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EPA07 Series 60 Operators Manual (DDC-SVC-MAN-0006)

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1 Introduction
- 1.1 Non-Genuine and Rebuilt Component Quality Alert
- 1.2 Personnel Requirements
- 1.3 Engine Conversions and Modifications
2 Caution Summary
- 2.1 Engine Operation
- 2.2 Preventive Maintenance
- 2.3 Electrical System
- 2.4 Cooling System
- 2.5 Air Intake System
- 2.6 Fuel System
- 2.7 Compressed Air
- 2.8 Starting Aids
- 2.9 Lubricating Oil and Filters
- 2.10 Aftertreatment System
3 Engine Identification
- 3.1 Engine Components
- 3.2 Engine Model and Serial Number Desiginaton
- 3.3 Certification Label
4 Operating Instructions for Starting the Engine
- 4.1 First Time Start Preparation
- 4.2 System Checks
  - 4.2.1 Cooling System Checks
  - 4.2.2 Lubrication System Checks
    - 4.2.2.1 Checking the Oil Level
    - 4.2.2.2 Extended Storage
  - 4.2.3 Fuel System Checks
    - 4.2.3.1 Adding Fuel
    - 4.2.3.2 Priming the Fuel System
  - 4.2.4 Other Checks
  - 4.2.5 Starting the Engine For The First Time
    - 4.2.5.1 Electric Starter
- 4.3 Running the Engine
  - 4.3.1 Oil Pressure
  - 4.3.2 Warm-up
  - 4.3.3 Inspection
    - 4.3.3.1 Transmission
    - 4.3.3.2 Fluid Leaks
    - 4.3.3.3 Crankcase
    - 4.3.3.4 Turbocharger
  - 4.3.4 Avoid Unnecessary Idling
- 4.4 Stopping the Engine
- 4.5 Emergency Jump Starting
- 4.6 Routine Engine Start
  - 4.6.1 Starting the Engine-Routine
  - 4.6.2 Checking the Coolant Level (Cold Check)
  - 4.6.3 Checking the Coolant Level (Hot Check)
- 4.7 Monitoring Engine Operation
  - 4.7.1 Battery Charge
  - 4.7.2 Oil Pressure
  - 4.7.3 Excessive Idling
- 4.8 Changing the Idle Speed
- 4.9 Shutting Down the Engine
  - 4.9.1 Shutting Down After High Load Operation
- 4.10 Emergency Running Mode
- 4.11 Stop Engine Override Option
- 4.12 Cold Weather Operation
  - 4.12.1 Winter Fronts
5 Ddec Vi System
- 5.1 Motor Control Module
- 5.2 Common Powertrain Controller
- 5.3 Ddec Features
  - 5.3.1 Cruise Control
  - 5.3.2 Data Recording Capability
  - 5.3.3 Engine Brakes
  - 5.3.4 Engine Protection
  - 5.3.5 California Engine Idle Limiting
  - 5.3.6 Idle Shutdown Timer
- 5.4 Ddec Vi Operation
  - 5.4.1 Stop Engine Override Switch
  - 5.4.2 Immediate Speed Reduction
  - 5.4.3 Red Stop Lamp
  - 5.4.4 Diagnostic Tool
    - 5.4.4.3 Inactive Codes
6 Ddec Vi Engine Driving Tips
- 6.1 Accelerating the Vehicle
- 6.2 Cruise Control
- 6.3 Engine Brakes and Cruise Control
- 6.4 Shifting
- 6.5 Idling
7 Engine Brake System
- 7.1 Driver Control Switches
  - 7.1.1 Low/High Switch
  - 7.1.2 Low/Med/High Switch
- 7.2 Clutch Pedal and Throttle Position Controls
- 7.3 Engine Brake Operation
- 7.4 Anti-Lock Braking Systems
- 7.5 Driving On Flat, Dry Pavement
- 7.6 Descending a Long, Steep Grade
- 7.7 Driving On Wet or Slippery Pavement
8 Engine Systems
- 8.1 Fuel System
- 8.2 Lubrication System
- 8.3 Air System
- 8.4 Cooling System
- 8.5 Electrical System
- 8.6 Exhaust System
- 8.7 Exhaust Gas Recirculation System
9 Aftertreatment System
- 9.1 Operating Requirements
- 9.2 Maintenance
- 9.3 Parked Regeneration Procedure
  - 9.3.1 Hazardous Applications
    - 9.3.1.1 DPF Stationary Regen Only = 0-Disabled
    - 9.3.1.2 DPF Stationary Regen Only = 1-Enabled
- 9.4 Service Record
10 Driver Actions
11 Instrument Panel Lamps
12 Maintenance
- 12.1 Scheduled Intervals
- 12.2 Preventive Maintenance Intervals
  - 12.2.1 Item 1 – Lubricating Oil
  - 12.2.2 Item 2 – Fuel and Fuel Tank
  - 12.2.3 Item 3 – Fuel Lines, Flexible Hoses
    - 12.2.3.1 Leaks
    - 12.2.3.2 Hoses and Fittings
    - 12.2.3.3 Hose Service Life
  - 12.2.4 Item 4 – Cooling System
    - 12.2.4.1 Coolant Level
    - 12.2.4.2 Coolant Inhibitors
    - 12.2.4.3 Coolant Drain Interval
  - 12.2.5 Item 5 – Turbocharger, Air-to-Air Charge Cooler
    - 12.2.5.1 Wastegated Turbochargers
  - 12.2.6 Item 6 – Battery
  - 12.2.7 Item 7 – Aftertreatment System
  - 12.2.8 Item 8 – Drive Belts
    - 12.2.8.1 V-Belts
    - 12.2.8.2 2-Groove PowerBand
    - 12.2.8.3 12–Rib Poly-V Belt
    - 12.2.8.4 Belt Replacement
  - 12.2.9 Item 9 – Air Compressor
  - 12.2.10 Item 10 – Air Cleaner
    - 12.2.10.1 Air Cleaner Replacement
  - 12.2.11 Item 11 – Lubricating Oil Filters
  - 12.2.12 Item 12 – Fuel Filters
    - 12.2.12.1 Fuel Pro® 382 Filters
    - 12.2.12.2 Spin-On Filters
  - 12.2.13 Item 13 – Water Pump and Coolant Inhibitor Element
    - 12.2.13.1 Water Pump Drain Hole
    - 12.2.13.2 Coolant Inhibitor Element
  - 12.2.14 Item 14 – Cranking Motor
  - 12.2.15 Item 15 – Air System
  - 12.2.16 Item 16 – Exhaust System
  - 12.2.17 Item 17 – Engine (Steam Clean)
  - 12.2.18 Item 18 – Radiator
  - 12.2.19 Item 19 – Oil Pressure
  - 12.2.20 Item 20 – Battery-Charging Alternator
    - 12.2.20.1 Bosch® T1 Alternator Service Requirements
    - 12.2.20.2 General Service Requirements – Bosch® and Delco Remy® Alternators
  - 12.2.21 Item 21 – Engine and Transmission Mounts
  - 12.2.22 Item 22 – Crankcase Pressure
  - 12.2.23 Item 23 – Fan Hub
  - 12.2.24 Item 24 – Thermostats and Seals
  - 12.2.25 Item 25 – Crankcase Breather
  - 12.2.26 Item 26 – Engine Tune-Up
  - 12.2.27 Item 27 – Vibration Damper
13 How-to Section
- 13.1 How to Select Lubricating Oil
  - 13.1.1 Lubricant Requirements
  - 13.1.2 Cold Weather Starting
  - 13.1.3 Synthetic Oils
  - 13.1.4 The Use of Supplemental Additives
- 13.2 When to Change Oil
  - 13.2.1 Disposing of Waste Oil
- 13.3 How to Replace the Lube Oil Filters
  - 13.3.1 Replace Spin-On Type Oil Filter
- 13.4 How to Select Diesel Fuel
  - 13.4.1 Quality
  - 13.4.2 Fuel Contamination
    - 13.4.2.1 Biodiesel
  - 13.4.3 Prohibited Additives
    - 13.4.3.3 Gasoline
    - 13.4.3.2 Fuel Additives with Sulfur or Sulfated Ash
- 13.5 How to Replace the Fuel Filters
  - 13.5.1 Replace Spin-On Type Primary or Secondary Fuel Filter Elements
  - 13.5.2 Replace Fuel/Water Separator Element
  - 13.5.3 Replace Fuel Pro® 382/382E Fuel Filter Element
- 13.6 Engine Out of Fuel — How to Restart
  - 13.6.1 Engines with Spin-On Filters
  - 13.6.2 Engines with Fuel Pro Filters
- 13.7 How to Clean the Engine
  - 13.7.1 High-Pressure Cleaning Equipment
- 13.8 How to Clean the Cooling System
  - 13.8.1 Degreasing
- 13.9 How to Select Coolant
  - 13.9.1 Definitions
  - 13.9.2 Approved Coolants
    - 13.9.2.6 Water Requirements
  - 13.9.3 Coolants Not Recommended
    - 13.9.3.1 All Antifreezes And Coolants Containing Phosphate
    - 13.9.3.2 Automotive Type Coolants
    - 13.9.3.3 Methyl Alcohol-Based Antifreeze
    - 13.9.3.4 Glycol-based Coolants Formulated For HVAC
  - 13.9.4 Additives Not Recommended
    - 13.9.4.1 Soluble Oil Additives
    - 13.9.4.2 Chromate Additives
  - 13.9.5 Coolant Inhibitor Test Intervals
    - 13.9.5.2 Maintenance Intervals
  - 13.9.6 SCA Test Procedures
  - 13.9.7 Coolant Filters (Non-OAT Systems)
  - 13.9.8 Dropout
  - 13.9.9 Coolant Extender Inhibitor Additive for “OAT” Coolant
    - 13.9.9.1 OAT Coolant Drain Interval
  - 13.9.10 Chronic Coolant System Problems
  - 13.9.11 Detroit Diesel Cooling System Maintenance Products
    - 13.9.11.3 Power Cool Cleaners
  - 13.9.12 Summary of Coolant Recommendations
    - 13.9.12.1 Coolant life of Glycol Coolant
    - 13.9.12.2 Coolant Life of OAT Coolant
    - 13.9.12.3 Coolant Life of Other Coolants
- 13.10 How to Drain and Flush the Cooling System
  - 13.10.1 Hoses
- 13.11 When to Service the Dry Type Air Cleaner
14 Troubleshooting
- 14.1 Abnormal Coolant Temperature
- 14.2 Hard Starting
- 14.3 Aftertreatment System
- 14.4 Abnormal Engine Operation
- 14.5 Abnormal Operating Conditions
15 Engine Storage
- 15.1 Preparing Engine for Storage
  - 15.1.1 Temporary Storage (30 Days or Less)
  - 15.1.2 Extended Storage (More than 30 Days)
  - 15.1.3 Procedure for Restoring to Service an Engine that Has Been in Extended Storage
16 Customer Assistance
- 16.1 Road Service in the U.s. or Canada
- 16.2 Working With Detroit™ Service Outlets
17 Specifications
- 17.1 Fuel and Lubricating Oil Filters
  - 17.1.1 OIL PAN CAPACITY
- 17.2 Power Cool Engine Products
  - 17.2.1 POWER COOL Fully Formulated IEG Coolant
  - 17.2.2 POWER COOL 2000 and 3000 Supplemental Coolant Additive
  - 17.2.3 POWER COOL 3000 Supplemental Additive Coolant Filters
  - 17.2.4 POWER COOL Supplemental Additive Need Release Coolant Filters
  - 17.2.5 POWER COOL Plus Extended Life OAT Coolant
  - 17.2.6 POWER COOL Plus Extender For Use With POWER COOL Plus OAT Coolant
  - 17.2.7 POWER COOL Cooling System Cleaners
  - 17.2.8 POWER TRAC Coolant Testing And Analysis Products

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