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EPA07 SERIES 60 ENGINE OPERATOR'S MANUAL
To the Operator
This guide contains instructions on
the safe operation and preventive
maintenance of your Detroit Diesel
Series 60® engine used in vehicle, or
fire fighting apparatus applications.
Maintenance instructions cover
routine engine services such as lube
oil and filter changes in enough detail
to permit self-servicing, if desired.
The operator should become familiar
with the contents of this guide before
operating the engine or carrying out
maintenance procedures.
Power-driven equipment is only
as safe as the person operating the
controls. You are urged, as the
operator of this diesel engine, to keep
fingers and clothing away from the
revolving belts, drive shafts, pulleys,
etc. on the engine installation.
Throughout this guide CAUTIONS
regarding personal safety and
NOTICES regarding engine
performance or service life will
appear. To avoid personal injury and
ensure long engine service life, always
heed these instructions.
Whenever possible, it will benefit
you to rely on an authorized Detroit
Diesel service outlet for all your
service needs from maintenance to
major parts replacement. Authorized
service outlets worldwide stock
factory-original parts and have
the specialized equipment and
experienced, trained personnel
to provide prompt preventive
maintenance and skilled engine
repairs.
The information and specifications
in this publication are based on the
information in effect at the time of
approval for printing. Contact an
authorized Detroit Diesel service
outlet for information on the latest
revision. The right is reserved to
make changes at any time without
obligation.
The Series 60 engine is built in
accordance with sound technological
principles and based on state-of-the-art
technology.
Despite this, the engine may constitute
a risk of damage to property or injury
to persons if it is not used for its
intended purpose.
The engine should not be modified or
converted in an incorrect manner or
the safety instructions included in this
manual disregarded.
All information subject to change without notice.
DDC-SVC-MAN-0006
Copyright © 2009 DETROIT DIESEL CORPORATION
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Trademark Information
NOTICE:
Coolant must be inhibited with the
recommended SCAs (supplemental
coolant additives) listed in the
How To section of this engine
operator's guide. In addition, the
engine can be equipped with a
coolant filter/inhibitor system as an
installed option or as an after-sale
item. Failure to check and
maintain SCA levels at required
concentrations will result in
severe damage (corrosion) to
the engine cooling system and
related components.
WARRANTY
The applicable engine warranty is
contained in the booklet “Warranty
Information for Series 60 Engines,”
available from authorized Detroit
Diesel service outlets.
DDC®, Detroit Diesel®, DDEC®,
Series 60®, Optimized Idle®,
Diagnostic Link®, reliabilt®,
POWER Trac®, POWER COOL®,
and POWER GUARD® are registered
trademarks of Detroit Diesel
Corporation. Delco Remy® is a
registered trademark of Delco Remy
America, Inc. Bosch® is a registered
trademark of Robert Bosch Company
N.A. Fuel Pro®, and Mega Filter®
are registered trademarks of Davco
Manufacturing, L.L.C. Nexiq™ is
a trademark of Nexiq Technologies,
Inc. PowerBand® is a registered
trademark of Gates Rubber Company.
Tectyl® is a registered trademark of
Daubert Chemical Company, Inc.
Biobor® is a registered trademark of
United States Borax and Chemical
Corporation. DuPont® is a registered
trademark of E.I. DuPont de Nemours
and Company, Inc. All other
trademarks used are the property of
their respective owners.
Keep this Operator's Guide
with the engine installation at
all times. It contains important
operating, maintenance, and safety
instructions.
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All information subject to change without notice.
Copyright © 2009 DETROIT DIESEL CORPORATION
EPA07 SERIES 60 ENGINE OPERATOR'S MANUAL
TABLE OF CONTENTS
INTRODUCTION ..................................................................................
NON-GENUINE AND REBUILT COMPONENT QUALITY ALERT ..
PERSONNEL REQUIREMENTS .....................................................
ENGINE CONVERSIONS AND MODIFICATIONS ..........................
1
1
2
2
CAUTION SUMMARY ..........................................................................
ENGINE OPERATION .....................................................................
PREVENTIVE MAINTENANCE .......................................................
ELECTRICAL SYSTEM ...................................................................
COOLING SYSTEM .........................................................................
AIR INTAKE SYSTEM ......................................................................
FUEL SYSTEM ................................................................................
COMPRESSED AIR .........................................................................
STARTING AIDS ..............................................................................
LUBRICATING OIL AND FILTERS ..................................................
AFTERTREATMENT SYSTEM ........................................................
3
3
5
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9
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10
11
12
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ENGINE IDENTIFICATION ..................................................................
ENGINE COMPONENTS .................................................................
ENGINE MODEL AND SERIAL NUMBER DESIGINATON .............
CERTIFICATION LABEL ..................................................................
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14
16
17
OPERATING INSTRUCTIONS FOR STARTING THE ENGINE ..........
FIRST TIME START PREPARATION ..............................................
SYSTEM CHECKS ..........................................................................
COOLING SYSTEM CHECKS ....................................................
LUBRICATION SYSTEM CHECKS .............................................
CHECKING THE OIL LEVEL ..................................................
EXTENDED STORAGE ..........................................................
FUEL SYSTEM CHECKS ............................................................
ADDING FUEL ........................................................................
PRIMING THE FUEL SYSTEM ...............................................
OTHER CHECKS ........................................................................
STARTING THE ENGINE FOR THE FIRST TIME ......................
ELECTRIC STARTER .............................................................
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TABLE OF CONTENTS
RUNNING THE ENGINE .................................................................
OIL PRESSURE ..........................................................................
WARM-UP ...................................................................................
INSPECTION ...............................................................................
TRANSMISSION .....................................................................
FLUID LEAKS .........................................................................
CRANKCASE ..........................................................................
TURBOCHARGER ..................................................................
AVOID UNNECESSARY IDLING .................................................
STOPPING THE ENGINE ................................................................
EMERGENCY JUMP STARTING ....................................................
ROUTINE ENGINE START ..............................................................
STARTING THE ENGINE-ROUTINE ...........................................
CHECKING THE COOLANT LEVEL (COLD CHECK) ................
CHECKING THE COOLANT LEVEL (HOT CHECK) ..................
MONITORING ENGINE OPERATION .............................................
BATTERY CHARGE ....................................................................
OIL PRESSURE ..........................................................................
EXCESSIVE IDLING ...................................................................
CHANGING THE IDLE SPEED .......................................................
SHUTTING DOWN THE ENGINE ...................................................
SHUTTING DOWN AFTER HIGH LOAD OPERATION ...............
EMERGENCY RUNNING MODE ....................................................
STOP ENGINE OVERRIDE OPTION ..............................................
COLD WEATHER OPERATION ......................................................
WINTER FRONTS .......................................................................
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DDEC VI SYSTEM ...............................................................................
MOTOR CONTROL MODULE .........................................................
COMMON POWERTRAIN CONTROLLER .....................................
DDEC FEATURES ...........................................................................
CRUISE CONTROL .....................................................................
DATA RECORDING CAPABILITY ...............................................
ENGINE BRAKES .......................................................................
ENGINE PROTECTION ..............................................................
CALIFORNIA ENGINE IDLE LIMITING .......................................
IDLE SHUTDOWN TIMER ..........................................................
DDEC VI OPERATION .....................................................................
STOP ENGINE OVERRIDE SWITCH .........................................
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All information subject to change without notice.
Copyright © 2009 DETROIT DIESEL CORPORATION
EPA07 SERIES 60 ENGINE OPERATOR'S MANUAL
IMMEDIATE SPEED REDUCTION .............................................
RED STOP LAMP ........................................................................
DIAGNOSTIC TOOL ....................................................................
FLASHING MALFUNCTION CODES ......................................
ACTIVE CODES ......................................................................
INACTIVE CODES ..................................................................
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DDEC VI ENGINE DRIVING TIPS .......................................................
ACCELERATING THE VEHICLE .....................................................
CRUISE CONTROL .........................................................................
ENGINE BRAKES AND CRUISE CONTROL ..................................
SHIFTING ........................................................................................
IDLING .............................................................................................
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ENGINE BRAKE SYSTEM ..................................................................
DRIVER CONTROL SWITCHES .....................................................
LOW/HIGH SWITCH ...................................................................
LOW/MED/HIGH SWITCH ..........................................................
CLUTCH PEDAL AND THROTTLE POSITION CONTROLS ..........
ENGINE BRAKE OPERATION ........................................................
ANTI-LOCK BRAKING SYSTEMS ...................................................
DRIVING ON FLAT, DRY PAVEMENT .............................................
DESCENDING A LONG, STEEP GRADE .......................................
DRIVING ON WET OR SLIPPERY PAVEMENT ..............................
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ENGINE SYSTEMS .............................................................................
FUEL SYSTEM ................................................................................
LUBRICATION SYSTEM .................................................................
AIR SYSTEM ...................................................................................
COOLING SYSTEM .........................................................................
ELECTRICAL SYSTEM ...................................................................
EXHAUST SYSTEM ........................................................................
EXHAUST GAS RECIRCULATION SYSTEM ..................................
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53
53
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53
53
AFTERTREATMENT SYSTEM ............................................................
OPERATING REQUIREMENTS ......................................................
MAINTENANCE ...............................................................................
PARKED REGENERATION PROCEDURE .....................................
HAZARDOUS APPLICATIONS ...................................................
DPF STATIONARY REGEN ONLY = 0-DISABLED ................
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All information subject to change without notice.
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TABLE OF CONTENTS
DPF STATIONARY REGEN ONLY = 1-ENABLED ................. 58
SERVICE RECORD ......................................................................... 58
DRIVER ACTIONS ............................................................................... 59
INSTRUMENT PANEL LAMPS ........................................................... 61
MAINTENANCE ...................................................................................
SCHEDULED INTERVALS ..............................................................
PREVENTIVE MAINTENANCE INTERVALS ..................................
ITEM 1 – LUBRICATING OIL ......................................................
ITEM 2 – FUEL AND FUEL TANK ...............................................
ITEM 3 – FUEL LINES, FLEXIBLE HOSES ................................
LEAKS .....................................................................................
HOSES AND FITTINGS ..........................................................
HOSE SERVICE LIFE .............................................................
ITEM 4 – COOLING SYSTEM .....................................................
COOLANT LEVEL ...................................................................
COOLANT INHIBITORS ..........................................................
COOLANT DRAIN INTERVAL .................................................
ITEM 5 – TURBOCHARGER, AIR-TO-AIR CHARGE COOLER .
WASTEGATED TURBOCHARGERS ......................................
ITEM 6 – BATTERY .....................................................................
ITEM 7 – AFTERTREATMENT SYSTEM ....................................
ITEM 8 – DRIVE BELTS ..............................................................
V-BELTS ..................................................................................
2-GROOVE POWERBAND .....................................................
12–RIB POLY-V BELT .............................................................
BELT REPLACEMENT ............................................................
ITEM 9 – AIR COMPRESSOR ....................................................
ITEM 10 – AIR CLEANER ...........................................................
AIR CLEANER REPLACEMENT .............................................
ITEM 11 – LUBRICATING OIL FILTERS .....................................
ITEM 12 – FUEL FILTERS ..........................................................
FUEL PRO® 382 FILTERS .....................................................
SPIN-ON FILTERS ..................................................................
ITEM 13 – WATER PUMP AND COOLANT INHIBITOR
ELEMENT ....................................................................................
WATER PUMP DRAIN HOLE .................................................
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All information subject to change without notice.
Copyright © 2009 DETROIT DIESEL CORPORATION
EPA07 SERIES 60 ENGINE OPERATOR'S MANUAL
COOLANT INHIBITOR ELEMENT ..........................................
ITEM 14 – CRANKING MOTOR ..................................................
ITEM 15 – AIR SYSTEM .............................................................
ITEM 16 – EXHAUST SYSTEM ..................................................
ITEM 17 – ENGINE (STEAM CLEAN) .........................................
ITEM 18 – RADIATOR .................................................................
ITEM 19 – OIL PRESSURE .........................................................
ITEM 20 – BATTERY-CHARGING ALTERNATOR ......................
BOSCH® T1 ALTERNATOR SERVICE REQUIREMENTS .....
GENERAL SERVICE REQUIREMENTS – BOSCH® AND
DELCO REMY® ALTERNATORS ...........................................
ITEM 21 – ENGINE AND TRANSMISSION MOUNTS ................
ITEM 22 – CRANKCASE PRESSURE ........................................
ITEM 23 – FAN HUB ....................................................................
ITEM 24 – THERMOSTATS AND SEALS ...................................
ITEM 25 – CRANKCASE BREATHER ........................................
ITEM 26 – ENGINE TUNE-UP ....................................................
ITEM 27 – VIBRATION DAMPER ................................................
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HOW-TO SECTION ..............................................................................
HOW TO SELECT LUBRICATING OIL ............................................
LUBRICANT REQUIREMENTS ..................................................
COLD WEATHER STARTING .....................................................
SYNTHETIC OILS .......................................................................
THE USE OF SUPPLEMENTAL ADDITIVES ..............................
WHEN TO CHANGE OIL .................................................................
DISPOSING OF WASTE OIL ......................................................
HOW TO REPLACE THE LUBE OIL FILTERS ................................
REPLACE SPIN-ON TYPE OIL FILTER ......................................
HOW TO SELECT DIESEL FUEL ...................................................
QUALITY .....................................................................................
FUEL CONTAMINATION .............................................................
BIODIESEL .............................................................................
PROHIBITED ADDITIVES ...........................................................
USED LUBRICATING OIL .......................................................
FUEL ADDITIVES WITH SULFUR OR SULFATED ASH ........
GASOLINE ..............................................................................
HOW TO REPLACE THE FUEL FILTERS .......................................
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TABLE OF CONTENTS
REPLACE SPIN-ON TYPE PRIMARY OR SECONDARY FUEL
FILTER ELEMENTS ....................................................................
REPLACE FUEL/WATER SEPARATOR ELEMENT ....................
REPLACE FUEL PRO® 382/382E FUEL FILTER ELEMENT .....
ENGINE OUT OF FUEL — HOW TO RESTART .............................
ENGINES WITH SPIN-ON FILTERS ...........................................
ENGINES WITH FUEL PRO FILTERS ........................................
HOW TO CLEAN THE ENGINE ......................................................
HIGH-PRESSURE CLEANING EQUIPMENT .............................
HOW TO CLEAN THE COOLING SYSTEM ....................................
DEGREASING .............................................................................
HOW TO SELECT COOLANT .........................................................
DEFINITIONS ..............................................................................
APPROVED COOLANTS ............................................................
EG & WATER PLUS SCA INHIBITOR OR P G & WATER
PLUS SCA INHIBITOR ............................................................
MIXING EG OR PG ANTIFREEZE AND WATER ...................
RECYCLED ANTIFREEZE ....................................................
EG/WATER + OAT INHIBITOR OR PG/WATER + OAT
INHIBITOR ..............................................................................
WATER ONLY + SCA OR WATER ONLY + OAT INHIBITOR
WATER REQUIREMENTS .....................................................
COOLANTS NOT RECOMMENDED ..........................................
ALL ANTIFREEZES AND COOLANTS CONTAINING
PHOSPHATE ...........................................................................
AUTOMOTIVE TYPE COOLANTS ..........................................
METHYL ALCOHOL-BASED ANTIFREEZE ...........................
GLYCOL-BASED COOLANTS FORMULATED FOR HVAC ...
ADDITIVES NOT RECOMMENDED ...........................................
SOLUBLE OIL ADDITIVES .....................................................
CHROMATE ADDITIVES ........................................................
COOLANT INHIBITOR TEST INTERVALS .................................
SUPPLEMENTAL COOLANT ADDITIVES FOR FULLY
FORMULATED COOLANT .....................................................
MAINTENANCE INTERVALS ..................................................
SCA TEST PROCEDURES .........................................................
COOLANT FILTERS (NON-OAT SYSTEMS) ..............................
DROPOUT ...................................................................................
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Copyright © 2009 DETROIT DIESEL CORPORATION
EPA07 SERIES 60 ENGINE OPERATOR'S MANUAL
COOLANT EXTENDER INHIBITOR ADDITIVE FOR “OAT”
COOLANT ...................................................................................
OAT COOLANT DRAIN INTERVAL ........................................
CHRONIC COOLANT SYSTEM PROBLEMS .............................
DETROIT DIESEL COOLING SYSTEM MAINTENANCE
PRODUCTS .................................................................................
POWER COOL SCAS .............................................................
POWER COOL COOLANT FILTER ELEMENTS ....................
POWER COOL CLEANERS ...................................................
SUMMARY OF COOLANT RECOMMENDATIONS ....................
COOLANT LIFE OF GLYCOL COOLANT ...............................
COOLANT LIFE OF OAT COOLANT ......................................
COOLANT LIFE OF OTHER COOLANTS ..............................
HOW TO DRAIN AND FLUSH THE COOLING SYSTEM ...............
HOSES ........................................................................................
WHEN TO SERVICE THE DRY TYPE AIR CLEANER ...................
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TROUBLESHOOTING .........................................................................
ABNORMAL COOLANT TEMPERATURE .......................................
HARD STARTING ............................................................................
AFTERTREATMENT SYSTEM ........................................................
ABNORMAL ENGINE OPERATION ................................................
ABNORMAL OPERATING CONDITIONS .......................................
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ENGINE STORAGE .............................................................................
PREPARING ENGINE FOR STORAGE ..........................................
TEMPORARY STORAGE (30 DAYS OR LESS) .........................
EXTENDED STORAGE (MORE THAN 30 DAYS) ......................
PROCEDURE FOR RESTORING TO SERVICE AN ENGINE
THAT HAS BEEN IN EXTENDED STORAGE .............................
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CUSTOMER ASSISTANCE .................................................................
ROAD SERVICE IN THE U.S. OR CANADA ...................................
WORKING WITH DETROIT DIESEL SERVICE OUTLETS ............
STEP ONE ...................................................................................
STEP TWO ..................................................................................
STEP THREE ..............................................................................
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SPECIFICATIONS ................................................................................ 138
FUEL AND LUBRICATING OIL REQUIREMENTS .......................... 138
All information subject to change without notice.
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TABLE OF CONTENTS
OIL PAN CAPACITY ....................................................................
POWER COOL ENGINE PRODUCTS ............................................
POWER COOL FULLY FORMULATED IEG COOLANT .............
2000 SUPPLEMENTAL COOLANT ADDITIVE ...........................
3000 SUPPLEMENTAL ADDITIVE FILTERS ..............................
NEED RELEASE COOLANT FILTERS .......................................
PLUS EXTENDED LIFE OAT COOLANT ....................................
PLUS EXTENDER FOR POWER COOL PLUS OAT COOLANT
COOLING SYSTEM CLEANERS ................................................
COOLANT TESTING AND ANALYSIS PRODUCTS ...................
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Copyright © 2009 DETROIT DIESEL CORPORATION
EPA07 SERIES 60 ENGINE OPERATOR'S MANUAL
INTRODUCTION
This guide is intended for use by
the operator of a Detroit Diesel
Series 60 engine used in the following
applications:
□ On-Highway Vehicles
□ Fire Truck or Crash/Rescue
Vehicles
Non-Genuine and Rebuilt
Component Quality Alert
Electronic engine controls have
been instrumental in aiding engine
manufacturers in meeting the stringent
emission requirements of the U.S.
Environmental Protection Agency
(U.S. EPA) and the California Air
Resources Board (CARB) and
also in meeting the ever-increasing
performance demands of the customer.
Maintenance procedures must
be followed in order to continue
satisfactory performance and
durability and to ensure coverage of
the engine under the manufacturer's
warranty. Many of these maintenance
procedures also ensure that the
engine continues to comply with
applicable emissions standards.
Proper maintenance procedures, using
specific components engineered to
comply with emissions regulations,
may be performed by an authorized
Detroit Diesel distributor or dealer,
an independent outlet or the operator
All information subject to change without notice.
DDC-SVC-MAN-0006
or owner. The owner is responsible
for determining the suitability of
components to maintain emissions
compliance during the engine's useful
emission life.
Detroit Diesel cautions that the
indiscriminate rebuilding of precision
components, without the benefit of
specifications, specialized equipment,
and knowledge of the electronic
operating system, will jeopardize
performance or lead to more serious
problems, and can take the engine
outside of compliance with U.S. EPA
or CARB emissions standards.
There are other components in
an engine, such as turbocharger,
camshaft, piston, etc., which
are specifically designed and
manufactured to exacting standards
for emissions compliance. It is
important that these components, if
replaced, modified or substituted, can
be verified to ensure that the engine
remains in compliance with emissions
standards. The use of inadequately
engineered, manufactured or tested
components in repair or rebuild of
the engine may be in violation of the
federal Clean Air Act and applicable
U.S. EPA or CARB regulations.
Copyright © 2009 DETROIT DIESEL CORPORATION
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INTRODUCTION
Furthermore, modern engines exhibit
operating parameters which require
the use of proper fluids, such as
fuel, coolant and lubricating oil, to
maintain long engine life. The use of
fluids that do not meet Detroit Diesel
specifications may result in early wear
out or engine failure.
Personnel Requirements
Work on the engine should be carried
out only by skilled technicians who
have been instructed in the specific
skills necessary for the type of work
being performed.
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Engine Conversions and
Modifications
The function and safety of the engine
could be affected if unauthorized
modifications are made to it. Detroit
Diesel will not accept responsibility
for any resulting damage.
Tampering with the fuel injection
system and engine electronics could
also affect the engine's power output or
exhaust emission levels. Compliance
with the manufacturer's settings
and with statutory environmental
protection regulations cannot then be
guaranteed.
All information subject to change without notice.
Copyright © 2009 DETROIT DIESEL CORPORATION
EPA07 SERIES 60 ENGINE OPERATOR'S MANUAL
CAUTION SUMMARY
The following cautions must be
observed by the operator of the
vehicle or equipment in which this
engine is installed and/or by those
performing basic engine preventive
maintenance. Failure to read and
heed these cautions and exercise
reasonable care for personal safety
and the safety of others when
operating the vehicle/equipment
or performing basic engine
preventive maintenance may result
in personal injury and engine
and/or vehicle/equipment damage.
Engine Operation
Observe the following cautions when
operating the engine.
HOT EXHAUST
During parked regeneration the
exhaust gases will be extremely
HOT and could cause a fire
if directed at combustible
materials. The vehicle must be
parked outside.
PERSONAL INJURY
To avoid injury from engine
shutdown in an unsafe situation,
ensure the operator knows how
to override the stop engine
condition on a DDEC-equipped
unit.
PERSONAL INJURY
To avoid injury from loss of
vehicle/vessel control, the
operator of a DDEC equipped
engine must not use or read
any diagnostic tool while the
vehicle/vessel is moving.
All information subject to change without notice.
DDC-SVC-MAN-0006
Copyright © 2009 DETROIT DIESEL CORPORATION
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CAUTION SUMMARY
PERSONAL INJURY
LOSS OF VEHICLE CONTROL
Diesel engine exhaust and some
of its constituents are known to
the State of California to cause
cancer, birth defects, and other
reproductive harm.
□ Always start and operate an
engine in a well ventilated
area.
□ If operating an engine in
an enclosed area, vent the
exhaust to the outside.
□ Do not modify or tamper
with the exhaust system or
emission control system.
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To avoid injury from loss of
vehicle control, do not activate
the Engine Brake system under
the following conditions:
□ On wet or slippery pavement,
unless the vehicle is equipped
with ABS (anti-lock braking
system) and you have had
prior experience driving
under these conditions.
□ When driving without a trailer
(bobtailing) or pulling an
empty trailer.
□ If the tractor drive wheels
begin to lock or there is
fishtail motion after the
Engine Brake is activated,
deactivate the brake system
immediately if this occurs.
All information subject to change without notice.
Copyright © 2009 DETROIT DIESEL CORPORATION
EPA07 SERIES 60 ENGINE OPERATOR'S MANUAL
LOSS OF VEHICLE CONTROL
To avoid injury from the loss of
vehicle control, do not use cruise
control under these conditions:
□ When it is not possible to
keep the vehicle at a constant
speed (on winding roads, in
heavy traffic, in traffic that
varies in speed, etc.).
□ On slippery roads
(wet pavement, ice-or
snow-covered roads, loose
gravel, etc.).
PERSONAL INJURY
To avoid injury when working
on or near an operating engine,
wear protective clothing,
eye protection, and hearing
protection.
HOT OIL
To avoid injury from hot oil, do
not operate the engine with the
rocker cover(s) removed.
Preventive Maintenance
Observe the following cautions when
performing preventative maintenance.
FIRE
PERSONAL INJURY
To avoid injury when working
near or on an operating engine,
remove loose items of clothing
and jewelry. Tie back or contain
long hair that could be caught in
any moving part causing injury.
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DDC-SVC-MAN-0006
To avoid injury from fire, contain
and eliminate leaks of flammable
fluids as they occur. Failure to
eliminate leaks could result in
fire.
Copyright © 2009 DETROIT DIESEL CORPORATION
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CAUTION SUMMARY
PERSONAL INJURY
USED ENGINE OIL
To avoid injury to skin from
contact with the contaminants in
used engine oil, wear protective
gloves and apron.
To avoid injury, use care when
working around moving belts and
rotating parts on the engine.
FIRE
To avoid injury from combustion
of heated lubricating-oil vapors,
stop the engine immediately if an
oil leak is detected.
PERSONAL INJURY
To avoid injury when using
caustic cleaning agents, follow
the chemical manufacturers
usage, disposal, and safety
instructions.
PERSONAL INJURY
PERSONAL INJURY
To avoid injury from hot surfaces,
wear protective gloves, or allow
engine to cool before removing
any component.
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To avoid injury from contact
with rotating parts when an
engine is operating with the air
inlet piping removed, install an
air inlet screen shield over the
turbocharger air inlet. The shield
prevents contact with rotating
parts.
All information subject to change without notice.
Copyright © 2009 DETROIT DIESEL CORPORATION
EPA07 SERIES 60 ENGINE OPERATOR'S MANUAL
HOT COOLANT
PERSONAL INJURY
To avoid scalding from the
expulsion of hot coolant, never
remove the cooling system
pressure cap while the engine is
at operating temperature. Wear
adequate protective clothing
(face shield, rubber gloves,
apron, and boots). Remove the
cap slowly to relieve pressure.
To avoid injury from rotating belts
and fans, do not remove and
discard safety guards.
PERSONAL INJURY
To avoid injury from slipping and
falling, immediately clean up any
spilled liquids.
FIRE
To avoid injury from fire, do not
smoke or allow open flames when
working on an operating engine.
FIRE
To avoid injury from fire from a
buildup of volatile vapors, keep
the engine area well ventilated
during operation.
All information subject to change without notice.
DDC-SVC-MAN-0006
Copyright © 2009 DETROIT DIESEL CORPORATION
7
CAUTION SUMMARY
Electrical System
Observe the following cautions when
jump starting an engine, charging
a battery, or working with the
vehicle/application electrical system.
ELECTRICAL SHOCK
To avoid injury from electrical
shock, do not touch battery
terminals, alternator terminals, or
wiring cables while the engine is
operating.
PERSONAL INJURY
To avoid injury from accidental
engine startup while servicing
the engine, disconnect/disable
the starting system.
Cooling System
Observe the following cautions when
servicing the cooling system.
HOT COOLANT
Battery Explosion and Acid Burn
To avoid injury from battery
explosion or contact with battery
acid, work in a well ventilated
area, wear protective clothing,
and avoid sparks or flames near
the battery. If you come in contact
with battery acid:
To avoid scalding from the
expulsion of hot coolant, never
remove the cooling system
pressure cap while the engine is
at operating temperature. Wear
adequate protective clothing
(face shield, rubber gloves,
apron, and boots). Remove the
cap slowly to relieve pressure.
□ Flush your skin with water.
□ Apply baking soda or lime to
help neutralize the acid.
□ Flush your eyes with water.
□ Get medical attention
immediately.
8
DDC-SVC-MAN-0006
All information subject to change without notice.
Copyright © 2009 DETROIT DIESEL CORPORATION
EPA07 SERIES 60 ENGINE OPERATOR'S MANUAL
Fuel System
PERSONAL INJURY
To avoid injury from slipping and
falling, immediately clean up any
spilled liquids.
Air Intake System
Observe the following cautions when
working on the air intake system.
Observe the following cautions when
fueling the vehicle or working with
the fuel system.
FIRE
To avoid injury from fire, keep all
potential ignition sources away
from diesel fuel, including open
flames, sparks, and electrical
resistance heating elements. Do
not smoke when refueling.
PERSONAL INJURY
To avoid injury from hot surfaces,
wear protective gloves, or allow
engine to cool before removing
any component.
FIRE
To avoid increased risk of a fuel
fire, do not mix gasoline and
diesel fuel.
PERSONAL INJURY
To avoid injury from contact
with rotating parts when an
engine is operating with the air
inlet piping removed, install an
air inlet screen shield over the
turbocharger air inlet. The shield
prevents contact with rotating
parts.
All information subject to change without notice.
DDC-SVC-MAN-0006
Copyright © 2009 DETROIT DIESEL CORPORATION
9
CAUTION SUMMARY
Compressed Air
Observe the following cautions when
using compressed air.
FIRE
To avoid injury from fire caused
by heated diesel-fuel vapors:
□ Keep those people who are not
directly involved in servicing
away from the engine.
□ Stop the engine immediately if
a fuel leak is detected.
□ Do not smoke or allow open
flames when working on an
operating engine.
EYE INJURY
To avoid injury from flying debris
when using compressed air, wear
adequate eye protection (face
shield or safety goggles) and do
not exceed 276 kPa (40 psi) air
pressure.
□ Wear adequate protective
clothing (face shield,
insulated gloves and apron,
etc.).
□ To prevent a buildup of
potentially volatile vapors,
keep the engine area well
ventilated during operation.
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DDC-SVC-MAN-0006
All information subject to change without notice.
Copyright © 2009 DETROIT DIESEL CORPORATION
EPA07 SERIES 60 ENGINE OPERATOR'S MANUAL
Starting Aids
Observe the following cautions when
using starting aids.
FLAMES, EXPLOSION AND
TOXICITY
To avoid injury from flames,
explosion, and toxicants when
using ether, the following
precautions must be taken:
□ Do not smoke when servicing
ether system.
□ Work in well ventilated area.
□ Do not work near open flames,
pilot flames (gas or oil
heaters), or sparks.
□ Do not weld or carry an open
flame near the ether system if
you smell ether or otherwise
suspect a leak.
All information subject to change without notice.
DDC-SVC-MAN-0006
FLAMES, EXPLOSION AND
TOXICITY
To avoid injury from flames,
explosion, and toxicants when
using ether, the following
precautions must be taken:
□ Always wear goggles when
testing.
□ If fluid enters the eyes or if
fumes irritate the eyes, wash
eyes with large quantities of
clean water for 15 minutes.
A physician, preferably an
eye specialist, should be
contacted.
□ Contents of cylinder are under
pressure. Store cylinders
in a cool dry area. Do not
incinerate, puncture or
attempt to remove cores from
cylinders.
Copyright © 2009 DETROIT DIESEL CORPORATION
11
CAUTION SUMMARY
Lubricating Oil and Filters
Observe the following cautions when
replacing the engine lubricating oil
and filters.
FIRE
To avoid injury from fire from a
buildup of volatile vapors, keep
the engine area well ventilated
during operation.
PERSONAL INJURY
To avoid injury from slipping and
falling, immediately clean up any
spilled liquids.
Aftertreatment System
Observe the following cautions when
servicing the Aftertreatment System
(ATS). Be advised that these two labels
are attached to the Aftertreatment
Device (ATD).
FIRE
To avoid injury from combustion
of heated lubricating-oil vapors,
stop the engine immediately if an
oil leak is detected.
FIRE
To avoid injury from fire, do not
smoke or allow open flames when
working on an operating engine.
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DDC-SVC-MAN-0006
All information subject to change without notice.
Copyright © 2009 DETROIT DIESEL CORPORATION
EPA07 SERIES 60 ENGINE OPERATOR'S MANUAL
Figure 1
Hot Surfaces External and Internal Caution
Figure 2
Heavy Aftertreatment Device Caution
All information subject to change without notice.
DDC-SVC-MAN-0006
Copyright © 2009 DETROIT DIESEL CORPORATION
13
ENGINE IDENTIFICATION
ENGINE IDENTIFICATION
The Series 60 engine has a certification
label, model number and engine serial
number for identification.
For a general view of the Series
60 engine, showing major
components,see Figure 3 and
Figure 4
1. Delivery Pipe
5. EGR Cooler
2. Delta P Sensor
6. Oil Filters
3. Engine Mounted Radiator Bracket
7. Turbocharger
4. Oil Pan
8. Actuator
Figure 3
14
Engine Components
Major Engine Components, Right Side
DDC-SVC-MAN-0006
All information subject to change without notice.
Copyright © 2009 DETROIT DIESEL CORPORATION
EPA07 SERIES 60 ENGINE OPERATOR'S MANUAL
1. Venturi
6. Primary Fuel Filter/Water Separator
2. EGR Valve
7. Intake Throttle Valve
3. Intake Manifold
8. Adaptor
4. Doser Block Assembly
9. Motor Control Module (MCM)
5. Mixer
10. Secondary Fuel Filter
Figure 4
Major Engine Components, Left Side
All information subject to change without notice.
DDC-SVC-MAN-0006
Copyright © 2009 DETROIT DIESEL CORPORATION
15
ENGINE IDENTIFICATION
Engine Model And Serial
Number Desiginaton
The engine serial number and model
number are laser etched on the
cylinder block in the left side just
Figure 5
16
below the intake manifold and above
the cast-in Detroit Diesel logo (as
viewed from the flywheel end).
See Figure 5
Location of Engine Serial and Model Numbers
DDC-SVC-MAN-0006
All information subject to change without notice.
Copyright © 2009 DETROIT DIESEL CORPORATION
EPA07 SERIES 60 ENGINE OPERATOR'S MANUAL
Certification Label
If required, a certification label is
attached to the valve rocker cover.
This label certifies that the engine
conforms to federal and certain state
Figure 6
emissions regulations for its particular
application. It also gives the operating
conditions under which certification
was made. See Figure 6.
Typical Engine Certification Label
All information subject to change without notice.
DDC-SVC-MAN-0006
Copyright © 2009 DETROIT DIESEL CORPORATION
17
OPERATING INSTRUCTIONS FOR STARTING THE ENGINE
OPERATING INSTRUCTIONS FOR STARTING THE
ENGINE
Following are instructions for starting
the engine.
First Time Start
Preparation
When preparing to start a new or
newly overhauled engine which has
been in storage, perform all of the
operations listed below. Also refer to
the “ENGINE STORAGE” section.
Failure to follow these instructions
may result in serious engine damage.
misfires, makes unusual noises, or
shows an unusual loss of power, turn
the engine off as soon as possible and
determine the cause of the problem.
Engine damage may be avoided by a
quick response to early indications of
problems.
When starting the engine in cold
weather, refer to “How to Select
Coolant” in the HOW-TO SECTION.
System Checks
Be sure you are familiar with all of
the instruments, gauges and controls
which are needed to operate the
engine.
Perform the following system checks
before starting for the first time.
Note especially the location and
function of the following:
Check the cooling system as follows:
1. Make sure all drain cocks in
the cooling system are installed
(drain cocks are often removed
for shipping) and are closed
tightly.
□ Oil pressure gauge
□ Low oil pressure warning light
□ Coolant temperature gauge
□ High coolant temperature warning
light
□ Water in fuel warning light
□ Air restriction indicator
Watch for any signs of engine
problems when starting or driving. If
the engine overheats, uses excessive
fuel or lubricating oil, vibrates,
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DDC-SVC-MAN-0006
Cooling System Checks
2. Remove the radiator pressure
control cap and fill with genuine
Detroit Diesel POWER COOL®
antifreeze or an equivalent quality
ethylene glycol or propylene
glycol-base antifreeze solution
in the required concentration.
In extremely hot environments,
properly inhibited water may
be used in the summer. Keep the
All information subject to change without notice.
Copyright © 2009 DETROIT DIESEL CORPORATION
EPA07 SERIES 60 ENGINE OPERATOR'S MANUAL
coolant level at the bottom of the
filler neck to allow for expansion
of the coolant. For more detailed
recommendations, refer to How
to Select Coolant in the HOW-TO
SECTION.
3. Entrapped air must be purged
after filling the cooling system.
To do this, allow the engine to
warm up with the pressure cap
removed. With the transmission
in neutral, increase engine speed
above 1,000 rpm and add coolant
to the radiator as required.
4. Check to make sure the front
of the radiator and air-to-air
charge cooler (if equipped) are
unblocked and free of debris.
Lubrication System Checks
The lubricating oil film on the rotating
parts and bearings of a new or newly
overhauled engine, or one which has
been in storage for six months or
more, may be insufficient when the
engine is started for the first time.
system should be charged with a
commercially available pressure
pre-lubricator. If this is impractical,
rocker covers should be removed and
clean lubricating oil should be poured
over the rocker arms. The oil should
be the same weight and viscosity
as that used in the crankcase. After
pre-lubricating, add additional oil to
bring the level to the proper mark on
the dipstick.
For lubricant recommendation, refer to
How to Select Lubricating Oil in the
HOW-TO SECTION.
Checking the Oil Level — Check
the oil level as follows:
1. Check the oil level using the oil
dipstick. The dipstick has an
operating range identified by a
crosshatch. If the oil meniscus
is within this crosshatch range
then the oil range is adequate for
engine operation. (See Figure 7).
NOTICE:
Insufficient lubrication at startup can
cause serious damage to engine
components.
To insure an immediate flow of
oil to all bearing surfaces at initial
engine startup, the engine lubrication
All information subject to change without notice.
DDC-SVC-MAN-0006
Figure 7
Check Lube Oil Level
Copyright © 2009 DETROIT DIESEL CORPORATION
19
OPERATING INSTRUCTIONS FOR STARTING THE ENGINE
Fuel System Checks
PERSONAL INJURY
To avoid injury from slipping and
falling, immediately clean up any
spilled liquids.
2. If necessary, top off by filling
engine oil through the oil fill
cap to the satisfactory fill
range on the oil dipstick. For
detailed procedures, refer to the
“MAINTENANCE” section. Do
not overfill.
Extended Storage — An engine
in storage for an extended period
of time (over winter, for example)
may accumulate water in the oil
pan through normal condensation of
moisture (always present in the air)
on the cold, internal surfaces of the
engine.
NOTICE:
Fill the tanks with the recommended
fuel. Keeping tanks full reduces water
condensation and helps keep fuel
cool, which is important to engine
performance. Full tanks also reduce
the chance for microbe (black slime)
growth. For fuel recommendations,
refer to How to Select Diesel Fuel in
the HOW-TO SECTION of this guide.
Make sure the fuel shutoff valve (if
used) is open.
NOTICE:
Prolonged use of the starting motor
and engine fuel pump to prime the
fuel system can result in damage to
the starter, fuel pump and injectors.
This may cause erratic engine
operation due to the amount of air
in the lines and filters from the fuel
supply tank to the cylinder head
NOTICE:
Failure to eliminate water-diluted
lubricating oil may lead to serious
engine damage at startup.
NEVER use a starting aid such as
ether to run the engine until the
fuel system is primed. Doing so
will result in injector damage.
Lube oil diluted by water cannot
provide adequate bearing protection
at engine startup. For this reason,
Detroit Diesel recommends replacing
the engine lubricating oil and filters
after extended storage.
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DDC-SVC-MAN-0006
All information subject to change without notice.
Copyright © 2009 DETROIT DIESEL CORPORATION
EPA07 SERIES 60 ENGINE OPERATOR'S MANUAL
If an external starting aid is used, the
heat generated by the external fuel
source will cause the injector tips to
be damaged when the fuel cools them.
The injector plunger and bushing
can be scored from running without
lubrication.
NOTICE:
Engines equipped with starting
devices dependent on compressed
air or gas reservoirs should always
be primed before initial startup.
Otherwise, reserve pressure can
be exhausted and injectors may be
damaged from lack of lubrication
and cooling.
To insure prompt starting and even
running, the fuel system must
be primed if air has entered the fuel
system. Priming is done by connecting
a manual or electric priming pump to
the secondary fuel filter adaptor.
Authorized Detroit Diesel service
outlets are properly equipped and have
the trained technicians to perform this
service.
Priming is not normally required if
the filter elements are filled with clean
fuel when installed and the manifolds
are not drained of fuel.
performance and may cause engine
damage. Detroit Diesel recommends
installation of a fuel/water separator
wherever water contamination is a
concern.
Adding Fuel — When adding fuel,
pay attention to the following:
□ Add winter or summer grade fuel
according to the season of the
year.
□ Work in the cleanest conditions
possible.
□ Prevent water from entering the
fuel tank.
For further information, refer to Diesel
Fuels in the “HOW-TO SECTION”
of this guide.
Priming the Fuel System —
Prime the fuel system as follows:
1. If equipped with a hand pump
on the fuel filter or fuel/water
separator, work the hand pump
until resistance is felt.
2. Crank the engine for 30 seconds
at a time, but no longer. Before
cranking the engine again, wait
at least two minutes. The engine
should start within six 30-second
attempts.
If the engine is equipped with a
fuel/water separator, drain off any
water that has accumulated. Water
in fuel can seriously affect engine
All information subject to change without notice.
DDC-SVC-MAN-0006
Copyright © 2009 DETROIT DIESEL CORPORATION
21
OPERATING INSTRUCTIONS FOR STARTING THE ENGINE
Other Checks
provide corrosion protection, apply
dielectric grease liberally to the
terminal pads.
Make sure the transmission is
filled to the proper level with the
fluid recommended by the gear
manufacturer. Do not overfill.
Battery Explosion and Acid Burn
Check the turbocharger for signs of
oil or exhaust leaks. Leaks should be
corrected before starting the engine.
Check engine mounting bolts for
tightness. Bolts should be retightened,
if necessary.
To avoid injury from battery
explosion or contact with battery
acid, work in a well ventilated
area, wear protective clothing,
and avoid sparks or flames near
the battery. If you come in contact
with battery acid:
□ Flush your skin with water.
□ Apply baking soda or lime to
help neutralize the acid.
□ Flush your eyes with water.
Figure 8
□ Get medical attention
immediately.
Make sure cable connections to
the storage batteries are clean and
tight. Check the hydrometer “eye” of
maintenance-free batteries for charge.
See Figure 8.
Maintenance-Free
Battery “Eye”
Starting the Engine For The First
Time
Before starting the engine the first
time, perform the operations listed in
the System Checks section.
If lead-acid or low-maintenance
batteries are used, make sure battery
electrolyte level is normal.
Use only batteries that have been
correctly filled and serviced. To
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DDC-SVC-MAN-0006
All information subject to change without notice.
Copyright © 2009 DETROIT DIESEL CORPORATION
EPA07 SERIES 60 ENGINE OPERATOR'S MANUAL
NOTICE:
The turbocharger may be seriously
damaged if the engine is cranked
with the air shutdown in the closed
position.
To start a Series 60 engine, make sure
the transmission is in neutral and turn
the ignition key on.
ENGINE EXHAUST
An emergency manual or automatic
shutdown system, must be set in the
open position before starting.
To avoid injury from inhaling
engine exhaust, always operate
the engine in a well-ventilated
area. Engine exhaust is toxic.
FLAMES, EXPLOSION AND
TOXICITY
To avoid injury from flames,
explosion, and toxicants when
using ether, the following
precautions must be taken:
□ Do not smoke when servicing
ether system.
PERSONAL INJURY
To avoid injury when working
near or on an operating engine,
remove loose items of clothing
and jewelry. Tie back or contain
long hair that could be caught in
any moving part causing injury.
□ Work in well ventilated area.
□ Do not work near open flames,
pilot flames (gas or oil
heaters), or sparks.
□ Do not weld or carry an open
flame near the ether system if
you smell ether or otherwise
suspect a leak.
The engine may require the use of a
cold weather starting aid if the ambient
temperature is below 40°F (4°C).
All information subject to change without notice.
DDC-SVC-MAN-0006
You will notice that both the Amber
Warning Lamp and the Red Stop Lamp
will come on. This is the result of
the Detroit Diesel Electronic Control
(DDEC®) computer diagnosing
the system to ensure everything is
functional, including the light bulbs
for the warning lights. If everything
is OK, both lights will go out in
approximately five seconds.
Start the engine after the lights go
out. If starting a vehicle, start the
engine with foot off the foot pedal.
Copyright © 2009 DETROIT DIESEL CORPORATION
23
OPERATING INSTRUCTIONS FOR STARTING THE ENGINE
NOTICE:
NOTICE:
If the warning lights stay on, or
do not come on momentarily after
turning on the ignition, contact
the Detroit Diesel Customer
Support Center at 313–592–5800.
Operating the engine under these
circumstances may result in engine
damage.
Do not rev the engine if the oil
pressure gauge indicates no oil
pressure. Shut down the engine
within approximately ten seconds
to avoid engine damage. Check to
determine the cause of the problem.
4. Monitor the oil pressure gauge
immediately after starting the
engine.
Electric Starter — Start an engine
equipped with an electric starting
motor as follows:
NOTICE:
NOTE:
Do not place the engine under full load
until it reaches operating temperature.
Running the Engine
To prevent serious starting motor
damage, do not press the starter
switch again after the engine has
started.
While the engine is operating, monitor
the battery charge indicator light,
the oil pressure and avoid excessive
idling.
1. Chock the tires, place the
transmission in neutral, and set
the parking brake.
Oil Pressure
2. With foot OFF the foot pedal,
turn on the ignition switch and
start the engine
3. If the engine doesn't start after
20 seconds, stop. Try again after
waiting about one minute.
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DDC-SVC-MAN-0006
Observe the oil pressure gage
immediately after starting the engine.
A good indicator that all moving parts
are getting lubrication is when the oil
pressure gage registers pressure 35
kPa or 5 psi at idle speed.
If no pressure is indicated within 10 to
15 seconds, stop the engine and check
the lubrication system.
All information subject to change without notice.
Copyright © 2009 DETROIT DIESEL CORPORATION
EPA07 SERIES 60 ENGINE OPERATOR'S MANUAL
The pressure should not drop below
193 kPa or 28 psi at 1800 rpm, and
normal operating pressure should be
higher. If oil pressure does not fall
within these guidelines, it should be
checked with a manual gage.
HOT OIL
To avoid injury from hot oil, do
not operate the engine with the
rocker cover(s) removed.
Warm-up
Run the engine at part throttle for
about five minutes to allow it to warm
up before applying a load.
Inspection
While the engine is idling, inspect the
transmission, check for fluid leaks,
check the crankcase and turbocharger.
Transmission — While the
engine is idling, check the automatic
transmission (if equipped) for proper
oil level and add oil as required.
Crankcase — If the engine oil
was replaced, stop the engine after
normal operating temperature has
been reached. Allow the oil to drain
back into the crankcase for about
twenty minutes, then check the oil
level. If necessary, add oil to bring
the level to the proper mark on the
dipstick. Use only the heavy-duty oils
recommended. Refer to How to Select
Lubricating Oil in this guide.
Turbocharger — Make a visual
inspection of the turbocharger for
oil leaks, exhaust leaks, excessive
noise or vibration. Stop the engine
immediately if a leak or unusual noise
or vibration is noted. Do not restart
the engine until the cause of the
concern has been investigated and
corrected. Authorized Detroit Diesel
service outlets are properly equipped
to perform this service.
Avoid Unnecessary Idling
Whenever possible, avoid unnecessary
idling.
During long engine idling periods
with the transmission in neutral, the
engine coolant temperature may fall
below the normal operating range.
Fluid Leaks — Look for coolant,
fuel or lubricating oil leaks. If any
are found, shut down the engine
immediately and have the leaks
repaired after the engine has cooled.
All information subject to change without notice.
DDC-SVC-MAN-0006
Copyright © 2009 DETROIT DIESEL CORPORATION
25
OPERATING INSTRUCTIONS FOR STARTING THE ENGINE
The incomplete combustion of fuel
in a cold engine will cause crankcase
oil dilution, formation of lacquer or
gummy deposits on the valves, pistons,
and rings, and rapid accumulation of
sludge in the engine. When prolonged
idling is necessary, maintain at least
850 rpm spring/summer and 1200 rpm
fall/winter.
Stopping the Engine
Emergency Jump Starting
The DDEC VI system operates on 12
volts DC. If a DDEC VI engine with
an electric starting motor requires
emergency jump starting, do not
exceed 16 volts DC.
BATTERY EXPLOSION
Stop an engine under normal operating
conditions as follows:
1. Reduce engine speed to idle and
put all shift levers in the neutral
position.
To avoid injury from battery
explosion when jump starting the
engine, do not attach the cable
end to the negative terminal of
the disabled battery.
NOTICE:
Do not stop a turbocharged engine
immediately after a high-speed
operation. Allow a sufficient
cool-down period to prevent the
turbo from continuing to turn without
an oil supply to the bearings.
2. Allow the engine to run between
idle and 1000 rpm with no load
for four or five minutes. This
allows the engine to cool and
permits the turbocharger to slow
down. After four or five minutes,
shut down the engine.
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DDC-SVC-MAN-0006
NOTICE:
Jump starting with voltages greater
than those indicated or reversing
battery polarity may damage the
Motor Control Module.
NOTICE:
Failure to connect jumper cables
in the proper sequence can result
in alternator and/or equipment
damage.
All information subject to change without notice.
Copyright © 2009 DETROIT DIESEL CORPORATION
EPA07 SERIES 60 ENGINE OPERATOR'S MANUAL
Before attempting to jump start the
engine, make sure the jumper cables
are connected properly (positive to
positive, negative to negative ground)
and in the proper sequence (negative
to negative ground last).
Routine Engine Start
Following are procedures for a routine
everyday engine start.
ENGINE EXHAUST
Battery Explosion and Acid Burn
To avoid injury from battery
explosion or contact with battery
acid, work in a well ventilated
area, wear protective clothing,
and avoid sparks or flames near
the battery. If you come in contact
with battery acid:
□ Flush your skin with water.
□ Apply baking soda or lime to
help neutralize the acid.
□ Flush your eyes with water.
□ Get medical attention
immediately.
To avoid injury from inhaling
engine exhaust, always operate
the engine in a well-ventilated
area. Engine exhaust is toxic.
PERSONAL INJURY
To avoid injury when working
near or on an operating engine,
remove loose items of clothing
and jewelry. Tie back or contain
long hair that could be caught in
any moving part causing injury.
Starting the Engine-Routine
Before a routine start, refer to the
MAINTENANCE section and see the
daily checks for your engine.
All information subject to change without notice.
DDC-SVC-MAN-0006
Copyright © 2009 DETROIT DIESEL CORPORATION
27
OPERATING INSTRUCTIONS FOR STARTING THE ENGINE
Important: Before starting the
engine, carefully read all operating
instructions in this manual and do all
the recommended pretrip inspections
and daily maintenance. Check the
engine oil and fuel levels, and drain
contaminants from the fuel/water
separator (optional).
4. Shut down the engine.
5. Approximately five minutes after
shutdown, check the engine oil
level. If necessary, add oil up to
the satisfactory fill range on the
oil dipstick (see Figure 9). Do not
overfill.
NOTE:
If you drain the fuel/water separator
completely, you may have to prime the
fuel system.
NOTE:
As a safety function, the electronic
engine control system may be wired to
start the engine only If the transmission
is in neutral. This is vehicle application
specific.
1. Turn on the ignition switch.
Figure 9
Oil Dipstick
6. Check all the mounting fasteners
on the engine for tightness.
2. With the accelerator pedal in the
idle position, start the engine.
Checking the Coolant Level
(Cold Check)
3. Check the engine for leaks.
Check coolant level as follows:
[a] Check all hoses, hose clamps,
and pipe unions on the engine
for tightness. Shut down the
engine and tighten them if
necessary.
[b] Check the oil feed and return
lines at the turbocharger for
tightness. Shut down the
engine and tighten them if
necessary.
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DDC-SVC-MAN-0006
1. Ensure that all coolant plugs in
the bottom of the radiator and on
the radiator outlet pipe are secure
and tight.
2. Check the coolant level. The
cooling system is correctly filled
when the coolant is between the
All information subject to change without notice.
Copyright © 2009 DETROIT DIESEL CORPORATION
EPA07 SERIES 60 ENGINE OPERATOR'S MANUAL
maximum and minimum marks
on the surge tank.
NOTE:
For more information, refer to the
“MAINTENANCE” section.
Checking the Coolant Level (Hot
Check)
Check the coolant levels as follows:
1. Allow the engine to run for
approximately five minutes at a
moderate speed.
briefly and the coolant level
again checked and corrected as
necessary.
Monitoring Engine
Operation
While the engine is operating, monitor
the battery charge indicator light,
the oil pressure and avoid excessive
idling.
Battery Charge
The battery charge indicator light
must go out once the engine
starts. See Figure 10
HOT COOLANT
To avoid scalding from the
expulsion of hot coolant, never
remove the cooling system
pressure cap while the engine is
at operating temperature. Wear
adequate protective clothing
(face shield, rubber gloves,
apron, and boots). Remove the
cap slowly to relieve pressure.
2. Then, with the coolant
temperature above 50°C (122°F),
recheck the coolant level.
3. Add more coolant if necessary.
Open the heater valves before
adding coolant.
Figure 10
Battery Charge Indicator
Light
If the indicator light comes on
while the engine is running, do the
following:
4. Do not close the heater valves
until the engine has been run
All information subject to change without notice.
DDC-SVC-MAN-0006
Copyright © 2009 DETROIT DIESEL CORPORATION
29
OPERATING INSTRUCTIONS FOR STARTING THE ENGINE
Excessive Idling
FIRE
To avoid injury from fire, keep all
potential ignition sources away
from diesel fuel, including open
flames, sparks, and electrical
resistance heating elements. Do
not smoke when refueling.
1. Shut down the engine.
Never allow the engine to idle for
more than 30 minutes. Excessive
idling can cause oil to leak from the
turbocharger.
Changing the Idle Speed
The rpm range of the Series 60 engine
is 600 to 850 rpm if the parameters in
the Common Powertrain Controller
(CPC) are set to the default range.
Change the idle speed as follows:
2. Check the poly-V belt for
tightness.
3. Charge or replace the batteries as
needed.
4. If necessary, visit the nearest
authorized dealer to have the
alternator voltage and output
checked. Do a load test on the
batteries.
1. Turn the cruise control switch to
the ON position.
2. To increase the idle speed, push
the RSM/ACL switch until the
idle is fast enough.
3. To decrease the idle speed, push
the SET/CST switch until the idle
is slow enough.
Oil Pressure
Shutting Down the Engine
When the engine has reached its
normal operating temperature, the
engine oil pressure must not drop
below the following values:
If the engine has been running at full
output or the coolant temperature has
been high, allow the engine to idle
for four or five minutes without load.
Then turn off the ignition key switch.
□ 193 kPa (28 psi) at rated speed
□ 35 kPa (5 psi) at idling speed
If oil pressure drops below these
values, stop the engine and determine
the cause.
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DDC-SVC-MAN-0006
If any of the following occur, shut
down the engine immediately.
□ The oil pressure swings back and
forth or falls sharply.
All information subject to change without notice.
Copyright © 2009 DETROIT DIESEL CORPORATION
EPA07 SERIES 60 ENGINE OPERATOR'S MANUAL
□ Engine power and rpm fall, even
though the accelerator pedal
remains steady.
□ The exhaust pipe gives off heavy
smoke.
□ The coolant and/or oil temperature
climb abnormally.
□ Abnormal sounds suddenly occur
in the engine or turbocharger.
Shutting Down After High Load
Operation
After high load operation, do the
following:
NOTICE:
An engine running at full output or
with high coolant temperature after
a high load operation, should idle
for one or two minutes without load.
Shutting down without idling may
cause damage to the turbocharger.
Turn off the ignition switch and shut
down the engine.
Emergency Running Mode
NOTICE:
To prevent possible serious engine
damage, have any faults corrected
without delay by an authorized
dealer.
□ In conjunction with any dashboard
or instrument panel display, the
code for the electronic control
unit reporting the fault can be read
immediately on the display.
□ If the fault is serious enough to
impair normal operation, DDEC
VI switches over to limp home
mode. The limp home speed is
dependent on MCM parameters
and could be idle speed or 1000
rpm. This allows you to move the
vehicle to a service location.
Stop Engine Override
Option
The Stop Engine Override Option
is used for a momentary override.
The Motor Control Module (MCM)
will record the number of times the
override is activated after a fault
occurs.
The engine is equipped with DDEC
VI which monitors the engine as it is
running.
As soon as a fault is detected, it is
evaluated and one of the following
measures is initiated.
All information subject to change without notice.
DDC-SVC-MAN-0006
Copyright © 2009 DETROIT DIESEL CORPORATION
31
OPERATING INSTRUCTIONS FOR STARTING THE ENGINE
Momentary Override – A Stop
Engine Override (SEO) switch
is used to override the shutdown
sequence (see Figure 11). This
override resets the 60 second (30
seconds for oil pressure) shutdown
timer, restoring power to the level
when the Red Stop Lamp (RSL)/Stop
Enginewas illuminated. The switch
must be recycled after five seconds to
obtain a subsequent override.
Figure 11
Cold Weather Operation
Special precautions must be taken
during cold weather. To protect
your engine, special cold weather
handling is required for fuel, engine
oil, coolant, and batteries. For detailed
information, refer to the service
manual.
Winter Fronts
A winter front may be used to improve
cab heating while idling. At least 25%
of the grill opening should remain
open in sectioned stripes that run
perpendicular to the charge air cooler
tube flow direction. This assures even
cooling across each tube and reduces
header to tube stress and possible
failure. Winter fronts should only be
used when the ambient temperature
remains below -12.2° C (10° F).
SEO Switch and
Warning Lamps
NOTE:
The operator has the responsibility to
take action to avoid engine damage.
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DDC-SVC-MAN-0006
All information subject to change without notice.
Copyright © 2009 DETROIT DIESEL CORPORATION
EPA07 SERIES 60 ENGINE OPERATOR'S MANUAL
DDEC VI SYSTEM
Detroit Diesel Series 60 engines
equipped with DDEC are identified
by the letter “G” in the sixth position
of the model number. Example:
6067HG6E. The Series 60 engine for
2007 is equipped with DDEC VI.
DDEC VI regulates the fuel
injection quantity and timing using
solenoid valves, allowing extremely
low-emission operation. Besides the
engine and its related sensors, the
system has two control modules:
□ The Motor Control Module
(MCM)
The Accelerator Pedal Assembly
(AP) eliminates the need for any
throttle linkage.
Motor Control Module
The MCM (see Figure 12) is typically
located on the left-hand side of the
engine.
The MCM processes the data received
from the CPC, for example the
position of the accelerator pedal,
engine brake, etc.
□ The Common Powertrain
Controller (CPC) located under
the right-hand dash panel
The two control units are connected by
a proprietary datalink through which
all necessary data and information can
be exchanged.
The CPC broadcasts all information
on the J1587 and J1939 datalinks,
where it can be read by the diagnostic
tool.
The MCM monitors both the engine
and the datalink. When a malfunction
or other problem is detected, the
system selects an appropriate
response; for example, the emergency
running mode may be activated.
All information subject to change without notice.
DDC-SVC-MAN-0006
Figure 12
MCM
These data are evaluated together
with the data from the sensors on
the engine, such as coolant and
fuel temperature and oil and charge
pressure. The data is then compared to
the characteristic maps or lines stored
in the MCM.
Copyright © 2009 DETROIT DIESEL CORPORATION
33
DDEC VI SYSTEM
From these data, quantity and timing
of injection are calculated.
NOTE:
To obtain a replacement MCM, all
the data given on the MCM label are
required.
The MCM data label has the 10 digit
engine serial number (see Figure 13).
Figure 14
CPC
The CPC receives data from the
following sources:
Figure 13
□ The operator (accelerator pedal
position, engine brake switch)
MCM Label
□ Other electronic control units
(for example, the anti-lock brake
system)
Common Powertrain
Controller
The CPC communicates with any
other MCM unit installed on the
vehicle over the J1939 data link.
See Figure 14.
□ The MCM (oil pressure and
coolant temperature)
Data for specific applications is stored
in the CPC. These include idle speed,
maximum running speed, and speed
limitation.
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DDC-SVC-MAN-0006
From these data, instructions are
computed for controlling the engine
and transmitted to the CPC via the
proprietary datalink.
All information subject to change without notice.
Copyright © 2009 DETROIT DIESEL CORPORATION
EPA07 SERIES 60 ENGINE OPERATOR'S MANUAL
DDEC Features
DDEC offers a variety of features and
options designed to warn the operator
of an engine malfunction.
Options can range from warning panel
lights to automatic reduction in engine
power followed by automatic engine
shutdown.
DDEC has the ability to perform
diagnostics for self-checks and
continuous monitoring of other
system components.
Depending on the application,
DDEC can monitor oil temperature,
coolant temperature, oil pressure, fuel
pressure, coolant level and remote
sensors (if used).
DDEC connects to the Amber Warning
Lamp (AWL)/Check Engine and the
Red Stop Lamp (RSL)/Stop Engine to
provide a visual warning of a system
malfunction.
Cruise Control
Cruise Control is available with any
DDEC engine. Cruise Control will
operate in either Engine or Vehicle
Speed Mode and maintain a targeted
speed (MPH or RPM) by increasing or
decreasing fueling. The targeted speed
can be selected and adjusted with
dash-mounted switches. See Figure 15
All information subject to change without notice.
DDC-SVC-MAN-0006
Figure 15
Typical Cruise Control
Switches
Cruise Control may also be
programmed to permit fast idle
using the Cruise Control switches.
With the engine at normal idle,
transmission in neutral and service
brakes on, press the SPD CNTL
Switch, and use the RSM/ACC
Switch. The engine rpm should
increase to a pre-defined speed. The
engine rpm can be raised or lowered
from this point using the SET/CST
and RSM/ACC switches.
Cruise Control will maintain the set
speed under normal road and load
conditions.
Copyright © 2009 DETROIT DIESEL CORPORATION
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DDEC VI SYSTEM
LOSS OF VEHICLE CONTROL
To avoid injury from the loss of
vehicle control, do not use cruise
control under these conditions:
□ When it is not possible to
keep the vehicle at a constant
speed (on winding roads, in
heavy traffic, in traffic that
varies in speed, etc.).
□ On slippery roads
(wet pavement, ice-or
snow-covered roads, loose
gravel, etc.).
NOTICE:
When descending a hill with Cruise
Control OFF, do not allow the
engine to exceed 2,500 rpm.
Failure to observe this can result in
over speeding and serious engine
damage.
It cannot limit vehicle speeds on
down grades if available engine
braking effort is exceeded, nor can it
maintain speed on upgrades if power
requirements exceed engine power
capability.
set vehicle speed. The vehicle speed
must be above Min Cruise Set Speed
and below Max Cruise Set Speed. It
is recommended that Max Cruise Set
Speed be set to the default to allow
proper operation of other features
such as Fuel Economy Incentive and
PasSmart. The Vehicle Speed Limit
should be used to limit vehicle throttle
speed.
When the SPD CNTL is in the ON
position, Cruise Control is engaged by
momentarily contacting the SET/CST
Switch. As a check after each engine
start, DDEC looks for a one time
activation of the clutch (if equipped)
and service brake before DDEC
allows Cruise Control to be enabled.
The MCM must also recognize that
the Cruise Enable Switch has changed.
If the Cruise Enable Switch is off, it
needs to be turned on. If the Cruise
Enable Switch is on, it must be turned
off then on for cruise to operate.
Holding the switch in the SET/CST
position allows the vehicle to slow to a
lower speed. Toggling the switch will
result in a one mile-per-hour (1.6 kph)
decrease in vehicle speed. If Cruise
Control has been disabled, toggling
the RSM/ACC Switch restores the
vehicle to the previously set cruise
speed.
Engine speed and power are varied
under Cruise Control to maintain the
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DDC-SVC-MAN-0006
All information subject to change without notice.
Copyright © 2009 DETROIT DIESEL CORPORATION
EPA07 SERIES 60 ENGINE OPERATOR'S MANUAL
Cruise Control can be overridden at
any time with the throttle pedal if
the vehicle is operating at less than
the programmed Max Road Speed.
Additionally, using either the brake or
the clutch will disable Cruise Control.
Data Recording Capability
DDEC VI contains the ability to
extract detailed data on the engine’s
use and performance using DDEC
Reports software. This data, known
as DDEC Data, is stored in the CPC
and contains information on engine
performance (such as fuel economy,
idle time, time in top gear) and critical
incidents (such as detailed diagnostic
data records and hard braking events).
DDEC Data can be downloaded using
DDEC Reports software to produce
reports.
DDEC Reports software is part of
the Detroit Diesel Diagnostic Link®
7.0 (DDDL 7.0) software package.
DDDL 7.0 requires at least a Pentium
II computer with at least 256 MB of
RAM.
Engine Brakes
Engine brakes are enabled by a
dash-mounted On/Off switch with a
separate intensity switch to select low,
medium or high braking power.
All information subject to change without notice.
DDC-SVC-MAN-0006
LOSS OF VEHICLE CONTROL
To avoid injury from loss of
vehicle control, do not activate
the Engine Brake system under
the following conditions:
□ On wet or slippery pavement,
unless the vehicle is equipped
with ABS (anti-lock braking
system) and you have had
prior experience driving
under these conditions.
□ When driving without a trailer
(bobtailing) or pulling an
empty trailer.
□ If the tractor drive wheels
begin to lock or there is
fishtail motion after the
Engine Brake is activated,
deactivate the brake system
immediately if this occurs.
The engine brakes will only operate
when the Accelerator Pedal is fully
released. Disengaging the clutch
will prevent the engine brakes from
operating.
Copyright © 2009 DETROIT DIESEL CORPORATION
37
DDEC VI SYSTEM
Engine brakes will supply braking
power even when in Cruise Control.
The MCM will control the amount
of engine braking with respect to
the Cruise Control set speed. The
maximum amount of braking (low,
medium, high) is selected with the
dash switches.
Engine Protection
The DDEC engine protection
system monitors all engine sensors
and electronic components, and
recognizes system malfunctions. If
a critical fault is detected, the AWL
(Check Engine) and RSL (Stop
Engine) illuminate. The malfunction
codes are logged into the MCM's
memory.
The standard parameters which are
monitored for engine protection
are: low coolant level, high coolant
temperature, low oil pressure, and
high oil temperature.
This system features a 30-second,
stepped-power shutdown sequence
or an immediate speed reduction
without shutdown in the event a major
engine malfunction occurs, such as
low oil pressure, high oil or coolant
temperature, or low coolant level.
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DDC-SVC-MAN-0006
PERSONAL INJURY
To avoid injury from engine
shutdown in an unsafe situation,
ensure the operator knows how
to override the stop engine
condition on a DDEC-equipped
unit.
NOTICE:
Engines equipped with the
power-down/shutdown option have
a system override button or switch
to allow engine operation for a
short period of time. Using the
override button so the engine does
not shutdown in 30 seconds but
operates for an extended period
may result in engine damage.
California Engine Idle Limiting
In order to meet the California Engine
Idle Limiting Standard, an engine
idle shutdown feature has been built
into the DDEC VI Engine Control
Strategy. When the California Engine
Idle Limiting feature is enabled, the
engine will generally shut down after
five minutes of continuous idling
when the transmission is in neutral
or park and the parking brake is set
or after fifteen minutes when the
transmission is in neutral or park and
the parking brake is not set.
All information subject to change without notice.
Copyright © 2009 DETROIT DIESEL CORPORATION
EPA07 SERIES 60 ENGINE OPERATOR'S MANUAL
Activating or momentarily changing
the position of the service brake
pedal, the clutch pedal, Stop Engine
Override, the accelerator pedal, or
park brake status during the final 30
seconds before a shutdown would
otherwise occur will prevent the
engine from shutting down and will
reset the shutdown timer. After an
automatic shutdown, the engine may
be restarted and operated normally.
The automatic shutdown feature
is generally disabled on engines
certified by the US EPA for use
outside California but is required to
be enabled for all California certified
engines with the exception of engines
used in specific vehicle types which
the state of California has determined
to be exempt from the idle shutdown
requirement. These include buses,
school buses, recreational vehicles,
medium duty vehicles, military tactical
vehicles, and authorized emergency
vehicles as they are defined by the
state of California. Owners of these
vehicle types that wish to have the
shutdown feature disabled should
consult with California authorities to
determine if their vehicles qualify for
the exemption.
allowing a turbocharger cool-down
period. To activate the shutdown, the
transmission must be in neutral with
the vehicle parking brakes set and the
engine in idle or fast-idle mode.
DDEC VI Operation
NOTE:
This engine is equipped with DDEC
software. This software generally
assures optimal engine performance.
The installation of software upgrades
may cause minor changes in features
and engine performance.
Since the DDEC system is electronic,
a battery is required to operate the
computer. The system operates at
12 volts. However, in the event of
a power supply malfunction, the
system will continue to operate at
reduced voltage. When this occurs,
the AWL (Check Engine) will come
on. See Figure 16.
Idle Shutdown Timer
This feature is an optional 1 –
100 minute idle shutdown system.
Its purpose is to conserve fuel by
eliminating excessive idling and
All information subject to change without notice.
DDC-SVC-MAN-0006
Figure 16
Warning Lamps and
SEO Switch
Copyright © 2009 DETROIT DIESEL CORPORATION
39
DDEC VI SYSTEM
The engine will only operate at
reduced rpm until the battery voltage
reaches a point where the MCM will
no longer function and the engine
shuts down.
Should the AWL (Check Engine)
come on for any reason, the vehicle
can still be operated and the driver can
proceed to the required destination.
This condition should be reported
to an authorized Detroit Diesel
distributor or dealer.
Stop Engine Override Switch
This feature allows the operator to
override the automatic stop engine
sequence.
This is done by pressing the Stop
Engine Override Switch every 15 to 20
seconds to prevent engine shutdown
from occurring.
NOTE:
The Stop Engine Override Switch and
the Diagnostic Request Switch are the
same.
NOTICE:
When the RSL (Stop Engine) comes
on, the computer has detected a
major malfunction in the engine
that requires immediate attention.
It is the operator responsibility
to shut down the engine to avoid
serious damage.
The engine can be configured to
give a warning only, to ramp down
(reduce power) or to shut down.
Ramp down will reduce engine rpm
to a pre-determined speed, but will
not shut down the engine. With
the 30-second shutdown option, the
engine will begin a 30-second, stepped
power-down sequence until it shuts
down completely.
NOTE:
Holding down the Stop Engine
Override Switch will not prevent the
engine shutdown sequence. You
must continue to reset the automatic
shutdown system by pressing the Stop
Engine Override Switch at intervals of
approximately 15 to 20 seconds.
It takes 30 seconds from the time the
automatic shutdown sequence begins
until engine shutdown. Therefore,
the operator must press the override
switch just prior to engine shutdown
and continue to do so until the vehicle
can be brought to a stop in a safe
location.
A “Stop Engine Override” can be
procured in case the vehicle is to
operate in a critical location.
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DDC-SVC-MAN-0006
All information subject to change without notice.
Copyright © 2009 DETROIT DIESEL CORPORATION
EPA07 SERIES 60 ENGINE OPERATOR'S MANUAL
Immediate Speed Reduction
The immediate speed reduction option
will bring engine rpm back to a
predetermined speed, but will not shut
down the engine.
least a Pentium II computer with at
least 256 MB of RAM.
Once the malfunction has been
corrected, the DDEC system will
return the engine to normal operation.
The engine should not be restarted
after it has been shut down by the
engine protection system, unless
the problem has been located and
corrected.
The temperature of air in the intake
system is increased with the addition
of an EGR. DDEC is programmed to
reduce fueling (power) for a short time
to reduce air and coolant temperatures
when necessary.
Red Stop Lamp
DDEC will store an information
code that this event occurred, but
no corrective action is required as
this action is designed to maintain
operation without a noticeable affect
on vehicle performance.
The conditions that will cause the RSL
(Stop Engine) to come on are:
□ High coolant temperature
□ Loss of coolant
□ High oil temperature
□ Low oil pressure
□ Auxiliary shutdown
Whenever the AWL (Check Engine)
or the RSL (Stop Engine) come on,
the DDEC computer will determine
where the problem is and will then
store this information in its memory.
If the malfunction is intermittent, the
lights will come on and go off as the
computer senses the changing engine
condition.
Diagnostic Tool
The diagnostic tool for DDEC VI is
DDDL 7.0. DDDL 7.0 requires at
All information subject to change without notice.
DDC-SVC-MAN-0006
Flashing Malfunction Codes —
All malfunction codes are four digits.
The malfunction code recorded in the
computer memory will remain until it
is erased by a technician.
The flashing malfunction code can
also be obtained by the operator.
To support flashing codes, a Stop
Engine Override/Diagnostic Request
Switch must be configured and the
AWL (Check Engine) and RSL (Stop
Engine) must be hard-wired. The CPC
cannot flash these lamps if they are
not hard-wired.
The flashing code feature may be
activated by satisfying one of the
following conditions:
Copyright © 2009 DETROIT DIESEL CORPORATION
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DDEC VI SYSTEM
□ Engine speed is <100 rpm and
the SEO switch is put in the ON
position.
□ Idle Governor is active and the
SEO switch is put in the ON
position.
seconds. The pause between codes
is 3.5 seconds. The same 3.5 second
pause occurs as the switch is made
from RSL (Stop Engine) to AWL
(Check Engine). See Figure 17.
The flashing code feature is
deactivated once the SEO switch
is returned to the OFF position or
the listed conditions are no longer
satisfied.
When code flashing is initiated,
the active codes will be flashed on
the RSL (Stop Engine). Then the
inactive codes will be flashed on the
AWL (Check Engine). When all the
inactive codes have been flashed, the
process of flashing all the active codes
followed by all the inactive codes will
repeat until the conditions for code
flashing are no longer satisfied.
Only one light will be flashing codes
at any time. All codes will be flashed
twice. The inter-digit pause is 1.5
If there are no active or inactive faults
the number 3 is flashed once followed
by an inter-code gap of 3 seconds.
□ Vehicle speed is <3 mph and Park
Brake is activated and the SEO
switch is put in the ON position.
Figure 17
42
RSL (Stop Engine) Flashing Code Example
DDC-SVC-MAN-0006
All information subject to change without notice.
Copyright © 2009 DETROIT DIESEL CORPORATION
EPA07 SERIES 60 ENGINE OPERATOR'S MANUAL
To Read Codes: Press and hold the
SEO/Diagnostic Request Switch.
Active codes will be flashed on the
RSL (Stop Engine) first, followed by
inactive codes being flashed on the
AWL (Check Engine).
The codes will continue to flash
and repeat as long as the Diagnostic
Request Switch is held in the ON
position. Both CPC and MCM faults
are included.
Active Codes — The active codes
will be flashed on the RSL (Stop
Engine) in the order of most recent
to least recent occurrence based on
engine hours.
Inactive Codes — The inactive
codes will be flashed on the AWL
(Check Engine) in the order of most
recent to least recent occurrence based
on engine hours.
All information subject to change without notice.
DDC-SVC-MAN-0006
Copyright © 2009 DETROIT DIESEL CORPORATION
43
DDEC VI ENGINE DRIVING TIPS
DDEC VI ENGINE DRIVING TIPS
Driving with an electronically
controlled engine feels different from
driving with a mechanically governed
engine.
Accelerating the Vehicle
Engine response versus pedal
movement may feel different from
the mechanical-governed engine you
were driving. The Accelerator Pedal
(AP) was designed to communicate
“percentage” foot pedal travel to
the engine's Motor Control Module
(MCM). The engine will respond
accordingly to the driver's demand.
Cruise Control
For added driver convenience and
comfort, DDEC VI also features a
Cruise Control option that works just
like the system in your car. It can
be operated in any gear above 1000
rpm or road speed faster than 20
mph (32 kph), up to the rated engine
speed. And it can be programmed to
hold your road speed at or below the
maximum vehicle speed. The switch
to energize Cruise Control is usually
mounted on the instrument panel.
See Figure 18
Another throttle or governor
characteristic you may need time to
get used to is the DDEC Limiting
Speed Governor. This allows the
driver to command total engine
response between idle and rated speed,
such as accelerating at half throttle
– an advantage when driving under
slippery conditions.
If you require wide-open throttle
engine response, either accelerating or
just plain pulling hard, the throttle AP
will have to be held to the floor. To
obtain 100% fueling at any speed, the
AP will have to be maintained at the
fully pressed position.
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DDC-SVC-MAN-0006
Figure 18
Typical Cruise Control
Switches
All information subject to change without notice.
Copyright © 2009 DETROIT DIESEL CORPORATION
EPA07 SERIES 60 ENGINE OPERATOR'S MANUAL
speed in one mile-per-hour (1.6
kilometer-per-hour) increments, press
the RSM/ACL Switch. To reduce road
speed, press and hold the SET/CST
Switch until the lower speed is
reached.
Turn the switch ON to energize the
system. Remember as a check after
each engine start, DDEC VI looks for
a one time activation of the clutch (if
equipped) and service brake before
DDEC VI allows Cruise Control to be
enabled.
Cruise Control is deactivated by
slightly pressing the service brakes,
clutch pedal, or trailer brake. The
On/Off Switch will also deactivate
Cruise Control.
DDEC VI must also see or recognize
that the Cruise Enable Switch has
changed. If the Cruise Enable Switch
is OFF it needs to be turned ON. If the
Cruise Enable Switch is left in the ON
position at key OFF, the switch must
be cycled OFF then ON for DDEC
VI to see a status change to allow
Cruise Control activation. The status
of DDEC VI inputs to activate Cruise
Control at key ON is listed in Table 1.
Cruise Control will maintain vehicle
speed even on up grades, unless power
requirements demand a downshift.
And, of course, Cruise Control does
not limit your speed on down grades.
Most likely, Cruise Control will feel
stronger than driving with the foot
pedal because of the instantaneous
and wide-open throttle response.
That's why Cruise Control use is not
suggested during slippery driving
conditions.
Once Cruise Control is enabled
and you reach your road speed,
press the Set Switch to activate
Cruise Control. The cruise light
will come on. To increase road
Input
Status of Input at
Key ON
Status of Input
Before Cruise
Control Activates
Service Brake Switch
ON
OFF
Clutch Release Switch
(Manual Trans only)
ON
OFF
Cruise Control Enable
Switch
OFF
ON
Table 1
Input Status to Activate Cruise Control
All information subject to change without notice.
DDC-SVC-MAN-0006
Copyright © 2009 DETROIT DIESEL CORPORATION
45
DDEC VI ENGINE DRIVING TIPS
Use Cruise Control after down shifting
on a hill to pull the hill. Hitting the
RSM/ACL Switch (not the Set Switch)
will keep the truck accelerating in the
lower gears up to the rated engine
speed.
Cruise Control will disengage below
1000 rpm or 20 mph (32 kph) road
speed. When using Cruise Control,
if you want to pull the engine below
1000 rpm, remember to hold the
throttle pedal to the floor to keep the
engine pulling at wide-open throttle.
The engine will pull to about 1050
rpm.
Remember: The electronic data
programmed into the DDEC VI
system will not allow you to hurt or
overfuel the engine at low or “lug”
engine speeds. There is enough oil
pressure to withstand hard pulls at low
engine speeds.
Engine Brakes and Cruise
Control
If your engine is equipped with both
Cruise Control and engine brake
retarders, the engine retarders can
operate automatically while you
are in Cruise Control. If the Cruise
Control/Engine Brake function is
turned ON in the DDEC system
programming, the engine retarders
will come on “low” when your
set road speed increases a few
miles-per-hour (kilometers per hour)
46
DDC-SVC-MAN-0006
above your cruise set speed. If
your speed continues to increase,
the DDEC system will increase the
engine retarders' braking power
progressively. When the vehicle
returns to the set cruise speed, the
engine retarders will turn off until you
need them.
For safety reasons, don't use Cruise
Control when it is not possible to keep
the vehicle at constant speed due to:
□ Winding roads
□ Heavy traffic
□ Slippery pavement
□ Descending grades that call for
engine brake assistance.
For an explanation of the engine brake
retarder system and recommendations
for proper operation, refer to ENGINE
BRAKE SYSTEM.
Shifting
Depending on your transmission
model, the gear split may vary from
500 to 300 rpm. The electronic
governor provides almost no overrun
capability; and, if the transmission
is downshifted too early, you will
experience a temporary loss of pulling
power until the engine speed falls
below rated speed.
All information subject to change without notice.
Copyright © 2009 DETROIT DIESEL CORPORATION
EPA07 SERIES 60 ENGINE OPERATOR'S MANUAL
In general, when using a 7- or 9-speed
transmission, you should always
downshift between 1250 and 1300
rpm. This is true even on steep grades
with heavy loads. When using an
18-, 15- or 13-speed transmission,
you will need to downshift at an rpm
that allows “less than rated” rpm
before throttle application in the next
gear down. You may want to limit
engine speed to 1900 rpm in all gears.
The Series 60 provides horsepower
through 2100 rpm, but fuel economy
is not as efficient above 1800 rpm.
Low rpm operation should feel greatly
enhanced due to the characteristics
of the variable nozzle turbocharger.
Engine response should be almost
instantaneous below peak torque
engine speeds. This should encourage
progressive shifting especially during
slow vehicle speed operation.
If you decide to drive at lower rpm's
for improved fuel economy, don't let
different engine noises throw you off
guard. The Series 60 sounds quiet
at 1400 rpm, almost as if it had quit
pulling. If you had a boost gage to
look at while driving, you would
notice the turbocharger maintaining
steady intake manifold pressure, even
as rpm falls. Depending on the air
intake arrangement, you may also
experience a “chuffing” sound as the
engine starts to pull hard at lower
rpm's. This is caused by the velocity
changes of the air flow within the air
All information subject to change without notice.
DDC-SVC-MAN-0006
intake plumbing. Electronic engines
can actually deliver more fuel at lower
engine speeds than at rated speed.
One difference you may notice with
the EGR equipped engine is under
hood noise. The gear train has been
redesigned for quieter operation,
and the EGR gas flow may be
noticeable to the tuned attentive ear.
The turbocharger operates at higher
boost pressure forcing EGR gas flow
through the EGR plumbing. In some
situations the driver may believe
he/she has experienced a charge air
cooler system leak. Even connecting
trailer light and air hoses, the driver
may hear a different tone (exhaust and
under hood with the engine idling.) If
equipped with a turbo boost gage, the
driver may occasionally note intake
manifold pressure exceeds 35 psi.
Idling
The common belief that idling a diesel
engine causes no engine damage is
wrong. Idling produces sulfuric acid,
which breaks down the oil and eats
into bearings, rings, valve stems and
engine surfaces. If you must idle
the engine for cab heat or cooling,
the high idle function of the Cruise
Control switches should be used.
An idle speed of 900 rpm should be
enough to provide cab heat in above
32°F (0°C) ambients.
Copyright © 2009 DETROIT DIESEL CORPORATION
47
ENGINE BRAKE SYSTEM
ENGINE BRAKE SYSTEM
Certain Series 60 vehicle engines
are equipped with engine brakes,
commonly referred to as retarders.
Before operating the vehicle, you
must familiarize yourself with the
retarder system to obtain optimum
benefit from it. Engine brake control
systems may vary slightly, depending
on the engine brake configuration and
cab design. However, basic operator
controls are similar for all models.
Driver Control Switches
Vehicles with manual transmissions
allow the driver to turn the engine
brake on and off and select a low,
medium or high level of braking. Two
types of switches are available.
The “Low” setting on this switch
activates three (3) brake cylinders,
supplying approximately 50% of
normal engine braking horsepower.
The “High” setting activates all six
(6) cylinders, providing full engine
braking horsepower.
Engine brakes have two additional
controls, one activated by the position
of the clutch pedal and the other
activated by the position of the
throttle. These controls permit fully
automatic operation of the engine
braking system.
Engine Brake Operation
NOTICE:
Low/Med/High Switch
The “Low” setting on this switch
activates two (2) brake cylinders,
yielding about one-third engine
braking horsepower. The “Medium”
activates four (4) cylinders, supplying
DDC-SVC-MAN-0006
Clutch Pedal and Throttle
Position Controls
The engine brake retarder system
depends on a full-pressure flow of
warm engine lubricating oil for proper
lubrication of moving parts and
optimum performance. .
Low/High Switch
48
about two-thirds engine braking
horsepower. The “High” setting
activates all six (6) cylinders,
providing full engine braking
horsepower.
Always allow the engine to reach
full normal operating temperature
before activating the engine brake
system to ensure positive engine
brake engagement.
All information subject to change without notice.
Copyright © 2009 DETROIT DIESEL CORPORATION
EPA07 SERIES 60 ENGINE OPERATOR'S MANUAL
you press the clutch pedal while
shifting gears.
LOSS OF VEHICLE CONTROL
To avoid injury from loss of
vehicle control, do not activate
the Engine Brake system under
the following conditions:
□ On wet or slippery pavement,
unless the vehicle is equipped
with ABS (anti-lock braking
system) and you have had
prior experience driving
under these conditions.
□ When driving without a trailer
(bobtailing) or pulling an
empty trailer.
□ If the tractor drive wheels
begin to lock or there is
fishtail motion after the
Engine Brake is activated,
deactivate the brake system
immediately if this occurs.
Under normal driving conditions the
engine brake system is left in the ON
position. However, this should change
if roads become wet or slippery.
NOTICE:
Do not attempt to “double clutch”
the transmission while the engine
brake system is turned on. Shifting
gears without pressing the clutch or
using the engine brake to reduce
engine rpm may result in serious
powertrain damage.
NOTE:
Some systems may be programmed
to activate themselves only when the
brake pedal is pressed, so read your
vehicle owner's manual thoroughly to
find out if you have this option.
Anti-Lock Braking
Systems
Vehicles equipped with ABS
(anti-lock braking systems) have
the ability to turn the engine brake
retarder OFF if a wheel-slip condition
is detected. The engine brake will
automatically turn itself ON once the
wheel slip is no longer detected.
After it is switched on, the engine
brake system is automatically
activated each time you remove
your feet completely from the clutch
pedal and throttle. The engine brake
automatically deactivates itself when
All information subject to change without notice.
DDC-SVC-MAN-0006
Copyright © 2009 DETROIT DIESEL CORPORATION
49
ENGINE BRAKE SYSTEM
The DDEC system will deactivate
the engine brake system when the
engine speed falls below 1000 rpm
or when the vehicle slows down to a
pre-set speed, depending on DDEC
programming. This prevents stalling
the engine. Engine brakes can also
be used with vehicle Cruise Control
TURNED ON.
Driving on Flat, Dry
Pavement
Use the following guidelines when
driving on flat, dry pavement:
1. If driving on flat, dry, open
stretches with a light load and
greater slowing power is not
required, place the progressive
braking switch in the LOW
position.
to LOW, and then to a higher
position.
Descending a Long, Steep
Grade
An explanation of “control speed”
may be helpful in understanding how
to use the engine brake system while
descending a grade. Control Speed
is the constant speed at which the
forces pushing the vehicle forward on
a grade are equal to the forces holding
it back, without using the vehicle
service brakes. In other words, this
is the speed the vehicle will maintain
without using the service brakes or
fueling.
Use the following guidelines when
descending a long, steep grade:
2. If you find you are still using the
service brakes, move the switch
to a higher position until you do
not need to use the service brakes
to slow the vehicle down.
1. Before beginning the descent,
determine if your engine brake
system is operating properly by
lifting your foot briefly off the
throttle. You should feel the
system activate.
3. If you are carrying a heavier load
and road traction is good, move
the progressive braking switch to
the “High” position.
4. Check your progressive braking
switch often for proper position,
since road conditions can change
quickly. Never skip a step when
operating the progressive braking
switch. Always go from OFF
50
DDC-SVC-MAN-0006
All information subject to change without notice.
Copyright © 2009 DETROIT DIESEL CORPORATION
EPA07 SERIES 60 ENGINE OPERATOR'S MANUAL
BRAKE FADE
To avoid injury, do not over
apply the vehicle service brakes
when descending a long, steep
grade. Excessive use of the
vehicle brakes will cause them
to heat up, reducing their
stopping ability. This condition,
referred to as “brake fade”, may
result in loss of braking, which
could lead to personal injury or
vehicle/property damage or both.
2. Ensure the progressive braking
switch is in the appropriate power
position.
PERSONAL INJURY
3. Do not exceed the safe control
speed of your vehicle. Example:
You could descend a 6% grade,
under control only at 10 mph (16
kph) without an engine brake, but
at 25 mph (40 kph) with an engine
brake. You could not descend
that same hill at 50 mph (80 kph)
and still expect to remain under
control. Get to know how much
slowing power your engine brake
can provide. So get to know
your engine brake system before
climbing hills and do not exceed
a safe control speed.
4. Check your progressive braking
switch often for proper position,
since road conditions can change
quickly. Never skip a step when
operating the progressive braking
switch. Always go from OFF
to LOW and then to a higher
position when on slippery roads.
Failure to keep the vehicle within
safe control speed limits while
descending a grade may result
in loss of vehicle control, which
could cause personal injury.
NOTICE:
Failure to keep the vehicle within
safe control speed limits while
descending a grade may result in
vehicle or property damage or both.
All information subject to change without notice.
DDC-SVC-MAN-0006
Copyright © 2009 DETROIT DIESEL CORPORATION
51
ENGINE BRAKE SYSTEM
Driving on Wet or Slippery
Pavement
Do not attempt to use the engine brake
system on wet or slippery roads until
you have some experience with it on
dry pavement.
LOSS OF VEHICLE CONTROL
To avoid injury from loss of
vehicle control, do not activate
the Engine Brake system under
the following conditions:
□ On wet or slippery pavement,
unless the vehicle is equipped
with ABS (anti-lock braking
system) and you have had
prior experience driving
under these conditions.
□ When driving without a trailer
(bobtailing) or pulling an
empty trailer.
□ If the tractor drive wheels
begin to lock or there is
fishtail motion after the
Engine Brake is activated,
deactivate the brake system
immediately if this occurs.
keep the trailer stretched out. Follow
the manufacturer's recommended
operating procedure when using your
trailer brakes.
On wet or slippery pavement, start
with the master switch in the OFF
position and use the gear you would
normally use under these conditions.
If the vehicle is maintaining traction,
place the selective braking switch in
the LOW position and turn ON the
engine brake system. If the drive
wheels are maintaining traction and
you desire greater slowing power,
move the braking switch to the next
highest position.
However, if the tractor drive wheels
begin to lock or there is a fishtail
motion, turn the engine brake system
OFF immediately and do not activate
it until road conditions improve.
Check your progressive braking
switch often for proper position, since
road conditions can change quickly.
Never skip a step when operating the
progressive braking system. Always
go from OFF to LOW and then to a
higher position.
NOTE:
On single trailers or combinations,
a light air application of the trailer
brakes may be desirable to help
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DDC-SVC-MAN-0006
All information subject to change without notice.
Copyright © 2009 DETROIT DIESEL CORPORATION
EPA07 SERIES 60 ENGINE OPERATOR'S MANUAL
ENGINE SYSTEMS
The engine systems are the following:
Fuel System
The fuel system consists of DDEC,
fuel injectors, fuel manifolds (integral
with the cylinder head), fuel pump,
a cooling plate for the Motor
Control Module (MCM), primary
and secondary fuel filters, and the
necessary connecting fuel lines.
Lubrication System
The lubricating oil system consists of
an oil pump, oil cooler, two full-flow
oil filters, bypass valves at the oil
pump and oil filter adaptor, and
oil pressure regulator valve in the
cylinder block vertical oil gallery.
Air System
The outside air drawn into the
engine passes through the air filter
and is pulled into the turbocharger
and compressed. It then moves to
the air-to-air charge cooler (heat
exchanger) and is cooled. Next it
flows to the intake manifold and into
the cylinders, where it mixes with
atomized fuel from the injectors.
For optimum protection of the
engine from dust and other airborne
contaminants, service the dry type
air cleaners used when the maximum
All information subject to change without notice.
DDC-SVC-MAN-0006
allowable air restriction has been
reached, or annually, whichever
occurs first.
Cooling System
A radiator/thermo-modulated fan
cooling system is used on Series 60
engines. This system has a centrifugal
type fresh water pump to circulate
coolant within the engine. Two
full-blocking type thermostats located
in a housing attached to the right side
of the cylinder head control the flow
of coolant.
Electrical System
The electrical system consists of
a starting motor, starting switch,
battery-charging alternator, storage
batteries, and the necessary wiring.
Exhaust System
Hot exhaust gas flowing from the
exhaust manifold into the exhaust riser
is used to drive the turbocharger.
Exhaust Gas Recirculation
System
The purpose of the Exhaust Gas
Recirculation System (EGR) is to
reduce engine exhaust gas emissions
in accordance with EPA regulations.
Copyright © 2009 DETROIT DIESEL CORPORATION
53
AFTERTREATMENT SYSTEM
AFTERTREATMENT SYSTEM
In order to meet current emissions
regulations, the traditional muffler has
been replaced by a new Aftertreatment
Device (ATD). This device consists
of a Diesel Oxidation Catalyst (DOC)
and a Diesel Particulate Filter (DPF).
Together these two components burn
off collected particulate matter in a
process called “regeneration.” The
Figure 19
54
key to successful regeneration is high
exhaust temperature for an extended
period of time. Without adequate
temperatures for regeneration, the
filter will continue to trap particulates
and eventually plug. In order to avoid
plugging, Detroit Diesel has designed
an actively regenerated Aftertreatment
System (ATS). See Figure 19.
Aftertreatment System
DDC-SVC-MAN-0006
All information subject to change without notice.
Copyright © 2009 DETROIT DIESEL CORPORATION
EPA07 SERIES 60 ENGINE OPERATOR'S MANUAL
Operating Requirements
Maintenance
Oxidation of the particulate matter
is the key to filter performance.
This requires that the catalyzing
agent (platinum coated passages)
are providing optimum enhancement
to the oxidation process. The
following requirements must be met,
otherwise the ATD warranty may be
compromised:
A high amount of black smoke
emitting from the vehicle or
illumination of the Amber Warning
Lamp or Red Stop Lamp are
indications of a system problem.
Should this occur, refer to the
Aftertreatment System Technician's
Guide (7SE63), or contact the Detroit
Diesel Customer Support Center at
313–592–5800.
NOTICE:
Illumination of the Diesel Particulate
Filter (DPF) Regeneration Lamp
indicates that a parked regeneration is
required.
Do not use kerosene or fuel blended
with used lube oil.
□ Use Ultra-Low Sulfur Fuel (ULSF)
with 15 ppm (0.0015 wt%) sulfur
content or less, based on ASTM
D2622 test procedure
□ Lube oil must have a sulfated ash
level less than 1.0 wt %; currently
referred to as CJ-4 oil.
NOTICE:
Not following the operating
requirements may result in damage
to the ATD or accelerated ash
plugging of the diesel particulate
filter.
All information subject to change without notice.
DDC-SVC-MAN-0006
There is a need to periodically remove
accumulated ash, derived from engine
lube oil, from the filter. This ash
does not oxidize in the filter during
the regeneration process and must
be removed through a cleaning
procedure. All Detroit Diesel ATD
equipped engines will illuminate a
dashboard warning lamp indicating the
need for ash cleaning. For information
on this cleaning procedure, refer to the
Aftertreatment System Technician's
Guide (7SE63), or contact the Detroit
Diesel Customer Support Center at
313–592–5800.
Copyright © 2009 DETROIT DIESEL CORPORATION
55
AFTERTREATMENT SYSTEM
Parked Regeneration
Procedure
NOTE:
The procedure will take up to
40 minutes (depends on engine type
and the amount of soot accumulated
in the filter).
Regeneration of the ATS is
fundamental for the oxidation of
soot. This process happens during
the normal operation cycle of the
vehicle; it can occur both passively
and actively. Regardless of this,
the operator will see no difference
in vehicle performance or vehicle
control. If the ATS is not capable
of completing an over-the-road
regeneration due to duty cycle
constraints or other restrictions, a
parked regeneration may need to
occur.
The driver will be notified of the
need for a DPF regeneration by
illumination of the DPF Regeneration
Lamp. Refer to section DRIVER
ACTIONS .
NOTE:
If the DDEC VI electronics have not
requested the initiation of a parked
regeneration (the DPF Regeneration
Lamp is not illuminated), the Regen
request switch is disabled.
NOTE:
The driver MUST stay with the vehicle
throughout the regeneration process.
NOTE:
Not all vehicles may be equipped
with a Regen request switch due to
application or user specification.
56
DDC-SVC-MAN-0006
All information subject to change without notice.
Copyright © 2009 DETROIT DIESEL CORPORATION
EPA07 SERIES 60 ENGINE OPERATOR'S MANUAL
To initiate a parked regeneration,
perform the following:
1. Keep engine at slow idle (cannot
be in PTO mode).
2. Transmission is in neutral with
parking brake ON.
3. Cycle the parking brake from
OFF to ON.
NOTE:
Air tank pressure must be high enough
for the parking brake switch to hold in
the OFF position.
4. Press and release clutch pedal (if
equipped with clutch pedal).
5. Cycle transmission to DRIVE
and back to NEUTRAL (if not
equipped with clutch pedal).
6. Hold DPF Switch in the ON
position for five seconds and
then release (engine speed will
increase and DPF Lamp will go
out).
The regeneration is completed when
the engine returns to low idle and the
DPF Lamp remains off. The High
Exhaust System Temperature (HEST)
Lamp will remain on but the vehicle
can be driven.
If the Parked Regeneration exits and
the DPF Lamp remains on, repeat the
procedure. If the second try also fails,
contact the Detroit Diesel Customer
Support Center at (313) 592-5800.
NOTE:
A Parked Regeneration will stop if the
key is turned to the OFF position, the
vehicle is put into gear, or the parking
brake is released.
Hazardous Applications
The MCM should be configured to
not allow automatically triggered
over-the-road regenerations (DPF
Manual Regen Only Enable =
Enabled).
NOTE:
This is for hazardous applications only.
There are two CPC options:
□ DPF Stationary Regen Only =
0-Disabled
□ DPF Stationary Regen Only =
1-Enabled
The regeneration will take up to 40
minutes.
All information subject to change without notice.
DDC-SVC-MAN-0006
Copyright © 2009 DETROIT DIESEL CORPORATION
57
AFTERTREATMENT SYSTEM
DPF Stationary Regen Only =
0-Disabled — This option allows
the DPF Regen Switch to request
a parked regeneration if the parked
regeneration entry conditions are met.
This option also allows MCM-initiated
over-the-road regenerations to occur.
DPF Stationary Regen Only =
1-Enabled — This option only
allows a parked regeneration to
occur by using the DPF Regeneration
Switch. The MCM will be unable
to initiate an active over-the-road
regeneration when this option is
enabled.
Service Record
It is mandatory that customers or
distributors maintain a proper record
of the particulate filter servicing and
cleaning. This record is an agent to
warranty considerations. The record
must include information such as:
□ Date of cleaning or replacement
□ Vehicle mileage at the time of
cleaning or replacement
□ Particulate filter part number and
serial number
58
DDC-SVC-MAN-0006
All information subject to change without notice.
Copyright © 2009 DETROIT DIESEL CORPORATION
EPA07 SERIES 60 ENGINE OPERATOR'S MANUAL
DRIVER ACTIONS
Name
Indicator
Lamp
SOLID: Exhaust is at
high temperature and
vehicle is at low speed
or parked.
High Exhaust
System
Temperature
(HEST) Lamp
FLASHING: A Parked
Regeneration is in
process and the system
is not up to temperature.
Indicates a failure of
an Emission Control
Device. The MIL may
illuminate at the same
time as the Check
Engine Lamp.
Malfunction
Indicator
Lamp (MIL)
SOLID: Indicates that
a Regeneration may be
needed.
DPF
Regeneration
Lamp
DPF
Regeneration
Lamp
+
Check
Engine Lamp
Description
FLASHING: Indicates
that a Regeneration is
required as soon as
possible.
FLASHING
+
No change in driving
style is required.
Vehicle can be
driven to end of
the shift. If the MIL
remains on after
three drive cycles,
call for service.
Perform a Parked
Regeneration OR
bring vehicle to
highway speeds
to allow for
an Automatic
Regeneration.
A Parked
Regeneration must
be performed.
ENGINE DERATE
All information subject to change without notice.
DDC-SVC-MAN-0006
Indicates that a Parked
Regeneration MUST be
performed.
Driver Action
Copyright © 2009 DETROIT DIESEL CORPORATION
59
DRIVER ACTIONS
Indicator
Lamp
Name
DPF
Regeneration
Lamp
+
Check
Engine Lamp
+
Red Stop
Lamp (RSL)
Table 2
60
FLASHING
+
+
Description
Indicates that a Parked
Regeneration MUST be
performed.
Driver Action
A Parked
Regeneration must
be performed.
ENGINE DERATE
Driver Actions
DDC-SVC-MAN-0006
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Copyright © 2009 DETROIT DIESEL CORPORATION
EPA07 SERIES 60 ENGINE OPERATOR'S MANUAL
INSTRUMENT PANEL LAMPS
Lamp
Table 3
Lamp
Name
Description
Results
Amber
Warning
Lamp (AWL)
Indicates a fault with the
engine controls.
Vehicle can be
driven to end
of shift. Call for
service.
Red Stop
Lamp (RSL)
Indicates a major engine
fault that may result in
engine damage. Engine
derate and/or shutdown
sequence will be initiated.
Move the vehicle
to the nearest
safe location and
shutdown the
engine. Call for
service
DPF Regeneration Lamp
Solid yellow indicates a
parked regeneration is
required. Blinking yellow,
derate, and/or shutdown
are possible as soot load
continues to increase.
Lamp will shut off during
parked regeneration.
Lamp Solid
- parked
regeneration
required
Lamp Flashing
- parked
regeneration
required
immediately.
High Exhaust
System
Temperature
Lamp
(HEST)
Indicates exhaust
temperature is above
a preset limit and the unit
is operating at low vehicle
speed. Lamp flashes once
every ten seconds during
a parked regen. Lamp is
yellow.
Vehicle can be
driven.
Malfunction
Indicator
Lamp (MIL)
Yellow lamp Indicates a
failure of an Emission
Control device. May
illuminate at the same time
as the Amber Warning
Lamp
Vehicle can be
driven to end of
the shift. Call for
service
Instrument Panel Lamps
All information subject to change without notice.
DDC-SVC-MAN-0006
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61
INSTRUMENT PANEL LAMPS
The activation conditions are
listed in Table 4.
Lamp
Lamp Solid
Lamp Flashing
□ Diagnostic Request Switch
□ At the start of every ignition
cycle (a bulb check).
□ When an electronic system
fault occurs (problem
should be diagnosed as
soon as possible).
□ At the start of every ignition
cycle (a bulb check).
□ A potential engine
damaging fault is
detected.
□ Parked regeneration is
required.
□ At the start of every ignition
cycle (a bulb check).
is used to activate the AWL
to flash inactive codes.
□ Last 90 seconds before idle
shutdown if programmed
for override.
□ Idle shutdown or the
Optimized Idle shutdown
occurs.
□ When Engine Protection
Shutdown occurs.
□ Diagnostic Request Switch
is used to activate the RSL
to flash active codes.
When a parked regeneration
is required immediately (If
the lamp flashing is ignored,
derate and/or shutdown could
occur.
□ At the start of every ignition
cycle (a bulb check).
□ Vehicle speed is less than
5 mph and the DPF outlet
temperature is greater
than 977°F (525°C).
Flashes every 10 seconds
during a parked regen
□ At the start of every ignition
cycle (a bulb check).
□ For any emission related
Never flashes
fault (light out when the
fault is inactive)
Table 4
62
Lamp Activation Conditions
DDC-SVC-MAN-0006
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Copyright © 2009 DETROIT DIESEL CORPORATION
EPA07 SERIES 60 ENGINE OPERATOR'S MANUAL
MAINTENANCE
The following is intended as a
guide for establishing preventive
maintenance intervals. The
recommendations given should
be followed as closely as possible
to obtain long life and optimum
performance from your engine.
Maintenance intervals indicated are
time (hours) of actual operation.
The intervals shown apply only to
the maintenance functions described.
These functions should be coordinated
with other regularly scheduled
maintenance.
NOTICE:
Failure to check and maintain
SCA (supplemental coolant
additive) levels at required
concentrations will result in
severe damage (corrosion) to
the engine cooling system and
related components. Coolant must
be inhibited with the recommended
SCAs listed in this guide. Refer to
“How to Select Coolant”. In addition,
the engine can be equipped with a
coolant filter/inhibitor system as an
installed option or as an after-sale
item.
Scheduled Intervals
A description of the maintenance to
be performed for each item in the
following tables can be found in the
Preventive Maintenance Intervals
section.
Recommended maintenance intervals
for Series 60 on-highway truck
and parlor coach engines are
listed in Table 5, Table 6 and Table
7. Recommended maintenance
intervals for Series 60 fire fighting,
crash/rescue, and emergency vehicle
engines are listed in Table 8, Table
9, and Table 10. Recommended
maintenance intervals for Series 60
crane engines are listed in Table 11,
Table 12, and Table 13.
All information subject to change without notice.
DDC-SVC-MAN-0006
Copyright © 2009 DETROIT DIESEL CORPORATION
63
MAINTENANCE
Daily
Checks
Item
1. Lubricating Oil
I
2. Fuel Tank
I
3. Fuel Lines & Flex Hoses
I
4. Cooling System
I
5. Turbocharger
I
6. Battery
7,500 Miles
(12,000 Km)
30,000 Miles
(48,280 Km)
R
I
I
7. Aftertreatment Device
Inspect every 6 months or 15,000
miles (24,000 Km)
8. Drive Belts
I
9. Air Compressor
I
10. Air Cleaner
I
11. Lube Oil Filters
R
12. Fuel Filters
R
13. Coolant/Inhibitor Level
I
All items are described in Preventive Maintenance Intervals.
I – Inspect, service, correct or replace as necessary.
R – Replace.
Table 5
64
On-Highway Truck and Parlor Coach Daily, 7,500 Mile, and
15,000 Mile Checks
DDC-SVC-MAN-0006
All information subject to change without notice.
Copyright © 2009 DETROIT DIESEL CORPORATION
EPA07 SERIES 60 ENGINE OPERATOR'S MANUAL
Months
6
12
18
24
30
36
Miles/Km
( X 1000)
15/
24
30/
48
45/
72
60/
96
75/
120
90/ 105/ 120/ 135/ 150/
144 168 192 216 240
Item
42
48
54
60
Procedure
1.
Lubricating Oil
Replace every 30,000 miles (48,280 km).
2.
Fuel Tank
I
4.
Cooling
System
I
I
I
I
I
I
I
I
I
I
5.
Turbocharger
7.
Aftertreatment
Device
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
Inspect every 6 months or 15,000 miles (24,000 Km)
Severe Duty: ash removal at 550,000 miles (893,185 Km)
Short-Haul: ash removal at 550,000 miles (893,185 Km)
Long-Haul: ash removal at 550,000 miles (893,185 Km)
11. Lube Oil Filter
Replace when lubricating oil is changed.
12. Fuel Filters
R
R
R
R
R
R
R
R
R
R
13. Water Pump/
Inhibitor Level
I
I
I
I
I
I
I
I
I
I
14. Cranking Motor
Follow manufacturer's recommendations.
15. Air System
I
I
I
I
I
I
I
I
I
I
Exhaust
16.
System
I
I
I
I
I
I
I
I
I
I
All items are described in Preventive Maintenance Intervals.
I – Inspect, service, correct or replace as necessary.
R – Replace.
Table 6
On-Highway Truck and Parlor Coach Regular Maintenance
Intervals
All information subject to change without notice.
DDC-SVC-MAN-0006
Copyright © 2009 DETROIT DIESEL CORPORATION
65
MAINTENANCE
Months
Miles/Km
( X 1000)
6
12 18
24
15/ 30/ 45/ 60/
24 48 72 96
Item
36
75/ 90/
120 144
42
48
I
I
60
I
I
I
I
I
I
I
22. Crankcase Pressure
I
I
I
I
I
I
I
I
I
I
I
I
23. Fan Hub
I
24. Thermostats & Seals
I
25. Crankcase Breather
I
I
I
26. Engine Tune-Up
27. Vibration Damper
54
105/ 120/ 135/ 150/
168 192 216 240
Procedures
17. Engine
(Steam Clean)
18. Radiator & A/A
Charge Cooler
19. Oil Pressure
20. Battery Charging
Alternator
21. Engine &
Transmission Mounts
30
I
Replace at major engine overhaul or earlier
if dented or leaking.
All items are described in Preventive Maintenance Intervals.
I – Inspect, service, correct or replace as necessary.
R – Replace.
Table 7
66
On-Highway Truck and Parlor Coach Regular Maintenance
Intervals (continued)
DDC-SVC-MAN-0006
All information subject to change without notice.
Copyright © 2009 DETROIT DIESEL CORPORATION
EPA07 SERIES 60 ENGINE OPERATOR'S MANUAL
Daily
Checks
Item
1. Lubricating Oil
I
2. Fuel Tank
I
3. Fuel Lines & Flexible Hoses
I
4. Cooling System
I
5. Turbocharger
I
6. Battery
100 Hours or
3,000 Miles
( 4,800 Km)
300 Hours or
6,000 Miles
( 9,600 Km)
R
I
7. Aftertreatment Device
8. Drive Belts
Inspect every 6 months or 15,000
miles (24,000 Km)
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
All items are described in Preventive Maintenance Intervals.
I – Inspect, service, correct or replace as necessary.
R – Replace.
Table 8
Fire Fighting, Crash/Rescue and Emergency Vehicle
Engine Daily, 100 Hour and 300 Hour Checks
All information subject to change without notice.
DDC-SVC-MAN-0006
Copyright © 2009 DETROIT DIESEL CORPORATION
67
MAINTENANCE
Hours
300
600
900
1,200
1,500
Miles/Km
(X 1000)
6/
9.6
12/
19.6
18/
28.8
24/
38.4
30/
48
Item
Procedures
Lubricating Oil
Change every 300 hours or 6,000 miles (1,600
km), whichever comes first.
2.
Fuel Tank
I
4.
Cooling
System
5.
Turbocharger
7.
Aftertreatment
Device
1.
I
I
I
Air
Compressor
Lube Oil
11.
Filters
9.
12. Fuel Filters
13. Water Pump/
Inhibitor Level
Cranking
14.
Motor
I
I
I
Inspect every 6 months or 15,000 miles (24,000 Km)
Severe Duty: ash removal at 400,000 miles (643,720 Km)
Short-Haul: ash removal at 500,000 miles (804,650 Km)
Long-Haul: ash removal at 600,000 miles (965580 Km)
I
I
I
I
I
Replace when lubricating oil is changed.
R
R
R
R
R
I
I
I
I
I
Follow manufacturer's recommendations.
15. Air System
I
I
I
I
I
Exhaust
16.
System
I
I
I
I
I
All items are described in Preventive Maintenance Intervals.
I – Inspect, service, correct or replace as necessary.
R – Replace.
Table 9
68
Fire Fighting, Crash/Rescue and Emergency Vehicle
Engine Regular Maintenance Intervals
DDC-SVC-MAN-0006
All information subject to change without notice.
Copyright © 2009 DETROIT DIESEL CORPORATION
EPA07 SERIES 60 ENGINE OPERATOR'S MANUAL
Hours
300
600
900
1,200
1,500
Miles/Km
(X 1000)
6/9.6
12/19.3
18/28.8
24/38.4
30/48
I
I
Item
Procedures
17.
Engine (Steam Clean)
18.
Radiator & A/A Charge
Cooler
19.
Oil Pressure
20.
Battery Charging
Alternator
Engine & Transmission
Mounts
21.
I
I
I
I
22.
Crankcase Pressure
23.
Fan Hub
24.
Thermostats & Seals
25.
Crankcase Breather
26.
Engine Tune-Up
27.
Vibration Damper
I
I
I
I
I
I
I
I
I
I
I
I
I
Replace at major engine overhaul or
earlier 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 Vehicle
Engine Regular Maintenance Intervals (continued)
All information subject to change without notice.
DDC-SVC-MAN-0006
Copyright © 2009 DETROIT DIESEL CORPORATION
69
MAINTENANCE
Item
Daily
Checks
1.
Lubricating Oil
I
2.
Fuel Tank
I
3.
Fuel Lines &
Flexible Hoses
I
4.
Cooling System
I
5.
Turbocharger
I
6.
Battery
7.
Tachometer Drive
8.
Drive Belts
9.
Air Compressor
100 Hr
or
3,000 Mi
150 Hr
or
4,500 Mi
200 Hr
or
6,000 Mi
300 Hr
or
9,000 Mi
I
I
I
I
I
10. Air Cleaner
11. Lube Oil Filters
12. Fuel Filters
I
—
R
13. Coolant/ Inhibitor
Level
I
18. Radiator
I
20. Battery Charging
Alternator
I
All items are described in Preventive Maintenance Intervals.
I – Inspect, service, correct or replace as necessary.
R – Replace.
Table 11
70
Crane Engine Daily, 100 Hour, 150 Hour, 200 Hour, and
300 Hour Checks
DDC-SVC-MAN-0006
All information subject to change without notice.
Copyright © 2009 DETROIT DIESEL CORPORATION
EPA07 SERIES 60 ENGINE OPERATOR'S MANUAL
Hours
Miles/Km
( X 1000)
150 300 450
600
750
900 1050 1200 1350 1500
4.5/ 9.0/ 13.5/ 18/ 22.5/ 27/ 31.5/ 36/ 40.5/ 45/
7.2 14.4 21.6 28.8 36 43.2 50.4 57.6 64.6 72
Item
Procedures
1. Lubricating Oil
Change lubricating oil every 250 hours or 1
year, whichever comes first.
2. Fuel Tank
I
I
4. Cooling
System
I
I
I
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 Filters
12. Fuel Filters
13. Coolant Pump/
Inhibitor Level
14. Cranking
Motor
15. Air System
Replace when lubricating oil is changed.
R
R
R
R
R
R
R
R
R
R
I
I
I
I
I
I
I
I
I
I
Follow manufacturer's recommendations.
I
I
I
I
I
I
I
I
I
I
All items are described in Preventive Maintenance Intervals.
I – Inspect, service, correct or replace as necessary.
R – Replace.
Table 12
Crane Regular Maintenance Intervals
All information subject to change without notice.
DDC-SVC-MAN-0006
Copyright © 2009 DETROIT DIESEL CORPORATION
71
MAINTENANCE
Hours
150 300 450 600 750 900 1050 1200 1350 1500
Miles/Km
( X 1000)
4.5/ 9.0/ 13.5/ 18/ 22.5/ 27/ 31.5/ 36/ 40.5/ 45/
7.2 14.4 21.6 28.8 36 43.2 50.4 57.6 64.6 72
Item
Procedures
16. Exhaust System
17. Engine
(Steam Clean)
18. Radiator & A/A
Charge Cooler
I
I
I
19. Oil Pressure
20. Battery
Charging
Alternator
21. Engine &
Transmission
Mounts
22. Crankcase
Pressure
I
I
I
I
I
I
I
23. Fan Hub
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
24. Thermostats &
Seals
25. Crankcase
Breather
I
26. Engine Tune-Up
27. Vibration
Damper
I
I
Replace at major engine overhaul or earlier
if dented or leaking.
All items are described in Preventive Maintenance Intervals.
I – Inspect, service, correct or replace as necessary.
R – Replace.
Table 13
72
Crane Regular Maintenance Intervals (continued)
DDC-SVC-MAN-0006
All information subject to change without notice.
Copyright © 2009 DETROIT DIESEL CORPORATION
EPA07 SERIES 60 ENGINE OPERATOR'S MANUAL
Preventive Maintenance
Intervals
This section describes the items listed
in the maintenance interval tables.
Add the proper grade of oil to maintain
the satisfactory range on the dipstick.
See Figure 20.
The “Daily” instructions apply to
routine or daily starting of the engine.
They do not apply to a new engine
or one that has been operated for a
considerable period of time.
For new or stored engines, refer to the
Series 60 Service Manual (6SE483).
Follow instructions in Section 13.1
under Preparations for Starting the
Engine the First Time.
Preventive maintenance other than the
“Daily” checks should be performed
by authorized Detroit Diesel service
outlets. These outlets have the trained
personnel and special tools to properly
perform all services.
Item 1 – Lubricating Oil
Check the oil level daily with the
engine stopped. If the engine has
just been stopped and is warm, wait
approximately 20 minutes to allow
the oil to drain back into the oil pan
before checking. The dipstick has
an operating range identified by a
crosshatch. If the oil meniscus is
within this crosshatch range then
the oil range is adequate for engine
operation.
All information subject to change without notice.
DDC-SVC-MAN-0006
Figure 20
Check Oil Level Daily
NOTICE:
When adding lubricating oil, do
not overfill. Oil may be blown out
through the crankcase breather if
the crankcase is overfilled.
All diesel engines are designed to
use some oil, so the periodic addition
of oil is normal. See Figure 21 to
determine the degree of oil usage.
Copyright © 2009 DETROIT DIESEL CORPORATION
73
MAINTENANCE
Figure 21
Engine Oil Consumption Guidelines
NOTICE:
If the oil level is constantly above
normal and excess oil has not been
added to the crankcase, consult
with an authorized Detroit Diesel
service outlet for the cause. Fuel or
coolant dilution of lubricating oil can
result in serious engine damage.
Service Application
Highway Truck & Motor Coach
Fire Fighting, Crash/Rescue, &
Emergency Vehicles
Before adding lubricating oil, refer to
How to Select Lubricating Oil in this
guide. Change lubricating oil and
filters at the intervals listed in Table 14
when using fuel with a sulfur content
of less than 0.05 mass percent. When
using fuel with a higher sulfur content,
refer to When to Change Oil in this
guide.
Lube Oil and Filter Change Interval*
30,000 Miles (48,280 Kilometers) —
Long Haul
20,000 Miles (32,000 Kilometers) —
Short Haul
15,000 Miles (24,000 Kilometers) —
Severe
6,000 Miles (9,600 Kilometers), 300 Hours
or 1 Year, whichever comes first
* Change both full-flow filters when lube oil is changed.
Table 14
74
Recommended Engine Oil Drain and Filter Change
Intervals (Diesel Fuel Sulfur Content Less Than
0.05 Mass % (0.0015 wt%))
DDC-SVC-MAN-0006
All information subject to change without notice.
Copyright © 2009 DETROIT DIESEL CORPORATION
EPA07 SERIES 60 ENGINE OPERATOR'S MANUAL
Item 2 – Fuel and Fuel Tank
Keep the fuel tank filled to reduce
condensation. See Figure 22.
PERSONAL INJURY
To avoid injury from improper use
of chemicals, follow the chemical
manufacturer’s usage, handling,
and disposal instructions.
Observe all manufacturer’s
cautions.
Figure 22
Filled Fuel Tank
Before adding fuel, refer to How to
Select Diesel Fuel in the HOW-TO
SECTION of this guide.
Refill the tank at the end of each day's
operation to prevent condensation
from contaminating the fuel.
Condensation formed in a partially
filled tank promotes the growth of
microorganisms that can clog fuel
filters and restrict fuel flow.
To prevent microbe growth,
add a biocide to the fuel tank
or primary fuel supply. Water
accumulation can be controlled by
using additives containing methyl
carbitol or butyl cellusolve. Follow
manufacturer's usage, handling and
safety precautions.
All information subject to change without notice.
DDC-SVC-MAN-0006
NOTICE:
Never use galvanized steel fuel
tanks, fittings, pipes or supply lines.
The fuel reacts chemically with the
zinc coating to form powdery flakes
that can quickly clog the fuel filters
and damage the fuel pump and
injectors.
Open the drain at the bottom of the
fuel tank every 30,000 miles (48,280
kilometers) to drain off any water
and/or sediment.
Every 120,000 miles (192,000
kilometers) or 12 months tighten all
fuel tank mountings and brackets. At
the same time, check the seal in the
fuel tank cap, the breather hole in the
cap and the condition of the flexible
fuel lines. Repair or replace the parts,
as necessary.
Copyright © 2009 DETROIT DIESEL CORPORATION
75
MAINTENANCE
Item 3 – Fuel Lines, Flexible
Hoses
A pre-start inspection of hoses and
fuel lines is recommended.
Leaks — Make a visual check for
fuel leaks at all engine-mounted fuel
lines and connections, and at the
fuel tank suction and return lines.
Since fuel tanks are susceptible to
road hazards, leaks in this area may
best be detected by checking for an
accumulation of fuel under the tank.
FIRE
To avoid injury from fire, contain
and eliminate leaks of flammable
fluids as they occur. Failure to
eliminate leaks could result in
fire.
Leaks are not only detrimental to
machine operation, but they can also
result in added expense caused by the
need to replace lost fluids.
Hoses and Fittings — Check
hoses daily as part of the pre-start
inspection. Examine hoses for leaks,
and check all fittings, clamps and
ties carefully. Make sure hoses are
not resting on or touching shafts,
couplings, heated surfaces including
exhaust manifolds, any sharp edges,
76
DDC-SVC-MAN-0006
or other obviously hazardous areas.
Since all machinery vibrates and
moves to a certain extent, clamps and
ties can fatigue with age. To ensure
continued proper support, inspect
fasteners frequently and tighten or
replace them as necessary. If fittings
have loosened or cracked or if hoses
have ruptured or worn through, take
corrective action immediately.
Hose Service Life — A hose has
a finite service life. With this in
mind, all hoses should be thoroughly
inspected at least every 500 operating
hours (1,000 hours for fire-resistant
fuel and lubricating oil hoses) and/or
annually. Look for cover damage
and/or indications of twisted, worn,
crimped, brittle, cracked or leaking
lines. Hoses with their outer cover
worn through or with damaged metal
reinforcements should be considered
unfit for further service.
All hoses in and out of machinery
should be replaced during major
overhaul and/or after a maximum of
five (5) years of service.
NOTE:
Fire-resistant fuel and lube oil hose
assemblies do not require automatic
replacement after five years of service
or at major overhaul, but should be
inspected carefully before being put
back into service.
All information subject to change without notice.
Copyright © 2009 DETROIT DIESEL CORPORATION
EPA07 SERIES 60 ENGINE OPERATOR'S MANUAL
Item 4 – Cooling System
The cooling system must be full for
proper operation of the engine.
HOT COOLANT
To avoid scalding from the
expulsion of hot coolant, never
remove the cooling system
pressure cap while the engine is
at operating temperature. Wear
adequate protective clothing
(face shield, rubber gloves,
apron, and boots). Remove the
cap slowly to relieve pressure.
Check the coolant level daily and
maintain it near the bottom of the
filler neck on the radiator. On some
installations this is done by checking
an overflow bottle or sight glass. Add
coolant as required, but do not overfill.
Before adding coolant, refer to How to
Select Coolant in this guide.
Coolant Level — Make a daily
visual check for cooling system leaks.
Look for an accumulation of coolant
when the engine is running and when
it is stopped. Coolant leaks may be
more apparent on a engine when it is
cold.
All information subject to change without notice.
DDC-SVC-MAN-0006
Coolant Inhibitors — The
inhibitors in antifreeze solutions must
be replenished with a non-chromate
corrosion inhibitor supplement when
indicated by testing the coolant.
Refer to How to Select Coolant in this
guide.for required test intervals and
inhibitor levels.
NOTICE:
Coolant must be inhibited with
the recommended SCAs listed in
this guide. Failure to check and
maintain SCA levels at required
concentrations will result in
severe damage (corrosion) to
the engine cooling system and
related components.
The cooling system is protected by a
supplemental coolant additive (SCA)
element In addition, the engine can be
equipped with a coolant filter/inhibitor
system as an installed option or as an
after-sale item.
Coolant Drain Interval — A
coolant system properly maintained
and protected with supplemental
coolant inhibitors can be operated
up to the intervals listed. At
these intervals the coolant must
be drained and disposed of in an
environmentally responsible manner
according to state and/or federal
(EPA) recommendations.
Copyright © 2009 DETROIT DIESEL CORPORATION
77
MAINTENANCE
Detroit Diesel recommends
replacing coolant at the intervals
listed in Table 15.
Coolant Type
Coolant Replacement Interval
With proper maintenance1 coolant
A 50/50 mix of POWER COOL® fully
can be operated 2 years, 300,000
formulated, inhibited ethylene glycol
miles (480,000 km), or 4,000 hours,
antifreeze and water or a 50/50 mix of
whichever comes first. At this time the
fully formulated, inhibited propylene
cooling system must be completely
glycol antifreeze and water
drained and cleaned before refill.
With proper maintenance1 coolant can
be operated for the life of the engine
until overhaul.2 For life to overhaul,
A 50/50 mix of phosphate-free TMC
pre-charged coolant in combination
RP-329 “Type A“ (propylene glycol)
with a need-release filter must be
antifreeze and water.
used. At this time the cooling system
must be completely drained and
cleaned before refill.
With proper maintenance coolant can
be operated 4 years, 600,000 miles
(960,000 km), or 10,000 operating
A 50/50 mix of OAT (organic acid
hours, whichever comes first. 3 At
technology) coolant and water.
this time the cooling system must
be completely drained and cleaned
before refill.
1
Proper maintenance involves periodic evaluation using PowerTrac®
3-Way Coolant Test Strips and the addition of required SCA, as
indicated by the test strip.
2
To verify coolant acceptability, submit a sample to Detroit Diesel for
coolant analysis every 3 years, 300,000 miles (480,000 km) or
6,000 operating hours, whichever comes first. Submit sample using
PowerTrac coolant analysis kit, part number 23516921 (IEG/IPG
coolant) or 23523398 (organic coolant).
3
OAT coolants require the addition of an extender every 2 years,
300,000 miles (480,000 km), or 5,000 hours, whichever comes first.
Use 1 pint to 20 gallons of OAT coolant.
Table 15
78
Coolant Drain Intervals
DDC-SVC-MAN-0006
All information subject to change without notice.
Copyright © 2009 DETROIT DIESEL CORPORATION
EPA07 SERIES 60 ENGINE OPERATOR'S MANUAL
Item 5 – Turbocharger, Air-to-Air
Charge Cooler
Visually inspect the turbocharger
mountings, intake and exhaust ducting
and connections for leaks daily.
is factory-calibrated and is not
adjustable. Check actuator operation
at the intervals shown in the
maintenance schedule.
EYE INJURY
PERSONAL INJURY
To avoid injury from hot surfaces,
wear protective gloves, or allow
engine to cool before removing
any component.
Check the lube oil inlet and outlet
lines for leaks or restrictions to oil
flow. Check for unusual noise or
vibration and, if excessive, stop the
engine and do not operate until the
cause is determined.
To avoid injury from flying debris
when using compressed air, wear
adequate eye protection (face
shield or safety goggles) and do
not exceed 276 kPa (40 psi) air
pressure.
Item 6 – Battery
Check the hydrometer “eye” of
maintenance-free batteries for charge.
See Figure 23.
Periodically inspect the air-to-air
charge cooler (if used) for buildup of
dirt, mud, etc. and wash off. Check
the charge cooler, ductwork, and
flexible connections for leaks and
have repaired or replaced, as required.
Check turbocharger heat-insulating
exhaust system blankets (if used) for
damage on a daily basis. Torn, matted,
crushed, oil-soaked or otherwise
damaged insulation blankets must be
replaced immediately.
Wastegated Turbochargers —
The turbocharger wastegate actuator
All information subject to change without notice.
DDC-SVC-MAN-0006
Figure 23
Maintenance-Free
Battery “Eye”
Copyright © 2009 DETROIT DIESEL CORPORATION
79
MAINTENANCE
if possible. Replace any battery that
fails to hold a charge.
PERSONAL INJURY
Periodically check battery connections
for corrosion and tightness. If
necessary, remove connections
and wire brush any corrosion from
terminals and cable ends. Replace
damaged wiring.
To avoid injury from accidental
engine startup while servicing
the engine, disconnect/disable
the starting system.
If lead-acid or low-maintenance
batteries are used, check the specific
gravity of each cell every 150
operating hours. Check more
frequently in warm weather due to
the more rapid loss of water through
evaporation.
Maintain the electrolyte level
according to the battery manufacturer's
recommendations, but do not overfill.
Overfilling can cause poor battery
performance or early failure.
Keep the terminal side of the battery
clean. When necessary, wash with
a solution of baking soda and water.
Rinse with fresh water. Do not allow
the soda solution to enter the cells.
Inspect the cables, clamps and
hold-down brackets regularly. Clean
and reapply a light coating of
petroleum jelly when needed. Have
corroded or damaged parts replaced.
If the engine is to be out of service
for more than 30 days, remove the
batteries and store in a cool, dry
place. Keep batteries fully charged,
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DDC-SVC-MAN-0006
Item 7 – Aftertreatment System
There is a need to periodically remove
accumulated ash, derived from engine
lube oil, from the filter. This ash
does not oxidize in the filter during
the regeneration process and must
be removed through a cleaning
procedure. All Detroit Diesel ATD
equipped engines will illuminate a
dashboard warning lamp indicating
the need for ash cleaning. Also inspect
the ATD for wiring concerns (chaffing
or melted) and loose connections.
Item 8 – Drive Belts
Belts should be neither too tight nor
too loose. Belts that are too tight
impose extra loads on the crankshaft,
fan and/or alternator bearings,
shortening both belt and bearing life.
Excessively overtightened belts can
result in crankshaft breakage. A loose
belt will slip and may cause damage
to accessory components.
All information subject to change without notice.
Copyright © 2009 DETROIT DIESEL CORPORATION
EPA07 SERIES 60 ENGINE OPERATOR'S MANUAL
of operation. Tighten V-belts as
listed in Table 16.
PERSONAL INJURY
To avoid injury from rotating belts
and fans, do not remove and
discard safety guards.
Use a belt tension gage, such as
Kent-Moore® tool J 23586–B
(V-belt), J 23600–B (poly-V belt),
J 41251 (PowerBand® and 12–rib
poly-V belt), or equivalent, when
tensioning drive belts. Tension belts
to the values listed in Table 16.
V-Belts — New standard V-belts
will stretch after the first few hours
Run the engine for 10 to 15 minutes
to seat the belts, then readjust tension.
Check and retension belts after 1/2
hour and again after 8 hours or
250 miles (400 km) of operation.
Thereafter, check the tension of the
drive belts every 100 hours or 6,000
miles (10,000 km) and adjust, if
necessary.
If a belt tension gage is not available,
adjust the belt tension so that a firm
push with the thumb, at a point
midway between the two pulleys, will
press the belt .50 in. – .75 in. (13 –
19 mm).
Fan Drive
Single Belt
2 or 3 Belts
80 – 100 lbs (356 – 445 N)
60 – 80 lbs (267 – 356 N)
Alternator Drive
Belt
New
Used
Two 1/2–in. V-Groove
125 lbs (556 N)
100 lbs (445 N)
2–Groove PowerBand®
200 lbs (890 N)
150 lbs (667 N)
12–Rib Poly-V (50 DN Alternator)
350 lbs (1,557 N)
250 lbs (1,112 N)
Table 16
Drive Belt Tensioning
All information subject to change without notice.
DDC-SVC-MAN-0006
Copyright © 2009 DETROIT DIESEL CORPORATION
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MAINTENANCE
2-Groove PowerBand — A 8-rib
belt is used with the 50 DN alternator
for motorcoach applications. To
provide proper running tension for the
belt, current Series 60 engines use an
auto belt tensioner, which requires no
adjustment. See Figure 24.
a 10 – 15 minute cool down period.
Check tension with tool J 41251–B
or equivalent. If tension is 250 lbs
(1,112 N) or more, no retensioning is
required. If tension is less than 250 lbs
(1,112 N), retension to 250 lbs (1,112
N). Measure belt tension every month
or every 7,500 miles (12,000 km),
whichever comes first. Retension to
250 lbs (1,112 N) as required.
Belt Replacement — Drive belts
(V and poly-V) should be replaced
every 2,000 hours or 100,000 miles
(160,000 km).
Figure 24
Replace all belts in a set when one
is worn. Single belts of similar size
should not be used as a substitute for a
matched belt set.
Auto Belt Tensioner
Assembly with 50 DN
Alternator
Tighten a new drive belt to 200 lbs
(890 N), then run the engine for 10
minutes at 1200 rpm. Stop the engine
and allow a 10 – 15 minute cool down
period. Check tension. If less than
150 lbs (667 N), retension to 150 lbs
(667 N). Following initial tensioning,
measure belt tension every month
or every 7,500 miles (12,000 km),
whichever comes first. Retension belt
to 150 lbs (667 N) at these intervals.
12–Rib Poly-V Belt — Tighten an
12–rib poly-V belt to 350 lbs (1,557
N), then run the engine at high idle for
30 minutes. Stop the engine and allow
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DDC-SVC-MAN-0006
Premature belt wear can result because
of belt length variation. All belts
within a matched set are within .032
in. (0.8 mm) of their specified center
distances.
When installing or adjusting an
accessory drive belt, be sure the bolt
at the accessory adjusting pivot point
is properly tightened, as well as the
bolt in the adjusting slot. In addition,
check the torque on the alternator and
bracket mounting bolts. Retighten as
required.
All information subject to change without notice.
Copyright © 2009 DETROIT DIESEL CORPORATION
EPA07 SERIES 60 ENGINE OPERATOR'S MANUAL
Item 9 – Air Compressor
All air compressor intake parts should
be removed and cleaned at 7,500 miles
(12,000 km).
To clean either the hair type or the
polyurethane type compressor air
strainer element, saturate it and
squeeze it in fuel oil or any other
cleaning agent that is not detrimental
to the element until it is dirt-free. Then
saturate the element in lubricating oil
and squeeze it dry before placing it
back into the air strainer.
For air strainer replacement,
contact the nearest servicing dealer.
Replace hair type elements with the
polyurethane type, if available.
The air compressor mounting bolts
should be tightened every 12 months
or 30,000 miles (48,280 km).
Item 10 – Air Cleaner
The air cleaner element should be
inspected every 15,000 miles (24,000
km) or more often if the engine is
operated under severe dust conditions.
Replace the element, if necessary.
Check the gaskets for deterioration
and replace, if necessary. If the dry
type air cleaner is equipped with an
aspirator, check for aspirator damage
or clogging. Clean, repair or replace,
as necessary.
All information subject to change without notice.
DDC-SVC-MAN-0006
NOTICE:
Do not allow the air inlet restriction to
exceed 20 in. H2O (5.0 kPa) under
any engine operating conditions.
A clogged air cleaner element will
cause excessive intake restriction
and reduced air supply to the
engine resulting in increased fuel
consumption, inefficient engine
operation and reduced engine life.
Inspect the entire air system for leaks
daily. Look especially for torn air inlet
piping or boots and loose or damaged
clamps. Have worn or damaged parts
repaired or replaced, as required.
Retighten loose connections.
Air Cleaner Replacement —
Dry type air cleaner elements should
be replaced after one year of service
or when the maximum allowable air
intake restriction has been reached,
whichever comes first. Refer to When
to Service the Dry Type Air Cleaner in
this guide for additional information.
Item 11 – Lubricating Oil Filters
Install new spin-on oil filters at a
maximum of 30,000 miles (48,280
km). For city transit coach engines,
install filters at a maximum of 6,000
miles (9,600 km).
Copyright © 2009 DETROIT DIESEL CORPORATION
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MAINTENANCE
Install the new filters, turning them
until they contact the gasket fully with
no side movement. Turn full-flow
filters an additional 2/3 turn by
hand, or as indicated on the filter.
See Figure 25.
PERSONAL INJURY
To avoid injury from slipping and
falling, immediately clean up any
spilled liquids.
Make a visual check of all lubricating
oil lines for wear and/or chafing. If
any indication of wear is evident,
replace the oil lines and correct the
cause.
Check for oil leaks after starting the
engine.
Item 12 – Fuel Filters
One method of determining when
filters are plugged to the extent that
they need replacing is based on the
fuel pressure at the cylinder head fuel
inlet fitting and the inlet restriction at
the fuel pump.
In a clean system the maximum pump
inlet restriction should not exceed 6
inches of mercury (20.3 kPa). In a
dirty system it must not exceed 12
inches of mercury (41 kPa).
At normal operating speed and with
the standard fuel pressure regulator,
the fuel pressure is 55 – 70 psi (375
– 483 kPa).
Change the fuel filters whenever the
inlet restriction at the pump reaches 12
inches of mercury (41 kPa) at normal
operating speeds and whenever the
fuel pressure at the inlet fitting falls to
the minimum fuel pressure of 6 inches
of mercury (20.3 kPa).
NOTE:
Filter change intervals may be
shortened to conform with established
preventive maintenance schedules,
but should never be extended.
Figure 25
84
Lubricating Oil Filters
DDC-SVC-MAN-0006
Fuel Pro® 382 Filters — Install
new Fuel Pro® 382 primary fuel filter
elements when the fuel level in the
see-thru cover reaches the top of the
element or after one year of service,
whichever comes first.
All information subject to change without notice.
Copyright © 2009 DETROIT DIESEL CORPORATION
EPA07 SERIES 60 ENGINE OPERATOR'S MANUAL
Spin-On Filters — Install new
spin-on primary and secondary fuel
filter elements on vehicle engines
every 15,000 miles (24,000 km) or
every six months, whichever comes
first. See Figure 26.
Replace spin-on filter elements
immediately if plugging is indicated,
regardless of mileage or hour intervals.
coolant does not leak from the drain
hole under normal conditions, do not
replace the water pump.
Coolant Inhibitor Element — If
the cooling system is protected by a
supplemental coolant additive (SCA)
element, the coolant must be tested
at required intervals and the element
replaced, if required. See Figure 27.
Item 13 – Water Pump and
Coolant Inhibitor Element
Check the water pump and the coolant
inhibitor element.
Figure 26
Spin-On Fuel Filter
Locations
Water Pump Drain Hole — The
water pump drain hole should be
inspected every 6 months to make sure
it is open. A small chemical build-up
or streaking at the drain hole may
occur. This is not an indication of a
defective water pump or seal.
Figure 27
Coolant Inhibitor
Element
Required test intervals are
listed in Table 24.
Remove the build-up with a mild
detergent cleaner and a brush. If
All information subject to change without notice.
DDC-SVC-MAN-0006
Copyright © 2009 DETROIT DIESEL CORPORATION
85
MAINTENANCE
For SCA test procedures refer to
How to Select Coolant and SCA Test
Procedures in this guide. Use the
coolant filter element required. The
valves mounted on the filter adaptor
head must be opened after the element
is replaced.
NOTICE:
Do not apply steam or solvent
directly to the battery-charging
alternator, starting motor, DDEC
components, sensors or other
electrical components, as damage
may result.
Item 14 – Cranking Motor
Item 18 – Radiator
For cranking motor (starter)
information, contact an authorized
Delco Remy® or Bosch® service
center, depending on manufacturer.
The exterior of the radiator core
should be inspected every 30,000
miles (48,280 km), 12 months, or 300
hours (industrial applications) and
cleaned, if necessary.
Item 15 – Air System
All the connections in the air system
should be checked to make sure
they are tight and leak free. Check
all hoses and ducting for punctures,
deterioration or other damage and
replace, if necessary.
Item 16 – Exhaust System
Have the exhaust manifold retaining
bolts and other connections checked
for tightness. Have the exhaust pipe
rain cap checked for proper operation,
if so equipped.
Item 17 – Engine (Steam Clean)
Steam clean the engine and engine
compartment every 60,000 miles
(96,000 km) or 2,000 hours,
whichever comes first.
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DDC-SVC-MAN-0006
EYE INJURY
To avoid injury from flying debris
when using compressed air, wear
adequate eye protection (face
shield or safety goggles) and do
not exceed 276 kPa (40 psi) air
pressure.
Use a quality grease solvent, such
as mineral spirits, and dry with
compressed air. Fuel oil, kerosene or
gasoline should not be used.
It may be necessary to clean the
radiator more frequently if the engine
is being operated in extremely dusty
or dirty areas.
All information subject to change without notice.
Copyright © 2009 DETROIT DIESEL CORPORATION
EPA07 SERIES 60 ENGINE OPERATOR'S MANUAL
If the low coolant level sensor is
installed in the top tank of the radiator,
it should be tested for proper operation
every 100,000 miles (160,000 km)
or 12 months, whichever comes first.
Authorized Detroit Diesel distributors
are properly equipped to perform this
service.
Item 19 – Oil Pressure
Under normal operation, oil pressure
is noted each time the engine is
started. In the event the equipment
has warning lights rather than pressure
indicators, the pressure should be
checked and recorded every 60,000
miles (96,000 km).
Item 20 – Battery-Charging
Alternator
Precautions must be taken when
working on or around the alternator.
The diodes and transistors in the
alternator circuit are very sensitive
and can be easily destroyed.
To avoid equipment damage, pay
attention to the following:
Battery Explosion and Acid Burn
To avoid injury from battery
explosion or contact with battery
acid, work in a well ventilated
area, wear protective clothing,
and avoid sparks or flames near
the battery. If you come in contact
with battery acid:
□ Flush your skin with water.
□ Apply baking soda or lime to
help neutralize the acid.
□ Flush your eyes with water.
□ Get medical attention
immediately.
□ Avoid grounding the output
terminal. Grounding an
alternator's output wire or terminal
(which is always “hot,” regardless
of whether or not the engine
is running) and accidentally
reversing the battery polarity will
result in equipment damage.
□ Do not reverse battery connections.
□ Never disconnect the battery
while the alternator is operating.
Disconnecting the battery can
result in damage to the battery
diodes. In applications which
have two (2) sets of batteries,
switching from one set to the
other while the engine is running
All information subject to change without notice.
DDC-SVC-MAN-0006
Copyright © 2009 DETROIT DIESEL CORPORATION
87
MAINTENANCE
will momentarily disconnect the
batteries.
□ If a booster battery is to be used,
batteries must be connected
correctly (negative to negative,
positive to positive).
□ Never use a fast charger with the
batteries connected or as a booster
for battery output.
For information on the alternator
assembly, contact an authorized
Delco Remy® or Bosch® distributor,
depending on manufacturer.
Bosch® T1 Alternator Service
Requirements — The transistor
regulator must be replaced every
100,000 miles (160,000 km) using
kit part number 23524613 (includes
regulator assembly and brushes).
Front and rear bearings must be
replaced every 200,000 miles
(320,000 km) using kit 23524614
(includes bearings, seals and spacer
ring). Authorized Bosch distributors
have the parts, tools and trained
personnel to perform these services.
General Service Requirements
– Bosch® and Delco Remy®
Alternators — Terminals should
be checked for corrosion and loose
connections and wiring inspected
for damage and frayed insulation.
Have wiring repaired or replaced, as
required.
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DDC-SVC-MAN-0006
Check torque on alternator mounting
bolts and bracketing every 15,000
miles (24,000 km). Retighten, if
necessary.
Item 21 – Engine and
Transmission Mounts
The engine and transmission mounting
bolts and the condition of the mounting
pads should be checked every 60,000
miles (96,000 km) or 600 hours.
Tighten and/or repair as necessary.
Item 22 – Crankcase Pressure
The crankcase pressure should be
checked and recorded every 60,000
miles (96,000 km) or 600 hours.
Item 23 – Fan Hub
If the fan bearing hub assembly has a
grease fitting, use a hand grease gun
to lubricate the bearings with one shot
of quality lithium-base, multi-purpose
grease every 100,000 miles (160,000
km).
Care should be taken not to overfill
the bearing housing.
Item 24 – Thermostats and Seals
Replace the thermostats and seals
every 240,000 miles (384,000 km) or
24 months, whichever comes first.
All information subject to change without notice.
Copyright © 2009 DETROIT DIESEL CORPORATION
EPA07 SERIES 60 ENGINE OPERATOR'S MANUAL
Item 25 – Crankcase Breather
The internally mounted (in the engine
rocker cover) crankcase breather
assembly (see Figure 28) should
be removed and the steel mesh pad
washed in clean fuel oil every 250,000
miles (402,300 km).
Figure 28
Internal Breather (in
Rocker Cover)
Item 26 – Engine Tune-Up
There is no scheduled interval for
performing an engine tune-up.
However, the valve lash and injector
heights must be measured and, if
necessary, adjusted at the initial
interval listed in Table 17.
Once the initial measurements/adjustments have been made, any
adjustments beyond this point should
be made only as required to maintain
satisfactory engine performance.
Table 17
Engine Application
Measurement/Adjustment Period
Vehicle Engines
60,000 Miles (96,000 km) or
24 Months, whichever comes first
Initial Valve Lash and Injector Height Adjustment
All information subject to change without notice.
DDC-SVC-MAN-0006
Copyright © 2009 DETROIT DIESEL CORPORATION
89
MAINTENANCE
Item 27 – Vibration Damper
The viscous vibration damper should
be inspected periodically and replaced
if dented or leaking. See Figure 29.
Figure 29
90
Heat from normal engine operation
may, over a period of time, cause the
fluid within the damper to break down
and lose its dampening properties.
For this reason the viscous vibration
damper must be replaced at time
of normal major engine overhaul,
regardless of apparent condition.
Viscous Vibration
Damper
DDC-SVC-MAN-0006
All information subject to change without notice.
Copyright © 2009 DETROIT DIESEL CORPORATION
EPA07 SERIES 60 ENGINE OPERATOR'S MANUAL
HOW-TO SECTION
This section covers Detroit Diesel's
recommendations on how to select
lubricating oil, diesel fuel, and coolant
and includes basic engine maintenance
procedures which can be performed
by the operator.
NOTICE:
Lubricating oil must have a sulfated
ash level less than 1.0 wt %;
currently referred to as CJ-4 oil.
NOTICE:
The manufacturer's warranty
applicable to Series 60 engines
provides in part that the provisions
of such warranty shall not apply
to any engine unit that has been
subject to misuse, negligence or
accident. Accordingly, malfunctions
attributable to neglect or failure to
follow the manufacturer's fuel or
lubricating recommendations may
not be within the coverage of the
warranty.
How to Select Lubricating
Oil
The selection of the proper lubricating
oil is important to achieve the long
and trouble-free service which Detroit
Diesel engines are designed to
provide. The proper lubricating oil for
model year 2007 Series 60 engines
is selected based on SAE viscosity
grade and API (American Petroleum
Institute) service designation. Only
oils licensed to display the API symbol
should be used. See Figure 30.
All information subject to change without notice.
DDC-SVC-MAN-0006
Figure 30
API Lubricant Symbol
Lubricant Requirements
API CJ-4 oils must be used in
engines meeting January 2007,
and later build, exhaust emission
regulations.
Cold Weather Starting
At ambient temperatures below
–20°C (–4°F) when sufficient starter
speed cannot be achieved with SAE
15W-40 oils, the use of 5W-XX oils
and 10W-XX oils (XX =30 or 40) is
allowed to improve starting.
Copyright © 2009 DETROIT DIESEL CORPORATION
91
HOW-TO SECTION
NOTICE:
Monograde oils should not
be used in Series 60 engines,
regardless of API service
classification. Monograde oils
gel at lower ambient temperatures,
reducing lubricant flow, and do not
provide adequate lubricity at higher
engine operating temperatures
resulting in severe engine damage.
The oils must be API CJ-4 that have
demonstrated field performance in
Detroit Diesel engines. These oils
must possess a High Temperature /
High Shear (HT/HS) of 3.7 minimum.
For further information, refer to
publication Engine Requirements –
Lubricating Oil, Fuel and Filters,
7SE270, available from authorized
Detroit Diesel distributors.
Synthetic Oils
Synthetic oils may be used in Detroit
Diesel engines, provided they are API
licensed and meet the performance
and chemical requirements of
non-synthetic oils outlined in this
publication. Synthetic oils offer
improved low-temperature flow
properties and high-temperature
oxidation resistance. However,
they are generally more costly than
non-synthetic oils.
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DDC-SVC-MAN-0006
Product information about synthetic
oils should be reviewed carefully.
Performance additive systems often
respond differently in synthetic oils.
Their use does not permit extension of
recommended oil drain intervals.
The Use of Supplemental
Additives
Lubricants meeting the Detroit
Diesel specifications outlined in this
publication already contain a balanced
additive treatment. Supplemental
additives are generally not necessary
and can even be harmful. These
additives may be marketed as either
oil treatments or engine treatments and
are discouraged from use in Detroit
Diesel engines.
Engine damage resulting from the
use of such materials is not covered
by your Detroit Diesel warranty.
Detroit Diesel will not provide
statements beyond this publication
relative to their use.
When to Change Oil
The length of time an engine may
operate before an oil change depends
upon the lubricant and fuel used,
engine oil consumption, and the
operating cycle.
All information subject to change without notice.
Copyright © 2009 DETROIT DIESEL CORPORATION
EPA07 SERIES 60 ENGINE OPERATOR'S MANUAL
USED ENGINE OIL
To avoid injury to skin from
contact with the contaminants in
used engine oil, wear protective
gloves and apron.
The maximum interval at which
the engine may operate before the
oil and filters must be changed is
listed in Table 18.
Oil analysis may be used to determine
whether this interval should be
shortened, but it should not be used to
lengthen the interval.
use of a higher TBN oil. For detailed
information refer to publication
Engine Requirements – Lubricating
Oil, Fuel and Filters (7SE270),
available from authorized Detroit
Diesel distributors.
Disposing of Waste Oil
Dispose of used lubricating oil
and filters in an environmentally
responsible manner, according
to federal (EPA) and/or state
recommendations. The disposal of
waste oil may be best addressed by the
engine oil supplier, who may accept
responsibility for proper disposal of
this material as part of the business of
providing lubricant.
The use of fuels with sulfur content
above 0.05 mass percent will require a
shortening of drain intervals and/or the
Engine Application
Drain Interval
Highway Truck & Motor Coach
30,000 Miles (48,280 km)
Fire Truck or Crash/Rescue Vehicle
6,000 Miles (9,600 km), 300 Hours or
1 Year, whichever comes first
Table 18
Maximum Oil Drain and Filter Change Interval (Fuel Sulfur
15 ppm Weight Percent or Less)
All information subject to change without notice.
DDC-SVC-MAN-0006
Copyright © 2009 DETROIT DIESEL CORPORATION
93
HOW-TO SECTION
How to Replace the Lube
Oil Filters
Filters are an integral part of the
lubricating oil system. Proper
filter selection and maintenance
are important to satisfactory engine
performance and service life.
Filters should be used to maintain
a clean system, not to clean up a
contaminated system.
Replace Spin-On Type Oil Filter
Replace spin-on type filters
(see Figure 31) as follows:
PERSONAL INJURY
To avoid injury from slipping and
falling, immediately clean up any
spilled liquids.
1. Place a suitable container under
the engine oil pan, remove drain
plug and drain the lubricating
oil. Replace the drain plug and
tighten securely.
2. Remove spin-on filters using
tool J–29917 or equivalent and a
1/2-in. drive socket wrench and
extension.
3. Dispose of used oil and
filters in an environmentally
responsible manner, according
to federal (EPA) and/or state
recommendations.
4. Clean the filter gasket-contact
surface of the adaptor head with a
clean, lint-free cloth.
5. Fill the new filters with clean
lubricating oil and lightly coat the
filter gaskets with the same oil.
NOTICE:
Overtightening the filter may crack
or distort the filter adaptor.
Figure 31
94
Spin-On Oil Filters
DDC-SVC-MAN-0006
6. Start the new filters on the adaptor
head and tighten by hand until
All information subject to change without notice.
Copyright © 2009 DETROIT DIESEL CORPORATION
EPA07 SERIES 60 ENGINE OPERATOR'S MANUAL
the gaskets touch the mounting
adaptor head. Tighten filters an
additional two-thirds turn by
hand, or as indicated on the
filter.
7. Add oil as required to bring the
level within the satisfactory range
on the dipstick. See Figure 32.
minutes). Add oil as required
to bring the level within the
satisfactory range on the dipstick.
See Figure 32.
NOTICE:
If the engine oil level is constantly
above normal and excess lube
oil has not been added to the
crankcase, consult with an
authorized Detroit Diesel service
outlet for the cause. Fuel or coolant
dilution of lube oil can result in
serious engine damage.
How to Select Diesel Fuel
Figure 32
Check Oil Level
All 2007 diesel engines in 2007 are
designed to operate on Ultra-Low
Sulfur Diesel (ULSD) fuel, see Figure
33
ENGINE EXHAUST
To avoid injury from inhaling
engine exhaust, always operate
the engine in a well-ventilated
area. Engine exhaust is toxic.
8. Start and run the engine for a
short period and check for leaks
Then shut down the engine.
9. After any leaks have been
corrected, stop the engine long
enough for oil from various parts
of the engine to drain back to
the crankcase (approximately 20
All information subject to change without notice.
DDC-SVC-MAN-0006
Figure 33
ULSD Sticker
Copyright © 2009 DETROIT DIESEL CORPORATION
95
HOW-TO SECTION
Quality
extended storage (“stale fuel”) also
affects fuel quality. The best treatment
for contamination is prevention by
maintaining a clean storage system
and choosing a reputable fuel supplier.
Fuel quality is an important factor
in obtaining satisfactory engine
performance, long engine life, and
acceptable exhaust emission levels.
In general, fuels meeting the
properties of ASTM designation
D 975 (grades 1-D and 2-D) have
provided satisfactory performance.
The fuels used must be clean,
completely distilled, stable, and
non-corrosive. For more information
regarding the significance of these
properties and selection of the proper
fuel, refer to publication, Engine
Requirements – Lubricating Oil, Fuel
and Filters (7SE270), available from
authorized Detroit Diesel distributors.
NOTICE:
Use only Ultra-Low Sulfur Diesel
(ULSD) fuel (15 ppm sulfur content
maximum), based on ASTM
D2622 test procedure. Using fuel
other than ULSD will damage the
Aftertreatment Device.
Fuel Contamination
Generally, fuel contamination
occurs as the result of improper fuel
handling. The most common types
of contamination are water, dirt, and
microbial growth (“black slime”).
The formation of varnishes and
gums resulting from poor stability or
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DDC-SVC-MAN-0006
Supplemental additives are not
recommended due to potential
injector system or engine damage.
Our experience has been that such
additives increase operating costs
without providing benefit.
The use of supplemental fuel additives
does not necessarily void the engine
warranty. However, repair expenses
which result from fuel system or
engine component malfunctions or
damage attributed to their use will
not be covered.
These products should be
accompanied by performance
data supporting their merit. It is not
the policy of Detroit Diesel to test,
evaluate, approve or endorse such
products.
Biodiesel — Biodiesel fuels meeting
ASTM D 6751 specification, prior
to blending can be mixed up to 5%
maximum by volume in petroleum
diesel fuel. Detroit Diesel highly
recommends biodiesel fuels made
from soybean or rapeseed oil through
the proper transesterification reaction
process. Other feedstock source
of biodiesel fuels such as animal
fat and used cooking oils are not
All information subject to change without notice.
Copyright © 2009 DETROIT DIESEL CORPORATION
EPA07 SERIES 60 ENGINE OPERATOR'S MANUAL
recommended by Detroit Diesel. The
resulting mixture must meet ASTM D
975 specification. More information
is available in the Detroit Diesel
publication Lubricating Oil, Fuel, and
Filters (7SE270).
loss of power and increased exhaust
emissions. In addition, the use of
drained lubricating oil will increase
maintenance requirements due to filter
plugging and combustion deposits.
Failures attributed to the use of
biodiesel fuel will not be covered
by Detroit Diesel product warranty.
Also, any engine performance
problem related to the use of biodiesel
fuel would not be recognized
nor considered Detroit Diesel's
responsibility.
Fuel Additives with Sulfur
or Sulfated Ash — Do not
use non-approved fuel additives
containing sulfur or sulfated ash.
Prohibited Additives
Gasoline — The addition of
gasoline to diesel fuel will create a
serious fire hazard. The presence
of gasoline in diesel fuel will reduce
fuel cetane number and increase
combustion temperatures.
The following fuel additives are not
allowed and MUST NOT be mixed
with diesel fuel:
Used Lubricating Oil — Do not use
fuel blended with used lubricating oil.
Detroit Diesel specifically prohibits
the use of used lubricating oil in diesel
fuel.
NOTICE:
Do not burn used lubricating oil
in fuel. It will cause the diesel
particulate filter to prematurely plug
with ash.
Used lubricating oil contains
combustion acids and particulate
materials which can severely erode
fuel injector components, resulting in
All information subject to change without notice.
DDC-SVC-MAN-0006
FIRE
To avoid increased risk of a fuel
fire, do not mix gasoline and
diesel fuel.
Tanks which contain a mixture of
gasoline and diesel fuel should be
drained and cleaned as soon as
possible.
Detroit Diesel will not be responsible
for any detrimental effects it
determines resulted from adding
drained lubricating oil or gasoline to
the diesel fuel.
Copyright © 2009 DETROIT DIESEL CORPORATION
97
HOW-TO SECTION
How to Replace the Fuel
Filters
Filters are an integral part of the
fuel system. Proper filter selection
and maintenance are important to
satisfactory engine operation and
service life. Filters should be used to
maintain a clean system, not to clean
up a contaminated system. Refer
to the Specifications section of this
guide for proper filter selection.
Spin-on type primary and secondary
fuel filters are used on Series 60
engines.
The primary filter (marked “P”) or
combination filter and fuel/water
separator removes large impurities
from the fuel. The secondary filter
(marked “S”) removes the smaller
particles.
Figure 34
The spin-on type filter consists of a
shell, element and gasket unitized into
a single cartridge and a filter adaptor
which includes threaded inserts
to accept the spin-on cartridges.
See Figure 34.
An optional fuel/water separator may
be installed in place of the standard
primary filter.
Typical Spin-On Type
Fuel Filter
Replace Spin-On Type Primary
or Secondary Fuel Filter
Elements
Replace spin-on fuel filter elements as
follows:
1. Shut down the engine and allow
it to cool.
2. With the engine at ambient
temperature and cool to the touch,
place a suitable container under
the filter.
3. If a fuel shutoff valve is installed
on the discharge side of the
secondary fuel filter, turn the
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Copyright © 2009 DETROIT DIESEL CORPORATION
EPA07 SERIES 60 ENGINE OPERATOR'S MANUAL
handle on the shutoff valve to the
closed position (perpendicular to
the valve).
8. Turn the handle on the shutoff
valve to the Open position (in
line with the valve).
NOTICE:
Have replacement filters filled with
fuel and ready to install immediately.
This prevents possible siphoning
and fuel system aeration.
4. Using a suitable band type filter
wrench, remove the primary and
secondary fuel filters. Dispose of
the filters in an environmentally
responsible manner, according
to federal (EPA) and/or state
recommendations.
5. If not previously filled, fill new
replacement filters with clean
diesel fuel and coat the gaskets
lightly with the fuel.
6. Thread the new filters onto the
adaptor inserts until the gaskets
make full contact with the adaptor
head and no side movement is
evident.
NOTICE:
Overtightening the filter may crack
or distort the adaptors.
ENGINE EXHAUST
To avoid injury from inhaling
engine exhaust, always operate
the engine in a well-ventilated
area. Engine exhaust is toxic.
9. Start the engine and check for
leaks. Shut down the engine.
Correct any leaks with the engine
off.
NOTICE:
Never use the starting motor and
fuel pump to prime the fuel filters.
Prolonged used of both to prime the
fuel system can result in damage to
the starter, fuel pump and injector.
If the engine fails to start after filter
replacement, the fuel system will
require priming with tool J 5956 (or
equivalent). Authorized Detroit Diesel
distributors are properly equipped to
perform this service.
7. Tighten filters an additional
one-half turn by hand, or as
indicated on the filter.
All information subject to change without notice.
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Copyright © 2009 DETROIT DIESEL CORPORATION
99
HOW-TO SECTION
Replace Fuel/Water Separator
Element
NOTICE:
To avoid damaging the bowl or
the filter, do not use tools when
tightening.
If an optional primary filter/water
separator is installed, replace the
element as follows:
1. Shut down the engine and allow
it to cool.
2. With the engine at ambient
temperature and cool to the touch,
place a suitable container under
the filter.
3. If a fuel shutoff valve is installed
on the discharge side of the
fuel/water separator, turn the
handle on the shutoff valve to the
closed position (perpendicular to
the valve).
4. Drain off some fuel by opening
the drain valve.
5. Using a strap wrench, remove
the element and bowl together,
then remove the bowl from the
element. The filter and bowl
have right-hand threads, so turn
counter-clockwise to remove.
6. Clean the bowl and the O-ring
seal.
7. Apply a light coating or clean
fuel or grease to the O-ring seal,
thread the bowl onto the new filter
and tighten by hand.
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DDC-SVC-MAN-0006
8. Apply a light coating of clean fuel
or grease to the new O-ring seal
on the top of the filter. Thread the
filter and bowl assembly onto the
filter head and tighten by hand
until snug.
9. To eliminate air from the filter,
operate the primer pump on the
filter head (if equipped) until the
fuel purges at the filter assembly.
10. Start the engine and check for
leaks. Shut down the engine.
Correct any leaks with the engine
off.
Replace Fuel Pro® 382/382E
Fuel Filter Element
The Fuel Pro 382/383E diesel fuel
filter system consists of a permanently
mounted fuel processor, a replaceable
filter element and sealing grommet
assembly, a filter spring, a see-thru
cover and seal, a cover collar, and a
vent cap and seal. See Figure 35.
All information subject to change without notice.
Copyright © 2009 DETROIT DIESEL CORPORATION
EPA07 SERIES 60 ENGINE OPERATOR'S MANUAL
3. A fuel shutoff valve may be
installed on the discharge side of
the fuel filter. If installed, turn the
handle on the shutoff valve to the
closed position (perpendicular to
the valve).
4. Open the drain valve at the base
of the fuel processor and drain the
fuel until it is below the bottom
of the filter in the see-thru cover.
Close the drain valve. The fuel
may be returned to the tank.
5. Using filter collar/vent cap
wrench P/N: 38202 or equivalent,
remove the collar by turning
counter-clockwise. Remove the
cover, filter spring and cover seal
ring by lifting straight up and over
the filter element.
Figure 35
Fuel Pro 382E Fuel
Processor Assembly
The system also includes a fuel heater
element, thermostatic switch and
wiring harness.
Replace the element as follows:
1. Shut down the engine and allow
it to cool.
2. With the engine at ambient
temperature and cool to the touch,
place a suitable container under
the filter.
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DDC-SVC-MAN-0006
6. Remove the element from the
center stud (fuel outlet pipe)
by pulling upward and twisting
slightly.
NOTE:
Current filter elements include an
integral sealing grommet. If a former
element is replaced, make sure the
separate sealing grommet is removed
from the center stud before installing
the new element.
7. Dispose of the used element and
grommet in an environmentally
responsible manner, according
to federal (EPA) and/or state
recommendations.
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HOW-TO SECTION
8. Check to make sure the sealing
grommet is included in the base
of the replacement filter element,
then install the element onto the
center stud by pushing down and
twisting slightly.
To avoid cover or vent cap damage,
do not use tools to tighten the vent
cap.
9. Check to make sure the spring is
installed at the top of the cover.
If missing, this spring must be
replaced to insure proper filter
operation. Wipe the cover lip and
cover seal clean.
12. Open the fuel shutoff valve (if
installed) and start the engine.
When the lubrication system
reaches its normal operating
pressure, increase engine speed to
high idle for 2 to 3 minutes.
NOTICE:
NOTICE:
Do not use a wrench of any kind to
tighten the collar. This may lead to
overtightening, which can damage
the collar and/or the cover.
Do not allow the fuel level in the
see-thru cover to fall below the top
of the collar, since this may lead
to interruption of the fuel flow and
engine stalling.
10. After making sure the seal is
properly positioned at the base of
the cover, install the cover and
collar onto the fuel processor.
Tighten the collar by hand until
secure.
11. Using filter collar/vent cap
wrench 232002 or equivalent,
remove the vent cap from the top
of the cover by turning the cap
counter-clockwise. Fill the cover
full of clean fuel. After making
sure the O-ring seal is installed on
the vent cap, reinstall the cap and
tighten by hand.
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NOTICE:
13. After the air is purged and with
the engine still running, loosen
the vent cap. The fuel level in
the cover will start falling. When
the fuel level falls to the top of
the collar, tighten the vent cap
quickly by hand.
14. Shut down the engine and tighten
the collar again by hand . Restart
the engine and check for leaks.
NOTE:
The filter cover will not fill completely
during engine operation. It will
gradually fill over time, and the fuel
level will rise as the filter medium
All information subject to change without notice.
Copyright © 2009 DETROIT DIESEL CORPORATION
EPA07 SERIES 60 ENGINE OPERATOR'S MANUAL
becomes clogged. The filter element
does not require changing until
the fuel level has risen to the top
of the element, or after one year of
service, whichever comes first.
Engine Out of Fuel — How
to Restart
When an engine has run out of fuel,
there is a definite procedure to follow
when restarting it.
NOTICE:
Never use the starting motor and
fuel pump to prime the fuel filters.
Prolonged use of the starting motor
and fuel pump to prime the fuel
system can result in damage to the
starter, fuel pump and injectors.
Priming the engine with the starting
motor and fuel pump causes erratic
engine running due to the amount of
air in the fuel lines and filters
head and remove the spin-on fuel
filters. Fill with clean fuel through
the fuel inlet holes (the outer ring
of small holes on the element) to
insure the fuel is filtered.
3. Thread the elements onto the
adaptor inserts until the gaskets
make full contact with the adaptor
head and no side movement
is evident. Tighten filters an
additional one-half turn by hand,
or as indicated on the filter.
4. Open the fuel shutoff valve (if
installed), start the engine and
check for leaks. Shut down the
engine before correcting leaks.
NOTE:
If the engine fails to start after
replacement of fuel filters, the fuel
system will require priming with tool
J 5956 or equivalent. Authorized
Detroit Diesel distributors are properly
equipped to perform this service.
Engines with Fuel Pro Filters
Engines with Spin-On Filters
Use the following procedure for an
engine with spin-on filters.
1. Fill the fuel tank with the
recommended grade of fuel. If
only partial filling is possible,
add a minimum of 10 gallons (38
liters) of fuel to the tank.
Use the following procedure for an
engine with Fuel Pro filters.
1. Remove the vent cap from
the top of the filter by turning
counter-clockwise. Fill the cover
full of clean fuel.
2. Close the fuel shutoff valve (if
installed) on the secondary filter
All information subject to change without notice.
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Copyright © 2009 DETROIT DIESEL CORPORATION
103
HOW-TO SECTION
NOTICE:
To avoid cover or vent dap damage,
do not use tools to tighten the vent
cap.
2. After making sure the O-ring
seal is installed on the vent plug,
reinstall the plug and tighten by
hand only.
NOTICE:
Do not allow the fuel level in the
see-thru cover to fall below the top
of the collar, since this may lead
to interruption of the fuel flow and
engine stalling.
3. Start the engine and allow the
lubrication system to reach its
normal operating pressure, then
increase engine speed to high idle
for 2 to 3 minutes.
4. After the air is purged and with
the engine still running, loosen
the vent cap on the filter cover.
The fuel level in the cover will
start falling. When the fuel level
falls to the top of the collar on the
Fuel Pro cover, tighten the vent
cap quickly by hand.
NOTE:
If the engine fails to start after
replacement of fuel filters, the fuel
system will require priming with tool
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DDC-SVC-MAN-0006
J 5956 or equivalent. Authorized
Detroit Diesel distributors are properly
equipped to perform this service.
How to Clean the Engine
Important: Observe all environmental
protection regulations.
High-Pressure Cleaning
Equipment
Information on suitable cleaning
and protective products is available
from any authorized dealer. Note the
equipment manufacturer's operating
instructions.
NOTICE:
To prevent damage to engine
components, keep the water
moving at all times while cleaning.
Never direct water onto electrical
components, plug connectors, seals
or flexible hoses.
To avoid injury, wear a face shield
or goggles.
Comply with the minimum working
distance between the high-pressure
nozzle and the surface being cleaned:
All information subject to change without notice.
Copyright © 2009 DETROIT DIESEL CORPORATION
EPA07 SERIES 60 ENGINE OPERATOR'S MANUAL
□ Approximately 28 inches (700
mm) for circular pattern jets
□ Approximately 12 inches (300
mm) for 25-degree flat jets and
dirt cutters
How to Clean the Cooling
System
Important: Collect the used coolant,
cleaning solutions, and washing
liquids and dispose of them in an
environmentally responsible manner.
Clean as follows:
NOTICE:
Clean at moderate pressures only
to avoid damaging the radiator grille
fins.
EYE INJURY
To avoid injury from flying debris
when using compressed air, wear
adequate eye protection (face
shield or safety goggles) and do
not exceed 276 kPa (40 psi) air
pressure.
2. Remove the debris by blowing
them through with compressed air
or spraying them out with water.
Work from the rear of the radiator
(in the opposite direction of the
normal cooling air flow).
3. Drain the coolant when the engine
is cold. For detailed procedures,
see the vehicle/chassis
maintenance manual. For
types of coolant, refer to the
“How to Select Coolant” section.
4. If the HVAC unit is connected
to the cooling system, open the
regulating valves all the way.
Degreasing
Degrease as follows:
1. Fill the cooling system with a 5%
solution (1.6 ounces per quart of
water—50 grams per liter) of a
mildly alkaline cleaning agent,
such as sodium carbonate.
2. Run the engine at moderate speed
until the thermostat starts to open,
at an operating temperature of
approximately 80°C (176°F).
Then run it for about five minutes
longer. Shut down the engine and
allow it to cool to approximately
50°C (112°F).
1. First remove debris (dust, insects,
etc.) from the fins of the radiator
grille.
All information subject to change without notice.
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105
HOW-TO SECTION
How to Select Coolant
This section covers selection of the
required coolant for Series 60 engines.
HOT COOLANT
To avoid scalding from the
expulsion of hot coolant, never
remove the cooling system
pressure cap while the engine is
at operating temperature. Wear
adequate protective clothing
(face shield, rubber gloves,
apron, and boots). Remove the
cap slowly to relieve pressure.
Definitions
To help ensure complete
understanding of the information, the
definitions of the following terms are
listed in Table 19.
3. Drain all the cleaning solution.
4. Flush the cleaning solution from
the cooling system.
[a] Immediately after draining
the cleaning solution, flush
the system with clean water.
[b] Once the clean water has
drained, fill the system again
with clean water.
[c] Run the engine. Allow
the engine to warm up to
approximately 80°C (176°F),
and then run it about five
minutes longer.
[d] Drain the hot water.
5. Fill the cooling system with new
coolant. For detailed procedures,
see the vehicle/chassis
maintenance manual. For
types of coolant, refer to the
“How to Select Coolant” section.
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All information subject to change without notice.
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EPA07 SERIES 60 ENGINE OPERATOR'S MANUAL
Term
Definition
Antifreeze
Ethylene glycol (EG) or propylene glycol (PG)
containing a corrosion inhibitor package and which
meets an appropriate heavy-duty specification (i.e.,
TMC RP-329 “Type A” for ethylene glycol or TMC
RP-330 “Type A” for propylene glycol).
Coolant
The fluid mixture circulating in the engine cooling
system, typically a mixture of 50% water and 50%
antifreeze.
Drop–Out
Precipitated sludge or deposit formation on cooling
system components.
Fully Formulated
Antifreeze
Contains all the necessary inhibitors to protect a diesel
engine, and does not, therefore, require a pre-charge
of SCA before its first use.
Initial–Fill Coolant
The coolant that is used in a new or rebuilt engine, or
any time the cooling system is emptied and then refilled
with coolant.
OAT
Organic Acid Technology. An inhibitor system based
on organic acid inhibitors, instead of traditional North
American inhibitor formulations.
SCA
Supplemental Coolant Additive. SCAs are used in a
preventive maintenance program to prevent corrosion,
cavitation, and the formation of deposits.
Table 19
Coolant Terms
Approved Coolants
Required specifications for water,
ethylene glycol, propylene glycol,
inhibitor packages and inhibitor
concentration are included in this
section.
All information subject to change without notice.
DDC-SVC-MAN-0006
NOTICE:
To avoid engine damage from
inadequate or over concentrated
coolant, the required specifications
must be adhered to before the
coolant is replaced.
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107
HOW-TO SECTION
The approved and preferred
coolants for Series 60 engines
are listed in Table 20.
Once installed, these coolants
should be maintained according
to the procedures discussed under
Maintenance in this section.
Product
Coolant Fill Option
Ethylene Glycol & Water + Corrosion
Inhibitors 1
Commercial Equivalent of DDC Power
Cool
Propylene Glycol & Water + Corrosion
Inhibitors 1
Ethylene Glycol & Water + OAT
Inhibitors
1
2
DDC Power Cool
Fully Formulated TMC RP-329 Type A
Antifreeze & Water
DDC Power Cool Plus
DDC Power Cool Plus
Water Only + Corrosion Inhibitors 2
Water + DDC Power Cool 3000
Water Only + OAT Inhibitors 2
Water + DDC Power Cool Plus 6000
Preferred Coolant
Water-only coolant systems offer no freeze protection and should not
be used where ambient temperatures can fall to 32° F (0° C).
Table 20
Initial Fill Coolant Options
EG & Water Plus SCA Inhibitor
or P G & Water Plus SCA
Inhibitor — These products are
available as fully formulated,
phosphate-free, extended service
interval (ESI) coolants. They are
commercially available from Detroit
Diesel (recommended) and other
manufacturers as either a concentrated
antifreeze or as a pre-mixed antifreeze.
The pre-mixed antifreeze is ready for
use, while the concentrated coolant
must be mixed with water prior to use.
Detroit Diesel Power Cool engine
coolant (P/N: 23512138) is the
preferred ethylene glycol (EG)
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DDC-SVC-MAN-0006
coolant. If other commercial brands of
ethylene glycol are used, they must be
equivalent to the Power Cool. Detroit
Diesel does not market a propylene
glycol (PG) coolant. If a propylene
glycol coolant is used, it must also
meet the following requirements:
□ Fully formulated ethylene
glycol-based, low silicate
antifreeze or coolant must
meet TMC RP-329 “Type A”
requirements.
□ Fully formulated propylene
glycol-based antifreeze or coolant
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Copyright © 2009 DETROIT DIESEL CORPORATION
EPA07 SERIES 60 ENGINE OPERATOR'S MANUAL
must meet TMC RP-330 “Type
A” requirements.
Fully formulated antifreeze does not
require a dosage of SCA prior to
initial use.
Mixing EG or PG Antifreeze
and Water — If a concentrated
ethylene glycol (EG) or propylene
glycol (PG) antifreeze is purchased,
mix the antifreeze with water meeting
the required quality standards
listed in Table 23 and fill the cooling
system.
If a pre-diluted, fully formulated
coolant is purchased, fill the
cooling system. For best overall
performance, a coolant consisting
of 50% concentration of antifreeze
(50% antifreeze, 50% water) is
recommended.
An antifreeze concentration over
67% (67% antifreeze, 33% water) is
not recommended due to poor heat
transfer, reduced freeze protection
(IEG only), and possible silicate
dropout. An antifreeze concentration
below 33% (33% antifreeze, 67%
water) offers too little freeze and/or
corrosion protection and is not
recommended.
Always verify that the freeze point
and nitrite concentration of the
antifreeze/water mixture are correct
by using a POWER Trac® 3–Way
Coolant Test Strip. If chemical
analysis is used, elements in the
coolant must fall within the limits
listed in Table 21.
Recycled Antifreeze — Antifreeze
or coolant recycled by reverse
osmosis, distillation, and ion
exchange, properly re-inhibited to
meet TMC RP-329 Type A or TMC
RP-330 Type A requirements, has
been demonstrated to provide service
equivalent to virgin antifreeze.
Fully Formulated Glycol Coolant Concentration Limits
Table 21
Boron
125 – 500 PPM
Nitrite
900 – 3200 PPM
Nitrate
200 – 1000 PPM
Silicon
50 – 250 PPM
Phosphorous
0 PPM
pH
8.0 – 11.0
Fully Formulated Glycol Coolant Limits with TMC RP-329,
TMC RP-330 Chemistry Type A (50/50 Coolant/Water
Mixture)
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HOW-TO SECTION
Recycled antifreeze or coolants of
these types are preferred. Other
recycled coolants, especially coolants
recycled through filtration processes,
are not recommended.
EG/Water + OAT Inhibitor or
PG/Water + OAT Inhibitor —
Ethylene glycol and propylene
glycol are also available with a OAT
corrosion package. These coolants
require less maintenance over the
useful life of the engine. OAT
coolants, maintained as detailed in
the Maintenance section of this
guide, may be operated up to 4 years,
600,000 miles (960,000 km), or
10,000 operating hours, whichever
comes first. Refer to Coolant Inhibitor
Test Intervals in this guide. The
cooling system should either be
equipped with a blank coolant filter,
or the coolant filter and piping may be
omitted from the system.
OAT fully formulated antifreezes
are available as concentrated and
pre-mixed. Concentrated antifreezes
should be mixed 50% (50% antifreeze,
50% water).
OAT coolants should not be mixed
with conventional coolants. If they
are mixed, no damage will result, but
the long-life advantages of the OAT
coolant will be lost. In this event,
the coolant should be maintained as a
fully formulated IEG coolant, not as
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DDC-SVC-MAN-0006
an OAT (Organic Acid Technology)
coolant.
Detroit Diesel markets a OATinhibited ethylene glycol coolant,
DDC Power Cool Plus, which
contains all the required additives.
If a non-DDC OAT antifreeze is
used, it must conform to TMC 338
specification. Do not add extender to
new OAT antifreeze or coolant.
Water Only + SCA or Water
Only + OAT Inhibitor — In
warm climates a coolant based
on water with corrosion inhibitors
is approved for use. Water-only
systems need to be treated with the
proper dosage of corrosion inhibitors.
Detroit Diesel-approved SCAs or
OAT corrosion inhibitors must be
added to the water to provide required
corrosion and cavitation erosion
protection. OAT inhibitors such as
Power Cool Plus 6000 are available
for water-only systems. Inhibitor
should be mixed at 7.5% – 10% by
volume with water. For a list of
Power Cool products, refer to section
SPECIFICATIONS in this guide.
Traditional SCA (Power Cool 3000)
can also be used to protect the engine.
Power Cool 3000 concentration limits
are listed in Table 22.
NOTE:
Do not use Power Trac 3–Way Test
Strips to test OAT coolant.
All information subject to change without notice.
Copyright © 2009 DETROIT DIESEL CORPORATION
EPA07 SERIES 60 ENGINE OPERATOR'S MANUAL
Power Cool 3000 Coolant Concentration Limits
Table 22
Boron
125 – 500 PPM
Nitrite
900 – 3200 PPM
Nitrate
200 – 1000 PPM
Silicon
50 – 250 PPM
Phosphorous
0 PPM
pH
8.0 – 11.0
Power Cool 3000 Concentration Limits (5% Power Cool
3000/ 95% Water)
or de-ionized water which eliminates
the adverse effects of minerals in tap
water is preferred.
POWER COOL® 3000 SCA inhibitors
should be mixed at 5% by volume
with water. This is 1 quart per 5
gallons of water. These additions
can be made by adding liquid SCAs
available in a variety of sizes. Coolant
filters are also available for different
cooling system capacities. These
filters release the proper amount of
SCA at initial fill.
High levels of dissolved chlorides,
sulfates, magnesium, and calcium in
some tap water causes scale deposits
and/or corrosion resulting in water
pump failures and poor heat transfer,
leading to overheating. If tap water
is used, the mineral content in the
water must be below the maximum
allowable limits listed in Table 23.
Water Requirements —
Distilled, reverse osmosis-purified,
Maximum Allowable
Parts per Million
Grains per Gallon
Chlorides
40
2.5
Sulfates
100
5.8
Total Dissolved Solids
340
20
Total Hardness –
Magnesium and Calcium
170
10
Table 23
Satisfactory Water Limits – Make-Up Water Only
All information subject to change without notice.
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HOW-TO SECTION
Glycol-based Coolants
Formulated For HVAC —
These coolants formulated for
Heating/Ventilation/Air Conditioning
(HVAC) should not be used. These
coolants generally contain high levels
of phosphates, which can deposit
on hot internal engine surfaces and
reduce heat transfer.
NOTICE:
Do not add additional SCA to
new, fully formulated antifreeze or
coolant. This can result in dropout
and/or the formation of deposits.
Coolants Not Recommended
The following coolants are not
recommended for use in Detroit Diesel
engines.
All Antifreezes And Coolants
Containing Phosphate — These
coolants are not recommended. Drop
out, overheating and water pump seal
failures can result from the use of
coolant or inhibitor packages based on
phosphate.
Automotive Type Coolants —
These coolants generally contain high
levels of phosphate and silicate, offer
no liner pitting protection, and are
not suitable for use in Detroit Diesel
engines.
Methyl Alcohol-Based
Antifreeze — This must not be
used because of its effect on the
non-metallic components of the
cooling system and its low boiling
point.
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DDC-SVC-MAN-0006
Additives Not Recommended
The following additives are not
recommended for use in Series 60
engines.
Soluble Oil Additives — These
additives are not approved for use in
Detroit Diesel engine cooling systems.
A small amount of oil adversely
affects heat transfer. For example, a
1.25% concentration of soluble oil
increases fire deck temperature 6%.
A 2.50% concentration increases fire
deck temperature 15%. The use of
soluble oil additives may result in
engine overheating and/or failure.
Chromate Additives — These
additives are not approved for use
in Detroit Diesel engine cooling
systems. Chromate additives can
form chromium hydroxide, commonly
called “green slime.” This, in turn,
can result in engine damage due to
poor heat transfer. Cooling systems
operated with chromium-inhibited
coolant must be chemically cleaned
All information subject to change without notice.
Copyright © 2009 DETROIT DIESEL CORPORATION
EPA07 SERIES 60 ENGINE OPERATOR'S MANUAL
with Power Cool dry chemical
cooling system cleaner/conditioner
listed in Table 33 (or equivalent
sulfamic acid/sodium carbonate
cleaner) and flushed.
Coolant Inhibitor Test Intervals
The coolant inhibitor level should be
checked at the intervals listed in Table
24.
Supplemental Coolant Additives
for Fully Formulated Coolant
— The concentrations of some
inhibitors will gradually deplete
during normal engine operation.
SCAs replenish the protection for
cooling system components. The
coolant must be maintained with the
proper concentration of SCA. Detroit
Diesel Power Cool maintenance SCAs
are recommended.
The proper application of SCA will
provide:
HOT COOLANT
To avoid scalding from the
expulsion of hot coolant, never
remove the cooling system
pressure cap while the engine is
at operating temperature. Wear
adequate protective clothing
(face shield, rubber gloves,
apron, and boots). Remove the
cap slowly to relieve pressure.
□ pH control.
□ Restored inhibitor levels to prevent
corrosion.
□ Water softening to deter formation
of mineral deposits.
□ Cavitation protection to protect
wet sleeve cylinder liners.
If topping off is needed, add coolant
which is identical to the initial fill
coolant.
Service Application
Inhibitor Test Interval
On-Highway Trucks and Motor Coaches
20,000 Miles (32,000 Kilometers)
Pick-Up and Delivery, Short Trip, and
Emergency Vehicles
6,000 Miles (9,600 Kilometers) or 3
Months, whichever comes first
Table 24
Required Coolant Inhibitor Test Intervals
All information subject to change without notice.
DDC-SVC-MAN-0006
Copyright © 2009 DETROIT DIESEL CORPORATION
113
HOW-TO SECTION
Maintenance Intervals — Check
the nitrite concentration at the regular
Coolant
Antifreeze / Water +
SCA Inhibitor (DDC
Power Cool)
Ethylene Glycol
/ Water + SCA
Inhibitor
or
Propylene Glycol
/ Water + SCA
Inhibitor
Ethylene Glycol
/ Water + OAT
Inhibitor
or
Propylene Glycol
/ Water + OAT
Inhibitor
intervals listed in Table 25 with a
Power Trac 3–Way Test Strip.
Interval 1
Action
20,000 Miles (32,000 km)
or 3 Months*
300,000 Miles
(480,000 km)
20,000 Miles (32,000 km)
or 3 Months*
Test nitrite concentration
with test strip. Add SCA or
dilute coolant as needed.
Drain and clean system.
Refill with new coolant.
Test nitrite concentration
with test strip. Add SCA or
dilute coolant as needed.
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 Plus
Extender
600,000 Miles
(960,000 km)
Drain and clean system.
Replace with new coolant.
Test nitrite concentration
with test strip. Add SCA or
Water Only + SCA
dilute coolant as needed.
Inhibitor
300,000 Miles
Drain and clean system.
(480,000 km)
Replace with new coolant.
300,000 Miles
Add Power Cool Plus
(480,000 km) or 2 Years*
Water Only + OAT
Extender
600,000 Miles
Clean and drain. Replace
Coolant
(960,000 km)
with new coolant.
1
Maintenance interval based on application. Drain interval dependent
on proper maintenance.
20,000 Miles (32,000 km)
or 3 Months*
Table 25
Coolant Maintenance Intervals
Nitrite levels must be within the
ranges listed in Table 21.
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DDC-SVC-MAN-0006
All information subject to change without notice.
Copyright © 2009 DETROIT DIESEL CORPORATION
EPA07 SERIES 60 ENGINE OPERATOR'S MANUAL
NOTICE:
Always maintain concentrations
of SCA at recommended levels.
Failure to properly maintain coolant
with SCA can result in damage to
the cooling system and its related
components, over-concentration of
SCA inhibitor can result in poor heat
transfer and engine damage.Do
not use traditional SCAs with OAT
coolant.
Additional SCA must be added to the
coolant when it becomes depleted, as
indicated by a nitrite concentration
of 900 PPM or less. If the nitrite
concentration is greater than 900
PPM, do not add additional SCA. If
the nitrite concentration is above 3200
PPM, the system is over-inhibited and
should be partially drained and filled
with a 50/50 mix of water and EG or
PG.
In this case the EG or PG should
contain no inhibitors and should
conform to ASTM D4985. This
will dilute the over-concentrated
inhibitors.
All information subject to change without notice.
DDC-SVC-MAN-0006
NOTE:
In non-OAT systems, nitrite
concentration of 5000 PPM or
higher on a Series 60 engine
suggests problematic additive
over-concentration. This condition
must be corrected by immediate
draining and flushing of the cooling
system. Refill the system with new fully
formulated or pre-charged coolant.
Check the nitrite concentration level at
the next maintenance interval with a
Power Trac 3–Way Test Strip.
SCA Test Procedures
Detroit Diesel Power Trac 3–Way
Coolant Test Strips should be
used to measure nitrite and
glycol concentrations. Part
numbers are listed in Table 34.
Cavitation/corrosion is indicated
on the strip by the level of nitrite
concentration. Freeze/boil over
protection is determined by glycol
concentration.
Copyright © 2009 DETROIT DIESEL CORPORATION
115
HOW-TO SECTION
Discard unused strips if they have
turned light pink or tan.
HOT COOLANT
To avoid scalding from the
expulsion of hot coolant, never
remove the cooling system
pressure cap while the engine is
at operating temperature. Wear
adequate protective clothing
(face shield, rubber gloves,
apron, and boots). Remove the
cap slowly to relieve pressure.
For best results make the test while
the coolant is between 50° – 140° F
(10.0° – 60° C). Wait at least 60, but
not longer than 75, seconds before
reading the nitrite level. Use the test
strips as follows:
1. Dip the strip into coolant for
one second. Remove and shake
briskly to eliminate excess fluid.
2. Immediately compare the pad end
(% glycol) to the color chart on
the container.
3. Sixty seconds (one minute) after
dipping, compare the nitrite pad
to the color chart.
A factory coolant analysis program
is available through authorized
Detroit Diesel service outlets. Part
numbers are listed in Table 34 in the
Specifications section. To verify
coolant acceptability, submit a sample
for coolant analysis every two (2)
years, 300,000 miles (480,000 km),
or 10,000 operating hours, whichever
comes first.
Coolant Filters (Non-OAT
Systems)
Spin-on coolant filters are available for
Detroit Diesel engines. Membranes
in the filters release SCAs before
the coolant approaches a corrosive
condition, protecting the engine from
corrosion. The elements release the
SCA charge as needed, as opposed to
the maintenance SCA elements, which
instantaneously release the SCA
charge. Coolant filter elements should
be replaced after one (1) year, 120,000
miles (192,000 km) or 2,000 operating
hours, whichever comes first.
4. Color change of the additive
indicator (middle pad) indicates
the presence of inhibitor that is
not approved by Detroit Diesel.
Promptly replace and tighten the test
strip container cap after each use.
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DDC-SVC-MAN-0006
All information subject to change without notice.
Copyright © 2009 DETROIT DIESEL CORPORATION
EPA07 SERIES 60 ENGINE OPERATOR'S MANUAL
Dropout
Excessive amounts of some inhibitors
in the coolant can cause a gel or
crystalline deposit that reduces heat
transfer and coolant flow. The deposit,
called “dropout,” takes the color of
the coolant when wet, but appears as a
white or gray powder when dry. It can
pick up solid particles in the coolant
and become gritty, causing excessive
wear of water pump seals and other
cooling system components.
PERSONAL INJURY
To avoid injury when using
caustic cleaning agents, follow
the chemical manufacturers
usage, disposal, and safety
instructions.
Coolant Extender Inhibitor
Additive for “OAT” Coolant
The inhibitors in OAT coolant must
also be maintained, but less often
than traditional SCA-type coolants.
A portable test is available to test the
levels of OAT inhibitors in coolant.
Where this is not used, fleet testing
has determined that a OAT coolant
extender package should be added to
the coolant at 300,000 miles (480,000
km), two (2) years, or 5,000 hours,
whichever comes first. The proper
maintenance dosages for all OAT
coolants are listed in Table 25 ,
reflecting 0.6% by volume extender.
This dosage should be added to the
water-only and the glycol systems at
the same interval.
The proper application of extender to
OAT coolant will provide:
□ pH Control
The wet gel can be removed by using
a non-acid (alkali) type heavy-duty
cleaner, such as Detroit Diesel Power
Cool On-Line Cleaner (sodium
nitrite/sodium tetraborate). Part
numbers are listed in Table 33.
NOTE:
If the gel is allowed to dry, it is
necessary to disassemble the
engine and clean it with a caustic
solution or physically clean individual
components.
All information subject to change without notice.
DDC-SVC-MAN-0006
□ Restored inhibitor levels to prevent
corrosion
□ Cavitation protection to protect
wet sleeve cylinder liners
NOTE:
Do not use traditional SCAs in
OAT coolant, and do not use
OAT extender in traditional coolant.
Copyright © 2009 DETROIT DIESEL CORPORATION
117
HOW-TO SECTION
OAT Coolant Drain Interval —
A properly maintained OAT-inhibited
coolant will last 600,000 miles
(960,000 km), four (4) years, or
10,000 operating hours, whichever
comes first. At this time the coolant
should be drained, and the cooling
system should be thoroughly cleaned,
flushed, and filled with new, properly
inhibited OAT coolant.
Chronic Coolant System
Problems
The most commonly seen coolant
system problems result from
maintenance and formulation factors
such as:
□ Hard water
□ Dilution of the coolant by the
addition of untreated water
□ Over dosage or under dosage of
corrosion inhibitors
□ Improper corrosion inhibitor (most
often phosphated)
□ Mixing SCAs
□ Improper testing
Detroit Diesel Cooling System
Maintenance Products
Power Cool SCAs — Power Cool
SCAs are water-soluble chemical
compounds. These products are
available in coolant filter elements,
liquid packages, and in fully
formulated Power Cool antifreeze.
NOTE:
Power Cool 3000 liquid SCA is more
compatible with hard water than
Power Cool 2000 SCA.
Power Cool Coolant Filter
Elements — Power Cool coolant
filter elements (spin-on canisters) are
available in various sizes suitable for
cooling systems of varying capacities.
Selection of the proper element size
is vital when pre-charging non-fully
formulated coolant at initial fill and
at maintenance intervals. A fully
formulated antifreeze must not
have SCA added at initial fill. Do
not use SCA-containing filters
with OAT antifreeze or coolant.
The need for maintenance elements
is determined by the results of the
nitrite concentration test performed
at each cooling system interval. Do
not automatically install maintenance
elements at maintenance intervals,
unless the nitrite concentration falls
below 900 parts per million.
The following products are available
to do maintenance on the cooling
system.
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DDC-SVC-MAN-0006
All information subject to change without notice.
Copyright © 2009 DETROIT DIESEL CORPORATION
EPA07 SERIES 60 ENGINE OPERATOR'S MANUAL
Power Cool Cleaners — Power
Cool Liquid On-Line Cleaner is used
for light deposits. Power Cool Dry
Chemical Cleaner/Conditioner is used
for heavy deposits or scale.
Summary of Coolant
Recommendations
HOT COOLANT
To avoid scalding from the
expulsion of hot coolant, never
remove the cooling system
pressure cap while the engine is
at operating temperature. Wear
adequate protective clothing
(face shield, rubber gloves,
apron, and boots). Remove the
cap slowly to relieve pressure.
1. Always maintain the engine
coolant to meet Detroit Diesel
specifications.
2. Only use water that meets the
specifications listed in Table 23.
Distilled, de-mineralized (reverse
osmosis) or de-ionized water is
preferred.
3. The proper dosage of inhibitors
must be included in the coolant
at initial fill for all Detroit Diesel
engines. This dosage is usually
included in the fully formulated
antifreeze used, or it may need to
All information subject to change without notice.
DDC-SVC-MAN-0006
be added if water alone or if less
than 50% antifreeze is used. The
user is urged to refer to the full
text of this section to determine
the proper dosage. Mixing
of different manufacturers'
technologies (brands) could cause
cooling system problems.
4. Maintain the inhibitor at the
prescribed concentration. Test
the nitrite concentration by using
a titration kit or Detroit Diesel
Power Trac 3-Way Coolant Test
Strips. Add SCA only if the nitrite
concentration is below 900 PPM.
Do not use SCA in OAT coolant,
and do not use Power Trac 3-Way
Coolant Test Strips to test OAT
coolant.
NOTE:
If the nitrite concentration exceeds
3,200 PPM, the coolant must be
drained and replaced with new
coolant. A thorough cleaning of the
cooling system may be required.
5. Do not use another manufacturer's
test kit to measure the SCA
concentration of Detroit Diesel
maintenance products.
6. Pre-mix coolant makeup solutions
to the proper concentration before
adding to the cooling system.
7. Do not mix OAT and other
coolants in the same engine.
Copyright © 2009 DETROIT DIESEL CORPORATION
119
HOW-TO SECTION
8. Do not use automotive coolants.
9. Where antifreeze/boil over
protection is required, use only
antifreeze that meets TMC
RP-329 “Type A” (EG) or
TMC RP-330 “Type A” (PG)
specifications. Always maintain
coolant at the proper level.
10. Do not use the following in
Detroit Diesel engine cooling
systems:
□ Soluble oil
□ High silicate, automotive-type
antifreeze
□ Chromate SCAs
□ Methoxy propanol-base
coolant
□ Methyl alcohol-base coolant
□ Sealer additives or coolant
containing sealer additives.
□ HVAC coolant
□ Phosphated coolants
Coolant life of Glycol Coolant —
A properly maintained cooling
system, filled with phosphate-free
coolant consisting of a 50/50 mix of
antifreeze and water per TMC RP-329
“Type A” (EG) or TMC RP-330
“Type A” (PG) specifications can be
operated to the limits recommended.
The proper maintenance involves
periodic evaluation using Power Trac
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DDC-SVC-MAN-0006
3-Way Coolant Test Strips and the
addition of SCA as needed, indicated
by the strip test. To verify coolant
acceptability, submit a sample for
coolant analysis every 300,000 miles
(480,000 km), three (3) years, or
5,000 operating hours, whichever
comes first. Submit the sample in
a DDC Power Trac Coolant Test
Bottle. Required part numbers are
listed in Table 34.
Coolant Life of OAT Coolant — A
properly maintained OAT coolant may
be operated 600,000 miles (960,000
km), four (4) years, or until overhaul,
whichever comes first. At this time the
system must be completely drained,
thoroughly cleaned, and refilled. OAT
Coolants require the addition of an
extender at 300,000 miles (480,000
km), two (2) years, or 5,000 hours,
whichever comes first. Use 1 pint
of extender for every 20 gallons of
coolant.
Coolant Life of Other Coolants —
Other properly maintained coolants
may be operated up to 250,000 miles
(480,000 km), two (2) years, or 4,000
operating hours, whichever comes
first. At this time the system must
be completely drained, thoroughly
cleaned, and refilled.
All information subject to change without notice.
Copyright © 2009 DETROIT DIESEL CORPORATION
EPA07 SERIES 60 ENGINE OPERATOR'S MANUAL
How to Drain and Flush the
Cooling System
Drain and flush the cooling system as
follows:
3. Start the engine and operate it for
fifteen minutes to circulate the
solution thoroughly.
4. Stop the engine and allow it to
cool.
5. With the engine cool, drain the
cooling system completely.
HOT COOLANT
To avoid scalding from the
expulsion of hot coolant, never
remove the cooling system
pressure cap while the engine is
at operating temperature. Wear
adequate protective clothing
(face shield, rubber gloves,
apron, and boots). Remove the
cap slowly to relieve pressure.
1. With the engine cool, drain the
previous solution from the engine
and radiator. Dispose of the
coolant in an environmentally
friendly manner, according
to state and/or federal (EPA)
recommendations.
2. Refill the cooling system
with clean, soft water and a
good cooling system cleaning
compound, such as those
listed in Table 33 in the
Specifications section. If
the engine is warm, fill slowly
to prevent the rapid cooling and
distortion of the metal castings.
All information subject to change without notice.
DDC-SVC-MAN-0006
6. Refill the cooling system with
clean, soft water and operate it for
fifteen minutes.
7. Stop the engine and allow it to
cool.
8. With the engine cool, drain the
cleaner residue from the cooling
system.
9. Refill the system with the required
coolant. Refer to section How to
Select Coolant.
10. Entrapped air must be purged
after filling the cooling system.
To do this, allow the engine to
warm up without the pressure cap
installed. With the transmission
in neutral, increase engine speed
above 1000 RPM and add coolant
as required. Install the pressure
cap after the coolant level has
stabilized at the bottom of the
radiator filler neck.
Copyright © 2009 DETROIT DIESEL CORPORATION
121
HOW-TO SECTION
NOTICE:
If the engine overheats and
the coolant level is satisfactory,
the cooling system may require
cleaning with a descaling solvent
and backflushing. Authorized
Detroit Diesel service outlets are
properly equipped to perform these
services.
In addition to the cleaning procedure,
other components of the cooling
system should be checked periodically
to keep the engine operating at peak
efficiency.
Hoses
Cooling system hoses should be
inspected and any hose that shows
obvious signs of damage or feels
abnormally soft or hard should be
replaced. Damaged clamps should
also be replaced. All external leaks
should be corrected as soon as
detected.
When to Service the Dry
Type Air Cleaner
Replace dry type air cleaner elements
when the maximum allowable air
cleaner restriction (20 inches of
water or 5.0 kPa) has been reached
or annually, whichever comes first.
Some air cleaners are equipped with
a restriction indicator which aids in
determining the servicing interval.
Cleaning and/or reusing dry paper
type air cleaner elements is not
recommended unless the cleaning
method used removes clogging
without damaging the element.
Inspection and cleaning of elements
must be done in accordance with
the air cleaner manufacturer's
recommendations, if any.
NOTE:
If Detroit Diesel Power Cool
antifreeze/coolant (or equivalent fully
formulated, precharged antifreeze
is used, a precharge element is not
required. Coolant inhibitor levels
must be checked at the intervals
listed in Table 24.
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DDC-SVC-MAN-0006
All information subject to change without notice.
Copyright © 2009 DETROIT DIESEL CORPORATION
EPA07 SERIES 60 ENGINE OPERATOR'S MANUAL
TROUBLESHOOTING
This section covers basic
troubleshooting of engine operation
or performance malfunctions and
their probable causes. In addition to
operating the engine carefully and
maintaining it properly make sure to
correct any malfunction promptly.
Abnormal Coolant
Temperature
Abnormal Coolant Temperature Symptoms and Probable Causes
Above
Below
Probable Causes
Normal
Normal
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
All information subject to change without notice.
DDC-SVC-MAN-0006
Copyright © 2009 DETROIT DIESEL CORPORATION
123
TROUBLESHOOTING
Hard Starting
Hard Starting Symptoms and Probable Causes
Engine Will
Not Rotate
Low
Cranking
Speed
Low Battery Voltage
Loose cranking motor
connections
Faulty cranking motor
X
X
Engine
Cranks But
Will Not
Start
—
X
—
—
X
X
—
Faulty cranking motor switch
X
X
X
Internal seizure
X
—
—
Improper lube oil
Circuit breaker/electronic control
malfunction
Fuse blown or missing
—
X
—
—
—
X
—
—
X
Air in fuel
—
—
X
Out of fuel
—
—
X
Loose fuel connections
—
—
X
Cracked fuel lines
—
—
X
Obstructed fuel filters/lines
—
—
X
Faulty fuel pump
—
—
X
Faulty injector operation
—
—
X
Restricted fuel fitting missing
—
—
X
DDEC Malfunction
Installation/operation of fuel
check valve or shutoff valve
Low Compression
—
—
X
—
—
X
Worn intake and exhaust valves
—
—
X
Worn piston rings/liners
—
—
X
Probable Causes
Insufficient Fuel Supply
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DDC-SVC-MAN-0006
All information subject to change without notice.
Copyright © 2009 DETROIT DIESEL CORPORATION
EPA07 SERIES 60 ENGINE OPERATOR'S MANUAL
Hard Starting Symptoms and Probable Causes
Probable Causes
Engine Will
Not Rotate
Low
Cranking
Speed
—
—
Engine
Cranks But
Will Not
Start
X
—
—
X
Leaking cylinder head gasket
Improper intake or exhaust valve
adjustments
Aftertreatment System
Engines that meet the EPA 2007
emissions standards are equiped
with an a Aftertreatment System that
prevents 95% of the particulate matter
(soot) from leaving the exhaust. This
will eliminate the use of visible smoke
diagnostics unless there is a system
failure issue. White smoke or steam
at start up or during cold weather
operation is still a characteristic of
engine operation. Abnormal amounts
of black/blue smoke may merit further
investigation.
All information subject to change without notice.
DDC-SVC-MAN-0006
Copyright © 2009 DETROIT DIESEL CORPORATION
125
TROUBLESHOOTING
Abnormal Engine
Operation
Abnormal Engine Operation Symptoms and Probable Causes
Rough
Running or
Low Power Detonation
Probable Causes
Frequent
Stalling
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/exhaust back pressure
—
X
—
Engine application
—
X
—
High air inlet temperature
—
X
—
High altitude operation
—
X
—
Incorrect engine gear train
timing
—
X
—
Low coolant temperature
—
—
X
Oil picked up by inlet airstream
—
—
X
Faulty injector operation
—
—
X
Incorrect injector height
setting
—
X
X
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DDC-SVC-MAN-0006
All information subject to change without notice.
Copyright © 2009 DETROIT DIESEL CORPORATION
EPA07 SERIES 60 ENGINE OPERATOR'S MANUAL
Abnormal Operating
Conditions
Abnormal Operating Condition Symptoms and Probable Causes
High Lube Oil
Low Oil
Probable Causes
Consumption
Pressure
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
Oil in air tanks (air compressor
malfunction)
Plugged crankcase breather
X
—
X
—
X
—
Oil level low
Improper engine oil viscosity (fuel in the
oil)
Faulty oil pressure regulator valve
Worn crankshaft, camshaft or
connecting rod bearings
Missing cup plugs in rocker arm shafts
—
X
—
X
—
X
—
X
—
X
Faulty oil pressure relief valve
—
X
Air leaks in oil pump (suction side)
—
X
Worn or damaged oil pump
—
X
Faulty oil pressure gage
—
X
Faulty electrical components (for gage)
—
X
Plugged oil line or orifice
—
X
* Indicates high crankcase pressure
All information subject to change without notice.
DDC-SVC-MAN-0006
Copyright © 2009 DETROIT DIESEL CORPORATION
127
ENGINE STORAGE
ENGINE STORAGE
When an engine is to be stored or
removed from operation for a period
of time, special precautions should
be taken to protect the interior and
exterior of the engine, transmission
and other parts from rust accumulation
and corrosion. The parts requiring
attention and the recommended
preparations are given below.
Preparing Engine for
Storage
It will be necessary to remove all
rust or corrosion completely from
any exposed part before applying rust
preventive compound. Therefore,
it is recommended that the engine
be processed for storage as soon as
possible after removal from operation.
The engine should be stored in
a building that is dry and can be
heated during the winter months.
Moisture-absorbing chemicals are
available commercially for use when
excessive dampness prevails in the
storage area.
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DDC-SVC-MAN-0006
Temporary Storage (30 Days or
Less)
To protect the engine for a temporary
period of time (30 days or less), follow
this procedure:
1. With the engine at ambient
temperature and cool to the touch,
drain engine crankcase oil into a
suitable container. Dispose of the
oil in an environmentally friendly
manner, according to state and/or
federal (EPA) recommendations.
2. Fill the crankcase to the proper
level with the recommended
viscosity and grade of oil.
3. Fill the fuel tank with the
recommended grade of fuel oil.
Operate the engine for two (2)
minutes at 1200 rpm and no load.
Do not drain the fuel system or
the crankcase after this run.
4. Check the air cleaner and service
it, if necessary.
5. If freezing weather is expected
during the storage period,
check the antifreeze/coolant for
required freeze and inhibitor
protection. Add antifreeze
solution to the cooling system in
accordance with Detroit Diesel's
All information subject to change without notice.
Copyright © 2009 DETROIT DIESEL CORPORATION
EPA07 SERIES 60 ENGINE OPERATOR'S MANUAL
recommendations. Refer to How
to Select Coolant in this guide.
NOTE:
If an antifreeze solution is not required
during storage, flush the cooling
system with a good soluble oil (3% –
5% by volume) rust inhibitor to prevent
rusting of the outside diameter of the
cylinder liners.
EYE INJURY
To avoid injury from flying debris
when using compressed air, wear
adequate eye protection (face
shield or safety goggles) and do
not exceed 276 kPa (40 psi) air
pressure.
6. Clean the exterior of the engine
(except electrical parts) with fuel
oil and dry with compressed air.
7. Seal all engine openings. The
material used must be waterproof,
vaporproof and possess sufficient
physical strength to resist
puncture and damage from the
expansion of entrapped air.
An engine prepared in this manner can
be returned to service in a short time
by removing the seals at the engine
openings and by checking the engine
coolant, fuel oil, lubricating oil and
transmission oil levels.
All information subject to change without notice.
DDC-SVC-MAN-0006
Extended Storage (More than 30
Days)
To prepare an engine for extended
storage (more than 30 days), follow
this procedure:
1. Drain the cooling system and
flush with clean, soft water. Refill
with clean, soft water and add
a rust inhibitor to the cooling
system.
2. Circulate the coolant by operating
the engine until normal operating
temperature is reached.
3. Stop the engine.
4. With the engine at ambient
temperature and cool to the touch,
drain the engine crankcase oil
into a suitable container. Remove
the oil filters. Dispose of the oil
and filters in an environmentally
friendly manner, according
to state and/or federal (EPA)
recommendations. Replace the
drain plug and tighten to 45 –
50 N·m (33 – 37 lb-ft) torque.
5. Install new lubricating oil
filters. Fill the crankcase to
the proper level with Tectyl®
930A preservative lubricating
oil or an equivalent 30–weight
preservative lubricating oil
meeting Mil-L-21260C, Grade 2
Specification.
6. Drain the fuel tank. Refill with
enough clean No. 1 diesel fuel to
Copyright © 2009 DETROIT DIESEL CORPORATION
129
ENGINE STORAGE
permit the engine to operate for
about ten (10) minutes. If draining
the fuel tank is not convenient,
use a separate, portable supply of
recommended fuel.
NOTE:
If engines are stored where
condensation of water in the fuel
tank may be a problem, additives
containing methyl carbitol or butyl
cellusolve may be added to the fuel.
Follow manufacturer's instructions
for treatment. Where biological
contamination of fuel may be a
problem, add a biocide such as
Biobor® JF (or equivalent) to the
fuel. When using a biocide, follow
the manufacturer's concentration
recommendations and observe all
cautions and warnings.
7. Drain the fuel system and remove
the fuel filters. Dispose of used
filters in an environmentally
responsible manner, according
to state and/or federal (EPA)
recommendations. Fill the new
filters with No. 1 diesel fuel or
pure kerosene and install on the
engine.
8. Operate the engine for five (5)
minutes to circulate the clean fuel
throughout the engine. Be sure
the engine fuel system is full.
9. Stop the engine and allow to
cool. Then disconnect the fuel
130
DDC-SVC-MAN-0006
return line and the inlet line at
the primary filter and securely
plug both to retain the fuel in the
engine.
10. Transmission: Follow the
manufacturer's recommendations
for prolonged storage.
11. Power Take-Off: If equipped,
follow manufacturer's
recommendations for prolonged
storage.
NOTICE:
Failure to properly seal off the
turbocharger air inlet and exhaust
outlet openings before engine
storage may permit air drafts to
circulate through the turbocharger
and rotate the turbine/compressor
shaft without an adequate flow of
lubricating oil to the center housing
bearings resulting in severe bearing
damage.
12. Turbocharger: Since
turbocharger bearings are
pressure lubricated through the
external oil line leading from
the oil filter adaptor while the
engine is operating, no further
attention is required. However,
the turbocharger air inlet and
turbine exhaust outlet connection
should be sealed off with
moisture-resistant tape.
All information subject to change without notice.
Copyright © 2009 DETROIT DIESEL CORPORATION
EPA07 SERIES 60 ENGINE OPERATOR'S MANUAL
13. Apply a non-friction rust
preventive compound to all
exposed engine parts. If
convenient, apply the rust
preventive compound to the
engine flywheel. If not, disengage
the clutch mechanism to prevent
the clutch disc from sticking to
the flywheel.
NOTE:
Do not apply oil, grease or any
wax-base compound to the flywheel.
The cast iron will absorb these
substances, which can “sweat” out
during operation and cause the clutch
to slip.
14. Drain the engine cooling system.
If the engine will be exposed
to freezing temperatures, install
genuine Detroit Diesel Power
Cool antifreeze or an equivalent
ethylene glycol-base or propylene
glycol-base antifreeze solution
that provides the required freeze,
boil over and inhibitor protection.
Refer to How to Select Coolant in
this guide.
15. Drain the preservative oil from
the engine crankcase. Reinstall
and torque the 3/4” – 14 square,
magnetic drain plug to 45 –
50 N·m (33 – 37 lb-ft).
with fresh water. Do not allow
the soda solution to enter the
battery. Add distilled water to
the electrolyte (if necessary) and
fully charge the battery. Store the
battery in a cool (never below 0°
C or 32° F) dry place. Keep the
battery fully charged and check
the level and specific gravity of
the electrolyte regularly.
17. Insert heavy paper strips between
the pulleys and drive belts to
prevent sticking.
18. Seal all engine openings,
including the exhaust outlet,
with moisture-resistant tape. Use
cardboard, plywood or metal
covers where practical.
19. Clean and dry the exterior painted
surfaces of the engine and spray
with a suitable liquid automobile
body wax, a synthetic resin
varnish, or a rust preventive
compound.
20. Protect the engine with a good
weather-resistant tarpaulin and
store it under cover, preferably
in a dry building which can be
heated during the winter months.
16. Remove and clean the battery
and battery cables with a baking
soda-water solution and rinse
All information subject to change without notice.
DDC-SVC-MAN-0006
Copyright © 2009 DETROIT DIESEL CORPORATION
131
ENGINE STORAGE
Outdoor storage of the engine is not
recommended. If units must be kept
out of doors, follow the preparation
and storage instructions already
given. Protect units with quality,
weather-resistant tarpaulins (or other
suitable covers) arranged to provide
for air circulation.
NOTICE:
Do not use plastic sheeting for
outdoor storage. Enough moisture
can condense on the inside of the
plastic to rust ferrous metal surfaces
and pit aluminum surfaces. If a unit
is stored outside for any extended
period of time, severe corrosion
damage can result.
Procedure for Restoring to
Service an Engine that Has Been
in Extended Storage
If an engine has been in extended
storage, prepare it for service as
follows:
1. Remove the covers and tape from
all the openings of the engine, fuel
tank and electrical equipment. Do
not overlook the exhaust outlet.
2. Remove the plugs from the inlet
and outlet fuel lines and reconnect
the lines to their proper positions.
3. Wash the exterior of the engine
with fuel oil to remove the
rust preventive. Do not wash
electrical components.
4. Remove the rust preventive from
the flywheel. Flush any soluble
oil rust inhibitor (if used) in the
cooling system.
NOTE:
Plastic is fine for indoor storage.
The stored engine should be inspected
periodically. If there are any
indications of rust or corrosion,
corrective steps must be taken to
prevent damage to the engine parts.
Perform a complete inspection at the
end of one year and apply additional
treatment as required.
5. Remove the paper strips from
between the pulleys and drive
belts.
6. Fill the crankcase to the proper
level with the required grade of
lubricating oil. Use a pressure
lubricator to insure all bearings
and rocker shafts are lubricated.
7. Fill the fuel tank with the required
fuel.
8. Close all drain cocks and fill the
engine cooling system with clean,
132
DDC-SVC-MAN-0006
All information subject to change without notice.
Copyright © 2009 DETROIT DIESEL CORPORATION
EPA07 SERIES 60 ENGINE OPERATOR'S MANUAL
soft water and required inhibitors.
If the engine is to be exposed
to freezing temperatures, install
genuine Detroit Diesel Power
Cool antifreeze or an equivalent
ethylene glycol-base or propylene
glycol-base antifreeze solution
which provides required freeze,
boil over, and inhibitor protection.
Refer to section How to Select
Coolant.
9. Install and connect the battery.
Make sure the average specific
gravity of the battery is 1.260
or higher. Charge the battery, if
necessary.
10. Service the air cleaner, if required.
11. Transmission: Follow the
manufacturer's recommendations
covering the return of the
transmission to service.
12. Power Take-Off: If equipped,
follow the manufacturer's
recommendations covering the
return of the power take-off to
service.
13. Turbocharger: Remove the
covers from the turbocharger
air inlet and turbine outlet
connections. Reconnect
piping as required. Prelube
the turbocharger center
bearing housing. Refer to
Lubrication System Checks in the
OPERATING INSTRUCTIONS
All information subject to change without notice.
DDC-SVC-MAN-0006
FOR STARTING THE ENGINE
section of this guide.
ENGINE EXHAUST
To avoid injury from inhaling
engine exhaust, always operate
the engine in a well-ventilated
area. Engine exhaust is toxic.
14. After all preparations are
completed, start the engine.
NOTE:
The small amount of rust preventive
which remains in the fuel system
will cause smoky exhaust for a few
minutes.
NOTE:
Before subjecting the engine to a load
or high speed, allow it to reach normal
operating temperature.
15. Check for trouble codes.
[a] If there are no codes, perform
a parked regeneration.
[b] If there are codes, repair what
is necessary then perform a
parked regeneration.
Copyright © 2009 DETROIT DIESEL CORPORATION
133
CUSTOMER ASSISTANCE
CUSTOMER ASSISTANCE
The satisfaction and goodwill of the
owners of Detroit Diesel engines are of
primary concern to Detroit Diesel and
Figure 36
134
its distributor/dealer organizations.
See Figure 36 for Detroit Diesel
NAFTA On-Highway service regions.
Detroit Diesel NAFTA On-Highway Service Regions
DDC-SVC-MAN-0006
All information subject to change without notice.
Copyright © 2009 DETROIT DIESEL CORPORATION
EPA07 SERIES 60 ENGINE OPERATOR'S MANUAL
NAFTA ON-HIGHWAY SERVICE REGIONS
DETROIT DIESEL REGIONAL
SALES OFFICES
DETROIT DIESEL REGIONAL
SERVICE OFFICES
NORTHEAST REGION
Detroit Diesel Corporation
Powder Miss Plaza, Suite 3A
51 Gibralter Drive
Morris Plains, NJ 07950-1274
Phone: 973-492-6555
Fax: 973-267-5922
NORTH EASTERN REGION
Detroit Diesel Corporation
13400 Outer Drive West
Detroit, MI 48239-4001
Telephone: 313-592-5420
Fax: 311-592-5887
CENTRAL REGION
Detroit Diesel Corporation
9255 Indian Creek Parkway, Suite 850
Overland Park, KS 66210
Phone: 678-570-2389
NORTH CENTRAL & WESTERN
REGIONS
Detroit Diesel Corporation
7700 Irvine Center, Suite 275
Irvine CA 92618
Phone: 949-753-7710
Fax: 949-753-7711
SOUTHERN REGION
Detroit Diesel Corporation
3325 Paddocks Parkway, Suite 230
Suwanne, GA 30024
Phone: 678-341-6100
Fax: 678-341-6150
SOUTHERN REGION
Detroit Diesel Corporation
3325 Paddocks Parkway, Suite 230
Suwanne, GA 30024
Phone: 678-341-6100
Fax: 678-341-6150
WESTERN REGION
Detroit Diesel Corporation
7700 Irvine Center, Suite 275
Irvine CA 92618
Phone: 949-753-7710
Fax: 949-753-7711
CANADA REGION
Detroit Diesel of Canada, Ltd.
150 Dufferin Ave., Suite 701
London ON N5A 5N6
Phone: 519-661-0149
Fax: 519-661-0171
CANADA REGION
Detroit Diesel of Canada, Ltd.
150 Dufferin Ave., Suite 701
London ON N5A 5N6
Phone: 519-661-0149
Fax: 519-661-0171
MEXICO REGION
Detroit Diesel Allison de Mexico, S.A.
Av. Santa Rosa 58
Col. Ampliacion Norte
San Juan Ixtacala, Tlanepantla
C.P. 54160, Edo de Mexico
Phone: 525-333-1802
Fax: 525-333-1870
All information subject to change without notice.
DDC-SVC-MAN-0006
Copyright © 2009 DETROIT DIESEL CORPORATION
135
CUSTOMER ASSISTANCE
Road Service in the U.S. or
Canada
If you require road service for any
reason in the U.S. or Canada, you may
call the 1–800–445–1980 customer
assistance phone number. An operator
will assist you in determining what
type of service is required. Not all
problems are engine related and not
all problems are covered by engine
or vehicle warranties. YOU MAY
BE RESPONSIBLE FOR REPAIR
EXPENSES.
Before calling Customer Assistance,
please do the following:
□ Check coolant level
□ Vehicle owner/company name
Working with Detroit Diesel
Service Outlets
As the owner of a Detroit Diesel
product you have a complete network
of Detroit Diesel service outlets in the
U.S. and Canada, plus many outlets
worldwide that are prepared to meet
your parts and service needs:
□ Service by trained personnel.
□ Sales team to help determine your
specific power requirements.
□ In many areas, emergency service
24 hours a day.
□ Check DDEC fuses
□ Complete parts support, including
reliabilt® remanufactured
components.
□ Check for fuel leaks
□ Product information and literature.
□ Make sure manual shutoff valve (if
installed) on the fuel filter adaptor,
fuel processor body or fuel supply
line is open.
We recognize however, that despite
the best intentions of everyone
concerned, misunderstandings may
occur. Normally, any situation
that arises in connection with the
sale, operation or service of your
product will be handled by the
authorized service outlet in your area
(in the U.S. and Canada, check the
Yellow Pages or service locator at
www.detroitdiesel.com for Detroit
Diesel service outlet nearest you).
□ Check fuel level
□ Check the oil level on the dipstick.
□ Check diagnostic codes.
If you call, have the following
information available:
□ Engine serial number
□ Vehicle make and model
□ Odometer mileage (kilometers) or
hourmeter hours
136
DDC-SVC-MAN-0006
All information subject to change without notice.
Copyright © 2009 DETROIT DIESEL CORPORATION
EPA07 SERIES 60 ENGINE OPERATOR'S MANUAL
Detroit Diesel has established a
three-step procedure that customers
should follow when experiencing
a problem with any Detroit Diesel
Product or Part. Detroit Diesel fully
realizes that ultimately the customer's
concerns will be resolved at the
Distributor/Dealer level and therefore
encourages customers to follow the
procedure outlined below:
Step One
Customers should discuss the problem
with a member of management
from the authorized service outlet.
Frequently, complaints are the result
of a breakdown in communication
and can quickly be resolved by a
member of management. If they have
already discussed the problem with
the Distributor or Dealer Sales or
Service Manager, they should contact
the General Manager.
Step Two
When it appears that the problem
cannot readily be resolved at the
Distributor/Dealer level without
additional assistance, the Detroit
Diesel Customer Support Center
(CSC) should be contacted at
313–592–5800.
The information provided to the CSC
will be forwarded to the appropriate
Regional Product Support Manager.
The customer will then be assisted
All information subject to change without notice.
DDC-SVC-MAN-0006
be a member of the Regional Product
Support Managers staff, depending on
the nature of his/her problem.
Prior to this contacting the CSC, the
customer should have the following
information available:
□ Name and location of authorized
service outlet
□ Type, make and vehicle
identification number of
equipment
□ Engine model and serial number
□ Engine delivery date and
accumulated miles/kilometers or
hours of operation
□ Nature of problem
□ Chronological summary of
engine's repair history
Step Three
If the customer is still not satisfied,
he/she should present the entire matter
in writing or by phone to:
Director of Technical Service or
Manager, Service Operations BX5
Detroit Diesel Corporation
13400 Outer Drive, West
Detroit, Michigan 48239–4001
Phone: 313–592–5000
Fax: 313–592–5888
Copyright © 2009 DETROIT DIESEL CORPORATION
137
SPECIFICATIONS
SPECIFICATIONS
This section lists the various POWER
COOL engine products.
Center (313–592–5800) if you need
this specific information.
Fuel and Lubricating Oil
Filters
POWER COOL ENGINE
PRODUCTS
Consult with a Detroit Diesel
Distributor to obtain the proper fuel
filters and lubricating oil filters.
Maintenance of the cooling system
requires the chemical make-up of the
system to be balanced.
OIL PAN CAPACITY
POWER COOL Fully Formulated
IEG Coolant
Engine oil capacity can vary,
depending on the oil pan used and
the engine application. Contact the
Detroit Diesel Customer Support
Coolant Type
Concentrated
Pre-Blended
50:50
Table 26
138
The part numbers and sizes of
concentrated POWER COOL and
pre-blended 50:50 POWER COOL are
listed in Table 26.
Part Number
Description
23512138
1 Gallon Jug – 6 Per Case
23512139
55 Gallon Drum
23529295
330 Gallon Tote
23512140
Bulk Delivery – 1,000 Gallon Min.
23528203
1 Gallon Jug – 6 Per Case
23518918
55 Gallon Drum
23528544
330 Gallon Tote
23513503
Bulk Delivery – 1,000 Gallon Min.
POWER COOL Fully Formulated IEG Coolant
DDC-SVC-MAN-0006
All information subject to change without notice.
Copyright © 2009 DETROIT DIESEL CORPORATION
EPA07 SERIES 60 ENGINE OPERATOR'S MANUAL
POWER COOL 2000 and 3000
Supplemental Coolant Additive
Coolant Type
For Power Cool IEG
Coolant
Table 27
Description
23507858
Pint Bottle – 12 Per case
23507859
Half Gallon Jug – 6 Per Case
23507860
5 Gallon Pail
23507861
55 Gallon Drum
POWER COOL 2000 Supplemental Coolant Additive
Coolant Type
For POWER COOL
IEG Coolant
Table 28
Part Number
Part Number
Description
23507854
Pint Bottle – 12 Per Case
23507855
Half Gallon Jug – 6 Per Case
23507856
5 Gallon Pail
23507857
55 Gallon Drum
POWER COOL 3000 Supplemental Coolant Additive
POWER COOL 3000
Supplemental Additive Coolant
Filters
Coolant Type
For POWER COOL
IEG Coolant
Table 29
Part Number
Description
23507545
4 Ounce (1 Pint Equivalent)
23508425
8 Ounce (2 Pint Equivalent)
23508426
12 Ounce (3 Pint Equivalent)
23507189
16 Ounce (4 Pint Equivalent)
23508427
32 Ounce (8 Pint Equivalent)
23508428
53 Ounce (13 Pint Equivalent)
POWER COOL 3000 Supplemental Additive Coolant Filters
All information subject to change without notice.
DDC-SVC-MAN-0006
Copyright © 2009 DETROIT DIESEL CORPORATION
139
SPECIFICATIONS
POWER COOL Supplemental
Additive Need Release Coolant
Filters
Coolant Type
Part Number
Description
For POWER COOL
IEG Coolant
NF2091
For 0 – 8 Gallon Systems
23516489
For 8 – 20 Gallon Systems
Table 30
POWER COOL Supplemental Additive Need Release
Coolant Filters
POWER COOL Plus Extended
Life OAT Coolant
Coolant Type
Concentrated
Pre-Blended 50:50
Table 31
Part Number
Description
23519397
1 Gallon Jug – 6 Per Case
23519394
55 Gallon Drum
23519395
Bulk Delivery – 1,000 Gallon Min.
23519396
One Gallon Jug – 6 Per Case
23519398
55 Gallon Drum
23519399
Bulk Delivery – 1,000 Gallon Min.
POWER COOL Plus Extended Life OAT Coolant
POWER COOL Plus Extender
For Use With POWER COOL
Plus OAT Coolant
Coolant Type
Part Number
Description
For Power Cool Plus
23519400
Quart Bottle – 6 Per Case
Table 32
140
POWER COOL Plus Extender for Use with POWER COOL
Plus OAT Coolant
DDC-SVC-MAN-0006
All information subject to change without notice.
Copyright © 2009 DETROIT DIESEL CORPORATION
EPA07 SERIES 60 ENGINE OPERATOR'S MANUAL
POWER COOL Cooling System
Cleaners
Coolant Type
On-Line Cleaner
Twin Pack
Table 33
Part Number
Description
200164
On-Half Gallon Jug – 6 Per Case
200105
5 Gallon Pail
200155
55 Gallon Drum
201549
Twin Pack – 2 Per Case
POWER COOL Cooling System Cleaners
POWER TRAC Coolant Testing
And Analysis Products
Application
Indicates Nitrite,
Molybdate & Glycol
Levels
Indicates Nitrite,
Molybdate & Glycol
Levels
Indicates Nitrite,
Molybdate & Glycol
Levels
Complete IEG/IPG
Coolant Analysis
Organic Coolant
Analysis
Table 34
Part
Number
Description
23519401
3-Way Coolant Test Strips
(Single Foil Packs)
23519402
3-Way Coolant Test Strips
(Bottle of 50)
23522774
3-Way Coolant Test Strips
(Bottle of 10)
23516921
23523398
Coolant Analysis Bottle
(Carton of 6)
Laboratory Coolant Analysis Bottle
(Carton of 6)
Power Trac Coolant Testing and Analysis Products
All information subject to change without notice.
DDC-SVC-MAN-0006
Copyright © 2009 DETROIT DIESEL CORPORATION
141
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