Detroit Diesel 60 Bedienungsanleitung

DDC-SVC-MAN-0039

Specifications are subject to change without notice. Detroit Diesel Corporation

Printed in U.S.A.

13400 Outer Drive, West, Detroit, Michigan 48239-4001

Telephone: 313-592-5000

www.detroitdiesel.com

EPA04 Series 60®

Operator’s Manual

SERIES 60 ON-HIGHWAY ENGINE OPERATOR'S GUIDE

To the Operator

This guide contains instructions on

the safe operation and preventive

maintenance of your Detroit Diesel

Series 60® engine used in vehicle or

ﬁre ﬁghting apparatus applications.

Maintenance instructions cover

routine engine services such as lube

oil and ﬁlter changes in enough detail

to permit self-servicing, if desired.

The operator should become familiar

with the contents of this guide before

operating the engine or carrying out

maintenance procedures.

Power-driven equipment is only

as safe as the person operating the

controls. You are urged, as the

operator of this diesel engine, to keep

ﬁngers and clothing away from the

revolving belts, drive shafts, pulleys,

etc. on the engine installation.

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

youtorelyonanauthorized Detroit

Diesel service outlet for all your

service needs from maintenance to

major parts replacement. Authorized

service outlets worldwide stock

factory-original parts and have

the specialized equipment and

experienced, trained personnel

to provide prompt preventive

maintenance and skilled engine

repairs.

The information and speciﬁcations

in this publication are based on the

information in effect at the time of

approval for printing. Contact an

authorized Detroit Diesel service

outlet for information on the latest

revision. The right is reserved to

make changes at any time without

obligation.

All information subject to change without notice. i

NOTICE:

Coolant must be inhibited with the

recommended SCAs (supplemental

coolant additives) listed in the

How To section of this engine

operator's guide. In addition, the

engine can be equipped with a

coolant ﬁlter/inhibitor system as an

installed option or as an after-sale

item. Failure to check and

maintain SCA levels at required

concentrations will result in

severe damage (corrosion) to

the engine cooling system and

related components.

WARRANTY

The applicable engine warranty is

contained in the booklet “Warranty

Information for Series 60 Engines,”

available from authorized Detroit

Diesel service outlets.

Keep this Operator's Guide

with the engine installation at

all times. It contains important

operating, 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®, and Mega Filter®

are registered trademarks of Davco

Manufacturing, L.L.C. PowerBand®

is a registered trademark of Gates

Rubber Company. Tectyl® is a

registered trademark of Daubert

Chemical Company, Inc. Biobor® is a

registered trademark of United States

Borax and Chemical Corporation.

DuPont® is a registered trademark

of E.I. DuPont de Nemours and

Company, Inc. All other trademarks

used are the property of their

respective owners.

ii All information subject to change without notice.

SERIES 60 ON-HIGHWAY ENGINE OPERATOR'S GUIDE

TABLE OF CONTENTS

INTRODUCTION .................................................................................. 1

NON-GENUINE AND REBUILT COMPONENT QUALITY ALERT .. 1

CAUTION SUMMARY .......................................................................... 3

ENGINE OPERATION ..................................................................... 3

PREVENTIVE MAINTENANCE ....................................................... 4

ELECTRICAL SYSTEM ................................................................... 7

COOLING SYSTEM ......................................................................... 8

AIR INTAKE SYSTEM ...................................................................... 8

FUEL SYSTEM ................................................................................ 9

STARTING AIDS .............................................................................. 9

COMPRESSED AIR ......................................................................... 11

LUBRICATING OIL AND FILTERS .................................................. 11

ENGINE MODEL AND SERIAL NUMBER DESIGNATION ................ 12

CERTIFICATION LABELS ............................................................... 13

OPERATING INSTRUCTIONS FOR A FIRST TIME START .............. 14

SYSTEM CHECKS .......................................................................... 14

COOLING SYSTEM CHECKS .................................................... 14

LUBRICATION SYSTEM CHECKS ............................................. 15

EXTENDED STORAGE .......................................................... 15

FUEL SYSTEM CHECKS ............................................................ 16

OTHER CHECKS ........................................................................ 17

STARTING THE ENGINE ................................................................ 17

INITIAL ENGINE START ............................................................. 18

ELECTRIC STARTER ............................................................. 18

AIR STARTER ......................................................................... 19

RUNNING THE ENGINE ................................................................. 19

OIL PRESSURE .......................................................................... 19

WARM-UP ................................................................................... 19

INSPECTION ............................................................................... 19

TRANSMISSION ..................................................................... 19

FLUID LEAKS ......................................................................... 19

CRANKCASE .......................................................................... 20

All information subject to change without notice. iii

TABLEOFCONTENTS

TURBOCHARGER .................................................................. 20

AVOID UNNECESSARY IDLING ................................................. 20

STOPPING THE ENGINE ................................................................ 20

EMERGENCY JUMP STARTING .................................................... 21

DDEC V SYSTEM ................................................................................ 22

DDEC FEATURES ........................................................................... 22

ENGINE PROTECTION .............................................................. 23

IDLE SHUTDOWN TIMER .......................................................... 23

CRUISE CONTROL ..................................................................... 23

ENGINE BRAKES ....................................................................... 25

DATA RECORDING CAPABILITY ............................................... 26

DDEC V OPERATION ...................................................................... 26

STOP ENGINE OVERRIDE SWITCH ......................................... 27

IMMEDIATE SPEED REDUCTION ............................................. 27

RED STOP LAMP ........................................................................ 27

DIAGNOSTIC DATA READER .................................................... 28

DDEC V ENGINE DRIVING TIPS ........................................................ 35

ACCELERATING THE VEHICLE ..................................................... 35

CRUISE CONTROL ......................................................................... 35

ENGINE BRAKES AND CRUISE CONTROL .................................. 37

SHIFTING ........................................................................................ 37

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 ........................................................ 40

ANTI-LOCK BRAKING SYSTEMS ................................................... 42

DRIVING ON FLAT, DRY PAVEMENT ............................................. 42

DESCENDING A LONG, STEEP GRADE ....................................... 42

DRIVING ON WET OR SLIPPERY PAVEMENT .............................. 44

ENGINE SYSTEMS ............................................................................. 45

FUEL SYSTEM ................................................................................ 45

LUBRICATION SYSTEM ................................................................. 45

iv All information subject to change without notice.

SERIES 60 ON-HIGHWAY ENGINE OPERATOR'S GUIDE

AIR SYSTEM ................................................................................... 45

COOLING SYSTEM ......................................................................... 45

ELECTRICAL SYSTEM ................................................................... 45

EXHAUST SYSTEM ........................................................................ 45

EXHAUST GAS RECIRCULATION SYSTEM .................................. 45

MAINTENANCE ................................................................................... 46

MAINTENANCE INTERVALS .......................................................... 46

PREVENTIVE MAINTENANCE INTERVALS .................................. 56

ITEM 1 – LUBRICATING OIL ...................................................... 56

ITEM 2 – FUEL AND FUEL TANK ............................................... 57

ITEM 3 – FUEL LINES, FLEXIBLE HOSES ................................ 59

LEAKS ..................................................................................... 59

HOSES AND FITTINGS .......................................................... 59

HOSE SERVICE LIFE ............................................................. 59

ITEM 4 – COOLING SYSTEM ..................................................... 60

COOLANT LEVEL ................................................................... 60

COOLANT INHIBITORS .......................................................... 60

COOLANT DRAIN INTERVAL ................................................. 60

ITEM 5 – TURBOCHARGER, AIR-TO-AIR CHARGE COOLER . 62

WASTEGATED TURBOCHARGERS ...................................... 62

ITEM 6 – BATTERY ..................................................................... 63

ITEM 7 – TACHOMETER DRIVE ................................................ 64

ITEM 8 – DRIVE BELTS .............................................................. 64

V-BELTS .................................................................................. 64

2-GROOVE POWERBAND ..................................................... 65

12–RIB POLY-V BELT ............................................................. 65

BELT REPLACEMENT ............................................................ 66

ITEM 9 – AIR COMPRESSOR .................................................... 66

ITEM 10 – AIR CLEANER ........................................................... 66

AIR CLEANER REPLACEMENT ............................................. 67

ITEM 11 – LUBRICATING OIL FILTERS ..................................... 67

ITEM 12 – FUEL FILTERS .......................................................... 68

FUEL PRO® 382 FILTERS ..................................................... 68

SPIN-ON FILTERS .................................................................. 68

ITEM 13 – WATER PUMP AND COOLANT INHIBITOR

ELEMENT .................................................................................... 68

WATER PUMP DRAIN HOLE ................................................. 68

COOLANT INHIBITOR ELEMENT .......................................... 69

All information subject to change without notice. v

TABLEOFCONTENTS

ITEM 14 – CRANKING MOTOR .................................................. 69

ITEM 15 – AIR SYSTEM ............................................................. 69

ITEM 16 – EXHAUST SYSTEM .................................................. 70

ITEM 17 – ENGINE (STEAM CLEAN) ......................................... 70

ITEM 18 – RADIATOR ................................................................. 70

ITEM 19 – OIL PRESSURE ......................................................... 71

ITEM 20 – BATTERY-CHARGING ALTERNATOR ...................... 71

BOSCH® T1 ALTERNATOR SERVICE REQUIREMENTS ..... 72

GENERAL SERVICE REQUIREMENTS – BOSCH® AND

DELCO REMY® ALTERNATORS ........................................... 72

ITEM 21 – ENGINE AND TRANSMISSION MOUNTS ................ 72

ITEM 22 – CRANKCASE PRESSURE ........................................ 72

ITEM 23 – FAN HUB .................................................................... 72

ITEM 24 – THERMOSTATS AND SEALS ................................... 72

ITEM 25 – CRANKCASE BREATHER ........................................ 73

ITEM 26 – ENGINE TUNE-UP .................................................... 73

ITEM 27 – VIBRATION DAMPER ................................................ 74

HOW-TO SECTION .............................................................................. 75

HOW TO SELECT LUBRICATING OIL ............................................ 75

LUBRICANT REQUIREMENTS .................................................. 75

EGR-EQUIPPED ENGINES .................................................... 75

NON-EGR ENGINES .............................................................. 75

ENGINES BUILT PRIOR TO 1998 .......................................... 75

COLD WEATHER STARTING ..................................................... 76

SYNTHETIC OILS ....................................................................... 76

THE USE OF SUPPLEMENTAL ADDITIVES .............................. 77

WHEN TO CHANGE OIL ................................................................. 77

DISPOSING OF WASTE OIL ...................................................... 78

HOW TO REPLACE THE LUBE OIL FILTERS ................................ 78

REPLACE SPIN-ON TYPE OIL FILTER ...................................... 78

HOW TO SELECT FUEL OIL .......................................................... 80

QUALITY ..................................................................................... 80

FUEL CONTAMINATION ............................................................. 80

PROHIBITED ADDITIVES ........................................................... 81

USED LUBRICATING OIL ....................................................... 81

GASOLINE ............................................................................. 81

HOW TO REPLACE THE FUEL FILTERS ....................................... 81

REPLACE SPIN-ON PRIMARY OR SECONDARY ELEMENTS 82

vi All information subject to change without notice.

SERIES 60 ON-HIGHWAY ENGINE OPERATOR'S GUIDE

REPLACE FUEL/WATER SEPARATOR ELEMENT .................... 84

REPLACE FUEL PRO ELEMENT ............................................... 85

ENGINE OUT OF FUEL — HOW TO RESTART ............................. 87

ENGINES WITH SPIN-ON FILTERS ........................................... 87

ENGINES WITH FUEL PRO FILTERS ........................................ 88

HOW TO SELECT COOLANT ......................................................... 89

DEFINITIONS .............................................................................. 89

APPROVED COOLANTS ............................................................ 90

EG & WATER OR PG & WATER PLUS SCA INHIBITOR ....... 91

MIXING EG OR PG ANTIFREEZE AND WATER ................... 91

RECYCLED ANTIFREEZE .................................................... 94

EG/WATER+OATINHIBITORORPG/WATER+OAT

INHIBITOR .............................................................................. 94

WATER ONLY + SCA OR WATER ONLY + OAT INHIBITOR 95

WATER REQUIREMENTS ..................................................... 96

COOLANTS NOT RECOMMENDED .......................................... 96

ALL ANTIFREEZES AND COOLANTS CONTAINING

PHOSPHATE ........................................................................... 96

AUTOMOTIVE TYPE COOLANTS .......................................... 96

METHYL ALCOHOL-BASED ANTIFREEZE ........................... 96

GLYCOL-BASED COOLANTS FORMULATED FOR HVAC ... 97

ADDITIVES NOT RECOMMENDED ........................................... 97

SOLUBLE OIL ADDITIVES ..................................................... 97

CHROMATE ADDITIVES ........................................................ 97

COOLANT INHIBITOR TEST INTERVALS ................................. 97

SUPPLEMENTAL COOLANT ADDITIVES FOR FULLY

FORMULATED COOLANT ..................................................... 98

MAINTENANCE INTERVALS .................................................. 98

SCA TEST PROCEDURES ......................................................... 100

NEED RELEASE COOLANT FILTERS (NON-OAT SYSTEMS) . 101

DROPOUT ................................................................................... 102

EXTENDER INHIBITOR ADDITIVE FOR “OAT” COOLANT ....... 102

OAT COOLANT DRAIN INTERVAL ........................................ 103

CHRONIC COOLANT SYSTEM PROBLEMS ............................. 103

COOLING SYSTEM MAINTENANCE PRODUCTS .................... 103

POWER COOL SCAS ............................................................. 103

POWER COOL COOLANT FILTER ELEMENTS .................... 103

POWER COOL CLEANERS ................................................... 103

All information subject to change without notice. vii

TABLEOFCONTENTS

SUMMARY OF COOLANT RECOMMENDATIONS .................... 104

COOLANT LIFE OF GLYCOL COOLANT ............................... 105

COOLANT LIFE OF OAT COOLANT ...................................... 105

COOLANT LIFE OF OTHER COOLANTS .............................. 105

HOW TO DRAIN AND FLUSH THE COOLING SYSTEM ............... 106

HOSES ........................................................................................ 107

WHEN TO SERVICE THE DRY TYPE AIR CLEANER ................... 107

BASIC TROUBLESHOOTING ............................................................. 108

ENGINE STORAGE ............................................................................. 113

PREPARING ENGINE FOR STORAGE .......................................... 113

TEMPORARY STORAGE (30 DAYS OR LESS) ......................... 113

EXTENDED STORAGE (MORE THAN 30 DAYS) ...................... 114

RESTORING AN ENGINE AFTER EXTENDED STORAGE ....... 117

SERIES 60 SERVICE PUBLICATIONS ............................................... 119

CUSTOMER ASSISTANCE ................................................................. 120

ROAD SERVICE IN THE U.S. OR CANADA ................................... 123

WORKING WITH DDC SERVICE OUTLETS .................................. 123

LIMITED WARRANTY ON HIGHWAY VEHICLE ENGINES ............... 126

TERMS OF COVERAGE ................................................................. 126

USES ........................................................................................... 126

DEFECTS .................................................................................... 126

REPAIRS ..................................................................................... 126

WARRANTY PERIOD .................................................................. 126

LIKE REPLACEMENT ENGINE .................................................. 126

SERVICE SUPPLIES .................................................................. 127

ENGINE REMOVAL AND REINSTALLATION ............................. 127

THIS WARRANTY DOES NOT COVER: ......................................... 127

REPAIRS DUE TO ACCIDENTS, MISUSE, STORAGE DAMAGE,

NEGLIGENCE OR CERTAIN MODIFICATIONS ......................... 127

BRAKING DEVICES .................................................................... 128

FUEL INJECTORS AFTER 200,000 MILES/320,000

KILOMETERS .............................................................................. 128

MAINTENANCE ........................................................................... 128

INCIDENTAL OR CONSEQUENTIAL DAMAGE ......................... 128

OTHER LIMITATIONS ................................................................. 128

viii All information subject to change without notice.

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