Diesel Engine, Truck, Heavy Equipment Service Manuals

Detroit Series 60 Diesel & Natural Gas Engine Service Manual

$19.99

Product Description

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Covers: Detroit Series 60 11.1L, 12.7L, 14L on-highway engines with DDEC I, II, III, IV, or V (Diesel and Natural Gas)
Pages: 1,685
Format: PDF
Compatibility: Windows/Mac/Tablet
Note: DDEC troubleshooting manuals sold separately

This manual contains complete instructions on operation, adjustment (tune-up), preventive maintenance, and repair (including complete overhaul) for the Detroit Series 60 diesel and natural gas engines. This service manual was written primarily for mechanics servicing and overhauling the Series 60 engine. In this service manual you will find detailed Series 60 mechanical repair instructions and illustrations. View this service manual on your computer or print off page as needed. This manual is also referred to as the Workshop Manual or Repair Manual.

Topics in the Detroit Series 60 Diesel & Natural Gas Engine Service Manual:

GENERAL INFORMATION
CLEARANCE OF NEW PARTS AND WEAR LIMITS
THE FOUR CYCLE PRINCIPLE FOR DIESEL ENGINES
FOUR CYCLE PRINCIPLE FOR NATURAL GAS ENGINES
GENERAL DESCRIPTION
GENERAL SPECIFICATIONS
ENGINE MODEL, SERIAL NUMBER AND OPTION LABEL
REPLACING AND REPAIRING
DISASSEMBLY
CLEANING
SAFETY PRECAUTIONS
ENGINE VIEWS
ENGLISH TO METRIC CONVERSION
DECIMAL AND METRIC EQUIVALENTS
SPECIFICATIONS

1 ENGINE
1.1 CYLINDER BLOCK AND CYLINDER LINER
1.2 CYLINDER HEAD
1.3 VALVE AND INJECTOR OPERATING MECHANISM
1.4 VALVES, SPRINGS, GUIDES, INSERTS, SEALS AND ROTATORS
1.5 ENGINE LIFTER BRACKETS
1.6 ROCKER COVER
1.7 CRANKSHAFT
1.8 CRANKSHAFT OIL SEALS
1.9 CRANKSHAFT MAIN BEARINGS
1.10 GEAR CASE COVER PRE-EGR
1.11 GEAR CASE COVER EGR MODEL
1.12 GEAR CASE PRE-EGR)
1.13 GEAR CASE EGR MODEL
1.14 CRANKSHAFT VIBRATION DAMPER
1.15 CRANKSHAFT PULLEY
1.16 FLYWHEEL
1.17 RING GEAR
1.18 FLYWHEEL HOUSING
1.19 PISTON AND PISTON RING
1.20 ONE-PIECE PISTON ASSEMBLY AND PISTON RING
1.21 PISTON AND CONNECTING ROD ASSEMBLY
1.22 CONNECTING ROD
1.23 CYLINDER LINER
1.24 GEAR TRAIN AND ENGINE TIMING
1.25 COMPACT GEAR TRAIN AND ENGINE TIMING
1.26 CAMSHAFT GEAR ASSEMBLY SERIES 60 (EGR) MODEL
1.27 THRUST PLATE PERIMETER SEAL
1.28 CAMSHAFT AND CAMSHAFT BEARING
1.29 CAMSHAFT DRIVE GEAR
1.30 ADJUSTABLE IDLER GEAR ASSEMBLY
1.31 ADJUSTABLE IDLER GEAR COMPACT GEAR TRAIN
1.32 BULL GEAR AND CAMSHAFT IDLER GEAR FOR THE COMPACT GEAR TRAIN
1.33 BULL GEAR AND CAMSHAFT IDLER GEAR ASSEMBLY
1.34 CRANKSHAFT TIMING GEAR AND TIMING WHEEL
1.35 ACCESSORY DRIVE
1.36 JAKE BRAKE
1.A ADDITIONAL INFORMATION

2 FUEL SYSTEM
2.1 DIESEL FUEL SYSTEM OVERVIEW
2.2 VEHICLE SAFETY FOR THE NATURAL GAS ENGINE
2.3 N2 ELECTRONIC UNIT INJECTOR
2.4 N2 FUEL INJECTOR TUBE AND O-RING
2.5 N3 ELECTRONIC UNIT INJECTOR
2.6 N3 FUEL INJECTOR TUBE
2.7 FUEL PUMP WITH SEPARATE DRIVE SHAFT AND HUB
2.8 FUEL PUMP WITH ONE-PIECE DRIVE SHAFT AND HUB ASSEMBLY
2.9 FUEL PUMP DRIVE
2.10 DIESEL FUEL FILTERS (SPIN-ON)
2.11 FUEL PRO 380/380E FUEL FILTER SYSTEM
2.12 FUEL FILTER TYPE FOR THE SERIES 60G ENGINE
2.13 ASSEMBLY FUEL FILTER AND WATER SEPARATOR
2.14 ELECTRONIC ENGINE CONTROL
2.15 DDEC V ELECTRONIC CONTROL UNIT
2.16 DDEC III/IV ELECTRONIC CONTROL MODULE
2.17 DDEC II ELECTRONIC CONTROL MODULE
2.18 DDEC I
2.19 PROGRAMMABLE READ-ONLY MEMORY (PROM) DDEC I
2.20 ELECTRONIC DISTRIBUTOR UNIT DDEC I
2.21 ELECTRONIC FOOT PEDAL ASSEMBLY
2.22 TURBO SPEED SENSOR (TSS)
2.23 TURBO BOOST PRESSURE SENSOR
2.24 AIR INTAKE PRESSURE SENSOR
2.25 OIL PRESSURE SENSOR
2.26 OIL TEMPERATURE SENSOR
2.27 AIR TEMPERATURE SENSOR
2.28 AIR TEMPERATURE SENSOR FOR HIGH PRESSURE FUEL SYSTEM
2.29 COOLANT TEMPERATURE SENSOR
2.30 SYNCHRONOUS REFERENCE SENSOR GEAR CASE MOUNTED
2.31 SYNCHRONOUS REFERENCE SENSOR \ CAMSHAFT POSITION SENSOR CAMSHAFT GEAR COVER MOUNTED
2.32 TIMING REFERENCE SENSOR
2.33 COOLANT LEVEL SENSOR
2.34 FUEL PRESSURE SENSOR
2.35 FUEL TEMPERATURE SENSOR
2.36 EXHAUST GAS OXYGEN SENSOR FOR SERIES 60G ENGINES
2.37 EXHAUST TEMPERATURE SENSOR FOR THE SERIES 60G ENGINES
2.38 KNOCK SENSOR AND SIGNAL NOISE ENHANCEMENT FILTER MODULE
2.39 BAROMETRIC PRESSURE SENSOR FOR THE SERIES 60G ENGINE WITH HIGH PRESSURE FUEL SYSTEM
2.40 OVERVIEW OF HIGH PRESSURE FUEL SYSTEM FOR SERIES 60G ENGINES
2.41 FUEL PRESSURE GAGES FOR THE SERIES 60G ENGINE WITH A HIGH PRESSURE FUEL SYSTEM
2.42 VENTING AND LEAK CHECKING PROCEDURES FOR A NATURAL GAS ENGINE (HIGH PRESSURE SYSTEM)
2.43 HIGH PRESSURE FUEL REGULATOR FOR THE SERIES 60G ENGINE
2.44 PULSE WIDTH MODULATED STEPPER MOTOR VALVE (PSV) FOR SERIES 60G AUTOMOTIVE ENGINES
2.45 FUEL MIXER FOR THE SERIES 60G HIGH PRESSURE FUEL SYSTEM
2.46 FUEL SHUTOFF VALVE FOR SERIES 60G ENGINE WITH HIGH PRESSURE FUEL SYSTEM
2.47 IMPCO LOW PRESSURE FUEL REGULATOR FOR THE SERIES 60G ENGINE HIGH PRESSURE FUEL SYSTEM
2.48 OVERVIEW OF THE LOW PRESSURE NATURAL GAS FUEL SYSTEM
2.49 LOW PRESSURE FUEL REGULATOR FOR THE SERIES 60G ENGINE
2.50 FUEL MIXER FOR THE SERIES 60G LOW PRESSURE SYSTEM
2.51 VENTING AND LEAK CHECKING PROCEDURES FOR NATURAL GAS ENGINE (LOW PRESSURE SYSTEM)
2.A ADDITIONAL INFORMATION

3 LUBRICATION SYSTEM
3.1 OVERVIEW OF LUBRICATING SYSTEM
3.2 OIL PUMP
3.3 OIL PRESSURE REGULATOR VALVE
3.4 OIL PRESSURE RELIEF VALVE
3.5 OIL FILTER
3.6 OIL FILTER ADAPTOR
3.7 THERMATIC OIL CONTROL VALVE
3.8 OIL COOLER (1991 AND LATER ENGINES)
3.9 OIL COOLER (PRE-1991 ENGINES)
3.10 OIL LEVEL DIPSTICK ASSEMBLY
3.11 OIL PAN
3.12 VENTILATING SYSTEM
3.A ADDITIONAL INFORMATION

4 COOLING SYSTEM
4.1 COOLING SYSTEM OVERVIEW
4.2 WATER PUMP (GEAR-CASE MOUNTED – 1991 AND LATER) (GCM)
4.3 WATER PUMP (FRONT MOUNTED) (FM)
4.4 THERMOSTAT
4.5 COOLANT PRESSURE CONTROL CAP
4.6 ENGINE COOLING FAN
4.7 COOLANT FILTER AND CONDITIONER
4.8 RADIATOR
4.A ADDITIONAL INFORMATION

5 FUEL, LUBRICATING OIL, AND COOLANT
5.1 FUEL
5.2 LUBRICATING OIL (DIESEL)
5.3 LUBRICATING OIL FOR THE SERIES 60G ENGINE
5.4 COOLANT

6 AIR INTAKE SYSTEM
6.1 AIR INTAKE SYSTEM OVERVIEW
6.2 AIR CLEANER
6.3 INTAKE MANIFOLD
6.4 CLOSED CRANKCASE BREATHER FOR SERIES 60G AUTOMOTIVE ENGINES
6.5 TURBOCHARGER (DIESEL)
6.6 TURBOCHARGER SERIES 60 NATURAL GAS (AUTOMOTIVE) ENGINE
6.7 RECIRCULATION VALVE FOR SERIES 60G AUTOMOTIVE ENGINE
6.8 CHARGE AIR COOLER
6.9 THROTTLE ACTUATOR FOR THE SERIES 60G ENGINE
6.10 AIR DRYER
6.A ADDITIONAL INFORMATION

7 EXHAUST SYSTEM
7.1 OVERVIEW OF EXHAUST MANIFOLD COMPONENTS
7.2 THREE-PIECE EXHAUST MANIFOLD WITH FEY RINGS
7.3 THREE-PIECE EXHAUST MANIFOLD WITHOUT FEY RINGS
7.4 THREE-PIECE EXHAUST MANIFOLD WITH HEAT SHIELD

8 EXHAUST GAS RECIRULATION (EGR) COMPONENTS
8.1 TUBE AND SHELL BOLTED FLANGE EGR COOLER
8.2 HYDRAULIC EGR VALVE
8.3 DELIVERY PIPE
8.4 EGR RATE MEASUREMENT SYSTEM
8.5 DDEC V VARIBLE PRESSURE OUTPUT DEVICE
8.6 DDEC IV VARIBLE PRESSURE OUTPUT DEVICES

9 ELECTRICAL EQUIPMENT
9.1 OVERVIEW OF ELECTRICAL SYSTEM
9.2 BATTERY CHARGING ALTERNATOR
9.3 STORAGE BATTERY
9.4 CRANKING MOTOR
9.5 TACHOMETER DRIVE
9.6 DDEC III/IV ENGINE SENSOR HARNESS
9.7 DDEC II ENGINE SENSOR HARNESS
9.8 METRI-PACK 150 SERIES CONNECTORS
9.9 MICRO-PACK SERIES CONNECTORS
9.10 WEATHER PACK AND METRI-PACK 280 SERIES CONNECTORS
9.11 CONNECTOR TOOLS
9.12 SPLICING GUIDELINES
9.A ADDITIONAL INFORMATION

10 POWER TAKE-OFF
10.1 FRONT MOUNTED POWER TAKE-OFF
10.2 REAR ENGINE POWER TAKE-OFF (REPTO) ASSEMBLY

11 SPECIAL EQUIPMENT
11.1 AIR COMPRESSOR (VEHICLE APPLICATIONS ONLY)
11.2 AIR COMPRESSOR DRIVE HUB
11.A ADDITIONAL INFORMATION

12 OPERATION AND VERIFICATION
12.1 PREPARATION FOR A FIRST TIME START
12.2 STARTING
12.3 RUNNING
12.4 STOPPING
12.5 OPERATING CONDITIONS
12.6 SERIES 60G AUTOMOTIVE ENGINE OPERATING CONDITIONS
12.7 ENGINE RUN-IN INSTRUCTIONS

13 ENGINE TUNE-UP
13.1 ENGINE TUNE-UP PROCEDURES
13.2 VALVE LASH, INJECTOR HEIGHT (TIMING) AND JAKE BRAKE LASH ADJUSTMENTS
13.3 ENGINE TUNE-UP PROCEDURES FOR THE SERIES 60G ENGINE
13.4 VALVE LASH FOR THE SERIES 60G ENGINE

14 PREVENTIVE MAINTENANCE
14.1 MAINTENANCE OVERVIEW
14.2 DAILY MAINTENANCE – ALL APPLICATIONS
14.3 MAINTENANCE OF VEHICLE ENGINES
14.4 PREVENTIVE MAINTENANCE FOR THE SERIES 60G AUTOMOTIVE ENGINE (CITY TRANSIT COACH)
14.5 MAINTENANCE OF SERIES 60G AUTOMOTIVE ENGINES
14.6 DESCRIPTION OF MAINTENANCE ITEMS
14.7 CLEANING CONTAMINATED LUBRICATION OIL SYSTEM

15 STORAGE
15.1 PREPARING ENGINE FOR STORAGE
15.2 RESTORING AN EXTENDED STORAGE ENGINE

16 IGNITION SYSTEM
16.1 OVERVIEW OF IGNITION SYSTEM
16.2 COIL OVER PLUG IGNITION SYSTEM
16.3 IGNITION COIL ASSEMBLY
16.4 IGNITION BOOT ASSEMBLY
16.5 IGNITER MODULE
16.6 IGNITER MODULE BRACKET
IGNITION COIL HARNESS
SPARK PLUGS

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