1 Manual de Servicio Serie 60



El EXTRACTO del MANUAL DE REPARACIONES de la SERIE

60 este manual proporciona la instrucción para la en-carretera de mantenimiento, la construcción y el sistema industrial, de generador, y los usos marinas de la serie diesel los motores Gas-Aprovisionados de combustible diesel y naturales de 60 de Detroit. Específicamente una descripción básica de cada componente y sistema importantes junto con las recomendaciones para el retiro, limpieza, inspección, los criterios para el reemplazo, reparación e instalación y localización de averías mecánica se contiene en este manual. Las preocupaciones de localización de averías de DDEC III/IV se contienen en la sola guía de localización de averías del ECM de DDEC III/IV, 6SE497.

Toda la información conforme a cambio sin el aviso. (Inversor de corriente. 2 004) © del del copy copyri righ ght t 6SE 6SE48 483 3 040 0401 1 DET DETRO ROIT IT 2004 2004 DIES DIESEL EL CORP CORPOR ORAT ATIO ION N i

las SERIES 60 del MANUAL DE REPARACIONES

del EXTRACTOR del MOTOR consideran el siguiente antes de mantener los motores:

El extractor del motor diesel y algo de sus componentes se saben al estado de California para causar el cáncer, los defectos de nacimient o, y el otro daño reproductivo. Encienda y funcione siempre un motor en un área bien ventilada. Si funciona un motor en un área incluida, exprese el extractor al exterior. No se modifique ni trate de forzar con el dispositivo de escape o el sistema de control de emisión.

(Inversor de corriente. 2004) Toda la información conforme a cambio sin el avi so. ii las las SER SERIE IES S 200 2004 4 de de DET DETRO ROIT IT DIES DIESEL EL CORP CORPOR ORAT ATIO ION N del del © del del copy copyri righ ght t 6SE 6SE48 483 3

0401 60 modificaciones de la NOTIFICACIÓN

de la REVISIÓN del MANUAL DE REPARACIONES a este manual se anuncian bajo la forma de boletines de informa ción de servicio. Los boletines incluyen incluyen las páginas páginas del accesorio accesorio y se fijan en el W orld Wide Web (www.detroitdiesel.com/svc/sibindex.htm). Las revisiones a este manual serán enviadas marcadas con una barra de la revisión (véa se el ejemplo 2). Las secciones que contienen revisiones tendrán tendrán una tercera tercera línea en el pie de la página (compare los ejemplos 1 y 2).

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MANUAL DE REPARACIONES de la SERIE 60

(inversor de corriente. 2004) Toda la información conforme a cambio sin el av iso. intr intrav aven enos oso o INFO INFORM RMAC ACIÓ IÓN N DE CARÁ CARÁCT CTER ER GENE GENERA RAL L 2004 2004 del del CON CONTE TENI NIDO DO del del MAN MANUA UAL L DE DE REP REP ARACIONES de la SERIE 60

de DETROIT DIESEL CORPORATION del ©

del copyright

6SE483 0401 ......................... ................................................. .......................................... .................. .. 1 ALCANCE Y USO DE ESTE MANUAL ........................................... ........................................... .......... 3 SEPARACIÓN DE NUEVOS PIEZAS Y LÍMITES DEL DESGASTE ......................... ..... 3 EL PRINCIPIO DE CUATRO TIEMPOS PARA LOS MOTORES DIESEL ................. ..... 4 PRINCIPIO DE CUATRO TIEMPOS PARA LOS MOTORES DE GAS NATURAL ............ ...... 6 DESCRIPCIÓN GENERAL ...................... ............................................... ................................ ....... ................ 8 ESPECIFICACIONES GENERALES ....................... ............................................. ...................... .................... 13 ESPECIFICACIONES GENERALES PARA El MOTOR de la SERIE 60G ............ 14 MODELO DEL MOTOR, NÚMERO DE SERIE Y ETIQUETA DE LA OPCIÓN .................. . 15 MODELO DEL MOTOR, NÚMERO DE SERIE Y ETIQUETA DE LA OPCIÓN (SERIE MOTOR 60G) ....................... ............................................... ...................................... .............. .... ...... .... .... .... .... .... .... .... .... .... .... .... ... . 18 EL SUBSTITUIR Y REPARACIÓN ....................... ............................................... ........................ ................. 19 DESMONTAJE ....................... ............................................... ...................................... .............. ........................... 19 LIMPIEZA ......................... ................................................. ...................................... .............. ................................ 20 MEDIDAS DE SEGURIDAD ................................................ ....................... .......................... . .... ...... .... .... .... .... .... .... .... .... .. 26 PRECAUCIÓN DE FLUOROELASTOMER (VITON) .................................... ......... 39 OPINIONES DEL MOTOR .................................................... .................................................... ................................... 40 INGLESES A LA CONVERSIÓN MÉTRICA ........................................... ........................................... ......... 45

EQUIVALENTES DECIMALES Y MÉTRICOS ........................................ ........................................ ........ 46 ESPECIFICACIONES ..................... .............................................. .................................. ......... .... ...... .... .... .... .... .... .... .... .... .... .... .... ... . 48 1 MOTOR 1.1 1.1 BLOQ BLOQUE UE DE CILI CILIND NDRO RO Y TRA TRAZA ZADO DOR R DE DE LÍN LÍNEA EAS S DEL DEL CILI CILIND NDRO RO ... ..... .... .... .... .... .... .... .... .... .. ..... ...... .... .... .... .... .... .... .... .. 1-3 1-3 1.2 CULATA CULATA ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ..... .. ................... 1-30 1.3 MECANI MECANISMO SMO DE FUNCIO FUNCIONAM NAMIEN IENTO TO DE LA VÁLVUL VÁLVULA A Y DEL INYECT INYECTOR OR ...... ......... ...... ...... ..... .. ............. 1-64 1.4 1.4 VÁLVU ÁLVULA LAS, S, RESO RESORT RTES ES, , GU GUÍAS, ÍAS, REL RELLENO LENOS, S, SELLO ELLOS S Y ROTO ROTORE RES S ... .... .... ... 1-8 1-86 1.5 SOPORT SOPORTES ES DEL LEVANT LEVANTADO ADOR R DEL DEL MOTOR MOTOR ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ..... .. ..... ...... .... .... .... .... .... .... .... ... ..... ...... .. 1-11 1-118 8 1.6 CUBIER CUBIERTA TA DEL EJE DE BALANC BALANCÍN ÍN ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ... .......... ............... .......... .......... .......... .......... ......... .... 1-126 1.7 CIGÜEÑ CIGÜEÑAL AL ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... .... . ..... ...... .... .... .... .... .... .... .... .. 1-14 1-148 8 1.8 SELLOS SELLOS DE ACEITE ACEITE DEL CIGÜEÑ CIGÜEÑAL AL ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... .... . .......... ............... .......... ........ ... 1-169 1.9 COJINE COJINETES TES PRINCI PRINCIPAL PALES ES DEL CIGÜEÑ CIGÜEÑAL AL ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ..... .. .................. 1-190 1.10 1.10 CUBIER CUBIERTA TA DE LA CAJA CAJA DEL ENGRAN ENGRANAJE AJE ..... ........ ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ... ........................................ 1-203 1.11 1.11 CAJA CAJA DEL ENGRANAJ ENGRANAJE E ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ..... .. .......... ............... .......... .......... .......... .......... ......... .... 1-237 1.12 1.12 APAGAD APAGADOR OR DE LA VIBRAC VIBRACIÓN IÓN DEL CIGÜEÑ CIGÜEÑAL AL ....... .......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ... ............. 1-269 1.13 POLEA DEL CIGÜEÑAL CIGÜEÑAL .......... ............... .......... .......... .......... .......... .......... .......... .......... .......... ....... .. ................. 1-278 1.14 1.14 RUEDA RUEDA VOLANT VOLANTE E ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ..... .. .... ...... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... ... . 1-29 1-294 4 1.15 1.15 ENGRAN ENGRANAJE AJE DEL ANILLO ANILLO ........ ........... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... .... . ..... ...... .... .... .... .... .... .... .... ... ..... ...... .... .... .... .... .... .... .... .. 1-30 1-304 4 1.16 1.16 CUBIER CUBIERTA TA DE LA RUEDA VOLAN VOLANTE TE ....... .......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ... .................................. 1-306 1.17 1.17 PISTÓN PISTÓN Y ANILLO ANILLO DE PISTÓN PISTÓN ........ ........... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ... ................. 1-314 1.18 1.18 ASAMBL ASAMBLEA EA DEL PISTÓN PISTÓN Y PIST PISTÓN ÓN DE DE UNA UNA PIEZA PIEZA DE ACER ACERO O FORJ FORJADO ADOS S ANILLO ....................... ............................................... .......................................... .................. .......... ............... .......... .......... .......... .......... ......... .... 1-337 1.19 PISTÓN Y ASAMBLEA DE BIELA ..................................... 1-352 All information subject to change without notice. (Rev. 6SE483 0401 Copyright © 2004 DETROIT DIESEL CORPORATION

2004) v

SERIES 60 SERVICE MANUAL

1.20 1.20 CONNEC CONNECTIN TING G ROD ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ..... .. ........................ 1-383 1.21 1.21 CYLIND CYLINDER ER LINER LINER ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ..... .. ........................... 1-398 1.22 1.22 GEAR GEAR TRAIN TRAIN AND ENGINE ENGINE TIMING TIMING ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ... ............ 1-413 1.23 1.23 THRUST THRUST PLATE PLATE PERIME PERIMETER TER SEAL SEAL .... ....... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... .... .

........... 1-443 1.24 1.24 CAMSHA CAMSHAFT FT AND CAMSHA CAMSHAFT FT BEARIN BEARING G ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ... ..... 1-458 1.25 1.25 CAMSHA CAMSHAFT FT DRIVE DRIVE GEAR GEAR ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ... ................... 1-510 1.26 1.26 ADJUST ADJUSTABL ABLE E IDLE IDLER R GEAR GEAR ASSEMB ASSEMBLY LY ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ..... .. .... ...... ... . 1-52 1-524 4 1.27 1.27 BULL BULL GEAR GEAR AND AND CAMS CAMSHA HAFT FT IDLE IDLER R GEAR GEAR ASSE ASSEMB MBLY LY .... ...... .... .... .... .... .... .... .... ... . 1-535 1.28 1.28 CRANKS CRANKSHAF HAFT T TIMING TIMING GEAR GEAR AND TIMING TIMING WHEEL WHEEL ...... ......... ...... ...... ...... ...... ...... ...... .... . 1-549 1.29 1.29 ACCESS ACCESSORY ORY DRIVE DRIVE ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ..... .. .......... ............... .......... ........ ... 1-570 1.30 1.30 JAKE JAKE BRAKE® BRAKE® ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... .... . ..... ...... .... .... .... .... .... .... .... ... ..... ...... .. 1-60 1-603 3 1.A 1.A ADDI ADDITI TION ONAL AL INFOR INFORMA MATI TION ON ..... ....... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .. ................. 1-663 2 FUEL SYSTEM 2.1 2.1 DIES DIESEL EL FUEL FUEL SYST SYSTEM EM OVER OVERVI VIEW EW .... ...... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... ... . ........... 2-5 2.2 2.2 VEHI VEHICL CLE E SAFE SAFETY TY FOR FOR THE THE NATU NATURA RAL L GAS GAS ENGI ENGINE NE .... ...... .... .... .... .... .... .... .... .... .... ... . 2-7 2.3 2.3 ELEC ELECTR TRON ONIC IC UNIT UNIT INJE INJECT CTOR OR .... ...... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .. ...... ......... ...... ...... ... 2-11 2-11 2.4 2.4 FUEL FUEL INJ INJEC ECTO TOR R TUBE TUBE AND AND O-R O-RIN ING G .... ...... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .. .......... 2-30 2.5 2.5 N3 ELEC ELECTR TRON ONIC IC UNIT UNIT INJE INJECT CTOR OR .... ...... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... ... . ............. 2-46 2.6 2.6 FUEL FUEL INJE INJECT CTOR OR TUBE TUBE .... ...... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .. .... ...... .... .... .... .... .... .... .... .... .. 2-60 2-60 2.7 2.7 FUEL FUEL PUMP PUMP WITH WITH SEPA SEPARA RATE TE DRIV DRIVE E SHAF SHAFT T AND AND HUB HUB .... ...... .... .... .... .... .... .... .... ... . 2-64 2.8 FUEL PU PUMP WI WITH ON ONE-PIECE DR DRIVE SH SHAFT AN AND HU HUB AS ASSEMBLY 2-87 2.9 2.9 FUEL FUEL PUMP PUMP DRIV DRIVE E ..... ....... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... ... . ......................... 2-110 2.10 2.10 DIESEL DIESEL FUEL FUEL FILTER FILTERS S (SPIN(SPIN-ON) ON) ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ..... .. ...... ......... ...... ...... ... 2-115 2-115 2.11 2.11 FUEL FUEL PRO 380/38 380/380E 0E FUEL FUEL FILTER FILTER SYSTEM SYSTEM ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ..... .. ..... 2-124 2.12 SEA PRO 150/300 DIESEL FUEL PROCESSOR SYSTEM (MARINE) .. 2-131 2.13 2.13 SEA SEA PRO PRO 152 152 FUE FUEL L FIL FILTE TER R SYS SYSTE TEM M (MAR (MARIN INE E ENGI ENGINE NE) ) .... ...... .... .... .... .... .... .... ... . 2-139 2.14 2.14 FUEL FUEL FILTER FILTER TYPE TYPE FOR THE SERIES SERIES 60G ENGINE ENGINE ...... ......... ...... ...... ...... ...... ...... ...... ... 2-148 2.15 FUEL COOLER (HEAT EXCHANGER-COOLED MARINE ENGINE) ..... 2-157 2.16 2.16 ASSEMB ASSEMBLY LY FUEL FUEL FILTER FILTER AND WATER WATER SEPARA SEPARATOR TOR ...... ......... ...... ...... ...... ...... ...... ...... ... 2-161 2.17 2.17 ELECTR ELECTRONI ONIC C ENGINE ENGINE CONTRO CONTROL L ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... .... . ........... 2-169 2.18 2.18 DDEC DDEC V ELEC ELECTRO TRONIC NIC CONTRO CONTROL L UNIT UNIT ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ..... .. .... ...... ... . 2-17 2-171 1 2.19 2.19 DDEC DDEC III/IV III/IV ELECTR ELECTRONI ONIC C CONTRO CONTROL L MODULE MODULE ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... .... . .. 2-179 2.20 2.20 DDEC DDEC II ELECTR ELECTRONI ONIC C CONTRO CONTROL L MODULE MODULE ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... .... . .... 2-187 2.21 2.21 DDEC DDEC I ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ..... .. .... ...... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .. 2-19 2-199 9 2.22 .22 PROGR ROGRAM AMMA MABL BLE E READEAD-ON ONLY LY MEM MEMORY ORY (PRO (PROM) M) DDEC DEC I ..... ...... .... .... .... .... ... . 2-2 2-205 2.23 2.23 ELECTR ELECTRONI ONIC C DISTRI DISTRIBUT BUTOR OR UNIT UNIT DDEC DDEC I ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ..... .. ...... 2-209

2.24 2.24 ELECTR ELECTRONI ONIC C FOOT FOOT PEDAL PEDAL ASSEMB ASSEMBLY LY ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... .... . ...... 2-213 2.25 2.25 TURBO TURBO BOOST BOOST PRESSU PRESSURE RE SENSOR SENSOR ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... .... . .... ...... ... . 2-21 2-214 4 2.26 2.26 AIR INTAKE INTAKE PRESSU PRESSURE RE SENSOR SENSOR ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ... ............ 2-216 2.27 2.27 OIL PRESSU PRESSURE RE SENSOR SENSOR ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ..... .. ................... 2-219 2.28 2.28 OIL TEMPER TEMPERATU ATURE RE SENSOR SENSOR ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ..... .. ...... ......... ...... ...... ... 2-221 2-221 2.29 2.29 AIR TEMPER TEMPERATU ATURE RE SENSOR SENSOR ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ... ...... ......... ...... ...... ... 2-223 2-223 2.30 2.30 AIR AIR TEM TEMPE PERA RATU TURE RE SENS SENSOR OR FOR FOR HIG HIGH H PRE PRESS SSUR URE E FUE FUEL L SYSTEM ................................................................ .................................. 2-227 2.31 2.31 COOLAN COOLANT T TEMPER TEMPERATU ATURE RE SENSOR SENSOR ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ... .... ...... ... . 2-22 2-229 9 2.32 2.32 SYNCHR SYNCHRONO ONOUS US REFERE REFERENCE NCE SENSOR SENSOR ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ... ... 2-231 (Rev. 2004) vi 6SE48 SE483 3

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2.33 2.33 TIMING TIMING REFERE REFERENCE NCE SENSOR SENSOR ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... .... . .............. 2-234 2.34 .34 COOLA OOLANT NT LEV LEVEL EL SEN SENS SOR .... ...... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... ... ..... ...... .... ... . .................. 2-236 2.35 .35 FUEL UEL PRES PRESSU SURE RE SEN SENS SOR .... ...... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... ... ..... ...... .... ... . .................. 2-240 2.36 2.36 FUEL FUEL TEMPER TEMPERATU ATURE RE SENSOR SENSOR ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... .... . ............. 2-243 2.37 2.37 EXHA EXHAUS UST T GAS GAS OXYG OXYGEN EN SENS SENSOR OR FOR FOR SERI SERIES ES 60G 60G ENGI ENGINE NES S .... ...... .... .. 2-24 2-247 7 2.38 2.38 EXHA EXHAUS UST T TEM TEMPE PERA RATU TURE RE SENS SENSOR OR FOR FOR THE THE SERI SERIES ES 60G 60G ENGINES ....................................................................... .......................... 2-251 2.39 2.39 KNOC KNOCK K SEN SENSO SOR R AND AND SIG SIGNA NAL L NOIS NOISE E ENH ENHAN ANCE CEME MENT NT FILT FILTER ER MODULE ....................... ............................................... ................................................. .......................... . ......................... 2-252 2.40 2.40 BARO BAROME METR TRIC IC PRES PRESSU SURE RE SENS SENSOR OR FOR FOR THE THE SERI SERIES ES 60G 60G ENGI ENGINE NE WITH HIGH PRESSURE FUEL SYSTEM .............................................. ..................... ......................... 2-255 2.41 2.41 OVER OVERVI VIEW EW OF OF HIGH HIGH PRE PRESS SSUR URE E FUEL FUEL SYS SYSTE TEM M FOR FOR SERI SERIES ES 60G 60G ENGINES ....................................................................... .......................... 2-257 2.42 2.42 FUEL FUEL PRES PRESSU SURE RE GAGE GAGES S FOR FOR THE THE SERI SERIES ES 60G 60G ENG ENGIN INE E WIT WITH H A HIGH PRESSURE FUEL SYSTEM ....................... ................................................ .............................. ..... .... 2-263 2.43 2.43 VENT VENTIN ING G AND AND LEAK LEAK CHE CHECK CKIN ING G PROC PROCED EDUR URES ES FOR FOR A NAT NATUR URAL AL GAS ENGINE (HIGH PRESSURE SYSTEM) ....................... ......................................... .................. 2 -265 2.44 2.44 HIGH HIGH PRES PRESSU SURE RE FUEL FUEL REGU REGULA LATO TOR R FOR FOR THE THE SER SERIE IES S 60G 60G ENGINE ........................................................................ ........................... 2-269 2.45 2.45 PULS PULSE E WIDT WIDTH H MOD MODUL ULAT ATED ED STEP STEPPE PER R MOTO MOTOR R VAL VALVE VE (PSV (PSV) ) FOR FOR

SERIES 60G AUTOMOTIVE ENGINES .................................................. .................................................. . 2-271 2.46 2.46 FUEL FUEL MIXE MIXER R FOR FOR THE THE SER SERIE IES S 60G 60G HIGH HIGH PRES PRESSU SURE RE FUEL FUEL SYST SYSTEM EM .............................................. ...................... ................................................. .................................. ......... .................................. 2-275 2.47 2.47 FUEL FUEL SHUT SHUTOF OFF F VAL VALVE VE FOR FOR SER SERIE IES S 60G 60G ENGI ENGINE NE WIT WITH H HIG HIGH H PRESSURE FUEL SYSTEM ........................ ................................................. .................................. ......... ......... 2-278 2.48 2.48 IMPC IMPCO O LOW LOW PRES PRESSU SURE RE FUEL FUEL REGU REGULA LATO TOR R FOR FOR THE THE SERI SERIES ES 60G 60G ENGINE HIGH PRESSURE FUEL SYSTEM ........................ .......................................... .................. 2 -280 2.49 2.49 OVER OVERVI VIEW EW OF THE THE LOW LOW PRES PRESSU SURE RE NATU NATURA RAL L GAS GAS FUEL FUEL SYSTEM ........................................................................ .......................... 2-284 2.50 2.50 LOW LOW PRE PRESS SSUR URE E FUE FUEL L REG REGUL ULAT ATOR OR FOR FOR THE THE SERI SERIES ES 60G 60G ENGINE ........................................................................ ........................... 2-289 2.51 2.51 FUEL FUEL MIXE MIXER R FOR FOR THE THE SERI SERIES ES 60G 60G LOW LOW PRES PRESSU SURE RE SYST SYSTEM EM .... ...... ... . 2-29 2-293 3 2.52 2.52 VENT VENTIN ING G AND AND LEAK LEAK CHEC CHECKI KING NG PROC PROCED EDUR URES ES FOR FOR NAT NATUR URAL AL GAS GAS ENGINE (LOW PRESSURE SYSTEM) ................................................ ....................... .......................... . . 2-296 2.A 2.A ADDI ADDITI TION ONAL AL INFOR INFORMA MATI TION ON ..... ....... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .. ................. 2-299 3 LUBRICATION SYSTEM 3.1 3.1 OVER OVERVI VIEW EW OF OF LUBR LUBRIC ICAT ATIN ING G SYST SYSTEM EM ... ..... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .. ..... ...... .. 3-3 3.2 3.2 OIL OIL PUMP PUMP .... ...... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .. .................................. 3-8 3.3 3.3 OIL OIL PRES PRESSU SURE RE REG REGUL ULAT ATOR OR VAL VALVE VE ... ..... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .. ......... 3-23 3.4 3.4 OIL OIL PRES PRESSU SURE RE RELI RELIEF EF VALV VALVE E .... ...... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... ... . ................ 3-30 3.5 3.5 OIL OIL FILT FILTER ER .... ...... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .. .................................. 3-36 3.6 3.6 OIL OIL FILT FILTER ER ADAP ADAPTO TOR R .... ...... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .. ........................ 3-40 3.7 3.7 THER THERMA MATI TIC C OIL OIL CONT CONTRO ROL L VALV VALVE E .... ...... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... ... . ............ 3-46 3.8 3.8 OIL OIL COO COOLE LER R (199 (1991 1 AND AND LAT LATER ER ENGI ENGINE NES) S) .... ...... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .. ...... 3-53 3.9 3.9 OIL OIL COOL COOLER ER (PRE (PRE-1 -199 991 1 ENGI ENGINE NES) S) .... ...... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... ... . ............. 3-64 3.10 3.10 OIL LEVEL LEVEL DIPSTI DIPSTICK CK ASSEMB ASSEMBLY LY ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ..... .. ..... ...... .... .... .... ... . 3-74 -74 All information subject to change without notice. (Rev. 6SE483 0401 Copyright © 2004 DETROIT DIESEL CORPORATION

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3.11 3.11 OIL PAN ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ... .... ...... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .. 3-79 3-79 3.12 3.12 VENTIL VENTILATI ATING NG SYSTEM SYSTEM ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... .... . .... ...... .... .... .... .... .... .... .... .... .. 3-87 3-87 3.A 3.A ADDI ADDITI TION ONAL AL INFOR INFORMA MATI TION ON ..... ....... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .. ................. 3-95

4 COOLING SYSTEM 4.1 4.1 COOL COOLIN ING G SYSTE SYSTEM M OVERV OVERVIE IEW W ..... ....... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... ... . ............. 4-3 4.2 WATER PUMP (GEAR CASE MOUNTED - 1991 AND LATER) (GCM) .. 4-11 4.3 4.3 WATE WATER R PUMP PUMP (FR (FRON ONT T MOUN MOUNTE TED) D) (FM (FM) ) .... ...... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .. ...... 4-43 4.4 CHARG HARGE E AI AIR COO COOLE LER R RAW RAW WATE WATER R PU PUMP (KEEL KEEL-C -COO OOLE LED D COMMERCIAL MARINE) ....................... ................................................ .............................. ..... .................... 4-72 4.5 4.5 THER THERMO MOST STAT AT .... ...... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... ... . .... ...... .... .... .... .... .... .... .... .... .... .... .... ... . 4-80 4-80 4.6 4.6 COOL COOLAN ANT T PRES PRESSU SURE RE CONT CONTRO ROL L CAP CAP .... ...... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .. ...... 4-92 4.7 4.7 ENGI ENGINE NE COOL COOLIN ING G FAN ... ..... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .. ..... ...... .... .... .... .... .... .... .... .. 4-96 4-96 4.8 4.8 COOL COOLAN ANT T FILT FILTER ER AND AND COND CONDIT ITIO IONE NER R .... ...... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .. ........ 4-106 4.9 4.9 RADI RADIAT ATOR OR .... ...... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .. ................................. 4-108 4.10 4.10 KEEL KEEL COOLIN COOLING G SYSTEM SYSTEM (COMME (COMMERCI RCIAL AL MARINE MARINE) ) ...... ......... ...... ...... ...... ...... ...... ...... .... . 4-109 4.11 4.11 HEAT HEAT EXCH EXCHAN ANGE GER R COO COOLI LING NG SYST SYSTEM EM (PLE (PLEAS ASUR URE E CRA CRAFT FT MARINE) ...................... .............................................. .......................................... .................. .................................. 4-110 4.12 4.12 HEAT HEAT EXCHAN EXCHANGER GER (PLEAS (PLEASURE URE CRAFT CRAFT MARINE MARINE) ) ...... ......... ...... ...... ...... ...... ...... ...... ...... ... 4-112 4.13 4.13 JABS JABSCO CO® ® ENGI ENGINE NE COOL COOLIN ING G RAW RAW WATE WATER R PUMP PUMP (MAR (MARIN INE) E) .... ...... .... .... .... ... . 4-12 4-128 8 4.A 4.A ADDI ADDITI TION ONAL AL INFOR INFORMA MATI TION ON ..... ....... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .. ................. 4-143 5 FUEL, LUBRICATING OIL, AND COOLANT 5.1 5.1 FUEL FUEL .... ...... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .. ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ..... .. 5-3 5.2 5.2 LUBR LUBRIC ICAT ATIN ING G OIL OIL (DIE (DIESE SEL) L) .... ...... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .. .................... 5-12 5.3 5.3 LUBR LUBRIC ICAT ATIN ING G OIL OIL FOR FOR THE THE SERI SERIES ES 60G 60G ENGI ENGINE NE .... ...... .... .... .... .... .... .... .... .... .... .... .... ... . 5-19 5.4 5.4 COOL COOLAN ANT T .... ...... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .. ................................ 5-22 6 AIR INTAKE SYSTEM 6.1 6.1 AIR AIR INTA INTAKE KE SYS SYSTE TEM M OVER OVERVI VIEW EW ... ..... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .. ............. 6-3 6.2 6.2 AIR AIR CLEA CLEANE NER R .... ...... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... ... . ...... ......... ...... ...... ...... ...... ...... ...... ...... ... 6-9 6.3 6.3 AIR AIR SEPA SEPARA RATO TOR R .... ...... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... ... . ..... ...... .... .... .... .... .... .... .... ... ..... ...... .. 6-11 6-11 6.4 6.4 INTA INTAKE KE MANI MANIFO FOLD LD .... ...... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... ... . .......................... 6-13 6.5 6.5 CLOS CLOSED ED CRAN CRANKC KCAS ASE E BREA BREATH THER ER FOR FOR SERI SERIES ES 60G 60G AUTO AUTOMO MOTI TIVE VE ENGINES ............................................................... .................................. 6-24 6.6 6.6 TURB TURBOC OCHA HARG RGER ER (DIE (DIESE SEL) L) .... ...... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... ... . ................. 6-26 6.7 6.7 TURB TURBOC OCHA HARG RGER ER SERI SERIES ES 60 GAS GAS ENGI ENGINE NES S (GEN (GENSE SET) T) .... ...... .... .... .... .... .... .... ... . 6-82 6.8 TURBO URBOCH CHAR ARGE GER R SER SERIE IES S 60 60 NAT NATUR URAL AL GAS GAS (AU (AUTO TOMO MOTI TIVE VE) ) ENGINE ................................................................ ................................... 6-97 6.9 RECIRCULATION VALVE FOR SERIES 60G AUTOMOTIVE ENGINE ... 6-116 6.10 6.10 CHARGE CHARGE AIR COOLER COOLER ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ... ..... ...... .... .... .... .... .... .... .... .. 6-11 6-118 8

6.11 6.11 THRO THROTT TTLE LE ACT ACTUA UATO TOR R FOR FOR THE THE SERI SERIES ES 60G 60G ENG ENGIN INE E .... ...... .... .... .... .... .... .... .... ... . 6-128 6.12 6.12 AIR DRYER DRYER ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ..... .. ................................ 6-133 6.A 6.A ADDI ADDITI TION ONAL AL INFOR INFORMA MATI TION ON ..... ....... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .. ................. 6-135 7 EXHAUST SYSTEM 7.1 7.1 OVER OVERVI VIEW EW OF OF EXHA EXHAUS UST T SYST SYSTEM EM ... ..... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .. .......... 7-3 7.2 7.2 EXHA EXHAUS UST T MANIFO MANIFOLD LD ..... ....... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .. .... ...... .... .... .... .... .... .... .... .... .. 7-6 7-6 (Rev. 2004) All information subject to change without notice. viii viii 6SE4 6SE483 83 0401 0401 Copy Copyri righ ght t © 2004 2004 DETR DETROI OIT T DIES DIESEL EL CORP CORPOR ORAT ATIO ION N

SERIES 60 SERVICE MANUAL 8 ELECTRICAL EQUIPMENT 8.1 8.1 OVER OVERVI VIEW EW OF ELEC ELECTR TRIC ICAL AL SYST SYSTEM EM .... ...... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... ... . ........ 8-3 8.2 8.2 BATT BATTER ERY Y CHARG CHARGIN ING G ALTER ALTERNA NATO TOR R ..... ....... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... ... . ......... 8-4 8.3 8.3 STOR STORAG AGE E BATTER BATTERY Y ...... ........ .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .. .......... ............... .......... ........ ... 8-26 8.4 8.4 CRAN CRANKI KING NG MOTO MOTOR R .... ...... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .. ........................ 8-29 8.5 8.5 TACH TACHOM OMET ETER ER DRIVE DRIVE ..... ....... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .. .... ...... .... .... .... .... .... .... .... .... .. 8-35 8-35 8.6 8.6 DDEC DDEC III/ III/IV IV ENGI ENGINE NE SENS SENSOR OR HARN HARNES ESS S .... ...... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... ... . ........ 8-41 8.7 8.7 DDEC DDEC II II ENGI ENGINE NE SEN SENSO SOR R HARN HARNES ESS S .... ...... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .. ......... 8-51 8.8 8.8 METR METRII-PA PACK CK 150 150 SER SERIE IES S CONN CONNEC ECTO TORS RS ... ..... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .. ..... 8-57 8.9 8.9 MICR MICROO-PA PACK CK SERI SERIES ES CONN CONNEC ECTO TORS RS .... ...... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .. ........ 8-63 8.10 WEATHER PACK AND METRI-PACK 280 SERIES CONNECTORS ....... 8-65 8.11 8.11 CONNEC CONNECTOR TOR TOOLS TOOLS ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... .... . .... ...... .... .... .... .... .... .... .... .... .. 8-69 8-69 8.12 8.12 SPLICI SPLICING NG GUIDEL GUIDELINE INES S ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ... .... ...... .... .... .... .... .... .... .... .... .. 8-70 8-70 8.A 8.A ADDI ADDITI TION ONAL AL INFOR INFORMA MATI TION ON ..... ....... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .. ................. 8-75 9 POWER TAKE-OFF 9.1 9.1 FRON FRONT T MOUN MOUNTE TED D POWE POWER R TAKE TAKE-O -OFF FF ... ..... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .. ...... 9-3 9.2 9.2 REAR REAR ENGI ENGINE NE POWE POWER R TAKE TAKE-O -OFF FF (REP (REPTO TO) ) ASSE ASSEMB MBLY LY .... ...... .... .... .... .... .... .... .... .. 9-8 10 SPECIAL EQUIPMENT 10.1 10.1 AIR COMPRE COMPRESSO SSOR R (VEHIC (VEHICLE LE APPLIC APPLICATI ATIONS ONS ONLY) ONLY) ...... ......... ...... ...... ...... ...... ...... ... 10-3 10.2 10.2 AIR COMPRE COMPRESSO SSOR R DRIVE DRIVE HUB ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ..... .. ............. 10-19 10.3 10.3 AIR AIR COMP COMPRE RESS SSOR OR/R /RAW AW WATE WATER R PUMP PUMP DRIV DRIVE E ASSE ASSEMB MBLY LY .... ...... .... .... .... .... .. 10-2 10-24 4 10.4 10.4 KIM HOT START START STARTI STARTING NG AID SYSTEM SYSTEM (MARIN (MARINE) E) ...... ......... ...... ...... ...... ...... ...... ...... ... 10-50 10.A 10.A ADDITI ADDITIONA ONAL L INFORM INFORMATI ATION ON ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... .... .

................. 10-51 11 OPERATION AND VERIFICATION 11.1 11.1 PREPAR PREPARATI ATION ON FOR A FIRST FIRST TIME TIME START START ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ... .... ...... ... . 11-3 11-3 11.2 11.2 STARTI STARTING NG ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ... ................................. 11-7 11.3 11.3 RUNNIN RUNNING G ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... .... . ................................. 11-8 11.4 11.4 STOPPI STOPPING NG ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ... ................................ 11-11 11.5 11.5 OPERAT OPERATING ING CONDIT CONDITION IONS S ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ... .................. 11-12 11.6 11.6 SERIES SERIES 60G GENSET GENSET ENGINE ENGINE OPERAT OPERATING ING CONDIT CONDITION IONS S ...... ......... ...... ...... .... . 11-16 11-16 11.7 11.7 SERI SERIES ES 60G 60G AUTO AUTOMO MOTI TIVE VE ENGI ENGINE NE OPER OPERAT ATIN ING G COND CONDIT ITIO IONS NS .... ...... .... .. 11-1 11-18 8 11.8 11.8 ENGINE ENGINE RUN-IN RUN-IN INSTRU INSTRUCTI CTIONS ONS ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ..... .. ..... ...... .... .... .... ... . 11-20 1-20 12 ENGINE TUNE-UP 12.1 12.1 ENGINE ENGINE TUNE-U TUNE-UP P PROCED PROCEDURE URES S ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ... ........... 12-3 12.2 12.2 VALV VALVE E LASH LASH, , INJE INJECT CTOR OR HEIG HEIGHT HT (TIM (TIMIN ING) G) AND AND JAKE JAKE BRAK BRAKE® E® LASH LASH ADJUSTMENTS ...................... .............................................. ...................................... .............. ........................... 12-5 12.3 12.3 ENGI ENGINE NE TUNE TUNE-U -UP P PRO PROCE CEDU DURE RES S FOR FOR THE THE SER SERIE IES S 60G 60G ENG ENGIN INE E ... ... 12-2 12-25 5 12.4 12.4 VALVE VALVE LASH LASH FOR THE SERIES SERIES 60G ENGINE ENGINE ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... .... . .... 12-27 13 PREVENTIVE MA MAINTENANCE 13.1 13.1 MAINTE MAINTENAN NANCE CE OVERVI OVERVIEW EW ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... .... . ................. 13-3 13.2 13.2 DAILY DAILY MAINTE MAINTENAN NANCE CE - ALL ALL APPLIC APPLICATI ATIONS ONS ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ..... .. ..... 13-4 13.3 13.3 DAILY DAILY MAINTE MAINTENAN NANCE CE - MARINE MARINE APPLIC APPLICATI ATIONS ONS ...... ......... ...... ...... ...... ...... ...... ...... ...... .... . . 13-5 13.4 13.4 MAINTE MAINTENAN NANCE CE OF MARINE MARINE ENGINE ENGINES S ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ..... .. .... ...... ... . 13-6 13-6 13.5 13.5 MAINTE MAINTENAN NANCE CE OF VEHICL VEHICLE E ENGINE ENGINES S ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... .... . .... ...... ... . 13-1 13-11 1 All information subject to change without notice. (Rev. 6SE483 0401 Copyright © 2004 DETROIT DIESEL CORPORATION

2004) ix

SERIES 60 SERVICE MANUAL 13.6 13.6

MAIN MAINTE TENA NANC NCE E OF OF ENG ENGIN INES ES USED USED IN STAT STATIO IONA NARY RY AND AND INDUSTRIAL APPLICATIONS ..................... .............................................. .......................... . .................. 13-16 13.7 13.7 MAIN MAINTE TENA NANC NCE E OF OF SERI SERIES ES 60 DIES DIESEL EL ENGI ENGINE NES S FOR FOR GENE GENERA RATO TOR R SET ................................................................... .......... ............... .......... .......... .......... .......... ......... .... 13-22 13.8 13.8 MAIN MAINTE TENA NANC NCE E OF SERI SERIES ES 60G 60G ENGI ENGINE NES S FOR FOR GENE GENERA RATO TOR R SET SET .. 13-2 13-25 5 13.9 3.9 LUBRI UBRICA CATI TING NG OIL OIL AN AND FI FILTER LTER CHA CHANGE NGE INT INTE ERVAL RVALS S FO FOR GE GENSET NSET 13-2 13-27 7 13.10 13.10 PREVEN PREVENTIV TIVE E MAIN MAINTEN TENANC ANCE E FOR FOR THE SERIES SERIES 60G AUTOMO AUTOMOTIV TIVE E ENGINE (CITY TRANSIT COACH) ..................... ........................................... ...................... ..... ...... .... .... .... ... . 13-28 3-28 13.11 13.11 MAINTE MAINTENAN NANCE CE OF SERIES SERIES 60G AUTOMO AUTOMOTIV TIVE E ENGINE ENGINES S ...... ......... ...... ...... ...... ... 13-31 13-31 13.12 13.12 LUBRIC LUBRICATI ATING NG OIL AND FILTER FILTER CHANGE CHANGE INTERV INTERVALS ALS FOR GENSET GENSET (WITH HIGH SULFUR FUELS) ..................... .............................................. .......................... . ................. 13-37

13.13 13.13 DESCRI DESCRIPTI PTION ON OF MAINTE MAINTENAN NANCE CE ITEMS ITEMS ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ..... .. ..... 13-38 13.14 13.14 AIR SEPAR SEPARATO ATOR R FILTER FILTER ELEMENT ELEMENT (MARI (MARINE) NE) ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... .... . ... 13-75 13.15 13.15 DETECT DETECTING ING INTERNA INTERNAL L FUEL LEAKS ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ... ......... 13-79 13.16 13.16 CLEANI CLEANING NG CONTA CONTAMIN MINATE ATED D LUBRIC LUBRICATI ATION ON OIL OIL SYSTEM SYSTEM .... ....... ...... ...... ...... ...... ... 13-87 14 STORAGE 14.1 14.1 PREPAR PREPARING ING ENGINE ENGINE FOR STORAG STORAGE E .... ....... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ... ........ 14-3 14.2 14.2 RESTOR RESTORING ING AN EXTEND EXTENDED ED STORAG STORAGE E ENGINE ENGINE ...... ......... ...... ...... ...... ...... ...... ...... ...... ..... .. 14-10 14.3 14.3 WINTER WINTER STORAG STORAGE E FOR MARINE MARINE ENGINE ENGINE ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... .... . .... 14-14 15 IGNITION SYSTEM 15.1 15.1 OVERVI OVERVIEW EW OF IGNITI IGNITION ON SYSTEM SYSTEM ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... .... . ............ 15-3 15.2 15.2 COIL COIL OVER OVER PLUG PLUG IGNITI IGNITION ON SYSTEM SYSTEM ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... .... . .......... 15-4 15.3 15.3 IGNITI IGNITION ON BOOT BOOT ASSEMB ASSEMBLY LY ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ... .................. 15-9 15.4 15.4 IGNITE IGNITER R MODULE MODULE ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... .... . .......................... 15-10 15.5 15.5 IGNITE IGNITER R MODULE MODULE BRACKE BRACKET T ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ... ................ 15-11 15.6 15.6 IGNITI IGNITION ON COIL COIL HARNES HARNESS S ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... .... . .................... 15-12 15.7 15.7 SPARK SPARK PLUGS PLUGS ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... .... . .... ...... .... .... .... .... .... .... .... .... .... .... .... ... . 15-1 15-16 6 16 MISFIRING CYLINDER 16.1 16.1 POOR POOR VEHICL VEHICLE E GROUND GROUND ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ... .................. 16-3 16.2 16.2 AERATE AERATED D FUEL FUEL ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ... ..... ...... .... .... .... .... .... .... .... ... ..... ...... .. 16-5 16-5 16.3 16.3 IMPR IMPROP OPER ER INJE INJECT CTOR OR CALI CALIBR BRAT ATIO ION N SETT SETTIN ING G (DDE (DDEC C III/ III/IV IV ENGINES ONLY) ........................ ................................................. .................................. ......... ..... ...... .... .... .... .... .... .... .... ... ..... ...... .. 16-7 16-7 16.4 16.4 IMPR IMPROP OPER ER VALV VALVE E CLEA CLEARA RANC NCE E OR OR INJ INJEC ECTO TOR R HEI HEIGH GHT, T, WORN WORN OR DAMAGED CAMSHAFT LOBES AND ROLLERS .................................. ..................... ............. 16-12 16.5 16.5 FAULTY FAULTY FUEL FUEL INJECT INJECTOR OR ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ..... .. ..... ...... .... .... .... .... .... .... .... .. 16-2 16-24 4 16.6 16.6 FAULTY FAULTY ELECTR ELECTRONI ONIC C CONTRO CONTROL L MODULE MODULE ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ..... .. ... 16-26 16.7 16.7 WORN WORN OR DAMAGE DAMAGED D VALVE VALVE OR CYLIND CYLINDER ER KIT ...... ......... ...... ...... ...... ...... ...... ...... ...... ..... .. 16-28 17 STARTING DIFFICULTY (ENGINE ROTATES) 17.1 17.1 ELEC ELECTR TRON ONIC IC CONT CONTRO ROL L MODU MODULE LE WIRI WIRING NG HARN HARNES ESS S .... ...... .... .... .... .... .... .... .... .... .. 17-3 17.2 17.2 EMPTY EMPTY FUEL FUEL TANK TANK ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... .... . ......................... 17-6 17.3 17.3 LOW BATTER BATTERY Y VOLTAG VOLTAGE E ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ... .................... 17-7 17.4 17.4 CORR CORROD ODED ED OR DAMA DAMAGE GED D BAT BATTE TERY RY TERM TERMIN INAL ALS S .... ...... .... .... .... .... .... .... .... .... .... .... .... .. 17-9 17.5 17.5 DEFECT DEFECTIVE IVE MAGNET MAGNETIC IC SWITCH SWITCH ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... .... . ............ 17-10 17.6 17.6 DEFECT DEFECTIVE IVE STARTE STARTER R ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ... .... ...... .... .... .... .... .... .... .... .... .. 17-1 17-13 3

17.7 17.7 LOW CRANKI CRANKING NG SPEED SPEED ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ..... .. ................... 17-15 (Rev. 2004) x 6SE483

All information subject to change without notice. 0401 Copyright © 2004 DETROIT DIESEL CORPORATION


17.8 17.8 FUEL FUEL SUPPLY SUPPLY VALVE VALVE ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ..... .. ........................ 17-17 17.9 17.9 PLUGGE PLUGGED D FUEL FUEL FILTER FILTER(S) (S) ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... .... . ................... 17-19 17.10 17.10 FUEL FUEL PUMP PUMP ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... .... . .......... ............... .......... .......... .......... ...... . 17-21 17.11 17.11 AERATE AERATED D FUEL FUEL ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ... ..... ...... .... .... .... .... .... .... .... ... ..... ...... .. 17-2 17-23 3 17.12 17.12 RESTRI RESTRICTI CTIVE VE AIR FILTER FILTER ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ... ..... ...... .... .... .... .... .... .... .... .. 17-2 17-25 5 17.13 17.13 LOW COMPRE COMPRESSI SSION ON ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ... .... ...... .... .... .... .... .... .... .... .... .. 17-2 17-27 7 18 NO START (ENGINE WILL NOT ROTATE) 18.1 18.1 DISCHA DISCHARGE RGED D BATTER BATTERY Y ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... .... . .................... 18-3 18.2 18.2 DEFECT DEFECTIVE IVE MAGNET MAGNETIC IC SWITCH SWITCH ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... .... . ............ 18-5 18.3 18.3 DEFECT DEFECTIVE IVE STARTE STARTER R ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ... .... ...... .... .... .... .... .... .... .... .... .. 18-8 18-8 18.4 18.4 INTERN INTERNAL AL ENGINE ENGINE DAMAGE DAMAGE ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ... ................ 18-10 19 EXCESSIVE OIL CONSUMPTION 19.1 19.1 MISCAL MISCALIBR IBRATE ATED D DIPSTI DIPSTICK CK ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ... ................... 19-3 19.2 19.2 EXTERN EXTERNAL AL OIL LEAKS LEAKS ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ..... .. .... ...... .... .... .... .... .... .... .... .... .. 19-4 19-4 19.3 19.3 LEAKIN LEAKING G OIL COOLER COOLER CORE CORE ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ..... .. ................ 19-6 19.4 19.4 DEFECT DEFECTIVE IVE AIR COMPRE COMPRESSO SSOR R ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... .... . ............. 19-8 19.5 19.5 DEFECT DEFECTIVE IVE TURBOC TURBOCHAR HARGER GER ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ... ............. 19-10 19.6 19.6 WORN WORN OR DAMAGE DAMAGED D VALVE VALVE OR CYLIND CYLINDER ER KIT ...... ......... ...... ...... ...... ...... ...... ...... ...... ..... .. 19-11 20 EXCESSIVE CRANKCASE PRESSURE 20.1 OBSTRUCTION OR DAMAGE TO ROCKER COVER BREATHER ......... 20-3 20.2 20.2 DEFECT DEFECTIVE IVE AIR COMPRE COMPRESSO SSOR R ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... .... . ............. 20-5 20.3 20.3 DEFECT DEFECTIVE IVE TURBOC TURBOCHAR HARGER GER ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ... ............. 20-7 20.4 20.4 WORN WORN OR DAMAGE DAMAGED D VALVE VALVE OR CYLIND CYLINDER ER KIT ...... ......... ...... ...... ...... ...... ...... ...... ...... ..... .. 20-8 21 EXCESSIVE EXHAUST SMOKE (BLACK OR GRAY) 21.1 21.1 IMPROP IMPROPER ER GRADE GRADE OF FUEL FUEL OIL ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ..... .. ............. 21-3 21.2 21.2 RESTRI RESTRICTE CTED D AIR CLEANE CLEANER R ELEMEN ELEMENT T ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... .... . .... ...... ... . 21-5 21-5 21.3 21.3 REST RESTRI RICT CTED ED OR CRAC CRACKE KED D CHARG CHARGE E AIR COOL COOLER ER .... ...... .... .... .... .... .... .... .... .... .... .... ..

21-7 21.4 21.4 FAULTY FAULTY EXHAUS EXHAUST T SYSTEM SYSTEM ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ..... .. ................. 21-9 21.5 21.5 FAULTY FAULTY FUEL FUEL INJECT INJECTOR OR ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ..... .. ..... ...... .... .... .... .... .... .... .... .. 21-1 21-11 1 21.6 21.6 DEFECT DEFECTIVE IVE TURBOC TURBOCHAR HARGER GER ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ... ............. 21-13 22 EXCESSIVE BLUE SMOKE 22.1 22.1 DEFECT DEFECTIVE IVE TURBOC TURBOCHAR HARGER GER ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ... ............. 22-3 22.2 22.2 WORN WORN OR DAMAGE DAMAGED D VALVE VALVE OR CYLIND CYLINDER ER KIT ...... ......... ...... ...... ...... ...... ...... ...... ...... ..... .. 22-6 23 EXCESSIVE WHITE SMOKE 23.1 23.1 IMPROP IMPROPER ER GRADE GRADE OF FUEL FUEL ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ... ................ 23-3 23.2 23.2 DEFECT DEFECTIVE IVE FUEL FUEL PUMP PUMP ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ... .................... 23-5 23.3 23.3 AERATE AERATED D FUEL FUEL ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ... ..... ...... .... .... .... .... .... .... .... ... ..... ...... .. 23-7 23-7 23.4 23.4 IMPR IMPROP OPER ER INJE INJECT CTOR OR CALI CALIBR BRAT ATIO ION N SETT SETTIN ING G (DDE (DDEC C III/ III/IV IV ENGINES ONLY) ........................ ................................................. .................................. ......... ..... ...... .... .... .... .... .... .... .... ... ..... ...... .. 23-9 23-9 23.5 23.5 IMPR IMPROP OPER ER VALV VALVE E CLEA CLEARA RANC NCE E OR OR INJ INJEC ECTO TOR R HEI HEIGH GHT, T, WORN WORN OR DAMAGED CAMSHAFT LOBES AND ROLLERS .................................. ..................... ............. 23-11 23.6 23.6 FAULTY FAULTY FUEL FUEL INJECT INJECTOR OR ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ..... .. ..... ...... .... .... .... .... .... .... .... .. 23-1 23-13 3 23.7 23.7 FAULTY FAULTY ELECTR ELECTRONI ONIC C CONTRO CONTROL L MODULE MODULE ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ..... .. ... 23-14 All information subject to change without notice. (Rev. 6SE483 0401 Copyright © 2004 DETROIT DIESEL CORPORATION

2004) xi


24 ROUGH RUNNING OR STALLING 24.1 24.1 LOW BATTER BATTERY Y VOLTAG VOLTAGE E ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ... .................... 24-3 24.2 24.2 AERATE AERATED D FUEL FUEL OIL ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... .... . ......................... 24-5 24.3 24.3 INSUFF INSUFFICI ICIENT ENT FUEL FUEL OIL FLOW FLOW ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ..... .. ................ 24-6 24.4 24.4 HIGH HIGH FUEL FUEL OIL TEMPER TEMPERATU ATURE RE RETURN RETURN ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ..... .. ..... 24-8 24.5 24.5 IMPR IMPROP OPER ER INJE INJECT CTOR OR CALI CALIBR BRAT ATIO ION N SETT SETTIN ING G (DDE (DDEC C III/ III/IV IV ENGINES ONLY) ........................ ................................................ .......................................... .................. .................... 24-11 24.6 24.6 LOW COMPRE COMPRESSI SSION ON PRESSU PRESSURE RE ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... .... . .......... 24-13 25 LACK OF POWER 25.1 25.1 AERATE AERATED D FUEL FUEL ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ... ..... ...... .... .... .... .... .... .... .... ... ..... ...... .. 25-3 25-3 25.2 25.2 HIGH HIGH FUEL FUEL PRESSU PRESSURE RE ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... .... . ..... ...... .... .... .... .... .... .... .... .. 25-5 25-5 25.3 25.3 HIGH HIGH FUEL FUEL OIL TEMPER TEMPERATU ATURE RE RETURN RETURN ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ..... ..

..... 25-9 25.4 25.4 RESTRI RESTRICTE CTED D AIR CLEANE CLEANER R ELEMEN ELEMENT T ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... .... . ....... 25-11 25.5 25.5 REST RESTRI RICT CTED ED OR OR CRAC CRACKE KED D CHAR CHARGE GE AIR AIR COO COOLE LER R OR LEA LEAKI KING NG INTAKE MANIFOLD ......................... ................................................. ...................................... .............. .................. 25-13 25.6 25.6 FAULTY FAULTY EXHAUS EXHAUST T SYSTEM SYSTEM ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ..... .. ................. 25-15 25.7 25.7 HIGH HIGH INLET INLET AIR TEMPER TEMPERATU ATURE RE ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ..... .. .............. 25-17 25.8 25.8 HIGH HIGH ALTITU ALTITUDE DE OPERAT OPERATION ION ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ..... .. ................. 25-19 25.9 25.9 INCORR INCORRECT ECT CAMSHA CAMSHAFT FT TIMING TIMING ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ... ............ 25-21 26 LOW OIL PRESSURE 26.1 26.1 IMPROP IMPROPER ER ENGINE ENGINE OIL LEVEL LEVEL ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ... ...... ......... ...... ...... ... 26-3 26-3 26.2 26.2 IMPROP IMPROPER ER LUBRIC LUBRICATI ATING NG OIL VISCOS VISCOSITY ITY ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ... ...... 26-5 26.3 26.3 LUBR LUBRIC ICAT ATIN ING G OIL OIL DILU DILUTE TED D WIT WITH H FUE FUEL L OIL OIL OR ENGI ENGINE NE COOL COOLAN ANT T 26-7 26-7 26.4 26.4 FAULTY FAULTY OIL PRESSU PRESSURE RE GAUGE GAUGE SENSOR SENSOR ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ... .... 26-9 26.5 26.5 OIL PRESSU PRESSURE RE GAUGE GAUGE LINE LINE OBSTRU OBSTRUCTE CTED D ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ... .. 26-11 26.6 26.6 ROCK ROCKER ER ARM ARM SHA SHAFT FT PLUG PLUGS S MIS MISSI SING NG (NEW (NEW OR REBU REBUIL ILT T ENG ENGIN INES ES ONLY) ........................ ................................................ .......................................... .................. .... ...... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... ... . 26-1 26-13 3 26.7 26.7 RESTRI RESTRICTE CTED D OIL COOLER COOLER ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... .... . .................. 26-15 26.8 26.8 NONF NONFUN UNCT CTIO IONA NAL L OR STI STICK CKIN ING G OIL OIL PRES PRESSU SURE RE REG REGUL ULAT ATOR OR VALVE ................................................................. .... ...... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... ... . 26-1 26-17 7 26.9 26.9 DEFECT DEFECTIVE IVE BYPASS BYPASS VALVE VALVE ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ... .................. 26-19 26.10 26.10 DEFECT DEFECTIVE IVE PRESSUR PRESSURE E RELIEF RELIEF VALVE ....... .......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ... .... ...... ... . 26-2 26-20 0 26.11 DEFECTIVE PICKUP SCREEN TUBE AND SCREEN ASSEMBLY ........ 26-22 26.12 26.12 DEFECT DEFECTIVE IVE CRANK CRANKSHA SHAFT FT MAIN MAIN BEARING BEARING SHELL SHELLS S ....... .......... ...... ...... ...... ...... ...... .... . 26-24 26.13 26.13 DEFECT DEFECTIVE IVE OIL PUMP ASSEMB ASSEMBLY LY ....... .......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... .... . ........... 26-26 27 HIGH ENGINE COOLANT TEMPERATURE 27.1 27.1 IMPROP IMPROPER ER ENGINE ENGINE COOLAN COOLANT T LEVE LEVEL L ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ... .... ...... ... . 27-3 27-3 27.2 27.2 INSUFF INSUFFICI ICIENT ENT RADIAT RADIATOR OR AIR CIRCUL CIRCULATI ATION ON ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ... .... 27-5 27.3 27.3 FAULTY FAULTY PRESSU PRESSURE RE CONTRO CONTROL L CAP CAP ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ..... .. ......... 27-7 27.4 27.4 DEFECT DEFECTIVE IVE COOLAN COOLANT T HOSES HOSES ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ..... .. ..... ...... .... .... .... ... . 27-9 7-9 27.5 27.5 FAN BELTS BELTS ARE INCORR INCORRECT ECTLY LY ADJUST ADJUSTED ED ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... .... . ... 27-11 27.6 27.6 INOPER INOPERATI ATIVE VE THERMO THERMO-MO -MODUL DULATE ATED D FAN ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ... ... 27-13 27.7 27.7 FAULTY FAULTY THERMO THERMOSTA STATS TS ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... .... . .................... 27-15 27.8 27.8 FAULTY FAULTY WATER WATER PUMP PUMP ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ... .... ...... .... .... .... .... .... .... .... .... .. 27-1 27-17 7 27.9 27.9 COMBUS COMBUSTIO TION N GASES GASES IN COOLAN COOLANT T ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... .... .

.........

27-19

(Rev. 2004) All information subject to change without notice. xii xii 6SE4 6SE483 83 0401 0401 Copy Copyri righ ght t © 2004 2004 DETR DETROI OIT T DIES DIESEL EL CORP CORPOR ORAT ATIO ION N


27.10 ABNORMAL RADIATOR COOLANT FLOW ... 27-21

......................................... ....................... ..................

28 LOW COOLANT TEMPERATURE 28.1 28.1 FAULTY FAULTY THERMO THERMOSTA STATS TS ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ... ..... ...... .... .... .... .... .... .... .... .. 28-3 28-3 28.2 28.2 INSUFF INSUFFICI ICIENT ENT RADIAT RADIATOR OR AIR CIRCUL CIRCULATI ATION ON ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ... .... 28-5 29 POOR FUEL ECONOMY 29.1 29.1 PROBAB PROBABLE LE CAUSE CAUSE #1 ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ... .... ...... .... .... .... .... .... .... .... .... .. 29-3 29-3 INDEX ......................................................................... ........................ Index-1

All information subject to change without notice. (Rev. 6SE483 0401 Copyright © 2004 DETROIT DIESEL CORPORATION


2004) xiii

(Rev. 2004) All information subject to change without notice. xiv xiv 6SE4 6SE483 83 0401 0401 Copy Copyri righ ght t © 2004 2004 DETR DETROI OIT T DIES DIESEL EL CORP CORPOR ORAT ATIO ION N

GENERAL INFORMATION

Sect Sectio ion n Page Page SCOPE AND USE OF THIS MANUAL ..... 3

................................................. ........................ .......................... .

CLEARANCE OF NEW PARTS AND WEAR LIMITS ...................... ................................. ........... 3 THE FOUR CYCLE PRINCIPLE PRINCIPLE FOR DIESEL DIESEL ENGINES ENGINES .......... ............... .......... .......... ..... 4 FOUR FOUR CYCL CYCLE E PRIN PRINCI CIPL PLE E FOR FOR NATU NATURA RAL L GAS GAS ENGI ENGINE NES S

.... ...... .... .... .... .... .... .... .... ... .

6

GENERAL DESCRIPTION ..................... ............................................. ...................................... .............. .............. 8 GENERAL SPECIFICATIONS ...................... ............................................... .................................. ......... ............ 13 GENERAL SP SPECIFICATIONS FO FOR TH THE SE SERIES 60 60G EN ENGINE .. ...............

14

ENGI ENGINE NE MODE MODEL, L, SERI SERIAL AL NUMB NUMBER ER AND AND OPTI OPTION ON LABE LABEL L

15

.... ...... .... .... .... .... .... .... .... ... .

ENGINE MODEL, SERIAL NUMBER AND OPTION LABEL (SERIES 60G ENGINE) ............... .............................................. ...................... ................................................. ................................. ........ 18 REPLACING AND REPAIRING ........... 19

.............................................. ..................... .................................. .........

DISASSEMBLY ................................................................... ........................ 19 CLEANING ......................... ................................................. .............................................. ...................... ........................... 20 SAFETY PRECAUTIONS ...................... .............................................. ...................................... .............. .............. 26 FLUOROELASTOMER (VITON) CAUTION ................................................ ................................................ 39 ENGINE VIEWS ......................... ................................................. .......................................... .................. ...... ......... ...... ...... ...... ...... ..... .. 40 ENGLISH TO METRIC CONVERSION ........................ ................................................. .......................... . .... 45 DECIMAL AND METRIC EQUIVALENTS ................................................. ................................................. .. 46 SPECIFICATIONS ................................................................ .... ...... .... .... .... .... .... .... .... .... .. 48


(Rev. 2004) 2 6SE483



SCOPE AND USE OF THIS MANUAL This manual contains complete instructions on operation, adjustment (tune-up), p reventive maintenance, and repair (including complete overhaul) for the Series 6 0 Inline Diesel Engines. This manual was written primarily for persons servicing and overhauling the engi ne. In addition, this manual contains all of the instructions essential to the o perators and users. Basic maintenance and overhaul procedures are common to all Series 60 Engines, and apply to all en gine models. This manual is divided into numbered sections. Section one covers the engine (l ess major assemblies). The following sections cover a complete system such as th e fuel system, lubrication lubrication system, or air system. Each section is divided into subsections which contain complete maintenance and operating instructions for a specific engine subassembly. Each section begins with a table of contents. Pages and illustrations are numbered consecutively wit hin each section. Information can be located by using the table of contents at the front of the ma nual or the table of contents contents at the beginning beginning of each section. Information on specific subassemblies or accessories within the major section is listed immedia tely following the section title. CLEARANCE OF NEW PARTS AND WEAR LIMITS New parts clearances apply only when all new parts are used at the point where t he various specifications apply. This also applies to references within within the tex tex t of the manual. The column entitled entitled "Limits" must must be qualified by the judgemen judgemen t of personnel responsible responsible for installing new parts. For additional information , refer to the section entitled "Inspection" within this section. Refer to secti on ADDITIONAL INFORMATION, "Table of Specifications, New Clearances, and Wear Limits" under "Specifications", for a listing of clearances of new part s and wear limits on used parts.


2004) 3


THE FOUR CYCLE PRINCIPLE FOR DIESEL ENGINES The diesel engine is an internal combustion engine, in which the energy of burni ng fuel is converted into energy to work the cylinder of the engine. In the die sel engine, air alone is compressed in the cylinder, cylinder, raising its temperature significantly. After the air has been compressed, a charge of fuel is sprayed into the cylinder and igni tion is accomplished by the heat of compression. compression. The four piston strokes of the cycle occur in in the followin g order: intake, compression, power and exhaust. See Figure 1.

Figure 1

The Four Stroke Cycle (Diesel)

Intake Stroke During the intake stroke, the piston travels downward, the intake valves are ope n, and the exhaust valves are closed. The down stroke of the piston facilitates air from the intake manifold to enter the cylinder through the open intake valve. The turbocharger, by increasing the air pressure in the engine intake manifold, assures a full charge of air is available for the cylind er. The intake charge consists of air only with no fuel mixture.

(Rev. 2004) 4 6SE483



Compression Stroke At the end of the intake stroke, the intake valves close and the piston starts u pward on the compression compression stroke. The exhaust valves remain remain closed. At the end of the compression stroke, the air in the combustion chamber has been compressed by the piston to occupy a space about one-fifteenth as great in volu me as it occupied at the beginning of the stroke. Thus, the compression ratio is 15:1. Compressing the air into a small space causes the temperature of that air to ris

e. Near the end of the compression stroke, the pressure of the air above the pis ton is approximately 3445 to 4134 kPa (500 to 600 lb/in.2) and the temperature of that air is approximately 538 C (1000 F). During the last part of the compression stroke and the early part of the power stroke, a small metered charge of fuel is injected into the combustion chamber. Almost immediately after the fuel charge is injected into the combustion chamber , the fuel is ignited by the hot air and starts to burn, beginning the power str oke. Power Stroke During the power stroke, the piston travels downward and all intake and exhaust valves are closed. As the fuel is added and burns, the gases get hotter, the pressure increases, pu shing the piston downward and adding to crankshaft rotation. Exhaust Stroke During the exhaust stroke, the intake valves are closed; the exhaust valves are open, and the piston is on its up stroke. The burned gases are forced out of the combustion chamber through the open exhau st valve port by the upward travel of the piston. From the preceding description, it is apparent that the proper operation of the engine depends upon the two separate functions: first, compression for ignition, and second, th at fuel be measured and injected into the compressed air in the cylinder in the proper quantity and at the proper time.


2004) 5


FOUR CYCLE PRINCIPLE FOR NATURAL GAS ENGINES This engine is a four cycle internal combustion engine, in which the energy of b urning fuel is is converted into energy to work the cylinder of the engine. Howeve r, unlike the diesel engine, a combustible air and fuel mixture is introduced to the cylinder during the intake stroke. stroke. Upon compression, compression, the temperature of th is mixture is increased to a temperature temperature below its auto-ignition auto-ignition threshold. Com bustion occurs through means of a spark plug which ignites the mixture. See Figure 2 for the four stroke cycle utilized on the natural gas engine.

Figure 2

The Four Stroke Cycle (Series 60G Engine)

(Rev. 2004) 6 6SE483



Intake Stroke During the intake stroke, the piston travels downward, the intake valves are ope n, and the exhaust valve are are closed. The downward stroke stroke of the piston piston increase s the volume in the cylinder and draws in a fresh air and fuel mixture through the intake valves. Compression Stroke At the end of the intake stroke, the intake valves close and the piston starts u pward on the compression compression stroke. The exhaust valves remain remain closed. At the end of the compression stroke, the air-fuel mixture in the combustion cha mber has been compressed by the piston to occupy a space about one-tenth as grea t in volume as it occupied at the beginning the stroke. stroke. Thus, the compression ratio is 10:1. 10:1. This act of compression dramatically increases the temperature of the air-fuel mixture, to a temperature below its auto-ignition threshold. It is a timed, externally externally supplied ignition through through th e spark plug that actually causes ignition to the mixture. The timed spark is introduced to the cy linder near the end of the compression stroke, which initiates combustion and begins the power strok e. Power Stroke During the power stroke, the piston travels downward and all intake and exhaust valves are closed. As the throttle is opened to introduce a greater charge of air-fuel mixture to t he cylinders, the increasing pressure of combustion against the pistons adds to crankshaft rotation. Exhaust Stroke During the exhaust stroke, the intake valves are closed, the exhaust valves are open, and the piston is on its up stroke.

The burning gases are forced out of the combustion chamber through the open exha ust valve port by the upward travel of the piston.


2004) 7


GENERAL DESCRIPTION The Series 60® 60® Diesel Engine described in this this manual is a four-stroke cycle, cycle, hig h speed, diesel engine. It uses an inline cast iron block and has a cast iron cylinder head that contain s a single single overhead camshaft. The camshaft actuates all the valves (two intake, two exhaust per cylinder), and operates the fuel injectors. The vertically ali gned gear train, located at the front end of the engine in a gear case, contains drive gears for the lubricating oil pump, cranks haft, camshaft, air compressor drive, fuel pump drive, water pump and alternator accessory drives. Each current engine is equipped with dual full-flow oil filters, an oil cooler, one or two fuel oil filters, a turbocharger and an electronic engine control sys tem. Full pressure lubrication is supplied to all main, connecting, camshaft and rock er assembly bearings and to other moving parts. A gear-type pump draws oil from the oil pan through a screen screen and delivers it to the oil oil filters. From the filter, a small p ortion of the oil is delivered directly to

the turbocharger by an external oil line. The remainder of of the oil flows flows to the oil cooler, or bypasses the cooler, and then enters a longitudinal oil gallery in the cylinder cylinder block where the supply divides. divides. Part of the oil goes to the cyl inder head where it feeds the camshaft bearings and rocker assemblies. assemblies. The remainder of the oil goes goes to the main main bearings and c onnecting rod bearings via the drilled oil passages in the crankshaft. Drilled p assages in the connecting rod feed oil to the piston pin and the inner surface of the piston crown. Coolant is circulated through through the engine by a centrifugal-type centrifugal-type water pump. The cooling system, system, including the radiator, is a closed closed system. Heat is removed fro m the coolant by the radiator. Control of the engine temperature is accomplished by thermostats that regulate the flow of the coolant within the cooling system. Fuel is drawn from the supply tank through the primary fuel filter by a gear-typ e fuel pump. From there, the fuel is forced through the secondary fuel filter an d into the fuel inlet in the cylinder head and to the injectors. Excess fuel is returned, through a restricted fitting, to the supply tank through the outlet co nnecting line. line. Since the fuel is constantly circulating circulating through the injectors, it serves to cool the injectors and to carry off any air in the fuel system. Air separato rs are available, as optional equipment. Air is supplied by the turbocharger to the intake manifold and into the engine c ylinders after passing through an air-to-air charge air cooler mounted ahead of the cooling system radiator. The charge air cooler cools the pressurized intake air charge coming from the turbocharger before it enters the intake manifold. Engine starting may be provided by an electric or air starting motor energized b y a storage battery or air pressure storage storage system. A battery charging alternator, alternator, with a suitable voltage regulator, serves to keep the battery charged. The Series 60 diesel engine was designed to be electronically electronically controlled. The D etroit Diesel Electronic Control (DDEC) system has evolved with the product.

(Rev. 2004) 8 6SE483



DDEC I DDEC I controls controls the timing and amount of fuel injected into each cylinder. cylinder. The system also monitors several engine functions using various sensors that send el ectrical signals signals to the the main Electronic Electronic Control Control Module (ECM). See Figure 3. The

ECM uses this information to send a command pulse to the Electronic Distributor Unit (EDU). The EDU functions as the high current switching unit for actuation of the Electronic Unit Injector (EUI) solenoids. The ECM also has the ability to limit or shut down the engine completely (depending on option selection) in the case of damaging engine conditions, such as low oil pressure, low coolant level , or high oil temperature.

Figure 3

Schematic Diagram of DDEC I


2004) 9


DDEC II DDEC II also controls the timing and amount of fuel injected into each cylinder. The system also monitors several engine sensors that send electrical signals to the main ECM. See Figure 4. Unlike DDEC I, the DDEC II ECM uses this information to actuate the EUI solenoid s. DDEC II incorporates all of the control electronics into one engine mounted ECM inste ad of the ECM and EDU that are required in DDEC I. The ECM also has the ability to limit or shut down the engine completely (depending on option selection) in t he case of damaging engine conditions, such as low oil pressure, low coolant lev el, or high oil temperature.

Figure 4

Schematic Diagram of DDEC II

(Rev. 2004) 10 6SE48 SE483 3



DDEC III/IV The DDEC III/IV ECM receives electronic inputs from sensors on the engine and ve hicle, and uses the information to control engine operation. It computes fuel timing and fu el quantity based upon predetermined calibration tables in its memory. Fuel is delivered to the cylinders by the EUIs, which are cam-driven to provide the mechanical mechanical input for for pressurization pressurization of the fuel. The ECM controls solenoid operated valves valves in the EUIs to provide precise fuel delivery. See Figure 5.

Figure 5

Schematic Diagram of DDEC III/IV

Portable equipment facilitates access to diagnostic capabilities of DDEC III/IV' s. The Diagnostic Data Reader (DDR) requests and receives engine data and diagno stic codes. This equipment provides many unique capabilities capabilities including cylinder cutout, printer output, and data snapshot. The DDR also provides limited programming capability.


2004) 11


DDEC III/IV (Series 60G Engine) The DDEC III/IV ECM receives electronic inputs from sensors on the engine and ve hicle, and uses the information to control engine operation. Fuel is controlled by DDEC. See Figure 6.

Figure 6

Schematic Di Diagram of of DD DDEC II III/IV (S (Series 60 60G En Engine)

Portable equipment facilitates access to diagnostic capabilities of DDEC III/IV' s. The Diagnostic Data Reader (DDR) requests and receives engine data and diagno stic codes. This equipment provides many unique capabilities capabilities including cylinder cutout, printer output, and data snapshot. The DDR also provides limited programming capability.

(Rev. 2004) 12 6SE48 SE483 3



GENERAL SPECIFICATIONS The general specifications specifications for the Series 60 Engine are listed listed in Table 1. Figure 7 for the cylinder designation and firing order. General Specifications 11.1L Family 12.7L Family Total Displacement (L) 11.1 12.7 14.0 Total Displacement (in.3) 677 775 855 Type 4-cycle 4-cycle 4-cycle Number of Cylinders 6 6 6 Bore (in.) 5.12 5.12 5.24 Bore (mm) 130 130 133 Stroke (in.) 5.47 6.30 6.61 Stroke (mm) 139 160 168 Compression Ratio 16.0:1 15.0:1 or 16.5:1 Number of Main Bearings 7 7 7

14L Family

15.0:1 or 16.5:1

Table 1 Specificat Specifications ions for the the Series Series 60 Engine Engine

Figure 7

Cylinder Designation and Firing Order


2004) 13

See


GENERAL SPECIFICATIONS FOR THE SERIES 60G ENGINE The general specifications specifications for the Series 60G Engine are listed listed in Table 2. See Figure 8 for cylinder designation and firing order. General Description Specification Total Total Displa Displacem cement ent (L) 12.7 12.7 Total Displacement (in.3) 775 Type Four-cycle Number of Cylinders 6 Bore (in.) 5.12 Bore (mm) 130 Stroke (in.) 6.30 Stroke (mm) 160 Compression Ratio 10:1 Number Number of Main Main Bearin Bearings gs 7 Table 2 General General Specificati Specifications ons for the Series Series 60G Engine Engine

Figure 8

Cylinder De Designation an and Fi Firing Or Order fo for th the Se Series 60 60G En Engine

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ENGINE MODEL, SERIAL NUMBER AND OPTION LABEL The engine serial and model numbers are stamped on the cylinder block. See Figur e 9. A guide to the meaning of the model number digits is listed in Table 3.

Figure 9

Location of Engine Serial and Model Number on Block


2004) 15


Digit 1 2 & 3 4 4 4 4 5 5 5 5 6 6 6 7 & 8 7 & 8 7 & 8 7 & 8

Value 6 2 3 5 7 W, G, P, F, T U K

S, S, T, T, B H

Meaning Series 60 Engine 06 Six Cylinders Marine Application Industrial Application Generator Application Automotive Application E, E, L 11.1 L Displacement M 12.7 L - Standard 12.7 L - Premium 14 L Displacement DDEC I Engine Control DDEC II Engine Control DDEC III/IV Engine Control 28 1991 and later Coach 32 Underground Mining 40 Pre-1991 Engine 60 1991 and later On-Highway Truck

Table 3 Model Number Number Descri Description ption for for Series Series 60 Engine Engine For example, 6067-WK60 represents an 11.1 liter Series 60 engine that is control led with DDEC III/IV electronics to be used in a 1991 or later truck. Option labels attached to the valve rocker cover contain the engine serial and m odel numbers and list any optional equipment used on the engine. See Figure 10. With any order for parts, the engine model number with serial number should be g iven. In addition, if a type number is shown on the option plate plate covering the e

quipment required, this number should also be included on the parts order.

(Rev. 2004) 16 6SE48 SE483 3



All groups or parts used on a unit are standard for the engine model unless othe rwise listed on the option plate.

Figure 10

Rocker Cover with Option Label


2004) 17


ENGINE MODEL, SERIAL NUMBER AND OPTION LABEL (SERIES 60G ENGINE) The engine serial and model numbers are stamped on the cylinder block. See Figur e 11. A guide to the meaning of the serial number digits is listed in Table 4.

Figur igure e 11 11 Engine)

Locat ocati ion of En Engine gine Ser Serial ial and and Mode Model l Nu Number mber on Bloc Block k (Se (Seri ries es 60G 60G

Digit 1 2 & 3 4 5 6 7 8

Meaning Series 60 Engine 06 Six Cylinders Generator Application / Automotive 12.7 L Displacement DDEC III / DDEC IV Alternate Fuel Engine Customer Designation

Value 6 3 / G / K G 5 /

7 T 8

Table 4 Model Number Number Descri Description ption for for Series Series 60G Engine Engine

(Rev. 2004) 18 6SE48 SE483 3



REPLACING AND REPAIRING In many cases, a technician is justified in replacing parts with new material ra ther than attempting repair. However, there are times when a slight amount of re working or reconditioning may save a customer considerable added expense. Exchan ge assemblies such as injectors, fuel pumps, water pumps and turbochargers are d esirable service items. Various factors such as the type of operation of the engine, hours in service an d the next overhaul period must be considered when determining whether new parts are installed or used parts are reconditioned to provide trouble-free operation . For convenience and logical order in disassembly and assembly, the various subas semblies and other related parts mounted on the cylinder block will be treated a s separate items in the various sections of the manual. DISASSEMBLY A technician can be severely injured if caught in pulleys, belts or the fan of a n engine that is accidentally started. To avoid such a misfortune, take the foll owing precautions before starting to work on an engine.

To avoid servicing

injury from the engine,

accidental engine startup disconnect/disable the

while starting system.

To avoid injury from the sudden release of a high-pressure hose connection, wear a face shield shield or goggles. goggles. Bleed the air from the air star ter system before disconnecting the air supply hose. Before any major disassembly, the engine must be drained of lubricating oil, coo lant and fuel. To perform a major overhaul or other extensive repairs, the complete engine asse mbly, after removal from the engine base and drive mechanism, should be mounted on an engine overhaul stand; then the various subassemblies should be removed fr om the engine. When only a few items need replacement, it is not always necessar y to mount the engine on an overhaul stand. Parts removed from an individual engine should be kept together so they will be available for inspection and assembly. Those items having machined faces, which might be easily damaged by steel or concrete, should be stored on suitable woode n racks or blocks, or a parts dolly.


2004) 19


CLEANING Before removing any of the subassemblies from the engine (but after removal of t he electrical equipment), the exterior of the engine should be thoroughly cleane d. NOTICE: The Series 60 engine is equipped with various sensors and other electronic compo nents which may be damaged if subjected to the high temperatures in a solvent ta nk. Do not immerse any electrical components in a solvent tank. Care should b e taken to ensure that all electronic components are removed from the various engine ass emblies before they are immersed in a solvent tank. Refer to section 8for a desc ription of these components. Then, after each subassembly is removed and disassembled, the individual parts s hould be cleaned. Thorough cleaning cleaning of each each part is is absolutely necessary before it can b e satisfactorily satisfactorily inspected. Various items of equipment needed for general clean ing are listed below. The cleaning procedure used for all ordinary cast iron parts is the same as the following cylinder block cleaning procedure. Any special cleaning procedures wil l be mentioned when required. Remove cylinder liners before putting the block in cleaning or descaling baths, to avoid trapping cleaning agents in block liner seating bores. After stripping and before removing the cylinder block from the overhaul stand f or cleaning and inspection, install the two metric eye bolts into head bolt hole s at each end of the cylinder block. Remove all oil and water gallery and weep hole plugs to allow the cleaning solut ion to enter the inside of the oil and water passages. 1. Usin Using g two two metr metric ic eye eye bol bolts ts inst instal alle led d in in the the head head bolt bolt hole holes s at at opp oppos osit ite e ends of the block, and with a suitable lifting device and spreader bar, immerse and agitate the block in a hot bath of a commercial, heavy-duty alkaline solution. 2. Wash Wash the the blo block ck in hot hot wat water er or stea steam m cle clean an it to remo remove ve the the alk alkal alin ine e sol sol ution. 3.

If th the wa water ter jac jacke kets ts are heavi eavily ly scale caled, d, proce roceed ed as fo follow llows: s:

[a] [a]

Agit Agitat ate e the the bloc block k in in a bath bath of inhi inhibi bite ted d pho phosp spho hori ric c aci acid. d.

[b] [b] Allo Allow w the the bloc block k to to rem remai ain n in in the the acid acid bath bath unti until l the the bubb bubbli ling ng acti action on sto sto ps (approximately 30 minutes). [c] [c] Lift Lift the the blo block ck, , dra drain in it and and imm immer erse se it agai again n in in the the same same acid acid solu soluti tion on for 10 more minutes. Repeat until all scale is removed removed from the water water jacket ar ea. [d] [d]

Rins Rinse e the the bloc block k in in cle clear ar, , hot hot wate water r to to rem remov ove e the the acid acid solu soluti tion on. .

[e] [e] Neut Neutra rali lize ze the the aci acid d tha that t may may clin cling g to to the the cast castin ing g by by imm immer ersi sing ng the the blo block ck in an alkaline bath. [f]

Wash ash the the bloc block k in clea clean n wa water ter or steam team cle clean it.

(Rev. 2004) 20 6SE48 SE483 3



To avoid injury from flying debris when using compressed air, wear adequate eye protection (face shield or not exceed 40 psi (276 kPa) air pressure. 4.

Dry the cylinder block with compressed air.


safety goggles) and do


Blow out all of the the bolt bolt holes and passages with compressed air.

NOTE: The above cleaning procedure may be used on all ordinary cast iron and steel par ts for the engine. Aluminum parts, parts, such as as flywheel housing, air intake manifol d, oil filter adaptor and the camshaft gear access cover should NOT be cleaned i n this manner. Mention will be made of special procedures when necessary. 6. Be certain certain that all water passages and oil galleries have been thoroughly c leaned. After the cylinder block has been thoroughly cleaned cleaned and dried, install weep hole plugs and

precoated pipe plugs. Install new cup plugs using a coating of good grade non-ha rdening sealant such as as Loctite® Loctite® 620 or equivalent. Loctite® is a registered trademark of The Loctite Corporation. Steam Cleaning A steam cleaner is a necessary item in a large shop and is useful for removing h eavy accumulations of grease and dirt from the exterior of the engine and its subassemblies. Solvent Tank Cleaner Chlorinated solvents such as 1,1,1 trichloroethane have been identified by the E PA (Environmental Protection Agency) as possessing ozone-depleting properties. Spec ial procedures have been developed for the handling and proper disposal of these chemicals. For environmental considerations, Detroit Diesel has replaced 1,1,1 trichloroethane with Tech Solv 340 branded solvent.


2004) 21


Tech Solv 340 is a petroleum-based solvent that contains no chlorinated or fluor inated compounds, has a controlled evaporation rate, leaves no residue, is odorless, ha s a high high flash point, and provides outstanding outstanding cleaning. To enhance its cleanin g and drying properties, it may be heated to 52 C (125 F). Spills can be cleaned up with commercially available oil absorbents, and conventional waste treatment methods for petroleum-based pro ducts can be used when disposing of this product. Detroit Diesel believes that a prudent environmental approach to the use of 1,1, 1 trichloroethane should be taken. Therefore, Detroit Diesel recommends replacin g 1,1,1 trichloroethane with Tech Solv 340 branded solvent wherever the former s olvent was used. Tech Solv 340 is manufactured by and available from the following supplier: Chem ical Technologies, Inc. 1610 Clara Street Jackson, MI 49203 Telephone: 800-688-8262

FAX: 517-782-2448 We believe this this source and their Tech Solv 340 solvent to be reliable. There ma y be other manufacturers manufacturers of solvents solvents that replace 1,1,1 trichloroethane. Detroi t Diesel does not endorse, indicate any preference for, or assume any responsibi lity for the solvents from these firms or for any such products that may be avai lable from other sources. Solvent Tank Cleaning A tank of sufficient size to accommodate the largest part that will require clea ning (usually the cylinder block) should be provided and provisions made for hea ting the cleaning solution.

To avoid injury, wear a face shield or goggles. Fill the tank with a commercial heavy-duty solvent, such as Tech Solv 340, that is heated to 52 C (125 F). Lower large parts directly into into the tank with a hoist. Place smal l parts in a wire mesh basket and lower lower them into the tank. Immerse the parts parts l ong enough to loosen all of the grease and dirt. Aluminum or plastic parts such as the flywheel housing, fuel pump drive, air int ake manifold, oil filter adaptor, camshaft gear access cover, oil pan or rocker covers, should not be cleaned in this manner.

(Rev. 2004) 22 6SE48 SE483 3



Rinsing Bath Provide another tank of similar size containing hot water for rinsing the parts. Drying

Parts may be dried with compressed air.

To avoid injury from flying debris when using compressed air, wear adequate eye protection (face shield or not exceed 40 psi (276 kPa) air pressure.


The heat from the hot tanks will quite frequently complete drying of the parts w ithout the use of compressed air. Rust Preventive If parts are not to be used immediately after cleaning, dip them in a suitable r ust preventive preventive compound. The rust preventive compound compound should be removed before installing the parts in an engine. Gasket Eliminator Removal The gasket eliminator used on numerous mating surface joints in the Series 60 en gine results in a very thin film that must be removed from both surfaces prior prior to reassembly. reassembly. A s many of the surfaces are aluminum and/or dimensionally critical, conventional scraping methods, or the use of emery cloth for removing gasket eliminator is no t recommended. Four-inch, 3M Scotch-Brite® Surface Conditioning Conditioning Discs, used with an electric or air powered hand drill (with a speed of 15,000-18,000 r/min), have proven succes sful in removing the gasket eliminator without damaging the mating surfaces of e ngine parts. See Figure 12. Scotch-Brite® is a registered trademark of of the 3M Corporation. Corporation.

All information subject to change without notice.

(Rev.

2004)

6SE483

0401

Copyright © 2004 DETROIT DIESEL CORPORATION

23


Figure 12

Gasket Eliminator Removal

A coarse pad, is suitable for steel surfaces. A medium pad is recommended for al uminum surfaces. surfaces. The pads are easily interchangeable. interchangeable. See Figure 13.

Figur igure e 13

Scotc cotch h-Bri -Brite te Surfa urface ce Condi onditi tion onin ing g Disc Disc Ins Install tallat atio ion n

(Rev. 2004) 24 6SE48 SE483 3



Inspection The purpose of parts inspection is to determine which parts can be used and whic h must be replaced. Although the engine overhaul specifications given given throughou t the text will aid in determining which parts should be replaced, considerable judgment must be exercised by the inspector. The guiding factors in determining the usability of worn parts, that are otherwise in good condition, is the clearance between the mating parts and the rate of wear o n each of the parts. If it is determined that the rate of wear will maintain the clearances within th e specified maximum allowable until the next overhaul period, the reinstallation of used parts may be justified. Rate of wear of a part is determined by dividin g the amount the part has worn by the hours it has operated Many service replacement parts are available in various undersize or oversize as well as standard sizes. Also, service kits for reconditioning certain parts an d service sets that include all of the parts necessary to complete a particular repair job are available. A complete discussion of the proper methods of precision measuring and inspectio n are outside the scope of this manual. However, every shop should be equipped with standard gages, such as dial bore gages, dial indicators, and inside and outside micrometers. In addition to measuring the used parts after cleaning, the parts should be care fully inspected for cracks, scoring, chipping and other detrimental conditions.


2004) 25


SAFETY PRECAUTIONS The following safety measures are essential when working on the Series 60 engine . Exhaust (Start/Run Engine) Before starting and running an engine, adhere to the following safety precaution s:

To avoid injury before starting and running the engine, ensure the vehicle is parked on a level surface, parking brake is set, and the wheels are blocked.

Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and ot her reproductive harm. Always start and operate an engine in a well ventilated area. If operating an engine in an enclosed area, vent the exhaust to the outside. Do not modify or tamper with the exhaust system or emission control system. Stands Safety stands are required in conjunction with hydraulic jacks or hoists. Do not rely on either the jack or the hoist to carry the load. load. When lifting an engine , ensure the lifting device is fastened securely. Ensure the item to be lifted does not exceed the capacity of the lifting device. Glasses Select appropriate safety glasses for the job. It is especially important to wea r safety glasses when using tools such as hammers, chisels, pullers or punches.

To avoid injury, wear a face shield or goggles.

(Rev. 2004) 26 6SE48 SE483 3



Welding Wear welding goggles and gloves when welding or using an acetylene torch.


2004) 27


To avoid injury from arc welding, gas welding, or cutting, wear required safety equipment such as an arc welder’s face plate or gas welder’s goggles, welding gloves, protective apron, long sleeve shirt, head protection, and safety shoes. Alway s perform welding or cutting operations in a well-ventilated area. The gas in oxygen/acetylene cy cylinders us used in in ga ga s weldin welding g and cuttin cutting g is under under high high pressu pressure. re. If a cylind cylinder er should should fall due to careless handling, the gage end could strike an obstructio n and fracture, resulting in a gas leak leading to fire or an explosion. If a cylinder should fall resulting in the gage end breaking off, the sudden r elease of cylinder pressure will turn the cylinder into a dangerous projectile. Observe th the following precautions when using ox ygen/acetylene gas cylinders: Always wear required safety shoes. Do not handle tanks in a careless manner or with greasy gloves or slippery hands . Use a chain, bracket, or other restraining device at all times to prevent gas cylinders from falling. Do not place gas cylinders on their sides, but stand them upright when in use. Do not drop, drag, roll, or strike a cylinder forcefully. Always close valves completely when finished welding or cutting.

To avoid injury from fire, check for fuel or oil leaks before welding or carrying an open flame near the engine. NOTICE: Use proper shielding around hydraulic lines when aulic line damage.

welding

to prevent hydr

Ensure that a metal shield separates the acetylene and oxygen that must be chain ed to a cart.

(Rev. 2004) 28 6SE48 SE483 3



Work Place Organize your work area and keep it clean. A fall could result in a serious inj ury. Eliminate the possibility possibility of a fall by: Wiping up oil spills Keeping tools and parts off the floor After servicing or adjusting the engine: Reinstall all safety devices, guards or shields Ensure that all tools and servicing equipment are removed from the engine Clothing Safe work clothing clothing fits and is in good repair. Work shoes are sturdy and roughroughsoled. Bare feet, sandals or sneakers are not acceptable foot wear when adjusti ng and/or servicing servicing an engine. Do not wear the following when working on an eng ine:

To avoid injury when working on or engine, wear protective clothing, tion.

near eye

an operating protection, and hearing protec

Rings Wrist watches Loose fitting clothing Any of these items could catch on moving parts causing serious injury. Power Tools Do not use defective portable power tools.

To avoid injury from electrical shock, follow OEM furnished operating instructions prior to usage. Check for frayed frayed cords prior to using the tool. Be sure all electric tools are grounded. Defective electrical equipment equipment can cause severe injury. Improper use of electrical equipm

ent can cause severe injury.


2004) 29


Air Recommendations regarding the use of compressed air are indicated throughout the manual.



Fuel Lines Remove fuel lines as an an assembly. assembly. Do not remove fuel lines individually. Avoid getting fuel injection lines mixed up. Fluids and Pressure Be extremely careful when dealing with fluids under pressure.

To avoid injury from penetrating fluids, do not put your hands hands in front front of fluid fluid under under pressu pressure. re. Fluids Fluids under under pressu pressure re can penet penet rate skin and clothing. Fluids under pressure can have enough force to penetrate the skin. These fluids can infect a minor cut or opening opening in the skin. skin. If injured by escaping fluid, see a doctor at once. Serious infection or reaction can result without immediate medical treatment.

(Rev. 2004) 30 6SE48 SE483 3



Fuel Keep the hose and nozzle or the funnel and container in contact with the metal o f the fuel tank when refueling to avoid the possibility of an electric spark ign iting the fuel.

To avoid injury from fire caused by heated diesel-fuel vapors: Keep those people who are not directly involved in servicing away from the engin e. 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 clothing (face shield, insulated gloves and apron, etc. ). To prevent a buildup of potentially volatile vapors, keep the engine area well v entilated during operation. Diesel fuel is relatively harmless at ambient temperatures.

To avoid injury from possible fuel vapor ignition when refueling, keep the hose, nozzle, funnel, or container in contact with t he metal metal opening opening of the fuel fuel tank. This will reduce reduce the likelihood of a danger ous spark. This caution applies to gasoline engines. The following cautions should be followed when filling a fuel tank:


2004) 31


To avoid injury from fire, do not overfill the fuel tank.

To avoid injury from fire, keep all potential ignition sources away from diesel fuel, open flames, sparks, and electrical resistance heating el ements. Do not smoke when refueling.

(Rev. 2004) 32 6SE48 SE483 3



Batteries Electrical storage batteries emit highly flammable hydrogen gas when charging an d continue to do so for some time after receiving a steady charge.

To avoid injury from battery explosion or contact with battery acid, work in a well-ventilated area, wear protective clothing, and a void sparks or flames near the battery. Always establish correct polarity before connecting cables to the battery or battery circuit. If you come in conta ct 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 immediately. Always disconnect the battery cable before working on the electrical system.

To avoid servicing

injury from the engine,

accidental engine startup disconnect/disable the

while starting system.

Disconnect the batteries or disable an air starter when working on the engine (e xcept DDEC) to prevent accidental starting.


2004) 33


Fire Keep a charged charged fire extinguisher extinguisher within reach. Be sure you have the correct correct typ e of extinguisher for the situation. Cleaning Agent Avoid the use of carbon tetrachloride as a cleaning agent because of the harmful vapors that it releases. releases. Ensure the work area is adequately ventilated. Use p rotective gloves, goggles or face shield, and apron.

To avoid injury from harmful vapors or skin contact, do not use carbon tetrachloride as a cleaning agent. Exercise caution against burns when using oxalic acid to clean the cooling passa ges of the engine. Working on a Running Engine When working on an engine that is running, accidental contact with the hot exhau st manifold can cause severe burns.

To avoid injury from unguarded rotating and moving engine components, check that all protective devices have been reinstalled after wo rking on the engine.

To avoid injury, use care when working around moving belts and rotating parts on the engine.

(Rev. 2004) 34 6SE48 SE483 3



Start Attempts Avoid excessive injection of ether into the engine during start attempts.

To avoid injury from from an explosion of natural natural gas, the following precautions must be taken: Do not smoke when installing or servicing the engine or fuel system. Installation or servicing of natural-gas equipment must only be conducted in well-ventilated, well-ventilated, natural gas compatible areas. Do not install or service equipment in an enclosed area where ignition sources are pre sent without first ensuring that an undetected gas leak may be safely vented without being ignited. Bleed natural gas lines before installing or servicing any component connected t o the fuel lines. Natural gas fuel systems are pressurized. Relieve pressure from any fuel system component prior to installation or service of that component. Use a combustible-gas detector. Liquefied natural gas (LNG) is odorless and cannot be detected by smell. Compressed Natural gas (CNG) may be odorless and may not be detected by smell. Equipment fuel systems are the responsibility of the Original Equipment Manufact urer (OEM). Equipment fuel system guidelines must be closely adhered to when ins talling or servicing equipment. equipment. Refer to OEM guidelines specifying which which mainte nance procedures require venting of fuel lines and fuel tanks. LNG systems are pressurized and contain extremely cold (-260 F [-162 C]) fluids. Contact the fuel supplier or OEM for LNG safety r equirements. Contact with LNG may cause personal personal injury (freezing). Vent systems on the equipment should be ducted to a safe area whenever equipment is in an enclosed area. Natural gas is highly flammable and explosive and may b e extremely cold (-260 F [-162 C]).


2004) 35


NOTICE: Avoid excessive injection of ether into the engine during start atte attemp mpts ts. . Inje Inject ctio ion n of exce excess ssiv ive e ethe ether r may may resu result lt in in an unco uncont ntro roll lle e d inte intern rnal al engi engine ne expl explos osio ion n that that coul could d caus cause e engi engine ne dama damage ge. . Foll Follow ow the the man man ufacturer's instructions on proper product use. Follow the instructions on the container or by the manufacturer of the starting aid.

(Rev. 2004) 36 6SE48 SE483 3



Turbocharger Compressor Inlet Shield A turbocharger compressor inlet shield, J 26554-A, is available and must be used anytime the engine engine is operated with the air inlet piping removed. See Figure 1 4. The shield helps helps to prevent foreign objects from entering and damaging the t urbocharger and will prevent the mechanic from accidentally touching the turboch arger impeller. The use of this this shield does NOT preclude any other safety pract ices contained in this manual. See Figure 15 for Series 60G engine.

To avoid injury from contact with rotating parts when an engine is operating with the air inlet piping removed, install an air inlet scre en shield over the turbocharger air inlet. The shield prevents contact with rota ting parts. Use of this shield does NOT preclude any other safety practices contained in thi s manual.

Figure 14

Turbocharger Compressor Inlet Shield



2004) 37

Figur igure e 15

Turbo urboc charg harger er Compr ompres esso sor r Inle Inlet t Shie Shield ld, , Seri Series es 60G Engin ngine e

(Rev. 2004) 38 6SE48 SE483 3



FLUOROELASTOMER (VITON) CAUTION Under normal design conditions, fluoroelastomer (VITON) parts, such as O-rings a nd seals, are perfectly safe to handle.

To avoid injury from chemical burns, wear a face shield and neoprene or PVC gloves when handling fluoroelastomer Orings or seals that have been degraded by excessive heat. Discard gloves after h andling degraded fluoroelastomer parts. However, a potential hazard may occur if these components are raised to a temper ature above 316 C (600 F), such as during a cylinder cylinder failure or engine fire. At temperature s above 316 C (600 F) fluoroelastomer will decompose (indicated by charring or the appearance of a black, sticky mass) and produce hydrofluoric hydrofluoric acid. This is extremely corro corro sive and, if touched by bare skin, may cause severe burns, sometimes with sympto ms delayed for several hours.


2004) 39


ENGINE VIEWS The engine views show the pre-1991 engine and 1991 and later engine as well as D DEC II and DDEC III/IV. See Figure 16. For Series 60G 60G engine views see Figure 17, see Figu re 18and see Figure 19.

Figure 16

Engine Views

(Rev. 2004) 40 6SE48 SE483 3



Figure 17

Engine Views (60G Genset Engine)



2004) 41

Figure 18 18

Engine Vi Views (6 (60G Au Automotive En Engine)

(Rev. 2004) 42 6SE48 SE483 3



Figure 19 19

Engine Vi Views (H (Heat-Exchanger-Cooled Ma Marine En Engine)



2004) 43

Figur igure e 20 20 Engine

Engin ngine e Vie Views Serie eries s 60 60 200 2002 Ex Exhaus haust t Ga Gas Re Recirc circul ulat atio ion n (EG (EGR) R)

(Rev. 2004) 44 6SE48 SE483 3



ENGLISH TO METRIC CONVERSION Listed in Table 5 are the English to metric conversions. Multiply Le Length Inch (i ( in.) Foot (ft) Yard (yd) Mile (mile) Multiply Area Inch2 (in.2)

By 25.4 0.3048 0.9144 1.609 By 645.2

To ge get eq equivalent nu number of of: Millimeters (mm) Meters (m) Meters (m) Kilometers (km) To get equivalent number of: Millimeters2 (mm2)

Inch2 (in.2) 6.45 Centimeters2 (cm2) Foot2 (ft2) 0.0929 Meters2 (m2) Yard2 (yd2) 0.8361 Meters2 (m2) Multiply Vo Volume By To ge get eq equivalent nu number of of: Inch3 (in.3) 16387 Millimeters3 (mm3) Inch3 nch3 (in.3 in.3) ) 16.38 6.387 7 Cent Centim imet eter ers3 s3 (cm3 (cm3) ) Inch3 (in.3) 0.0164 Liters (L) Quart (qt) 0.9464 Liters (L) Gallon (gal) 3.785 Liters (L) Yard3 (yd3) 0.7646 Meters3 (m3) Multiply Mass By To get equivalent number of: Pound (lb) 0.4536 Kilograms (kg) Ton (ton) 907.18 Kilograms (kg) Ton (ton) 0.907 Tonne (t) Multiply Force By To get equivalent number of: Kilogram (kg) 9.807 Newtons (N) Ounce (oz) 0.2780 Newtons (N) Pound (lb) 4.448 Newtons (N) Multiply Temperature By To get equivalent number of: Degre egree e Fa Fahren hrenhe heit it ( F) F) ( F-3 F-32 2) ÷ 1.8 1.8 Degr Degree ee Cel Celsius sius ( C) C) Multiply Ac Acceleration By To ge get eq equivalent nu number of of: Foot Foot/s /sec econ ond2 d2 (ft/s (ft/sec ec2) 2) 0.30 0.3048 48 Mete Meter/ r/se seco cond nd2 2 (m/s2 (m/s2) ) Inch/second2 (in./sec2) 0.0254 Meter/second2 (m/s2) Multiply To Torque By To ge get eq equivalent nu number of of: Pound-inch (l (lb·in.) 0.11298 Newton-meters (N·m) Pound-foot (l (lb·ft) 1.3558 Newton-meters (N (N·m) Multiply Power By To get equivalent number of:


2004) 45


Multiply Le Length By To ge get eq equivalent nu number of of: Horse orsepo powe wer r (hp) (hp) 0.746 .746 Kilo Kilowa watt tts s (kW) (kW) Multiply Power By To get equivalent number of: Inches of water (in. H2 O) 0.2491 Kilopascals (kPa) Pounds/square in. (lb/in.2) 6.895 Kilopascals (kPa) Multiply En Energy or or Wo Work By To ge get eq equivalent nu number of of: British Thermal Unit (Btu) 1055 Joules (J) Foot-pound (ft·lb) 1.3558 Joules (J) kilowatt-hour (kW·hr) 3,600,000. or 3.6 x 106 Joules (J = one W/s) Multiply Light By To get equivalent number of: Foot candle (fc) 10.764 Lumens/meter2 (lm/m2) Multiply Fuel Performance By To get equivalent number of: Miles iles/g /gal al (mi (mile/g le/gal al) ) 0.42 0.4251 51 Kilo Kilome mete ters rs/l /lit iter er (km/L km/L) ) Gall Gallon ons/ s/mi mile le (gal (gal/m /mil ile) e) 2.35 2.3527 27 Lite Liter/ r/ki kilo lome mete ter r (L/k (L/km) m) Multiply Velocity By To get equivalent number of: Miles iles/h /hou our r (mil (mile/ e/hr hr) ) 1.60 1.6093 93 Kilo Kilome mete ters rs/h /hou our r (km/ (km/hr hr) ) Table 5 English English to Metric Metric Conversi Conversion on Table Table DECIMAL AND METRIC EQUIVALENTS

Listed in Table 6 are the decimal and metric equivalents:

(Rev. 2004) 46 6SE48 SE483 3



Fractions of an inch Decimal(in.) Decimal (in.) Metric(mm) 1/64 0.015625 0.39688 33/64 1/32 0.03125 0.79375 17/32 0.53125 3/64 0.046875 1.19062 35/64 1/16 0.0625 1.58750 9/16 0.5625 5/64 0.078125 1.98437 37/64 3/32 0.09375 2.38125 19/32 0.59375 7/64 0.109375 2.77812 39/64 1/8 0.125 3.175 5/8 0.625 9/64 0.140625 3.57187 41/64 5/32 0.15625 3.96875 21/32 0.65625 11/64 0.171875 4.36562 43/64 3/16 0.1875 4.76250 11/16 0.6875 13/64 0.203125 5.15937 45/64 7/32 0.21875 5.55625 23/32 0.71875

Metric(mm)

Fractions of an inch

0.515625 13.49375 0.546875 14.28750 0.578125 15.08125 0.609375 15.87500 0.640625 16.66875 0.671875 17.46250 0.703125 18.25625

13.09687 13.89062 14.68437 15.47812 16.27187 17.06562 17.85937

15/64 1/4 17/64 9/32 19/64 5/16 21/64 11/32 23/64 3/8 25/64 13/32 27/64 7/16 29/64 15/32 31/64 1/2

0.234375 5.95312 47/64 0.250 6.35000 3/4 0.750 0.265625 6.74687 49/64 0.28125 7.14375 25/32 0.78125 0.296875 7.54062 51/64 0.3125 7.93750 13/16 0.8125 0.328125 8.33437 53/64 0.34375 8.73125 27/32 0.84375 0.359375 9.12812 55/64 0.375 9.52500 7/8 0.875 0.390625 9.92187 57/64 0.40625 10.31875 29/32 0.421875 10.71562 0.4375 11.11250 15/16 0.453125 11.50937 0.46875 11.90625 31/32 0.484375 12.30312 0.500 12.70000 1

0.734375 18.65312 19.05000 0.765625 19.44687 19.84375 0.796875 20.24062 20.63750 0.828125 21.03437 21.43125 0.859375 21.82812 22.22500 0.890625 22.62187 0.90625 23.01875 59/64 0.921875 23.41562 0.9375 23.81250 61/64 0.953125 24.20937 0.96875 24.60625 63/64 0.984375 25.00312 1.00 25.40000

Table 6 Conversion Conversion Chart-Cu Chart-Customa stomary ry and Metric Metric Units


2004) 47


SPECIFICATIONS This section contains fastener torque specifications and pipe plug torque specif ications. Torque Specifications - Fasteners The proper bolt and nut torque is dependent on its size. Standard (non-metric) (non-metric) nut and bolt torque specifications are listed in Table 7. The proper torque torque spe cifications for metric nuts and bolts are listed in Table 8. Nut an and Bo Bolt Si Size, mm mm b·ft No.10-24 5-7 1/4 in.-20 9-12 1/4 in.-28 11-14 5/16 in.-18 18-23 5/16 in.-24 20-26 3/8 in.-16 41-47 3/8 in.-24 47-53 7/16 in.-14 62-68 7/16 in.-20 77-83 1/2 in.-13 96-102

280M or or Be Better To Torque, N· N·m 4-5 7-9 8-10 13-17 15-19 30-35 35-39 46-50 57-61 71-75

280M or or Be Better To Torque, l

1/2 in.-20 9/16 in in.-12 9/16 in.-18 5/8 in in.-11 5/8 in in.-18 3/4 in in.-10 3/4 in in.-16 7/8 in.-9 7/8 in in.-14 1 in.-8 in.-8 1 in.-14 in.-14

112-126 122-136 145-159 186-199 228-241 325-339 393-407 556-569 644-657 789-79 789-799 9 928-94 928-942 2

83-93 90-100 107-117 137-147 168-178 240-250 290-300 410-420 475-485 580-59 580-590 0 685-69 685-695 5

Table 7 Standard Standard (Non-metric (Non-metric) ) Fastener Torque Torque Specificati Specifications ons

(Rev. 2004) 48 6SE48 SE483 3



Nut and Bolt Bolt Size Size, , mm mm ue, lb·ft M6 X 1.0 13-16 M8 X 1. 1.25 30-38 M10 X 1.5 58-73 M12 X 1.75 101-126 M14 X 2.0 160-200 M16 X 2.0 245-306 M20 X 2.5 478-598

Proper Property ty Class Class 10.9 10.9 Torq Torque, ue, N·m Proper Property ty Class Class 10.9 10.9 Torq Torq 10-12 22-28 43-54 75-93 118-148 181-226 353-441

Table 8 Class 10.9 10.9 Torque Specifica Specifications tions for Metric Metric Fasteners Fasteners Torque Specification - Pipe Plugs Standard pipe plug torque specifications supporting the Series 60 engine are lis ted in Table 9. *Pipe Plug Si Size, NPTF b·ft 1/8 in. 14-18 1/4 in. 19-24 3/8 in. 24-31

Torque Specifications, N·m 10-13 14-18 18-23

Torque Specifications, l

1/2 in. 3/4 in. 1 in. in. 1-1/4 in. 1-1/2 in.

31-39 45-56 101101-12 126 6 129-161 149-187

23-29 33-41 75-9 75-93 3 95-119 110-138

*Use sealant such as Pipe Plug Sealant with with Teflon®, PT-7271 PT-7271 (Loctite® 592), or equ ivalent on all uncoated pipe plugs. Table 9 Standard Standard Pipe Plug Plug Torque Torque Specifica Specifications tions



2004) 49

(Rev. 2004) 50 6SE48 SE483 3


1

ENGINE

Sect Sectio ion n Page Page 1.1 1.1 .....

CYLI CYLIND NDER ER BLOC BLOCK K AND AND CYLI CYLIND NDER ER LINE LINER R 1-3

.... ...... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... ... .

1.2 1.2 CYLI CYLIND NDER ER HEAD HEAD .... ...... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... ... . ........................... 1-30 1.3 1.3 VALV VALVE E AND AND INJE INJECT CTOR OR OPER OPERAT ATIN ING G MECH MECHAN ANIS ISM M .... ...... .... .... .... .... .... .... .... .... .... .... .... .... .. 1-64 1.4 VALVES, SPRINGS, GUIDES, INSERTS, SEALS AND ROTATORS ....... 1-86 1.5 1.5 ENGI ENGINE NE LIFT LIFTER ER BRAC BRACKE KETS TS .... ...... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... ... . ................. 1-118 1.6 1.6 ROCK ROCKER ER COVE COVER R .... ...... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .. .......................... 1-126 1.7 1.7 CRAN CRANKS KSHA HAFT FT .... ...... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .. ..... ...... .... .... .... .... .... .... .... ... ..... ...... .. 1-14 1-148 8 1.8 1.8 CRAN CRANKS KSHA HAFT FT OIL OIL SEAL SEALS S .... ...... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .. ................... 1-169 1.9 1.9 CRAN CRANKS KSHA HAFT FT MAIN MAIN BEAR BEARIN INGS GS .... ...... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .. ............. 1-190 1.10 1.10 GEAR GEAR CASE CASE COVER COVER ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ..... .. .... ...... .... .... .... .... .... .... .... .... .. 1-20 1-203 3 1.11 1.11 GEAR GEAR CASE CASE ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... .... . .......... ............... .......... .......... .......... ...... . 1-237 1.12 1.12 CRANKS CRANKSHAF HAFT T VIBRAT VIBRATION ION DAMPER DAMPER ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ..... .. ......... 1-269 1.13 1.13 CRANKS CRANKSHAF HAFT T PULLEY PULLEY ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ..... .. ..... ...... .... .... .... .... .... .... .... .. 1-27 1-278 8 1.14 1.14 FLYWHE FLYWHEEL EL ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... .... . ................................ 1-294 1.15 1.15 RING RING GEAR GEAR ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... .... . ................................ 1-304 1.16 1.16 FLYWHE FLYWHEEL EL HOUSIN HOUSING G ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... .... . .... ...... .... .... .... .... .... .... .... .... .. 1-30 1-306 6 1.17 1.17 PISTON PISTON AND PISTON PISTON RING RING ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ... ................... 1-314 1.18 1.18

FORG FORGED ED STEE STEEL L ONE ONE PIE PIECE CE PIST PISTON ON ASSE ASSEMB MBLY LY AND AND PIS PISTO TON N RING .................................................................. ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ..... .. 1-337 1-337 1.19 1.19 PISTON PISTON AND CONNEC CONNECTIN TING G ROD ASSEMB ASSEMBLY LY ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ... . 1-352 1.20 1.20 CONNEC CONNECTIN TING G ROD ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ..... .. ........................ 1-383 1.21 1.21 CYLIND CYLINDER ER LINER LINER ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ..... .. ........................... 1-398

1.22 1.22 GEAR GEAR TRAIN TRAIN AND ENGINE ENGINE TIMING TIMING ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ... ............ 1-413 1.23 1.23 THRUST THRUST PLATE PLATE PERIME PERIMETER TER SEAL SEAL .... ....... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... .... . ........... 1-443 1.24 1.24 CAMSHA CAMSHAFT FT AND CAMSHA CAMSHAFT FT BEARIN BEARING G ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ... ..... 1-458 1.25 1.25 CAMSHA CAMSHAFT FT DRIVE DRIVE GEAR GEAR ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ... ................... 1-510 1.26 1.26 ADJUST ADJUSTABL ABLE E IDLE IDLER R GEAR GEAR ASSEMB ASSEMBLY LY ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ..... .. .... ...... ... . 1-52 1-524 4 1.27 1.27 BULL BULL GEAR GEAR AND AND CAMS CAMSHA HAFT FT IDLE IDLER R GEAR GEAR ASSE ASSEMB MBLY LY .... ...... .... .... .... .... .... .... .... ... . 1-535 1.28 1.28 CRANKS CRANKSHAF HAFT T TIMING TIMING GEAR GEAR AND TIMING TIMING WHEEL WHEEL ...... ......... ...... ...... ...... ...... ...... ...... .... . 1-549 1.29 1.29 ACCESS ACCESSORY ORY DRIVE DRIVE ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ..... .. .......... ............... .......... ........ ... 1-570 1.30 1.30 JAKE JAKE BRAKE® BRAKE® ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... .... . ..... ...... .... .... .... .... .... .... .... ... ..... ...... .. 1-60 1-603 3 1.A 1.A ADDI ADDITI TION ONAL AL INFOR INFORMA MATI TION ON ..... ....... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .. ................. 1-663 (Rev. 2004) All information subject to change without notice. 1-2 1-2 6SE4 6SE483 83 0401 0401 Copy Copyri righ ght t © 2004 2004 DETR DETROI OIT T DIES DIESEL EL CORP CORPOR ORAT ATIO ION N


1.1

CYLINDER BLOCK AND CYLINDER LI LINER

The cylinder block is the basic engine structure, establishing and maintaining t he alignment of all engine working parts. In the Series 60 Engine, the cylinder bores are not an integral part of the block casting, but are in the form of rep laceable, wet type cylinder liners. See Figure 1-1. Flanges at the liner upper ends seat in counterbores in the block deck, and proj ect slightly above the deck to compress the head gasket for a good compression s eal. Below the water jacket the lower end of the cylinder liner has has two D-shape d seal rings and a lipped crevice seal to prevent leakage between the water jack et and crankcase.

1.

Cylinder Block

2.

D-rin -rings gs

3.

Crevice Seal

Figure 11-1

5.

4.

Cylinder Liner

Inte Integr gral al Coola oolant nt Inlet nlet Man Manifol ifold d 6.

Oil Galleries

Series 60 Cylinder Block an and Li Liner


1.1

2004) 1-3


An integral coolant coolant inlet manifold manifold is cored into the right side of the block. I t distributes the water pump output output along the length of the block. Oil galleries are are machined int o the cooler side of the block. See Figure Figure 1-1. The integral oil galleries direct the oil pump output through the external oil c ooler and filters, to the main oil gallery and to drilled passages in the crankcase webs which supply oil under pressure

to each main bearing. In the crankcase, crankcase, five integral webs plus front and rear bulkheads support support the crankshaft in seven main bearings. See Figure 1-2.

Figure 11-2

Series 60 60 Cy Cylinder Bl Block Cr Crankcase

An improved cylinder block has replaced the former block on all Series 60 engine s. This change took effect with unit serial number 6R210293, built November 30, 1994. The former cylinder cylinder block was used on engines engines built prior to this serial number. The Series 60 cylinder block was further improved by the addition of a drilled l ubrication orifice orifice and bolt hole hole at the base base of each cylinder cylinder bore. See Figure 1-2. The orifices are drilled into the the main oil gallery gallery and are required for in in stallation of bolt-on oil spray nozzles used with forged steel pistons on premium engines. When blocks are used for non-premium engines w ith cast-iron pistons, the lubrication orifices are closed with bolt-on steel plates. First us age of the drilled block was on May 2, 1998, effective with engine serial number 6R408505.

(Rev. 2004) All information subject to change without notice. 1-4 1-4 6SE4 6SE483 83 0401 0401 Copy Copyri righ ght t © 2004 2004 DETR DETROI OIT T DIES DIESEL EL CORP CORPOR ORAT ATIO ION N


The improved block permits installation of adaptorless Bendix and Midland air co mpressors onto the gear case. case. The improved block block is similar to the former block, except that that i t has a slightly modified sidewall configuration that eliminates interference be tween the block and the adaptorless adaptorless compressor. To compensate for the eliminati on of the adaptor, air compressor mounting bracket bolt holes have have been moved forward 130.3 mm mm (5.13 in.) on the block. See Figur Figur e 1-3. Since these holes holes have a different different spacing than the former holes, an imp roved compressor mounting bracket is required. A new air compressor coolant supply port has also been adde d forward of the former supply port. The former port is plugged when the adaptor less compressor is installed.

Figur igure e 1-3 1-3

Cylin ylind der Block lock Sho Showing wing Cur Current rent Mod Modific ificat atio ions ns

When replacing a former block with an improved block, it is recommended (but not necessary) that an adaptorless air compressor, improved compressor mounting bra cket, and improved compressor compressor coolant supply hose be installed. Refer to sectio n 10.1.3, of this manual for information on installing the adaptorless air compr essor.


1.1


1.1. 1.1.1 1

Repa Repair ir or Repl Replac acem emen ent t of of Cyl Cylin inde der r Blo Block ck

2004) 1-5

To determine if repair is possible or replacement is necessary, perform the foll owing procedure. See Figure 1-4.

Figur igure e 11-4

Flowc lowch hart art for for Repa Repair ir or Re Replac placem emen ent t of of Cyl Cylin inde der r Bl Block ock



1.1.2 1.1.2

Remova Removal l and and Disas Disassem sembly bly of Engi Engine ne from from the Vehicl Vehicle e or Vessel Vessel

Before mounting an engine on an overhaul stand, it must be disconnected from the transmission. Details for removing an engine will vary from one application to another. However, the following steps will be necessary, regardless of applicati on: 1.

Disconnect the battery cable(s) from the battery(s).

2. Drain the the cooling system completely by removing removing the the drain plug in the oil c ooler and opening the drain cocks in the cylinder block, thermostat housing and water pump housing. Refer to section 13.13.4. NOTE:

On marine engines, drain the heat exchanger, charge air cooler and water-cooled intake manifold, if installed. 3.

Drain the lubricating oil.

Refer to section 13.13.1.

4. Disconnect the inlet fuel line from the primary fuel filter and the outlet line from the upper fitting at the rear of the cylinder head. head. Refer to section 2.10.1. 5. Remove the air cleaner ducting as necessary for engine removal. Refer to OE OE M guidelines. 6. Remove the charge air cooler ducting from the turbocharger and intake manif old. Refer to section 6.10.2. 7. 2.

Disconnect the exhaust piping from the turbocharger. Refer to section 6.6.

8.

Disconnect DDEC:

[a] [a] For For DDEC DDEC I, disc discon onne nect ct the the section 2.21.2.

22-p 22-pin in DDEC DDEC elec electr tric ical al conn connec ecto tor. r. Refe Refer r to

[b] [b] For For DDE DDEC C II II or or III III, , dis disco conn nnec ect t the the 30-p 30-pin in DDEC DDEC vehi vehicl cle e ele elect ctri rica cal l con conne nec c tor and the six-pin DDEC II power connector or DDEC III/IV five pin power connec tor. Refer to section 2.19.2, or refer to section 2.20.3. 9.

Disconnect and remove the cranking motor. Refer to section 8.4.2.

10. Remove the alternator and other electrical equipment, as necessary. Refer to section 8.2.2. 11. Remove the air compressor compressor and any air lines, as necessary. Refer to sectio sectio n 10.1.5. 12.

Disconnect and remove the coolant hoses.

13.

On marine engines, remove the raw water pump.Refer to section 4.4.2.

14. Remove the charge air cooler, radiator, fan guard and other cooling system related parts as necessary to remove the engine. Refer to section 6.10.2. NOTE: On certain keel cooled marine engines, remove the front-mounted charge air coole r and mounting, if if installed. Refer to section 4.4.2. 4.4.2.


1.1


2004) 1-7

15. 15. Conn Connec ect t a suit suitab able le lift liftin ing g dev devic ice e to to the the engi engine ne usin using g all all thre three e lif lifti ting ng brackets (two at the rear and one at the front). 16. 16.

Sepa Separa rate te the the eng engin ine e fro from m the the tran transm smis issi sion on or mari marine ne gear gear. .

17.

Remove th the en engine mounting bolts.

To avoid injury from a falling engine, an adequate lifting device with a spreader bar and sling should be used to lift the engine. The slin g and spreader bar should be adjusted so the lifting hooks are vertical to preve nt bending the lifter brackets. To ensure proper weight distribution, all provid ed lifter brackets must be used. 18. 18. Lift Lift the the eng engin ine e fro from m its its moun mounts ts usin using g a suit suitab able le lift liftin ing g dev devic ice. e. See See Fig Fig ure 1-5.

Figure 1-5

Lifting Engine



To avoid injury from a falling engine, ensure the engine is securely attached to the engine overhaul stand before releasing the l ifting sling. 19. Use engine overhaul stand, J 29109, with stand adaptor plate, J 35635-1 35635-1 pa rt of J 35635–A for support when stripping a Series 60 engine cylinder block. See Figure 1-6.

Figure 11-6

Engine Overhaul St Stand and Adaptor


1.1

2004) 1-9


20. 20. Bolt Bolt cyli cylind nder er bloc block k ada adapt ptor or, , J 3563 356355-2 2 par part t of of J 3563 35635– 5–A, A, to the the cyl cylin inde der r block and mate it with the stand adaptor, J 35635-1 part of J 35635–A. See Figure 1-7.

Figure 1-7

Cylinder Block Adaptor

21. 21. The The engi engine ne is left left-s -sid ide e moun mounte ted d in an upri uprigh ght t posi positi tion on. . ther direction and lock it into position. 22.

Rota Rotate te it in ei

Remove the fuel filters and adaptor.

[a] [a] For For DDE DDEC C I engi engine nes, s, remo remove ve the the inl inlet et and and out outle let t fue fuel l lin lines es conn connec ecte ted d to to the Electronic Distributor Unit (EDU) cold plate, the EDU mounting bolts, and th e EDU. Refer to section 2.21.2. [b] [b] For For DDE DDEC C II II eng engin ines es, , rem remov ove e the the inle inlet t and and outl outlet et fuel fuel line lines s con conne nect cted ed to the Electronic Control Module (ECM) cold plate, the ECM mounting bolts, and the ECM. Refer to section 2.20.3. NOTE: DDC has discontinued the use of the ECM cold plate on all Series 60 automotive e ngine models, effective with unit serial number 06R0008950. In place of the ECM cold plate, a No. 6 x 37.92 in. (963 mm) long hose assembly (23504785) is now ro uted from the fuel pump discharge fitting to the inlet of the secondary fuel fil ter.



[c] [c] Curr Curren ent t DDE DDEC C III III/I /IV V Ser Serie ies s 60 60 veh vehic icle le, , ind indus ustr tria ial l and and gene genera rato tor r set set engi engi nes do not have a cold plate. NOTE: Series 60 marine engines DO have a cold plate. 23. Disconnect the harness connector (gray) from the timing reference sensor ( TRS) at the lower left corner corner of the gear gear case. Remove the TRS TRS from the gear gear ca se. Refer to section 2.33.2. 24.

Disconnect the harness (black) connector from the synchronous reference se

nsor (SRS) at the left rear wall of the gear case. Remove the SRS from the gear case. Refer to section 2.32.2. 25. ne.

Remove any electrical components, connectors or wiring looms from the engi

26. With the engine mounted on the the overhaul overhaul stand, remove all of any remaining subassemblies and parts from the cylinder block. [a] [a]

To remo remove ve the the one one piec piece e valv valve e roc rocke ker r cov cover er, , refe refer r to to sec secti tion on 1.6 1.6.2 .2. .

[b] [b]

To remo remove ve the the two two piec piece e valv valve e roc rocke ker r cov cover er, , refe refer r to to sec secti tion on 1.6 1.6.3 .3. .

[c] [c]

To remo remove ve the the thre three e piec piece e valv valve e rock rocker er cove cover. r. Refe Refer r to sect sectio ion n 1.6. 1.6.5. 5.

[d] [d]

Remo Remove ve the the eng engin ine e lif lifte ter r bra brack cket ets, s, refe refer r to to sec secti tion on 1.5. 1.5.2. 2.

[e] [e]

Remo Remove ve the the cra crank nksh shaf aft t pull pulley ey, , refe refer r to to sect sectio ion n 1.13 1.13.2 .2. .

[f] [f]

Remo Remove ve the the cra crank nksh shaf aft t vibr vibrat atio ion n damp damper er, , refe refer r to sec secti tion on 1.1 1.12. 2.2. 2.

[g] [g]

Remo Remove ve the the acce access ssor ory y driv drive, e, refe refer r to sect sectio ion n 1.29 1.29.2 .2. .

[h] [h]

Remo Remove ve the the gear gear case case cove cover, r, refe refer r to sect sectio ion n 1.10 1.10.2 .2. .

[i] [i]

Remo Remove ve the the cam camsh shaf aft t dri drive ve gear gear, , ref refer er to sect sectio ion n 1.2 1.25. 5.2. 2.

[j] [j] Remo Remove ve the the bul bull l gea gear r and and cams camsha haft ft idle idler r gea gear r ass assem embl bly, y, refe refer r to to sec secti tion on 1.27.2. [k] [k]

Remo Remove ve the the adj adjus usta tabl ble e idle idler r gea gear r ass assem embl bly, y, refe refer r to to sec secti tion on 1.26 1.26.2 .2. .

[l] [l] 8.2.

Remo Remove ve the the cra crank nksh shaf aft t tim timin ing g gea gear r and and timi timing ng whee wheel, l, refe refer r to to sec secti tion on 1.2 1.2

[m]

Remov emove e th the gea gear r ca case, se, refe refer r to to sec section tion 1.1 1.11.2. 1.2.

[n]

Remov emove e th the cam camsh shaf aft, t, refer efer to sect sectio ion n 1.24 1.24.2 .2. .

[o]

Remov emove e th the cyl cylin inde der r he head, ad, ref refe er to to sec secti tion on 1.2 1.2.2. .2.

[p]

Remov emove e th the fly flywh whee eel, l, refer efer to sect sectio ion n 1.14 1.14.2 .2. .

[q] [q]

Remo Remove ve the the fly flywh whee eel l hou housi sing ng, , ref refer er to sect sectio ion n 1.16 1.16.2 .2. .

[r]

Remov emove e the the oil oil pan pan, refe refer r to secti ection on 3.11. .11.2. 2.

[s] [s]

Remo Remove ve the the pis pisto ton n and and conn connec ecti ting ng rod rod ass assem embl bly, y, refe refer r to to sec secti tion on 1.19 1.19.2 .2. .

[t]

Remov emove e th the cra crank nksh shaf aft, t, ref refer to se sectio ction n 1. 1.7.2. 7.2.


2004) 1-11

1.1


NOTICE: Before removing main bearing caps, be sure each is stamped or punch-marked in numerical order, beginning with No. 1 at the front, to ensure installati on in their original position. Mark all caps on the oil cooler side (right side) of the engine to prevent reversal at assembly. Failure to mark numerical order may result in the caps being put back in incorrect order, improper crankshaft support and s evere crankshaft or bearing damage or both. [u] [u]

Remo Remove ve the the cra crank nksh shaf aft t mai main n bea beari ring ngs, s, refe refer r to to sec secti tion on 1.9. 1.9.2. 2.

1.1. 1.1.3 3

Clea Cleani ning ng the the Cyli Cylind nder er Bloc Block k

Before removing cylinder liners for block cleaning, the liner bores should be ga ged to determine whether whether liner replacement is necessary. Refer to section 1.21. 2.2. Remove cylinder liners with the cylinder liner removal tool, J 35791, before put ting the block in cleaning or descaling baths, to avoid trapping cleaning agents in block liner seating bores. See Figure 1-8.

Figure 1-8

Cylinder Liner Removal Tool



After disassembling and before removing the cylinder block from the overhaul sta nd for cleaning and inspection, install the two metric eye bolts J 35595 to the cylinder block. See Figure 1-9.


Cylin ylind der Block lock Tes Test Deck Deck Plate late Ins Install tallat atio ion n

Clean the cylinder block as follows: 1. Remove all all oil and water water gallery gallery and weep hole hole plugs to allow the cleaning cleaning solution to enter enter the inside of the oil and water passages. passages. On current block, block, r

emove bolt-on plate or piston-cooling oil spray nozzle at the base of each cylin der bore. 2. Immerse and agitate agitate the block in a hot bath bath of a commercial, commercial, heavy-duty alk aline solution. 3. Wash the block in hot water water or steam clean it to remove remove the alkaline soluti on. 4. [a] [a]

If the water jackets are heavily scaled, proceed as follows: Imme Immers rse e and and agit agitat ate e the the bloc block k in in a bath bath of inhi inhibi bite ted d pho phosp spho hori ric c aci acid. d.

[b] [b] Allo Allow w the the bloc block k to to rem remai ain n in in the the acid acid bath bath unti until l the the bubb bubbli ling ng acti action on sto sto ps (approximately 30 minutes). [c] [c] Lift Lift the the blo block ck, , dra drain in it and and imm immer erse se it agai again n in in the the same same acid acid solu soluti tion on for 10 more minutes. Repeat until all scale is removed removed from the water water jacket ar ea. [d] [d]

Rins Rinse e the the bloc block k in in cle clear ar, , hot hot wate water r to to rem remov ove e the the acid acid solu soluti tion on. .

[e] [e] Neut Neutra rali lize ze the the aci acid d tha that t may may clin cling g to to the the cast castin ing g by by imm immer ersi sing ng the the blo block ck in an alkaline bath. [f]

Wash ash the the bloc block k in clea clean n wa water ter or steam team cle clean it.


1.1

2004) 1-13




5. Dry Dry the the cyli cylind nder er bloc block k with with comp compre ress ssed ed air. air. Blow Blow out out all all of the the bolt bolt ho les and passages with compressed air. NOTE: The above cleaning procedure may be used on all ordinary cast iron and steel par ts for the engine. Aluminum parts, parts, such as as flywheel housing, air intake manifol d, oil filter adaptor and the camshaft gear access cover should NOT be cleaned i n this manner. Mention will be made of special procedures when necessary.

6. Be cert certai ain n tha that t all all wate water r pas passa sage ges s and and oil oil gal galle leri ries es have have been been thor thorou ough ghl l y cleaned and dried. Install weep hole plugs and precoated pipe plugs. Install new cup plugs using a coating of good grade non-hardening non-hardening sealant such as Loctite® 620 or equivalent. Refer to section ADDITIONAL INFORMATION1.A, "Engine Plug and Dowel Chart." 7. Pres Pressu sure re test test the the cyli cylind nder er bloc block. k. Two Two meth method ods s of cyli cylind nder er bloc block k pres pressu sur r e testing may be used depending on the test facilities available: [a]

Immer mmersi sion on meth method od; ; refe refer r to sec section tion 1.1 1.1.3.1 .3.1. .

[b]

Leakeak-ma mark rker er meth method od; ; re refer fer to to sec secti tion on 1.1.3 .1.3.2 .2. .



1.1.3.1 1.1.3.1 Testing Testing the Cylinder Block Block (Immersion (Immersion Pressure Pressure Method) Use cylinder block pressure test kit, J 36223–D, for immersion method pressure tes

ting as follows: 1. Install cylinder liners with new seal rings and crevice seals. Refer to sec tion 1.21.3. Seat the liners firmly in the block counterbores counterbores with cylinder lin er installation tool, J 35597. 2. Install two metric metric eye bolts, J 35595, 35595, in the head head bolt holes at opposite opposite e nds of the block. See Figure 1-10.

Figu Figure re 1-10 1-10 3.

Cyli Cylind nder er Bloc Block k Test Test Deck Deck Plat Plate e Inst Instal alla lati tion on

Install the cylinder block test strips and rings.

See Figure 1-10.

4. Install the bolts through the strips and into the cylinder block. Torque t he bolts on the ring strips strips to 230-237 N·m (170-175 lb·ft). lb·ft). Torque the bolts bolts on the outside strips to 14 N·m (10 lb·ft). NOTE: Because of a design change to the 1991 cylinder block, the water inlet cover pla te tool has changed. Refer to section ADDITIONAL ADDITIONAL INFORMATION1.A, INFORMATION1.A, for instructio instructio ns on modifying the former tool, J 36223-7, part of J 36223–D.


1.1

2004) 1-15


5. Inst Instal all l the the wate water r inle inlet t cove cover r plat plate, e, J 3622 362233-7A 7A, , part part of J 3622 36223– 3–D. D. See See F igure 1-11. Use the bolt supplied with the tool to secure it to the cylinder block.

Figur igure e 11-11

Water ater Inle Inlet t Co Cover ver Plat Plate e In Instal stalla lati tion on

NOTE: At the base of each liner, the space between upper and lower liner seals is vent ed to the block surface on the left side. Any coolant leakage past the upper sea l is drained to the outside rather than into the crankcase, and is easily detect ed by a visual inspection. 6. With With a sui suita tabl ble e lif lifti ting ng devi device ce and and spr sprea eada dabl ble e bar bars, s, imme immers rse e the the cyli cylind nder er block for twenty minutes in a tank of water heated to 82-93 C (180-200 F). 7. Atta Attach ch an air air lin line e to to the the wate water r inl inlet et cove cover r pla plate te and and app apply ly 138 138 kPa kPa (20 (20 lb/in.2) air pressure to the water jacket. Observe the water water in the tank tank for bubbles that will indica indica te cracks or leaks. A cracked cylinder cylinder block must be replaced by a new block.



8. Remo Remove ve the the blo block ck from from the the wat water er tank tank. . Rem Remov ove e the the plat plates es and and gas gaske kets ts and and blow out all of the passages in the block with compressed air. 9. Remo Remoun unt t the the cyli cylind nder er bloc block k to to the the engi engine ne over overha haul ul stan stand, d, J 291 29109 09. . See See Fi gure 1-6.



1.1.3.2 1.1.3.2 Testing Testing the Cylinder Cylinder Block (Leak-Mar (Leak-Marker ker Pressure) Pressure) When a large water tank is not available, or when it is desired to check the blo ck for cracks without removing the engine from the vehicle cylinder block, leak-marker pressur e testing may be used. However, it is necessary to remove remove the cylinder head, oi l cooler, and oil pan. 1. Install cylinder liners with new seal rings and crevice seals. Refer to sec tion 1.21.3. Seat the liners firmly in the block counterbores counterbores with cylinder lin er installation tool, J 35597. 2. Install two metric metric eye bolts, J 35595, 35595, in the head head bolt holes at opposite opposite e nds of the block. See Figure 1-10. 3. Fill the water jacket jacket with with a mixture of water and 3.8 liters (1 U.S. gallon ) of permanent-type antifreeze. The antifreeze will penetrate small cracks and its c olor will aid in detecting their presence. 4.

Install the cylinder block test strips and rings.

See Figure 1-10.

5. Install the bolts through the strips and into the cylinder block. Torque t he bolts on the ring strips strips to 230-237 N·m (170-175 lb·ft). lb·ft). Torque the bolts bolts on the outside strips to 14 N·m (10 lb·ft). 6. Install the water inlet cover plate, J 36223-7A part of J 36223–D. See Figur e 1-11. Use the bolt supplied with the the tool to secure secure it to the the cylinder block. block.

NOTE: At the base of each liner, the space between upper and lower liner seals is vent ed to the block surface, on the left side. Any coolant leakage past the upper se al is drained to the outside rather than into the crankcase, and is easily detec ted by a visual inspection. NOTE: Because of a design change to the 1991 cylinder block, the water inlet cover pla te tool has changed. Refer to section ADDITIONAL ADDITIONAL INFORMATION1.A, INFORMATION1.A, for instructio instructio ns on modifying the former tool, J 36223-7 part of J 36223–D.


1.1

2004) 1-17


7. Appl Apply y 138 138 kPa kPa (20 (20 lb/i lb/in. n.2) 2) air air pre press ssur ure e to to the the wate water r jac jacke ket t and and main mainta tain in this pressure for at least two hours to give the water and antifreeze mixture ample time to work i ts way through any cracks which may exist. 8. At the the end end of this this test test peri period od, , exa exami mine ne the the out outsi side de diam diamet eter er area area of the the liner flanges, oil passages, crankcase and exterior of the block for presence o f the water and antifreeze mixture, which will indicate the presence of cracks. A cracked cylinder block must be replaced with a new block.

To avoid injury from flying debris when using compressed

air, wear adequate eye protection (face shield not exceed 40 psi (276 kPa) air pressure.

or


9. Afte After r the the pres pressu sure re test test is comp comple lete ted, d, remo remove ve the the tes test t dec deck k pla plate te and and gas gas ket and the water inlet cover plate. Drain the water jacket. Then blow out all of the passages in the cylinder block with compressed air. 10. 10. Remo Remoun unt t the the cyli cylind nder er bloc block k to to the the engi engine ne over overha haul ul stan stand, d, J 291 29109 09. . See See Fi gure 1-6.



1.1.3.3 1.1.3.3 Inspection Inspection of the Cylinder Cylinder Block Block Perform the following for cylinder block inspection: 1. Remove the cylinder liners and regage to determine whether liner replacemen t is necessary. Refer to section 1.21.2. 2. Measure the bore of each each cylinder with cylinder bore gage, J 5347-B, which has a dial indicator calibrated in 0.0001 in. increments. See Figure 1-12.

Figure 11-12

Gaging Cy Cylinder Bo Bores


1.1

2004) 1-19


3. Meas Measur ure e cyl cylin inde der r blo block ck bore bore, , at at the the posi positi tion ons s on on axi axis s 90 90 deg degre rees es apar apart. t. See Figure 1-13. If the diameter does not exceed the dimensions listed in Table 1-1, the block may b e reused. NOTE: The above measurements are average gage readings at each position. Also, the ou t-of-round must not exceed 0.0254 mm (0.001 in.).

Figu Figure re 1-1 1-13 3 Clean-up)

Maxi Maximu mum m Cyli Cylind nder er Blo Block ck Bor Bore e Diam Diamet eter ers s by Loc Locat atio ion n (Aft (After er

Location A 149.050 B 146.050 C 146.050

Diameter, - 149.120 - 146.120 - 146.120

Table 1-1

Acceptable Cylinder Bore Diameters

mm

Diameter, in. 5.868 - 5.871 5.750 - 5.753 5.750 - 5.753



1.1.3.4 1.1.3.4 Inspection Inspection of Deck Deck Flatnes Flatness s Check the cylinder block deck for flatness with an accurate straightedge and fee ler gage. See Figure 1-14.

Figure 11-14

Checking Bl Block De Deck fo for Fl Flatness

Check front-to-rear flatness next to the cylinder liner flanges on both sides, a nd side-to-side flatness between the liner flanges. The deck must be flat within 0.127 mm (0.005 in.) front-to-rear, front-to-rear, and flat flat within 0.076 mm (0.003 in.) side-to-side. If not, the deck must be resurfaced.


1.1

2004) 1-21


NOTICE: The camshaft is mounted in the cylinder head so resurfacing of the block affects the position of the camshaft in relation to the adjustable idler gear and gear train. Record the amount of stock removed from the cylinder block by stamping the amoun t removed on the the cylinder cylinder block pad. See Figure Figure 1-15. 1-15.

Figu Figure re 1-15 1-15

Reco Record rdin ing g Stoc Stock k Rem Remov oval al on Cyli Cylind nder er Bloc Block k Pad Pad



1.1.3.5 1.1.3.5 Inspection Inspection of Main Main Bearing Bearing Bores Bores Perform the following steps for main bearing bore inspection: 1. Install the main bearing caps in their original positions. Lubricate the ca p bolt threads and head contact surfaces with a small quantity of International Compound #2®. International Compound #2® is a registered trademark of IRMCO. 2.

Install the main cap bolts and torque to 470-530 N·m (347-391 lb·ft).

3. Measure the main bearing bores using using dial bore gage gage which has a dial indica indica tor calibrated in 0.0001 in. increments. Set the cylinder bore gage on zero in master setting fixture. See Figure 1-16.

Figure 11-16

Gaging Main Be Bearing Bo Bores

The bore diameter specifications specifications is 133.00-133.025 mm (5.236-5.237 in.). Line b oring is also necessary when a bearing cap must be replaced due to breakage or s pun-bearing damage. Refer to section ADDITIONAL INFORMATION1.A, for line bore specifications which a re listed in Table 1-17. NOTE:

Dial bore master setting fixture should be used to zero the cylinder bore gage.


1.1

2004) 1-23


1.1.3. 1.1.3.6 6 Genera General l Inspec Inspectio tion n Check all machined surfaces for nicks or burrs that could affect the fit of mati ng parts. Clean up as necessary by stoning. stoning. Also inspect all all tapped holes for thread dama dama ge and retap or install helical thread inserts as necessary. Replace any loose or damaged do wel pins. Refer to section ADDITIONAL INFORMATION1.A, "Engine Plug and Dowel Charts" for s pecifications. 1.1.3. 1.1.3.7 7 Rust Rust Preven Preventio tion n After inspection, if the cylinder block is not to be used immediately, spray the machined surfaces with engine oil. NOTICE: Castings free of grease or oil will rust when exposed re. Rust on machined surfaces may result in leakage.

to the atmosphe

If the block is to be stored for an extended period of time, spray or dip it in a polar-type rust preventive such such as "Tectyl® "Tectyl® 502-C" from Valvoline Oil Company (or equivalent). Tectyl® is a registered trademark trademark of Ashland Oil, Inc.



1.1. 1.1.4 4

Reas Reasse semb mbly ly of Cyli Cylind nder er Bloc Block k

After the cylinder block has been cleaned and inspected, assemble the engine as follows:



1. Before a reconditioned or new service replacement cylinder block is used, s team clean it to remove the rust preventive and blow out the oil galleries with compressed air . 2.

If a new service replacement block is used, stamp the engine serial number

and model number on the pad provided on the left side of the block, just below the d eck. See Figure 1-17.

Figur igure e 11-17

Locat ocati ion of En Engine gine Ser Serial ial and and Mode Model l Nu Number mbers s

3. Also stamp stamp the position numbers on the the main bearing caps and the position o f the No. 1 bearing on the cooler side of the oil pan mounting flange of the block. 4. Install the main bearing caps in their original positions; refer to section 1.9.3.


1.1

NOTICE:


2004) 1-25

Always check to make sure cooling nozzles are open and aligned after piston piston instal installat lation ion. . An obstru obstructe cted, d, misali misaligne gned, d, bent, bent, or damage damaged d nozzle nozzle may not provide proper piston cooling. A loosened nozzle may cause a loss of main gallery oil pressure. In either case, piston overheating or lack of adequate lubrication may result in severe engine damage. 5. On curr curren ent t non non-p -pre remi mium um engi engine nes s wit with h cas cast t iro iron n pis pisto tons ns, , ins insta tall ll the the bol boltton plate over the oil gallery orifice at the base of each cylinder bore. On premium engines with c losed-end rods and forged steel pistons, install oil spray nozzles into these op enings. See Figure 1-18 for location of nozzle. Torque plate nozzle retaining bo lts to 30–38 N·m (22–28 lb·ft).

Figure 11-18

Oil Sp Spray Nozzle Lo Location



6. Install all of the required cup plugs. Use a good grade of non-hardening s ealant such as Loctite® Loctite® 620 (or equivalent). Apply a thin coat coat of sealant just inside inside the ch amfer where the plug is to be installed and install using cup plug installation tool s et, J 35653. See Figure 1-19.

Figure 11-19

Cup Pl Plug In Installation Tool Set


1.1

2004) 1-27


7. Inst Instal all l all all of the the requ requir ired ed pipe pipe plug plugs. s. Refe Refer r to sect sectio ion n ADDI ADDITI TION ONAL AL INF INF ORMATION 1.A, "Engine Plug and Dowel Charts". NOTE: Whenever a pipe plug is removed from the cylinder block, the threads must be coa ted with Loctite®, PT-7260, pipe sealant with Teflon, or equivalent, before reasse mbly. Certain plugs available from the parts depot already have a sealer applied to th e threads. Although unnecessary, this pre-coating will not be affected if pipe s ealer with Teflon is also applied. 8. With With the the eng engin ine e mou mount nted ed on the the ove overh rhau aul l sta stand nd, , ins insta tall ll all all of of any any rema remain in ing subassemblies and parts on the cylinder block. [a] [a]

To inst instal all l the the cra crank nksh shaf aft t mai main n bea beari ring ngs, s, ref refer er to sect sectio ion n 1.9 1.9.3 .3. .

[b]

To in instal stall l the the cra cranksh nkshaf aft, t, ref refer to se sectio ction n 1. 1.7.3. 7.3.

[c] [c] .5.

To inst instal all l the the pist piston on and and con conne nect ctin ing g rod rod asse assemb mbly ly, , ref refer er to sect sectio ion n 1.1 1.19 9

[d]

To in instal stall l the the oil oil pan pan, , re refer fer to to sec secti tion on 3.11. .11.4. 4.

[e] [e]

To inst instal all l the the flyw flywhe heel el hous housin ing, g, refe refer r to to sec secti tion on 1.16 1.16.3 .3. .

[f]

To in instal stall l the the fly flywhee wheel, l, refer efer to sect sectio ion n 1.1 1.14 4.3. .3.

[g] [g]

To inst instal all l the the cyli cylind nder er head head, , refe refer r to sect sectio ion n 1.2. 1.2.5. 5.

[h]

To in instal stall l the the cam camshaf shaft, t, refer efer to sect sectio ion n 1.2 1.24 4.6. .6.

[i]

To in instal stall l the the gea gear ca case, se, ref refe er to to sec secti tion on 1.1 1.11.3. 1.3.

[j] [j] To inst instal all l the the cran cranks ksha haft ft timi timing ng gear gear and and tim timin ing g whe wheel el, , ref refer er to sect sectio ion n 1.28.3. [k] [k]

To inst instal all l the the adju adjust stab able le idle idler r gea gear r ass assem embl bly, y, refe refer r to to sec secti tion on 1.26 1.26.3 .3. .

[l] [l] To inst instal all l the the bull bull gear gear and and cam camsh shaf aft t idl idler er gear gear asse assemb mbly ly, , ref refer er to sect sect ion 1.27.3. [m] [m]

To inst instal all l the the cams camsha haft ft driv drive e gea gear, r, refe refer r to to sec secti tion on 1.25 1.25.4 .4. .

[n] [n]

To inst instal all l the the gear gear case case cove cover, r, refe refer r to to sec secti tion on 1.10 1.10.3 .3. .

[o] [o]

To inst instal all l the the acce access ssor ory y dri drive ve, , ref refer er to sect sectio ion n 1.2 1.29. 9.5. 5.

[p] [p]

To inst instal all l the the cran cranks ksha haft ft vibr vibrat atio ion n dam dampe per, r, refe refer r to sect sectio ion n 1.1 1.12. 2.3. 3.

[q] [q]

To inst instal all l the the cran cranks ksha haft ft pull pulley ey, , ref refer er to sect sectio ion n 1.1 1.13. 3.3. 3.

[r] [r]

To inst instal all l the the engi engine ne lift lifter er brac bracke kets ts, , ref refer er to sect sectio ion n 1.5 1.5.3 .3. .

[s] [s] To inst instal all l the the valv valve e roc rocke ker r cov cover er, , ref refer er to sect sectio ion n 1.6 1.6.8 .8(o (one ne piec piece) e) and and refer to section 1.6.9(two piece and three piece). [t] [t] Inst Instal all l any any elec electr tric ical al comp compon onen ents ts, , con conne nect ctor ors s or or wir wirin ing g loo looms ms that that were were removed during disassembly. [u]

Install th the SR SRS, re refer to to se section 2. 2.32.3.

[v]

Install th the TR TRS, re refer to to se section 2. 2.33.3.



[w] [w] Inst Instal all l the the ECM, ECM, refe refer r to to sec secti tion on 2.21 2.21.3 .3fo for r DDE DDEC C I, I, ref refer er to sect sectio ion n 2.2 2.2 0.4for DDEC II, refer to section 2.19.3for DDEC III/IV, and cold plate if required, ref er to section 2.19.3. [x] [x]

Inst Instal all l a suit suitab able le lift liftin ing g devi device ce to the the engi engine ne. .

See See Figu Figure re 1-5. 1-5.

To avoid injury from a falling engine, ensure the engine is securely attached to the engine overhaul stand before releasing the l ifting sling. [y] [y]

Remo Remove ve the the engi engine ne from from the the over overha haul ul stan stand. d. See See Figu Figure re 1-6. 1-6.

Transfer the engine to a suitable engine dynamometer dynamometer test stand. Operate the en gine on a dynamometer following the Run-in procedure; refer to section 11.8.3.2. Install the engine in the equipment from which it was removed.


(Rev.

2004)

6SE483

0401


1.2

CYLINDER HEAD

1.2

CYLINDER HEAD

1-29

The Series 60 cylinder head combines intake and exhaust valve porting and fuel i njector seats with water jacketing to cool the ports, injectors and combustion c hamber area. See Figure 1-20.


Cyli Cylind nder er Head Head Asse Assemb mbly ly and and Mati Mating ng Comp Compon onen ents ts

With the overhead camshaft design, the cylinder head assembly includes: Cylinder head Valve and injector operating mechanism Injector, valve guide and related parts Camshaft and camshaft bearings



The nested roller follower type rocker arms transmit camshaft motion directly to the valves and injectors. See Figure 1-21.

1.

Rolle oller r Foll Follow ower er

4. Exha Exhaus ust t Valv Valve e Rock Rocker er Arm

2. Injector Injector Rocker Rocker Arm 5. Camshaft Camshaft 3.

Intake Valve Rocker Arm

Figure 1-21

Cylinder Head Assembly


1.2

2004) 1-31

CYLINDER HEAD

The nested roller follower type rocker arms transmit cam motion directly to the valves. See Figure 1-22.

1.

Rolle oller r Foll Follow ower er

3. Exha Exhaus ust t Valv Valve e Rock Rocker er Arm

2.

Intake Valve Rocker Arm

4.

Camshaft

5. Spacer Figur igure e 11-22

Cylin ylind der Head ead Ass Asse embly mbly (Se (Series ries 60G 60G Eng Engin ine) e)



The porting within the cylinder head is cross-flow, with intake and exhaust port s on opposite sides for minimum restriction restriction and maximum exposure to coolant flow. Four valves are used per cylinder, two intake and two exhaust. See Figure 1-23.

Figure 11-23

Intake an and Ex Exhaust Va Valve Po Porting


1.2

2004) 1-33

CYLINDER HEAD

Replaceable valve guides, valve spring seats, valve stem seals, valve rotators a nd valve seat inserts are used used on all valves. valves. See Figure Figure 1-24. 1-24.

1. Valve Guide 5. Valve Stem Oil Seal 2. Valv Valve e Spri Spring ng Seat Seat

6. Valv Valve e Spri Spring ng

3. Valv Valve e Seat Seat Inse Insert rt

7. Valv Valve e Rota Rotato tor r

4.

Va Valve

Figure 11-24

8.

Va Valve Keepers

Valve Guides an and Re Related Pa Parts



Copper injector tubes extending through the cylinder head water jacket are requi red for the fuel injectors. The tubes tubes are directly exposed to the coolant. An O-ring seals the injector tube tube upper end in in the recess. The lower end of the injector tube must be expanded and flared during the installation process to contain a tight f it in the firedeck bore. A beveled seat machined in the tube provides a compress ion-tight seal when the injector is seated, as well as affording effective heat transfer transfer facilitating facilitating injector injector cooling. Refer to section 2.4. 2.4. Fuel galleries machined into the head supply fuel under fuel pump pressure to al l injectors, and excess fuel is returned to the fuel tank. The fuel gallery outl et (restricted) fitting is installed installed in the rear of the cylinder head. See Figu re 1-25.

Figur igure e 11-25

Fuel uel Gal Galle lery ry Inlet nlet and and Out Outle let t Fit Fitt tings ings


1.2

CYLINDER HEAD

1.2. 1.2.1 1

Repa Repair ir or Repl Replac acem emen ent t of Cyli Cylind nder er Head Head

2004) 1-35



Flow Flowch char art t for for Repa Repair ir or Repl Replac acem emen ent t of of Cyl Cylin inde der r Hea Head d



1.2. 1.2.2 2

Remo Remova val l and and Clea Cleani ning ng of Cyli Cylind nder er Head Head

Because optional and accessory equipment varies with the engine application, thi s procedure covers covers only the basic engine. If the engine is equipped with with access ories that affect cylinder head removal, note the mounting details of each to as sure correct installation at reassembly. Remove the cylinder head as follows: 1.

Drain the cooling system. Refer to section 13.13.4.

2.

Disconnect the exhaust pipe at the turbocharger. Refer to section 6.6.2.

3. Remove the air cleaner and charge air cooler ducting from turbocharger and intake manifold. manifold. Refer to section 6.2.2and 6.2.2and refer to section 6.4.2.


1.2

2004) 1-37

CYLINDER HEAD

4. Disc Discon onne nect ct the the tur turbo boch char arge ger r coo coola lant nt supp supply ly (if (if wat water er-c -coo oole led) d), , oil oil supp supply ly and drain lines, and remove remove the turbocharger if necessary. necessary. See Figure 1-27.

1.

Elbow, Oil Drain Tube

10.

Connector, Oil Supply Tube

2.

Bolt, olt, Mou Mountin nting g Bra Bracket cket

11. 11.

Tube ube Asse Assemb mbly ly, , Turb Turbo o Oil Oil Supp Supply ly

3. Bolt Bolt, , Oil Oil Drai Drain n Tube Tube Clip Clip

12. 12.

Clip Clip, , Oil Oil Supp Supply ly Tube Tube

4.

13.

Bolt, Oil Supply Tube Clip

Tube, Turbo Oil Drain

5. Bolt, olt, Oil Oil Dra Drain Tube Tube Mount ountin ing g charger)

14. 14. Conn Connec ecto tor, r, Oil Oil Sup Supply ply Tube Tube (to (to turb turbo o

6.

15.

Gasket, Turbo Oil Drain Tube

Gasket, Turbo Exhaust Inlet

7. Nut, Turbo Mounting Mounting 16. Clip, Oil Drain Tube 8. Wash Washer er, , Turb Turbo o Moun Mounti ting ng

17. 17. Brac Bracke ket, t, Oil Oil Drai Drain n Tube Tube Clip Clip Moun Mounti ting ng

9.

18.

Turbocharger Assembly

Figure 1-27

Nut, Oil Drain Tube Clip

Turbocharger Oil Lines



5. On pleasure craft marine engines, remove water-cooled charge air cooler fro m cylinder head. See Figure 1-28

1.

Hose

8.

Gasket

2.

El Elbow

9.

CA CAC Mixer

3.

Gasket

10.

Housing Lower

4.

Sleeve

11.

Sensor

5.

Seal Ring

12.

Seal Ring

6.

Bolt

13.

Air Temperature Sensor

7. Ho Housing Upper

14. Br Bracket

15. Bolt Figu Figure re 1-28 1-28 Inta Intake ke Mani Manifo fold ld and and Rel Relat ated ed Part Parts s (Se (Seri ries es 60 Heat Heat Exchanger-Cooled Pleasure Craft Marine Engine)


2004) 1-39

1.2

CYLINDER HEAD

6. Seal Seal the the tur turbo boch char arge ger r com compr pres esso sor r inl inlet et and and dis disch char arge ge with with cove covers rs or mask mask ing tape. Plug the oil supply fitting in the turbocharger housing. 7. Remo Remove ve and and insp inspec ect t the the exha exhaus ust t mani manifo fold ld if nece necess ssar ary. y. Refe Refer r to sect sectio ion n 7.2.2 and refer to section 7.2.3.1. 7.2.3.1. See Figure 1-29, and see Figure 1-30.

1.

Exhaust Manifold

Figur igure e 11-29

2.

Heat Shield

Exhau xhaus st Ma Manifo nifold ld (Seri Series es 60G Engin ngine) e)




Exha Exhaus ust t Mani Manifo fold ld (Se (Seri ries es 60 60 Comm Commer erci cial al Mari Marine ne Engi Engine ne) )


1.2

2004) 1-41

CYLINDER HEAD

8. Remo Remove ve and and ins inspe pect ct the the int intak ake e man manif ifol old. d. Refe Refer r to to sec secti tion on 6.4. 6.4.2a 2and nd refe refer r to section 6.4.3.1. See Figure 1-31for all diesel except pleasure craft craft marine. See Figure 1-28 for pleasure craft marine and see Figure 1-32 for natural gas.

1. Air Air Inle Inlet t 2.

6. Air Air Temp Temper erat atur ure e Sens Sensor or

Short hort Bol Bolt (2) (2)

7. Tur Turbo Boost oost Pre Pressur ssure e Sens Sensor or Bol Bolt (2) (2)

3. Intake Intake Manifold Manifold Gasket Gasket (3) 8. Turbo Boost Pressure Pressure Sensor Sensor 4.

Cy Cylinder Head

9.

5. Mani Manifo fold ld Bolt Bolt (7) (7)

10. 10.

OO-ring Inta Intake ke Mani Manifo fold ld

Figu Figure re 1-3 1-31 1 Inta Intake ke Man Manif ifol old d and and Rela Relate ted d Part Parts s (All (All Die Diese sel l Exce Except pt Hea Heat t Exchanger-Cooled Pleasure Craft Marine)



1.

Intake Manifold

2.

Intake Manifold Inlet

6.

Bolt

3.

Intake Manifold Gasket

7.

Air Temperature Sensor

4.

Cylinder Head


5.

8.

Pipe Plug

Turbo Boost Pressure Sensor

Inta Intake ke Mani Manifo fold ld and and Rel Relat ated ed Part Parts s (Na (Natu tura ral l Gas Gas) )


1.2

2004) 1-43

CYLINDER HEAD

9. Open Open the the dra drain in cock cock loca locati tion on at the the bot botto tom m of of the the ther thermo most stat at hous housin ing g to to allow the coolant in the housing to drain. 10. 10. Disc Discon onne nect ct radi radiat ator or or heat heat exch exchan ange ger, r, bypa bypass ss pipe pipe and and hos hose e cla clamp mps, s, and and remove the thermostat housing. housing. Refer to section 4.5.2and 4.5.2and see Figure 1-33.

1.

Thermostat (2)

2. Pipe Pipe Plug Plug

6.

Bypass Tube

7. Ther Thermo most stat at Hous Housin ing g

3. Bolt Bolts, s, The Thermos rmosta tat t Housi ousing ng-t -too-Cy Cyli lind nder er Head ead (4) (4) 4.

Hose, Coolant

9.

5.

Hose Clamps (2)

10.

Figure 1-33

8. Drai Drain n Cock Cock

Seals, Thermostat Housing (2) Cylinder Head

Thermostat Housing Removal



11. Remove, disassemble, and inspect the valve rocker cover. Refer to section 1.6.2, (one-piece), refer to section 1.6.3, (two-piece), refer to section 1.6.5, (three -piece) for removal. Refer to section 1.6.6 for disassembly, and refer to sectio n 1.6.2.1for inspection. 12. Remove Jake Brakes®, if equipped. Refer to section 1.30.2. Jake Brake® Brake® is a registered trademark trademark of Jacobs Vehicle Vehicle Systems. 13.

Remove rocker arm assemblies. Refer to section 1.3.2.

NOTE: On heat exchanger-cooled pleasure craft marine engines the heat exchanger must b e removed before the camshaft can be disassembled from the engine. Refer to sect ion 4.12.2. 14.

Remove the camshaft. Refer to section 1.24.2.

NOTE: Using the camshaft gear pilot tool, J 35906, pull the camshaft gear and thrust p late forward in the gear case until there is approximately a 6.35 mm (1/4 in.) gap be tween the cylinder head and the diamond-shaped camshaft thrust plate seal when r emoving the cylinder head. See Figure 1-34.


Posit ositi ionin oning g Cams Camsha haft ft Thrus hrust t Plat Plate e

15. Inspect the rocker arm assemblies and camshaft lobes. Refer to section 1. 3.2.2, and refer to section 1.24.3.1.


1.2

2004) 1-45

CYLINDER HEAD

16. 16. Disc Discon onne nect ct the the fue fuel l inl inlet et and and out outle let t lin lines es at the the rea rear r of of the the cyli cylind nder er h ead. See Figure 1-35.


Remo Removi ving ng Fuel Fuel from from Cyli Cylind nder er Head Head Inte Intern rnal al Pass Passag ages es



17. 17. Blow Blow low low pre press ssur ure e com compr pres esse sed d air air into into the the inl inlet et fitt fittin ing g for for 20 to 30 sec sec onds or until all of the fuel is purged from the cylinder head. 18. 18. Disc Discon onne nect ct the the inje inject ctor or wire wire harn harnes ess s at each each inje inject ctor or. . 2.3.2.

Refe Refer r to sect sectio ion n

19. 19. Remo Remove ve the the har harne ness ss moun mounti ting ng flan flange ge from from the the rea rear r of of the the cyli cylind nder er head head an d carefully remove the harness from the head by pulling the harness through the hole in the cylinder head. See Figure Figure 1-25. 1-25.



NOTICE: To avoid possible damage to the injector spray tips, remove the injectors before lifting the head from the block. If the injectors are not removed, handle the h ead carefully when it is off the block and support the head fire deck on wooden blocks. 20.

Remove the fuel injectors. Refer to section 2.3.2.

NOTE: Fuel must be removed from the cylinder head fuel galleries prior to removing the injectors. 21. Remove the gear case stabilizer bracket at the the right right and/or left front cor ner of the head. 22. Remove the head bolts, refer to section 1.2.2, and install the cylinder he ad lifter bracket, J 35641-A, using using the bolt hole at the inboard center, No. 3 cam cap and and two tap ped Jake Brake® bolt holes. See Figure 1-36.


Cylin ylind der Head ead Lift Lift Bra Bracket cket Rem Removal oval


1.2

2004) 1-47

CYLINDER HEAD

23. 23. Atta Attach ch a sui suita tabl ble e lif lifti ting ng hook hook to the the eye eyele let t in in the the lift lift brac bracke ket, t, and and li li fter the cylinder head off the engine. See Figure 1-37.

Figure 11-37

Cylinder He Head Re Removal

24. 24. Drai Drain n the the engi engine ne lubr lubric icat atin ing g oil oil, , ref refer er to sect sectio ion1 n13. 3.13 13.1 .1, , to to rem remov ove e any any coolant that may have drained into the oil pan when the water jacket was opened . Remove any coolant coolant from the cylinder cylinder bores. bores.



1.2.3 .2.3

Clean leanin ing g of of Cy Cylind linder er Head ead

Clean the cylinder head as follows: 1. Keep parts segregated according to original position to assure proper reass embly, if parts are to be reused. 2.

Remove all threaded plugs.

3.

Steam clean the cylinder head once it has been stripped.

4. If coolant coolant passages are heavily coated with scale, remove the injector tube s and cup plugs, refer to section 2.4.2. Clean the head in a descaling bath, re fer to section 1.2.2.



5. Clean the camshaft and camshaft bearings, valves, springs, valve rotators a nd rocker shafts in fuel oil and blow dry with compressed air. 6.

Clean the rocker arm assemblies.

1.2.3.1 1.2.3.1 Inspection Inspection of Cylinde Cylinder r Head Head The following steps must be performed before inspecting the cylinder head: 1. Replace the plugs removed for cleaning. If the old plugs are reused, coat the plugs with Loctite® PT-7260 , pipe sealant sealant with Teflon, or equivalent. NOTE: If both front fuel galley plugs have been removed, it will be necessary to repla ce both plugs. 2. If injector injector tubes have been removed, install new injector tubes. Refer to s ection 2.4.1. 3. Install new cup plugs plugs using a good grade non-hardening sealant such as Loct ite® 620 or equivalent. 4.

Perform the following tests for cylinder head inspection.

[a]

Pressure te test, re refer to to se section 1. 1.2.3.2.

[b] [b]

Fire Firede deck ck stra straig ight htne ness ss test test, , ref refer er to sect sectio ion n 1.2 1.2.3 .3.3 .3. .


1.2

2004) 1-49

CYLINDER HEAD

1.2.3.2 1.2.3.2 Pressure Pressure Testing Testing of of Cylinder Cylinder Head Head Perform the following steps to pressure test the cylinder head: 1. Inst Instal all l the the test test stri strips ps (par (part t of of cyl cylin inde der r blo block ck pres pressu sure re test test kit, kit, J 362 362 23) to the firedeck on the cylinder head. See Figure 1-38.


Cyli Cylind nder er Head Head Pres Pressu sure re Test Test Equi Equipm pmen ent t Ins Insta tall llat atio ion n

2. Inse Insert rt the the cyl cylin inde der r hea head d bol bolts ts thro throug ugh h the the cyli cylind nder er head head and and tes test t str strip ips s . Attach and torque the nuts (supplied in J 36223) to 14 N·m (10 lb·ft).



3. Install the thermostat opening cover plate, and gasket to the cylinder head using the bolts provided with the cover plate. plate. See Figure Figure 1-39. 1-39.


Ther Thermo most stat at Open Openin ing g Cove Cover r Plat Plate e Inst Instal alla lati tion on


1.2

2004) 1-51

CYLINDER HEAD

4. Inst Instal all l dum dummy my fuel fuel inje inject ctor ors, s, to the the inj injec ecto tor r bor bores es to assu assure re prop proper er sea sea ting of the fuel injector tubes. See Figure 1-40.

Figure 11-40

Dummy Fu Fuel In Injector In Installation

5. Inst Instal all l the the fuel fuel inje inject ctor or crab crabs s and and hold hold-d -dow own n bolt bolts. s. Torq Torque ue the the bolt bolts s t o 58-66 N·m (43-49 lb·ft). See Figure 1-40. 6.

Atta Attach ch an air air hos hose e to to the the fitt fittin ing g on on the the ther thermo most stat at open openin ing g cov cover er plat plate. e.

7. Appl Apply y 207 207 kPa kPa (30 (30 lb/i lb/in. n.2) 2) air air pre press ssur ure e to to the the cyli cylind nder er head head and and imm immer erse se the head in a water bath heated to 82-93 C (180-200 F). 8. Leav Leave e the the head head in the the bat bath h for for at leas least t 20 20 min minut utes es to heat heat thor thorou ough ghly ly, , w hile watching for bubbles indicating a crack or leak. [a] [a] If an inje inject ctor or tube tube leak leaks, s, repl replac ace e tube tube(s (s). ). Refe Refer r to sect sectio ion n 2.4. 2.4.1f 1for or r emoval and refer to section 2.4.6for installation of new injector tube. [b] [b] If a cra crack cked ed cyli cylind nder er head head is dete detect cted ed, , rep repla lace ce the the cyl cylin inde der r hea head. d. Refe Refer r to section 1.2.5.



1.2.3.3 1.2.3.3 Inspection Inspection and Rework Rework for Firedeck Firedeck Straightne Straightness ss The large mass and length of the head casting may contain longitudinal warp afte r it is unbolted and removed from the engine block. At the time of factory manuf acture, the longitudinal warp is normalized by using a fixture and clamping the casting during machining. The casting is placed in a fixture and clamped from its locating surfaces (datums). (datums). When unclamped, t he head casting resumes its original shape until it is bolted and tightened to t he engine block. Inspect the bottom (firedeck) of the cylinder head for straightness as follows: 1. Use a heavy, heavy, accurate straight-edge and feeler gages to check check for transvers e and longitudinal warpage. See Figure 1-41.

Figure 11-41

Checking Fi Firedeck St Straightness


1.2

CYLINDER HEAD

2004) 1-53

2. Also Also, , che check ck for for lon longi gitu tudi dina nal l war warpa page ge in five five plac places es and and tra trans nsve vers rse e war warpa pa ge in 12 places, indicated as A through L in the the next illustration. illustration. See Figure 1-42.

Figur igure e 11-42

Cylin ylind der Head ead Meas Measur urem emen ent t Loca Locati tion ons s

3. The The nat natur ural al warp warp cont contai aine ned d in in the the cast castin ing g mus must t be be con consi side dere red d whe when n ins inspe pec c ting firedeck straightness with with the head head unbolted and unclamped. Natural warpag e is not a cause for correction. correction. The firedeck (unclamped) (unclamped) must be straight with in 0.279 mm (0.011 in.) front-to-rear and 0.076 mm (0.003 in.) side-to-side. Cylinder head specificati ons are listed in Table 1-33. If the cylinder head flatness is outside of the specifications, Detroit Diesel C orporation recommends replacing the cylinder head.



1.2.3.4 1.2.3.4 Verificati Verification on of Countersi Countersink nk Geometry Geometry To verify countersink geometry, perform the following steps. 1.

Install new injector tubes. Refer to section 2.4.6.

2. Place valves valves into proper location and check check to be sure sure that valve heads are are recessed from the firedeck surface by at least 1.4-1.8 mm (0.055 -0.071 in.). Listed in Table 1-33. See Figure 1-43. If not, reduced-thickness valve seat inserts must be installed . Refer to section 1.4.6.


Valve alve Head Head-t -too-Cy Cyli lind nder er Hea Head Meas Measur urem emen ent t


1.2

2004) 1-55

CYLINDER HEAD

1.2.3.5 1.2.3.5 Inspection Inspection and Reworkin Reworking g of Head Bolt Counterbore Counterbore To assure clean and non-brinnelled cylinder head bolt counterbores, use J 38189 to resurface the head bolt washer area. The procedure and steps for proper use of the tool are as follows: NOTICE: There must be no space between the bottom of the cylinder head and the table top to properly resurface the counterbores. 1. Plac Place e the the cyli cylind nder er head head on a sol solid id flat flat surf surfac ace e (pr (pref efer erab ably ly a ste steel el tabl tabl e top) that completely covers the bottom of head. NOTICE: Proper use of the J 38189 is important. Failure to use J 38189 properly may result in an incorrect counterbore depth.

2. Prot Protec ect t the the valv valve e spr sprin ings gs and and inj injec ecto tor r cou count nter erbo bore re to keep keep any any loo loose se met met al shavings from getting into valve springs and counterbore during cutting operation. 3. With With cyli cylind nder er head head on a flat flat surf surfac ace e usin using g the the 1/8 1/8 in. in. hex hex wren wrench ch supp suppl l ied with tool, loosen the stop collar and cutter to permit sliding on pilot. 4. Star Starti ting ng at the the fro front nt of the the cyl cylin inde der r hea head, d, plac place e the the pilo pilot t of of the the cutt cutte e r into a cylinder head bolt hole until the pilot contacts the flat surface benea th the cylinder head. 5. Allo Allow w the the cutt cutter er to cont contac act t the the coun counte terb rbor ore e sur surfa face ce. . Loc Lock k the the stop stop coll colla a r while against the cutter. The cutter now will resurface the counterbore 0.508 0.508 mm (0.020 in.). 6. Remo Remove ve the the tool tool and and plac place e a 0.02 0.020 0 in. in. d the locked stop collar.

feel feeler er gage gage betw betwee een n the the cutt cutter er an

7. With With feel feeler er gage gage in plac place, e, lock lock the the set set scre screw w of of the the cutt cutter er, , the then n rem remov ove e the feeler gage and loosen the set screw on the stop collar and slide it down t ight against the cutter and retighten. Perform the following steps to resurface the counterbore 0.508 (0.020 in.): 1. Usin Using g a dril drill l moto motor r with with a 1/2 1/2 in. in. chuc chuck k and and a maxi maximu mum m of 450 450 r/mi r/min n and and a suitable cutting oil to prolong the life of the cutter and to lubricate the p ilot turning in bolt hole, 2. Appl Apply y a mode modera rate te pres pressu sure re on the the dri drill ll moto motor, r, cont contin inue ue cutt cuttin ing g ope opera rati tion on until pilot bottoms on flat surface and then do not stop drill motor until after being lifte d from cutting surface. surface. This is to eliminate eliminate surface marks. NOTE: The J 38189 tool pilot has a shoulder stop that will not allow the cutter to rem ove material in excess of the Detroit Diesel Corporation specifications.



3. If some some of the the bolt bolt holes holes do not clean up completely, continue resurfacing remaining holes, repeating the operation in. 0.005 in. increments. This will clean up a ny holes that may not have cleaned up completely during the first cut. 4. .

After all counterbores have been resurfaced, remove any loose cutting chips

5.

Steam clean the complete cylinder head.

6.

After steam cleaning, inspect the cylinder head for any remaining chips.

7. Reinstall the cylinder head assembly, using 38 of the new ground head bolt washers. 1.2.4 .2.4

Assem ssembl bly y of of Cy Cylind linder er Head ead

Perform the following steps for cylinder head assembly:



NOTICE: If the cylinder head is to be replaced, the new head must be thoroug hly cleaned before installation to remove all rust and preventive compo und, especially from the fuel and oil galleries. This can be done by im mersion in a bath of fuel oil or mineral-spirits-based solvent and scrubbing out all openings with a soft bristle brush. When clean, blow the head dry with c ompressed air. 1. Install new precoated precoated pipe pipe plugs or coat the used plugs with with pipe sealant w ith Teflon, PT-7260, or equivalent. equivalent. Refer to section ADDITIONAL ADDITIONAL INFORMATION1.A, INFORMATION1.A, "Engine "Engine Plug and Dowel Charts" for specifications. 2. Install all of the required required cup cup plugs using a good grade grade of non-hardening s ealant, such as Loctite® Loctite® 620 or equivalent, on the the cup plugs. Use cup plug insta insta llation tool set, J 35653. Refer to section ADDITIONAL INFORMATION1.A, "Engine P lug and Dowel Charts" for specifications. 3. Ensure that that all cup and and pipe plugs on the front front face of the cylinder head a re flush or below the surface. 4. Install valve guides and seats, valves, valve stem seals, valve springs and rotators. Refer to section 1.4.8and refer to section 1.4.7.


2004) 1-57

1.2

CYLINDER HEAD

1.2. 1.2.5 5

Inst Instal alla lati tion on of Cyli Cylind nder er Head Head

Perform the following steps for cylinder head installation: 1. Ensu Ensure re pist piston on dome domes s and and the the cyl cylin inde der r hea head d and and cyli cylind nder er bloc block k fir fired edec eck k su su rfaces are clean clean and free of foreign matter. matter. Inspect the head bolt holes in bot h block and head for the presence of oil, water, dirt, or damaged threads, clean or retap as necessary. NOTE: Series 60 Engines built after September 2002 will use a new cylinder head gasket . This gasket will be identified identified with a new new part number and date code. This new gasket must be used with the new cylinder head bolts. 2. Posi Positi tion on the the hea head d gas gaske ket t on on the the bloc block k and and inst instal all l cyl cylin inde der r hea head d gui guide de st uds, J 35784, at front and rear of the block. See Figure 1-44.

Figure 11-44

Cylinder He Head Guide St Studs



3. Lift the head into into position position with lift bracket, bracket, J 35641. See See Figure 1-45. Lo Lo wer it into place over the guide studs, J 35784, until it seats on the block deck dowels. See Figu re 1-44.

Figure 1-45 4.

Cylinder Head Installation

Remove the guide studs.

5. Install the head bolts with special hardened washers, lubricating the threa ds and bolt-head contact areas with a small amount of International Compound #2®, or equivalent. NOTICE: Cylinder head mounting bolts are considered single-use items and must not be reused. Failure to install new bolts when replacing a cylinder head may result in impr oper bolt clamp load, which could cause gasket failure and severe engine damage. 6. Torque the head bolts to 250-285 N·m (185-210 lb·ft) in the the following following sequence. See Figure 1-46. After September 2002 a new new cylinder cylinder head bolt will be used for all Series 60 Off-Highway and On-Highway engines. The new bolt will be identified with white paint and groove on top of bolt. See Figure 1-47. Torq ue the new head bolts to 298 N·m (220 lb·ft). There is no change to the procedure other than the new torque v alue. The new head bolt can be used with the former cylinder head gaskets, the f ormer head bolts cannot be used with the new head gasket. Former and new bolts must not be mixed.


1.2

CYLINDER HEAD

2004) 1-59

Figur igure e 11-46

Cylin ylind der Head ead Bol Bolt t Tig Tight hten enin ing g Seq Sequ uence ence

Figu Figure re 1-47 1-47 2002

Bolt Bolt Iden Identi tifi fica cati tion on For For Ser Serie ies s 60 60 Eng Engin ines es Buil Built t Aft After er Sept Septem embe ber r



NOTICE: Failure to repeat the cylinder head bolt torque tightening seque nce can result in some head bolts losing their torque when others are t ightened resulting in insufficient clamp load.

7. Repeat the the torque sequence to verify verify all of the head bolts are are torqued to s pecification. NOTICE: The hemispherical portion of the injector hold-down crab washers must be installed facing the crab (pointing down) in order to prevent da mage to the washers. See Figure 1-48. 8. Visually inspect each injector hole tube to ensure ensure they are clean. Install the fuel injectors. Refer to section section 2.3.5. Be sure the injector hold-down hold-down crabs are clear of the v alve and injector springs.


Inje Inject ctor or Hold Hold-D -Dow own n Crab Crab Wash Washer er Inst Instal alla lati tion on

9. Install the clamp bolts with hemispherical washers, torque to 58-66 N·m (43-49 lb·ft). 10.

Install the camshaft. Refer to section 1.24.6.

NOTE: If a cylinder head other than the one removed from the engine, or if a resurface d cylinder head is being installed, the three nuts retaining the adjustable idle r gear must be loosened before installing and torquing the camshaft drive gear retaining bolt.


1.2

2004) 1-61

CYLINDER HEAD

NOTICE: The camshaft drive gear-to-adjustable idler gear lash must be measured/adjusted before the rocker arm shaft assemblies are installed. 11. 11. Meas Measur ure e and and adju adjust st the the cam camsh shaf aft t dri drive ve gear gear-t -too-ad adju just stab able le idle idler r gea gear r las lash h . Refer to section 1.22.2.1 12. 12.

Inst Instal all l the the rock rocker er arm arm shaf shaft t asse assemb mbli lies es. .

Refe Refer r to sect sectio ion n 1.3. 1.3.3. 3.

13. 13. .

Inst Instal all l Jaco Jacob' b's s Brak Brake e asse assemb mbli lies es (if (if equi equipp pped ed). ). Refe Refer r to sect sectio ion n 1.30 1.30.5 .5

14. 14. Feed Feed the the inj injec ecto tor r har harne ness ss wire wires s thr throu ough gh the the ope openi ning ng at the the rea rear r of of the the c ylinder head. Secure the harness mounting flange to the cylinder head by torque the bolts to 10-15 N·m (7-11 lb·ft). 15. 15. Conn Connec ect t the the inje inject ctor or harn harnes ess s wir wires es to thei their r res respe pect ctiv ive e inj injec ecto tors rs. . Ref Refer er to section 2.3.5. NOTICE: Bolts attaching brackets to the gear case are torqued first then torque the bolt (s) to the cylinder head next.

16. 16. Inst Instal all l the the gear gear case case stab stabil iliz izer er brac bracke ket t at at the the righ right t and and/o /or r lef left t fro front nt corner of the head. Refer to section 1.11.3. 17. 17. Inst Instal all l the the ther thermo most stat ats s and and seal seals s to to the the ther thermo most stat at hous housin ing. g. Refe Refer r to to se se ction 4.5.5. 18. 18.

Clea Clean n the the cool coolan ant t out outle let t sur surfa face ces s of of the the head head and and the therm rmos osta tat t hou housi sing ng. .

19. 19. With With the the the therm rmos osta tats ts seat seated ed in the the hou housi sing ng coun counte terb rbor ores es, , ins insta tall ll the the hou hou sing to the cylinder head, torque the housing housing bolts to 58-73 N·m (43-54 lb·ft). Con nect the radiator or heat exchanger and bypass hose couplings and vent line. 20. 20. Remo Remove ve all all tra trace ces s of of the the old old gas gaske ket t fro from m the the cyli cylind nder er head head and and exh exhau aust st m anifold joint surfaces. Install the exhaust manifold with new gaskets. Refer t o section 7.2.4. 21. 21. Clea Clean n the the exha exhaus ust t man manif ifol old d and and turb turboc ocha harg rger er join joint t sur surfa face ces s and and inst instal all l t he turbocharger with a new gasket. Refer to section 6.6.7. If turbocharger is water cooled, conn ect coolant supply and return lines.

22. 22. Fill Fill and and vent vent the the cool coolin ing g syst system em. . Refe Refer r to sect sectio ion n 13.1 13.13. 3.4. 4. Fill Fill the the e ngine lubrication system. Refer to section 13.13.1. 23. 23. Conn Connec ect t the the exha exhaus ust t and and airair-to to-a -air ir cool cooler er air air duc ducti ting ng and and ins insta tall ll the the ai ai r cleaner or air separator. 24. 24. Inst Instal all l any any othe other r com compo pone nent nts s tha that t wer were e rem remov oved ed and and fil fill l wit with h the the requ requir ire e d fluids, fluids, as recommended. Refer to to OEM guidelines.



Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and ot her reproductive harm. Always start and operate an engine in a well ventilated area. If operating an engine in an enclosed area, vent the exhaust to the outside. Do not modify or tamper with the exhaust system or emission control system. 25. Start the engine and check for fuel, coolant or oil leaks. e running while you check. 26.

Shut down the engine.

Keep the engin


1.3

VALVE AN AND IN INJECTOR OP OPERATING ME MECHANISM

1.3


2004) 1-63

The valve and injector operating mechanism is located entirely in the cylinder h ead. The Series 60 overhead camshaft design eliminates the need for push rods. Separ ate camshaft followers are not needed, since the rocker arms incorporate followe r rollers riding directly on the camshaft lobes, transmitting camshaft motion to the valves and injectors. See Figure 1-49.

Figure 11-49

Camshaft an and Re Related Pa Parts



Each of the three rocker arm assemblies contain bushings where the rocker arms a re supported on the rocker arm shafts. These bushings are not serviced separately. Each int

ake rocker arm assembly operates two intake valves in each cylinder. Each exhaus t rocker arm assembly operates two exhaust valves valves in each cylinder. In each set of rocker arm assemblies, the exhaust rocker assembly is the widest, straddling the intake and fuel injector rocker rocker arm assembly. assembly. The center rocker operates t he fuel injector follower. See Figure 1-50.

Figure 11-50

Rocker Ar Arm Id Identification


1.3

2004) 1-65


The fuel injector rocker arm assembly is located between the intake and exhaust rocker arm assemblies and and has a single bushing bushing (not serviced serviced separately). separately). A rocker arm sha ft carries three sets of rocker arm assemblies and is mounted in seats machined into the camshaft bearing caps. See Figure 1-51and see Figure 1-52.

1. Unitized Valve Adjusting Screw Assembly; Intake position 5. Rocker Arm Shaft

2. Locknut 6. Unitized Valve Adjusting Screw Assembly; Exhaust position 3. Intake Intake Rocker Rocker Arm Assembly Assembly 7. Exhaust Exhaust Rocker Rocker Arm Assembly Assembly 4. Fue Fuel l Inje Inject ctor or Roc Rocke ker r Arm Arm Asse Assemb mbly ly Assembly; Injector position Figure 1-51

8. Uni Uniti tize zed d Valv Valve e Adju Adjust stin ing g Scre Screw w

Rocker Arm and Related Parts




2. Locknut 6. Unitized Valve Adjusting Screw Assembly; Exhaust position 3. Intake Intake Rocker Rocker Arm Assembly Assembly 7. Exhaust Exhaust Rocker Rocker Arm Assembly Assembly 4. Spacer Figu Figure re 1-52 1-52

Rock Rocker er Arm Arm and and Rela Relate ted d Par Parts ts (Ser (Serie ies s 60G 60G Engi Engine ne) )


1.3


2004) 1-67

A new injector rocker arm assembly replaced the former injector rocker arm assem bly on all model 6067-GK60 engines beginning with serial number 06R0133091, and on all model 6067-GU60 and 6067-WU60 engines beginning with serial number 06R0157655. NOTE: When the current rocker is installed on a phosphated shaft, the shaft should be turned 180 to present a fresh phosphated area to the loaded region of of the bushing. The current assembly has a honed rocker arm shaft bushing, a ceramic cam followe r and a new phosphated (black in color) rocker arm shaft which provides improved wear characteristics. The phosphated surface is required for the proper break-i n of the steel rocker arm shaft bushings. Current Series 60 engines have rocker arm shafts without flats at the mounting b olt locations. For these engines, a spacer is installed between the rocker arm s haft and the mounting bolts or nuts rather than than a washer. This allows the rocke r arm shaft to be rotated when installing new rocker arms. When reusing rocker a rm assemblies, the rocker arm shaft should not be rotated so that the same surfa ces of the rocker arm assemblies and rocker shafts are in contact with each othe r. Vertical oil passages at the front and rear of the cylinder head deliver oil fro m the cylinder cylinder block front and rear oil galleries to the the No. 1 and 7 lower cams haft bearing saddles. From there, the oil is directed directed upward (through (through the enlarged stud hole) to the No. 1 and 7 uppe uppe r bearing caps. A drilled passage in each of these caps exits at the rocker arm shaft seat area, where it indexes with a hole in each rocker arm shaft. The rocker arm shafts have internal oil passages that deliver oil to the rocker arm bushings and intermediate upper camshaft bearings. Some of the oil supplied to the rocker arm bushings passes through the oil hole in the bushing to the roc ker arm assemblies. The rocker arm assemblies contain drilled passages that supply oil to the camshaft roller follower, the ro ller pin and the bushing. The rocker arm assemblies also contain drilled passag es that supply oil to the unitized valve adjusting screw assembly and exhaust va lve stems and the fuel injector follower. NOTE: In December 2000, a new unitized adjusting valve screw assembly now replaces the former valve adjusting screw, valve button and retainer clip. The No. 4 camshaft cap is "Y" drilled, forming an oil path connection between th e front and rear rocker arm shafts, to ensure complete lubrication. The oil pass age within one rocker arm cylinder set is is shown. See Figure Figure 1-53and 1-53and see Figure 1-54. 1-54.



1. Exhaust Exhaust Rocker Rocker Arm Assembly Assembly 4. Rocker Rocker Arm Shaft 2. Fuel Fuel Inje Inject ctor or Rock Rocker er Arm Arm Asse Assemb mbly ly 3.

Camshaft Cap

6.

5. Cyli Cylind nder er Head Head

Intake Rocker Arm Assembly

Figu Figure re 1-53 1-53 Rock Rocker er Arm Arm Asse Assemb mbly ly Lubr Lubric icat atio ion n Sch Schem emat atic ic with with Form Former er Valv Valve e Adjusting Screw Assembly


1.3


2004) 1-69

1. Exhaust Exhaust Rocker Rocker Arm Assembly Assembly 4. Rocker Rocker Arm Shaft 2. Fuel Fuel Inje Inject ctor or Rock Rocker er Arm Arm Asse Assemb mbly ly 3.

Camshaft Cap

6.

5. Cyli Cylind nder er Head Head

Intake Rocker Arm Assembly

Figu Figure re 1-54 1-54 Rock Rocker er Arm Arm Ass Assem embl bly y Lub Lubri rica cati tion on Sche Schema mati tic c wit with h Uni Uniti tize zed d Val Valve ve Adjusting Screw Assemblies



1.3.1 1.3.1 Repair Repair or Replac Replaceme ement nt of Valve Valve and Inject Injector or Operat Operating ing Mechanism To determine if repair is possible or replacement is necessary, perform the foll owing procedure. See Figure 1-55.


1.3


2004) 1-71

Figu Figure re 1-5 1-55 5 Flow Flowch char art t for for Repa Repair ir or or Repl Replac acem emen ent t of Val Valve ve and and Inj Injec ecto tor r Operating Mechanism and Camshaft



1.3. 1.3.2 2

Remo Remova val l of of Roc Rocke ker r Arm Arm Asse Assemb mbly ly

Perform the following steps for rocker arm assembly removal: NOTE: If unit is equipped with Jake Brake®, remove brake. Refer to section 1.30.2. NOTE: Jake Brakes are not used on the Series 60G engine. 1. If necessary, necessary, steam clean the engine around the valve rocker cover and cyli nder head mating area. NOTE: High pressure water or steam cleaning should be avoided in the valve rocker cove r/cylinder head area of the Series 60 gas. The ignition system can be affected. 2. Remove the valve rocker cover. Refer to section 1.6.2(one-piece), refer to section 1.6.3(two piece), and refer to section 1.6.5(three-piece). 3. Remove the rocker arm shaft bolts (No. 2, 3, 4 or 5, 6, 7) and nuts (No. 1 or 8) that retain the rocker rocker arm shaft assembly to the the cylinder head. See Figure 1-56 for Series 60 diesel engine and see Figure 1-57for Series 60 gas engine. For camshaf t or cylinder head removal, both rocker arm shaft assemblies must be removed. NOTE: Whenever nuts No. 1 or 8 are loosened or removed, removed, the torque on the correspondi correspondi ng rocker shaft stud must be checked. Torque to 126–146 N·m (93–108 lb·ft). lb·ft).


1.3


2004) 1-73


Rock Rocker er Arm Arm Sha Shaft ft Bol Bolts ts and and Nut Nut Iden Identi tifi fica cati tion on Numb Number ers s

Figu Figure re 1-57 1-57 60G Engine)

Rock Rocker er Arm Arm Sha Shaft ft Bolt Bolts s and and Nut Nut Ide Ident ntif ific icat atio ion n Num Numbe bers rs (Ser (Serie ies s



4. Use rocker rocker arm and shaft shaft assembly assembly removal removal tool, tool, J 35996-A, to remove remove the ro cker arm shafts, with with rocker arm assemblies assemblies in place. See Figure 1-58. NOTE: Some engines may be equipped equipped with ceramic injector rollers. Use extra caution w

hile removing and handling.

Figure 11-58 5.

Rocker Ar Arm Sh Shaft As Assembly Re Removal

Remove unitized valve adjusting screw assemblies. Then proceed to step 7.

NOTE: If the unitized valve button separates from the screw, the button and screw must be replaced with a new new Unitized Valve Adjusting Adjusting Screw assembly. Do not attempt attempt to reassemble them for reuse in engine. Unitized Valve Adjusting Screws Screws will n ot be serviced separately. NOTE: If removing a former valve adjusting screw with valve button and retainer clip, proceed to step 6.


(Rev.

2004)

6SE483

0401


1.3


1-75

6. To remo remove ve the the val valve ve butt button on or valv valve e but butto ton n ret retai aini ning ng clip clip, , the the valv valve e adj adj usting screw must be removed from the rocker arm as follows: NOTICE: To avoid possible component damage, the valve button retainer MUST NOT be expand ed more than 15.5 mm (0.610 in.). An adjusting screw is provided on the expander tool to limit the amount of travel. [a] [a] Spre Spread ad the the ret retai aini ning ng clip clip with with expa expand nder er and and rem remov ove e the the butt button on. . See See Figu Figur r e 1-59.


Valve alve Butt Button on Retai etaine ner r Clip Clip Rem Removal oval

[b] [b] Slid Slide e the the reta retain inin ing g clip clip, , open open end end firs first, t, down down the the adju adjust stin ing g scre screw. w. It is necessary to spread the clip slightly so that the open end can pass over the ball head of the adjusting screw. [c] [c] Inse Insert rt the the tip tips s of of the the expa expand nder er, , J 3634 36347, 7, betw betwee een n the the legs legs of the the ret retai ain n ing clip and expand the clip.

[d] [d] p.

Inse Insert rt the the gro groov ove e on on the the valv valve e but butto ton n int into o the the legs legs of the the ret retai aini ning ng cli cli

[e] [e] Remo Remove ve the the exp expan ande der r and and hold hold the the leg legs s of of the the reta retain iner er with with the the thu thumb mb and and index finger. [f] [f] Pres Press s the the valv valve e but butto ton n tow towar ards ds the the scr screw ew to seat seat both both legs legs of the the ret retai ain n er completely in the groove.



7. ing the ere

If further further disassembly is necessary, slide the rockers off the shafts, mark or segregating parts so that they may be reinstalled in the same position from which they w removed.

NOTE: Front and rear rocker arm shaft sections look identical, but must not be reverse d, and must be installed as as removed, due to bolt hole center line distances. distances. Th e DDC logo is stamped on the outboard end of each rocker shaft to ensure correct assembly and installation. See Figure 1-60.

Figur igure e 11-60

Rocke ocker r Arm Arm Sha Shaft Ident dentif ific icat atio ion n Ma Mark


1.3

2004) 1-77


1.3.2.1 1.3.2.1 Cleaning Cleaning of Rocker Rocker Arm Arm Assemblie Assemblies s Clean the rocker arm assemblies as follows: 1. Remo Remove ve the the cup cup plug plug at one one end end of the the roc rocke ker r arm arm shaf shafts ts to faci facili lita tate te th e removal of any foreign material lodged behind the plug. NOTICE: Do not soak the rocker arms in solvent because this will remove the lubricant fr om the cam follower roller bushings. 2.

Clean the exterior of the rocker ar arms only.


Blow dry with compressed air.

4.

Soak the rocker sh shaft in cl clean fuel oi oil.


5. Run Run a wire wire brus brush h thr throu ough gh the the oil oil pass passag age e to to rem remov ove e any any fore foreig ign n mat mater eria ial l or sludge. 6. Clea Clean n the the exte exteri rior or of the the sha shaft ft and and blo blow w out out the the pas passa sage ges s and and oil oil hol holes es; ; and dry with compressed air.



1.3.2.2 1.3.2.2 Inspection Inspection of Rocker Rocker Arm Assemblies Assemblies and Camshaft Camshaft Lobes Lobes Prior to inspection:

1. Install new cup plugs with tool, tool, J 36326, until they they are 1.0-1.3 mm mm (0.040(0.0400.050 in.) below the surface surface of the shaft. shaft. See Figure Figure 1-61. 1-61.

Figur igure e 11-61

Rocke ocker r Arm Arm Sha Shaft Ident dentif ific icat atio ion n Ma Mark

2. Remove all of the old gasket sealer from the joint face of the No. 1 and 7 camshaft bearing caps and the cylinder head. Refer to"Gasket Eliminator Removal" in the " General Information" section.


1.3

2004) 1-79


Inspect the rocker arm assemblies and camshaft lobes as follows: 1. es.

Insp Inspec ect t the the rock rocker er arm arm sha shaft ft bush bushin ing g sur surfa face ces s and and rock rocker er arm arm bus bushi hing ng bor bor

[a] [a] Chec Check k the the rock rocker er arm arm sha shaft ft bush bushin ing g sur surfa face ces s and and rock rocker er arm arm bus bushi hing ng bore bores s for wear or scoring. scoring. If damage was found, found, replace replace component. component. [b]

If no no da damage wa was fo found, re reuse co component.

2.

Inspect the cam follower rollers.

[a] [a] Chec Check k the the cam cam foll follow ower er roll roller ers s for for scor scorin ing, g, pitt pittin ing, g, or flat flat spot spots. s. If damage was found, replace the component. [b]

If no no da damage wa was fo found, re reuse co component.

3. pins.

Chec Check k the the cam cam fol follo lowe wer r rol rolle lers rs to ensu ensure re they they turn turn free freely ly on the the rol rolle ler r

[a] [a] Clea Cleara ranc nce e bet betwe ween en the the rol rolle lers rs and and pin pins s sho shoul uld d not not be more more than than 0.08 0.08 mm ( 0.003 in.). [b]

Replace as necessary.

4.

Inspect the camshaft lobes and journals.

[a] [a] Chec Check k the the cams camsha haft ft lobe lobes s and and jour journa nals ls for for sco scori ring ng, , pit pitti ting ng, , or or fla flat t spo spot t s. If damage damage was found, replace replace the the component. component. [b] [b] If ther there e is is dou doubt bt as to the the acc accep epta tabi bili lity ty of the the cam camsh shaf aft t for for furt furthe her r se se rvice, determine determine the extent extent of camshaft lobe wear. Refer to section 1.24.3.1. 1.24.3.1. 5.

Inspect the valve adjusting screw assemblies.

[a] [a] If form former er styl style e val valve ve adju adjust stin ing g scr screw ew asse assemb mbly ly is dama damage ged; d; repl replac ace e wit with h new unitized valve adjusting screw assembly. NOTE: Replace with unitized valve adjusting screw assembly of the correct position. [b] [b] If any any dam damag age e is is fou found nd on the the uni uniti tize zed d val valve ve adju adjust stin ing g scr screw ew asse assemb mbly ly; ; r eplace with new unitized screw assembly. [c] [c]

If no dama damage ge is foun found d on on the the form former er styl style e val valve ve adju adjust stin ing g scr screw ew or on th

e new unitized valve adjusting screw assembly; reuse the components. NOTE: Former style valve adjusting screw assemblies and the unitized valve adjusting s crew assemblies are interchangeable and can be mixed in the same engine.



1.3. 1.3.3 3

Inst Instal alla lati tion on of Rock Rocker er Arm Arm Sha Shaft ft Asse Assemb mbly ly

Perform the following for rocker arm shaft assembly installation: 1. Ensure the the cup plugs are properly properly installed installed to to each end of of the rocker arm s hafts before the shafts are installed to the engine. See Figure 1-62. Refer to s ection 1.3.2.2, step 1.


2. Locknut 6. Unitized Valve Adjusting Screw Assembly; Exhaust position 3. Intake Intake Rocker Rocker Arm Assembly Assembly 7. Exhaust Exhaust Rocker Rocker Arm Assembly Assembly 4. Fuel Fuel Inject Injector or Rocker Rocker Arm Assemb Assembly ly Assembly; Injector position Figure 1-62

8. Unitiz Unitized ed Valve Valve Adjust Adjusting ing Screw Screw

Rocker Arm and Related Parts


1.3

2004) 1-81


2. Chec Check k the the torq torque ue on the the roc rocke ker r sha shaft ft stud studs s to to ens ensur ure e the they y wer were e not not loos loose e ned when the nuts were removed. removed. Torque the studs to 101-116 N·m (75-86 lb·ft). lb·ft). 3. Inst Instal all l the the unit unitiz ized ed valv valve e adj adjus usti ting ng scre screw w ass assem embl blie ies s to to the the rock rocker er arm arm assemblies. See Figure 1-62.

NOTE: There are three different unitized valve adjusting screw screw assemblies. Ensure the correct unitized valve adjusting screw assembly is used in the correct location . See Figure 1-63. NOTE: Former style valve adjusting screw assemblies can be mixed with new unitized val ve adjusting screw assemblies.

Figu Figure re 1-63 1-63 and Intake)

Unit Unitiz ized ed Valv Valve e Adj Adjus usti ting ng Scre Screw w Ass Assem embl blie ies s (Ex (Exha haus ust, t, Inje Inject ctor or

4. Inst Instal all l the the rock rocker er arm arm ass assem embl blie ies s to to the the rock rocker er arm arm sha shaft fts s in in the their ir orig orig inal positions. positions. Use the rocker rocker arm identification marks to ensure correct compo nent assembly. If the rocker arm shaft does not have flats, flats, decide on the posit ion of the worn surfaces and rotate the rocker shaft accordingly.

(Rev. 2004)


1-82 1-82

6SE4 6SE483 83 0401 0401 Copy Copyri righ ght t © 2004 2004 DETR DETROI OIT T DIES DIESEL EL CORP CORPOR ORAT ATIO ION N


5. Using care to locate the valve button of the unitized valve adjusting screw assemblies to their respective valve stems and injector followers, install the rocker arm shaf t assemblies to the cylinder head. See Figure 1-64.

Figur igure e 11-64

Rocke ocker r Arm Arm Sha Shaft Assem ssembl bly y Ins Inst talla allati tion on

6. If the rocker arm shafts shafts do not have have flats flats in the bolt bolt hole locations, rock er shaft spacers are required. [a] [a] If the the roc rocke ker r sha shaft fts s do do not not have have flat flats s in in the the bolt bolt hole hole loca locati tion ons, s, inst insta a ll the rocker shaft spacers on the cap bolts and studs. [b] [b] If the the roc rocke ker r sha shaft fts s do do hav have e fla flats ts in the the bol bolt t hol hole e loc locat atio ions ns, , roc rocke ker r sh sh aft spacers are not required. 7. Install the inboard camshaft cap bolts for each rocker arm assembly, throug h the rocker arm shaft and camshaft cap and into the cylinder head. 8.

Install the nuts to the No.

7 and 8 cap studs.

NOTE: If new rocker arm components are installed, engine oil should be poured over the

rocker arms, rocker shaft, and camshaft as a pre-lubricant.


1.3

2004) 1-83


9. Torq Torque ue the the roc rocke ker r arm arm shaf shaft t nut nuts s to to 101 101-1 -116 16 N·m N·m (75 (75-8 -86 6 lb· lb·ft ft) ) usi using ng the the seq sequ u ence. See Figure 1-65.


Rock Rocker er Arm Arm Shaf Shaft t Ret Retai aini ning ng Bolt Bolt and and Nut Nut Tigh Tighte teni ning ng Sequ Sequen ence ce

10. 10. Adju Adjust st the the int intak ake e and and exha exhaus ust t val valve ve clea cleara ranc nces es and and set set the the inj injec ecto tor r hei heig g hts. Refer to section 12.2.

11. 11. Inst Instal all l the the valv valve e roc rocke ker r cov cover er. . Ref Refer er to sect sectio ion n 1.6 1.6.8 .8(o (one ne-p -pie iece ce), ), refe refer r to section 1.6.9(two- piece) and (three-piece). 12. 12.

Inst Instal all l any any othe other r comp compon onen ents ts that that were were remo remove ved d for for this this proc proced edur ure. e.



Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and ot her reproductive harm. Always start and operate an engine in a well ventilated area. If operating an engine in an enclosed area, vent the exhaust to the outside. Do not modify or tamper with the exhaust system or emission control system. 13.

Start the engine and check for leaks.

14.

Shut down the engine when completed.


1.4 1.4

VALV VALVES ES, , SPRI SPRING NGS, S, GUID GUIDES ES, , INSE INSERT RTS, S, SEAL SEALS S AND AND ROTA ROTATO TORS RS

1.4 1.4


2004) 1-85

Four valves per cylinder, two each intake and exhaust, give the Series 60 engine excellent breathing and cooling cooling characteristics. characteristics. See Figure Figure 1-66. 1-66.

Figur igure e 11-66

Intak ntake e and and Exh Exhaust aust Val Valve Arran rrange geme ment nts s

Valves are made of heat-treated alloys, with heads and stems precision ground. Stem ends are hardened to minimize wear in contact with the valve rocker buttons . Hard-alloy valve seat inserts, pressed into both intake and exhaust ports, can b e replaced when worn to restore new engine performance.



Valves are positioned and aligned by replaceable valve guides pressed into the c ylinder head. See Figure 1-67.

1. Valve Guide 5. Valve Stem Oil Seal 2. Valv Valve e Spri Spring ng Seat Seat

6. Valv Valve e Spri Spring ng

3.

Valve Insert

7.

4.

Va Valve

Figure 1-67

8.

Valve Rotator

Va Valve Keepers

Valve Guide and Related Parts

Replacement guides are reamed to close tolerances, and do not require reaming af ter installation. All valves are retained by valve rotator spring caps and two-p iece tapered valve locks.


1.4 1.4

2004) 1-87


Valve stem oil seals, installed on both intake and exhaust valves, provide contr olled valve stem lubrication while limiting oil consumption. NOTE: New valve seat inserts are pre-ground and only need to be checked for concentric ity after installation. Do not grind a new seat insert unless concentricity exce eds 0.05 mm (0.002 in.). Before grinding, be sure the valve guide is not excessi vely worn or bent, which could cause an erroneous concentricity reading. If the firedeck has been resurfaced, the valves will have to be seated deeper to restor e the valve head recess depth to specification limits. Do not grind seat inserts for this purpose. Reduced thickness inserts ar e available that are 0.2540, 0.2540, 0.5080 and 0.7620 mm (0.010, (0.010, 0.020 and 0.030 in.) shallower th an standard. When a reduced thickness valve seat insert is used, a corresponding ly thicker valve valve spring seat must be used. See Figure 1-68, 1-68, and see Figure Figure 1-69 .

Figur igure e 11-68

Stand tanda ard Valve alve Sea Seat In Insert sert Thi Thickne ckness ss



When servicing exhaust valves, determine which type of exhaust valve is containe d in the engine. If an exhaust valve must be replaced, use the same type that was removed. removed. Do no t mix exhaust valve types within within an engine. Both exhaust valves are available available f rom service stock for this purpose. Exhaust valve lash settings are affected by the type of exhaust valve that is contained in the engine. engine. The valve lash settings and injector injector timing height height are listed on the valve valve rocker cover. Refer to section 12.2.

Figure 1-69

Minimum Valve Stem Diameter

Two types of exhaust valves are are used on Series Series 60 engines. Pre-1991 model engin es use a nickel-based alloy which can be identified by a forged "U" on the combustion fac e. 1991 model and and beyond engines use an austenitic austenitic based alloy which can be ide ntified by a forged "H" on the combustion face, and by a machined identification ring above the valve lo ck groove. See Figure 1-70. The identification ring can be seen from the right side of the engine with rocker cover removed.


1.4 1.4


2004) 1-89

Series 60G exhaust valves for automotive engines are an inconnel based material. They are marked with a "J" on the face of the valve and a "J6-E-5" and a green dot on the top of the stem of the valve.

Figure 11-70

Exhaust Va Valve Identification



Beginning with engine model number 6R572448, distinguishing an intake valve from an exhaust valve can be identified by the different size dimples located under the head of the valve, rather then forged lettering. See Figure 1-70and see Figure 1-71. T his applies to all Series 60 diesel applications with the exception of the marin e engine.

Figur igure e 1-71 1-71 1.4. 1.4.1 1

Locat ocati ion of Dimp Dimple les s on Int Intake ake Valv Valves es

Repa Repair ir or Repl Replac acem emen ent t of of Val Valve ves s



1.4 1.4


2004) 1-91

Figu Figure re 1-72 1-72 1.4.2 1.4.2

Flow Flowch char art t for for Repa Repair ir or Repl Replac acem emen ent t of of Valv Valves es

Remova Removal l and and Clean Cleaning ing of Valv Valve e Sprin Spring g (Cyli (Cylinde nder r Head Head Inst Install alled) ed)

Perform the following steps for valve spring removal:



1. Clean any any dirt and debris debris from from the valve rocker cover cover joint joint area around the top of the cylinder head. Remove the valve rocker cover. Refer to section 1.6.2(one-piece ), refer to section 1.6.3(two-piece), refer to section 1.6.5(three-piece). 2. If the engine has a Jake Brake®, remove the Jake Brake® housings that cover th e rocker arm and shaft assembly for the valve to be serviced refer to section 1. 30.2.

3.

Remove the rocker arm shaft assembly, refer to section 1.3.2.

4.

Remove the injector from the appropriate cylinder. Refer to section 2.3.2.

NOTE: Fuel must be removed from the cylinder head fuel galleries prior to removing the injectors. Refer to section 2.3.2. 5.

Bar the engine over until the cylinder is at top-dead-center (TDC).

6. Insert the threaded portion of the valve spring compressor, J 35580into the threaded inboard camshaft cap hole adjacent to the valve being worked on. See F igure 1-73.


Insta nstal lling ling Val Valve Sprin pring g Comp Compre ress ssor or

7. Position the spring compressor cage portion of the valve spring compressor directly over the valve spring to be compressed. Engage the dowel of the cage in the closest slot of the valve spring compressor handle.


2004) 1-93

1.4 1.4


NOTICE: Do not contact the valve with the compressor tool. 8. Comp Compre ress ss the the val valve ve spri spring ng and and rem remov ove e the the valv valve e loc locks ks usin using g a smal small l mag magne ne t to prevent the locks from falling into the cylinder head oil return galleries. 9. Rele Releas ase e the the spri spring ng and and rem remov ove e the the valv valve e rot rotat ator or and and val valve ve spri spring ng. . If If the the valve stem oil seal is to be replaced, remove the seal and discard it. 10. 10. On the the oth other er thre three e val valve ves s it it may may be nece necess ssar ary y to to rep repea eat t the these se step steps s for for cylinders being worked on. Refer to step step 1and the following steps. Last, refer to step 9. NOTE: All valve spring or seal removal and replacement must be completed for each cyli nder being serviced while the piston is at top-dead-center, before turning the c rankshaft to work on another cylinder. 1.4.3 1.4.3 Remova Removal l and and Clea Cleanin ning g of of the the Valve Valve Spring Spring (Cylin (Cylinder der Head Head Removed) With the cylinder head assembly removed from the engine, remove the valve spring s as follows: 1. Bolt Bolt the the eng engin ine e ove overh rhau aul l sta stand nd adap adapto tor, r, J 356 35635 35-A -A, , to to the the engi engine ne over overha hau u l stand, J 29109, using the the hardware provided provided with the adaptor. See Figure 1-74 1-74 .

Figure 11-74

Engine Ov Overhaul St Stand



2. Bolt the cylinder head adaptor plate, J 35636-A, 35636-A, to the the cylinder cylinder head using the bolts provided with the adaptor. See Figure 1-74. 3. Mount the cylinder head and adaptor plate to the overhaul stand adaptor by engaging the slots in the cylinder head adaptor plate to the dowels on the overh aul stand adaptor. 4. Install the six nut nut and and bolt bolt assemblies that secure the cylinder head adapt or plate to the overhaul stand adaptor. 5.

Remove the cylinder head lifting hardware.

6. Turn the crank of the engine engine overhaul overhaul stand stand to position the cylinder cylinder head head i n an upright position. 7. Remove the valve locks using valve spring compressor, J 8062, 8062, with jaws, J 8062–3 installed, to compress each valve spring. See Figure 1-75.

Figure 11-75

Compressing Va Valve Sp Spring

8.

Release the spring and remove the valve, valve rotator and valve spring.

9.

Remove the valve stem oil seal and discard the seal.

10.

Remove the valve spring seat.

11. As parts are removed, mark or segregate them according to their original p osition for possible reuse.


1.4 1.4

2004) 1-95


1.4.3.1 1.4.3.1 Cleaning Cleaning of Valves Valves and and Related Related Parts Parts Clean the valves and parts as follows:



1. Usin Using g pro prope per r eye eye prot protec ecti tion on, , cle clean an all all of of the the disa disass ssem embl bled ed part parts s wit with h fu fu el oil and dry with compressed air. 2.

Clea Clean n the the carb carbon on from from the the val valve ve stem stems s and and wash wash the the val valve ves s wit with h fue fuel l oil oil. .

3.

Clean lean the the val valv ve gu guide ide bor bore e to to rem remo ove all gum and carbo arbon n de deposi posit ts.

[a] [a] For For die diese sel l eng engin ines es; ; use use bore bore brus brush, h, J 543 5437 7 (or (or equi equiva vale lent nt) ) for for this this proc proc edure. [b] [b] For For nat natur ural al gas gas eng engin ines es; ; a clot cloth h or or sof soft t nyl nylon on brus brush h is is rec recom omme mend nded ed for for this procedure. NOTE: Do not use bore brush (wire) on natural gas powdered metal guides.



1.4.4 .4.4

Remov emoval al of Val Valve Guide uide

Perform the following steps for valve guide removal: NOTE: Valve guides are not replaceable on natural gas or heat exchanger-cooled pleasur e craft marine engines. 1. Assemble the valve valve guide remover, J 34696-B, 34696-B, to an air air chisel. chisel. See Figure 1 -76.

Figure 11-76

Valve Guide Re Removal To Tools

2. Position the cylinder cylinder head, head, firedeck firedeck side up, on a turn over stand or suppo rted on 102 x 102 mm (4 x 4 in.) wooden blocks blocks on a workbench. workbench.


1.4 1.4

2004) 1-97


3. Inse Insert rt the the too tool l int into o val valve ve guid guide e fro from m the the fire firede deck ck side side of the the cyl cylin inde der r head. See Figure 1-77.

Figure 1-77

Valve Guide Removal

4. Hold Hold the the too tool l ver verti tica cal l to to the the cyli cylind nder er head head and and dri drive ve the the val valve ve guid guide e un un til it is free of the cylinder head. 5. Clea Clean n the the valv valve e gui guide de bore bore with with bore bore brus brush, h, J 543 5437 7 (or (or equi equiva vale lent nt), ), to r emove all gum and carbon deposits.



1.4. 1.4.5 5

Remo Remova val l of Inta Intake ke and and Exh Exhau aust st Val Valve ve Sea Seat t Inse Insert rt

As the intake and exhaust valve seats are different in size, two different tools are required for removal. Use the cam-operated valve valve seat remover, J 23479-460 A, with collet, J 23479-100–A, to remove the larger intake valve valve seat insert. Use valve seat remover, J 2347923479271, with collet J 23479-29 to remove the smaller exhaust valve seat insert. See Figure 1-78.

1.

Collet

4.

2.

Kn Knurled Knob

Valve Seat Insert Puller 5.

Co Collar

3. Sp Spring

6. Co C ollet Lever

Figure 11-78

Valve Se Seat In Insert Re Removal To Tools

Remove the intake and exhaust valve seats as follows: 1. Place the cylinder head in a horizontal position with the valve seats facin g up. NOTICE: Follow instructions supplied J 23479-100, J 23479-271, and unnecessary collet damage.

J

with tools J 23479-460A, 23479-29 to ensure longer tool life and

2. Using a new valve seat insert insert as a guide, turn the the knurled knurled knob on the end of the shaft to tighten and expand the collet until the valve seat insert will just slip off the collet. Refer to instructions supplied with the valve seat remover tool for cor rect tool operation.


1.4 1.4

2004) 1-99


1.4.5. 1.4.5.1 1 Inspec Inspectio tion n of Valve Valve The valve stems must be free from scratches or scuff marks, and, the valve faces must be free from ridges or cracks. Some pitting of the valve face is normal, and is acceptable acceptable as long as no leak paths paths are evident. evident. If leak paths exist, re face the valves valves or install new valves. If the valve heads are warped warped or the val val ve stem is bent, replace the valves. If suitable for reuse, a valve may be refaced as long as the valve rim width, af ter refacing,

is not not less than 2.0 mm (0.078 in.) for intake intake valves valves and 2.2 mm (0.086 in.) in.) f or exhaust valves. Refer to section ADDITIONAL ADDITIONAL INFORMATION1.A, INFORMATION1.A, for "Intake "Intake and Exhaust Val ve" specifications which are listed in Table 1-38and listed in Table 1-40. See Figu re 1-79.


Inta Intake ke and and Exh Exhau aust st Valv Valve e Fac Face e Ref Refac acin ing g and and Rim Rim Wid Width th

(Rev. 2004) All information subject to change without notice. 1-100 1-100 6SE483 6SE483 0401 0401 Copyri Copyright ght © 2004 2004 DETROI DETROIT T DIESEL DIESEL CORPOR CORPORATI ATION ON


1.4.5.2 1.4.5.2 Inspection Inspection of Valve Valve Spring Springs s Inspect the valve valve springs and replace any that are pitted or cracked. The entir e spring should be inspected. When a broken spring is replaced, replaced, the rotator rotator and valve locks for that valve and spring should also be replaced. Use valve spring tester, J 22738-02, to test the springs. See Figure 1-80.

Figure 1-80

Testing Valve Spring

If the spring load is less than 280 N (63 lb) at a compressed length of 67.25 mm (2.648 in.), the spring should be replaced and the valve locks should be discar ded. 1.4.5.3 1.4.5.3 Inspection Inspection of Valve Valve Guides Guides Inspect the guides for cracks, chipping, scoring or excessive wear. Measure the valve guide bore with a small hole gage or gage pin, and measure the valve stem diameter with a micrometer. Compare the measurements to determine va

lve stem clearance. If the clearance is greater than 0.152 mm (0.006 in.), the v alve guide must be replaced. 1.4.5.4 1.4.5.4 Inspection Inspection of Valve Valve Seat Seat Inserts Inserts Inspect valve seat inserts for wear, cracking or incorrect seat angle, which sho uld be 31 degrees, standard valve seat insert thickness. See Figure 1-68.


1.4 1.4


1.4.6 1.4.6

Instal Installat lation ion of Intake Intake and Exhaus Exhaust t Valv Valve e Seat Seat Insert Insert

2004) 1-101

Perform the following steps for intake and exhaust valve seat insert installatio n:



1. Clea Clean n the the seat seat inse insert rt coun counte terb rbor ores es and and the the new new sea seat t ins inser erts ts with with a sui suita ta ble solvent and blow dry with compressed air. 2. Use Use val valve ve seat seat inse insert rt inst instal alle lers rs, , J 3319 33190 0 (in (inta take ke) ) and and J 349 34983 83 (exh (exhau aust st) ) , to install new inserts. inserts. See Figure Figure 1-81. 1-81.

Figur igure e 11-81

Valve alve Seat Seat Ins Insert ert Inst Instal alla lati tion on Too Tools



3. Start the insert squarely into its counterbore with the seat facing up. See Figure 1-82.

1.

Seat

2.

Valve Seat Insert

Figure 1-82

3.

Cylinder Fire Deck

Valve Seat Insert Insertion


1.4 1.4


2004) 1-103

4. Pilo Pilot t the the inst instal alle ler r int into o the the valv valve e gui guide de from from the the fir fired edec eck k sur surfa face ce. . See See Figure 1-83.

Figure 11-83 5. 1-84.

Valve Se Seat In Insert In Installation

Driv Drive e the the inse insert rt soli solidl dly y into into its its seat seat in the the cyli cylind nder er head head. .

See See Figu Figure re

Figure 11-84

Seating Va Valve Seat Insert



6. Check the concentricity of valve seat with the valve guide using dial indic ator, J 8165-2, and pilot, J 35623-A. See Figure 1-85.

Figure 11-85 [a] [a] red.

Check Va Valve Se Seat Co Concentricity

If the the con conce cent ntri rici city ty is with within in 0.05 0.05 mm (0.0 (0.002 02 in.) in.), , no no gri grind ndin ing g is is req requi ui


1.4 1.4

2004) 1-105


[b] [b] If the the con conce cent ntri rici city ty is not not wit withi hin n 0.0 0.05 5 mm mm (0. (0.00 002 2 in. in.), ), grin grind d the the seat seat o nly enough to true it up, being sure to lightly grind a full 360 degrees. NOTE: Valve seat insert grinding should be limited to light clean-up or concentricity truing. For a fine, accurate finish, the eccentric grinding method using tool J 7040-A is recommended, because the grinding wheel contacts the insert at only on e point at any time, and a micrometer feed permits controlled fine adjustment. See Figure 1-86. Seats must be ground to a 31 degree angle.

Figure 11-86

Grinding Va Valve Se Seat In Insert



7. The valve head recess depth from the firedeck is increased by valve and/or insert grinding. It should be checked with a sled gage, J 22273-01 (or equivalent). See Figure 187.

Figure 11-87

Measuring Va Valve He Head Re Recess De Depth

[a] [a] If the the die diese sel l int intak ake e exh exhau aust st valv valve e hea head d rec reces ess s dep depth th is not not bet betwe ween en 1.4 1.4 to 1.8 mm (0.055-0.071 in.), the valve and seat must be replaced. [b] [b] If the the gas gas inta intake ke valv valve e hea head d rec reces ess s dep depth th is betw betwee een n 0.7 0.79 9 to to 1.1 1.17 7 mm mm (0. (0. 031-0.046 in.), the valve and seat are correctly installed. [c] [c] If the the gas gas exha exhaus ust t val valve ve head head rece recess ss dept depth h is is not not betw betwee een n 0.9 0.976 76-1 -1.4 .4 mm ( 0.030-0.053 in.), the intake intake 0.79-1.17 mm (0.031 -0.046 in.) in.) valve and seat must be replace replace d for the Series 60G engine. 8. After light clean-up, thoroughly clean the valve seat with fuel oil and blo w dry with compressed air. Check seat-to-valve face contact by applying a light coat of Prussian Blue (or equivalent) to the valve seat land. Insert the valve in the guide and "bounc e" the valve head on the seat insert without rotating the valve. A full 360 c ontact line should appear approximately centered on the valve face.


1.4 1.4


1.4. 1.4.7 7

Inst Instal alla lati tion on of Valv Valve e Guid Guide e

2004) 1-107

Perform the following steps for valve guide installation: NOTE: Valve guides are not replaceable on natural gas or heat exchanger-cooled pleasur e craft marine engines. 1. Star Start t the the cham chamfe fere red d end end of the the val valve ve guid guide e int into o the the cyli cylind nder er head head from from t he top. See Figure 1-88.

Figure 11-88

Valve Gu Guide In Installation



2. Insert the driver into an air chisel. Insert the driver into the valve gui de limiting sleeve J 33191-A and install this assembly over the valve guide. Drive the guide into t he cylinder head head until the driver bottoms in the limiting sleeve. See Figure 189.

Figure 11-89

Valve Gu Guide In Installation

3. Properly used, the installer ensures the correct protrusion of the valve gu ide from the cylinder head of 37.75 mm (1.486 in.).


1.4 1.4


1.4. 1.4.8 8

Inst Instal alla lati tion on of of Valv Valve, e, Spr Sprin ing, g, Sea Seal l and and Rota Rotato tor r

2004) 1-109

Perform the following steps for valve installation: 1. Posi Positi tion on the the cyl cylin inde der r hea head d ver verti tica call lly y on on the the over overha haul ul stan stand. d. Lubr Lubric icat ate e t he valve stems with clean engine lubricating oil and slide them into their respe ctive valve guides and against the valve seats. If reusing valves, install install them to their original positions. positions. 2. Inst Instal all l the the valv valve e spri spring ng seat seat over over the the valv valve e guid guide. e. Inst Instal all l the the valv valve e s tem oil seals using valve stem oil seal installation tools. tools. See Figure 1-90.

1. Valv Valve e Stem Stem Seal Seal Inst Instal alle ler r

4. Valv Valve e Guid Guide e

2.

5.

Oil Seal Protector Cap

3. Valv Valve e Spri Spring ng Seat Seat Figur igure e 11-90

Valve

6. Valv Valve e Stem Stem Oil Oil Seal Seal

Valve alve Stem Stem Oil Oil Sea Seal l In Instal stalla lati tion on Tools ools



3. Check the the length of the plastic seal protector cap relative relative to to the lock gro gro ove on the valve stem. If the seal protector protector cap cap extends extends more than 1.6 mm (1/16 (1/16 in.) beyond the groove, trim off the excess length of the cap. See Figure 1-91.

Figure 11-91

Oil Se Seal Pr Protection Ca Cap Si Sizing


1.4 1.4


4.

Install the cap over the valve stem.

Figur igure e 11-92

2004) 1-111

See Figure 1-92.

Oil Seal Seal Prote rotect ctio ion n Ca Cap In Instal stalla lati tion on



NOTICE: Ensure all valve spring seats have seal is installed.

been installed before

the valve stem

5. The valve stem oil seal may be installed with or without oil. l over the protector. See Figure 1-93.

Push the sea

NOTE: The valve stem oil seal on the natural gas engine has a larger inside diameter t han the diesel diesel engine. The seal portion portion of the natural natural gas oil seal is black in color.

Figure 11-93

Valve St Stem Oi Oil Se Seal In Installation


1.4 1.4

2004) 1-113


6. Push Push the the sea seal l dow down n on on the the valv valve e ste stem m usi using ng the the sea seal l ins insta tall ller er, , J 3910 39109, 9, while holding the valve head against against the seal. See Figure Figure 1-94.

Figure 1-94

Valve Stem Oil Seal Installer

7. When When the the ins insta tall ller er tool tool cont contac acts ts the the cyl cylin inde der r hea head, d, the the sea seal l is is cor corre rect ctl l y positioned. Be sure the installer is square against the cylinder head. Remov e the seal installer and protector cap.

(Rev. 2004)


1-114 1-114

6SE483 6SE483 0401 0401

Copyri Copyright ght © 2004 2004 DETROI DETROIT T DIESEL DIESEL CORPOR CORPORATI ATION ON


8. Install the valve spring and rotator. install them to their original positions.

See Figure 1-95.

If reusing parts,

1. Valve Locks 4. Valve Stem Oil Seal 2.

Valve Rotator

5.

Valve Guide

3.

Valve Spring

6.

Valve Spring Seat

Figure 11-95

Valve Spring an and Re Related Pa Parts

9. Using the valve spring compressor tool, J 8062, compress the valve spring o nly as much as required to to install the valve locks. After installing the valve locks, rap t he end of the valve stem sharply with a plastic mallet to seat the valve locks. NOTE: Always install new valve stem locks when installing valves. NOTE: Be sure the valve rotator is properly centered and aligned to avoid scoring the valve stem. Do not compress the spring any more than necessary to install the lo cks, to avoid damaging the oil seal.


1.4 1.4

2004) 1-115


10. 10. Afte After r all all of the the val valve ves s are are inst instal alle led, d, chec check k the the spri spring ng open openin ing g pre press ssur ure e on each valve using spring load gage. See Figure 1-96.

Figure 11-96

Checking Va Valve Sp Spring Lo Load



11. Note the the gage reading when the the valve just starts starts to unseat. The force requ ired to unseat the valve must not be less than 280 N (63 lb). 12. Remove the cylinder cylinder head from the the overhaul overhaul stand and install install it on the the eng ine. Refer to section 1.2.5. 13. Install the camshaft and rocker arm assemblies. Lightly lubricate the over head assemblies assemblies with clean engine engine oil. Refer to section 1.24.5. 1.24.5. 14. If the engine is equipped with a Jake Brake®, Brake®, install install the the brake. Refer to se ction 1.30.5. 15.

Adjust the valve clearance and injector timing. Refer to section 12.2.

16. If the engine is equipped with a Jake Brake®, Brake®, lash lash the brake. Refer to to secti on 12.2. 17.

Install any other components that were removed.

18. Fill the engine crankcase (refer to section 13.13.1) with the proper lubri cant. Refer to section 5.2.1. 19. Close any drain cocks that were opened and fill the cooling system. Refer to section section 13.13.4. Purge the air from the system system using the vent in the t hermostat housing. Complete filling of the cooling system is essential for prope r engine operation.

Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and ot her reproductive harm. Always start and operate an engine in a well ventilated area. If operating an engine in an enclosed area, vent the exhaust to the outside. Do not modify or tamper with the exhaust system or emission control system. 20.

Start the engine and check for leaks.


1.5

ENGINE LIFTER BRACKETS

1.5


2004) 1-117

A total of three engine lifter brackets are installed on each Series 60 engine a nd are utilized when removing and replacing the engine.See Figure 1-97 and see F igure 1-98.

Figure 1-97

Lifting Engine




Lift Liftin ing g Hea Heat t Exc Excha hang nger er-C -Coo oole led d Plea Pleasu sure re Craf Craft t Mar Marin ine e Eng Engin ine e


1.5

2004) 1-119


To avoid injury from a falling engine, do not use the engine lifter brackets alone when lifting the engine with a marine gear, main alternato r, engine skid, engine module, radiator, radiator, or similar similar component attached. The eng ine lifter brackets are designed to lift the engine only. NOTICE: To lift the engine, use a suitable lifting device. See Figure 1-97. A spreader spreader bar bar should be used with a sling and adequate adequate chain chain hoist hoist when lifti ng any engine. The lifting device should be adjusted so the lifting hook hooks s are are vert vertic ical al to prev preven ent t bend bendin ing g the the engi engine ne lift lift brac bracke kets ts. . To ensu ensu re proper weight distribution, all three engine lift brackets provided must be used in lifting the engine. Be sure the spreader bar is adequate to prevent lifter brackets from contacting the engine rocker cover and causing d amage. A lifter bracket should always be reinstalled whenever whenever removal is necessary. Se e Figure 1-99 and see Figure 1-100.



Figure 1-99

Engine Lifter Brackets


1.5


2004) 1-121

1. Left Left Fron Front t Lift Lifter er Brac Bracke ket t 2.

3. Rear Rear Lift Lifter er Brac Bracke ket t

Right Front Lifter Bracket


Plea Pleasu sure re Craf Craft t Mari Marine ne Engi Engine ne Lift Lifter er Brac Bracke kets ts



On some older installations, the front engine lifter bracket may be integral wit h the fan support bracket. See Figure 1-101.


Fan Fan Sup Suppo port rt and and Eng Engin ine e Lif Lifte ter r Bra Brack cket et


1.5


1.5. 1.5.1 1

Repa Repair ir or Repl Replac acem emen ent t of of the the Lif Lifte ter r Brac Bracke ket t

2004) 1-123



Flow Flowch char art t for for Repa Repair ir or or Repl Replac acem emen ent t of Lift Lifter er Bra Brack cket et



1.5. 1.5.2 2

Remo Remova val l and and Clea Cleani ning ng of Lift Lifter er Brac Bracke ket t

Perform the following steps for lifter bracket removal: 1.

Remove the bolts securing the lifter bracket to the engine.

2. On applications applications with the integral fan support and engine lifter bracket, re move the fan. Refer to section 1.10.2. 1.5.2.1 1.5.2.1 Inspection Inspection of Lifter Lifter Bracket Bracket

Perform the following for lifter bracket inspection:

To avoid injury from a falling engine, do not use a damaged lifter bracket when lifting the engine. 1.

Inspect the lifter brackets for cracks, bending or other damage.

2.

Replace the bracket if any of these conditions exist.

1.5. 1.5.3 3

Inst Instal alla lati tion on of Lift Lifter er Brac Bracke ket t

Perform the following steps for lifter bracket installation: 1. Install the bracket to the engine. Torque the mounting bolts to 101-126 N·m (75-93 lb·ft). 2. Install the fan support, support, heat exchanger support, or charge charge air cooler suppo rt bracket, refer to section 1.10.3.


1.6

ROCKER COVER

2004) 1-125

1.6

ROCKER COVER

The rocker cover completely encloses the valve and injector operating mechanism on top of the cylinder head (and in some cases an engine brake), including the o verhead camshaft. Depending on the installation, the rocker cover may be a one-piece, two-piece or three-piece design. design. See Figure 1-104, see Figure 1-105, and see Figure 1-106. The one-piece rocker cover is molded of a sound-dampening, fiberglass-reinforced fiberglass-reinforced , synthetic material. It is internally internally ribbed to distribute the hold-down bolt clamp load load for effective, full perimeter perimeter sealing. See Figure 1-103. Effective July 1993, a breather baffle is installed on the low-profile aluminum rocker cover. NOTE: Effective May 1999, all Series 60 engines are built with a reusable rocker cover gasket. This gasket does not need to be replaced at the time of removal provide d there is not any damage observed.

1.

Ga Gasket

5.

Co Cover Plug

2.

Ro Rocker Cover

3.

Isolator

7.

Element

4.

Washer

8.

Clip

6.

Bolt


OneOne-pi piec ece e Roc Rocke ker r Cov Cover er - Ser Serie ies s 60 60 Die Diese sel l Eng Engin ine e



1.

Limiting Sleeve

2.

Isolator

6.

Diamond-Shaped Seal

3.

Washer

7.

Rocker Cover Base

4.

Bolt

8.

Isolator Rim Seal


5.

Rocker Cover Cap

TwoTwo-pi piec ece e Roc Rocke ker r Cov Cover er - Ser Serie ies s 60 60 Die Diese sel l Eng Engin ine e


1.6

ROCKER COVER

2004) 1-127

1.

Cy Cylinder Head

4.

2.

Rocke ocker r Cove Cover r Base Base

5. Gask Gasket et

3.

Rocke ocker r Cove Cover r Cap Cap

6. Isol Isolat ator or Rim Seal eal

7.

Ventilation Fitting

Figu Figure re 1-1 1-105 05 Engine)

Bo Bolt

Thre Threee-pi piec ece e Rock Rocker er Cov Cover er - (Hea (Heat t Exch Exchan ange gerr-Co Cool oled ed Mar Marin ine e




1.6

2004) 1-129

ROCKER COVER

1. Gasket 2. Sea Seal Ring 3. Tube 4. Seal Ring 5. Screw 6. Cover 7. Bolt

8. Cover 9. Bol Bolt 10. Isolator 11. Spacer 12. Rocker Cover Base 13. Gasket

Figu Figure re 1-1 1-106 06 Plug Ignition

Two Two Piec Piece e Rock Rocker er Cov Cover er - Seri Series es 60G 60G Eng Engin ine e with with Coi Coil l Over Over



The two-piece rocker cover is constructed of cast aluminum. The top piece or cap is held in place by eight bolts and is removable for access to the valve, engine brake and fuel i njector adjusting adjusting mechanisms. A one-piece diamond shaped perimeter seal is loca ted in a groove in the rocker cover base base and seals the cap to the base. See Fig ure 1-107.

1.

Limiting Sleeve

2.

Isolator

6.

Diamond-Shaped Seal

3.

Washer

7.

Rocker Cover Base

4.

Bolt

8.

Isolator Rim Seal

Figure 11-107

5.

Rocker Cover Cap

Two-piece Ro Rocker Co Cover


1.6

2004) 1-131

ROCKER COVER

The three-piece rocker cover is similar to the two-piece cover but with an addit ional intermediate cover and diamond seal and new cover cap. See Figure 1-108.

1.

Limiting Sleeve

6.

Rocker Cover Cap

2.

Isolator

7.

Bolt

3.

Washer

8.

Intermediate Cover

4.

Bolt

9.

Rocker Cover Base

5. Bolt Figur igure e 1-10 1-108 8

Three hree-piec piece e Rock Rocker er Cov Cover

Two caps are available with the Series 60 diesel engines. One is for use with a Jake Brake®, and one without a Jake Brake®. Only one cap is available with the Series 60G engines. The rocker cover base is attached to the cylinder head using ten assemblies cons isting of a bolt, limiter sleeve, isolator and flat washer. washer. All rocker covers covers u se a silicone rim seal, seated in a groove around the bottom edge of the rocker cover base to provide an effective effective oil seal. The one-piece and two-piece design rocker covers incorporate a crankcase ventilation breather outlet. The three-piece design and the Series 60G cap incorporate a co mbination filler/breather at the camshaft cover (gear case cover) position.



1.6. 1.6.1 1

Repa Repair ir or Repl Replac acem emen ent t of Rock Rocker er Cove Cover r



Flow Flowch char art t for for Repa Repair ir or or Repl Replac acem emen ent t of Rock Rocker er Cove Cover r


1.6

2004) 1-133

ROCKER COVER

1.6.2 1.6.2 Remova Removal l and and Clea Cleanin ning g of of One-p One-piec iece e Rock Rocker er Cove Cover r For For Diesel Diesel Engines Only Preclean the rocker cover, especially around its seat on the head, and in the at taching bolt recesses, to keep dirt and debris out of the valve gear chamber. Perform the following steps to remove the one-piece rocker cover: 1.

Remo Remove ve the the cent center er plug plugs, s, hold hold-d -dow own n bolt bolts, s, wash washer ers s and and isol isolat ator ors. s.

2.

Lift the rocker co cover straight up off the engine.

1.6.2.1 1.6.2.1 Cleaning Cleaning and Inspection Inspection of the One-piece One-piece Rocker Rocker Cover For Diesel Engines Only Inspect the rocker cover as follows: 1.

Remove the breather element and retainer clip.

NOTICE: To avoid damaging the silicone isolators, do not clean them with mineral spirits , fuel oil or any petroleum based solvents. 2. Remo Remove ve bolt bolt asse assemb mbli lies es and and iso isola lato tors rs and and cle clean an in dete deterg rgen ent t and and wate water r so so lution. 3. Remo Remove ve gask gasket et from from rock rocker er cove cover r and and clea clean n the the gask gasket et and and roc rocke ker r cov cover er. . Remove old RTV sealant from the corners of the gasket and clean the gasket and rocker c over components in clean fuel oil. NOTE: Pay special attention to the breather element. Clean thoroughly or replace as re quired.


Blow dry with compressed air.

5.

Clean the breather recess in the rocker cover.

6.

Check for damage.

7.

Reinstall th the br breather el element an and re retainer cl clip.


Replace as necessary.


1 Manual de Servicio Serie 60

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