Engines Detroit Diesel Series 60, service e-manual

Content General information Scope and use of this manual Clearance of new parts and wear limits The four cycle principle for diesel engines Four cycle principle for natural gas engines General description General specifications General specifications for the series 60G engine Engine model, serial number and option label Replacing and repairing Disassembly Cleaning Safety precautions Fluoroelastomer (viton) caution Engine views English to metric conversion Decimal and metric equivalents Specifications Engine Cylinder block and cylinder liner Cylinder head Valve and injector operating mechanism Valves, springs, guides, inserts, seals and rotators Engine lifter brackets Rocker cover Crankshaft Crankshaft oil seals Crankshaft main bearings Gear case cover pre-exhaust gas recirculation Gear case cover exhaust gas recirculation Gear case pre-exhaust gas recirculation Gear case exhaust gas recirculation (EGR) model Crankshaft vibration damper Crankshaft pulley Flywheel Ring gear Flywheel housing Piston and piston ring One-piece piston assembly and piston ring Piston and connecting rod assembly Connecting rod Cylinder liner Gear train and engine timing Compact gear train and engine timing Camshaft gear assembly series 60 exhaust gas Recirculation (EGR) model Thrust plate perimeter seal Camshaft and camshaft bearing Camshaft drive gear Adjustable idler gear assembly Adjustable idler gear compact gear train Bull gear and camshaft idler gear for the compact gear train Bull gear and camshaft idler gear assembly Crankshaft timing gear and timing wheel Accessory drive Jake brake Additional information Fuel system Diesel fuel system overview Vehicle safety for the natural gas engine Electronic unit injector Fuel injector tube and o-ring Electronic unit injector Fuel injector tube Fuel pump with separate drive shaft and hub Fuel pump with one-piece drive shaft and hub assembly Fuel pump drive Diesel fuel filters (spin-on) Fuel pro 380/380e fuel filter system Fuel filter type for the series 60G engine Assembly fuel filter and water separator Electronic engine control DDEC V electronic control unit DDEC III/IV electronic control module DDEC II electronic control module DDEC I Programmable read-only memory (prom) DDEC I Electronic distributor unit DDEC I Electronic foot pedal assembly Turbo speed sensor Turbo boost pressure sensor Air intake pressure sensor Pressure sensor Oil temperature sensor Air temperature sensor Air temperature sensor for high pressure fuel system Coolant temperature sensor Synchronous reference sensor gear case mounted Synchronous reference sensor camshaft position sensor camshaft gear cover mounted Timing reference sensor Coolant level sensor Fuel pressure sensor Fuel temperature sensor Exhaust gas oxygen sensor for series 60G engines Exhaust temperature sensor for the series 60G engines Knock sensor and signal noise enhancement filter module Barometric pressure sensor for the series 60G engine with high pressure fuel system Overview of high pressure fuel system for series 60G engines Fuel pressure gages for the series 60G engine with a high pressure fuel system Venting and leak checking procedures for a natural gas engine (high pressure system) High pressure fuel regulator for the series 60G engine Pulse width modulated stepper motor valve (psv) for series 60G automotive engines Fuel mixer for the series 60G high pressure fuel system Fuel shutoff valve for series 60G engine with high pressure fuel system Impco low pressure fuel regulator for the series 60G engine high pressure fuel system Overview of the low pressure natural gas fuel system Low pressure fuel regulator for the series 60G engine Fuel mixer for the series 60G low pressure system Venting and leak checking procedures for natural gas engine (low pressure system) Additional information Lubrication system Overview of lubricating system Oil pump Pressure regulator valve Oil pressure relief valve Oil filter Oil filter adaptor Thermatic oil control valve Oil cooler (1991 and later engines) Oil cooler (pre-1991 engines) Oil level dipstick assembly Oil pan Ventilating system Additional information Cooling system Cooling system overview Water pump (gear-case mounted - 1991 and later) Water pump (front mounted) Thermostat Coolant pressure control cap Engine cooling fan Coolant filter and conditioner Radiator Additional information Fuel, lubricating oil, and coolant Fuel Lubricating oil (diesel) Lubricating oil for the series 60G engine Coolant Air intake system Air intake system overview Air cleaner Intake manifold Closed crankcase breather for series 60G automotive engines Turbocharger (diesel) Turbocharger series 60 natural gas (automotive) engine Recirculation valve for series 60G automotive engine Charge air cooler Throttle actuator for the series 60G engine Air dryer Additional information Exhaust system Overview of exhaust manifold components Three-piece exhaust manifold with fey rings Three-piece exhaust manifold without fey rings Three-piece exhaust manifold with heat shield Exhaust gas recirulation (EGR) components Tube and shell bolted flange EGR cooler Hydraulic EGR valve Delivery pipe EGR rate measurement system DDEC v varible pressure output device DDEC iv varible pressure output devices Electrical equipment Overview of electrical system Battery charging alternator Storage battery Cranking motor Tachometer drive DDEC III/IV engine sensor harness DDEC II engine sensor harness Metri-pack 150 series connectors Micro-pack series connectors Weather pack and metri-pack 280 series connectors Connector tools Splicing guidelines Additional information Power take-off Front mounted power take-off Rear engine power take-off (repto) assembly Special equipment Air compressor (vehicle applications only) Air compressor drive hub Additional information Operation and verification Preparation for a first time start Starting Running Stopping Operating conditions Series 60G automotive engine operating conditions Engine run-in instructions Engine tune-up Engine tune-up procedures Valve lash, injector height (timing) and jake brake® lash adjustments Engine tune-up procedures for the series 60G engine Valve lash for the series 60G engine Preventive maintenancep Maintenance overview Daily maintenance - all applications Maintenance of vehicle engines Preventive maintenance for the series 60G automotive engine (city transit coach) Maintenance of series 60G automotive engines Description of maintenance items Cleaning contaminated lubrication oil system Storage Preparing engine for storage Restoring an extended storage engine Ignition system Overview of ignition system Coil over plug ignition system Ignition coil assembly Ignition boot assembly Igniter module Igniter module bracket Ignition coil harness Spark plugs

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