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Detroit Diesel 60 Series User Manual

Detroit Diesel 60 Series
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Engine Operator's Guide
Series 60
DETROIT
DIESEL
~

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Detroit Diesel 60 Series Specifications

General IconGeneral
AspirationTurbocharged and Aftercooled
Displacement12.7L or 14.0L
Bore130 mm (5.12 in)
Stroke160 mm (6.30 in)
Fuel SystemElectronic Unit Injector (EUI)
Cooling SystemLiquid-cooled

Summary

Introduction to Detroit Diesel Series 60 Engines

Non-Genuine and Rebuilt Component Quality Alert

Alert regarding the quality of non-genuine and rebuilt engine components.

Caution Summary for Engine Operation and Maintenance

Engine Model and Serial Number Designation

Option Labels

Description of labels attached to the valve rocker cover detailing engine options.

Certification Labels

Description of labels certifying engine conformity to emissions regulations.

Operating Instructions

Preparations for Starting the Engine the First Time

Steps for preparing a new or overhauled engine before its first start.

Cooling System Checks

Procedures for checking the engine's cooling system before starting.

Lubricating System Checks

Procedures for checking the engine's lubrication system before starting.

Starting the Engine

Step-by-step guide on how to start the engine.

Running the Engine

Procedures and checks for running the engine after starting.

Oil Pressure

How to interpret and check engine oil pressure after starting.

Warm-up

How to warm up the engine before applying load.

Inspection

Inspections to perform while the engine is running.

Avoid Unnecessary Idling

Stopping the Engine

Normal Stopping

Steps for normal engine shutdown, including cool-down.

Emergency Jump Starting

Instructions for jump-starting DDEC III and IV electronic control systems.

DDEC III/IV Options and Operation

Cruise Control

Jake Brakes

Data Recording Capability

DDEC III/IV Operation

Welding Precaution

DDEC III/IV Engine Driving Tips

Accelerating the Vehicle

Understanding engine response and throttle characteristics with DDEC.

Cruise Control

How to use cruise control for driver convenience and comfort.

Shifting

Idling

Engine Systems Overview

Fuel System

Components and function of the engine's fuel system.

Lubrication System

Components and function of the engine's lubricating oil system.

Air System

Components and function of the engine's air intake system.

Cooling System

Components and function of the engine's cooling system.

Electrical System

Components of the engine's electrical system.

Exhaust System

Function of the engine's exhaust system.

Maintenance Interval Schedules

Lubrication and Preventive Maintenance Intervals

Item 1 - Lubricating Oil

Daily check and maintenance for engine lubricating oil.

Item 2 — Fuel and Fuel Tank

Procedures for maintaining the fuel tank and preventing condensation.

Fuel Lines and Hoses Maintenance

Item 3 — Fuel Lines, Flexible Hoses

Pre-start inspection of fuel lines and hoses.

Item 4 - Cooling System

Maintenance and checks for the engine's cooling system.

Turbocharger and Battery Maintenance

Item 5 — Turbocharger, Air-to-Air Charge Cooler

Inspection and maintenance of the turbocharger and charge cooler.

Item 6 — Battery

Checks and maintenance for the engine battery.

Drive Belts and Air Compressor Maintenance

Item 7 — Tachometer Drive

Lubrication and maintenance of the tachometer drive.

Item 8 — Drive Belts

Inspection, tensioning, and replacement of drive belts.

Air Cleaner and Fuel Filter Replacement

Item 9 — Air Compressor

Cleaning and tightening of air compressor intake parts.

Item 10 — Air Cleaner

Inspection and replacement of the air cleaner element.

Oil and Fuel Filter Replacement Procedures

Item 11 — Lubricating Oil Filters

Procedures for replacing lubricating oil filters.

Item 12 — Fuel Filters

Procedures for replacing fuel filters.

Water Pump, Air, and Exhaust System Maintenance

Item 13 — Water Pump and Coolant Inhibitor Element

Inspection of water pump drain hole and coolant inhibitor element.

Item 15 — Air System

Checking air system connections for leaks.

Item 16 — Exhaust System

Checking exhaust manifold bolts and rain cap.

Engine Cleaning and Alternator Maintenance

Item 17 — Engine (Steam Clean)

Procedure for steam cleaning the engine compartment.

Item 18 — Radiator

Inspection and cleaning of the radiator core.

Item 20 — Battery-Charging Alternator

Checking alternator terminals, connections, and bolt torque.

Mounts, Pressure, Hub, and Seals Maintenance

Item 21 — Engine and Transmission Mounts

Checking engine and transmission mounting bolts.

Item 22 — Crankcase Pressure

Checking and recording crankcase pressure.

Item 23 — Fan Hub

Lubrication of the fan bearing hub assembly.

Item 24 — Thermostats and Seals

Replacement interval for thermostats and seals.

Breather, Tune-up, and Vibration Damper Maintenance

Item 25 — Crankcase Breather

Cleaning or replacement of the crankcase breather assembly.

Item 26 — Engine Tune-up

Initial valve lash and injector height measurement and adjustment.

Item 27 — Vibration Damper

Inspection and replacement of the viscous vibration damper.

How To Section: Lubricant, Fuel, and Coolant Selection

A. How to Select Lubricating Oil

Guidance on selecting the proper lubricating oil for Detroit Diesel engines.

Lubricant Selection in North America

Information on lubricant selection for North American applications.

Synthetic Oils

Use of synthetic oils in Detroit Diesel engines and their properties.

The Use of Supplemental Additives

Recommendations regarding the use of supplemental oil additives.

B. When to Change Oil

Information on oil drain intervals and when to change oil.

Oil Drain Intervals

Factors affecting oil drain intervals and maximum recommended intervals.

Oil Filter and Fuel Oil Selection

Disposing of Waste Oil

Proper and environmentally responsible disposal of used oil and filters.

C. How to Replace the Lube Oil Filters

Step-by-step guide on how to replace lube oil filters.

Replace Spin-on Type Oil Filter

Instructions for replacing spin-on type oil filters.

Fuel Oil Selection and Filter Replacement

D. How to Select Fuel Oil

Importance of fuel quality and general recommendations for fuel selection.

Quality

Fuel quality requirements for satisfactory engine performance and emission levels.

Fuel Contamination and Prohibited Additives

Fuel Contamination

Common types of fuel contamination and prevention methods.

Supplemental additives are not recommended...

Reasons why supplemental fuel additives are not recommended.

Prohibited Additives

List of additives that are not allowed and must not be mixed with diesel fuel.

Fuel Filter Replacement Procedures

E. How to Replace the Fuel Filters

Procedures for selecting and replacing fuel filters.

Spin-on type primary and secondary fuel filters

Instructions for replacing spin-on type primary and secondary fuel filters.

Fuel/Water Separator and Fuel Filter Element Replacement

Replace Fuel/Water Separator

Procedure for replacing the fuel/water separator element and bowl.

Replace “Fuel Pro® 380/380E” Fuel Filter Element

Steps for replacing the Fuel Pro 380/380E diesel fuel filter element.

Engine Restart Procedure After Running Out of Fuel

Coolant Selection and Approved Coolants

G. How to Select Coolant

Information on selecting the required coolant for Series 60 engines.

APPROVED COOLANTS

Lists approved and preferred coolants for Series 60 engines.

Water Requirements and Recommended Coolants

Water Requirements

Requirements for water used in engine cooling systems.

COOLANTS NOT RECOMMENDED

Coolants that are not recommended for use in Series 60 engines.

Additives and Coolant Maintenance Intervals

ADDITIVES NOT RECOMMENDED

Additives that are not recommended for use in Series 60 engines.

Coolant Inhibitor Test Intervals

Intervals for checking coolant inhibitor levels.

Coolant Filters for Non-NOAT Systems

NOAT Coolant Drain Interval and System Problems

NOAT Coolant Drain Interval

Drain interval for properly maintained NOAT-inhibited coolant.

CHRONIC COOLANT SYSTEM PROBLEMS

Common coolant system problems and their causes.

Cooling System Maintenance Products and Recommendations

DETROIT DIESEL COOLING SYSTEM MAINTENANCE PRODUCTS

Information on Detroit Diesel cooling system maintenance products.

Power Cool SCAs

Information on water-soluble chemical compounds for cooling systems.

Power Cool 3000 liquid SCA

Information on Power Cool 3000 liquid SCA.

Power Cool Coolant Filter Elements

Information on Power Cool coolant filter elements.

Summary of Coolant Recommendations

Summary of recommendations for maintaining engine coolant.

How to Drain and Flush the Cooling System

Air Cleaner Service Procedures

I. When to Service the Dry Type Air Cleaner

When to service or replace the dry type air cleaner element.

Basic Troubleshooting Guide

HARD STARTING

Probable causes for hard starting engines.

Insufficient Fuel Supply

Probable causes for insufficient fuel supply.

Low Compression

Probable causes for low engine compression.

Objectionable Exhaust Troubleshooting

Abnormal Engine Operation Troubleshooting

Rough Running or Frequent Stalling

Probable causes for rough running or frequent engine stalling.

Low Power

Probable causes for low engine power.

Detonation

Probable causes for engine detonation.

Abnormal Operating Conditions Troubleshooting

High Lubricating Oil Consumption

Probable causes for high engine oil consumption.

Low Oil Pressure

Probable causes for low engine oil pressure.

Abnormal Coolant Temperatures Troubleshooting

Above Normal

Probable causes for engine coolant temperature being above normal.

Below Normal

Probable causes for engine coolant temperature being below normal.

Engine Storage Procedures

Preparing Engine for Storage

Steps for preparing an engine for storage.

Temporary Storage (30 Days or Less)

Procedures for temporary storage of the engine.

Extended Storage Procedures

Extended Storage (More than 30 Days)

Procedures for preparing an engine for extended storage (more than 30 days).

Restoring Engine to Service After Extended Storage

Service Publications and Customer Assistance

SERVICE PUBLICATIONS

List of service manuals and reference works for Detroit Diesel Series 60 engines.

DETROIT DIESEL CUSTOMER ASSISTANCE

Information on contacting customer assistance for road service and support.

Limited Warranty: On-Highway Vehicle Applications

TERMS OF COVERAGE

Explains the terms and conditions of the warranty.

Uses

Defines the applications covered by the warranty.

Defects

What the warranty covers regarding engine defects.

Repairs

How to obtain warranty repairs and related procedures.

Like Replacement Engine

How warranty coverage applies to replacement engines.

Service Supplies

Coverage of service supplies under the warranty.

Engine Removal and Reinstallation

Coverage of labor costs for engine removal and reinstallation.

THIS WARRANTY DOES NOT COVER:

List of repairs and conditions not covered by the warranty.

Braking Devices

DDC's responsibility for braking devices.

Fuel Injectors After 100,000 Miles/160,000 Kilometers

Fuel injector coverage after a certain mileage.

Warranty Maintenance and Damages Exclusions

Maintenance

DDC's responsibility for maintenance costs.

Incidental or Consequential Damages

Exclusion of incidental or consequential costs and expenses.

Other Limitations

Other limitations and disclaimers related to the warranty.

Limited Warranty: Urban Bus, Motor Coach, Motor Home Applications

TERMS OF COVERAGE:

Explanation of the terms and conditions of the warranty.

Uses

Defines the specific vehicle applications covered by this warranty.

Defects

What the warranty covers regarding engine defects.

Repairs

How to obtain warranty repairs and related procedures.

Service Supplies

Coverage of service supplies under the warranty.

Like Replacement Engine

How warranty coverage applies to replacement engines.

Engine Removal and Reinstallation

Coverage of labor costs for engine removal and reinstallation.

THIS WARRANTY DOES NOT COVER:

List of repairs and conditions not covered by the warranty.

Braking Devices

DDC's responsibility for braking devices.

Fuel Injectors and Starting Motors After 100,000 Miles/160 000 Kilometers

Fuel injector and starting motor coverage after a certain mileage.

Warranty Maintenance and Limitations

Maintenance

DDC's responsibility for maintenance costs.

Incidental or Consequential Damages

Exclusion of incidental or consequential costs and expenses.

Other Limitations

Other limitations and disclaimers related to the warranty.

Limited Warranty: Construction/Industrial Applications

TERMS OF COVERAGE

Explanation of the terms and conditions of the warranty.

Uses

Defines the applications covered by this warranty.

Defects

What the warranty covers regarding engine defects.

Repairs

How to obtain warranty repairs and related procedures.

Warranty Period

Defines the start and end of the warranty period.

Service Supplies

Coverage of service supplies under the warranty.

Engine Removal and Reinstallation - Construction/Industrial Applications

Coverage of labor costs for engine removal and reinstallation.

Mechanic’s Travel Expenses

DDC paying travel expenses for mechanics.

Like Replacement Engine

How warranty coverage applies to replacement engines.

THIS WARRANTY DOES NOT COVER:

List of repairs and conditions not covered by the warranty.

Non-DDC Supplied/Manufactured Components

DDC's non-responsibility for non-DDC components.

Warranty Maintenance and Limitations for Construction/Industrial

Maintenance

DDC's responsibility for maintenance costs.

Incidental or Consequential Damages

Exclusion of incidental or consequential costs and expenses.

Other Limitations

Other limitations and disclaimers related to the warranty.

Limited Warranty: Fire Truck or Crash Rescue Vehicle Applications

TERMS OF COVERAGE

Explanation of the terms and conditions of the warranty.

Uses

Defines the applications covered by this warranty.

Defects

What the warranty covers regarding engine defects.

Repairs

How to obtain warranty repairs and related procedures.

Warranty Period

Defines the start and end of the warranty period.

Like Replacement Engine

How warranty coverage applies to replacement engines.

Service Supplies

Coverage of service supplies under the warranty.

Mechanic’s Travel Expenses

DDC paying travel expenses for mechanics.

THIS WARRANTY DOES NOT COVER:

List of repairs and conditions not covered by the warranty.

Service Supplies

Cost of service supplies not covered by warranty.

Engine Removal and Reinstallation

Coverage of labor costs for engine removal and reinstallation.

Warranty Exclusions and Limitations for Fire/Rescue

THIS WARRANTY DOES NOT COVER:

List of repairs and conditions not covered by the warranty.

Maintenance

DDC's responsibility for maintenance costs.

Incidental or Consequential Damages

Exclusion of incidental or consequential costs and expenses.

Other Limitations

Other limitations and disclaimers related to the warranty.

Limited Warranty: Agricultural Machinery Applications

TERMS OF COVERAGE

Explanation of the terms and conditions of the warranty.

Uses

Defines the applications covered by this warranty.

Defects

What the warranty covers regarding engine defects.

Repairs

How to obtain warranty repairs and related procedures.

Warranty Period

Defines the start and end of the warranty period.

Engine Removal and Reinstallation

Engine R&R not covered by this warranty.

Non-DDC Supplied/Manufactured Components

DDC's non-responsibility for non-DDC components.

Maintenance

DDC's responsibility for maintenance costs.

Warranty Exclusions and Limitations for Agricultural Machinery

Incidental or Consequential Damages

Exclusion of incidental or consequential costs and expenses.

Other Limitations

Other limitations and disclaimers related to the warranty.

Limited Warranty: Prime Power Generator Set Applications

TERMS OF COVERAGE

Explanation of the terms and conditions of the warranty.

Uses

Defines the applications covered by this warranty.

Defects

What the warranty covers regarding engine defects.

Repairs

How to obtain warranty repairs and related procedures.

Warranty Period

Defines the start and end of the warranty period.

Like Replacement Engine

How warranty coverage applies to replacement engines.

Service Supplies

Coverage of service supplies under the warranty.

Mechanic’s Travel Expenses

DDC paying travel expenses for mechanics.

THIS WARRANTY DOES NOT COVER:

List of repairs and conditions not covered by the warranty.

Engine Removal and Reinstallation

Coverage of labor costs for engine removal and reinstallation.

Non-DDC Supplied/Manufactured Components

DDC's non-responsibility for non-DDC components.

Warranty Exclusions and Limitations for Prime Power Generators

Maintenance

DDC's responsibility for maintenance costs.

Incidental or Consequential Damages

Exclusion of incidental or consequential costs and expenses.

Other Limitations

Other limitations and disclaimers related to the warranty.

Limited Warranty: Stand-by Power Generator Set Applications

TERMS OF COVERAGE

Explanation of the terms and conditions of the warranty.

Uses

Defines the applications covered by this warranty.

Defects

What the warranty covers regarding engine defects.

Repairs

How to obtain warranty repairs and related procedures.

Warranty Period

Defines the start and end of the warranty period.

Like Replacement Engine

How warranty coverage applies to replacement engines.

Service Supplies

Coverage of service supplies under the warranty.

Mechanic’s Travel Expenses

DDC paying travel expenses for mechanics.

THIS WARRANTY DOES NOT COVER:

List of repairs and conditions not covered by the warranty.

Engine Removal and Reinstallation

Coverage of labor costs for engine removal and reinstallation.

Non-DDC Supplied/Manufactured Components

DDC's non-responsibility for non-DDC components.

Maintenance

DDC's responsibility for maintenance costs.

Incidental or Consequential Damages

Exclusion of incidental or consequential costs and expenses.

Other Limitations

Other limitations and disclaimers related to the warranty.

Specifications

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