Detroit Diesel EPA07 SERIES 60 ENGINE OPERATOR’S Manual – PDF DOWNLOAD

Description

Detroit Diesel EPA07 SERIES 60 ENGINE OPERATOR’S Manual – PDF DOWNLOAD

DESCRIPTION:

Detroit Diesel EPA07 SERIES 60 ENGINE OPERATOR’S Manual – PDF DOWNLOAD

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.

TABLE OF CONTENTS:

Detroit Diesel EPA07 SERIES 60 ENGINE OPERATOR’S Manual – PDF DOWNLOAD

INTRODUCTION ………………………………………………………………………. 1
NON-GENUINE AND REBUILT COMPONENT QUALITY ALERT .. 1
PERSONNEL REQUIREMENTS …………………………………………….. 2
ENGINE CONVERSIONS AND MODIFICATIONS …………………….. 2
CAUTION SUMMARY ……………………………………………………………….. 3
ENGINE OPERATION …………………………………………………………… 3
PREVENTIVE MAINTENANCE ………………………………………………. 5
ELECTRICAL SYSTEM …………………………………………………………. 8
COOLING SYSTEM ………………………………………………………………. 8
AIR INTAKE SYSTEM ……………………………………………………………. 9
FUEL SYSTEM …………………………………………………………………….. 9
COMPRESSED AIR ………………………………………………………………. 10
STARTING AIDS …………………………………………………………………… 11
LUBRICATING OIL AND FILTERS ………………………………………….. 12
AFTERTREATMENT SYSTEM ……………………………………………….. 12
ENGINE IDENTIFICATION ………………………………………………………… 14
ENGINE COMPONENTS ……………………………………………………….. 14
ENGINE MODEL AND SERIAL NUMBER DESIGINATON …………. 16
CERTIFICATION LABEL ………………………………………………………… 17
OPERATING INSTRUCTIONS FOR STARTING THE ENGINE ………. 18
FIRST TIME START PREPARATION ………………………………………. 18
SYSTEM CHECKS ……………………………………………………………….. 18
COOLING SYSTEM CHECKS ……………………………………………. 18
LUBRICATION SYSTEM CHECKS ……………………………………… 19
CHECKING THE OIL LEVEL ………………………………………….. 19
EXTENDED STORAGE …………………………………………………. 20
FUEL SYSTEM CHECKS …………………………………………………… 20
ADDING FUEL ……………………………………………………………… 21
PRIMING THE FUEL SYSTEM ……………………………………….. 21
OTHER CHECKS ……………………………………………………………… 22
STARTING THE ENGINE FOR THE FIRST TIME …………………. 22
ELECTRIC STARTER ……………………………………………………. 24
RUNNING THE ENGINE ……………………………………………………….. 24
OIL PRESSURE ……………………………………………………………….. 24
WARM-UP ……………………………………………………………………….. 25
INSPECTION ……………………………………………………………………. 25
TRANSMISSION …………………………………………………………… 25
FLUID LEAKS ………………………………………………………………. 25
CRANKCASE ……………………………………………………………….. 25
TURBOCHARGER ………………………………………………………… 25
AVOID UNNECESSARY IDLING …………………………………………. 25
STOPPING THE ENGINE ………………………………………………………. 26
EMERGENCY JUMP STARTING ……………………………………………. 26
ROUTINE ENGINE START …………………………………………………….. 27
STARTING THE ENGINE-ROUTINE ……………………………………. 27
CHECKING THE COOLANT LEVEL (COLD CHECK) ……………. 28
CHECKING THE COOLANT LEVEL (HOT CHECK) ……………… 29
MONITORING ENGINE OPERATION ……………………………………… 29
BATTERY CHARGE ………………………………………………………….. 29
OIL PRESSURE ……………………………………………………………….. 30
EXCESSIVE IDLING …………………………………………………………. 30
CHANGING THE IDLE SPEED ………………………………………………. 30
SHUTTING DOWN THE ENGINE …………………………………………… 30
SHUTTING DOWN AFTER HIGH LOAD OPERATION …………… 31
EMERGENCY RUNNING MODE ……………………………………………. 31
STOP ENGINE OVERRIDE OPTION ………………………………………. 31
COLD WEATHER OPERATION ……………………………………………… 32
WINTER FRONTS …………………………………………………………….. 32
DDEC VI SYSTEM ……………………………………………………………………. 33
MOTOR CONTROL MODULE ………………………………………………… 33
COMMON POWERTRAIN CONTROLLER ………………………………. 34
DDEC FEATURES ………………………………………………………………… 35
CRUISE CONTROL …………………………………………………………… 35
DATA RECORDING CAPABILITY ……………………………………….. 37
ENGINE BRAKES …………………………………………………………….. 37
ENGINE PROTECTION …………………………………………………….. 38
CALIFORNIA ENGINE IDLE LIMITING ………………………………… 38
IDLE SHUTDOWN TIMER …………………………………………………. 39
DDEC VI OPERATION …………………………………………………………… 39
STOP ENGINE OVERRIDE SWITCH ………………………………….. 40
iv All information subject to change without notice.
DDC-SVC-MAN-0006 Copyright © 2009 DETROIT DIESEL CORPORATION
EPA07 SERIES 60 ENGINE OPERATOR’S MANUAL
IMMEDIATE SPEED REDUCTION ……………………………………… 41
RED STOP LAMP ……………………………………………………………… 41
DIAGNOSTIC TOOL ………………………………………………………….. 41
FLASHING MALFUNCTION CODES ……………………………….. 41
ACTIVE CODES ……………………………………………………………. 43
INACTIVE CODES ………………………………………………………… 43
DDEC VI ENGINE DRIVING TIPS ………………………………………………. 44
ACCELERATING THE VEHICLE …………………………………………….. 44
CRUISE CONTROL ………………………………………………………………. 44
ENGINE BRAKES AND CRUISE CONTROL ……………………………. 46
SHIFTING ……………………………………………………………………………. 46
IDLING ………………………………………………………………………………… 47
ENGINE BRAKE SYSTEM ………………………………………………………… 48
DRIVER CONTROL SWITCHES …………………………………………….. 48
LOW/HIGH SWITCH …………………………………………………………. 48
LOW/MED/HIGH SWITCH …………………………………………………. 48
CLUTCH PEDAL AND THROTTLE POSITION CONTROLS ………. 48
ENGINE BRAKE OPERATION ……………………………………………….. 48
ANTI-LOCK BRAKING SYSTEMS …………………………………………… 49
DRIVING ON FLAT, DRY PAVEMENT ……………………………………… 50
DESCENDING A LONG, STEEP GRADE ………………………………… 50
DRIVING ON WET OR SLIPPERY PAVEMENT ………………………… 52
ENGINE SYSTEMS ………………………………………………………………….. 53
FUEL SYSTEM …………………………………………………………………….. 53
LUBRICATION SYSTEM ……………………………………………………….. 53
AIR SYSTEM ……………………………………………………………………….. 53
COOLING SYSTEM ………………………………………………………………. 53
ELECTRICAL SYSTEM …………………………………………………………. 53
EXHAUST SYSTEM ……………………………………………………………… 53
EXHAUST GAS RECIRCULATION SYSTEM ……………………………. 53
AFTERTREATMENT SYSTEM …………………………………………………… 54
OPERATING REQUIREMENTS ……………………………………………… 55
MAINTENANCE ……………………………………………………………………. 55
PARKED REGENERATION PROCEDURE ………………………………. 56
HAZARDOUS APPLICATIONS …………………………………………… 57
DPF STATIONARY REGEN ONLY = 0-DISABLED ……………. 58
All information subject to change without notice. v
DDC-SVC-MAN-0006 Copyright © 2009 DETROIT DIESEL CORPORATION
TABLE OF CONTENTS
DPF STATIONARY REGEN ONLY = 1-ENABLED …………….. 58
SERVICE RECORD ………………………………………………………………. 58
DRIVER ACTIONS ……………………………………………………………………. 59
INSTRUMENT PANEL LAMPS ………………………………………………….. 61
MAINTENANCE ……………………………………………………………………….. 63
SCHEDULED INTERVALS …………………………………………………….. 63
PREVENTIVE MAINTENANCE INTERVALS ……………………………. 73
ITEM 1 – LUBRICATING OIL ……………………………………………… 73
ITEM 2 – FUEL AND FUEL TANK ……………………………………….. 75
ITEM 3 – FUEL LINES, FLEXIBLE HOSES ………………………….. 76
LEAKS …………………………………………………………………………. 76
HOSES AND FITTINGS …………………………………………………. 76
HOSE SERVICE LIFE ……………………………………………………. 76
ITEM 4 – COOLING SYSTEM …………………………………………….. 77
COOLANT LEVEL …………………………………………………………. 77
COOLANT INHIBITORS …………………………………………………. 77
COOLANT DRAIN INTERVAL …………………………………………. 77
ITEM 5 – TURBOCHARGER, AIR-TO-AIR CHARGE COOLER . 79
WASTEGATED TURBOCHARGERS ……………………………….. 79
ITEM 6 – BATTERY …………………………………………………………… 79
ITEM 7 – AFTERTREATMENT SYSTEM ……………………………… 80
ITEM 8 – DRIVE BELTS …………………………………………………….. 80
V-BELTS ………………………………………………………………………. 81
2-GROOVE POWERBAND …………………………………………….. 82
12–RIB POLY-V BELT ……………………………………………………. 82
BELT REPLACEMENT …………………………………………………… 82
ITEM 9 – AIR COMPRESSOR ……………………………………………. 83
ITEM 10 – AIR CLEANER ………………………………………………….. 83
AIR CLEANER REPLACEMENT ……………………………………… 83
ITEM 11 – LUBRICATING OIL FILTERS ………………………………. 83
ITEM 12 – FUEL FILTERS …………………………………………………. 84
FUEL PRO® 382 FILTERS …………………………………………….. 84
SPIN-ON FILTERS ………………………………………………………… 85
ITEM 13 – WATER PUMP AND COOLANT INHIBITOR
ELEMENT ………………………………………………………………………… 85
WATER PUMP DRAIN HOLE …………………………………………. 85
COOLANT INHIBITOR ELEMENT …………………………………… 85
ITEM 14 – CRANKING MOTOR ………………………………………….. 86
ITEM 15 – AIR SYSTEM ……………………………………………………. 86
ITEM 16 – EXHAUST SYSTEM ………………………………………….. 86
ITEM 17 – ENGINE (STEAM CLEAN) ………………………………….. 86
ITEM 18 – RADIATOR ……………………………………………………….. 86
ITEM 19 – OIL PRESSURE ………………………………………………… 87
ITEM 20 – BATTERY-CHARGING ALTERNATOR …………………. 87
BOSCH® T1 ALTERNATOR SERVICE REQUIREMENTS ….. 88
GENERAL SERVICE REQUIREMENTS – BOSCH® AND
DELCO REMY® ALTERNATORS ……………………………………. 88
ITEM 21 – ENGINE AND TRANSMISSION MOUNTS ……………. 88
ITEM 22 – CRANKCASE PRESSURE …………………………………. 88
ITEM 23 – FAN HUB ………………………………………………………….. 88
ITEM 24 – THERMOSTATS AND SEALS …………………………….. 88
ITEM 25 – CRANKCASE BREATHER …………………………………. 89
ITEM 26 – ENGINE TUNE-UP ……………………………………………. 89
ITEM 27 – VIBRATION DAMPER ………………………………………… 90
HOW-TO SECTION …………………………………………………………………… 91
HOW TO SELECT LUBRICATING OIL …………………………………….. 91
LUBRICANT REQUIREMENTS ………………………………………….. 91
COLD WEATHER STARTING …………………………………………….. 91
SYNTHETIC OILS …………………………………………………………….. 92
THE USE OF SUPPLEMENTAL ADDITIVES ………………………… 92
WHEN TO CHANGE OIL ……………………………………………………….. 92
DISPOSING OF WASTE OIL ……………………………………………… 93
HOW TO REPLACE THE LUBE OIL FILTERS ………………………….. 94
REPLACE SPIN-ON TYPE OIL FILTER ……………………………….. 94
HOW TO SELECT DIESEL FUEL …………………………………………… 95
QUALITY …………………………………………………………………………. 96
FUEL CONTAMINATION ……………………………………………………. 96
BIODIESEL ………………………………………………………………….. 96
PROHIBITED ADDITIVES ………………………………………………….. 97
USED LUBRICATING OIL ………………………………………………. 97
FUEL ADDITIVES WITH SULFUR OR SULFATED ASH …….. 97
GASOLINE …………………………………………………………………… 97
HOW TO REPLACE THE FUEL FILTERS ………………………………… 98
REPLACE SPIN-ON TYPE PRIMARY OR SECONDARY FUEL
FILTER ELEMENTS ………………………………………………………….. 98
REPLACE FUEL/WATER SEPARATOR ELEMENT ……………….. 100
REPLACE FUEL PRO® 382/382E FUEL FILTER ELEMENT ….. 100
ENGINE OUT OF FUEL — HOW TO RESTART ……………………….. 103
ENGINES WITH SPIN-ON FILTERS ……………………………………. 103
ENGINES WITH FUEL PRO FILTERS …………………………………. 103
HOW TO CLEAN THE ENGINE ……………………………………………… 104
HIGH-PRESSURE CLEANING EQUIPMENT ……………………….. 104
HOW TO CLEAN THE COOLING SYSTEM ……………………………… 105
DEGREASING ………………………………………………………………….. 105
HOW TO SELECT COOLANT ………………………………………………… 106
DEFINITIONS …………………………………………………………………… 106
APPROVED COOLANTS …………………………………………………… 107
EG & WATER PLUS SCA INHIBITOR OR P G & WATER
PLUS SCA INHIBITOR …………………………………………………… 108
MIXING EG OR PG ANTIFREEZE AND WATER ………………. 109
RECYCLED ANTIFREEZE ……………………………………………. 109
EG/WATER + OAT INHIBITOR OR PG/WATER + OAT
INHIBITOR …………………………………………………………………… 110
WATER ONLY + SCA OR WATER ONLY + OAT INHIBITOR 110
WATER REQUIREMENTS …………………………………………….. 111
COOLANTS NOT RECOMMENDED …………………………………… 112
ALL ANTIFREEZES AND COOLANTS CONTAINING
PHOSPHATE ………………………………………………………………… 112
AUTOMOTIVE TYPE COOLANTS …………………………………… 112
METHYL ALCOHOL-BASED ANTIFREEZE ……………………… 112
GLYCOL-BASED COOLANTS FORMULATED FOR HVAC … 112
ADDITIVES NOT RECOMMENDED ……………………………………. 112
SOLUBLE OIL ADDITIVES …………………………………………….. 112
CHROMATE ADDITIVES ……………………………………………….. 112
COOLANT INHIBITOR TEST INTERVALS …………………………… 113
SUPPLEMENTAL COOLANT ADDITIVES FOR FULLY
FORMULATED COOLANT …………………………………………….. 113
MAINTENANCE INTERVALS ………………………………………….. 114
SCA TEST PROCEDURES ………………………………………………… 115
COOLANT FILTERS (NON-OAT SYSTEMS) ………………………… 116
DROPOUT ……………………………………………………………………….. 117
COOLANT EXTENDER INHIBITOR ADDITIVE FOR “OAT”
COOLANT ……………………………………………………………………….. 117
OAT COOLANT DRAIN INTERVAL …………………………………. 118
CHRONIC COOLANT SYSTEM PROBLEMS ……………………….. 118
DETROIT DIESEL COOLING SYSTEM MAINTENANCE
PRODUCTS ……………………………………………………………………… 118
POWER COOL SCAS ……………………………………………………. 118
POWER COOL COOLANT FILTER ELEMENTS ……………….. 118
POWER COOL CLEANERS …………………………………………… 119
SUMMARY OF COOLANT RECOMMENDATIONS ……………….. 119
COOLANT LIFE OF GLYCOL COOLANT …………………………. 120
COOLANT LIFE OF OAT COOLANT ……………………………….. 120
COOLANT LIFE OF OTHER COOLANTS ………………………… 120
HOW TO DRAIN AND FLUSH THE COOLING SYSTEM …………… 121
HOSES ……………………………………………………………………………. 122
WHEN TO SERVICE THE DRY TYPE AIR CLEANER ………………. 122
TROUBLESHOOTING ………………………………………………………………. 123
ABNORMAL COOLANT TEMPERATURE ………………………………… 123
HARD STARTING …………………………………………………………………. 124
AFTERTREATMENT SYSTEM ……………………………………………….. 125
ABNORMAL ENGINE OPERATION ………………………………………… 126
ABNORMAL OPERATING CONDITIONS ………………………………… 127
ENGINE STORAGE ………………………………………………………………….. 128
PREPARING ENGINE FOR STORAGE …………………………………… 128
TEMPORARY STORAGE (30 DAYS OR LESS) ……………………. 128
EXTENDED STORAGE (MORE THAN 30 DAYS) …………………. 129
PROCEDURE FOR RESTORING TO SERVICE AN ENGINE
THAT HAS BEEN IN EXTENDED STORAGE ……………………….. 132
CUSTOMER ASSISTANCE ……………………………………………………….. 134
ROAD SERVICE IN THE U.S. OR CANADA …………………………….. 136
WORKING WITH DETROIT DIESEL SERVICE OUTLETS ………… 136
STEP ONE ……………………………………………………………………….. 137
STEP TWO ………………………………………………………………………. 137
STEP THREE …………………………………………………………………… 137
SPECIFICATIONS …………………………………………………………………….. 138
FUEL AND LUBRICATING OIL REQUIREMENTS …………………….. 138
OIL PAN CAPACITY ………………………………………………………….. 138
POWER COOL ENGINE PRODUCTS …………………………………….. 138
POWER COOL FULLY FORMULATED IEG 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
COOLING SYSTEM CLEANERS ………………………………………… 141
COOLANT TESTING AND ANALYSIS PRODUCTS ………………. 141

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DETROIT DIESEL EPA07 SERIES 60 ENGINE OPERATOR’S MANUAL – PDF DOWNLOAD:

PLEASE NOTE:

• This is not a physical manual but a digital manual – meaning no physical copy will be couriered to you. The manual can be yours in the next 2 mins as once you make the payment, you will be directed to the download page IMMEDIATELY.
• This is the same manual used by the dealers inorder to diagnose your vehicle of its faults.
• Require some other service manual or have any queries: please WRITE to us at [email protected]

S.V