Detroit Diesel 60 User manual

DDC-SVC-MAN-0039
Specifications are subject to change without notice. Detroit Diesel Corporation
is registered to ISO 9001:2001. Copyright © Detroit Diesel Corporation.
All rights reserved. Detroit Diesel Corporation is a Daimler company.
Printed in U.S.A.
13400 Outer Drive, West, Detroit, Michigan 48239-4001
Telephone: [phone]
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
DDC-SVC-MAN-0039 Copyright © 2009 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
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.
DDC-SVC-MAN-0039 Copyright © 2009 DETROIT DIESEL CORPORATION

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
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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
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DDC-SVC-MAN-0039 Copyright © 2009 DETROIT DIESEL CORPORATION

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
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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.
DDC-SVC-MAN-0039 Copyright © 2009 DETROIT DIESEL CORPORATION

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
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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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SERIES 60 ON-HIGHWAY ENGINE OPERATOR'S GUIDE
LIMITED WARRANTY ON URBAN BUS, MOTOR COACH OR
MOTOR HOME ENGINES ................................................................... 130
TERMS OF COVERAGE ................................................................. 130
USES ........................................................................................... 130
DEFECTS .................................................................................... 130
REPAIRS ..................................................................................... 130
WARRANTY PERIOD .................................................................. 130
SERVICE SUPPLIES .................................................................. 130
LIKE REPLACEMENT ENGINE .................................................. 131
ENGINE REMOVAL AND REINSTALLATION ............................. 131
THIS WARRANTY DOES NOT COVER: ......................................... 131
REPAIRS DUE TO ACCIDENTS, MISUSE, ALTERATION,
STORAGE DAMAGE, NEGLIGENCE OR CERTAIN
MODIFICATIONS ........................................................................ 131
BRAKING DEVICES .................................................................... 132
FUEL INJECTORS AFTER 200,000 MILES/320,000
KILOMETERS .............................................................................. 132
MAINTENANCE ........................................................................... 132
INCIDENTAL OR CONSEQUENTIAL DAMAGE ......................... 132
OTHER LIMITATIONS ................................................................. 132
LIMITED WARRANTY ON FIRE TRUCK OR CRASH RESCUE
VEHICLE ENGINES ............................................................................. 134
TERMS OF COVERAGE ................................................................. 134
USES ........................................................................................... 134
DEFECTS .................................................................................... 134
REPAIRS ..................................................................................... 134
WARRANTY PERIOD .................................................................. 134
LIKE REPLACEMENT ENGINE .................................................. 134
SERVICE SUPPLIES .................................................................. 134
ENGINE REMOVAL AND REINSTALLATION ............................. 135
THIS WARRANTY DOES NOT COVER: ......................................... 135
REPAIRS DUE TO ACCIDENTS, MISUSE, ALTERATION,
STORAGE DAMAGE, NEGLIGENCE OR CERTAIN
MODIFICATIONS ........................................................................ 135
MAINTENANCE ........................................................................... 135
INCIDENTAL OR CONSEQUENTIAL DAMAGE ......................... 136
OTHER LIMITATIONS ................................................................. 136
All information subject to change without notice. ix
DDC-SVC-MAN-0039 Copyright © 2009 DETROIT DIESEL CORPORATION

TABLEOFCONTENTS
SPECIFICATIONS ................................................................................ 137
FUEL AND LUBRICATING OIL REQUIREMENTS .......................... 137
OIL PAN CAPACITY .................................................................... 137
OIL PAN CAPACITY ................................................................ 137
TOTAL OIL CAPACITY OF THE ENGINE ............................... 137
POWER COOL ENGINE PRODUCTS ............................................ 138
FULLY FORMULATED IEG COOLANT ....................................... 138
LATIN AMERICAN COOLANT .................................................... 138
2000 SUPPLEMENTAL COOLANT ADDITIVE ........................... 139
3000 SUPPLEMENTAL ADDITIVE FILTERS .............................. 139
NEED RELEASE COOLANT FILTERS ....................................... 140
PLUS EXTENDED LIFE OAT COOLANT .................................... 140
PLUS EXTENDER FOR POWER COOL PLUS OAT COOLANT 140
PLUS 6000 OAT INHIBITOR FOR WATER-ONLY SYSTEMS .... 141
COOLING SYSTEM CLEANERS ................................................ 141
COOLANT TESTING AND ANALYSIS PRODUCTS ................... 142
xAll information subject to change without notice.
DDC-SVC-MAN-0039 Copyright © 2009 DETROIT DIESEL CORPORATION

SERIES 60 ON-HIGHWAY 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
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 435,000 miles (700,000
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.
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 benefitof
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.
All information subject to change without notice. 1
DDC-SVC-MAN-0039 Copyright © 2009 DETROIT DIESEL CORPORATION

INTRODUCTION
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.
DDC-SVC-MAN-0039 Copyright © 2009 DETROIT DIESEL CORPORATION

SERIES 60 ON-HIGHWAY 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. 3
DDC-SVC-MAN-0039 Copyright © 2009 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 an
empty trailer.
□Ifthetractordrivewheels
begin to lock or there is
fishtail motion after the
EngineBrakeisactivated,
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 trafficthat
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.
DDC-SVC-MAN-0039 Copyright © 2009 DETROIT DIESEL CORPORATION

SERIES 60 ON-HIGHWAY 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 when using
caustic cleaning agents, follow
the chemical manufacturers
usage, disposal, and safety
instructions.
PERSONAL INJURY
To avoid injury from hot surfaces,
wear protective gloves, or allow
engine to cool before removing
any component.
PERSONAL INJURY
To avoid injury, use care when
working around moving belts and
rotating parts on the engine.
All information subject to change without notice. 5
DDC-SVC-MAN-0039 Copyright © 2009 DETROIT DIESEL CORPORATION

CAUTION SUMMARY
FIRE
To avoid injury from combustion
of heated lubricating-oil vapors,
stop the engine immediately if an
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 open flames when
workingonanoperatingengine.
FIRE
To avoid injury from fire from a
buildup of volatile vapors, keep
the engine area well ventilated
during operation.
PERSONAL INJURY
To avoid injury from rotating belts
and fans, do not remove and
discard safety guards.
6All information subject to change without notice.
DDC-SVC-MAN-0039 Copyright © 2009 DETROIT DIESEL CORPORATION

SERIES 60 ON-HIGHWAY ENGINE OPERATOR'S GUIDE
PERSONAL INJURY
To avoid injury from slipping and
falling, immediately clean up any
spilled liquids.
Electrical System
Observe the following cautions when
jump starting an engine, charging
a battery, or working with the
vehicle/application electrical system.
ELECTRICAL SHOCK
To avoid injury from electrical
shock, do not touch battery
terminals, alternator terminals, or
wiring cables while the engine is
operating.
Battery Explosion and Acid Burn
To avoid injury from battery
explosion or contact with battery
acid, work in a well ventilated
area, wear protective clothing,
and avoid sparks or flames near
the battery. If you come in contact
with battery acid:
□Flush your skin with water.
□Applybakingsodaorlimeto
help neutralize the acid.
□Flush your eyes with water.
□Get medical attention
immediately.
PERSONAL INJURY
To avoid injury from accidental
engine startup while servicing
the engine, disconnect/disable
the starting system.
All information subject to change without notice. 7
DDC-SVC-MAN-0039 Copyright © 2009 DETROIT DIESEL CORPORATION

CAUTION SUMMARY
Cooling System
Observe the following cautions when
servicing the cooling system.
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.
PERSONAL INJURY
To avoid injury from slipping and
falling, immediately clean up any
spilled liquids.
Air Intake System
Observe the following cautions when
working on the air intake system.
PERSONAL INJURY
To avoid injury from hot surfaces,
wear protective gloves, or allow
engine to cool before removing
any component.
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.
8All information subject to change without notice.
DDC-SVC-MAN-0039 Copyright © 2009 DETROIT DIESEL CORPORATION