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EPA07 SERIES 60 ENGINE OPERATOR'S MANUALTo the OperatorThis guide contains instructions onthe safe operation and preventivemaintenance of your Detroit DieselSeries 60 engine used in vehicle, orfire fighting apparatus applications.Maintenance instructions coverroutine engine services such as lubeoil and filter changes in enough detailto permit self-servicing, if desired.The operator should become familiarwith the contents of this guide beforeoperating the engine or carrying outmaintenance procedures.Power-driven equipment is onlyas safe as the person operating thecontrols. You are urged, as theoperator of this diesel engine, to keepfingers and clothing away from therevolving belts, drive shafts, pulleys,etc. on the engine installation.Throughout this guide CAUTIONSregarding personal safety andNOTICES regarding engineperformance or service life willappear. To avoid personal injury andensure long engine service life, alwaysheed these instructions.Whenever possible, it will benefityou to rely on an authorized DetroitDiesel service outlet for all yourservice needs from maintenance tomajor parts replacement. Authorizedservice outlets worldwide stockfactory-original parts and havethe specialized equipment andexperienced, trained personnelto provide prompt preventivemaintenance and skilled enginerepairs.The information and specificationsin this publication are based on theinformation in effect at the time ofapproval for printing. Contact anauthorized Detroit Diesel serviceoutlet for information on the latestrevision. The right is reserved tomake changes at any time withoutobligation.The Series 60 engine is built inaccordance with sound technologicalprinciples and based on state-of-the-arttechnology.Despite this, the engine may constitutea risk of damage to property or injuryto persons if it is not used for itsintended purpose.The engine should not be modified orconverted in an incorrect manner orthe safety instructions included in thismanual disregarded.All information subject to change without notice.DDC-SVC-MAN-0006Copyright 2009 DETROIT DIESEL CORPORATIONi
Trademark InformationNOTICE:Coolant must be inhibited with therecommended SCAs (supplementalcoolant additives) listed in theHow To section of this engineoperator's guide. In addition, theengine can be equipped with acoolant filter/inhibitor system as aninstalled option or as an after-saleitem. Failure to check andmaintain SCA levels at requiredconcentrations will result insevere damage (corrosion) tothe engine cooling system andrelated components.WARRANTYThe applicable engine warranty iscontained in the booklet “WarrantyInformation for Series 60 Engines,”available from authorized DetroitDiesel service outlets.DDC , Detroit Diesel , DDEC ,Series 60 , Optimized Idle ,Diagnostic Link , reliabilt ,POWER Trac , POWER COOL ,and POWER GUARD are registeredtrademarks of Detroit DieselCorporation. Delco Remy is aregistered trademark of Delco RemyAmerica, Inc. Bosch is a registeredtrademark of Robert Bosch CompanyN.A. Fuel Pro , and Mega Filter are registered trademarks of DavcoManufacturing, L.L.C. Nexiq isa trademark of Nexiq Technologies,Inc. PowerBand is a registeredtrademark of Gates Rubber Company.Tectyl is a registered trademark ofDaubert Chemical Company, Inc.Biobor is a registered trademark ofUnited States Borax and ChemicalCorporation. DuPont is a registeredtrademark of E.I. DuPont de Nemoursand Company, Inc. All othertrademarks used are the property oftheir respective owners.Keep this Operator's Guidewith the engine installation atall times. It contains importantoperating, maintenance, and safetyinstructions.iiDDC-SVC-MAN-0006All information subject to change without notice.Copyright 2009 DETROIT DIESEL CORPORATION
EPA07 SERIES 60 ENGINE OPERATOR'S MANUALTABLE OF CONTENTSINTRODUCTION .NON-GENUINE AND REBUILT COMPONENT QUALITY ALERT .PERSONNEL REQUIREMENTS .ENGINE CONVERSIONS AND MODIFICATIONS .1122CAUTION SUMMARY .ENGINE OPERATION .PREVENTIVE MAINTENANCE .ELECTRICAL SYSTEM .COOLING SYSTEM .AIR INTAKE SYSTEM .FUEL SYSTEM .COMPRESSED AIR .STARTING AIDS .LUBRICATING OIL AND FILTERS .AFTERTREATMENT SYSTEM .335889910111212ENGINE IDENTIFICATION .ENGINE COMPONENTS .ENGINE MODEL AND SERIAL NUMBER DESIGINATON .CERTIFICATION LABEL .14141617OPERATING 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 .18181818191920202121222224All information subject to change without notice.DDC-SVC-MAN-0006Copyright 2009 DETROIT DIESEL CORPORATIONiii
TABLE OF CONTENTSRUNNING 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 232DDEC 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 .333334353537373838393940ivDDC-SVC-MAN-0006All information subject to change without notice.Copyright 2009 DETROIT DIESEL CORPORATION
EPA07 SERIES 60 ENGINE OPERATOR'S MANUALIMMEDIATE SPEED REDUCTION .RED STOP LAMP .DIAGNOSTIC TOOL .FLASHING MALFUNCTION CODES .ACTIVE CODES .INACTIVE CODES .414141414343DDEC VI ENGINE DRIVING TIPS .ACCELERATING THE VEHICLE .CRUISE CONTROL .ENGINE BRAKES AND CRUISE CONTROL .SHIFTING .IDLING .444444464647ENGINE 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 .48484848484849505052ENGINE SYSTEMS .FUEL SYSTEM .LUBRICATION SYSTEM .AIR SYSTEM .COOLING SYSTEM .ELECTRICAL SYSTEM .EXHAUST SYSTEM .EXHAUST GAS RECIRCULATION SYSTEM .5353535353535353AFTERTREATMENT SYSTEM .OPERATING REQUIREMENTS .MAINTENANCE .PARKED REGENERATION PROCEDURE .HAZARDOUS APPLICATIONS .DPF STATIONARY REGEN ONLY 0-DISABLED .545555565758All information subject to change without notice.DDC-SVC-MAN-0006Copyright 2009 DETROIT DIESEL CORPORATIONv
TABLE OF CONTENTSDPF STATIONARY REGEN ONLY 1-ENABLED . 58SERVICE RECORD . 58DRIVER ACTIONS . 59INSTRUMENT PANEL LAMPS . 61MAINTENANCE .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 INHIBITORELEMENT .WATER PUMP DRAIN HOLE 9808081828282838383838484858585All information subject to change without notice.Copyright 2009 DETROIT DIESEL CORPORATION
EPA07 SERIES 60 ENGINE OPERATOR'S MANUALCOOLANT 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 ANDDELCO 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 .858686868686878788HOW-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 .91919191929292939494959696969797979798All information subject to change without notice.viiDDC-SVC-MAN-0006Copyright 2009 DETROIT DIESEL CORPORATION8888888888898990
TABLE OF CONTENTSREPLACE SPIN-ON TYPE PRIMARY OR SECONDARY FUELFILTER 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 & WATERPLUS SCA INHIBITOR .MIXING EG OR PG ANTIFREEZE AND WATER .RECYCLED ANTIFREEZE .EG/WATER OAT INHIBITOR OR PG/WATER OATINHIBITOR .WATER ONLY SCA OR WATER ONLY OAT INHIBITORWATER REQUIREMENTS .COOLANTS NOT RECOMMENDED .ALL ANTIFREEZES AND COOLANTS CONTAININGPHOSPHATE .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 FULLYFORMULATED COOLANT .MAINTENANCE INTERVALS .SCA TEST PROCEDURES .COOLANT FILTERS (NON-OAT SYSTEMS) .DROPOUT 2113113114115116117All information subject to change without notice.Copyright 2009 DETROIT DIESEL CORPORATION
EPA07 SERIES 60 ENGINE OPERATOR'S MANUALCOOLANT EXTENDER INHIBITOR ADDITIVE FOR “OAT”COOLANT .OAT COOLANT DRAIN INTERVAL .CHRONIC COOLANT SYSTEM PROBLEMS .DETROIT DIESEL COOLING SYSTEM MAINTENANCEPRODUCTS .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 .118118118119119120120120121122122TROUBLESHOOTING .ABNORMAL COOLANT TEMPERATURE .HARD STARTING .AFTERTREATMENT SYSTEM .ABNORMAL ENGINE OPERATION .ABNORMAL OPERATING CONDITIONS .123123124125126127ENGINE STORAGE .PREPARING ENGINE FOR STORAGE .TEMPORARY STORAGE (30 DAYS OR LESS) .EXTENDED STORAGE (MORE THAN 30 DAYS) .PROCEDURE FOR RESTORING TO SERVICE AN ENGINETHAT HAS BEEN IN EXTENDED STORAGE .128128128129CUSTOMER ASSISTANCE .ROAD SERVICE IN THE U.S. OR CANADA .WORKING WITH DETROIT DIESEL SERVICE OUTLETS .STEP ONE .STEP TWO .STEP THREE .134136136137137137117118118132SPECIFICATIONS . 138FUEL AND LUBRICATING OIL REQUIREMENTS . 138All information subject to change without notice.DDC-SVC-MAN-0006Copyright 2009 DETROIT DIESEL CORPORATIONix
TABLE OF CONTENTSOIL 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 COOLANTCOOLING SYSTEM CLEANERS .COOLANT TESTING AND ANALYSIS PRODUCTS l information subject to change without notice.Copyright 2009 DETROIT DIESEL CORPORATION
EPA07 SERIES 60 ENGINE OPERATOR'S MANUALINTRODUCTIONThis guide is intended for use bythe operator of a Detroit DieselSeries 60 engine used in the followingapplications: On-Highway Vehicles Fire Truck or Crash/RescueVehiclesNon-Genuine and RebuiltComponent Quality AlertElectronic engine controls havebeen instrumental in aiding enginemanufacturers in meeting the stringentemission requirements of the U.S.Environmental Protection Agency(U.S. EPA) and the California AirResources Board (CARB) andalso in meeting the ever-increasingperformance demands of the customer.Maintenance procedures mustbe followed in order to continuesatisfactory performance anddurability and to ensure coverage ofthe engine under the manufacturer'swarranty. Many of these maintenanceprocedures also ensure that theengine continues to comply withapplicable emissions standards.Proper maintenance procedures, usingspecific components engineered tocomply with emissions regulations,may be performed by an authorizedDetroit Diesel distributor or dealer,an independent outlet or the operatorAll information subject to change without notice.DDC-SVC-MAN-0006or owner. The owner is responsiblefor determining the suitability ofcomponents to maintain emissionscompliance during the engine's usefulemission life.Detroit Diesel cautions that theindiscriminate rebuilding of precisioncomponents, without the benefit ofspecifications, specialized equipment,and knowledge of the electronicoperating system, will jeopardizeperformance or lead to more seriousproblems, and can take the engineoutside of compliance with U.S. EPAor CARB emissions standards.There are other components inan engine, such as turbocharger,camshaft, piston, etc., whichare specifically designed andmanufactured to exacting standardsfor emissions compliance. It isimportant that these components, ifreplaced, modified or substituted, canbe verified to ensure that the engineremains in compliance with emissionsstandards. The use of inadequatelyengineered, manufactured or testedcomponents in repair or rebuild ofthe engine may be in violation of thefederal Clean Air Act and applicableU.S. EPA or CARB regulations.Copyright 2009 DETROIT DIESEL CORPORATION1
INTRODUCTIONFurthermore, modern engines exhibitoperating parameters which requirethe use of proper fluids, such asfuel, coolant and lubricating oil, tomaintain long engine life. The use offluids that do not meet Detroit Dieselspecifications may result in early wearout or engine failure.Personnel RequirementsWork on the engine should be carriedout only by skilled technicians whohave been instructed in the specificskills necessary for the type of workbeing performed.2DDC-SVC-MAN-0006Engine Conversions andModificationsThe function and safety of the enginecould be affected if unauthorizedmodifications are made to it. DetroitDiesel will not accept responsibilityfor any resulting damage.Tampering with the fuel injectionsystem and engine electronics couldalso affect the engine's power output orexhaust emission levels. Compliancewith the manufacturer's settingsand with statutory environmentalprotection regulations cannot then beguaranteed.All information subject to change without notice.Copyright 2009 DETROIT DIESEL CORPORATION
EPA07 SERIES 60 ENGINE OPERATOR'S MANUALCAUTION SUMMARYThe following cautions must beobserved by the operator of thevehicle or equipment in which thisengine is installed and/or by thoseperforming basic engine preventivemaintenance. Failure to read andheed these cautions and exercisereasonable care for personal safetyand the safety of others whenoperating the vehicle/equipmentor performing basic enginepreventive maintenance may resultin personal injury and engineand/or vehicle/equipment damage.Engine OperationObserve the following cautions whenoperating the engine.HOT EXHAUSTDuring parked regeneration theexhaust gases will be extremelyHOT and could cause a fireif directed at combustiblematerials. The vehicle must beparked outside.PERSONAL INJURYTo avoid injury from engineshutdown in an unsafe situation,ensure the operator knows howto override the stop enginecondition on a DDEC-equippedunit.PERSONAL INJURYTo avoid injury from loss ofvehicle/vessel control, theoperator of a DDEC equippedengine must not use or readany diagnostic tool while thevehicle/vessel is moving.All information subject to change without notice.DDC-SVC-MAN-0006Copyright 2009 DETROIT DIESEL CORPORATION3
CAUTION SUMMARYPERSONAL INJURYLOSS OF VEHICLE CONTROLDiesel engine exhaust and someof its constituents are known tothe State of California to causecancer, birth defects, and otherreproductive harm. Always start and operate anengine in a well ventilatedarea. If operating an engine inan enclosed area, vent theexhaust to the outside. Do not modify or tamperwith the exhaust system oremission control system.4DDC-SVC-MAN-0006To avoid injury from loss ofvehicle control, do not a
EPA07 SERIES 60 ENGINE OPERATOR'S MANUAL INTRODUCTION This guide is intended for use by the operator o
