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EPA98 04 Series 60 Operators Manual (DDC-SVC-MAN-0039)

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1 Introduction
- 1.1 Non-Genuine and Rebuilt Component Quality Alert
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 Starting Aids
- 2.8 Compressed Air
- 2.9 Lubricating Oil and Filters
3 Engine Model and Serial Number Designation
- 3.1 Certification Labels
4 Operating Instructions for a First Time Start
- 4.1 System Checks
  - 4.1.1 Cooling System Checks
  - 4.1.2 Lubrication System Checks
    - 4.1.2.1 Extended Storage
  - 4.1.3 Fuel System Checks
  - 4.1.4 Other Checks
- 4.2 Starting the Engine
  - 4.2.1 Initial Engine Start
    - 4.2.1.1 Electric Starter
    - 4.2.1.2 Air 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
5 Ddec V System
- 5.1 Ddec Features
  - 5.1.1 Engine Protection
  - 5.1.2 Idle Shutdown Timer
  - 5.1.3 Cruise Control
  - 5.1.4 Engine Brakes
  - 5.1.5 Data Recording Capability
- 5.2 Ddec V Operation
  - 5.2.1 Stop Engine Override Switch
  - 5.2.2 Immediate Speed Reduction
  - 5.2.3 Red Stop Lamp
  - 5.2.4 Diagnostic Data Reader
6 Ddec V 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
  - 6.5.1 Winter Fronts
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 Maintenance
- 9.1 Scheduled Intervals
- 9.2 Preventive Maintenance Intervals
  - 9.2.1 Item 1 – Lubricating Oil
  - 9.2.2 Item 2 – Fuel and Fuel Tank
  - 9.2.3 Item 3 – Fuel Lines, Flexible Hoses
    - 9.2.3.1 Leaks
    - 9.2.3.2 Hoses and Fittings
    - 9.2.3.3 Hose Service Life
  - 9.2.4 Item 4 – Cooling System
    - 9.2.4.1 Coolant Level
    - 9.2.4.2 Coolant Inhibitors
    - 9.2.4.3 Coolant Drain Interval
  - 9.2.5 Item 5 – Turbocharger, Air-to-Air Charge Cooler
    - 9.2.5.1 Wastegated Turbochargers
  - 9.2.6 Item 6 – Battery
  - 9.2.7 Item 7 – Tachometer Drive
  - 9.2.8 Item 8 – Drive Belts
    - 9.2.8.1 V-Belts
    - 9.2.8.2 2-Groove PowerBand
    - 9.2.8.3 12–Rib Poly-V Belt
    - 9.2.8.4 Belt Replacement
  - 9.2.9 Item 9 – Air Compressor
  - 9.2.10 Item 10 – Air Cleaner
    - 9.2.10.1 Air Cleaner Replacement
  - 9.2.11 Item 11 – Lubricating Oil Filters
  - 9.2.12 Item 12 – Fuel Filters
    - 9.2.12.1 Fuel Pro® 382 Filters
    - 9.2.12.2 Spin-On Filters
  - 9.2.13 Item 13 – Water Pump and Coolant Inhibitor Element
    - 9.2.13.1 Water Pump Drain Hole
    - 9.2.13.2 Coolant Inhibitor Element
  - 9.2.14 Item 14 – Cranking Motor
  - 9.2.15 Item 15 – Air System
  - 9.2.16 Item 16 – Exhaust System
  - 9.2.17 Item 17 – Engine (Steam Clean)
  - 9.2.18 Item 18 – Radiator
  - 9.2.19 Item 19 – Oil Pressure
  - 9.2.20 Item 20 – Battery-Charging Alternator
    - 9.2.20.1 Bosch® T1 Alternator Service Requirements
    - 9.2.20.2 General Service Requirements – Bosch® and Delco Remy® Alternators
  - 9.2.21 Item 21 – Engine and Transmission Mounts
  - 9.2.22 Item 22 – Crankcase Pressure
  - 9.2.23 Item 23 – Fan Hub
  - 9.2.24 Item 24 – Thermostats and Seals
  - 9.2.25 Item 25 – Crankcase Breather
  - 9.2.26 Item 26 – Engine Tune-Up
  - 9.2.27 Item 27 – Vibration Damper
10 How-to Section
- 10.1 How to Select Lubricating Oil
  - 10.1.1 Lubricant Requirements
  - 10.1.2 Cold Weather Starting
  - 10.1.3 Synthetic Oils
  - 10.1.4 The Use of Supplemental Additives
- 10.2 When to Change Oil
  - 10.2.1 Disposing of Waste Oil
- 10.3 How to Replace the Lube Oil Filters
  - 10.3.1 Replace Spin-On Type Oil Filter
- 10.4 How to Select Fuel Oil
  - 10.4.1 Quality
  - 10.4.2 Fuel Contamination
  - 10.4.3 Prohibited Additives
  - 10.4.4 Biodiesel Fuels
- 10.5 How to Replace the Fuel Filters
  - 10.5.1 Replace Spin-On Type Primary or Secondary Fuel Filter Elements
  - 10.5.2 Replace Fuel/Water Separator Element
  - 10.5.3 Replace Fuel Pro® 382/382E Fuel Filter Element
- 10.6 Engine Out of Fuel — How to Restart
  - 10.6.1 Engines with Spin-On Filters
  - 10.6.2 Engines with Fuel Pro Filters
- 10.7 How to Select Coolant
  - 10.7.1 Definitions
  - 10.7.2 Coolant Fill Options
  - 10.7.3 Coolant for Detroit Diesel Engines
    - 10.7.3.1 Ethylene Glycol / Water + Conventional Corrosion Inhibitor, Propylene Glycol / Water + Conventional Corrosion Inhibitor
    - 10.7.3.2 Mixing Ethylene Glycol or Propylene Glycol Antifreeze and Water
    - 10.7.3.3 Recycled Antifreeze
    - 10.7.3.4 Ethylene Glycol / Water + OAT Or NOAT Inhibitor, Propylene Glycol / Water + OAT or NOAT Inhibitor
    - 10.7.3.5 Water Only + Supplemental Coolant Additive (Traditional/Conventional), Water Only + OAT Or NOAT Inhibitor
    - 10.7.3.6 Supplemental Coolant Additives For Fully Formulated Coolant (Conventional Coolant Formulations Only)
    - 10.7.3.7 Water Requirements
  - 10.7.4 Coolant and Additives Not Recommended
    - 10.7.4.1 Coolants Not Recommended
    - 10.7.4.2 Non-Formulated Additives Not Recommended
  - 10.7.5 Maintenance
    - 10.7.5.1 Coolant Maintenance Intervals
    - 10.7.5.2 Supplemental Coolant Additive Test Procedures
    - 10.7.5.3 Need-Release Coolant Filters (Not Available In OAT or NOAT Applications)
    - 10.7.5.4 Drop-Out
    - 10.7.5.5 Coolant Extender Inhibitor Additive For OAT Or NOAT Coolant
    - 10.7.5.6 Detroit Diesel Cooling System Maintenance Products
    - 10.7.5.7 Coolant Filter Elements
    - 10.7.5.8 Liquid Supplemental Coolant Additive
    - 10.7.5.9 Cleaners
    - 10.7.5.10 Summary Of Coolant Recommendations
- 10.8 How to Drain and Flush the Cooling System
  - 10.8.1 Hoses
- 10.9 When to Service the Dry Type Air Cleaner
11 Basic Troubleshooting
12 Engine Storage
- 12.1 Preparing Engine for Storage
  - 12.1.1 Temporary Storage (30 Days or Less)
  - 12.1.2 Extended Storage (More than 30 Days)
  - 12.1.3 Procedure for Restoring to Service an Engine that Has Been in Extended Storage
13 Series 60 Service Publications
14 Customer Assistance
- 14.1 Road Service in the U.s. or Canada
- 14.2 Working With Detroit™ Service Outlets
15 Limited Warranty On Series 60 Ddec V Egr Engines Used in On-Highway Vehicle Applications
- 15.1 Terms of Coverage
  - 15.1.1 Uses
  - 15.1.2 Defects
  - 15.1.3 Repairs
  - 15.1.4 Warranty Period
  - 15.1.5 Like Replacement Engine
  - 15.1.6 Service Supplies
  - 15.1.7 Engine Removal and Reinstallation
- 15.2 This Warranty Does Not Cover:
  - 15.2.1 Repairs Due to Accidents, Misuse, Storage Damage, Negligence or Certain Modifications
  - 15.2.2 Braking Devices
  - 15.2.3 Fuel Injectors after 200,000 Miles/320,000 Kilometers
  - 15.2.4 Maintenance
  - 15.2.5 Incidental or Consequential Damage
  - 15.2.6 Other Limitations
16 Limited Warranty On Engines Powering Urban Bus, Motor Coach or Motor Home Applications
- 16.1 Terms of Coverage
  - 16.1.1 Uses
  - 16.1.2 Defects
  - 16.1.3 Repairs
  - 16.1.4 Warranty Period
  - 16.1.5 Service Supplies
  - 16.1.6 Like Replacement Engine
  - 16.1.7 Engine Removal and Reinstallation
- 16.2 This Warranty Does Not Cover:
  - 16.2.1 Repairs Due to Accidents, Misuse, Alteration, Storage Damage, Negligence or Certain Modifications
  - 16.2.2 Braking Devices
  - 16.2.3 Fuel Injectors after 200,000 Miles/320,000 Kilometers
  - 16.2.4 Maintenance
  - 16.2.5 Incidental or Consequential Damage
  - 16.2.6 Other Limitations
17 Limited Warranty On Engines Used in Fire Truck or Crash Rescue Vehicle Applications
- 17.1 Terms of Coverage
  - 17.1.1 Uses
  - 17.1.2 Defects
  - 17.1.3 Repairs
  - 17.1.4 Warranty Period
  - 17.1.5 Like Replacement Engine
  - 17.1.6 Service Supplies
  - 17.1.7 Engine Removal and Reinstallation
- 17.2 This Warranty Does Not Cover:
  - 17.2.1 Repairs Due To Accidents, Misuse, Alteration, Storage Damage, Negligence Or Certain Modifications
  - 17.2.2 Maintenance
  - 17.2.3 Incidental or Consequential Damage
  - 17.2.4 Other Limitations
18 Limited Warranty On Engines Used in Construction and Industrial Applications
- 18.1 Terms of Coverage
  - 18.1.1 Uses
  - 18.1.2 Defects
  - 18.1.3 Repairs
  - 18.1.4 Warranty Period
  - 18.1.5 Service Supplies
  - 18.1.6 Mechanic’s Travel Expenses
  - 18.1.7 Engine Removal and Reinstallation
  - 18.1.8 Like Replacement Engine
- 18.2 This Warranty Does Not Cover:
  - 18.2.1 Repairs Due to Accidents, Misuse, Alteration, Storage Damage, Negligence or Certain Modifications
  - 18.2.2 Non-DDC Supplied/Manufactured Components
  - 18.2.3 Maintenance
  - 18.2.4 Incidental or Consequential Damage
  - 18.2.5 Other Limitations
19 Specifications
- 19.1 Fuel and Lubricating Oil Filters
  - 19.1.1 OIL PAN CAPACITY
    - 19.1.1.1 Oil Pan Capacity
    - 19.1.1.2 Total Oil Capacity Of The Engine
- 19.2 Detroit Diesel Genuine Engine Products
  - 19.2.1 Detroit Diesel Genuine Fully Formulated IEG Coolant
  - 19.2.2 Detroit Diesel Genuine Latin American Coolant
  - 19.2.3 Detroit Diesel Genuine 2000 and 3000 Supplemental Coolant Additive
  - 19.2.4 Detroit Diesel Genuine 3000 Supplemental Additive Coolant Filters
  - 19.2.5 Detroit Diesel Genuine Supplemental Additive Need Release Coolant Filters
  - 19.2.6 Detroit Diesel Genuine Plus Extended Life OAT Coolant
  - 19.2.7 Detroit Diesel Genuine Plus Extender For Use With Detroit Diesel Genuine Plus OAT Coolant
  - 19.2.8 Detroit Diesel Genuine Plus 6000 OAT Inhibitor For Water-Only Systems
  - 19.2.9 Detroit Diesel Genuine Cooling System Cleaners
  - 19.2.10 POWER TRAC Coolant Testing And Analysis Products

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