Detroit Diesel Series 60 Diesel & Natural Gas- Fueled Engines Service Manual – PDF DOWNLOAD
DESCRIPTION:
Detroit Diesel Series 60 Diesel & Natural Gas- Fueled Engines Service Manual – PDF DOWNLOAD
SCOPE AND USE OF THIS MANUAL :
This manual contains complete instructions on operation, adjustment (tune-up },
preventive maintenance, and repair (including complete overhaul) for the Series 60
Inline Diesel Engines.
- This manual was written primarily for persons servicing and
overhauling the engine. In addition, this manual contains all of the instructions
essential to the operators and users. Basic maintenance and overhaul procedures
are common to all Series 60 Engines, and apply to all engine models.
This manual is divided into numbered sections. - The section one covers the engine (less major assemblies). The following sections cover а complete system such as
the fuel system, lubrication system, or air system. Each section is divided into subsections which contain complete maintenance and operating instructions for а specific engine subassembly. - Each section begins with а tаЫе of contents. Pages and illustrations are numbered consecutively within each section.
Information can Ье located Ьу using the tаЫе of contents at the front of the manual or the tаЫе of contents at the beginning of each section. - Information on specific sub-assemblies or accessories within the major section is listed immediately
following the section title.
TABLE OF CONTENTS:
Detroit Diesel Series 60 Diesel & Natural Gas- Fueled Engines Service Manual – PDF DOWNLOAD
1 ENGINE ………………………………………………………… 1-1
1.1 CYLINDER BLOCK AND CYLINDER LINER …………….. . …… . …… 1-3
1.2 CYLINDER HEAD …………………………… ……… ………… 1-28
1.3 VALVE AND INJECTOR OPERATING MECHANISM …… ……………. . . 1-59
1.4 VALVES, SPRINGS, GUIDES, INSERTS, SEALS AND ROTATORS ………. 1-74
1.5 ENGINE LIFТER BRACKETS …………………………………….. 1-102
1.6 ROCKER COVER …. . . ………… ……. ….. …………….. ……. 1-107
1.7 CRANKSHAFT … . . . ……… ……… ……………… … . .. … . ….. 1-127
1.8 CRANKSHAFT OIL SEALS … . .. … . …. …. …… … .. …………. …. 1-145
1.9 CRANKSHAFT MAIN BEARINGS …………………………………. 1-158
1.10 GEAR CASE COVER ………………….. …… …………………. 1-171
1.11 GEAR CASE .. ….. ………………….. . ….. ………… ……….. 1-203
1.12 CRANKSHAFT VIBRATION DAMPER …. . …………… . …………… 1-225
1.13 CRANKSHAFТ PULLEY ….. …… . …………… ………. .. …. . . . . . . 1-233
1.14 FLYWHEEL … … ……. …………….. …………………. …….. 1-240
1.15 RING GEAR ………… ….. … ………. . ………… . . ….. ……… 1-250
1.16 FLYWHEEL HOUSING ………… …… . … ………… .. ………….. 1-252
1.17 PISTON AND PISTON RING ……………………………………… 1-259
1.18 PISTON AND CONNECTING ROD ASSEMBLY . …… . ……………….. 1-275
1.19 CONNECTING ROD ……….. ………… … . ………. .. .. .. …… .. . 1-289
1.20 CYLINDER LINER ……………. .. . … . …… ……. ……. . .. … .. … 1-298
1.21 GEAR TRAIN AND ENGINE TIMING ……….. ……….. . …. . . …….. 1-313
1.22 CAMSHAFT AND CAMSHAFT BEARING …………………………… 1-339
1.23 CAMSHAFТ DRIVE GEAR …. …………. …. …. .. .. ….. ………… 1-368
1.24 ADJUSTABLE IDLER GEAR ASSEMBLY ……………………………. 1-380
1.25 BULL GEAR AND CAMSHAFT IDLER GEAR ASSEMBLY …….. … …. …. 1-390
1.26 CRANKSHAFT TIMING GEAR AND TIMING WHEEL ………………….. 1-404
1.27 ACCESSORY DRIVE …….. .. . ……………… ……… . ……….. . 1-423
1.28 JAKE BRAKE …….. …………. . …. .. . ………………. …….. .. 1-451
1.А ADDITIONAL INFORMATION …………………………………….. 1-461
2 FUEL SYSTEM …………………………………………………… 2-1
2.1 DIESEL FUEL SYSTEM OVERVIEW ………………………………. 2-3
2.2 ELECTRONIC UNIT INJECTOR …….. ….. …. .. . .. …. .. .. ……. ….. 2-6
2.3 FUEL INJECTOR TUBE AND O-RING ……. ….. . ……………… …. . 2-25
2.4 FUEL PUMP WITH SEPARATE DRIVE SHAFT AND HUB …………. …… 2-37
2.5 FUEL PUMP WITH ONE-PIECE DRIVE SHAFТ AND HUB ASSEMBLY ……. 2-58
2.6 FUEL PUMP DRIVE …. ……………. . …………. …………….. . 2-79
2.7 DIESEL FUEL FILTERS (SPIN-ON) .. ………………… ………… . .. 2-83
2.8 FUEL PRO® 380/380Е FUEL FILTER SYSTEM … …. ….. …………… . 2-87
2.9 ASSEMBLY FUEL FILTER AND WATER SEPARATOR …………………. 2-91
2.10 ELECTRONIC ENGINE CONTROL . .. . …. . . ……………………….. 2-98
2.11 DDEC 111 ELECTRONIC CONTROL MODULE …… .. ….. …………….. 2-99
2.12 DDEC II ELECTRONIC CONTROL MODULE . ………………….. . ….. 2-106
2.13 DDEC 1 … … ……………….. .. ………….. .. … …………….. 2-116
2.14 PROGRAMMABLE READ-ONLY MEMORY (PROM) DDEC 1 ……………. 2-121
2.15 ELECTRONIC DISTRIBUTOR UNIT DDEC 1 … ……… . …. ………….. 2-126
2.16 ELECTRONIC FOOT PEDAL ASSEMBLY …………………………… 2-128
2.17 TURBO BOOST PRESSURE SENSOR …………………………….. 2-129
2.18 AIR PRESSURE SENSOR ………………………………………. 2-132
2.19 OIL PRESSURE SENSOR ….. . . .. …… .. ……. .. .. .. . …….. ….. … 2-134
2.20 OIL TEMPERATURE SENSOR ……………………………………. 2-136
2.21 AIR TEMPERATURE SENSOR …………………………………… 2-138
2.22 COOLANT TEMPERATURE SENSOR …….. ……… . . ……… …… .. 2-141
2.23 SYNCHRONOUS REFERENCE SENSOR …………………… . …….. 2-143
2.24 TIMING REFERENCE SENSOR …. ……… ….. .. ….. …. … … . ….. 2-146
2.25 COOLANT LEVEL SENSOR ……… .. . . …….. … … …… ………… 2-148
2.26 FUEL PRESSURE SENSOR . . .. …………………. . …… . . .. …… . . 2-151
2.27 FUEL TEMPERATURE SENSOR ………………………………….. 2-153
2.28 KNOCK SENSOR AND SIGNAL NOISE ENHANCEMENT FILTER MODULE .. 2-156
2.29 VEHICLE SAFETY FOR ТНЕ NATURAL GAS ENGINE ….. . ….. ……… . 2-159
2.30 OVERVIEW OF ТНЕ LOW PRESSURE NATURAL GAS FUEL SYSTEM …… 2-163
2.31 LOW PRESSURE FUEL REGULATOR FOR ТНЕ SERIES 60G ENGINE …. .. 2-168
2.32 PULSE WIDTH MODULATED STEPPER MOTOR VALVE (PSV)
FOR ТНЕ SERIES 60G ENGINE ………………………………….. 2-170
2.33 FUEL MIXER FOR ТНЕ SERIES 60G LOW PRESSURE SYSTEM . … .. … . . 2-174
2.34 VENTING AND LEAK CHECКING PROCEDURES FOR А
NATURAL GAS ENGINE (LOW PRESSURE SYSTEM) . .. . … . . … . .. . ….. 2-178
2.А ADDITIONAL INFORMATION …………………………………….. 2-181
З LUBRICATION SYSTEM ………………………………………… . .. 3-1
3.1 OVERVIEW OF LUBRICATING SYSTEM ……. . ………… .. . .. …. …. 3-3
3.2 OIL PUMP ……………………………………………………. 3-8
3.3 OIL PRESSURE REGULATOR VALVE ……………………………… 3-22
3.4 OIL PRESSURE RELIEF VALVE ………………………………….. 3-29
3.5 OIL FILTER …. …. ………….. .. . ………. .. .. . … . ….. …. .. . . … 3-34
3.6 OIL FILTER ADAPTOR …. …. … ……………………… … ……… 3-36
3.7 THERMATIC OIL CONTROL VALVE . ……. . … . …. .. . . …… …. … …. 3-41
3.8 OIL COOLER (1991 AND LATER ENGINES) …………………………. 3-47
3.9 OIL COOLER (PRE-1991 ENGINES) . …………. …. …………… . … 3-57
3.10 OIL LEVEL DIPSTICK ASSEMBLY . …. . ………. ……. ……. . … . …. 3-66
3.11 OIL PAN ……………………………………………………… 3-71
3.12 VENTILATING SYSTEM ………………………………………… 3-78
3.А ADDITIONAL INFORMATION … ….. .. . …… …………….. .. …….. 3-87
А// information subjвct to сhвпgв without noticв.
6SE483 9610 © 1996 DEТROTT DIESEL CORPORAТION
SER/ES 60 SERVICE MANUAL
4 COOLING SYSTEM ……………………………………………….. 4-1
4.1 COOLING SYSTEM OVERVIEW …… .. .. . . ….. … . …. . …………… 4-3
4.2 WATER PUMP – (GEAR CASE MOUNTED-1991 AND LATER) .. .. .. . .. … . 4-7
4.3 WATER PUMP (FRONT MOUNTED) (FM) ………… …………. . ……. 4-35
4.4 THERMOSTAT ………………………………………………… 4-64
4.5 COOLANT PRESSURE CONTROL САР …………………….. . ……. 4-75
4.6 ENGINE COOLING FAN . . . . ……. … .. .. ………. … …………….. 4-78
4.7 COOLANT FILTER AND CONDITIONER ….. .. … . ……………… … . . 4-89
4.8 RADIATOR ….. . …. . ……………… . …. . . . ….. … . . . . .. .. ……. 4-91
4 . А ADDITIONAL INFORMATION …………………………………….. 4-93
5 FUEL, LUBRICATING OIL, AND COOLANT ……………………………. 5-1
5.1 FUEL …………………………….. ………………………… 5-3
5.2 LUBRICATING OIL (Diesel) . …… ….. . .. … . ………………… …… 5-9
5.3 LUBRICATING OIL FOR ТНЕ SERIES 60G ENGINE . ….. … . …….. ….. 5-15
5.4 COOLANT … …… ………. . … .. ….. … .. . …. …. . …… . …… . .. 5-17
6 AIR INTAKE SYSTEM ……………………………………………… 6-1
6.1 AIR INTAKE SYSTEM OVERVIEW .. …. . ……………… …… . ……. 6-3
6.2 AIR CLEANER ………. …. .. ………… … ………….. .. ….. ….. 6-6
6.3 INTAKE MANIFOLD (Diesel) …….. ……………. ….. ……… . . ….. 6-8
6.4 TURBOCHARGER (Diesel) …………………………….. . … ….. . . 6-19
6.5 TURBOCHARGER SERIES 60 GAS ENGINE ………………… ……. . . 6-33
6.6 CHARGE AIR COOLER …………………………………………. 6-48
6.7 THROTTLE ACTUATOR FOR ТНЕ SERIES 60G ENGINE ………. …. … . 6-53
6.8 AIR DRYER …. . …………………………… ……………… … 6-56
6.А ADDITIONAL INFORMATION . …. … . . . …….. . .. .. .. .. ……………. 6-57
7 EXHAUST SYSTEM ……………………………………………….. 7-1
7.1 OVERVIEW OF EXHAUST SYSTEM …. … ………. . … . …………… 7-3
7.2 EXHAUST MANIFOLD . ……….. ….. …. . …… …. . . …… ………. 7-4
7.А ADDITIONAL INFORMATION …………………………. . . . ….. .. . . . 7-11
8 ELECTRICAL EQUIPMENT …………………………………………. 8-1
8.1 OVERVIEW OF ELECTRICAL SYSTEM ……………………………. 8-3
8.2 ВАТТЕRУ CHARGING ALTERNATOR ……………………………… 8-4
8.3 STORAGE ВАТТЕRУ … ……………………………………… … 8-12
8.4 CRANKING MOTOR …. . . . ………………… …. … …. . . . ………. 8-15
8.5 TACHOMETER DRIVE … ……. . ……………………………. ….. 8-21
8.6 DDEC 111 WIRING HARNESS …. …… …………………… ………. 8-27
8.7 DDEC 11 WIRING HARNESS ……………… ………………… .. .. .. 8-31
8.8 METRI-PACK 150 SERIES CONNECTORS …………………………. 8-37
8.9 MIRCO-PACK SERIES CONNECTORS ……… . … .. ……………….. 8-42
8.1 О WEATHER РАСК AND METRI-PACK 280 SERIES CONNECTORS ….. ….. 8-44
8.11 CONNECTOR TOOLS ……. .. …….. …. . . …… . .. . … …. ………. 8-48
8.12 SPLICING GUIDELINES … … ……………………. . … ……. . . … . 8-49
В.А ADDITIONAL INFORMATION ……….. . . . ….. . …. .. . . . . . .. . . ……… 8-53
9 POWER TAKE-OFF ………………………………………………. 9-1
9.1 REAR MOUNTED POWER TAKE-OFF …………………………….. 9-3
9.2 FRONT MOUNTED POWER TAKE-OFF ……………………………. 9-4
9.А ADDITIONAL INFORMATION …………………………………….. 9-9
10 SPECIAL EQUIPMENT …………………………………………….. 1()-1
10.1 AIR COMPRESSOR (Vehicle Applications Only} ….. ……. ….. …… ….. 10-3
10.2 AIR COMPRESSOR DRIVE HUB ……. . ……….. …. ……………… 10-15
10.3 AIR COMPRESSOR DRIVE ASSEMBLY ……… ……. …. …….. …… 10-20
1 О.А ADDITIONAL INFORMATION …………………………………….. 1 Q-43
11 OPERATION AND VERIFICATION ……………………………………. 11-1
11.1 PREPARATION FOR А FIRST TIME START …………………… ….. .. 11-3
11.2 STARTING …………………………………………………… 11-6
11.3 RUNNING ……………………………………………………. 11-7
11.4 STOPPING …………………………………………………… 11-9
11.5 OPERATING CONDITIONS …….. ….. ……… ………… …….. … 11-10
11.6 SERIES 60G ENGINE OPERATING CONDITIONS ……………………. 11-12
11.7 ENGINE RUN-IN INSTRUCTIONS . … .. …………………………… 11-14
12 ENGINE TUNE UP ………………………………………………… 12-1
12.1 ENGINE TUNE-UP PROCEDURES ………….. . ………………….. 12-3
12.2 VALVE LASH, INJECTOR HEIGHT (TIMING) AND JAKE BRAKE
LASH ADJUSTMENTS ……………. .. …… ………….. ………… 12-5
12.3 ENGINE TUNE-UP PROCEDURES FOR ТНЕ SERIES 60G ENGINE …….. 12-17
12.4 VALVE LASH FOR ТНЕ SERIES 60G ENGINE ……………………….. 12-19
12.А ADDITIONAL INFORMATION …………………………………….. 12-23
13 PREVENTIVE MAINTENANCE ………………………………………. 13-1
13.1 MAINTENANCE OVERVIEW ………………….. .. … ….. .. …….. . 13-3
13.2 DAIL У MAINTENANCE – ALL APPLICATIONS …… … … … ….. ….. …. 13-4
13.3 MAINTENANCE OF VEHICLE ENGINES ……………………………. 13-5
13.4 MAINTENANCE OF ENGINES USED IN STATIONARY AND
INDUSTRIAL APPLICATIONS . . ………………………………….. 13-12
13.5 MAINTENANCE OF SERIES 60G ENGINES FOR GENERATOR SET …….. 13-17
13.6 LUBRICATING OIL AND FILTER CHANGE INTERVALS FOR GENSET ……. 13-19
13.7 LUBRICATING OIL AND FILTER CHANGE INTERVALS FOR GENSET
(WITH HIGH SULFUR FUELS) …… ……………………… …….. .. 13-20
13.8 DESCRIPTION OF MAINTENANCE ITEMS ………………………. … 13-21
13.А ADDITIONAL INFORMATION …………………………….. ……… 13-45
14 ENGINE STORAGE ……………………………………………….. 14-1
14.1 PREPARING ENGINE FOR STORAGE …………………………….. 14-3
14.2 RESTORING AN EXTENDED STORAGE ENGINE …………… …….. .. 14-9
15 IGNITION SYSTEM ………………………. . …….. . ………….. . … 15-1
15.1 OVERVIEW OF IGNITION SYSTEM …… . ……. . .. . . . .. .. . ….. .. . . . . .. 15-3
15.2 COIL OVER PLUG IGNITION SYSTEM . . . . . .. . . .. .. ………….. .. … . .. 15-4
15.3 IGNITION ВООТ ASSEMBLY . ………… .. .. . . .. ………… ……. . … 15-9
15.4 IGNITER MODULE .. . . . . … . . . . …. . .. .. . . .. …. .. ….. . …………… 15-10
15.5 IGNITER MODULE BRACKET . . . . … .. …. . . . .. . .. . ….. . …… . . .. . .. .. 15-11
15.6 IGNITION COIL HARNESS …. . . .. .. . … . . . . .. … . …. . .. . …. . ……. .. 15-12
15.7 SPARK PLUGS …… .. . .. . ……. . …….. . .. . .. . … . . . …. . . . …. . … 15-16
INDEX ………………………………………………………………… INDEX-1
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