Detroit Diesel Engine Series 60 All models 11.1L 12.7L 14L Service Repair Manual
Detroit Diesel Engine Series 60 All models 11.1L 12.7L 14L Service Repair Manual -Official Manual !!
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This manual provides instruction for servicing on-highway, construction and industrial, generator
set, and marine applications of the Detroit Diesel Series 60 Diesel and Natural Gas-Fueled
Engines.
Specifically a basic overview of each major component and system along with recommendations
for removal, cleaning, inspection, criteria for replacement, repair and installation and mechanical
troubleshooting are contained in this manual.
Models Coverd :
- DDEC I
- DDEC II
- DDEC III
- DDEC IV
- Series 60 14-liter
Contents :
TABLE OF CONTENTS
GENERAL INFORMATION ..................................................................... 1
SCOPE AND USE OF THIS MANUAL ..................................................... 3
CLEARANCE OF NEW PARTS AND WEAR LIMITS .............................. 3
THE FOUR CYCLE PRINCIPLE FOR DIESEL ENGINES ...................... 4
FOUR CYCLE PRINCIPLE FOR NATURAL GAS ENGINES .................. 6
GENERAL DESCRIPTION ...................................................................... 8
GENERAL SPECIFICATIONS ................................................................. 13
GENERAL SPECIFICATIONS FOR THE SERIES 60G ENGINE ............ 14
ENGINE MODEL, SERIAL NUMBER AND OPTION LABEL ................... 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
1 ENGINE
1.1 CYLINDER BLOCK AND CYLINDER LINER .......................................... 1-3
1.2 CYLINDER HEAD .................................................................................... 1-30
1.3 VALVE AND INJECTOR OPERATING MECHANISM .............................. 1-64
1.4 VALVES, SPRINGS, GUIDES, INSERTS, SEALS AND ROTATORS ....... 1-86
1.5 ENGINE LIFTER BRACKETS .................................................................. 1-118
1.6 ROCKER COVER .................................................................................... 1-126
1.7 CRANKSHAFT ........................................................................................ 1-148
1.8 CRANKSHAFT OIL SEALS ..................................................................... 1-169
1.9 CRANKSHAFT MAIN BEARINGS ........................................................... 1-190
1.10 GEAR CASE COVER .............................................................................. 1-203
1.11 GEAR CASE ............................................................................................ 1-237
1.12 CRANKSHAFT VIBRATION DAMPER ..................................................... 1-269
1.13 CRANKSHAFT PULLEY .......................................................................... 1-278
1.14 FLYWHEEL ............................................................................................. 1-294
1.15 RING GEAR ............................................................................................. 1-304
1.16 FLYWHEEL HOUSING ............................................................................. 1-306
1.17 PISTON AND PISTON RING ................................................................... 1-314
1.18 FORGED STEEL ONE PIECE PISTON ASSEMBLY AND PISTON
RING ........................................................................................................ 1-337
1.19 PISTON AND CONNECTING ROD ASSEMBLY ..................................... 1-352
1.20 CONNECTING ROD ................................................................................ 1-383
1.21 CYLINDER LINER ................................................................................... 1-398
1.22 GEAR TRAIN AND ENGINE TIMING ...................................................... 1-413
1.23 THRUST PLATE PERIMETER SEAL ....................................................... 1-443
1.24 CAMSHAFT AND CAMSHAFT BEARING ............................................... 1-458
1.25 CAMSHAFT DRIVE GEAR ...................................................................... 1-510
1.26 ADJUSTABLE IDLER GEAR ASSEMBLY ................................................ 1-524
1.27 BULL GEAR AND CAMSHAFT IDLER GEAR ASSEMBLY ..................... 1-535
1.28 CRANKSHAFT TIMING GEAR AND TIMING WHEEL ............................ 1-549
1.29 ACCESSORY DRIVE ............................................................................... 1-570
1.30 JAKE BRAKE® ......................................................................................... 1-603
1.A ADDITIONAL INFORMATION .................................................................. 1-663
2 FUEL SYSTEM
2.1 DIESEL FUEL SYSTEM OVERVIEW ...................................................... 2-5
2.2 VEHICLE SAFETY FOR THE NATURAL GAS ENGINE ......................... 2-7
2.3 ELECTRONIC UNIT INJECTOR ............................................................. 2-11
2.4 FUEL INJECTOR TUBE AND O-RING .................................................... 2-30
2.5 N3 ELECTRONIC UNIT INJECTOR ........................................................ 2-46
2.6 FUEL INJECTOR TUBE .......................................................................... 2-60
2.7 FUEL PUMP WITH SEPARATE DRIVE SHAFT AND HUB ..................... 2-64
2.8 FUEL PUMP WITH ONE-PIECE DRIVE SHAFT AND HUB ASSEMBLY 2-87
2.9 FUEL PUMP DRIVE ................................................................................. 2-110
2.10 DIESEL FUEL FILTERS (SPIN-ON) ........................................................ 2-115
2.11 FUEL PRO 380/380E FUEL FILTER SYSTEM ........................................ 2-124
2.12 SEA PRO 150/300 DIESEL FUEL PROCESSOR SYSTEM (MARINE) .. 2-131
2.13 SEA PRO 152 FUEL FILTER SYSTEM (MARINE ENGINE) ................... 2-139
2.14 FUEL FILTER TYPE FOR THE SERIES 60G ENGINE ........................... 2-148
2.15 FUEL COOLER (HEAT EXCHANGER-COOLED MARINE ENGINE) ..... 2-157
2.16 ASSEMBLY FUEL FILTER AND WATER SEPARATOR ........................... 2-161
2.17 ELECTRONIC ENGINE CONTROL ......................................................... 2-169
2.18 DDEC V ELECTRONIC CONTROL UNIT ................................................ 2-171
2.19 DDEC III/IV ELECTRONIC CONTROL MODULE .................................... 2-179
2.20 DDEC II ELECTRONIC CONTROL MODULE ......................................... 2-187
2.21 DDEC I ..................................................................................................... 2-199
2.22 PROGRAMMABLE READ-ONLY MEMORY (PROM) DDEC I ................ 2-205
2.23 ELECTRONIC DISTRIBUTOR UNIT DDEC I ......................................... 2-209
2.24 ELECTRONIC FOOT PEDAL ASSEMBLY .............................................. 2-213
2.25 TURBO BOOST PRESSURE SENSOR .................................................. 2-214
2.26 AIR INTAKE PRESSURE SENSOR ......................................................... 2-216
2.27 OIL PRESSURE SENSOR ..................................................................... 2-219
2.28 OIL TEMPERATURE SENSOR .............................................................. 2-221
2.29 AIR TEMPERATURE SENSOR ............................................................... 2-223
2.30 AIR TEMPERATURE SENSOR FOR HIGH PRESSURE FUEL
SYSTEM .................................................................................................. 2-227
2.31 COOLANT TEMPERATURE SENSOR .................................................... 2-229
2.32 SYNCHRONOUS REFERENCE SENSOR ............................................. 2-231
2.33 TIMING REFERENCE SENSOR ............................................................ 2-234
2.34 COOLANT LEVEL SENSOR .................................................................. 2-236
2.35 FUEL PRESSURE SENSOR .................................................................. 2-240
2.36 FUEL TEMPERATURE SENSOR ........................................................... 2-243
2.37 EXHAUST GAS OXYGEN SENSOR FOR SERIES 60G ENGINES ........ 2-247
2.38 EXHAUST TEMPERATURE SENSOR FOR THE SERIES 60G
ENGINES ................................................................................................. 2-251
2.39 KNOCK SENSOR AND SIGNAL NOISE ENHANCEMENT FILTER
MODULE .................................................................................................. 2-252
2.40 BAROMETRIC PRESSURE SENSOR FOR THE SERIES 60G ENGINE
WITH HIGH PRESSURE FUEL SYSTEM .............................................. 2-255
2.41 OVERVIEW OF HIGH PRESSURE FUEL SYSTEM FOR SERIES 60G
ENGINES ................................................................................................. 2-257
2.42 FUEL PRESSURE GAGES FOR THE SERIES 60G ENGINE WITH A
HIGH PRESSURE FUEL SYSTEM ......................................................... 2-263
2.43 VENTING AND LEAK CHECKING PROCEDURES FOR A NATURAL
GAS ENGINE (HIGH PRESSURE SYSTEM) ......................................... 2-265
2.44 HIGH PRESSURE FUEL REGULATOR FOR THE SERIES 60G
ENGINE ................................................................................................... 2-269
2.45 PULSE WIDTH MODULATED STEPPER MOTOR VALVE (PSV) FOR
SERIES 60G AUTOMOTIVE ENGINES ................................................... 2-271
2.46 FUEL MIXER FOR THE SERIES 60G HIGH PRESSURE FUEL SYSTEM
.................................................................................................................. 2-275
2.47 FUEL SHUTOFF VALVE FOR SERIES 60G ENGINE WITH HIGH
PRESSURE FUEL SYSTEM ................................................................... 2-278
2.48 IMPCO LOW PRESSURE FUEL REGULATOR FOR THE SERIES 60G
ENGINE HIGH PRESSURE FUEL SYSTEM .......................................... 2-280
2.49 OVERVIEW OF THE LOW PRESSURE NATURAL GAS FUEL
SYSTEM .................................................................................................. 2-284
2.50 LOW PRESSURE FUEL REGULATOR FOR THE SERIES 60G
ENGINE ................................................................................................... 2-289
2.51 FUEL MIXER FOR THE SERIES 60G LOW PRESSURE SYSTEM ....... 2-293
2.52 VENTING AND LEAK CHECKING PROCEDURES FOR NATURAL GAS
ENGINE (LOW PRESSURE SYSTEM) .................................................. 2-296
2.A ADDITIONAL INFORMATION .................................................................. 2-299
3 LUBRICATION SYSTEM
3.1 OVERVIEW OF LUBRICATING SYSTEM ................................................ 3-3
3.2 OIL PUMP ................................................................................................ 3-8
3.3 OIL PRESSURE REGULATOR VALVE .................................................... 3-23
3.4 OIL PRESSURE RELIEF VALVE ............................................................. 3-30
3.5 OIL FILTER .............................................................................................. 3-36
3.6 OIL FILTER ADAPTOR ............................................................................ 3-40
3.7 THERMATIC OIL CONTROL VALVE ....................................................... 3-46
3.8 OIL COOLER (1991 AND LATER ENGINES) .......................................... 3-53
3.9 OIL COOLER (PRE-1991 ENGINES) ...................................................... 3-64
3.10 OIL LEVEL DIPSTICK ASSEMBLY .......................................................... 3-74
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