Detroit diesel series 60 service shop manual free download

In , it was popular on many USA buses in the Detroit Diesel prescribed overhaul intervals of , miles , km , then raised that to , miles 1,, km after more experience was gained with the new engine. In , the The Detroit Diesel Series 60 Both the Once the Detroit Diesel began making Series 60 marine engines in , with wider availability starting in The bullgear is a straight cut gear that now rides on bushings.

Page 2 1. Remove the five bolts for the camshaft gear cover inspection plate and remove the plate. To verify camshaft timing proceed as follows: [a] Look at the timing hole in the camshaft gear.

Page 3 [c] If the timing holes are not aligned correctly remove the crankshaft timing pin and rotate the engine one more complete revolution. When the timing pin drops back into the hole in the crankshaft check the timing of the camshaft. Refer to step 2. Page 4 3. Remove bolt from front of camshaft gear cover. See Figure 3. Bolt 2. Camshaft Gear Cover Figure 3 Camshaft Gear Cover Bolt NOTE: If timing is correct and the repair being made does not require that the engine is turned over, clean off an area where the camshaft gear and idler gear teeth mesh and mark the teeth with a suitable marker for a reference point when reassembling the camshaft.

Page 5 4. Remove four camshaft gear cover bolts. See Figure 4. Page 6 5. Remove three bolts inside of camshaft gear cover. See Figure 5. Page 7 6. Remove one bolt and one stud bolt from camshaft caps No. See Figure 6. Remove the remaining five camshaft cap bolts, and camshaft caps. To avoid injury when removing or installing a heavy engine component, ensure the component is properly supported and securely attached to an adequate lifting device to prevent The most popular among the manufacturers of equipment are the following product lines:.

S40E — production began in th. The series immediately received electronic control and is characterized by economy and low level of vibration. S — the most powerful series, developed in conjunction with specialists MTU. The power range is hp. Detroit Diesel closely cooperates with manufacturers of Volvo Penta, Daimler Chrysler, Koler, and invests huge funds in researching new technologies.

For this purpose, the company has about dynamometer stands in Europe and the USA. Priority of the brand has not changed since — these are engines for heavy trucks. In this segment, Detroit Diesel achieved phenomenal success. Your email address will not be published. For these engines, a spacer is installed between the rocker arm shaft and the mounting bolts or nuts rather than a washer.

This allows the rocker arm shaft to be rotated when installing new rocker arms. When reusing rocker arm assemblies, the rocker arm shaft should not be rotated so that the same surfaces of the rocker arm assemblies and rocker shafts are in contact with each other. Vertical oil passages at the front and rear of the cylinder head deliver oil from the cylinder block front and rear oil galleries to the No. From there, the oil is directed upward through the enlarged stud hole to the No.

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 rocker arm assemblies.

The rocker arm assemblies contain drilled passages that supply oil to the camshaft roller follower, the roller pin and the bushing. The rocker arm assemblies also contain drilled passages that supply oil to the unitized valve adjusting screw assembly and exhaust valve stems and the fuel injector follower. NOTE: In December , a new unitized adjusting valve screw assembly now replaces the former valve adjusting screw, valve button and retainer clip.

The No. The oil passage within one rocker arm cylinder set is shown. If necessary, steam clean the engine around the valve rocker cover and cylinder head mating area. The ignition system can be affected. Remove the valve rocker cover. Remove the rocker arm shaft bolts No.

See Figure for Series 60 diesel engine and see Figure for Series 60 gas engine. For camshaft or cylinder head removal, both rocker arm shaft assemblies must be removed. Torque to Nm lbft. Use rocker arm and shaft assembly removal tool, J A, to remove the rocker arm shafts, with rocker arm assemblies in place.

NOTE: Some engines may be equipped with ceramic injector rollers. Use extra caution while removing and handling. Remove unitized valve adjusting screw assemblies. Then proceed to step 7. Do not attempt to reassemble them for reuse in engine.

Unitized Valve Adjusting Screws will not be serviced separately. NOTE: If removing a former valve adjusting screw with valve button and retainer clip, proceed to step 6. An adjusting screw is provided on the expander tool to limit the amount of travel.

Slide the retaining clip, open end first, down the adjusting screw. It is necessary to spread the clip slightly so that the open end can pass over the ball head of the adjusting screw. Insert the tips of the expander, J , between the legs of the retaining clip and expand the clip. Press the valve button towards the screw to seat both legs of the retainer completely in the groove. If further disassembly is necessary, slide the rockers off the shafts, marking or segregating the parts so that they may be reinstalled in the same position from which they were removed.

NOTE: Front and rear rocker arm shaft sections look identical, but must not be reversed, and must be installed as removed, due to bolt hole center line distances. The DDC logo is stamped on the outboard end of each rocker shaft to ensure correct assembly and installation. Clean the rocker arm assemblies as follows: 1. Remove the cup plug at one end of the rocker arm shafts to facilitate the removal of any foreign material lodged behind the plug.

NOTICE: Do not soak the rocker arms in solvent because this will remove the lubricant from the cam follower roller bushings. Clean the exterior of the rocker arms only.

Blow dry with compressed air. Soak the rocker shaft in clean fuel oil. Run a wire brush through the oil passage to remove any foreign material or sludge. Clean the exterior of the shaft and blow out the passages and oil holes; and dry with compressed air. Prior to inspection: 1. Install new cup plugs with tool, J , until they are 1. Remove all of the old gasket sealer from the joint face of the No.

Inspect the rocker arm assemblies and camshaft lobes as follows: 1. Inspect the rocker arm shaft bushing surfaces and rocker arm bushing bores. Check the rocker arm shaft bushing surfaces and rocker arm bushing bores for wear or scoring. If damage was found, replace component. Check the cam follower rollers for scoring, pitting, or flat spots. If damage was found, replace the component. Check the camshaft lobes and journals for scoring, pitting, or flat spots.

If there is doubt as to the acceptability of the camshaft for further service, determine the extent of camshaft lobe wear. If former style valve adjusting screw assembly is damaged; replace with new unitized valve adjusting screw assembly. NOTE: Replace with unitized valve adjusting screw assembly of the correct position. If any damage is found on the unitized valve adjusting screw assembly; replace with new unitized screw assembly.

If no damage is found on the former style valve adjusting screw or on the new unitized valve adjusting screw assembly; reuse the components. NOTE: Former style valve adjusting screw assemblies and the unitized valve adjusting screw assemblies are interchangeable and can be mixed in the same engine.

Perform the following for rocker arm shaft assembly installation: 1. Ensure the cup plugs are properly installed to each end of the rocker arm shafts before the shafts are installed to the engine.

Check the torque on the rocker shaft studs to ensure they were not loosened when the nuts were removed. Torque the studs to Nm lbft. Install the unitized valve adjusting screw assemblies to the rocker arm assemblies.

NOTE: There are three different unitized valve adjusting screw assemblies. Ensure the correct unitized valve adjusting screw assembly is used in the correct location. NOTE: Former style valve adjusting screw assemblies can be mixed with new unitized valve adjusting screw assemblies.

Install the rocker arm assemblies to the rocker arm shafts in their original positions. Use the rocker arm identification marks to ensure correct component assembly. If the rocker arm shaft does not have flats, decide on the position of the worn surfaces and rotate the rocker shaft accordingly.

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 shaft assemblies to the cylinder head. If the rocker arm shafts do not have flats in the bolt hole locations, rocker shaft spacers are required.

If the rocker shafts do not have flats in the bolt hole locations, install the rocker shaft spacers on the cap bolts and studs. If the rocker shafts do have flats in the bolt hole locations, rocker shaft spacers are not required. Install the inboard camshaft cap bolts for each rocker arm assembly, through the rocker arm shaft and camshaft cap and into the cylinder head. Install the nuts to the No.

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. Torque the rocker arm shaft nuts to Nm lbft using the sequence. Adjust the intake and exhaust valve clearances and set the injector heights.

Install the valve rocker cover. Install any other components that were removed for this procedure. Start the engine and check for leaks. Shut down the engine when completed. Four valves per cylinder, two each intake and exhaust, give the Series 60 engine excellent breathing and cooling characteristics. 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 be replaced when worn to restore new engine performance. Valves are positioned and aligned by replaceable valve guides pressed into the cylinder head. Replacement guides are reamed to close tolerances, and do not require reaming after installation. All valves are retained by valve rotator spring caps and two-piece tapered valve locks. Valve stem oil seals, installed on both intake and exhaust valves, provide controlled valve stem lubrication while limiting oil consumption.

NOTE: New valve seat inserts are pre-ground and only need to be checked for concentricity after installation. Do not grind a new seat insert unless concentricity exceeds 0. Before grinding, be sure the valve guide is not excessively 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 restore the valve head recess depth to specification limits.

Do not grind seat inserts for this purpose. Reduced thickness inserts are available that are 0. When a reduced thickness valve seat insert is used, a correspondingly thicker valve spring seat must be used.

When servicing exhaust valves, determine which type of exhaust valve is contained in the engine. If an exhaust valve must be replaced, use the same type that was removed. Do not mix exhaust valve types within an engine. Both exhaust valves are available from service stock for this purpose. Exhaust valve lash settings are affected by the type of exhaust valve that is contained in the engine.

The valve lash settings and injector timing height are listed on the valve rocker cover. Two types of exhaust valves are used on Series 60 engines. Pre model engines use a nickel-based alloy which can be identified by a forged "U" on the combustion face. The identification ring can be seen from the right side of the engine with rocker cover removed.

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.

Beginning with engine model number 6R, 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. This applies to all Series 60 diesel applications with the exception of the marine engine. Clean any dirt and debris from the valve rocker cover joint area around the top of the cylinder head.

If the engine has a Jake Brake, remove the Jake Brake housings that cover the rocker arm and shaft assembly for the valve to be serviced refer to section 1. Remove the rocker arm shaft assembly, refer to section 1. Remove the injector from the appropriate cylinder. Bar the engine over until the cylinder is at top-dead-center TDC.

Insert the threaded portion of the valve spring compressor, J into the threaded inboard camshaft cap hole adjacent to the valve being worked on. 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. Compress the valve spring and remove the valve locks using a small magnet to prevent the locks from falling into the cylinder head oil return galleries.

Release the spring and remove the valve rotator and valve spring. If the valve stem oil seal is to be replaced, remove the seal and discard it. On the other three valves it may be necessary to repeat these steps for cylinders being worked on. Refer to step 1and the following steps. Last, refer to step 9. NOTE: All valve spring or seal removal and replacement must be completed for each cylinder being serviced while the piston is at top-dead-center, before turning the crankshaft to work on another cylinder.

With the cylinder head assembly removed from the engine, remove the valve springs as follows: 1. Bolt the engine overhaul stand adaptor, J A, to the engine overhaul stand, J , using the hardware provided with the adaptor. Bolt the cylinder head adaptor plate, J A, to the cylinder head using the bolts provided with the adaptor.

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 overhaul stand adaptor. Install the six nut and bolt assemblies that secure the cylinder head adaptor plate to the overhaul stand adaptor.

Remove the cylinder head lifting hardware. Turn the crank of the engine overhaul stand to position the cylinder head in an upright position. Remove the valve locks using valve spring compressor, J , with jaws, J installed, to compress each valve spring. Release the spring and remove the valve, valve rotator and valve spring. Remove the valve stem oil seal and discard the seal. Remove the valve spring seat. As parts are removed, mark or segregate them according to their original position for possible reuse.

Using proper eye protection, clean all of the disassembled parts with fuel oil and dry with compressed air. Clean the carbon from the valve stems and wash the valves with fuel oil.

Clean the valve guide bore to remove all gum and carbon deposits. Perform the following steps for valve guide removal: NOTE: Valve guides are not replaceable on natural gas or heat exchanger-cooled pleasure craft marine engines. Assemble the valve guide remover, J B, to an air chisel. Position the cylinder head, firedeck side up, on a turn over stand or supported on x mm 4 x 4 in. Insert the tool into valve guide from the firedeck side of the cylinder head.

Hold the tool vertical to the cylinder head and drive the valve guide until it is free of the cylinder head. Clean the valve guide bore with bore brush, J or equivalent , to remove all gum and carbon deposits. As the intake and exhaust valve seats are different in size, two different tools are required for removal. Use the cam-operated valve seat remover, J A, with collet, J A, to remove the larger intake valve seat insert.

Use valve seat remover, J , with collet J to remove the smaller exhaust valve seat insert. Remove the intake and exhaust valve seats as follows: 1.

Place the cylinder head in a horizontal position with the valve seats facing up. Using a new valve seat insert as a guide, turn the 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 correct tool operation. 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 as long as no leak paths are evident.

If leak paths exist, reface the valves or install new valves. If the valve heads are warped or the valve stem is bent, replace the valves. If suitable for reuse, a valve may be refaced as long as the valve rim width, after refacing, is not less than 2.

A, for "Intake and Exhaust Valve" specifications which are listed in Table and listed in Table Inspect the valve springs and replace any that are pitted or cracked. The entire spring should be inspected. When a broken spring is replaced, the rotator and valve locks for that valve and spring should also be replaced. Use valve spring tester, J , to test the springs.

If the spring load is less than N 63 lb at a compressed length of 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 valve stem clearance. If the clearance is greater than 0.

Inspect valve seat inserts for wear, cracking or incorrect seat angle, which should be 31 degrees, standard valve seat insert thickness. Clean the seat insert counterbores and the new seat inserts with a suitable solvent and blow dry with compressed air.

Use valve seat insert installers, J intake and J exhaust , to install new inserts. Check the concentricity of valve seat with the valve guide using dial indicator, J , and pilot, J A. If the concentricity is not within 0. 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 A is recommended, because the grinding wheel contacts the insert at only one point at any time, and a micrometer feed permits controlled fine adjustment. Seats must be ground to a 31 degree angle. It should be checked with a sled gage, J or equivalent.

If the diesel intake exhaust valve head recess depth is not between 1. If the gas intake valve head recess depth is between 0. If the gas exhaust valve head recess depth is not between 0.

After light clean-up, thoroughly clean the valve seat with fuel oil and blow 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 "bounce" the valve head on the seat insert without rotating the valve. A full contact line should appear approximately centered on the valve face. Perform the following steps for valve guide installation: NOTE: Valve guides are not replaceable on natural gas or heat exchanger-cooled pleasure craft marine engines.

Start the chamfered end of the valve guide into the cylinder head from the top. Insert the driver into an air chisel. Insert the driver into the valve guide limiting sleeve J A and install this assembly over the valve guide. Drive the guide into the cylinder head until the driver bottoms in the limiting sleeve. Properly used, the installer ensures the correct protrusion of the valve guide from the cylinder head of Perform the following steps for valve installation: 1.

Position the cylinder head vertically on the overhaul stand. Lubricate the valve stems with clean engine lubricating oil and slide them into their respective valve guides and against the valve seats. If reusing valves, install them to their original positions. Install the valve spring seat over the valve guide. Install the valve stem oil seals using valve stem oil seal installation tools.

Check the length of the plastic seal protector cap relative to the lock groove on the valve stem. If the seal protector cap extends more than 1. The valve stem oil seal may be installed with or without oil.

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

Push the seal down on the valve stem using the seal installer, J , while holding the valve head against the seal. When the installer tool contacts the cylinder head, the seal is correctly positioned. Be sure the installer is square against the cylinder head. Remove the seal installer and protector cap. Install the valve spring and rotator. If reusing parts, install them to their original positions.

Using the valve spring compressor tool, J , compress the valve spring only as much as required to install the valve locks. After installing the valve locks, rap the 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 locks, to avoid damaging the oil seal. After all of the valves are installed, check the spring opening pressure on each valve using spring load gage. Note the gage reading when the valve just starts to unseat.

The force required to unseat the valve must not be less than N 63 lb. Remove the cylinder head from the overhaul stand and install it on the engine. Install the camshaft and rocker arm assemblies.

Lightly lubricate the overhead assemblies with clean engine oil. If the engine is equipped with a Jake Brake, install the brake. Adjust the valve clearance and injector timing.

If the engine is equipped with a Jake Brake, lash the brake. Install any other components that were removed. Fill the engine crankcase refer to section Refer to section 5. Close any drain cocks that were opened and fill the cooling system.

Purge the air from the system using the vent in the thermostat housing. Complete filling of the cooling system is essential for proper engine operation. A total of three engine lifter brackets are installed on each Series 60 engine and are utilized when removing and replacing the engine. To avoid injury from a falling engine, do not use the engine lifter brackets alone when lifting the engine with a marine gear, main alternator, engine skid, engine module, radiator, or similar component attached.

The engine lifter brackets are designed to lift the engine only. A spreader bar should be used with a sling and adequate chain hoist when lifting any engine. The lifting device should be adjusted so the lifting hooks are vertical to prevent bending the engine lift brackets. To ensure 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 damage. A lifter bracket should always be reinstalled whenever removal is necessary.

On some older installations, the front engine lifter bracket may be integral with the fan support bracket. Perform the following steps for lifter bracket removal: 1. Remove the bolts securing the lifter bracket to the engine.

On applications with the integral fan support and engine lifter bracket, remove the fan. To avoid injury from a falling engine, do not use a damaged lifter bracket when lifting the engine. Inspect the lifter brackets for cracks, bending or other damage.

Replace the bracket if any of these conditions exist. Perform the following steps for lifter bracket installation: 1. Install the bracket to the engine. Torque the mounting bolts to Nm lbft. Install the fan support, heat exchanger support, or charge air cooler support bracket, refer to section 1.

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 overhead camshaft.