MAN EPA07 Series 60 Engine Operator's Manual (EN)

EPA07 SERIES 60 ENGINE OPERATOR'S MANUAL To the Operator Whenever possible, it will benefit you to rely on an authorized 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. 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. 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. 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. The Series 60 engine is built in accordance with sound technological principles and based on state-of-the-art technology. Despite this, the engine may constitute a risk of damage to property or injury to persons if it is not used for its intended purpose.

The engine should not be modified or converted in an incorrect manner or the safety instructions included in this manual disregarded. All information subject to change without notice. i DDC-SVC-MAN-0006 Copyright © 2009 DETROIT DIESEL CORPORATION

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NOTICE: Trademark Information 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. 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. Nexiq™is a trademark of Nexiq Technologies, Inc. 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.

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. ii All information subject to change without notice. DDC-SVC-MAN-0006 Copyright © 2009 DETROIT DIESEL CORPORATION

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EPA07 SERIES 60 ENGINE OPERATOR'S MANUAL TABLE OF CONTENTS 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 All information subject to change without notice. iii DDC-SVC-MAN-0006 Copyright © 2009 DETROIT DIESEL CORPORATION

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TABLE OF CONTENTS 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

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