Detroit Diesel 60 Manual

SERIES 60 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,
stationary, construction/industrial,
agricultural, generator set 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. (Rev. 01/04) i
6SE484 0401 Copyright © 2004 DETROIT DIESEL CORPORATION

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
installedoptionorasanafter-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
withtheengineinstallationat
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®,andPower
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
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. (Rev. 01/04)
6SE484 0401 Copyright © 2004 DETROIT DIESEL CORPORATION

SERIES 60 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 .............................................................................. 10
COMPRESSED AIR ......................................................................... 11
LUBRICATING OIL AND FILTERS ................................................... 11
ENGINE MODEL AND SERIAL 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
TRANSMISSION ..................................................................... 20
FLUID LEAKS ......................................................................... 20
All information subject to change without notice. (Rev. 01/04) iii
6SE484 0401 Copyright © 2004 DETROIT DIESEL CORPORATION

TABLEOFCONTENTS
CRANKCASE .......................................................................... 21
TURBOCHARGER .................................................................. 21
AVOID UNNECESSARY IDLING ................................................. 21
STOPPING THE ENGINE ................................................................ 21
EMERGENCY JUMP STARTING .................................................... 22
DDEC V SYSTEM ................................................................................ 23
DDEC FEATURES ........................................................................... 23
ENGINE PROTECTION ............................................................... 24
IDLE SHUTDOWN TIMER ........................................................... 24
CRUISE CONTROL ..................................................................... 24
ENGINE BRAKES ....................................................................... 26
DATA RECORDING CAPABILITY ................................................ 27
DDEC V OPERATION ...................................................................... 27
STOP ENGINE OVERRIDE SWITCH .......................................... 28
IMMEDIATE SPEED REDUCTION .............................................. 28
RED STOP LAMP ........................................................................ 28
DIAGNOSTIC DATA READER ..................................................... 29
DDEC 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 GRADE ....................................... 42
DRIVING ON WET OR SLIPPERY PAVEMENT .............................. 44
ENGINE SYSTEMS ............................................................................. 45
FUEL SYSTEM ................................................................................ 45
iv All information subject to change without notice. (Rev. 01/04)
6SE484 0401 Copyright © 2004 DETROIT DIESEL CORPORATION

SERIES 60 ENGINE OPERATOR'S GUIDE
LUBRICATION SYSTEM .................................................................. 45
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 ................................... 62
ITEM 1 – LUBRICATING OIL ....................................................... 62
ITEM 2 – FUEL AND FUEL TANK ............................................... 64
ITEM 3 – FUEL LINES, FLEXIBLE HOSES ................................ 65
LEAKS ..................................................................................... 65
HOSES AND FITTINGS .......................................................... 65
HOSE SERVICE LIFE ............................................................. 65
ITEM 4 – COOLING SYSTEM ..................................................... 66
COOLANT LEVEL ................................................................... 66
COOLANT 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 PRO®382 FILTERS ...................................................... 74
SPIN-ON FILTERS .................................................................. 74
ITEM 13 – WATER PUMP AND COOLANT INHIBITOR
ELEMENT .................................................................................... 75
WATER PUMP DRAIN HOLE .................................................. 75
All information subject to change without notice. (Rev. 01/04) v
6SE484 0401 Copyright © 2004 DETROIT DIESEL CORPORATION

TABLEOFCONTENTS
COOLANT INHIBITOR ELEMENT .......................................... 75
ITEM 14 – CRANKING MOTOR .................................................. 75
ITEM 15 – AIR SYSTEM ............................................................. 76
ITEM 16 – EXHAUST SYSTEM ................................................... 76
ITEM 17 – ENGINE (STEAM CLEAN) ......................................... 76
ITEM 18 – RADIATOR ................................................................. 76
ITEM 19 – OIL PRESSURE ......................................................... 77
ITEM 20 – BATTERY-CHARGING ALTERNATOR ...................... 77
BOSCH®T1 ALTERNATOR SERVICE REQUIREMENTS ...... 78
GENERAL SERVICE REQUIREMENTS – BOSCH®AND
DELCO REMY®ALTERNATORS ............................................ 78
ITEM 21 – ENGINE AND TRANSMISSION MOUNTS ................ 78
ITEM 22 – CRANKCASE PRESSURE ........................................ 78
ITEM 23 – FAN HUB .................................................................... 78
ITEM 24 – THERMOSTATS AND SEALS .................................... 79
ITEM 25 – CRANKCASE BREATHER ......................................... 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 TYPE OIL FILTER ...................................... 84
HOW TO SELECT FUEL OIL ........................................................... 86
QUALITY ...................................................................................... 86
FUEL CONTAMINATION ............................................................. 86
PROHIBITED ADDITIVES ........................................................... 87
USED LUBRICATING OIL ....................................................... 87
GASOLINE ............................................................................. 87
HOW TO REPLACE THE FUEL FILTERS ....................................... 87
vi All information subject to change without notice. (Rev. 01/04)
6SE484 0401 Copyright © 2004 DETROIT DIESEL CORPORATION

SERIES 60 ENGINE OPERATOR'S GUIDE
REPLACE SPIN-ON PRIMARY OR SECONDARY ELEMENTS . 88
REPLACE FUEL/WATER SEPARATOR ELEMENT .................... 89
REPLACE FUEL PRO ELEMENT ............................................... 90
ENGINE OUT OF FUEL — HOW TO RESTART ............................. 93
ENGINES WITH SPIN-ON FILTERS ........................................... 93
ENGINES WITH FUEL PRO FILTERS ........................................ 93
HOW TO SELECT COOLANT ......................................................... 94
DEFINITIONS .............................................................................. 94
APPROVED COOLANTS ............................................................ 95
EG & WATER OR PG & WATER PLUS SCA INHIBITOR ....... 96
MIXING EG OR PG ANTIFREEZE AND WATER .................... 96
RECYCLED ANTIFREEZE .................................................... 98
EG/WATER+OATINHIBITORORPG/WATER+OAT
INHIBITOR .............................................................................. 98
WATERONLY+SCAORWATERONLY+OATINHIBITOR . 99
WATER REQUIREMENTS ..................................................... 100
COOLANTS NOT RECOMMENDED ........................................... 100
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 FILTERS (NON-OAT SYSTEMS) .. 105
DROPOUT ................................................................................... 106
EXTENDER INHIBITOR ADDITIVE FOR “OAT” COOLANT ....... 106
OAT COOLANT DRAIN INTERVAL ......................................... 107
CHRONIC COOLANT SYSTEM PROBLEMS ............................. 107
COOLING SYSTEM MAINTENANCE PRODUCTS .................... 107
POWER COOL SCAS ............................................................. 107
POWER COOL COOLANT FILTER ELEMENTS .................... 107
All information subject to change without notice. (Rev. 01/04) vii
6SE484 0401 Copyright © 2004 DETROIT DIESEL CORPORATION

TABLEOFCONTENTS
POWER COOL CLEANERS ................................................... 107
SUMMARY OF COOLANT RECOMMENDATIONS .................... 108
HOW TO DRAIN AND FLUSH THE COOLING SYSTEM ............... 110
HOSES ........................................................................................ 111
WHEN TO SERVICE THE DRY TYPE AIR CLEANER .................... 111
BASIC TROUBLESHOOTING ............................................................. 112
ENGINE STORAGE ............................................................................. 117
PREPARING ENGINE FOR STORAGE ........................................... 117
TEMPORARY STORAGE (30 DAYS OR LESS) .......................... 117
EXTENDED STORAGE (MORE THAN 30 DAYS) ....................... 118
RESTORING AN ENGINE AFTER EXTENDED STORAGE ....... 121
SERIES 60 SERVICE PUBLICATIONS ............................................... 123
CUSTOMER ASSISTANCE ................................................................. 124
ROAD SERVICE IN THE U.S. OR CANADA ................................... 127
WORKING WITH 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 200,000 MILES/320,000
KILOMETERS .............................................................................. 131
MAINTENANCE ........................................................................... 131
INCIDENTAL OR CONSEQUENTIAL DAMAGE ......................... 131
OTHER LIMITATIONS .................................................................. 131
LIMITED WARRANTY ON URBAN BUS, MOTOR COACH OR
MOTOR HOME ENGINES ................................................................... 133
viii All information subject to change without notice. (Rev. 01/04)
6SE484 0401 Copyright © 2004 DETROIT DIESEL CORPORATION

SERIES 60 ENGINE OPERATOR'S GUIDE
TERMS OF COVERAGE ................................................................. 133
USES ........................................................................................... 133
DEFECTS .................................................................................... 133
REPAIRS ..................................................................................... 133
WARRANTY PERIOD .................................................................. 133
SERVICE SUPPLIES ................................................................... 133
LIKE REPLACEMENT ENGINE .................................................. 134
ENGINE REMOVAL AND REINSTALLATION .............................. 134
THIS WARRANTY DOES NOT COVER: ......................................... 135
REPAIRS DUE TO ACCIDENTS, MISUSE, ALTERATION,
STORAGE DAMAGE, NEGLIGENCE OR CERTAIN
MODIFICATIONS ......................................................................... 135
BRAKING DEVICES .................................................................... 135
FUEL INJECTORS AFTER 200,000 MILES/320,000
KILOMETERS .............................................................................. 135
MAINTENANCE ........................................................................... 135
INCIDENTAL OR CONSEQUENTIAL DAMAGE ......................... 135
OTHER LIMITATIONS .................................................................. 135
LIMITED WARRANTY 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 REMOVAL AND REINSTALLATION – AGRICULTURAL
MACHINERY AND STAND-BY PUMP APPLICATIONS .............. 139
NON-DDC SUPPLIED/MANUFACTURED COMPONENTS ....... 139
MAINTENANCE ........................................................................... 139
INCIDENTAL OR CONSEQUENTIAL DAMAGE ......................... 139
All information subject to change without notice. (Rev. 01/04) ix
6SE484 0401 Copyright © 2004 DETROIT DIESEL CORPORATION

TABLEOFCONTENTS
OTHER LIMITATIONS .................................................................. 140
LIMITED WARRANTY ON FIRE TRUCK OR CRASH RESCUE
VEHICLE ENGINES ............................................................................. 141
TERMS OF COVERAGE ................................................................. 141
USES ........................................................................................... 141
DEFECTS .................................................................................... 141
REPAIRS ..................................................................................... 141
WARRANTY PERIOD .................................................................. 141
LIKE REPLACEMENT ENGINE .................................................. 141
SERVICE SUPPLIES ................................................................... 141
ENGINE REMOVAL AND REINSTALLATION .............................. 142
THIS WARRANTY DOES NOT COVER: ......................................... 142
REPAIRS DUE TO ACCIDENTS, MISUSE, ALTERATION,
STORAGE DAMAGE, NEGLIGENCE OR CERTAIN
MODIFICATIONS ......................................................................... 142
MAINTENANCE ........................................................................... 142
INCIDENTAL 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 SUPPLIED/MANUFACTURED COMPONENTS ....... 145
MAINTENANCE ........................................................................... 145
INCIDENTAL OR CONSEQUENTIAL DAMAGE ......................... 146
OTHER LIMITATIONS .................................................................. 146
xAll information subject to change without notice. (Rev. 01/04)
6SE484 0401 Copyright © 2004 DETROIT DIESEL CORPORATION

SERIES 60 ENGINE OPERATOR'S GUIDE
LIMITED WARRANTY ON PRIME POWER GENERATOR SET
ENGINES ............................................................................................ 147
TERMS OF COVERAGE ................................................................. 147
USES ........................................................................................... 147
DEFECTS .................................................................................... 147
REPAIRS ..................................................................................... 147
WARRANTY PERIOD .................................................................. 147
LIKE REPLACEMENT ENGINE .................................................. 148
SERVICE SUPPLIES ................................................................... 148
MECHANIC'S TRAVEL EXPENSES ........................................... 148
THIS WARRANTY DOES NOT COVER: ......................................... 148
REPAIRS DUE TO ACCIDENTS, MISUSE, STORAGE DAMAGE,
NEGLIGENCE OR CERTAIN MODIFICATIONS ......................... 148
ENGINE REMOVAL AND REINSTALLATION .............................. 148
NON-DDC SUPPLIED/MANUFACTURED COMPONENTS ....... 149
MAINTENANCE ........................................................................... 149
INCIDENTAL 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 REINSTALLATION .............................. 151
NON-DDC SUPPLIED/MANUFACTURED COMPONENTS ....... 151
MAINTENANCE ........................................................................... 151
INCIDENTAL OR CONSEQUENTIAL DAMAGE ......................... 152
OTHER LIMITATIONS .................................................................. 152
SPECIFICATIONS ................................................................................ 153
All information subject to change without notice. (Rev. 01/04) xi
6SE484 0401 Copyright © 2004 DETROIT DIESEL CORPORATION

TABLEOFCONTENTS
FUEL AND LUBRICATING OIL REQUIREMENTS .......................... 153
OIL PAN CAPACITY ..................................................................... 153
OIL PAN CAPACITY ................................................................ 153
TOTAL OIL CAPACITY OF THE ENGINE ............................... 153
POWER COOL ENGINE PRODUCTS ............................................. 154
FULLY FORMULATED IEG COOLANT ....................................... 154
LATIN AMERICAN COOLANT ..................................................... 154
2000 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 © 2004 DETROIT DIESEL CORPORATION

SERIES 60 ENGINE OPERATOR'S GUIDE
INTRODUCTION
This guide is intended for use by the
operator of a Detroit Diesel Series
60®engine used in the following
applications:
On-Highway Vehicles
Fire Truck or Crash/Rescue
Vehicles
Construction/Industrial
Agricultural Machinery
Generator Drive Engines
Operators of Series 60 marine engines
should refer to the Detroit Diesel
Series 60 Marine Engine Operator's
Guide, 6SE559. Operators of Series
60 engines used in prime power or
stand-by generator set applications
should also refer to the Detroit
Diesel Generator Set Power Engine
Operator's Guide, 6SE513. Guides
are available from authorized Detroit
Diesel distributors.
Non-Genuine and Rebuilt
Component Quality Alert
In recent years, electronic engine
controls have been instrumental
in aiding engine manufacturers in
meeting the stringent emission
requirements of the U.S.
Environmental 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 to comply with applicable
emissions standards. The U.S. EPA
specifically defines an engine's
“useful emission life” — currently
established as 290,000 miles (464,000
kilometers) for on-highway engines.
Proper maintenance procedures, using
specific components engineered to
comply with emissions regulations,
may be performed by an authorized
Detroit Diesel distributor or dealer,
an independent outlet or the operator
or owner. The owner is responsible
for determining the suitability of
components to maintain emissions
compliance during the engine's useful
emission life.
All information subject to change without notice. (Rev. 01/04) 1
6SE484 0401 Copyright © 2004 DETROIT DIESEL CORPORATION

INTRODUCTION
Electronic controls and components
have significantly increased in
sophistication, but the fundamental
objective remains the same — precise
timing and delivery of fuel. The very
heart of the Detroit Diesel Electronic
Controls (DDEC®) is the electronic
unit injector (EUI). The proper
functioning of the EUI is absolutely
paramount if the benefits of electronic
controls are to be realized. Detroit
Diesel Corporation has built over
650,000 engines with electronic unit
injectors — more than anyone else in
the business.
Detroit Diesel cautions that the
indiscriminate rebuilding of precision
components, without the benefit of
specifications, specialized equipment,
and knowledge of the electronic
operating system, will jeopardize
performance or lead to more serious
problems, and can take the engine
outside 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. The use of inadequately
engineered, manufactured or tested
components in repair or rebuild of
the engine may be in violation of the
federal Clean Air Act and applicable
U.S. EPA or CARB regulations.
Furthermore, modern engines exhibit
operating parameters which require
the use of proper fluids, such as
fuel, coolant and lubricating oil, to
maintain long engine life. The use of
fluids that do not meet Detroit Diesel
Corporation specifications may result
in early wear out or engine failure.
2All information subject to change without notice. (Rev. 01/04)
6SE484 0401 Copyright © 2004 DETROIT DIESEL CORPORATION

SERIES 60 ENGINE OPERATOR'S GUIDE
CAUTION SUMMARY
The following cautions must be
observed by the operator of the
vehicle or equipment in which this
engine is installed and/or by those
performing basic engine preventive
maintenance. Failure to read and
heed these cautions and exercise
reasonable care for personal safety
and the safety of others when
operating the vehicle/equipment
or performing basic engine
preventive maintenance may result
in personal injury and engine
and/or vehicle/equipment damage.
Engine Operation
Observe the following cautions when
operating the engine.
PERSONAL INJURY
To avoid injury 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 in
an enclosed area, vent the
exhaust to the outside.
Do not modify or tamper
with the exhaust system or
emission control system.
PERSONAL INJURY
To avoid injury from engine
shutdown in an unsafe situation,
ensure the operator knows how
to override the stop engine
condition on a DDEC-equipped
unit.
All information subject to change without notice. (Rev. 01/04) 3
6SE484 0401 Copyright © 2004 DETROIT DIESEL CORPORATION

CAUTION SUMMARY
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
system) and you have had
prior experience driving
under these conditions.
When driving without a trailer
(bobtailing) or pulling and
empty trailer.
If the tractor drive wheels
begin to lock or there is
fishtail motion after the
Engine Brake is activated.
Deactivate the brake system
immediately, if this occurs.
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
performing preventative maintenance.
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.
4All information subject to change without notice. (Rev. 01/04)
6SE484 0401 Copyright © 2004 DETROIT DIESEL CORPORATION

SERIES 60 ENGINE OPERATOR'S GUIDE
PERSONAL INJURY
To avoid injury when working
on or near an operating engine,
wear protective clothing,
eye protection, and hearing
protection.
HOT OIL
To avoid injury from hot oil, do
not operate the engine with the
rocker cover(s) removed.
FIRE
To avoid injury from fire, contain
and eliminate leaks of flammable
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 before removing
any component.
All information subject to change without notice. (Rev. 01/04) 5
6SE484 0401 Copyright © 2004 DETROIT DIESEL CORPORATION

CAUTION SUMMARY
PERSONAL INJURY
To avoid injury, use care when
working around moving belts and
rotating parts on the engine.
FIRE
To avoid injury from combustion
of heated lubricating-oil vapors,
stoptheengineimmediatelyifan
oil leak is detected.
PERSONAL INJURY
To avoid injury from contact
with rotating parts when an
engine is operating with the air
inlet piping removed, install an
air inlet screen shield over the
turbocharger air inlet. The shield
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 openflames when
working on an operating engine.
FIRE
To avoid injury from fire from a
buildup of volatile vapors, keep
the engine area well ventilated
during operation.
6All information subject to change without notice. (Rev. 01/04)
6SE484 0401 Copyright © 2004 DETROIT DIESEL CORPORATION