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

Some states do not allow the limitation
of how long this warranty may last
or the limitation or exclusion of
incidental or consequential damages,
so the above may not apply to you.
This warranty gives you specific legal
rights, and you may also have other
rights which may vary from state to
state.

132

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

6SE484

0401

Copyright © 2004 DETROIT DIESEL CORPORATION

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Summary of Contents for 60

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Page 3: ...tallation 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 Authoriz...

Page 4: ...g maintenance and safety instructions Trademark Information 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 Sea Pro and Mega Filter are registered ...

Page 5: ...IAL NUMBER DESIGNATION 12 OPTION LABELS 13 CERTIFICATION LABELS 14 OPERATING INSTRUCTIONS FOR A FIRST TIME START 15 SYSTEM CHECKS 15 COOLING SYSTEM CHECKS 15 LUBRICATION SYSTEM CHECKS 16 EXTENDED STORAGE 16 FUEL SYSTEM CHECKS 17 OTHER CHECKS 18 STARTING THE ENGINE 18 INITIAL ENGINE START 19 ELECTRIC STARTER 19 AIR STARTER 20 RUNNING THE ENGINE 20 OIL PRESSURE 20 WARM UP 20 INSPECTION 20 TRANSMISSI...

Page 6: ...C V ENGINE DRIVING TIPS 36 ACCELERATING THE VEHICLE 36 CRUISE CONTROL 36 ENGINE BRAKES AND CRUISE CONTROL 38 SHIFTING 38 IDLING 39 WINTER FRONTS 39 ENGINE BRAKE SYSTEM 40 DRIVER CONTROL SWITCHES 40 LOW HIGH SWITCH 40 LOW MED HIGH SWITCH 40 CLUTCH PEDAL AND THROTTLE POSITION CONTROLS 40 ENGINE BRAKE OPERATION 41 ANTI LOCK BRAKING SYSTEMS 42 DRIVING ON FLAT DRY PAVEMENT 42 DESCENDING A LONG STEEP GR...

Page 7: ...ANT INHIBITORS 66 COOLANT DRAIN INTERVAL 66 ITEM 5 TURBOCHARGER AIR TO AIR CHARGE COOLER 68 WASTEGATED TURBOCHARGERS 68 ITEM 6 BATTERY 69 ITEM 7 TACHOMETER DRIVE 70 ITEM 8 DRIVE BELTS 70 V BELTS 70 2 GROOVE POWERBAND 71 12 RIB POLY V BELT 71 BELT REPLACEMENT 72 ITEM 9 AIR COMPRESSOR 72 ITEM 10 AIR CLEANER 72 AIR CLEANER REPLACEMENT 73 ITEM 11 LUBRICATING OIL FILTERS 73 ITEM 12 FUEL FILTERS 74 FUEL...

Page 8: ...REATHER 79 ITEM 26 ENGINE TUNE UP 79 ITEM 27 VIBRATION DAMPER 80 HOW TO SECTION 81 HOW TO SELECT LUBRICATING OIL 81 LUBRICANT REQUIREMENTS 81 EGR EQUIPPED ENGINES 81 NON EGR ENGINES 81 ENGINES BUILT PRIOR TO 1998 81 COLD WEATHER STARTING 82 SYNTHETIC OILS 82 THE USE OF SUPPLEMENTAL ADDITIVES 83 WHEN TO CHANGE OIL 83 DISPOSING OF WASTE OIL 84 HOW TO REPLACE THE LUBE OIL FILTERS 84 REPLACE SPIN ON T...

Page 9: ...00 ALL ANTIFREEZES AND COOLANTS CONTAINING PHOSPHATE 100 AUTOMOTIVE TYPE COOLANTS 100 METHYL ALCOHOL BASED ANTIFREEZE 100 GLYCOL BASED COOLANTS FORMULATED FOR HVAC 101 ADDITIVES NOT RECOMMENDED 101 SOLUBLE OIL ADDITIVES 101 CHROMATE ADDITIVES 101 MAINTENANCE 101 SUPPLEMENTAL COOLANT ADDITIVES FOR FULLY FORMULATED COOLANT 102 MAINTENANCE INTERVALS 102 SCA TEST PROCEDURES 104 NEED RELEASE COOLANT FI...

Page 10: ... DDC SERVICE OUTLETS 127 LIMITED WARRANTY ON HIGHWAY VEHICLE ENGINES 129 TERMS OF COVERAGE 129 USES 129 DEFECTS 129 REPAIRS 129 WARRANTY PERIOD 129 LIKE REPLACEMENT ENGINE 129 SERVICE SUPPLIES 130 ENGINE REMOVAL AND REINSTALLATION 130 THIS WARRANTY DOES NOT COVER 130 REPAIRS DUE TO ACCIDENTS MISUSE STORAGE DAMAGE NEGLIGENCE OR CERTAIN MODIFICATIONS 130 BRAKING DEVICES 131 FUEL INJECTORS AFTER 200 ...

Page 11: ...Y ON CONSTRUCTION INDUSTRIAL ENGINES 137 TERMS OF COVERAGE 137 USES 137 DEFECTS 137 REPAIRS 137 WARRANTY PERIOD 137 SERVICE SUPPLIES 137 ENGINE REMOVAL AND REINSTALLATION CONSTRUCTION INDUSTRIAL APPLICATIONS 138 MECHANIC S TRAVEL EXPENSES 138 LIKE REPLACEMENT ENGINE 138 THIS WARRANTY DOES NOT COVER 139 REPAIRS DUE TO ACCIDENTS MISUSE STORAGE DAMAGE NEGLIGENCE OR CERTAIN MODIFICATIONS 139 ENGINE RE...

Page 12: ...AL OR CONSEQUENTIAL DAMAGE 143 OTHER LIMITATIONS 143 LIMITED WARRANTY ON AGRICULTURAL MACHINERY ENGINES 144 TERMS OF COVERAGE 144 USES 144 DEFECTS 144 REPAIRS 144 WARRANTY PERIOD 144 LIKE REPLACEMENT ENGINE 144 SERVICE SUPPLIES 145 THIS WARRANTY DOES NOT COVER 145 REPAIRS DUE TO ACCIDENTS MISUSE STORAGE DAMAGE NEGLIGENCE OR CERTAIN MODIFICATIONS 145 ENGINE REMOVAL AND REINSTALLATION 145 NON DDC SU...

Page 13: ...L OR CONSEQUENTIAL DAMAGE 149 OTHER LIMITATIONS 149 LIMITED WARRANTY ON STAND BY GENERATOR SET ENGINES 150 TERMS OF COVERAGE 150 USES 150 DEFECTS 150 REPAIRS 150 WARRANTY PERIOD 150 LIKE REPLACEMENT ENGINE 151 SERVICE SUPPLIES 151 MECHANIC S TRAVEL EXPENSES 151 THIS WARRANTY DOES NOT COVER 151 REPAIRS DUE TO ACCIDENTS MISUSE STORAGE DAMAGE NEGLIGENCE OR CERTAIN MODIFICATIONS 151 ENGINE REMOVAL AND...

Page 14: ...000 SUPPLEMENTAL COOLANT ADDITIVE 155 3000 SUPPLEMENTAL ADDITIVE FILTERS 155 NEED RELEASE COOLANT FILTERS 156 PLUS EXTENDED LIFE OAT COOLANT 156 PLUS EXTENDER FOR POWER COOL PLUS OAT COOLANT 156 PLUS 6000 OAT INHIBITOR FOR WATER ONLY SYSTEMS 157 COOLING SYSTEM CLEANERS 157 COOLANT TESTING AND ANALYSIS PRODUCTS 158 xii All information subject to change without notice Rev 01 04 6SE484 0401 Copyright...

Page 15: ...ntal 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 are to 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 ...

Page 16: ...tside 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...

Page 17: ...ry 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 PERSONAL INJURY 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 ...

Page 18: ...s 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 Preventive Maintenance Observe the following cautions when performin...

Page 19: ...le fluids as they occur Failure to eliminate leaks could result in fire USED ENGINE OIL To avoid injury to skin from contact with the contaminants in used engine oil wear protective gloves and apron PERSONAL INJURY To avoid injury from slipping and falling immediately clean up any spilled liquids PERSONAL INJURY To avoid injury from hot surfaces wear protective gloves or allow engine to cool befor...

Page 20: ...hield prevents contact with rotating parts 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 FIRE To avoid injury from fire do not smoke or allow open flames when working on an o...

Page 21: ...cing the engine disconnect disable the starting system ELECTRICAL SHOCK To avoid injury from electrical shock do not touch battery terminals alternator terminals or wiring cables while the engine is operating 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...

Page 22: ...falling immediately clean up any spilled liquids Air Intake System Observe the following cautions when working on the air intake system PERSONAL INJURY To avoid injury from hot surfaces wear protective gloves or allow engine to cool before removing any component PERSONAL INJURY To avoid injury from contact with rotating parts when an engine is operating with the air inlet piping removed install an...

Page 23: ...n fire 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 Wear adequate protective clothing face shield insulated gloves and apron etc To prevent a buildup of potentially volati...

Page 24: ...tents of cylinder are under pressure Store cylinders in a cool dry area Do not incinerate puncture or attempt to remove cores from cylinders 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 o...

Page 25: ...ng oil and filters PERSONAL INJURY To avoid injury from slipping and falling immediately clean up any spilled liquids 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 FIRE To avoid injury from fire from a buildup of volatil...

Page 26: ...ser etched on the cylinder block in the left side just below the intake manifold and above the cast in Detroit Diesel logo as viewed from the flywheel end See Figure 1 Figure 1 Location of Engine Serial and Model Numbers 12 All information subject to change without notice Rev 01 04 6SE484 0401 Copyright 2004 DETROIT DIESEL CORPORATION ...

Page 27: ...ith any order for parts the engine model and serial number must be given If a type number is shown on the option label covering the equipment required this number should also be included on the parts order See Figure 2 Transmissions and power take offs generally carry their own name plates The model and serial number information on these plates is useful when ordering parts for these assemblies Fi...

Page 28: ...s that the engine conforms to federal and certain state emissions regulations for its particular application It also gives the operating conditions under which certification was made See Figure 3 Figure 3 Typical Engine Certification Labels 14 All information subject to change without notice Rev 01 04 6SE484 0401 Copyright 2004 DETROIT DIESEL CORPORATION ...

Page 29: ... 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 System Checks Perform the following system checks before starting for the first time Cooling System Checks Check the cooling system as follows 1 Make sure all drain cocks in the cooling sy...

Page 30: ...artup 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 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 visc...

Page 31: ...ave 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 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 and may cause erratic engine operation due to the amount of...

Page 32: ... maintenance batteries are used make sure battery electrolyte level is normal 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 Starting the Engine Before starting the engine the first time ensure that you have preformed the operations listed in the System ...

Page 33: ...f 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 NOTICE If the warning lights stay on or do not come on momentarily after turning on the ignition contact DDC Technical Service Operating the engine under these circumstances may result in engine damage Electric Starter...

Page 34: ...s pressure 5 psi or 35 kPa at idle speed If no pressure is indicated within 10 to 15 seconds stop the engine and check the lubrication system The pressure should not drop below 28 psi or 193 kPa 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 ...

Page 35: ...ion in neutral the engine coolant temperature may fall below the normal operating range 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 ...

Page 36: ...the proper sequence can result in alternator and or equipment damage 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 Battery Explosion and Acid Burn To avoid injury from battery explosion or contact with battery acid work in a well ventilated ar...

Page 37: ... has no mechanical governor Engine horsepower torque idle and engine speed are contained in the internal electronics Therefore there are no mechanical governor spring adjustments for idle and high speed control There is no need for a throttle delay Emission control is performed through the ECU The Accelerator Pedal Assembly AP eliminates the need for any throttle linkage DDEC Features DDEC offers ...

Page 38: ...t 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 Idle Shutdown Timer This feature is an optional 1 100 minute idle shutdown system Its purpose is to conserve ...

Page 39: ...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 under any conditions ...

Page 40: ... cruise speed Using either the brake or the clutch will disable Cruise Control 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 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 unles...

Page 41: ...ly 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 or 24 volts However in the event of a power supply malfunction the system will continue to operate at reduced voltage When this occurs the AWL will come on S...

Page 42: ...Switch and the Diagnostic Test Mode Switch are the same 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 There...

Page 43: ...e 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 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 m...

Page 44: ...active codes or code 25 will be flashed on the AWL When all the inactive codes or code 25 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 To Read Codes Use the DDR or press and hold the Diagnostic Test Mode Switch with the ignition ON and the engine AT IDLE or NOT RUNNING Pr...

Page 45: ...ensor Input Voltage High 22 Throttle Position Sensor Input Voltage Low 23 Fuel Temp Sensor Input Voltage High 23 Oxygen Content Circuit Input Voltage High 24 Fuel Temp Sensor Input Voltage Low 24 Oxygen Content Circuit Input Voltage Low 25 Reserved for No Codes 26 Aux Shutdown 1 or 2 Active 27 Intake Manifold Temp or Ambient Air Temp or Air Temp Sensor Input Voltage High 28 Intake Manifold Temp or...

Page 46: ...Boost Power 39 VNT Vanes at Max Jake 39 VNT Vanes Not Responding Boost Jake 39 EGR Flow too Low 39 VNT Vanes Not Responding EGR 41 Too Many CKP Sensor missing CMP Sensor 42 Too few CKP Sensor missing CKP Sensor 43 Coolant Level Low 44 Intercooler Coolant Coolant Intake Manifold Air Inlet or Oil Temp High 44 Engine Power Derate Due to Intake Manifold Temp Oil Temp or Coolant Temp 45 High Range Oil ...

Page 47: ...her ECU Fault Logged in conjunction with another fault 55 J1939 Data Link Fault Proprietary Data Link Fault Master or Proprietary Data Link Fault Receiver 56 J1587 Data Link Fault or J1922 Data Link Fault 58 Torque Overload or Two speed Axle Switch Status not Responding or Failed 61 Injector xxx Response Time Long 62 Aux Output 1 2 5 6 7 8 9 10 or 11 Short to Battery 62 Aux Output 1 2 5 6 7 8 9 10...

Page 48: ...njector xxx Response Time Short 72 Vehicle Overspeed or Vehicle Overspeed Absolute 72 Oxygen Content Too High or Too Low 73 Air Filter Restriction High 73 Gas Valve Position Above or Below Normal Range 73 Gas Valve Position Input Voltage High or Low 73 Gas Metering Valve Not Responding 74 Optimized Idle Safety Loop Short to Ground 74 Oil Filter Restriction High 75 Injector V reg Injector V slope o...

Page 49: ...t Failed Low 82 Exhaust Port Temp 1 16 Sensor Voltage Low 82 EGR Temperature Smart Sensor not Responding or Failed 83 Pump Pressure Oil Level Crankcase Pressure Extended Crankcase Pressure Exhaust Temp EGR Delta Pressure or EGR Temp High 83 Exhaust Port Temperature 1 17 High 83 Coolant Ingress Fault Detected 83 Change Oil Now 84 Oil Level Crankcase Pressure or Extended Crankcase Pressure Low 84 Ch...

Page 50: ...ottle 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 Accelerator Pedal will have to be maintained at the fully pressed position Cruise Control For added driver convenience and comfort DDEC V also features a Cr...

Page 51: ...aintain 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 Use Cruise Control afte...

Page 52: ...ssistance 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 ...

Page 53: ...ually deliver more fuel at lower engine speeds than at rated speed 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 s...

Page 54: ...vates 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 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 about two thirds engine braking horse...

Page 55: ...time you remove your feet completely from the clutch pedal and throttle The engine brake automatically deactivates itself when 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...

Page 56: ...reater slowing power is not required place the progressive braking switch in the LOW position 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 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 progressiv...

Page 57: ...rol 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 3 Do not exceed the safe control speedof your vehicle Example You could descend a 6 grade under control only at 10 mph 16 kph without an engine ...

Page 58: ...ion of the trailer brakes may be desirable to help 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 posi...

Page 59: ... For optimum protection of the engine from dust and other airborne contaminants service the dry type air cleaners used when the maximum 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 ...

Page 60: ...ransit coach engines are listed in Table 4 Table 5 and Table 6 Recommended maintenance intervals for Series 60 construction industrial and stationary engines are listed in Table 7 Table 8 and Table 9 Recommended maintenance intervals for Series 60 fire fighting crash rescue and emergency vehicle engines are listed in Table 10 Table 11 and Table 12 Recommended maintenance intervals for Series 60 ge...

Page 61: ...rive 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 1 On Highway Truck and Parlor Coach Daily 7 500 Mile and 15 000 Mile Checks All information subject to change without notice Rev 01 04 47 6SE484 0401 Copyri...

Page 62: ... 11 Lube Oil Filter Replace when lubricating oil is changed 12 Fuel Filters R R R R R R R R R R 13 Coolant Pump Inhibitor Level I I I I I I I I I I 14 Cranking Motor Follow manufacturer s recommendations 15 Air System I I I I I I I I I I 16 Exhaust System I I I I I I I I I I All items are described in PREVENTIVE MAINTENANCE INTERVALS I Inspect service correct or replace as necessary R Replace Tabl...

Page 63: ...n Mounts I I 22 Crankcase Pressure I I 23 Fan Hub I 24 Thermostats Seals I 25 Crankcase Breather I 26 Engine Tune Up I 27 Vibration Damper Replace at major engine overhaul or earlier if dented or leaking All items are described in PREVENTIVE MAINTENANCE INTERVALS I Inspect service correct or replace as necessary R Replace Table 3 On Highway Truck and Parlor Coach Regular Maintenance Intervals cont...

Page 64: ...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 4 Transit Coach Daily 6 000 Mile 7 500 Mile and 15 000 Mile Checks 50 All information subject to change without notice Rev 01 04 6SE484 0401 Copyright 2004 DETRO...

Page 65: ...I 9 Air Compressor I I I I I I I I I I 11 Lube Oil Filters Replace when lubricating oil is changed 12 Fuel Filters R R R R R R R R R R 13 Coolant Pump Inhibitor Level I I I I I I I I I I 14 Cranking Motor Follow manufacturer s recommendations 15 Air System I I I I I I I I I I All items are described in PREVENTIVE MAINTENANCE INTERVALS I Inspect service correct or replace as necessary R Replace Tab...

Page 66: ...ne Transmission Mounts I I 22 Crankcase Pressure I I 23 Fan Hub I 24 Thermostats Seals I 25 Crankcase Breather I 26 Engine Tune Up I 27 Vibration Damper Replace at major engine overhaul or earlier if dented or leaking All items are described in PREVENTIVE MAINTENANCE INTERVALS I Inspect service correct or replace as necessary R Replace Table 6 Transit Coach Regular Maintenance Intervals continued ...

Page 67: ... Compressor I 10 Air Cleaner I 11 Lube Oil Filters 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 7 Stationary or Construction Industrial Engine Daily 100 Hour 150 Hour 200 Hour and 300 Hour Checks All information subject to ch...

Page 68: ...I I I R I I 9 Air Compressor I I I I I I I I I I 11 Lube Oil Filters Replace when lubricating oil is changed 12 Fuel Filters R R R R R R R R R R 13 Coolant Pump Inhibitor Level I I I I I I I I I I 14 Cranking Motor Follow manufacturer s recommendations 15 Air System I I I I I I I I I I All items are described in PREVENTIVE MAINTENANCE INTERVALS I Inspect service correct or replace as necessary R R...

Page 69: ...I I 21 Engine Transmission Mounts I I 22 Crankcase Pressure I I 23 Fan Hub I 24 Thermostats Seals 25 Crankcase Breather I 26 Engine Tune Up I 27 Vibration Damper Replace at major engine overhaul 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 9 Stationary or Construction Industrial Regular...

Page 70: ... 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 10 Fire Fighting Crash Rescue and Emergency Vehicle Engine Daily 100 Hour and 300 Hour Checks 56 All information subject to change without no...

Page 71: ...place when lubricating oil is changed 12 Fuel Filters R R R R R 13 Coolant Pump Inhibitor Level I I I I I 14 Cranking Motor Follow manufacturer s recommendations 15 Air System I I I I I 16 Exhaust 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 11 Fire Fighting Crash Rescue and Emergency Vehicle Engine R...

Page 72: ...I 24 Thermostats Seals 25 Crankcase Breather I 26 Engine Tune Up I 27 Vibration Damper 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 12 Fire Fighting Crash Rescue and Emergency Vehicle Engine Regular Maintenance Intervals continued 58 All information sub...

Page 73: ...ssure I I Load Test P All items are described in PREVENTIVE MAINTENANCE INTERVALS I Inspect service correct or replace as necessary P Perform Perform these items at time of load test Load test should be at least 35 of the unit s full rated output Refer to generator set manufacturer s instructions Table 13 Generator Set Engine Prime Daily and Standby Monthly Maintenance Intervals All information su...

Page 74: ...lace when lubricating oil is changed 12 Fuel Filters Standby Replace every 150 hours or 1 year whichever comes first Prime Replace every 250 hours or 3 months whichever comes first 13 Coolant Pump Inhibitor Level I 14 Cranking Motor Follow manufacturer s recommendations All items are described in PREVENTIVE MAINTENANCE INTERVALS I Inspect service correct or replace as necessary R Replace Table 14 ...

Page 75: ...b I 24 Thermostat Seals R 25 Crankcase Breather I R 26 Engine Tune Up I 27 Vibration Damper 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 15 Generator Set Engine Regular Maintenance Intervals continued All information subject to change without notice Rev ...

Page 76: ... 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 Add the proper grade of oil to maintain the correct level on the dipstick See Figure 11 Figure 11 Check Oil Level D...

Page 77: ...e Oil in this guide Service Application Lube Oil and Filter Change Interval Highway Truck Motor Coach 15 000 Miles 24 000 Kilometers City Transit Coach 6 000 Miles 9 600 Kilometers Fire Fighting Crash Rescue Emergency Vehicles 6 000 Miles 9 600 Kilometers 300 Hours or 1 Year whichever comes first Construction Industrial Agricultural 250 Hours or 1 Year whichever comes first Stationary Generator Pr...

Page 78: ...s follow the chemical manufacturer s usage handling and disposal instructions Observe all manufacturer s cautions NOTICE Galvanized steel fuel tanks fittings pipes or supply lines should never be used 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 eve...

Page 79: ... 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 thoro...

Page 80: ...ine is running and when it is stopped Coolant leaks may be more apparent on a engine when it is cold 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 ...

Page 81: ... combination with a need release filter must be used At this time the cooling system must be completely drained and cleaned before refill A 50 50 mix of OAT organic acid technology coolant and water With proper maintenance coolant can be operated 4 years 600 000 miles 960 000 km or 10 000 operating hours whichever comes first 3 At this time the cooling system must be completely drained and cleaned...

Page 82: ...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 is factory calibrated and is not adjustable Check actuator operation at the intervals shown in the maintenance schedule EYE INJURY To avoid injury from flying deb...

Page 83: ...rmance 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 serv...

Page 84: ...amage to accessory components 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 18 V Belts New standard V belts will stretch after the ...

Page 85: ... 15 Figure 15 Auto Belt Tensioner Assembly with 50 DN Alternator Earlier built Series 60 engines have a manual belt tensioner assembly See Figure 16 Figure 16 Manual Tensioner Assembly with 50 DN Alternator Tighten a new PowerBand 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 6...

Page 86: ...Air Compressor All air compressor intake parts should be removed and cleaned at the following intervals On Highway Vehicle Engines 7 500 miles 12 000 km Industrial Engines 150 Hours or 4 500 miles 7 200 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 u...

Page 87: ...nections 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 For on highway vehicle engines install new spin on oil filters at a maximum o...

Page 88: ...ttings 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 sche...

Page 89: ...itions 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 19 Required test intervals are listed in Table 25 For SCA test procedures refer to How to Select Coolant and SCA Test Procedures in this guide Use the coolant...

Page 90: ... exterior of the radiator core should be inspected every 30 000 miles 48 000 km 12 months or 300 hours industrial applications and cleaned if necessary 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 40 psi 276 kPa air pressure Use a quality grease solvent such as mineral spirits and dry with compr...

Page 91: ... 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 whi...

Page 92: ...hecked for corrosion and loose connections and wiring inspected for damage and frayed insulation Have wiring repaired or replaced as required Check torque on alternator mounting bolts and bracketing every 15 000 miles 24 000 km on truck and coach engines or every 300 hours on all other engines Retighten if necessary Item 21 Engine and Transmission Mounts The engine and transmission mounting bolts ...

Page 93: ...in Rocker Cover The rocker cover mounted breather assembly part number 23512984 used in the closed crankcase breather system should be replaced every 4000 operating hours It is not reusable and no attempt should be made to clean or reuse it 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 nece...

Page 94: ... replaced if dented or leaking See Figure 21 Figure 21 Viscous Vibration Damper 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 80 All information subject to change withou...

Page 95: ... Detroit Diesel engines are designed to provide The proper lubricating oil for all Detroit Diesel 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 22 Figure 22 API Lubricant Symbol Lubricant Requirements Lubricant requirements are different for the EGR equipped and non EG...

Page 96: ...ese oils must possess a HT HS of 3 7 minimum NOTE Do not use fuel with sulfur content above 0 05 mass percent for Detroit Diesel EGR equipped engines When the use of high sulfur fuel greater than 0 05 mass sulfur in non EGR engines is unavoidable high alkalinity TBN lubricants are recommended High sulfur fuels require modification to oil drain intervals For further information refer to publication...

Page 97: ...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 20 Oil analysis may be used to determine whether this interval should be shortened but it should not be used to lengthen the interval Engine Application Drain...

Page 98: ...he engine oil supplier who may accept responsibility for proper disposal of this material as part of the business of providing lubricant 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...

Page 99: ...e filter adaptor 6 Start the new filters on the adaptor head and tighten by hand until 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 to the Full mark on the dipstick PERSONAL INJURY Diesel engine exhaust and some of its constituents are known to the State of California to caus...

Page 100: ...Requirements Lubricating Oil Fuel and Filters 7SE270 available from authorized Detroit Diesel distributors NOTE Do not use fuel with sulfur content above 0 05 mass percent for Detroit Diesel EGR engines 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 o...

Page 101: ...rease combustion temperatures Tanks which contain a mixture of gasoline and diesel fuel should be drained and cleaned as soon as possible FIRE To avoid increased risk of a fuel fire do not mix gasoline and diesel fuel Detroit Diesel Corporation will not be responsible for any detrimental effects it determines resulted from adding drained lubricating oil or gasoline to the diesel fuel How to Replac...

Page 102: ... 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 handle on the shutoff valve to the closed position perpendicular to 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 fil...

Page 103: ...check for leaks Shut down the engine Correct any leaks with the engine off 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 NOTICE Tthe starting motor and fuel pump should never be used to prime the fuel filters Prolonged used of the starting...

Page 104: ...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 Ele...

Page 105: ...ank 5 Using filter collar vent cap wrench part number 232002 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 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 ...

Page 106: ...ent cap reinstall the cap and tighten by hand NOTICE To avoid cover or vent cap damage do not use tools to tighten the vent cap 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 Do not allow the fuel level in the see thru cover to fall below the top of the c...

Page 107: ...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 fue...

Page 108: ...rform this service How to Select Coolant This section covers selection of the required coolant for Series 60 engines Definitions To help ensure complete understanding of the information the definitions of the following terms are provided Antifreeze Ethylene glycol or propylene glycol containing a corrosion inhibitor package and which meets an appropriate heavy duty specification i e TMC RP 329 for...

Page 109: ...his section To avoid possible engine damage from inadequate or overconcentrated coolant this information should be read thoroughly before the coolant is replaced Coolant Fill Option Product Ethylene Glycol Water Corrosion Inhibitors 1 DDC Power Cool Commercial Equivalent of DDC Power Cool Fully Formulated TMC RP 329 Type A Antifreeze Water Propylene Glycol Water Corrosion Inhibitors 1 DDC Power Co...

Page 110: ...TMC RP 329 Type A requirements Fully formulated propylene glycol based antifreeze or coolant 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 stan...

Page 111: ...n versus freezing and boiling temperatures Figure 27 Coolant Temperatures vs IPG Concentration Sea Level 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 22 All information subject to change without ...

Page 112: ...ith 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 coo...

Page 113: ... 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 23 NOTE Do not use Power Trac 3 Way Test Strips to test OAT coolant Power Cool 3000 SCA inhibitors should be mixed at 5 by volume with water This is 1 quart per 5 gallons...

Page 114: ...troit 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 Detroi...

Page 115: ...es 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 with Power Cool dry chemical cooling system cleaner conditioner listed in Table 46 or equivalent sulfamic acid sodium carbonate cleaner and flushed Coolant Inhibitor Test Intervals The coola...

Page 116: ...lete 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 pH control Restored inhibitor levels to prevent corrosion Water softening to deter formation of mineral deposits Cavitation protection...

Page 117: ...ne Glycol Water OAT Inhibitor A 600 000 Miles 960 000 km B 4 Years or 10 000 Hrs Drain and clean system Replace with new coolant A 20 000 Miles 32 000 km or 3 Months B 500 Hours or 3 Months Test nitrite concentration with test strip Add SCA or dilute coolant as needed Water Only SCA Inhibitor A 300 000 Miles 480 000 km B 2 Years or 4 000 Hrs Drain and clean system Replace with new coolant A 300 00...

Page 118: ...his case the EG or PG should contain no inhibitors and should conform to ASTM D4985 This will dilute the over concentrated inhibitors 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 form...

Page 119: ...el Promptly replace and tighten the test strip container cap after each use Discard unused strips if they have turned light pink or tan A factory coolant analysis program is available through authorized Detroit Diesel service outlets Part numbers are listed in Table 47 in the Specifications section To verify coolant acceptability submit a sample for coolant analysis every two 2 years 300 000 miles...

Page 120: ... or physically clean individual components 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 30...

Page 121: ... 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 wh...

Page 122: ...ed 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 ...

Page 123: ... in Table 47 11 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 exten...

Page 124: ...pid cooling and distortion of the metal castings 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 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 clean...

Page 125: ...l 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 25 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 ...

Page 126: ...ke Blue Smoke White Smoke Damaged or dirty air cleaner X Improper grade of fuel X Excessive exhaust back pressure X Misfiring cylinders X Lubricating oil not burned in cylinder being burned in exhaust manifold or turbocharger X Faulty injector timing X Faulty oil control rings X Excessive installation angle X Excessive oil in crankcase X High ambient temperature X Thin air high altitude X Cetane r...

Page 127: ...blown or missing X Insufficient Fuel Supply 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 X Installation operation of fuel check valve or shutoff valve X Low Compression Worn intake and exhaust valves X Worn piston rings liners X Leaking cyli...

Page 128: ...ssion X X DDEC malfunction X X High air inlet restriction ex haust back pressure X Engine application X High air inlet temperature X High altitude operation X Incorrect engine gear train timing X Low coolant temperature X Oil picked up by inlet airstream X Faulty injector operation X Incorrect injector height setting X X 114 All information subject to change without notice Rev 01 04 6SE484 0401 Co...

Page 129: ...kcase overfilled X Oil in air tanks air compressor malfunction X Plugged crankcase breather X Oil level low X Improper engine oil viscosity fuel in the oil X Faulty oil pressure regulator valve X Worn crankshaft camshaft or connecting rod bearings X Missing cup plugs in rocker arm shafts X Faulty oil pressure relief valve X Air leaks in oil pump suction side X Worn or damaged oil pump X Faulty oil...

Page 130: ...ulty 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 116 All information subject to change without notice Rev 01 04 6SE484 0401 Copyright 2004 ...

Page 131: ... the storage area 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 pr...

Page 132: ... the engine coolant fuel oil lubricating oil and transmission oil levels 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 temp...

Page 133: ...ith 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 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 manufactur...

Page 134: ...ctrolyte 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 p...

Page 135: ...es 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 5 Remove the paper strips from between the pulleys and drive belts 6 Fill the crankcase to the proper level with the requ...

Page 136: ...is guide PERSONAL INJURY 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 14 After all prepa...

Page 137: ... Engine Service Manual 6SE483 DDEC V Troubleshooting Guide 6SE565 U S and Canada Distributor Dealer Directory 6SE280 International Distributor Dealer Directory 6SE281 Series 60 Service Outlet Directory 6SA336 Lube Oil Fuel and Filter Requirements 7SE270 Coolant Requirements for Engine Cooling Systems 7SE298 Technician s Guide Used Lubricating Oil Analysis 7SE398 Technician s Guide Turbocharger 7SE...

Page 138: ...d goodwill of the owners of Detroit Diesel engines are of primary concern to Detroit Diesel Corporation and its distributor dealer organizations 124 All information subject to change without notice Rev 01 04 6SE484 0401 Copyright 2004 DETROIT DIESEL CORPORATION ...

Page 139: ...and Customer Assurance Center Offices Construction Industrial and Mining Sales BX7 13400 Outer Drive West Detroit MI 48239 4001 Phone 313 592 5608 Fax 313 592 5625 Marine Sales BX6 13400 Outer Drive West Detroit MI 48239 4001 Phone 313 592 5124 Fax 313 592 5137 Powergen and Oilfield Sales BX11 13400 Outer Drive West Detroit MI 48239 4001 Phone 313 592 7459 Fax 313 592 5158 Government Sales BX11 13...

Page 140: ...A PACIFIC REGION Off Highway Singapore No 1 Benoi Place Singapore 629923 Phone 65 686 15922 Fax 65 686 11550 PACIFIC REGION Off Highway Australia 11 13 Garling RoadRoad Kings Park NSW 2148 Beaumaris Victoria 3193 Australia Phone 612 8822 7000 Fax 612 8822 7083 AUSTRALIAN REGION On Highway P O Box 1472 Canterbury Victoria 3124 Australia Phone 61 39 836 0775 Fax 61 39 836 0770 MEXICO On Off Highway ...

Page 141: ...del Odometer mileage kilometers or hourmeter hours Truck bus or equipment owner company name Working with DDC Service Outlets As the owner of a Detroit Diesel product you have a complete network of over 2 000 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 determi...

Page 142: ...epending upon the nature of your problem Prior to this contact have the following information available Engine model 606_ _ _ _ _ Engine serial number 06R0_ _ _ _ _ _ Type and make of equipment Engine delivery date and accumulated miles or hours of operation Nature of problem Chronological summary of engine s history Name and location of authorized service outlet Important Your engine model number...

Page 143: ...WARRANTY PERIOD from an authorized DDC service outlet Only new genuine parts or remanufactured parts or components supplied or approved by DDC will be used DDC may at its discretion replace rather than repair components A reasonable time must be allowed to perform the warranty repair after taking the engine to the authorized service outlet The owner is responsible for the percentage of repair cost...

Page 144: ...haft Camshaft Main Bearing Bolts Flywheel Housing Connecting Rod Assemblies Oil Cooler Housing Water Pump Housing and Air Inlet Housing Table 28 Warranty Period Chart On Highway Vehicle Applications Service Supplies The cost of service supplies such as coolant oil and filters which are not reusable due to needed warranty repairs is covered by this warranty Engine Removal and Reinstallation Reasona...

Page 145: ...sible for incidental or consequential costs or expenses which the owner may incur as a result of a malfunction or failure covered by this warranty such as communication expenses meals lodging overtime loss of use of the engine or vehicle downtime loss of time inconveniences cargo loss or damage and other similar costs and expenses Other Limitations The performance of REPAIRS is the exclusive Owner...

Page 146: ...ranty may last or the limitation or exclusion of incidental or consequential damages so the above may not apply to you This warranty gives you specific legal rights and you may also have other rights which may vary from state to state 132 All information subject to change without notice Rev 01 04 6SE484 0401 Copyright 2004 DETROIT DIESEL CORPORATION ...

Page 147: ...needed repairs within the WARRANTY PERIOD from an authorized DDC service outlet Only new genuine parts or remanufactured parts or components supplied or approved by DDC will be used DDC may at its discretion replace rather than repair components A reasonable time must be allowed to perform the warranty repair after taking the engine to the authorized service outlet The owner is responsible for the...

Page 148: ... Vehicle Systems braking devices 50DN or T1 alternators if so equipped Cylinder Block Head Crankshaft Camshaft Main Bearing Bolts Flywheel Housing Connecting Rod Assemblies Oil Cooler Housing Water Pump Housing and Air Inlet Housing Table 29 Warranty Period Chart Urban Bus Motor Coach and Motor Home Applications Like Replacement Engine Engine s supplied by DDC as a replacement for an engine still ...

Page 149: ...ces or the failure to use fuel oil lubricants and coolant meeting DDC recommended specifications Performance of the required maintenance and use of proper fuel oil lubricants and coolant are the responsibility of the owner Refer to the MAINTENANCE section in this guide for details Incidental or Consequential Damage Detroit Diesel Corporation is not responsible for incidental or consequential costs...

Page 150: ...NTABILITY OR FITNESS FOR A PARTICULAR PURPOSE DETROIT DIESEL CORPORATION SHALL NOT BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES AS DESCRIBED ABOVE Some states do not allow the limitation of how long this warranty may last or the limitation or exclusion of incidental or consequential damages so the above may not apply to you This warranty gives you specific legal rights and you may also ha...

Page 151: ...hin the WARRANTY PERIOD from an authorized DDC service outlet Only new genuine parts or remanufactured parts or components supplied or approved by DDC will be used DDC may at its discretion replace rather than repair components A reasonable time must be allowed to perform the warranty repair after taking the engine to the authorized service outlet Repairs will be performed during normal business h...

Page 152: ...art Construction Industrial Applications Engine Removal and Reinstallation Construction Industrial Applications Reasonable labor costs for Engine removal and reinstallation when necessary to make a warranty repair are covered by this warranty during the first twelve 12 months of service Mechanic s Travel Expenses DDC will pay reasonable travel expenses for the repairing mechanic to travel to and f...

Page 153: ...systems Such items are covered by the equipment manufacturer Maintenance DDC is not responsible for the cost of maintenance or repairs due to lack of performance of required maintenance services as recommended by DDC or the failure to use fuel oil lubricants and coolant meeting DDC recommended specifications Performance of the required maintenance and use of proper fuel oil lubricants and coolant ...

Page 154: ...ERY AND STAND BY PUMP APPLICATIONS DETROIT DIESEL CORPORATION MAKES NO OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE DETROIT DIESEL CORPORATION SHALL NOT BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES AS DESCRIBED ABOVE Some states do not allow the limitation of how long this warranty may last or the limitation or e...

Page 155: ...DC service outlet Only new genuine parts or remanufactured parts or components supplied or approved by DDC will be used DDC may at its discretion replace rather than repair components A reasonable time must be allowed to perform the warranty repair after taking the engine to the authorized service outlet Repairs will be performed during normal business hours Warranty Period The WARRANTY PERIOD beg...

Page 156: ...arranty THIS WARRANTY DOES NOT COVER Repairs Due to Accidents Misuse Alteration Storage Damage Negligence or Certain Modifications Repairs due to an accident misuse alteration misapplication storage damage negligence or modification exceeding DDC specifications are not covered by this warranty Maintenance DDC is not responsible for the cost of maintenance or repairs due to the lack of performance ...

Page 157: ... or the Accessories THIS LIMITED WARRANTY AND THE EMISSIONS CONTROL WARRANTY ARE THE ONLY WARRANTIES APPLICABLE TO THE ENGINE AS USED IN FIRE TRUCK OR CRASH RESCUE VEHICLE APPLICATIONS DETROIT DIESEL CORPORATION MAKES NO OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE DETROIT DIESEL CORPORATION SHALL NOT BE LIABLE FOR ANY IN...

Page 158: ...zed DDC service outlet Only new genuine parts or remanufactured parts or components supplied or approved by DDC will be used DDC may at its discretion replace rather than repair components A reasonable time must be allowed to perform the warranty repair after taking the engine to the authorized service outlet Repairs will be performed during normal business hours The owner is responsible for the p...

Page 159: ...nstallation Labor costs for Engine removal and reinstallation when necessary to make a warranty repair are not covered by this warranty Non DDC Supplied Manufactured Components DDC is not responsible for repair of components and or assemblies which are manufactured or supplied by another manufacturer such as intake and exhaust systems Such items are covered by warranties issued by the manufacturer...

Page 160: ...he Accessories THIS LIMITED WARRANTY IS THE ONLY WARRANTY APPLICABLE TO THE ENGINE AND ACCESSORIES AS USED IN AGRICULTURAL MACHINERY APPLICATIONS DETROIT DIESEL CORPORATION MAKES NO OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE DETROIT DIESEL CORPORATION SHALL NOT BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES AS DE...

Page 161: ...m defects in material or workmanship Repairs To obtain warranty repairs you must request the needed repairs within the WARRANTY PERIOD from an authorized DDC service outlet Only new genuine parts or remanufactured parts or components supplied or approved by DDC will be used DDC may at its discretion replace rather than repair components A reasonable time must be allowed to perform the warranty rep...

Page 162: ...aced and be entitled to the remaining warranty coverage Service Supplies The cost of service supplies such as coolant oil and filters which are not reusable due to warranted repairs is covered by this warranty Mechanic s Travel Expenses DDC will pay reasonable travel expenses for the repairing mechanic to travel to and from the repair site THIS WARRANTY DOES NOT COVER Repairs Due to Accidents Misu...

Page 163: ... without limitation communication expenses meals lodging loss of use of the Engine loss of time inconvenience overtime transportation of the Engine or any other cost or expense resulting from a defect covered by this warranty Other Limitations THIS LIMITED WARRANTY IS THE ONLY WARRANTY APPLICABLE TO THE ENGINE AND ACCESSORIES AS USED IN PRIME POWER GENERATORS DETROIT DIESEL CORPORATION MAKES NO OT...

Page 164: ...repairs within the WARRANTY PERIOD from an authorized DDC service outlet Only new genuine parts or remanufactured parts or components supplied or approved by DDC will be used DDC may at its discretion replace rather than repair components A reasonable time must be allowed to perform the warranty repair after taking the engine to the authorized service outlet Repairs will be performed during normal...

Page 165: ...installation Labor costs for Engine removal and reinstallation when necessary to make a warranty repair are not covered by this warranty Non DDC Supplied Manufactured Components DDC is not responsible for repair of components and or assemblies which are manufactured or supplied by another manufacturer such as intake and exhaust systems and fuel storage tanks Such items may be covered by warranties...

Page 166: ...ERATORS DETROIT DIESEL CORPORATION MAKES NO OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE DETROIT DIESEL CORPORATION SHALL NOT BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES AS DESCRIBED ABOVE Some states do not allow the limitation of how long this warranty may last or the limitation or exclusion of incidental or c...

Page 167: ...tended service element optional Optional May be used in place of but not together with the primary filter Table 35 Fuel Filters Series 60 Regular Service Lubricating Oil Filters Filter Type Detroit Diesel Part Number Full Flow 23530573 Full Flow High Capacity DELF3998 Table 36 Lubricating Oil Filters OIL PAN CAPACITY All Series 60 truck oil pans front sump and rear sump require the same amount of ...

Page 168: ...n Tote Concentrated 23512140 Bulk Delivery 1 000 Gallon Min 23528203 1 Gallon Jug 6 Per Case 23518918 55 Gallon Drum 23528544 330 Gallon Tote Pre Blended 50 50 23513503 Bulk Delivery 1 000 Gallon Min Table 37 POWER COOL Fully Formulated IEG Coolant POWER COOL Latin American Coolant Coolant Type Part Number Description 23524737 1 Gallon Jug 6 Per Case 23524923 55 Gallon Drum Pre Blended 67 33 23524...

Page 169: ...856 5 Gallon Pail For POWER COOL IEG Coolant 23507857 55 Gallon Drum Table 40 POWER COOL 3000 Supplemental Coolant Additive POWER COOL 3000 Supplemental Additive Coolant Filters Coolant Type 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 For POW...

Page 170: ...3519394 55 Gallon Drum Concentrated 23519395 Bulk Delivery 1 000 Gallon Min 23519396 One Gallon Jug 6 Per Case 23519398 55 Gallon Drum Pre Blended 50 50 23519399 Bulk Delivery 1 000 Gallon Min Table 43 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 ...

Page 171: ...L Plus 6000 OAT Inhibitor for Water Only Systems POWER COOL Cooling System Cleaners Coolant Type Part Number Description 200164 On Half Gallon Jug 6 Per Case 200105 5 Gallon Pail On Line Cleaner 200155 55 Gallon Drum Twin Pack 201549 Twin Pack 2 Per Case Table 46 POWER COOL Cooling System Cleaners All information subject to change without notice Rev 01 04 157 6SE484 0401 Copyright 2004 DETROIT DIE...

Page 172: ...olant Test Strips Bottle of 50 Indicates Nitrite Molybdate Glycol Levels 23522774 3 Way Coolant Test Strips Bottle of 10 Complete IEG IPG Coolant Analysis 23516921 Coolant Analysis Bottle Carton of 6 Organic Coolant Analysis 23523398 Laboratory Coolant Analysis Bottle Carton of 6 Table 47 Power Trac Coolant Testing and Analysis Products 158 All information subject to change without notice Rev 01 0...

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