Detroit Diesel Series 60 Engine Application & Installation Manual

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This manual discusses the proper application and installation of the Detroit Diesel Series 60 engine.

The following is a list of topics covered in the Application and Installation Manual:

TABLE OF CONTENTS
1 INTRODUCTION
2 SAFETY PRECAUTIONS
3 ENGINE AND ACCESSORY IDENTIFICATION
4 AIR INLET SYSTEM
4.1 AIR INLET SYSTEM DESCRIPTION
4.1.1 SERIES 60 ON-HIGHWAY ENGINES
4.2 INSTALLATION REQUIREMENTS
4.2.1 DRY PAPER ELEMENT AIR CLEANERS
LIGHT-DUTY AIR CLEANER
MEDIUM-DUTY USE AIR CLEANER
HEAVY-DUTY USE AIR CLEANER
EXTRA HEAVY-DUTY USE
FOAM TYPE AIR CLEANERS
OIL-BATH AIR CLEANERS
AUXILIARY PRECLEANERS
INLET SCREENS
RAIN CAPS AND INLET HOODS
WATER DRAINS
INLET SILENCERS
AIR CLEANER SELECTION
4.2.2 RESTRICTION INDICATOR
4.2.3 PIPEWORK
PIPEWORK MATERIAL SPECIFICATIONS
DIFFUSERS
4.2.4 HOSE CONNECTIONS
4.3 DESIGN GUIDELINES
4.3.1 MAXIMUM AIR INLET FLOW
4.3.2 AIR INLET SYSTEM RESTRICTION

4.3.3 INLET LOCATION
4.3.4 AIR-TO-AIR CHARGE AIR COOLER
RESTRICTION AND TEMPERATURE REQUIREMENTS
CLEANLINESS
LEAKAGE
SIZE
COOLING AIR FLOW RESTRICTION
MATERIAL
HEADER TANKS
LOCATION
FAN SYSTEMS
SHUTTERS
WINTERFRONTS
4.4 TESTING REQUIREMENTS
4.4.1 TESTING LOCATION
4.4.2 INLET SYSTEM RESTRICTION
4.4.3 AIR-TO-AIR SYSTEM EVALUATION TESTS
MAXIMUM TEMPERATURE RISE–AMBIENT TO INTAKE MANIFOLD
CHARGE AIR COOLER SYSTEM RESTRICTION
4.5 TEST
4.5.1 MOBILE AIR-TO-AIR
5 EXHAUST GAS RECIRCULATION SYSTEM
5.1 EGR SYSTEM DESCRIPTION
5.2 INSTALLATION REQUIREMENTS
5.3 DESIGN REQUIREMENTS
5.3.1 COOLING SYSTEM
5.3.2 AUXILIARY COOLERS
5.4 TESTING REQUIREMENTS
6 EXHAUST SYSTEM
6.1 EXHAUST SYSTEM DESCRIPTION
6.1.1 VARIABLE GEOMETRY TURBOCHARGER (VGT)
6.2 INSTALLATION REQUIREMENTS
6.2.1 BACK PRESSURE
6.2.2 NOISE
6.2.3 FLEXIBLE FITTINGS
6.2.4 MATERIAL SPECIFICATIONS FOR PIPEWORK
6.3 DESIGN REQUIREMENTS
6.3.1 TEMPERATURE DROP FROM TURBOCHARGER OUTLET TO AFTERTREATMENT DEVICE
6.3.2 DISTANCE FROM HYDROCARBON DOSER TO ATD INLET
6.3.3 OUTLET LOCATION
6.3.4 DRAINAGE
6.3.5 SYSTEM INSULATION
6.3.6 BENDING MOMENT CALCULATIONS
6.4 TESTING REQUIREMENTS
6.4.1 MEASUREMENT OF EXHAUST BACK PRESSURE
6.4.2 MEASUREMENT OF TEMPERATURE DROP FROM TURBOCHARGER TO ATD INLET
6.4.3 MEASUREMENT OF EXHAUST LEAKAGE BETWEEN TURBOCHARGER AND ATD INLET
7 AFTERTREATMENT SYSTEM
7.1 AFTERTREATMENT SYSTEM DESCRIPTION
7.2 SYSTEM DESCRIPTION / OPERATION
7.2.1 AFTERTREATMENT DEVICE
7.2.2 INTAKE THROTTLE
7.2.3 HYDROCARBON (HC) DOSER
7.3 AFTERTREATMENT DEVICE DESIGN FEATURES
7.3.1 FEET / HOOKS
7.3.2 LOCATING DEVICE
7.3.3 SENSOR BOX DISCUSSION
7.3.4 V-BAND CLAMPS
7.3.5 SENSOR AND HARNESS
7.4 AFTERTREATMENT DEVICE VARIATIONS
7.5 NOISE ATTENUATION
7.6 MASS OF THE AFTERTREATMENT DEVICE
7.7 MOUNTING REQUIREMENTS
7.7.1 MOUNTING ZONES
7.7.2 BENDING MOMENT FOR INLETS AND OUTLETS
7.7.3 DRAINAGE
8 COOLING SYSTEM — AIR-TO-AIR CHARGE COOLING
8.1 JACKET WATER COOLING SYSTEM
8.2 THERMOSTAT
8.2.1 VENTING
8.3 WATER PUMP
8.4 TYPES OF COOLING SYSTEMS
8.4.1 RAPID WARM-UP COOLING SYSTEM RECOMMENDED DESIGN
8.4.2 AUXILIARY AIR-COOLED COOLER CORES
8.4.3 COOLANT HEATERS
8.5 AIR-TO-AIR CHARGE COOLING
8.5.1 CHARGE AIR COOLER
8.6 COOLING SYSTEM PERFORMANCE REQUIREMENTS
8.6.1 SYSTEM FILL
8.6.2 SYSTEM DRAIN
8.6.3 DEAERATION
8.6.4 SYSTEM COOLANT CAPACITY
8.6.5 DRAWDOWN CAPACITY
8.6.6 CORE CONSTRUCTION
8.6.7 WATER PUMP INLET PRESSURE/MAXIMUM STATIC HEAD
8.6.8 COOLANT FLOW RATE/EXTERNAL PRESSURE DROP
8.6.9 MINIMUM COOLANT TEMPERATURE
8.6.10 SYSTEM PRESSURIZATION
8.6.11 COOLANTS
8.7 CHARGE AIR COOLING REQUIREMENTS
8.7.1 COOLING CAPABILITY
8.7.2 MAXIMUM PRESSURE LOSS
8.7.3 CLEANLINESS
8.7.4 LEAKAGE
8.8 VEHICLE SIGN-OFF
8.9 END PRODUCT QUESTIONNAIRE
8.10 COOLING SYSTEM DESIGN CONSIDERATIONS
8.10.1 COOLING SYSTEM REQUIREMENTS
ENGINE OPERATING TEMPERATURE
INTAKE MANIFOLD TEMPERATURE
8.10.2 ENGINE PERFORMANCE
ENGINE HEAT REJECTION
COOLANT FLOW
HEAT TRANSFER CAPABILITIES
8.10.3 ENVIRONMENTAL AND OPERATING CONDITIONS
AMBIENT TEMPERATURE
ALTITUDE
SPACE CONSTRAINTS
NOISE LIMITS
TILT OPERATIONS OR INSTALLATIONS
8.10.4 SYSTEM COMPONENTS
ADDITIONAL HEAT LOADS TO COOLANT
ADDITIONAL HEAT LOADS TO AIR
COOLANT TYPE .
PLUMBING
AUXILIARY COOLANT FLOW PATH CIRCUITRY
WATER COOLED EXHAUST SYSTEMS
WATER PUMPS
8.11 CHARGE AIR COOLING DESIGN GUIDELINES
8.11.1 SIZE
8.11.2 COOLING AIR FLOW RESTRICTION
8.11.3 MATERIAL
8.11.4 HEADER TANKS
8.11.5 LOCATION
8.11.6 PIPEWORK
8.12 HEAT EXCHANGER SELECTION
8.12.1 SHELL AND TUBE HEAT EXCHANGERS
8.13 FAN SYSTEM RECOMMENDATIONS AND FAN SELECTION
8.13.1 BLOWER VS. SUCTION FANS
FAN PERFORMANCE
FAN POSITION
FAN SHROUDS
FAN SYSTEM ASSEMBLIES
FAN DRIVES
BAFFLES TO PREVENT AIR RECIRCULATION
SHUTTERS
WINTERFRONTS
8.14 RADIATOR COMPONENT DESIGN
8.14.1 DOWN FLOW AND CROSS FLOW RADIATORS
HORIZONTAL RADIATOR
RAPID WARM-UP DEAERATION TANK — DOWN FLOW RADIATOR
REMOTE MOUNTED RADIATORS/HEAT EXCHANGER
INTEGRAL TOP TANK
REMOTE TANK
RADIATOR BOTTOM TANK
COOLANT PRESSURE CONTROL CAPS AND RELIEF VALVES
THERMOSTAT
COOLANT SENSOR DEVICES
COOLANT RECOVERY SYSTEM
8.14.2 COLD WEATHER OPERATING OPTIMIZATION
ENGINE
VEHICLE
COOLING SYSTEM
HEATER CIRCUIT
8.14.3 COOLANT HEATERS
8.14.4 MULTI-DUTY CYCLE
8.14.5 OTHER CONSIDERATIONS
8.15 COOLING SYSTEM EVALUATION TESTS
8.15.1 SYSTEM DESCRIPTION
8.15.2 INSTRUMENTATION
THERMOCOUPLES AND ASSOCIATED HARDWARE
PRESSURE GAUGES AND ASSOCIATED HARDWARE
THERMOSTATS
SIGHT GLASS AND TRANSPARENT TUBING
GRADUATED CONTAINER
PRESSURE CAP
STOP WATCH
LIGHT
WATER SUPPLY AND HOSE
ENGINE LOADING METHOD
TAPE MEASURE
FLOWMETERS AND ASSOCIATED HARDWARE
8.15.3 TEST PREPARATIONS
8.15.4 TYPES OF TESTS
CONTINUOUS FILL
INTERRUPTED FILL
BUCKET FILL
TOTAL SYSTEM CAPACITY
DRAINING CAPABILITY
WATER PUMP BINDING TEST
DEAERATION TEST
DRAWDOWN TEST
WATER FLOW AND PRESSURE TEST
COOLING INDEX TEST
8.15.5 CHARGE AIR COOLING EVALUATION TEST …………………………………………………. 8-85
8.15.6 SYSTEM DESCRIPTION ………………………………………………………………………………. 8-87
8.15.7 INSTRUMENTATION …………………………………………………………………………………….. 8-87
TEMPERATURE MEASUREMENT ……………………………………………………………. 8-87
PRESSURE MEASUREMENT ………………………………………………………………….. 8-88
8.15.8 LOCATION …………………………………………………………………………………………………… 8-91
8.15.9 INLET SYSTEM RESTRICTION …………………………………………………………………….. 8-91
MAXIMUM TEMPERATURE RISE — AMBIENT TO TURBOCHARGER INLET . 8-91
AIR-TO-AIR SYSTEM EVALUATION TESTS ………………………………………………. 8-91
MAXIMUM TEMPERATURE RISE — AMBIENT TO INTAKE MANIFOLD ………. 8-92
CHARGE AIR COOLER SYSTEM RESTRICTION ………………………………………. 8-92
8.15.10 TEST …………………………………………………………………………………………………………… 8-92
8.15.11 TEST ANALYSIS ………………………………………………………………………………………….. 8-93
8.16 COOLING SYSTEM DIAGNOSTICS AND TROUBLESHOOTING GUIDE ……………….. 8-94
8.16.1 ENGINE OVERHEAT ……………………………………………………………………………………. 8-94
TROUBLESHOOTING FOR ENGINE OVERHEAT ………………………………………. 8-94
8.16.2 COLD RUNNING ENGINE (OVERCOOLING) ………………………………………………….. 8-96
8.16.3 POOR CAB HEATER PERFORMANCE ………………………………………………………….. 8-96
THERMOSTAT LEAKAGE TEST ………………………………………………………………. 8-98
CAC AIR LEAKAGE TEST ……………………………………………………………………….. 8-99
8.17 MAINTENANCE ……………………………………………………………………………………………….. 8-100
9 FUEL SYSTEM ……………………………………………………………………………………………………. 9-1
9.1 FUEL SYSTEM DESCRIPTION ………………………………………………………………………….. 9-2
9.2 FUEL SYSTEM EQUIPMENT/INSTALLATION GUIDELINES …………………………………. 9-4
9.2.1 FUEL TANK …………………………………………………………………………………………………. 9-4
MATERIAL ……………………………………………………………………………………………… 9-4
DESIGN …………………………………………………………………………………………………. 9-4
CAPACITY ……………………………………………………………………………………………… 9-5
POSITION ………………………………………………………………………………………………. 9-5
9.2.2 PRIMARY FUEL/WATER SEPARATOR ………………………………………………………….. 9-6
9.2.3 FUEL FILTER CONFIGURATION ……………………………………………………………………. 9-6
9.2.4 FUEL LINES ………………………………………………………………………………………………… 9-6
DESIGN …………………………………………………………………………………………………. 9-7
MATERIAL ……………………………………………………………………………………………… 9-7
SIZE ………………………………………………………………………………………………………. 9-7
9.3 FUEL SELECTION ……………………………………………………………………………………………. 9-9
10 LUBRICATION SYSTEM ……………………………………………………………………………………… 10-1
10.1 LUBRICATION SYSTEM DESCRIPTION …………………………………………………………….. 10-2
10.2 LUBRICATION OIL SELECTION ………………………………………………………………………… 10-4
10.3 LUBRICATION FILTER ……………………………………………………………………………………… 10-5
10.3.1 REMOTE-MOUNTED FILTERS ……………………………………………………………………… 10-5
10.4 ENGINE COMPONENT OIL SUPPLY REQUIREMENTS ………………………………………. 10-6
10.4.1 TURBOCHARGER LUBRICATION …………………………………………………………………. 10-6
10.4.2 AIR COMPRESSOR LUBRICATION ……………………………………………………………….. 10-6

10.5 INSTALLATION REQUIREMENTS ……………………………………………………………………… 10-7
10.5.1 SUPPLEMENTAL FILTRATION SYSTEMS ………………………………………………………. 10-7
REMOTE MOUNT SUPPLEMENTAL OIL FILTER REQUIREMENTS …………….. 10-7
REMOTE MOUNT SUPPLEMENTAL OIL FILTER CONNECTIONS ………………. 10-7
10.5.2 OIL SAMPLING VALVE ………………………………………………………………………………… 10-10
10.5.3 MECHANICAL OIL PRESSURE GAUGES ………………………………………………………. 10-10
10.6 COMPONENT OPTIONS …………………………………………………………………………………… 10-11
10.6.1 OIL CHECKS AND FILLS ………………………………………………………………………………. 10-11
10.6.2 BREATHERS ……………………………………………………………………………………………….. 10-11
10.6.3 OIL SUMPS …………………………………………………………………………………………………. 10-11
……………………………………………………………………………………………………………… 10-11
10.6.4 ENVIRONMENTALLY SAFE OIL CHANGE (ESOC) FITTINGS ………………………….. 10-11
10.6.5 OIL IMMERSION HEATERS ………………………………………………………………………….. 10-12
10.6.6 OIL LEVEL SENSORS ………………………………………………………………………………….. 10-12
10.7 OPERATION AND MAINTENANCE ……………………………………………………………………. 10-13
10.7.1 FIRST TIME START ……………………………………………………………………………………… 10-13
10.7.2 OIL LEVEL MEASUREMENTS ………………………………………………………………………. 10-13
10.7.3 USED OIL ANALYSIS ……………………………………………………………………………………. 10-13
10.7.4 OIL DRAIN INTERVALS ………………………………………………………………………………… 10-13
11 ELECTRICAL SYSTEM ………………………………………………………………………………………… 11-1
11.1 ELECTRICAL SYSTEM DESCRIPTION ………………………………………………………………. 11-2
11.2 INSTALLATION GUIDELINES ……………………………………………………………………………. 11-4
11.2.1 BATTERY ……………………………………………………………………………………………………. 11-4
FILLER CAP BATTERIES ………………………………………………………………………… 11-4
SEMI-MAINTENANCE FREE BATTERIES …………………………………………………. 11-4
MAINTENANCE-FREE BATTERIES ………………………………………………………….. 11-4
DEEP CYCLE BATTERIES ………………………………………………………………………. 11-4
GEL-CELL AND NICKEL CADMIUM BATTERIES ……………………………………….. 11-5
BATTERY CAPACITY ………………………………………………………………………………. 11-5
BATTERY MOUNTING AND LOCATION ……………………………………………………. 11-5
11.2.2 CRANKING MOTOR …………………………………………………………………………………….. 11-8
11.2.3 ALTERNATORS ……………………………………………………………………………………………. 11-11
……………………………………………………………………………………………………………… 11-12
ALTERNATOR MOUNTING ………………………………………………………………………. 11-12
11.2.4 GROUNDING REQUIREMENTS ……………………………………………………………………. 11-13
11.2.5 WIRING ………………………………………………………………………………………………………. 11-13
GUIDELINES FOR ELECTRICAL WIRING …………………………………………………. 11-13
CABLE LOSS TEST PROCEDURE …………………………………………………………… 11-14
MEASURING CIRCUIT RESISTANCE ……………………………………………………….. 11-15
CALCULATING CIRCUIT RESISTANCE ……………………………………………………. 11-15
12 MOUNTING SYSTEM …………………………………………………………………………………………… 12-1
12.1 MOUNTING SYSTEM DESCRIPTION ………………………………………………………………… 12-2
12.1.1 THREE-POINT MOUNTING …………………………………………………………………………… 12-2
12.2 SOLID MOUNTING SYSTEMS …………………………………………………………………………… 12-5
12.3 FLEXIBLE MOUNTING SYSTEMS ……………………………………………………………………… 12-6
12.3.1 FLEXIBLE MOUNT SELECTION ……………………………………………………………………. 12-6

METHOD A …………………………………………………………………………………………….. 12-7
METHOD B …………………………………………………………………………………………….. 12-8
12.4 INSTALLATION CHECK LIST …………………………………………………………………………….. 12-9
12.5 ENGINE SUPPORT ………………………………………………………………………………………….. 12-10
13 TORSIONAL ANALYSIS ………………………………………………………………………………………. 13-1
13.1 MASS ELASTIC DATA ………………………………………………………………………………………. 13-2
14 ENGINE ELECTRONIC CONTROLS ……………………………………………………………………… 14-1
14.1 ORIGINAL EQUIPMENT MANUFACTURER REQUIREMENTS – ON-HIGHWAY …….. 14-2
14.2 MOTOR CONTROL MODULE ……………………………………………………………………………. 14-3
14.3 COMMON POWERTRAIN CONTROLLER ………………………………………………………….. 14-4
14.4 ELECTRONIC FUEL INJECTOR ………………………………………………………………………… 14-5
14.5 ON-HIGHWAY HARNESSES ……………………………………………………………………………… 14-7
14.5.1 INJECTOR HARNESSES ………………………………………………………………………………. 14-7
14.5.2 VEHICLE INTERFACE HARNESS ………………………………………………………………….. 14-7
14.5.3 COMMUNICATION BETWEEN ELECTRONIC SYSTEMS …………………………………. 14-9
14.5.4 ENGINE SENSOR HARNESS ……………………………………………………………………….. 14-9
14.5.5 DIESEL PARTICULATE FILTER HARNESS …………………………………………………….. 14-9
14.6 SYSTEM SENSORS …………………………………………………………………………………………. 14-10
14.7 WELDING ……………………………………………………………………………………………………….. 14-11
15 EFFECTS OF ENVIRONMENTAL CONDITIONS …………………………………………………….. 15-1
15.1 AIR INLET TEMPERATURE ………………………………………………………………………………. 15-2
15.2 EXHAUST BACK PRESSURE ……………………………………………………………………………. 15-3
15.3 FUEL TEMPERATURE ……………………………………………………………………………………… 15-4
15.4 ALTITUDE ……………………………………………………………………………………………………….. 15-5
16 AUXILIARY AIR SYSTEMS …………………………………………………………………………………… 16-1
16.1 AIR START ………………………………………………………………………………………………………. 16-2
16.1.1 SYSTEM RECOMMENDATIONS ……………………………………………………………………. 16-2
AIR TANKS …………………………………………………………………………………………….. 16-2
AIR CONTROL SYSTEM …………………………………………………………………………. 16-2
AIR STARTERS REQUIRING LUBRICATORS ……………………………………………. 16-3
16.2 AIR COMPRESSOR …………………………………………………………………………………………. 16-4
16.2.1 16 CFM AND 32 CFM COMPRESSORS …………………………………………………………. 16-5
17 ACCESSORY DRIVES …………………………………………………………………………………………. 17-1
17.1 BENDING MOMENT …………………………………………………………………………………………. 17-5
18 COLD WEATHER STARTING AND STARTING AID SYSTEMS ………………………………… 18-1
18.1 PREPARATION ………………………………………………………………………………………………… 18-3
18.1.1 LUBRICATING OIL ……………………………………………………………………………………….. 18-3
18.1.2 DIESEL FUEL ………………………………………………………………………………………………. 18-3
18.1.3 COOLANT …………………………………………………………………………………………………… 18-4
18.1.4 BATTERY ……………………………………………………………………………………………………. 18-6
18.1.5 STARTER MOTOR ……………………………………………………………………………………….. 18-7
ELECTRIC STARTER MOTOR …………………………………………………………………. 18-7
AIR STARTER MOTOR ……………………………………………………………………………. 18-8
18.2 COLD WEATHER STARTING …………………………………………………………………………….. 18-9

18.2.1 STARTING SYSTEMS …………………………………………………………………………………… 18-9
……………………………………………………………………………………………………………… 18-9
COOLANT TANK TYPE HEATERS ……………………………………………………………. 18-9
ETHER START ………………………………………………………………………………………. 18-11
18.2.2 STARTING AIDS ………………………………………………………………………………………….. 18-15
FUEL ……………………………………………………………………………………………………… 18-15
FUEL HEATERS …………………………………………………………………………………….. 18-15
BATTERY HEATER TYPES …………………………………………………………………….. 18-15
HEATING ENGINE COMPARTMENT ……………………………………………………….. 18-16
HEATING ENGINE COMPARTMENT ……………………………………………………….. 18-16
18.2.3 STARTING PROCEDURES …………………………………………………………………………… 18-16
18.2.4 ENGINE STARTING REQUIREMENTS ………………………………………………………….. 18-17
18.3 COLD WEATHER OPERATION …………………………………………………………………………. 18-18
18.3.1 IDLING AND LIGHT LOAD …………………………………………………………………………….. 18-18
18.3.2 MAINTENANCE ……………………………………………………………………………………………. 18-18
18.3.3 WIND PROTECTION …………………………………………………………………………………….. 18-18
18.3.4 BATTERY AND CHARGING SYSTEM …………………………………………………………….. 18-18
18.3.5 AIR CLEANER MAINTENANCE ……………………………………………………………………… 18-19
18.3.6 UNDERHOOD AIR VALVE OPERATION …………………………………………………………. 18-19
18.3.7 SUPPLEMENTAL HEATING DEVICE ……………………………………………………………… 18-19
18.3.8 DDC COLD START RECOMMENDATIONS …………………………………………………….. 18-19
APPENDIX A: ABBREVIATIONS / ACRONYMS ………………………………………………………………. A-1
APPENDIX B: VENDORS ………………………………………………………………………………………………. B-1
GLOSSARY ……………………………………………………………………………………………………………………. G-1
INDEX ………………………………………………………………………………………………………………………….. INDEX-1

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