Detroit Diesel Series 60

Contents As Follows: 

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 

Fluoroelastomer (Viton) Caution 

Engine Views 

English To Metric Conversion 

Decimal And Metric Equivalents 

Specifications 

 Engine

 Cylinder Block And Cylinder Liner 

 Cylinder Head 

 Valve And Injector Operating Mechanism 

 Valves, Springs, Guides, Inserts, Seals And Rotators 

 Engine Lifter Brackets 

 Rocker Cover 

 Crankshaft 

 Crankshaft Oil Seals 

 Crankshaft Main Bearings 

 Gear Case Cover Preexhaust Gas Recirculation (Egr) 

 Gear Case Cover Exhaust Gas Recirculation (Egr)model 

 Gear Case Preexhaust Gas Recirculation (Egr) 

 Gear Case Exhaust Gas Recirculation (Egr) Model 

 Crankshaft Vibration Damper 

 Crankshaft Pulley 

 Flywheel 

 Ring Gear 

 Flywheel Housing 

 Piston And Piston Ring 

 Onepiece 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 

 Additional Information 

 Fuel System 

 Diesel Fuel System Overview 

 Vehicle Safety For The Natural Gas Engine 

 N Electronic Unit Injector 

 N Fuel Injector Tube And Oring 

 N Electronic Unit Injector 

 N Fuel Injector Tube 

 Fuel Pump With Separate Drive Shaft And Hub 

 Fuel Pump With Onepiece Drive Shaft And Hub Assembly 

 Fuel Pump Drive 

 Diesel Fuel Filters (Spinon) 

 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 Readonly 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 Positionsensor 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) 

 Additional Information 

 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 ( And Later Engines) 

 Oil Cooler (Pre Engines) 

 Oil Level Dipstick Assembly 

 Oil Pan 

 Ventilating System 

 Additional Information 

 Cooling System

 Cooling System Overview 

 Water Pump (Gearcase Mounted And Later) (Gcm) 

 Water Pump (Front Mounted) (Fm) 

 Thermostat 

 Coolant Pressure Control Cap 

 Engine Cooling Fan 

 Coolant Filter And Conditioner 

 Radiator 

 Additional Information 

 Fuel, Lubricating Oil, And Coolant

 Fuel 

 Lubricating Oil (Diesel) 

 Lubricating Oil For The Series 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 

 Additional Information 

 Exhaust System

 Overview Of Exhaust Manifold Components 

 Threepiece Exhaust Manifold With Fey Rings 

 Threepiece Exhaust Manifold Without Fey Rings 

 Threepiece 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 

 Metripack Series Connectors 

 Micropack Series Connectors 

 Weather Pack And Metripack Series Connectors 

 Connector Tools 

 Splicing Guidelines 

 Additional Information 

 Power Takeoff

 Front Mounted Power Takeoff 

 Rear Engine Power Takeoff (Repto) Assembly 

 Special Equipment

 Air Compressor (Vehicle Applications Only) 

 Air Compressor Drive Hub 

 Additional Information 

 Operation And Verification

 Preparation For A First Time Start 

 Starting 

 Running 

 Stopping 

 Operating Conditions 

 Series G Automotive Engine Operating Conditions 

 Engine Runin Instructions 

 Engine Tuneup

 Engine Tuneup Procedures 

 Valve Lash, Injector Height (Timing) And Jake Brake® Lashadjustments 

 Engine Tuneup 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 

Index Index

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