member of management.

If you have already discussed theproblem with the Sales or ServiceManager, contact the GeneralManager. If your complaint originateswith a dealer, explain the matterto a management member of thedistributorship with whom the dealerhas a service agreement.

Step Two

When it appears that your problemcannot be readily resolved at thedistributor level without additionalassistance, contact the Detroit DieselRegional Product Support Manageror Operations Manager responsiblefor your local distributor. You will beassisted by a member of the manager'sstaff, depending upon the nature ofyour problem.

Prior to this contact, have thefollowing information available:

□ Engine model* 606_ _ _ _ _ .

□ Engine serial number* 06R0_ _ __ _ _ .

□ Type and make of equipment.

□ Engine delivery date andaccumulated miles or hoursof operation.

□ Nature of problem.

□ Chronological summary ofengine's history.

□ Name and location of authorizedservice outlet.

*Important: Your engine modelnumber and serial number should bewritten on the lines provided. Theywill identify your engine and allservice parts, plus provide warrantyand extended coverage information.

Step Three

If you are still not satisfied, present theentire matter in writing or by phone to:

Sr. Vice President, CustomerAssurance, Parts, Service andCustomer SupportDetroit Diesel Corporation13400 Outer Drive, WestDetroit, MI 48239–4001Phone: 313–592–5000FAX: 313–592–7244



Ultimately your problem will likelybe resolved at the distributorship ordealership, utilizing their facilities,equipment, and personnel. Therefore,it is suggested that you followthe above steps in sequence whenexperiencing a problem.


LIMITED WARRANTY ON SERIES 60 DDEC V EGR ENGINES USED INON-HIGHWAY VEHICLE APPLICATIONS

LIMITED WARRANTY ON SERIES 60 DDEC VEGR ENGINES USED IN ON-HIGHWAY VEHICLEAPPLICATIONS

TERMS OF COVERAGE

Uses

This warranty applies to the first retailpurchaser and subsequent ownersduring the WARRANTY PERIODof new Detroit Diesel Series 60®DDEC V EGR Engines (referred toas Engine) manufactured by DetroitDiesel Corporation and/or suppliedby Detroit Diesel Corporation,Detroit Diesel of Canada Limited, orDetroit Diesel Overseas DistributionCorporation (all which are collectivelyreferred to as DDC) which are used inon-highway vehicle applications soldat retail on and after January 1, 2004.

Defects

This warranty covers EngineREPAIRS to correct any malfunctionoccurring during the WARRANTYPERIOD resulting from defects inmaterial and workmanship.

Repairs

To obtain warranty repairs, you mustrequest the needed repairs withinthe WARRANTY PERIOD from anauthorized DDC service outlet. Onlynew genuine parts or remanufactured

parts or components supplied orapproved by DDC will be used. DDCmay, at its discretion, replace ratherthan repair components. A reasonabletime must be allowed to performthe warranty repair after taking theengine to the authorized service outlet.The owner is responsible for thepercentage of repair costs shown inthe warranty period chart. Repairs willbe performed during normal businesshours.

Warranty Period

The WARRANTY PERIOD beginson the date the engine is deliveredto the first retail purchaser or put inuse prior to sale at retail, whicheverdate comes first, and ends at the timeor mileage/kilometer limits in theWARRANTY PERIOD chart (Table23).

Like Replacement Engine

Engine(s) supplied by DDC as areplacement for an engine still underwarranty will assume the identity ofthe Engine being replaced and beentitled to the remaining warrantycoverage.



Warranty PeriodWarranty Limitations

(Whichever Occurs First)Repair Charges to Be

Paid by OwnerItem

Months Miles /Kilometers Parts Labor

Engine # 0–24 Unlimited No Charge No Charge

Accessories 0–24 0–100,000 Miles0–160,000 Km

No ChargeNo Charge

No ChargeNo Charge

Upon expiration of the 24 month warranty coverage, but within 500,000miles/800,000 km of use, the warranty continues to apply as follows:

MajorComponents † 25–60 0 – 500,000 Miles

0–800,000 Km No Charge100% of ServiceOutlet's Normal

Charge# Includes Jacobs Vehicle Systems braking devices and 50DN or T1

alternators, if installed.† Cylinder Block/Head, Crankshaft, Camshaft, Main Bearing Bolts,

Flywheel Housing, Connecting Rod Assemblies, Oil Cooler Housing,Water Pump Housing and Air Inlet Housing.

Table 23 Warranty Period Chart – On-Highway Vehicle Applications

Service Supplies

The cost of service supplies suchas coolant, oil and filters which arenot reusable due to needed warrantyrepairs is covered by this warranty.

Engine Removal andReinstallation

Reasonable labor costs for Engineremoval and reinstallation, whennecessary to make a warranty repair,are covered by this warranty.

THIS WARRANTY DOESNOT COVER:

Repairs Due to Accidents,Misuse, Storage Damage,Negligence or CertainModifications

Repairs due to an accident, misuse,misapplication, storage damage,negligence or modification exceedingDDC specifications are not covered bythis warranty.


LIMITED WARRANTY ON SERIES 60 DDEC V EGR ENGINES USED INON-HIGHWAY VEHICLE APPLICATIONS

Braking Devices

DDC is not responsible for therepair of non-Jacobs Vehicle Systemsmechanical braking devices installedon the Engine. Such devices arewarranted by the brake manufacturer.

Fuel Injectors after 200,000Miles/320,000 Kilometers

The repair or replacement of fuelinjectors after 200,000 miles/320,000kilometers of operation is not coveredby this warranty.

Maintenance

DDC is not responsible for thecost of maintenance or repairsdue to the lack of performanceof required maintenance servicesas recommended by DDC, or thefailure to use fuel, oil, lubricants andcoolant meeting DDC-recommendedspecifications. Performance of therequired maintenance and use ofproper fuel, oil, lubricants and coolantare the responsibility of the owner.Refer to the MAINTENANCE sectionin this guide for details.

Incidental or ConsequentialDamage

Detroit Diesel Corporation isnot responsible for incidental orconsequential costs or expenseswhich the owner may incur as a

result of a malfunction or failurecovered by this warranty, such ascommunication expenses, meals,lodging, overtime, loss of use of theengine or vehicle (“downtime”), lossof time, inconveniences, cargo loss ordamage, and other similar costs andexpenses.

Other Limitations

The performance of REPAIRS is theexclusive Owner's remedy under thiswarranty. DDC does not authorizeany person to assume or create forit any other obligation or liabilityin connection with the engine oraccessories.

THIS LIMITED WARRANTYAND THE EMISSIONS CONTROLWARRANTY ARE THE ONLYWARRANTIES APPLICABLETO THE ENGINE ANDACCESSORIES AS USEDIN ON-HIGHWAY VEHICLEAPPLICATIONS. DETROIT DIESELCORPORATION MAKES NOOTHER WARRANTIES EXPRESSOR IMPLIED, INCLUDINGANY IMPLIED WARRANTYOF MERCHANTABILITY ORFITNESS FOR A PARTICULARPURPOSE. DETROIT DIESELCORPORATION SHALL NOT BELIABLE FOR ANY INCIDENTALOR CONSEQUENTIAL DAMAGESAS DESCRIBED ABOVE.



Some states do not allow the limitationof how long this warranty may lastor the limitation or exclusion ofincidental or consequential damages,so the above may not apply to you.This warranty gives you specific legalrights, and you may also have otherrights which may vary from state tostate.


LIMITED WARRANTY ON ENGINES POWERING URBAN BUS, MOTORCOACH OR MOTOR HOME APPLICATIONS

LIMITED WARRANTY ON ENGINES POWERING URBANBUS, MOTOR COACH OR MOTOR HOME APPLICATIONS

TERMS OF COVERAGE

Uses

This warranty applies to the first retailpurchaser and subsequent ownersduring the WARRANTY PERIODof new Detroit Diesel Series 60®DDEC V EGR Engines (referred toas Engine) manufactured by DetroitDiesel Corporation and/or suppliedby Detroit Diesel Corporation,Detroit Diesel of Canada Limited, orDetroit Diesel Overseas DistributionCorporation (all which are collectivelyreferred to as DDC) powering urbanbus, motor coach or motor homeapplications sold at retail on and afterJanuary 1, 2004.

Defects


Repairs

To obtain warranty repairs, you mustrequest the needed repairs withinthe WARRANTY PERIOD from anauthorized DDC service outlet. Onlynew genuine parts or remanufactured

parts or components supplied orapproved by DDC will be used. DDCmay, at its discretion, replace ratherthan repair components. A reasonabletime must be allowed to performthe warranty repair after taking theengine to the authorized service outlet.The owner is responsible for thepercentage of repair costs shown in theWarranty Period Chart. Repairs willbe performed during normal businesshours.

Warranty Period


Service Supplies




Warranty Period

Item Warranty Limitations(Whichever Occurs First)

Repair Charge to BePaid By Owner

Months Miles /Kilometers Parts Labor

Engine # 0 – 24 Unlimited No Charge No Charge

Accessories 0–24 0–100,000 Miles0–160,000 Km

No ChargeNo Charge

No ChargeNo Charge

Upon expiration of the 24 month warranty coverage, butwithin 500,000 miles/800,000 km of use, the warranty

continues to apply as follows:

MajorComponents † 25 – 60 0 – 500,000 Miles

0 – 800,000 Km No Charge100% of

service outlet'snormal charge

# Includes Jacobs Vehicle Systems braking devices, 50DN or T1alternators, if so equipped.

† Cylinder Block/Head, Crankshaft, Camshaft, Main Bearing Bolts,Flywheel Housing, Connecting Rod Assemblies, Oil Cooler Housing,Water Pump Housing and Air Inlet Housing.

Table 24 Warranty Period Chart – Urban Bus, Motor Coach andMotor Home Applications






Repairs Due to Accidents,Misuse, Alteration, StorageDamage, Negligence or CertainModifications

Repairs due to an accident, misuse,alteration, misapplication, storagedamage, negligence or modificationexceeding DDC specifications are notcovered by this warranty.


LIMITED WARRANTY ON ENGINES POWERING URBAN BUS, MOTORCOACH OR MOTOR HOME APPLICATIONS

Braking Devices

DDC is not responsible for therepair of non-Jacobs Vehicle Systemsmechanical braking devices installedon the Engine. Such devices arewarranted by the brake manufacturer.

Fuel Injectors after 200,000Miles/320,000 Kilometers

The repair or replacement of fuelinjectors after 200,000 miles/320,000kilometers of operation is not coveredby this warranty.

Maintenance

DDC is not responsible for the costof maintenance or repairs due tothe lack of performance of requiredmaintenance services or the failureto use fuel, oil, lubricants andcoolant meeting DDC-recommendedspecifications. Performance of therequired maintenance and use ofproper fuel, oil, lubricants and coolantare the responsibility of the owner.Refer to the MAINTENANCE sectionin this guide for details.


Detroit Diesel Corporation isnot responsible for incidental orconsequential costs or expenseswhich the owner may incur as aresult of a malfunction or failure

covered by this warranty, such ascommunication expenses, meals,lodging, overtime, loss of use of theengine or vehicle (“downtime”), lossof time, inconvenience, cargo loss ordamage, and other similar costs andexpenses.

Other Limitations

The performance of REPAIRS is theexclusive Owner's remedy under thiswarranty. DDC does not authorizeany person to assume or create forit any other obligation or liability inconnection with the Engine.

THIS LIMITED WARRANTYAND THE EMISSIONS CONTROLWARRANTY ARE THE ONLYWARRANTIES APPLICABLE TOTHESE ENGINES POWERINGURBAN BUS, MOTORCOACH OR MOTOR HOMEAPPLICATIONS. DETROIT DIESELCORPORATION MAKES NOOTHER WARRANTIES EXPRESSOR IMPLIED, INCLUDINGANY IMPLIED WARRANTYOF MERCHANTABILITY ORFITNESS FOR A PARTICULARPURPOSE. DETROIT DIESELCORPORATION SHALL NOT BELIABLE FOR ANY INCIDENTALOR CONSEQUENTIAL DAMAGESAS DESCRIBED ABOVE.





LIMITED WARRANTY ON ENGINES USED IN FIRE TRUCK OR CRASHRESCUE VEHICLE APPLICATIONS

LIMITED WARRANTY ON ENGINES USED IN FIRE TRUCKOR CRASH RESCUE VEHICLE APPLICATIONS

TERMS OF COVERAGE

Uses

This warranty applies to the first retailpurchaser and subsequent ownersduring the WARRANTY PERIOD ofnewDetroit Diesel Series 60® Engines(referred to as Engine) manufacturedby Detroit Diesel Corporationand/or supplied by Detroit DieselCorporation, Detroit Diesel of CanadaLimited, or Detroit Diesel OverseasDistribution Corporation (all whichare collectively referred to as DDC)for use in fire truck or crash rescuevehicle applications sold at retail onand after January 1, 2004.

Defects


Repairs

To obtain warranty repairs, you mustrequest the needed repairs withinthe WARRANTY PERIOD from anauthorized DDC service outlet. Onlynew genuine parts or remanufacturedparts or components supplied or

approved by DDC will be used. DDCmay, at its discretion, replace ratherthan repair components. A reasonabletime must be allowed to performthe warranty repair after taking theengine to the authorized service outlet.Repairs will be performed duringnormal business hours.

Warranty Period




Service Supplies




Warranty PeriodWarranty Limitations

(Whichever Occurs First)Repair Charges to Be

Paid by OwnerItemMonths Miles / Kilometers Parts Labor

Engine 0 – 60 0 – 100,000 Miles0 – 160,000 Km No Charge No Charge

Accessories* 0 – 24 0 – 100,000 Miles0 – 160,000 Km No Charge No Charge

* Electronic Fire Commander warranty is two year/unlimited mileage

Table 25 Warranty Period Chart – Fire Truck or Crash RescueVehicle Applications




Repairs Due to Accidents,Misuse, Alteration, StorageDamage, Negligence or CertainModifications

Repairs due to an accident, misuse,alteration, misapplication, storagedamage, negligence or modificationexceeding DDC specifications are notcovered by this warranty.

Maintenance

DDC is not responsible for thecost of maintenance or repairsdue to the lack of performanceof required maintenance servicesas recommended by DDC, or thefailure to use fuel, oil, lubricants andcoolant meeting DDC-recommendedspecifications. Performance of therequired maintenance and use ofproper fuel, oil, lubricants and coolantare the responsibility of the owner.Refer to the MAINTENANCE sectionin this guide for details.


LIMITED WARRANTY ON ENGINES USED IN FIRE TRUCK OR CRASHRESCUE VEHICLE APPLICATIONS


Detroit Diesel Corporation isnot responsible for incidental orconsequential costs or expenseswhich the owner may incur as aresult of a malfunction or failurecovered by this warranty, such ascommunication expenses, meals,lodging, overtime, loss of use of theengine or vehicle (“downtime”), lossof time, inconvenience, cargo loss ordamage, and other similar costs andexpenses.

Other Limitations

The performance of REPAIRS is theexclusive Owner's remedy under thiswarranty. DDC does not authorizeany person to assume or create forit any other obligation or liability inconnection with the Engine or theAccessories.

THIS LIMITED WARRANTYAND THE EMISSIONSCONTROL WARRANTY ARETHE ONLY WARRANTIESAPPLICABLE TO THE ENGINEAS USED IN FIRE TRUCKOR CRASH RESCUE VEHICLEAPPLICATIONS. DETROIT DIESELCORPORATION MAKES NOOTHER WARRANTIES EXPRESSOR IMPLIED, INCLUDINGANY IMPLIED WARRANTYOF MERCHANTABILITY OR

FITNESS FOR A PARTICULARPURPOSE. DETROIT DIESELCORPORATION SHALL NOT BELIABLE FOR ANY INCIDENTALOR CONSEQUENTIAL DAMAGESAS DESCRIBED ABOVE.




SPECIFICATIONS

This section lists the fuel andlubrication oil filters needed for theSeries 60 engine. Also listed asthe various POWER COOL engineproducts.

Fuel and Lubricating OilFiltersThe fuel filters and their part numbersare listed in Table 26. The lubricatingoil filters and their part numbers arelisted in Table 27.

Filter Type Detroit Diesel Part NumberPrimary — Spin-On 23530706

Primary Fuel/Water Separator — Spin-On† 23512317†

Secondary — Spin-On 23530707 or 23533726‡

Primary — Fuel Pro 380/382 Element 23521528 or 23529168*

* Elemax™ extended service element (optional).† Optional. May be used in place of, but not together with, the primary

filter.‡ Used on engines equipped with DDEC V.

Table 26 Fuel Filters – Series 60 Regular Service

Filter Type Detroit Diesel Part NumberFull Flow 23530573

Full Flow (High Capacity) DELF3998

Table 27 Lubricating Oil Filters

OIL PAN CAPACITY

All Series 60 truck oil pans (frontsump and rear sump) require the sameamount of engine oil

Oil Pan Capacity — 26 quarts tothe LOW mark without oil filters

32 quarts to the FULL mark withoutoil filters

Total Oil Capacity Of TheEngine — 40 quarts to the FULLmark with oil filters installed andfilters and oil galleries charged.


SPECIFICATIONS

POWER COOL ENGINEPRODUCTSMaintenance of the cooling systemrequires the chemical make-up of thesystem to be balanced.

POWER COOL Fully FormulatedIEG Coolant

The part numbers and sizes ofconcentrated POWER COOL andpre-blended 50:50 POWER COOL arelisted in Table 28.

Coolant Type Part Number Description23512138 1 Gallon Jug – 6 Per Case

23512139 55 Gallon Drum

23529295 330 Gallon ToteConcentrated

23512140 Bulk Delivery – 1,000 Gallon Min.

23528203 1 Gallon Jug – 6 Per Case


23528544 330 Gallon TotePre-Blended

50:50


Table 28 POWER COOL Fully Formulated IEG Coolant

POWER COOL Latin AmericanCoolant

Coolant Type Part Number Description

23524737 1 Gallon Jug – 6 Per Case

23524923 55 Gallon DrumPre-Blended 67:33

23524924 Bulk Delivery – 1,000 Gallon Minimum

Table 29 POWER COOL Latin American Coolant



POWER COOL 2000 and 3000Supplemental Coolant Additive

Coolant Type Part Number Description23507858 Pint Bottle – 12 Per case

23507859 Half Gallon Jug – 6 Per Case

23507860 5 Gallon PailFor Power Cool IEG

Coolant


Table 30 POWER COOL 2000 Supplemental Coolant Additive

Coolant Type Part Number Description23507854 Pint Bottle – 12 Per Case

23507855 Half Gallon Jug – 6 Per Case

23507856 5 Gallon PailFor POWER COOL

IEG Coolant


Table 31 POWER COOL 3000 Supplemental Coolant Additive

POWER COOL 3000Supplemental Additive CoolantFilters

Coolant Type Part Number Description23507545 4 Ounce (1 Pint Equivalent)

23508425 8 Ounce (2 Pint Equivalent)




For POWER COOLIEG Coolant


Table 32 POWER COOL 3000 Supplemental Additive Coolant Filters


SPECIFICATIONS

POWER COOL SupplementalAdditive Need Release CoolantFilters

Coolant Type Part Number Description23516488 For 0 – 8 Gallon SystemsFor POWER COOL

IEG Coolant 23516489 For 8 – 20 Gallon Systems

Table 33 POWER COOL Supplemental Additive Need ReleaseCoolant Filters

POWER COOL Plus ExtendedLife OAT Coolant


23519394 55 Gallon DrumConcentrated


23519396 One Gallon Jug – 6 Per Case

23519398 55 Gallon DrumPre-Blended 50:50


Table 34 POWER COOL Plus Extended Life OAT Coolant

POWER COOL Plus ExtenderFor Use With POWER COOLPlus OAT Coolant

Coolant Type Part Number Description

For Power Cool Plus 23519400 Quart Bottle – 6 Per Case

Table 35 POWER COOL Plus Extender for Use with POWER COOLPlus OAT Coolant



POWER COOL Plus 6000OAT Inhibitor For Water-OnlySystems


Water Only23522128 5 Gallon Pail

Table 36 POWER COOL Plus 6000 OAT Inhibitor for Water-OnlySystems

POWER COOL Cooling SystemCleaners

Coolant Type Part Number Description200164 On-Half Gallon Jug – 6 Per Case

200105 5 Gallon PailOn-Line Cleaner


Twin Pack 201549 Twin Pack – 2 Per Case

Table 37 POWER COOL Cooling System Cleaners


SPECIFICATIONS

POWER TRAC Coolant TestingAnd Analysis Products

Application PartNumber Description

Indicates Nitrite,Molybdate & Glycol

Levels23519401 3-Way Coolant Test Strips

(Single Foil Packs)



(Bottle of 50)



(Bottle of 10)

Complete IEG/IPGCoolant Analysis 23516921 Coolant Analysis Bottle

(Carton of 6)Organic Coolant

Analysis 23523398 Laboratory Coolant Analysis Bottle(Carton of 6)

Table 38 Power Trac Coolant Testing and Analysis Products


Detroit Series 60 Operation Manual

Documents

Detroit Series 60 Operation Manual