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SERIES 60 ENGINE
OWNERS MANUAL
CONTACT
FITZGERALD GLIDER KITS
www.fitzgeraldgliderkits.com
ENGINE MODEL AND
SERIAL NUMBER
DESIGNATION
The engine serial number and model number are
stamped on the cylinder block in the following
location (as viewed from the flywheel end):
1
DDEC II NOTICE:
Detroit Diesel Series 60 engines equipped
If the warning lights stay on, or if they
with DDEC II electronic control systems are
do not come on momentarily after
identified by a “U” in the sixth position of the
turning on the ignition, consult with a
model number. Example: 6067GU60.
DDEC technician. Operating the engine
Detroit Diesel Electronic Controlled Series
under these circumstances may result
60 engines can be equipped with a variety of
in engine damage.
options designed to warn the operator of an
engine malfunction. The options can range
from “Check Engine” and “Stop Engine” panel The Series 60 DDEC engine is equipped
lights to automatic reduction in engine power with an electronically controlled fuel
followed by automatic engine shutdown. injection system. There are no control racks
The power-down/shutdown option may be or mechanical linkage to adjust. This system
activated by low coolant level, low oil pressure, not only helps to improve fuel economy
or high engine oil or coolant temperature. and vehicle performance, but also helps
to reduce cold starting time and increase
initial idle speed for fast engine warm-up and
DDEC III/IV virtual elimination of cold smoke.
The DDEC engine has no mechanical
Detroit Diesel Series 60 engines equipped with
governor. Engine horsepower, torque, idle,
DDEC III or DDEC IV electronic control systems
and engine speed are contained in the
are identified by a “K” in the sixth position of
internal electronics. Therefore, there are no
the model number. Example: 6067GK60.
mechanical governor spring adjustments for
Detroit Diesel Electronic Controlled Series
idle and high speed control.
60 engines can be equipped with a variety of
There is no need for a throttle delay
options designed to warn the operator of an
either, since emission control is performed
engine malfunction. The options can range
through the Electronic Control Module (ECM).
from “Check Engine” and “Stop Engine” panel
The Electronic Foot Pedal Assembly (EFPA),
lights to automatic reduction in engine power
eliminates the need for any throttle linkage.
followed by automatic engine shutdown.
The DDEC engine has the ability to
The power-down/shutdown option may be
perform diagnostics for self-checks and
activated by low coolant level, low oil pressure,
continuous monitoring of other system
or high engine oil or coolant temperature.
components. Depending on the application,
DDEC can also monitor oil temperature,
coolant temperature, oil pressure, fuel
pressure, coolant level, and remote sensors
(if used). This diagnostic system is connected
to the “Check Engine” light (CEL) and the
“Stop Engine” light (SEL) to provide a visual
warning of a system malfunction.
2
DDEC III/IV ENGINE The immediate speed reduction option will
bring engine RPM back to a predetermined
PROTECTION speed, but will not shut down the engine.
The engine should not be restarted after it
Since many vehicles are equipped with the has been shut down by the engine protection
DDEC engine protection system, the “Stop system unless the problem has been located
Engine” malfunction is recorded in the and corrected.
Electronic Control Module. With the 30 The conditions that will cause the “Stop
second shutdown option, the engine will Engine” light to come on are:
begin a 30 second stepped power down
sequence until it shuts down completely. ■ Loss of coolant
To allow for the possibility of the “Stop ■ High oil temperature
Engine” automatic shutdown function being ■ Low oil pressure
activated while the vehicle is operating in a ■ Auxiliary shutdown
critical situation, an override is provided.
In such a situation the operator may elect It is important to point out that whenever the
to “override” the automatic stop engine CEL or the SEL comes on, the DDEC computer
sequence by pressing the “Stop Engine will determine where the problem is, and will
Override” switch, located on the instrument then store this information in its memory.
panel, until a safe stop can be made. The If the malfunction is intermittent, the lights
operator only needs to press the override will come on and go off as the computer
switch every 15 to 20 seconds to prevent the senses the changing engine condition.
engine shutdown from occurring. A special diagnostics tool (Diagnostics
An important thing to remember is that Data Reader, or “DDR”) is available that
it takes 30 seconds from the time the can be plugged into the engine computer
automatic shutdown sequence begins until memory to extract information related to the
engine shutdown. Therefore the operator cause of the problem.
must press the override switch just prior to
engine shutdown and continue to do so until
the vehicle can be brought to a safe stop.
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Once the malfunction has been corrected,
the DDEC system will return the engine to
EMERGENCY JUMP
normal operation. STARTING
The DDR can distinguish between
codes now active and those stored in the The DDEC II electronic control system operates
historic code memory. on 12 volt DC. If a DDEC II engine with an
The malfunction code recorded in the electronic starting motor requires emergency
computer memory will remain until it is jump starting, do not exceed 16 volts DC.
erased by a technician. DDEC III and DDEC IV electronic control
The malfunction code can also be systems operate on 12 or 24 volts DC. If a
obtained by the operator. A “Diagnostic DDEC III or DDEC IV engine with an electronic
Request” switch may be provided which, starting motor requires emergency jump
when pressed, will cause the CEL to flash a starting do not exceed 32 volts DC.
code number. It will, for example, flash twice
… pause … flash five times … pause. In other
words a code 25.
Code 25 will continue to flash and repeat
NOTICE:
as long as the check engine switch is held Jump starting with voltages greater
in the “On” position with the ignition on. than those indicated or reversing
battery polarity may damage the ECM
(Electronic Control Module).
4
DDEC II Diagnostic Codes
Diagnostic Connector
Error Error
Code # Description Code # Description
11 Power Take-off Sensor Lo Volt 42 Synchronous Ref Sensor
12 Power Take-off Sensor Hi Volt 43 Low Coolant Level
13 Coolant Sensor Lo Volt 44 Engine Over Temperature
14 Eng Temp Sensor Hi Volt 45 Low Oil Pressure
15 Eng Temp Sensor Lo Volt 46 Low Battery Voltage
16 Coolant Sensor Hi Volt 47 Hi Fuel Pressure
21 Throttle Pos Sensor Hi Volt 48 Lo Fuel Pressure
22 Throttle Pos Sensor Lo Volt 51 EEPROM Error
23 Fuel Temp Sensor Hi Volt 52 ECM - A/D Fail
24 Fuel Temp Sensor Lo Volt 53 EEPROM Memory Failure
25 No Codes 54 Vehicle Speed Sensor
26 Power Control Enabled 55 Proprietary Comm. Link
31 Fault on Auxiliary Output 56 ECM - A/D Fail
32 ECM Backup System Fail 58 Cruise Ctl/Press Gov Ctl Switch
33 Turbo Bst Sensor Hi Volt 61-68 Inj Response Time Long
34 Turbo Bst Sensor Lo Volt 71-78 Inj Response Time Short
35 Oil Prs Sensor Hi Volt 84 Crankcase Pressure Hi
36 Oil Prs Sensor Lo Volt 85 Engine Overspeed
37 Fuel Prs Sensor Hi Volt 86 Press Gov Ctl - Hi Volt
38 Fuel Prs Sensor Lo Volt 87 Press Gov Ctl - Lo Volt
41 Timing Reference Sensor
CEL Examples
CEL CEL
1 Flash 3 Flashes 2 Flashes 1 Flash
5
DDEC III/IV Diagnostic Codes
Flash Flash
Code DDEC III/IV Description Code DDEC III/IV Description
11 VSG Sensor Input Voltage Low 44 Oil or Coolant or Intake Air, Temp. High
12 VSG Sensor Input Voltage High 45 Oil Pressure Low
13 Coolant Level Sensor Input Voltage Low 46 ECM Battery Voltage Low
14 Oil or Coolant Temp. Sensor Input 47 Fuel, Air Inlet, or Turbo Boost
Voltage High Pressure High
15 Oil or Coolant Temp. Sensor Input 48 Fuel or Air Inlet Pressure Low
Voltage Low 52 ECM A/D Conversion Fail
16 Coolant Level Sensor Input 53 ECM Non Volatile Memory Fault
Voltage High 54 Vehicle Speed Sensor Fault
17 Throttle Valve Position Sensor Input 55 J1939 Data Link Fault
Voltage High 56 J1587 Data Link Fault
18 Throttle Valve Position Sensor Input 57 J1922 Data Link Fault
Voltage Low 61 Injector Response Time Long
21 TPS Input Voltage High 62 Aux. Output Short To Battery (+) or
22 TPS Input Voltage Low Open Circuit, or Mech. Fault
23 Fuel Temp. Sensor Input Voltage High 63 PWM Drive Short to Battery (+) or
24 Fuel Temp. Sensor Input Voltage Low Open Circuit
25 No Active Codes 64 Turbo Speed Sensor Input Fault
26 Aux. Engine Shutdown #1 or #2, 65 Throttle Valve Position Input Fault
Input Active 66 Engine Knock Sensor Input Fault
27 Air Inlet or Intake Air, Temp. Sensor 67 Air Inlet Pressure Sensor Input
Input Voltage High Voltage Fault
28 Air Inlet or Intake Air, Temp. Sensor 68 TPS Idle Validation Switch Open Circuit
Input Voltage Low or Short to Ground
31 Aux. High Side Output Open Circuit or 71 Injector Response Time Short
Short to Ground 72 Vehicle Overspeed
32 CEL or SEL Short to Battery (+) or 73 Gas Valve Position Input Fault or
Open Circuit ESS Fault
33 Turbo Boost Sensor Input Voltage High 74 Optimized Idle® Safety Loop Short
34 Turbo Boost Sensor Input Voltage Low to Ground
35 Oil Pressure Sensor Input Voltage High 75 ECM Battery Voltage High
36 Oil Pressure Sensor Input Voltage Low 76 Engine Overspeed with Engine Brake
37 Fuel Pressure Sensor Input 77 Fuel Temperature High
Voltage High 85 Engine Overspeed
38 Fuel Pressure Sensor Input Voltage Low 86 External Pump Pressure Sensor Input
41 Too Many SRS (Missing TRS) Voltage High
42 Too Few SRS (Missing SRS) 87 External Pump Pressure Sensor Input
43 Coolant Level Low Voltage Low
TO READ CODES: Use the diagnostic data reader or depress and hold the diagnostic
request switch with the ignition on, engine at idle or not running. Press and hold the switch.
Active codes will be flashed on the “Stop Engine” light (SEL) followed by the inactive codes
being flashed on the “Check Engine” Light (CEL). The cycle will repeat until the operator
releases the diagnostic request switch.
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S-60 ENGINE DRIVING TIPS
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S-60 ENGINE DRIVING TIPS
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FITZGERALD WARRANTY STATEMENT
Fitzgerald Glider Kits is not responsible for the cost of maintenance or repairs due to lack of
performance of required maintenance services or the failure to use Fuel, Oil, Lubricants, and
coolants meeting Detroit Diesel recommended specifications. Performance of said required
maintenance and use of proper fuel, oil, lubricants and coolants are the responsibility of the owner.
9
LUBRICANT SELECTION IN LUBRICANT
NORTH AMERICA REQUIREMENTS
The selection of the proper lubricating Lubricants meeting these criteria have
oil is important to achieve the long and provided maximum engine life when used in
trouble-free service which Detroit Diesel conjunction with specified oil drain and filter
engines are designed to provide. The proper maintenance schedules.
lubricating oil for all Detroit Diesel engines is
selected based on SAE viscosity grade and
API (American Petroleum Institute) service
designation. Only oils licensed to display the
American Petroleum Institute (API) symbol
shown should be used.
(P/N 23512703)
10
LUBRICATING OIL CHECKS NOTICE:
Check the oil level daily with the engine
Do not overfill. Oil may be blown out
stopped. If the engine has just been stopped
through the crankcase breather if the
and is warm, wait approximately 20 minutes
crankcase is overfilled
to allow the oil to drain back to the oil pan
before checking. Add the proper grade of oil
to maintain the correct level on the dipstick.
COOLANT
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SUPPLEMENTAL COOLANT Wait at least 60, but no longer than 75,
seconds before reading the nitrite level.
ADDITIVE (SCA) TEST Promptly replace and tighten the test strip
container cap after each use. Discard unused
PROCEDURES strips if they have turned light pink or tan.
Pencool 3-Way Coolant Test Strips should A factory analysis program is available
be used to measure nitrite and glycol through authorized Detroit Diesel service
concentrations. Cavitation/corrosion outlets. To verify coolant acceptability, submit
protection is indicated on the strip by the a sample for coolant analysis every three
level of nitrite concentration. Freeze/boil- (3) years, 300,000 miles, (480,000 km), or
over protection is determined by glycol 6,000 operating hours, whichever comes first.
concentration. Use the test strips as follows: If any other coolant additive is used, follow
that particular manufacterers guidlines.
1. Dip the strip into coolant for one second.
Remove and shake briskly to eliminate excess fluid.
12
FUEL PROCESSORS DIESEL FUEL
Many vehicles are now equipped with The quality of fuel used in the Detroit Diesel
optional fuel processors, such as Detroit engine is a very important factor in obtaining
Diesel’s Fuel Pro 382. This single filter satisfactory engine performance, long
system replaces traditional primary and engine life and long injector life. Biodiesel
secondary filters. By reducing the number fuels can decrease the life of fuel filters
of filters and extending the change interval, and degrade their water coalescing ability.
filter expense can be reduced by up to 75%. Failures attributed to the use of fuels which
do not meet industry standards are not the
fault of Fitzgerald Glider Kits, and will not be
covered by Fitzgerald Glider Kits warranty.
1. When new, the fuel level in the 382 filter 3. Restriction remains consistently low. Even
will be very low. The filter is causing minimal though the fuel level is now over more than
restriction. as the filter used in Model 382, dirt half of the element, the fuel is still flowing
collects on the filter from the bottom up. Fuel through clean new media.
rises on the filter indicating remaining filter life.
4. The filter element is now covered by fuel,
2. Fuel level remains low. As dirt is trapped on the and it is using all of the media’s surface
filter, the fuel rises over the dirt and flows through area. Restriction is just starting to rise and
clean filter media to keep flow restriction low. the element should be changed at the next
scheduled maintenance interval.
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AFTERMARKET FILTRATION PARTS LIST FOR OUR
SYSTEMS 6067GK60 MODEL
Aftermarket Fuel supplemental filtration ENGINES ONLY
systems may be used, provided they do
Detroit Fuel Filter 23538657
not replace the factory installed system,
reduce fuel volumes, pressures, or flow rates Luber Finer Oil Filter LFP2160
delivered to the engine.
Borg Warner Turbo 171702
ADDITIONAL
Water Pump R23522707
MAINTENANCE ITEMS:
Injectors R23555915
Transmission: 50wt synthetic oil drain/flush
at 500,000 miles Cam Sensor 8929387
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FITZGERALD GLIDER KITS Do Not Perform Repairs On This Vehicle
Until Making Contact With Our Warranty
WARRANTY INFORMATION Department.” It also includes our phone
number, displayed for contact. You may
As a customer of Fitzgerald Glider Kits, we instruct the shop before hand of this, and
would like to take a moment to explain and expedite this process somewhat if you
make you familiar with our warranty process. choose. Not following this procedure may
We will break this down in 5 steps. jeopardize your warranty availability and
increase your out-of-pocket expense. We will
Step 1. Contact give the shop permission to now diagnose
your problem, and in turn give us an estimate
We may be contacted at 866-597-3836
for parts and labor of the repair. After we
or 931-864-4886, Monday through Friday
receive this estimate, we will review it and
from 8:00am to 5:00pm CST. After hours we
make sure labor times are within Motor
may be reached at 931-337-5794, Monday
Manual SRT Guidelines. We will also evaluate
through Friday from 5:00pm to 8:00pm CST,
the parts required to determine if the parts
and Saturday from 8:00 to 12:00pm CST.
are something that can be purchased there,
Step 2. Repair facility or if they need to be shipped from our facility.
Our department staff will stay in close
When a problem does arise with your Glider, contact with the repair shop throughout
please contact this warranty department first. the repair process, and will give you, the
This will allow our involvement and guidance customer, updates as often as you request.
from the beginning, which will make for a
more pleasant experience for us all during Step 4. Billing
this process. Fitzgerald Glider Kits warranty
After the repair is completed, Fitzgerald Glider
department would like to remind you, that
Kits will pay the final invoice for all agreed
while every effort will be made by our staff to
upon warranty items from the estimate.
see that your truck is repaired correctly and
in a timely manner, we are not a breakdown Step 5. Completion
service. Upon receiving your call, we will assess
the issue, and guide you towards a facility to Now that the repair has been completed and
make the necessary repair. Due to certain the invoice is paid, you can get your truck
parts specific warranty policies, (such as; OEM, back into service, which is WHY you made
Eaton, Bendix, Etc.), some repairs must be the purchase in the first place. This will be
made at the facilities that can file warranties the process that you will use any time there
through these companies. Otherwise, the is a warranty issue. Please feel free to call our
warranty for repairs will not be available, and warranty department with any questions you
will result in out-of-pocket expenses. Our may have about your truck warranty. We are
department will guide you in this process and here to help you make your experience with our
make you aware of their locations. warranty as pleasant as possible, and to keep
your truck in service and remain profitable.
Step 3. Repairs
NOTE: Custom painted engine parts will require
After you have contacted us and now have and extra day of shipping due to painting.
your truck at a repair shop, it is time for the
repair. The shop will notice a distinctive decal
on your engine valve cover. It says “STOP!
15
YOUR FITZGERALD GLIDER
KIT WITH DETROIT SERIES
60 ENGINE
When your Fitzgerald Glider Kit leaves our
factory floor it is filled with the following fluids:
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NOTES:
NOTES:
NOTES:
NOTES:
DETROIT DIESEL
SERIES 60 ENGINE