Detroit Diesel 60 Manual

Engine Operator's Guide
Series 60
DETROIT DIESEL ~

To the Operator
This guide contains instructions on the
safe operation and preventive mainte-
nance of your Detroit Diesel Series 60
engine used in vehicle, stationary, con-
struction/industrial, agricultural, gener-
ator set 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 con-
trols. You are urged, as the operator of
this diesel engine, to keep fingers and
clothing away from the revolving belts,
drive shafts, etc. on the engine installa-
tion.
Throughout this guide CAUTIONS
regarding personal safety and
NOTICES regarding engine perfor-
mance or service life will appear. To
avoid personal injury and ensure long
engine service life, always heed these
instructions.
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 out-
lets worldwide stock factory original
parts and have the specialized equip-
ment and experienced, trained person-
nel to provide prompt preventive
maintenance and skilled engine
repairs.
The information and specifications in
this publication are based on the infor-
mation in effect at the time of approval
for printing. Contact an authorized
Detroit Diesel service outlet for infor-
mation on the latest revision. The right
is reserved to make changes at any
time without obligation.
WARRANTY
The applicable engine warranty is contained in the booklet entitled “Warranty
Information for Series 60 Engines,” available from authorized Detroit Diesel service
outlets.
Keep this Operators Guide with the engine installation at all times. It con-
tains important operating, maintenance, and safety instructions.
Detroit Diesel®, DDC®, the spinning arrows design®, Series 60®, DDEC®, Optimized Idle®, reliabilt®, PowerTrac®, and Power Guard®are registered trademarks
of Detroit Diesel Corporation. Jake Brake®is a registered trademark of Jacobs Vehicle Systems. Delco-Remy is a registered trademark of Delco-Remy®
America, Inc. The API lubricant service mark is a registered mark of the American Petroleum Institute. Fuel Pro®is a registered trademark of Davco
Manufacturing, L.L.C. PowerBand®is a registered trademark of the Gates Rubber Company. Biobor®is a registered trademark of U.S. Borax and Chemical
Corporation. Tectyl®is a registered trademark of Ashland Oil Corporation.
6SE484 0007 © Copyright 2000. Detroit Diesel Corporation. All rights reserved. Printed in U.S.A.
CALIFORNIA
Proposition 65 Warning
Diesel Engine exhaust and some of its constituents are
known to the State of California to cause cancer, birth
defects and other reproductive harm.
NOTICE:
Coolant must be inhibited with the recommended SCA’s (supplemental coolant addi-
tives) listed in the “How to Select Coolant” 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.

i
Table of Contents
Subject Page
INTRODUCTION.................................................................................................ii
NON-GENUINE AND REBUILT COMPONENT QUALITY ALERT.........................ii
CAUTION SUMMARY...................................................................................iv-viii
ENGINE MODEL AND SERIAL NUMBER DESIGNATION................................1-2
Option and Certification Labels...........................................................................1
OPERATING INSTRUCTIONS.........................................................................3-9
Preparations for Starting the Engine the First Time .............................................3
Starting the Engine.............................................................................................5
Running the Engine............................................................................................7
Stopping the Engine...........................................................................................8
Emergency Jump Starting..................................................................................8
DDEC III/IV OPTIONS....................................................................................9-16
DDEC III/IV ENGINE DRIVING TIPS.............................................................17-18
ENGINE SYSTEMS.....................................................................................19-20
ENGINE MAINTENANCE SCHEDULES.......................................................21-25
LUBRICATION AND PREVENTIVE MAINTENANCE INTERVALS.................26-38
“HOW TO” SECTION..................................................................................38-61
How to Select Lubricating Oil......................................................................38-39
When to Change Oil....................................................................................39-40
How to Replace the Lube Oil Filters ............................................................40-41
How to Select Fuel Oil.................................................................................41-43
How to Replace the Fuel Filters...................................................................43-47
Engine Out of Fuel—How to Restart ...........................................................47-48
How to Select Coolant................................................................................48-60
How to Drain and Flush the Cooling System ...............................................60-61
When to Service the Dry Type Air Cleaner........................................................61
BASIC TROUBLESHOOTING......................................................................62-66
ENGINE STORAGE.....................................................................................67-71
SERVICE PUBLICATIONS................................................................................72
CUSTOMER ASSISTANCE.........................................................................73-74
LIMITED NEW ENGINE WARRANTY ..........................................................75-92
SPECIFICATIONS.......................................................................................93-96

ii
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
■Construction/Industrial
■Agricultural Machinery
■Generator Drive Engine
Operators of Series 60 marine
engines should refer to the Detroit Diesel
Series 60 Marine Engine Operator’s
Guide, 6SE559. Operators of Series 60
engines used in prime power or stand-
by generator set applications should
also refer to the Detroit Diesel
Generator Set Operator’s Guide,
6SE513. Guides are available from
authorized Detroit Diesel distributors.
NON-GENUINE AND
REBUILT COMPONENT
QUALITY ALERT
In recent years, electronic engine con-
trols 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
meeting the ever-increasing perfor-
mance demands of the customer.
Proper engine maintenance by the
owner or operator ensures that the con-
trol system will meet such emission and
performance standards.
Maintenance procedures are to be fol-
lowed 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 estab-
lished as 290,000 miles for on-highway
engines. Proper maintenance proce-
dures, using specific components engi-
neered 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 respon-
sible for determining the suitability of
components to maintain emissions com-
pliance during the engine’s useful emis-
sion life.

iii
Electronic controls and components
have significantly increased in sophistica-
tion, but the fundamental objective
remains the same – precise timing and
delivery of fuel. The very heart of the
Detroit Diesel Electronic Controls 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 500,000
engines with electronic unit injectors –
more than anyone else in the business.
Detroit Diesel cautions that the indiscrim-
inate rebuilding of precision compo-
nents, without the benefit of
specifications, specialized equipment,
and knowledge of the electronic operat-
ing system, will jeopardize performance
or lead to more serious problems, and
can take the engine outside of compli-
ance with EPA or California emissions
standards.
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 specifi-
cations may result in early wear out or
engine failure.

iv
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 oper-
ating the vehicle/equipment or per-
forming basic engine preventive
maintenance may result in personal
injury and engine and/or vehicle/
equipment damage.
1. Observe the following cautions
when operating the engine:
CAUTION:
To avoid injury from engine shut-
down in an unsafe situation,
ensure the operator knows how to
override the stop engine condition
on a DDEC-equipped unit.
CAUTION:
To avoid injury from loss of vehi-
cle/vessel control, the operator of
a DDEC equipped engine must not
attempt to use or read the
Diagnostic Data Reader when the
vehicle/vessel is moving.
CAUTION:
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 traffic that varies in
speed, etc.).
■On slippery roads (wet pave-
ment, ice or snow-covered
roads, loose gravel, etc.).
2. Observe the following cautions
when performing basic preventive
maintenance on the engine:
CAUTION:
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 the
engine in a well-ventilated area.
■If operating the engine in an
enclosed area, vent the exhaust
to the outside.
■Do not modify or tamper with
the exhaust system or emission
control system.
CAUTION:
To avoid injury when working near
or on an operating engine, remove
loose items of clothing, jewelry,
and tie back or contain long hair
that could be caught in any mov-
ing part, causing injury.
CAUTION:
To avoid injury from hot oil, do not
operate the engine with the rocker
cover(s) removed.
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v
CAUTION:
To avoid injury from fire, contain
and eliminate leaks of flammable
fluids as they occur. Failure to
eliminate leaks could result in fire.
CAUTION:
To avoid injury from contact with
the contaminates in used engine
oil, wear protective gloves and
apron.
CAUTION:
To avoid injury from slipping and
falling, immediately clean up any
spilled liquids.
CAUTION:
To avoid injury from the expulsion
of hot coolant, never remove the
cooling system pressure cap while
the engine is at operating temper-
ature. Remove the cap slowly to
relieve pressure. Wear adequate
protective clothing (face shield or
safety goggles, rubber gloves,
apron, and boots).
CAUTION:
To avoid injury from burns, shut
down the engine and allow it to
cool to ambient temperature
before performing basic preven-
tive maintenance.
CAUTION:
To avoid injury from the protection
of tools or other objects that may
fall on or behind the vibration
damper of an engine, always
check and remove these items
before starting the engine.
CAUTION:
To avoid injury from fire caused by
heated lubricating-oil vapors:
■Keep those people who are not
directly involved in servicing
away from the engine.
■Stop the engine immediately if
an oil leak is detected.
■Do not allow open flames or
smoke when working on an
operating engine.
■Wear adequate protective cloth-
ing (face shield, insulated
gloves, apron, etc.) to avoid
burns.
■To prevent a buildup of poten-
tially volatile vapors, keep the
engine area well ventilated dur-
ing operation.
Lubricating oil is relatively harm-
less at ambient temperatures.
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vi
CAUTION:
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.
CAUTION:
To avoid injury when using caustic
cleaning agents, follow the chemi-
cal manufacturers usage, disposal,
and safety instructions.
3. Observe the following cautions
when using compressed air:
CAUTION:
To avoid injury from flying debris
when using compressed air, wear
adequate eye protection (face
shield or safety goggles) and do
not exceed 40 psi (276 kPa) air
pressure.
CAUTION:
Do not apply compressed air to
any part of the body or clothing.
Compressed air directed at the
face or body may cause eye or
hearing injury or other serious
physical injury.
4. Observe the following caution
when using starting aids:
CAUTION:
To avoid personal injury when using
ether during an engine startup,
ensure to follow these precautions:
■Do not smoke when servicing
ether system.
■Work in well-ventilated area.
■Do not work near open flames,
pilot flames (gas or oil heaters), or
sparks.
■Do not weld or carry an open
flame near the ether system if you
smell ether or otherwise suspect a
leak.
■Always wear goggles when
testing.
■Opening in the valve, tube, or noz-
zle (nozzle opening indicated by
red dot) must be pointed away
from you when testing.
■The engine starting fluid used in
DDEC®Ether Start Systems con-
tains ethyl ether and is extremely
flammable and toxic. It can be
harmful or fatal if swallowed. Avoid
contact with skin or eyes. Avoid
breathing fumes. If swallowed, DO
NOT INDUCE VOMITING. Call a
physician immediately.
■If fluid enters the eyes or if fumes
irritate the eyes, wash eyes with
large quantities of clean water for
15 minutes. A physician, preferably
an eye specialist, should be con-
tacted.
■Contents of cylinder are under
pressure. Store cylinders in a cool
dry area. Do not incinerate, punc-
ture or attempt to remove cores
from cylinders.
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vii
5. Observe the following cautions
when jump starting an engine,
charging a battery, or working
with the vehicle electrical system:
CAUTION:
To avoid injury from accidental
engine startup while servicing the
engine, disconnect/disable the
starting system.
CAUTION:
The addition of gasoline to diesel
fuel will create a serious fire haz-
ard. Do not mix gasoline with
diesel fuel.
CAUTION:
To avoid injury from fire, keep all
potential ignition sources away
from diesel fuel, including open
flames, sparks, and electrical
resistance heating elements. Do
not smoke when refueling.
CAUTION:
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. Always establish cor-
rect polarity before connecting
cables to the battery or battery
circuit. If you come in contact
with battery acid:
■Flush your skin with water.
■Apply baking soda or lime to
help neutralize the acid.
■Flush your eyes with water.
■Get medical attention immedi-
ately.
CAUTION:
To avoid injury from fire caused
by heated diesel-fuel vapors:
■Keep those people who are not
directly involved in servicing
away from the engine.
■Stop the engine immediately if a
fuel leak is detected.
■Do not allow open flames or
smoke when working on an
operating engine.
■Wear adequate protective cloth-
ing (face shield, insulated gloves
and apron, etc.).
■To prevent a buildup of poten-
tially volatile vapors, keep the
engine area well ventilated dur-
ing operation.
Diesel fuel is relatively harmless at
ambient temperatures.
6. Observe the following cautions
when fueling the vehicle, replac-
ing fuel filters or working with the
engine fuel system:
CAUTION:
To avoid injury from electrical
shock, do not touch battery termi-
nals, alternator terminals, or writ-
ing cables while the engine is
operating.
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viii
7. Observe the following cautions
when servicing the cooling
system:
CAUTION:
To avoid injury from the expulsion
of hot coolant, never remove the
cooling system pressure cap while
the engine is at operating temper-
ature. Remove the cap slowly to
relieve pressure. Wear adequate
protective clothing (face shield or
safety goggles, rubber gloves,
apron, and boots).
CAUTION:
To avoid injury from slipping and
falling, immediately clean up any
spilled liquids.
CAUTION:
To avoid injury from slipping and
falling, immediately clean up any
spilled liquids.
CAUTION:
To avoid injury from fire, contain
and eliminate leaks of flammable
fluids as they occur. Failure to
eliminate leaks could result in fire.
8. Observe the following cautions
when working on the engine air
intake system:
CAUTION:
To avoid injury from hot surfaces,
allow engine to cool before
removing any component. Wear
protective gloves.
CAUTION:
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.
9. Observe the following cautions
when replacing the engine lubri-
cating oil and filters:
CAUTION:
To avoid injury from fire caused by
heated lubricating-oil vapors:
■Keep those people who are not
directly involved in servicing away
from the engine.
■Stop the engine immediately if
an oil leak is detected.
■Do not allow open flames or
smoke when working on an
operating engine.
■Wear adequate protective cloth-
ing (face shield, insulated
gloves, apron, etc.) to avoid
burns.
■To prevent a buildup of poten-
tially volatile vapors, keep the
engine area well ventilated dur-
ing operation.
Lubricating oil is relatively harm-
less at ambient temperatures.
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1
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):
Left side just below the intake mani-
fold and above the cast-in Detroit
Diesel logo. See Figure 1.
Option Labels
Computerized engine option labels are
attached to the valve rocker cover.
These labels contain the engine serial
number and model number and, in
addition, list any optional equipment
used on the engine. Labels also include
required tune-up information (injection
timing, valve lash, max. no-load RPM,
etc.). See Figure 2.
With any order for parts, the engine
model and serial number must be given.
If a type number is shown on the option
label covering the equipment required,
this number should also be included on
the parts order.
Transmissions and power take-offs
generally carry their own name plates.
The model and serial number informa-
tion on these plates is useful when
ordering parts for these assemblies.
Certification Labels
If required, a certification label is
attached to the valve rocker cover. This
label certifies that the engine conforms
to federal and certain state emissions
regulations for its particular application. It
also gives the operating conditions
under which certification was made. See
Figure 2.
SERIAL NUMBER
MODEL NUMBER
06R0091517
6067GK60
Figure 1. Location of Engine Serial and Model Numbers

2
Figure 2. Typical Engine Option and Certification Labels
Option Labels
Certification Labels
U.S.A.
IMPORTANT ENGINE INFORMATION
1999 THIS ENGINE CONFORMS TO U.S. EPA AND CALIFORNIA
5OS REGULATIONS APPLICABLE TO 1999 MODEL YEAR NEW HEAVY DUTY
DIESEL CYCLE ENGINES. THIS ENGINE HAS A PRIMARY INTENDED
SERVICE APPLICATION AS A HEAVY HEAVY DUTY ENGINE.
FUEL RATE AT ADV. HP 250.6 MM3/STROKE ADV. HP 500 AT 2100 RPM
INITIAL INJECTION TIMING 14 DEG. BTC DISP. 12.7 LITERS
ENGINE FAMILY XDDXH12.7EGL MIN. IDLE 600 RPM
MODEL SERIES 60, 12.7 L MFG. DATE DEC 1999
UNIT 06R0_______ CONFORMS TO AUSTRALIAN DESIGN RULE 30
U.S.A.
0262 FUEL PUMP 2261 GEN MOUNT 0688 INJ CONT ELEC
0409 INJECTOR 1405 OIL COOLER 0594 OIL DIST
0638 OIL FILTER 0919 OIL PAN 0169 OILFILSHPGONL
0444 PWR STR ADAP 0445 PWR STR ADAPT 0583 ROCKER COVER
0358 THERMOSTAT 1743 TURBOCHARGER 0650 VALVEMECH
0893 VENT SYSTEM 1072 VENT SYSTEM 0161 VIB DAMPER
0464 WAT BYPASS 0459 WATER CONN 0306 WATER PUMP
UNIT O6RO_______ S.O._______ MODEL 606________ SPEC________
U.S.A.
EER 14B07 0438 ACC DRIVE THIS ENGINE WAS
1404 AIR COMP 0028 AIR INTK MFLD TESTED AT 430 HP
0178 C/S COVER 0387 C/S PULLEY AT 2100 RPM
0693 CONN ROD/PSTN 0131 CRANKSHAFT INJ. SETTING 81.0 MM
0566 CYL BLOCK 1448 DIPSTICK VALVE LASH
0260 ENG LIFT BRKT 0765 ENGINE MOUNTS EXHAUST .660 MM
0715 EXH MANIFOLD 0871 F/W HOUSING INTAKE .203 MM
1758 FAN MOUNTS 1260 FLYWHEEL MAX RPM NL 2225
0840 FUEL FILTER 2126 FUEL LINES STD CAM TIMING
UNIT O6RO_______ S.O._______ MODEL 606________ SPEC________
U.S.A.
THIS ENGINE IS NOT CERTIFIED FOR USE IN AN URBAN BUS AS
DEFINED AT 40 CFR 86.093 2. SALE OF THIS ENGINE FOR
USE IN AN URBAN BUS IS A VIOLATION OF FEDERAL LAW UNDER
THE CLEAN AIR ACT.
THIS ENGINE IS CERTIFIED TO OPERATE ON
LOW SULFUR DIESEL FUEL.
UNIT 06R0__________
DETROIT DIESEL
DETROIT DIESEL
DETROIT DIESEL
DETROIT DIESEL

3
OPERATING
INSTRUCTIONS
Preparations for Starting
the Engine
the First Time
When preparing to start a new or newly
overhauled engine or an engine which
has been in storage, perform all of the
operations listed below. Failure to follow
these instructions may result in serious
engine damage. Before a routine start,
see “Daily” checks in the Engine
Maintenance charts (pages 21-25).
Cooling System Checks
1. Make sure all the drain cocks in the
cooling system are installed (drain
CAUTION:
To avoid injury when working near
or on an operating engine, remove
loose items of clothing, jewelry,
and tie back or contain long hair
that could be caught in any mov-
ing part, causing injury.
cocks are often removed for shipping)
and are closed tightly.
2. Remove the radiator pressure control
cap and fill with genuine Detroit Diesel
Power Cool antifreeze or an equiva-
lent quality ethylene glycol or propy-
lene glycol-base antifreeze solution in
the required concentration. In
extremely hot environments, clean,
soft, properly inhibited water may
be used in the summer. Keep the
coolant level at the bottom of the filler
neck to allow for expansion of the
coolant. For more detailed coolant
recommendations, refer to How to
Select Coolant (page 48).
3. Entrapped air must be purged after
filling the cooling system. To do this,
allow the engine to warm-up with
the pressure cap off. With the trans-
mission in neutral, increase engine
speed above 1,000 RPM and add
coolant as required.
4. Check to make sure the front of the
radiator and air-to-air charge cooler
(if equipped) are unblocked and free
of debris.
Lubricating System Checks
The lubricating oil film on the rotating
parts and bearings of a new or newly
overhauled engine, or one which has
been in storage for six months or more,
may be insufficient when the engine is
started for the first time. Insufficient lubri-
cation at start-up can cause serious
damage to engine components.
To insure an immediate flow of oil to
all bearing surfaces at initial engine start-
up, the engine lubrication system should
be charged with a commercially avail-
able pressure pre-lubricator. If this is
impractical, rocker covers should be
removed and clean lubricating oil should
be poured over the rocker arms. The oil
CAUTION:
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 the
engine in a well-ventilated area.
■If operating the engine in an
enclosed area, vent the exhaust
to the outside.
■Do not modify or tamper with
the exhaust system or emission
control system.
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4
should be the same weight and viscosity
as that used in the crankcase. After pre-
lubricating, add additional oil to bring the
level to the proper mark on the dipstick.
See Figure 3. Refer to How to Select
Lubricating Oil (page 38) for lubricant
recommendation.
Extended Storage—An engine in stor-
age for an extended period of time (over
winter, for example) may accumulate
water in the oil pan through normal con-
densation of moisture (always present in
the air) on the cold internal surfaces of
the engine. Lube oil diluted by water
cannot provide adequate bearing pro-
tection at engine startup. For this rea-
son, Detroit Diesel recommends
replacing the engine lube oil and filter(s)
after extended storage.
Make sure the transmission is filled to
the proper level with the fluid recom-
mended by the gear manufacturer.
Fuel System Checks
Fill the tank with the recommended fuel.
Keeping tanks full reduces water con-
densation and helps keep fuel cool,
which is important to engine perfor-
mance. Full tanks also reduce the
chances for microbe (black slime)
growth. Refer to How to Select Fuel
Oil (page 41) for fuel recommendation.
Make sure the fuel supply shutoff valve
(if used) is open.
To insure prompt starting and even
running, the fuel system must be primed
if air has entered the fuel system.
Priming is done by connecting a manual
or electric priming pump to the sec-
ondary fuel filter. Authorized Detroit
Diesel service outlets are properly
equipped to perform this service.
Priming is not normally necessary if
the filter elements are filled with fuel
when installed and the manifolds are not
drained of fuel.
NOTICE:
Prolonged use of the starting motor
and engine fuel pump to prime the fuel
system can result in damage to the
starter, fuel pump, and injectors, and
cause erratic engine operation due to
the amount of air in the lines and filters
from the supply tank to the cylinder
head.
Engines equipped with starting
devices dependent on compressed air
or gas reservoirs should always be
primed before initial startup.
Otherwise, reserve pressure can be
exhausted and injectors may be dam-
aged from lack of lubrication and cool-
ing.
Under no circumstances should
a starting aid such as ether be
used to run the engine until the
fuel system is primed. Injector
damage will occur if this method
is used. The heat generated by the
external fuel source will cause the
injector tips to be damaged when the
fuel cools them. The plunger and
bushing can be scored from running
without lubrication.
NOTICE:
Failure to eliminate water-diluted lube
oil may lead to serious engine damage
at startup.
L
F
Figure 3. Check Lube Oil Level
Before Starting
I I
1;?71

5
If the engine is equipped with a
fuel/water separator, drain off any water
that has accumulated. Water in fuel can
seriously affect engine performance and
may cause engine damage. Detroit
Diesel recommends installation of a
fuel/water separator wherever water
contamination is a concern.
If a manual transmission is installed,
check the oil level. Add required trans-
mission fluid to bring the level to the “full”
mark on the dipstick. Do not overfill.
Other Checks
Check drive belts to make sure they are
in good condition (not cracked, torn,
worn, or glazed) and are properly adjust-
ed.
Make sure cable connections to the
storage batteries are clean and tight.
Check the hydrometer “eye” of mainte-
nance-free batteries for charge. See
Figure 4. If lead-acid or low maintenance
batteries are used, make sure battery
electrolyte level is normal.
Check turbocharger for signs of oil or
exhaust leaks. Leaks should be correct-
ed before starting the engine. Check
engine mounting bolts for tightness.
Retighten, if necessary.
Starting the Engine
Before starting the engine the first time,
perform the operations listed under
Preparations for Starting the Engine
the First Time (pages 3-4).
If the engine has an emergency man-
ual or automatic shutdown system,
make sure the control is set in the open
position before starting. The turbocharg-
er may be seriously damaged if the
engine is cranked with the air shutdown
in the closed position.
The engine may require the use of a
cold weather starting aid if the ambient
temperature is below 40°F (4°C).
Figure 4. Check “Eye” of Maintenance-Free
Batteries
Eye

6
Initial Engine Start
To start a Series 60 DDEC engine be
sure the transmission is in neutral or
park and turn the ignition key on.
You will notice that both the “Check
Engine” and “Stop Engine” lights will
come on. See Figure 5. This is the
result of the DDEC computer diagnos-
ing the system to ensure everything is
functional, including the light bulbs for
the “Check Engine” and “Stop Engine”
warning lights. If everything is okay,
both lights will go out in approximately
five seconds.
Start the engine after the lights
go out. If starting a vehicle, start the
engine with foot off the foot pedal.
1. Press the starter switch firmly.
NOTICE:
To prevent serious starting motor
damage, do not press the starter
switch again after the engine has
started.
Figure 5. Typical Shut-Down Override
Switch and Engine Lights
STOP ENGINE CHECK STOP
OVERRIDE
DIAGNOSTIC
SWITCH ENGINE ENGINE
NOTICE:
If the warning lights stay on, consult
with a DDEC technician. Operating the
engine under these circumstances may
result in engine damage.
CAUTION:
To avoid personal injury when using
ether during an engine startup,
ensure to follow these precautions:
■Do not smoke when servicing
ether system.
■Work in well-ventilated area.
■Do not work near open flames,
pilot flames (gas or oil heaters), or
sparks,
■Do not weld or carry an open
flame near the ether system if you
smell ether or otherwise suspect a
leak.
■Always wear goggles when
testing.
■Opening in the valve, tube, or noz-
zle (nozzle opening indicated by
red dot) must be pointed away
from you when testing.
■The engine starting fluid used in
DDEC®Ether Start Systems con-
tains ethyl ether and is extremely
flammable and toxic. It can be
harmful or fatal if swallowed. Avoid
contact with skin or eyes. Avoid
breathing fumes. If swallowed, DO
NOT INDUCE VOMITING. Call a
physician immediately.
■If fluid enters the eyes or if fumes
irritate the eyes, wash eyes with
large quantities of clean water for
15 minutes. A physician, preferably
an eye specialist, should be con-
tacted.
■Contents of cylinder are under
pressure. Store cylinders in a cool
dry area. Do not incinerate, punc-
ture or attempt to remove cores
from cylinders.
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7
Warm-up
Run the engine at part throttle for about
five (5) minutes to allow it to warm up
before applying a load.
Inspection
Transmission—While the engine is
idling, check the automatic transmission (if
equipped) for proper oil level and add oil
as required. Look for coolant, fuel, or lubri-
cating oil leaks at this time. If any are
found, shut down the engine immediately
and have leaks repaired after the engine
has cooled.
Crankcase—If the engine oil was
replaced, stop the engine after normal
operating temperature has been reached.
Allow the oil to drain back into the
crankcase for approximately 20 minutes,
and check the oil level. If necessary, add
oil to bring the level to the proper mark on
the dipstick. Use only the heavy-duty oils
recommended in How to Select
Lubricating Oil (page 38) in this guide.
Turbocharger—Make a visual inspection
of the turbocharger for oil leaks, exhaust
leaks, excessive noise or vibration. Stop
the engine immediately if a leak or unusual
noise or vibration is noted. Do not restart
the engine until the cause of the con-
cern has been investigated and cor-
rected. Authorized Detroit Diesel service
outlets are properly equipped to perform
this service.
CAUTION:
To avoid injury from hot oil, do not
operate the engine with the rocker
cover(s) removed.
2.If the engine fails to start within 15
seconds, release the starter switch
and allow the starting motor to cool
for 15 seconds before trying again. If
the engine fails to start after four
attempts, an inspection should be
made to determine the cause.
Air Starter—Because of the limited vol-
ume of most storage tanks and the rela-
tively short duration of the cranking
cycle, it is important to make sure the
engine is ready to start before acti-
vating the air starter. Start an engine
equipped with an air starter as follows:
1. Check the pressure in the air storage
tank. If necessary, add air to bring the
pressure up to at least the recom-
mended minimum for starting.
2. With foot OFF the foot pedal, press
the starter button firmly and hold until
the engine starts.
Running the Engine
Oil Pressure
Observe the oil pressure gauge immedi-
ately after starting the engine. A good
indicator that all of the moving parts are
getting lubrication is when the oil pres-
sure gauge registers pressure (5 psi -
34.5 kPa at idle speed). If there is no oil
pressure indicated within 10 to 15 sec-
onds, stop the engine and check the
lubricating system. The pressure should
not fall below 28 psi (193 kPa) at 1800
rpm, and normal operating pressure
should be higher. If pressure does not
fall within these guidelines, it should be
checked with a manual gauge.

8
Avoid Unnecessary Idling
During long engine idling periods with the
transmission in neutral, the engine coolant
temperature may fall below the normal
operating range. The incomplete com-
bustion of fuel in a cold engine will cause
crankcase dilution, formation of lacquer or
gummy deposits on the valves, pistons,
and rings, and rapid accumulation of
sludge in the engine. When prolonged
idling is necessary, maintain at least 850
rpm spring/summer and 1200 rpm
fall/winter.
Stopping the Engine
Normal Stopping
1. Decrease engine speed back to normal
idle and put all shift levers in the neutral
position.
2.Allow the engine to run between idle
and 1000 rpm with no load for four or
five minutes. This allows the engine to
cool and permits the turbocharger to
slow down. After four or five minutes,
shut down the engine.
Emergency Jump
Starting
DDEC III and DDEC IV electronic con-
trol systems operate on 12 or 24 volts
DC. If a DDEC III or IV engine with an
electronic starting motor requires emer-
gency jump starting, do not exceed 32
volts DC.
NOTICE:
Stopping a turbocharged engine
immediately after high speed opera-
tion may cause damage to the tur-
bocharger, as it will continue to turn
without an oil supply to the bearings.
NOTICE:
Jump starting with voltages greater
than those indicated or reversing
battery polarity may damage the
ECM (Electronic Control Module).
CAUTION:
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 the
engine in a well-ventilated area.
■If operating the engine in an
enclosed area, vent the exhaust
to the outside.
■Do not modify or tamper with
the exhaust system or emission
control system.
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9
NOTICE:
Failure to observe this precaution
can result in alternator and/or equip-
ment damage.
CAUTION:
To avoid injury from battery explo-
sion or contact with battery acid,
work in a well-ventilated area,
wear protective clothing, and
avoid sparks or flames near the
battery. Always establish correct
polarity before connecting cables
to the battery or battery circuit. If
you come in contact with battery
acid:
■Flush your skin with water.
■Apply baking soda or lime to
help neutralize the acid.
■Flush your eyes with water.
■Get medical attention immedi-
ately.
DDEC III/IV OPTIONS
Detroit Diesel Series 60 engines
equipped with DDEC III or DDEC IV
electronic control systems are identified
by a “K” in the sixth position of the
model number. Example: 6067GK60.
Detroit Diesel Electronic Controlled
Series 60 engines can be equipped
with a variety of options designed to
warn the operator of an engine mal-
function. The options can range from
“Check Engine” and “Stop Engine”
panel lights (see Figure 6) to automatic
reduction in engine power followed by
automatic engine shutdown. The
power-down/shutdown option may be
activated by low coolant level, low oil
pressure or high engine oil or coolant
temperature.
The Series 60 DDEC engine is
equipped with an electronically con-
trolled fuel injection system. There
NOTICE:
If the warning lights stay on, or if they
do not come on momentarily after
turning on the ignition, consult with a
DDEC technician. Operating the
engine under these circumstances
may result in engine damage.
STOP ENGINE CHECK STOP
OVERRIDE
DIAGNOSTIC
SWITCH ENGINE ENGINE
Figure 6. Typical Shut-Down Override
Switch and Engine Lights
Before attempting to jump start the
engine, make sure jumper cables are
connected properly (positive to positive,
negative to negative) and in the proper
sequence (negative to negative last).
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The DDEC engine may also have
an optional 1-100 minute idle shut-
down system. The purpose of this sys-
tem is to conserve fuel by eliminating
excessive idling and to allow for a tur-
bocharger cool down period. To activate
the shutdown, the transmission must be
in neutral, with the vehicle parking
brakes set and with the engine in idle or
fast idle mode.
NOTICE:
If the engine is equipped with the
power-down/shutdown option, there
will be a system override button or
switch which may be used to allow
engine operation for a short period of
time. If the shutdown override button
is not used, the shutdown will occur in
30 seconds. Using the override button
so that the engine operates for an
extended period may result in engine
damage.
CAUTION:
To avoid injury from engine shut-
down in an unsafe situation,
ensure the operator knows how to
override the stop engine condition
on a DDEC-equipped unit.
10
are no control racks or mechanical link-
age to adjust. This system not only
helps to improve fuel economy and vehi-
cle performance, it also helps to reduce
cold starting time and increase initial idle
speed for fast engine warm-up and vir-
tual elimination of cold smoke.
The DDEC engine has no
mechanical governor. Engine horse-
power, torque, idle, and engine speed
are contained in the internal electronics.
Therefore, there are no mechanical gov-
ernor spring adjustments for idle and
high speed control.
There is no need for a throttle
delay either, since emission control is
performed through the Electronic
Control Module (ECM).
The Electronic Foot Pedal Assembly
(EFPA), eliminates the need for any
throttle linkage.
The DDEC engine has the ability to
perform diagnostics for self-checks
and continuous monitoring of other
system 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.
The DDEC engine can be
equipped with an engine protection
system that features a 30 second,
stepped-power shutdown sequence
or an immediate speed reduction
without shutdown in the event a major
engine malfunction occurs, such as low
oil pressure, high oil or coolant tempera-
ture, or low coolant level.
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