Detroit Series 60 Diesel, Natural Gas-Fueled & Marine Engines Service Manual

TABLE OF CONTENTS:

GENERAL INFORMATION
SCOPE AND USE OF THIS MANUAL
CLEARANCE OF NEW PARTS AND WEAR LIMITS
THE FOUR CYCLE PRINCIPLE FOR DIESEL ENGINES
FOUR CYCLE PRINCIPLE FOR NATURAL GAS ENGINES
GENERAL DESCRIPTION
GENERAL SPECIFICATIONS
GENERAL SPECIFICATIONS FOR THE SERIES G ENGINE
ENGINE MODEL, SERIAL NUMBER AND OPTION LABEL
ENGINE MODEL, SERIAL NUMBER AND OPTION LABEL (SERIES G ENGINE)
REPLACING AND REPAIRING
DISASSEMBLY
CLEANING
SAFETY PRECAUTIONS
ENGINE VIEWS
ENGLISH TO METRIC CONVERSION
DECIMAL AND METRIC EQUIVALENTS
SPECIFICATIONS
ENGINE
CYLINDER BLOCK AND CYLINDER LINER
CYLINDER HEAD
VALVE AND INJECTOR OPERATING MECHANISM
VALVES, SPRINGS, GUIDES, INSERTS, SEALS AND ROTATORS
ENGINE LIFTER BRACKETS
ROCKER COVER
CRANKSHAFT
CRANKSHAFT OIL SEALS
CRANKSHAFT MAIN BEARINGS
GEAR CASE COVER PRE EXHAUST GAS RECIRCULATION (EGR)
GEAR CASE COVER EXHAUST GAS RECIRCULATION (EGR) MODEL
GEAR CASE PRE EXHAUST GAS RECIRCULATION (EGR)
GEAR CASE EXHAUST GAS RECIRCULATION (EGR) MODEL
CRANKSHAFT VIBRATION DAMPER
CRANKSHAFT PULLEY
FLYWHEEL
RING GEAR
FLYWHEEL HOUSING
PISTON AND PISTON RING
ONE PIECE PISTON ASSEMBLY AND PISTON RING
PISTON AND CONNECTING ROD ASSEMBLY
CONNECTING ROD
CYLINDER LINER
GEAR TRAIN AND ENGINE TIMING
COMPACT GEAR TRAIN AND ENGINE TIMING
CAMSHAFT GEAR ASSEMBLY SERIES EXHAUST GAS
RECIRCULATION (EGR) MODEL
THRUST PLATE PERIMETER SEAL
CAMSHAFT AND CAMSHAFT BEARING
CAMSHAFT DRIVE GEAR
ADJUSTABLE IDLER GEAR ASSEMBLY
ADJUSTABLE IDLER GEAR COMPACT GEAR TRAIN
BULL GEAR AND CAMSHAFT IDLER GEAR FOR THE COMPACT GEAR TRAIN
BULL GEAR AND CAMSHAFT IDLER GEAR ASSEMBLY
CRANKSHAFT TIMING GEAR AND TIMING WHEEL
ACCESSORY DRIVE
JAKE BRAKE
FUEL SYSTEM
DIESEL FUEL SYSTEM OVERVIEW
VEHICLE SAFETY FOR THE NATURAL GAS ENGINE
N ELECTRONIC UNIT INJECTOR
N FUEL INJECTOR TUBE AND O RING
N ELECTRONIC UNIT INJECTOR
N FUEL INJECTOR TUBE
FUEL PUMP WITH SEPARATE DRIVE SHAFT AND HUB
FUEL PUMP WITH ONE PIECE DRIVE SHAFT AND HUB ASSEMBLY
FUEL PUMP DRIVE
DIESEL FUEL FILTERS (SPIN ON)
FUEL PRO / E FUEL FILTER SYSTEM
FUEL FILTER TYPE FOR THE SERIES G ENGINE
ASSEMBLY FUEL FILTER AND WATER SEPARATOR
ELECTRONIC ENGINE CONTROL
DDEC V ELECTRONIC CONTROL UNIT
DDEC III/IV ELECTRONIC CONTROL MODULE
DDEC II ELECTRONIC CONTROL MODULE
DDEC I
PROGRAMMABLE READ ONLY MEMORY (PROM) DDEC I
ELECTRONIC DISTRIBUTOR UNIT DDEC I
ELECTRONIC FOOT PEDAL ASSEMBLY
TURBO SPEED SENSOR (TSS)
TURBO BOOST PRESSURE SENSOR
AIR INTAKE PRESSURE SENSOR
OIL PRESSURE SENSOR
OIL TEMPERATURE SENSOR
AIR TEMPERATURE SENSOR
AIR TEMPERATURE SENSOR FOR HIGH PRESSURE FUEL SYSTEM
COOLANT TEMPERATURE SENSOR
SYNCHRONOUS REFERENCE SENSOR GEAR CASE MOUNTED
SYNCHRONOUS REFERENCE SENSOR \ CAMSHAFT POSITION
SENSOR CAMSHAFT GEAR COVER MOUNTED
TIMING REFERENCE SENSOR
COOLANT LEVEL SENSOR
FUEL PRESSURE SENSOR
FUEL TEMPERATURE SENSOR
EXHAUST GAS OXYGEN SENSOR FOR SERIES G ENGINES
EXHAUST TEMPERATURE SENSOR FOR THE SERIES G ENGINES
KNOCK SENSOR AND SIGNAL NOISE ENHANCEMENT FILTER MODULE
BAROMETRIC PRESSURE SENSOR FOR THE SERIES G ENGINE
WITH HIGH PRESSURE FUEL SYSTEM
OVERVIEW OF HIGH PRESSURE FUEL SYSTEM FOR SERIES G ENGINES
FUEL PRESSURE GAGES FOR THE SERIES G ENGINE WITH A
HIGH PRESSURE FUEL SYSTEM
VENTING AND LEAK CHECKING PROCEDURES FOR A NATURAL
GAS ENGINE (HIGH PRESSURE SYSTEM)
HIGH PRESSURE FUEL REGULATOR FOR THE SERIES G ENGINE
PULSE WIDTH MODULATED STEPPER MOTOR VALVE (PSV) FOR
SERIES G AUTOMOTIVE ENGINES
FUEL MIXER FOR THE SERIES G HIGH PRESSURE FUEL SYSTEM
FUEL SHUTOFF VALVE FOR SERIES G ENGINE WITH HIGH
PRESSURE FUEL SYSTEM
IMPCO LOW PRESSURE FUEL REGULATOR FOR THE
SERIES G ENGINE HIGH PRESSURE FUEL SYSTEM
OVERVIEW OF THE LOW PRESSURE NATURAL GAS FUEL SYSTEM
LOW PRESSURE FUEL REGULATOR FOR THE SERIES G ENGINE
FUEL MIXER FOR THE SERIES G LOW PRESSURE SYSTEM
VENTING AND LEAK CHECKING PROCEDURES FOR NATURAL GAS
ENGINE (LOW PRESSURE SYSTEM)
LUBRICATION SYSTEM
OVERVIEW OF LUBRICATING SYSTEM
OIL PUMP
OIL PRESSURE REGULATOR VALVE
OIL PRESSURE RELIEF VALVE
OIL FILTER
OIL FILTER ADAPTOR
THERMATIC OIL CONTROL VALVE
OIL COOLER
OIL LEVEL DIPSTICK ASSEMBLY
OIL PAN
VENTILATING SYSTEM
COOLING SYSTEM
COOLING SYSTEM OVERVIEW
WATER PUMP (GEAR CASE MOUNTED AND LATER) (GCM)
WATER PUMP (FRONT MOUNTED) (FM)
THERMOSTAT
COOLANT PRESSURE CONTROL CAP
ENGINE COOLING FAN
COOLANT FILTER AND CONDITIONER
RADIATOR
FUEL, LUBRICATING OIL, AND COOLANT
FUEL
LUBRICATING OIL (DIESEL)
LUBRICATING OIL FOR THE SERIES G ENGINE
COOLANT
AIR INTAKE SYSTEM
AIR INTAKE SYSTEM OVERVIEW
AIR CLEANER
INTAKE MANIFOLD
CLOSED CRANKCASE BREATHER FOR SERIES G AUTOMOTIVE ENGINES
TURBOCHARGER (DIESEL)
TURBOCHARGER SERIES NATURAL GAS (AUTOMOTIVE) ENGINE
RECIRCULATION VALVE FOR SERIES G AUTOMOTIVE ENGINE
CHARGE AIR COOLER
THROTTLE ACTUATOR FOR THE SERIES G ENGINE
AIR DRYER
EXHAUST SYSTEM
OVERVIEW OF EXHAUST MANIFOLD COMPONENTS
THREE PIECE EXHAUST MANIFOLD WITH FEY RINGS
THREE PIECE EXHAUST MANIFOLD WITHOUT FEY RINGS
THREE PIECE EXHAUST MANIFOLD WITH HEAT SHIELD
EXHAUST GAS RECIRULATION (EGR) COMPONENTS
TUBE AND SHELL BOLTED FLANGE EGR COOLER
HYDRAULIC EGR VALVE
DELIVERY PIPE
EGR RATE MEASUREMENT SYSTEM
DDEC V VARIBLE PRESSURE OUTPUT DEVICE
DDEC IV VARIBLE PRESSURE OUTPUT DEVICES
ELECTRICAL EQUIPMENT
OVERVIEW OF ELECTRICAL SYSTEM
BATTERY CHARGING ALTERNATOR
STORAGE BATTERY
CRANKING MOTOR
TACHOMETER DRIVE
DDEC III/IV ENGINE SENSOR HARNESS
DDEC II ENGINE SENSOR HARNESS
METRI PACK SERIES CONNECTORS
MICRO PACK SERIES CONNECTORS
WEATHER PACK AND METRI PACK SERIES CONNECTORS
CONNECTOR TOOLS
SPLICING GUIDELINES
POWER TAKE OFF
FRONT MOUNTED POWER TAKE OFF
REAR ENGINE POWER TAKE OFF (REPTO) ASSEMBLY
SPECIAL EQUIPMENT
AIR COMPRESSOR (VEHICLE APPLICATIONS ONLY)
AIR COMPRESSOR DRIVE HUB
OPERATION AND VERIFICATION
PREPARATION FOR A FIRST TIME START
STARTING
RUNNING
STOPPING
OPERATING CONDITIONS
SERIES G AUTOMOTIVE ENGINE OPERATING CONDITIONS
ENGINE RUN IN INSTRUCTIONS
ENGINE TUNE UP
ENGINE TUNE UP PROCEDURES
VALVE LASH, INJECTOR HEIGHT (TIMING) AND JAKE BRAKE® LASH ADJUSTMENTS
ENGINE TUNE UP PROCEDURES FOR THE SERIES G ENGINE
VALVE LASH FOR THE SERIES G ENGINE
PREVENTIVE MAINTENANCE
MAINTENANCE OVERVIEW
DAILY MAINTENANCE ALL APPLICATIONS
MAINTENANCE OF VEHICLE ENGINES
PREVENTIVE MAINTENANCE FOR THE SERIES G AUTOMOTIVE
ENGINE (CITY TRANSIT COACH)
MAINTENANCE OF SERIES G AUTOMOTIVE ENGINES
DESCRIPTION OF MAINTENANCE ITEMS
CLEANING CONTAMINATED LUBRICATION OIL SYSTEM
STORAGE
PREPARING ENGINE FOR STORAGE
RESTORING AN EXTENDED STORAGE ENGINE
IGNITION SYSTEM
OVERVIEW OF IGNITION SYSTEM
COIL OVER PLUG IGNITION SYSTEM
IGNITION COIL ASSEMBLY
IGNITION BOOT ASSEMBLY
IGNITER MODULE
IGNITER MODULE BRACKET
IGNITION COIL HARNESS
SPARK PLUGS

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