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

Description

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

DESCRIPTION:

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

SCOPE AND USE OF THIS MANUAL :

• This manual contains complete instructions on operation, adjustment (tune-up), preventive
  maintenance, and repair (including complete overhaul) for the Series 60 Inline Diesel Engines.
• This manual was written primarily for persons servicing and overhauling the engine. In addition,
  this manual contains all of the instructions essential to the operators and users. Basic maintenance
  and overhaul procedures are common to all Series 60 Engines, and apply to all engine models.
• This manual is divided into numbered sections. Section one covers the engine (less major
  assemblies). The following sections cover a complete system such as the fuel system, lubrication
  system, or air system. Each section is divided into subsections which contain complete
  maintenance and operating instructions for a specific engine subassembly. Each section begins
  with a table of contents. Pages and illustrations are numbered consecutively within each section.
• Information can be located by using the table of contents at the front of the manual or the table of
  contents at the beginning of each section. Information on specific subassemblies or accessories
  within the major section is listed immediately following the section title.

TABLE OF CONTENTS:

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

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
All information subject to change without notice. (Rev. 2004)
6SE483 0401 Copyright © 2004 DETROIT DIESEL CORPORATION v
SERIES 60 SERVICE MANUAL
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
3.11 OIL PAN ……………………………………………………………………………………… 3-79
3.12 VENTILATING SYSTEM ……………………………………………………………….. 3-87
3.A ADDITIONAL INFORMATION ………………………………………………………… 3-95
4 COOLING SYSTEM
4.1 COOLING SYSTEM OVERVIEW ……………………………………………………. 4-3
4.2 WATER PUMP (GEAR CASE MOUNTED – 1991 AND LATER) (GCM) .. 4-11
4.3 WATER PUMP (FRONT MOUNTED) (FM) ………………………………………. 4-43
4.4 CHARGE AIR COOLER RAW WATER PUMP (KEEL-COOLED
COMMERCIAL MARINE) ………………………………………………………………. 4-72
4.5 THERMOSTAT ……………………………………………………………………………. 4-80
4.6 COOLANT PRESSURE CONTROL CAP ………………………………………… 4-92
4.7 ENGINE COOLING FAN ……………………………………………………………….. 4-96
4.8 COOLANT FILTER AND CONDITIONER ………………………………………… 4-106
4.9 RADIATOR ………………………………………………………………………………….. 4-108
4.10 KEEL COOLING SYSTEM (COMMERCIAL MARINE) ………………………. 4-109
4.11 HEAT EXCHANGER COOLING SYSTEM (PLEASURE CRAFT
MARINE) …………………………………………………………………………………….. 4-110
4.12 HEAT EXCHANGER (PLEASURE CRAFT MARINE) ………………………… 4-112
4.13 JABSCO® ENGINE COOLING RAW WATER PUMP (MARINE) …………. 4-128
4.A ADDITIONAL INFORMATION ………………………………………………………… 4-143
5 FUEL, LUBRICATING OIL, AND COOLANT
5.1 FUEL ………………………………………………………………………………………….. 5-3
5.2 LUBRICATING OIL (DIESEL) ………………………………………………………… 5-12
5.3 LUBRICATING OIL FOR THE SERIES 60G ENGINE ……………………….. 5-19
5.4 COOLANT …………………………………………………………………………………… 5-22
6 AIR INTAKE SYSTEM
6.1 AIR INTAKE SYSTEM OVERVIEW …………………………………………………. 6-3
6.2 AIR CLEANER …………………………………………………………………………….. 6-9
6.3 AIR SEPARATOR …………………………………………………………………………. 6-11
6.4 INTAKE MANIFOLD ……………………………………………………………………… 6-13
6.5 CLOSED CRANKCASE BREATHER FOR SERIES 60G AUTOMOTIVE
ENGINES ……………………………………………………………………………………. 6-24
6.6 TURBOCHARGER (DIESEL) ………………………………………………………… 6-26
6.7 TURBOCHARGER SERIES 60 GAS ENGINES (GENSET) ………………. 6-82
6.8 TURBOCHARGER SERIES 60 NATURAL GAS (AUTOMOTIVE)
ENGINE ……………………………………………………………………………………… 6-97
6.9 RECIRCULATION VALVE FOR SERIES 60G AUTOMOTIVE ENGINE … 6-116
6.10 CHARGE AIR COOLER ………………………………………………………………… 6-118
6.11 THROTTLE ACTUATOR FOR THE SERIES 60G ENGINE ………………… 6-128
6.12 AIR DRYER …………………………………………………………………………………. 6-133
6.A ADDITIONAL INFORMATION ………………………………………………………… 6-135
7 EXHAUST SYSTEM
7.1 OVERVIEW OF EXHAUST SYSTEM ………………………………………………. 7-3
7.2 EXHAUST MANIFOLD ………………………………………………………………….. 7-6
8 ELECTRICAL EQUIPMENT
8.1 OVERVIEW OF ELECTRICAL SYSTEM …………………………………………. 8-3
8.2 BATTERY CHARGING ALTERNATOR …………………………………………….. 8-4
8.3 STORAGE BATTERY ……………………………………………………………………. 8-26
8.4 CRANKING MOTOR …………………………………………………………………….. 8-29
8.5 TACHOMETER DRIVE ………………………………………………………………….. 8-35
8.6 DDEC III/IV ENGINE SENSOR HARNESS ……………………………………… 8-41
8.7 DDEC II ENGINE SENSOR HARNESS …………………………………………… 8-51
8.8 METRI-PACK 150 SERIES CONNECTORS …………………………………….. 8-57
8.9 MICRO-PACK SERIES CONNECTORS ………………………………………….. 8-63
8.10 WEATHER PACK AND METRI-PACK 280 SERIES CONNECTORS ……. 8-65
8.11 CONNECTOR TOOLS ………………………………………………………………….. 8-69
8.12 SPLICING GUIDELINES ………………………………………………………………. 8-70
8.A ADDITIONAL INFORMATION ………………………………………………………… 8-75
9 POWER TAKE-OFF
9.1 FRONT MOUNTED POWER TAKE-OFF …………………………………………. 9-3
9.2 REAR ENGINE POWER TAKE-OFF (REPTO) ASSEMBLY ……………….. 9-8
10 SPECIAL EQUIPMENT
10.1 AIR COMPRESSOR (VEHICLE APPLICATIONS ONLY) …………………… 10-3
10.2 AIR COMPRESSOR DRIVE HUB …………………………………………………… 10-19
10.3 AIR COMPRESSOR/RAW WATER PUMP DRIVE ASSEMBLY ………….. 10-24
10.4 KIM HOT START STARTING AID SYSTEM (MARINE) ……………………… 10-50
10.A ADDITIONAL INFORMATION ………………………………………………………… 10-51
11 OPERATION AND VERIFICATION
11.1 PREPARATION FOR A FIRST TIME START ……………………………………. 11-3
11.2 STARTING …………………………………………………………………………………… 11-7
11.3 RUNNING ……………………………………………………………………………………. 11-8
11.4 STOPPING ………………………………………………………………………………….. 11-11
11.5 OPERATING CONDITIONS …………………………………………………………… 11-12
11.6 SERIES 60G GENSET ENGINE OPERATING CONDITIONS ……………. 11-16
11.7 SERIES 60G AUTOMOTIVE ENGINE OPERATING CONDITIONS …….. 11-18
11.8 ENGINE RUN-IN INSTRUCTIONS …………………………………………………. 11-20
12 ENGINE TUNE-UP
12.1 ENGINE TUNE-UP PROCEDURES ……………………………………………….. 12-3
12.2 VALVE LASH, INJECTOR HEIGHT (TIMING) AND JAKE BRAKE® LASH
ADJUSTMENTS …………………………………………………………………………… 12-5
12.3 ENGINE TUNE-UP PROCEDURES FOR THE SERIES 60G ENGINE … 12-25
12.4 VALVE LASH FOR THE SERIES 60G ENGINE ……………………………….. 12-27
13 PREVENTIVE MAINTENANCE
13.1 MAINTENANCE OVERVIEW ………………………………………………………… 13-3
13.2 DAILY MAINTENANCE – ALL APPLICATIONS …………………………………. 13-4
13.3 DAILY MAINTENANCE – MARINE APPLICATIONS ………………………….. 13-5
13.4 MAINTENANCE OF MARINE ENGINES ………………………………………… 13-6
13.5 MAINTENANCE OF VEHICLE ENGINES ……………………………………….. 13-11
SERIES 60 SERVICE MANUAL
13.6 MAINTENANCE OF ENGINES USED IN STATIONARY AND
INDUSTRIAL APPLICATIONS ……………………………………………………….. 13-16
13.7 MAINTENANCE OF SERIES 60 DIESEL ENGINES FOR GENERATOR
SET ……………………………………………………………………………………………. 13-22
13.8 MAINTENANCE OF SERIES 60G ENGINES FOR GENERATOR SET .. 13-25
13.9 LUBRICATING OIL AND FILTER CHANGE INTERVALS FOR GENSET 13-27
13.10 PREVENTIVE MAINTENANCE FOR THE SERIES 60G AUTOMOTIVE
ENGINE (CITY TRANSIT COACH) ………………………………………………… 13-28
13.11 MAINTENANCE OF SERIES 60G AUTOMOTIVE ENGINES ……………… 13-31
13.12 LUBRICATING OIL AND FILTER CHANGE INTERVALS FOR GENSET
(WITH HIGH SULFUR FUELS) ………………………………………………………. 13-37
13.13 DESCRIPTION OF MAINTENANCE ITEMS ……………………………………. 13-38
13.14 AIR SEPARATOR FILTER ELEMENT (MARINE) ………………………………. 13-75
13.15 DETECTING INTERNAL FUEL LEAKS …………………………………………… 13-79
13.16 CLEANING CONTAMINATED LUBRICATION OIL SYSTEM ………………. 13-87
14 STORAGE
14.1 PREPARING ENGINE FOR STORAGE …………………………………………… 14-3
14.2 RESTORING AN EXTENDED STORAGE ENGINE ………………………….. 14-10
14.3 WINTER STORAGE FOR MARINE ENGINE ………………………………….. 14-14
15 IGNITION SYSTEM
15.1 OVERVIEW OF IGNITION SYSTEM ………………………………………………. 15-3
15.2 COIL OVER PLUG IGNITION SYSTEM ………………………………………….. 15-4
15.3 IGNITION BOOT ASSEMBLY ………………………………………………………… 15-9
15.4 IGNITER MODULE ……………………………………………………………………… 15-10
15.5 IGNITER MODULE BRACKET ………………………………………………………. 15-11
15.6 IGNITION COIL HARNESS …………………………………………………………… 15-12
15.7 SPARK PLUGS …………………………………………………………………………… 15-16
16 MISFIRING CYLINDER
16.1 POOR VEHICLE GROUND …………………………………………………………… 16-3
16.2 AERATED FUEL …………………………………………………………………………. 16-5
16.3 IMPROPER INJECTOR CALIBRATION SETTING (DDEC III/IV
ENGINES ONLY) ………………………………………………………………………….. 16-7
16.4 IMPROPER VALVE CLEARANCE OR INJECTOR HEIGHT, WORN OR
DAMAGED CAMSHAFT LOBES AND ROLLERS ……………………………. 16-12
16.5 FAULTY FUEL INJECTOR …………………………………………………………….. 16-24
16.6 FAULTY ELECTRONIC CONTROL MODULE ………………………………….. 16-26
16.7 WORN OR DAMAGED VALVE OR CYLINDER KIT ………………………….. 16-28
17 STARTING DIFFICULTY (ENGINE ROTATES)
17.1 ELECTRONIC CONTROL MODULE WIRING HARNESS …………………. 17-3
17.2 EMPTY FUEL TANK …………………………………………………………………….. 17-6
17.3 LOW BATTERY VOLTAGE …………………………………………………………….. 17-7
17.4 CORRODED OR DAMAGED BATTERY TERMINALS ………………………. 17-9
17.5 DEFECTIVE MAGNETIC SWITCH …………………………………………………. 17-10
17.6 DEFECTIVE STARTER …………………………………………………………………. 17-13
17.7 LOW CRANKING SPEED ……………………………………………………………… 17-15
17.8 FUEL SUPPLY VALVE ………………………………………………………………….. 17-17
17.9 PLUGGED FUEL FILTER(S) ………………………………………………………….. 17-19
17.10 FUEL PUMP ……………………………………………………………………………….. 17-21
17.11 AERATED FUEL …………………………………………………………………………. 17-23
17.12 RESTRICTIVE AIR FILTER …………………………………………………………… 17-25
17.13 LOW COMPRESSION …………………………………………………………………. 17-27
18 NO START (ENGINE WILL NOT ROTATE)
18.1 DISCHARGED BATTERY ……………………………………………………………… 18-3
18.2 DEFECTIVE MAGNETIC SWITCH …………………………………………………. 18-5
18.3 DEFECTIVE STARTER …………………………………………………………………. 18-8
18.4 INTERNAL ENGINE DAMAGE ………………………………………………………. 18-10
19 EXCESSIVE OIL CONSUMPTION
19.1 MISCALIBRATED DIPSTICK …………………………………………………………. 19-3
19.2 EXTERNAL OIL LEAKS ………………………………………………………………… 19-4
19.3 LEAKING OIL COOLER CORE ……………………………………………………… 19-6
19.4 DEFECTIVE AIR COMPRESSOR ………………………………………………….. 19-8
19.5 DEFECTIVE TURBOCHARGER ……………………………………………………. 19-10
19.6 WORN OR DAMAGED VALVE OR CYLINDER KIT ………………………….. 19-11
20 EXCESSIVE CRANKCASE PRESSURE
20.1 OBSTRUCTION OR DAMAGE TO ROCKER COVER BREATHER ……… 20-3
20.2 DEFECTIVE AIR COMPRESSOR ………………………………………………….. 20-5
20.3 DEFECTIVE TURBOCHARGER ……………………………………………………. 20-7
20.4 WORN OR DAMAGED VALVE OR CYLINDER KIT ………………………….. 20-8
21 EXCESSIVE EXHAUST SMOKE (BLACK OR GRAY)
21.1 IMPROPER GRADE OF FUEL OIL ………………………………………………… 21-3
21.2 RESTRICTED AIR CLEANER ELEMENT ……………………………………….. 21-5
21.3 RESTRICTED OR CRACKED CHARGE AIR COOLER …………………….. 21-7
21.4 FAULTY EXHAUST SYSTEM …………………………………………………………. 21-9
21.5 FAULTY FUEL INJECTOR …………………………………………………………….. 21-11
21.6 DEFECTIVE TURBOCHARGER ……………………………………………………. 21-13
22 EXCESSIVE BLUE SMOKE
22.1 DEFECTIVE TURBOCHARGER ……………………………………………………. 22-3
22.2 WORN OR DAMAGED VALVE OR CYLINDER KIT ………………………….. 22-6
23 EXCESSIVE WHITE SMOKE
23.1 IMPROPER GRADE OF FUEL ………………………………………………………. 23-3
23.2 DEFECTIVE FUEL PUMP …………………………………………………………….. 23-5
23.3 AERATED FUEL …………………………………………………………………………. 23-7
23.4 IMPROPER INJECTOR CALIBRATION SETTING (DDEC III/IV
ENGINES ONLY) ………………………………………………………………………….. 23-9
23.5 IMPROPER VALVE CLEARANCE OR INJECTOR HEIGHT, WORN OR
DAMAGED CAMSHAFT LOBES AND ROLLERS ……………………………. 23-11
23.6 FAULTY FUEL INJECTOR …………………………………………………………….. 23-13
23.7 FAULTY ELECTRONIC CONTROL MODULE ………………………………….. 23-14
24 ROUGH RUNNING OR STALLING
24.1 LOW BATTERY VOLTAGE …………………………………………………………….. 24-3
24.2 AERATED FUEL OIL …………………………………………………………………….. 24-5
24.3 INSUFFICIENT FUEL OIL FLOW …………………………………………………… 24-6
24.4 HIGH FUEL OIL TEMPERATURE RETURN ……………………………………. 24-8
24.5 IMPROPER INJECTOR CALIBRATION SETTING (DDEC III/IV
ENGINES ONLY) ………………………………………………………………………….. 24-11
24.6 LOW COMPRESSION PRESSURE ……………………………………………….. 24-13
25 LACK OF POWER
25.1 AERATED FUEL …………………………………………………………………………. 25-3
25.2 HIGH FUEL PRESSURE ………………………………………………………………. 25-5
25.3 HIGH FUEL OIL TEMPERATURE RETURN ……………………………………. 25-9
25.4 RESTRICTED AIR CLEANER ELEMENT ……………………………………….. 25-11
25.5 RESTRICTED OR CRACKED CHARGE AIR COOLER OR LEAKING
INTAKE MANIFOLD ……………………………………………………………………… 25-13
25.6 FAULTY EXHAUST SYSTEM …………………………………………………………. 25-15
25.7 HIGH INLET AIR TEMPERATURE …………………………………………………. 25-17
25.8 HIGH ALTITUDE OPERATION ………………………………………………………. 25-19
25.9 INCORRECT CAMSHAFT TIMING ………………………………………………… 25-21
26 LOW OIL PRESSURE
26.1 IMPROPER ENGINE OIL LEVEL …………………………………………………… 26-3
26.2 IMPROPER LUBRICATING OIL VISCOSITY …………………………………… 26-5
26.3 LUBRICATING OIL DILUTED WITH FUEL OIL OR ENGINE COOLANT 26-7
26.4 FAULTY OIL PRESSURE GAUGE SENSOR ……………………………………. 26-9
26.5 OIL PRESSURE GAUGE LINE OBSTRUCTED ……………………………….. 26-11
26.6 ROCKER ARM SHAFT PLUGS MISSING (NEW OR REBUILT ENGINES
ONLY) …………………………………………………………………………………………. 26-13
26.7 RESTRICTED OIL COOLER …………………………………………………………. 26-15
26.8 NONFUNCTIONAL OR STICKING OIL PRESSURE REGULATOR
VALVE ………………………………………………………………………………………… 26-17
26.9 DEFECTIVE BYPASS VALVE ………………………………………………………… 26-19
26.10 DEFECTIVE PRESSURE RELIEF VALVE ……………………………………….. 26-20
26.11 DEFECTIVE PICKUP SCREEN TUBE AND SCREEN ASSEMBLY …….. 26-22
26.12 DEFECTIVE CRANKSHAFT MAIN BEARING SHELLS …………………….. 26-24
26.13 DEFECTIVE OIL PUMP ASSEMBLY ………………………………………………. 26-26
27 HIGH ENGINE COOLANT TEMPERATURE
27.1 IMPROPER ENGINE COOLANT LEVEL …………………………………………. 27-3
27.2 INSUFFICIENT RADIATOR AIR CIRCULATION ………………………………. 27-5
27.3 FAULTY PRESSURE CONTROL CAP …………………………………………….. 27-7
27.4 DEFECTIVE COOLANT HOSES ……………………………………………………. 27-9
27.5 FAN BELTS ARE INCORRECTLY ADJUSTED …………………………………. 27-11
27.6 INOPERATIVE THERMO-MODULATED FAN …………………………………… 27-13
27.7 FAULTY THERMOSTATS ……………………………………………………………… 27-15
27.8 FAULTY WATER PUMP …………………………………………………………………. 27-17
27.9 COMBUSTION GASES IN COOLANT ……………………………………………. 27-19
(Rev. 2004) All information subject to change without notice.
xii 6SE483 0401 Copyright © 2004 DETROIT DIESEL CORPORATION
SERIES 60 SERVICE MANUAL
27.10 ABNORMAL RADIATOR COOLANT FLOW …………………………………….. 27-21
28 LOW COOLANT TEMPERATURE
28.1 FAULTY THERMOSTATS ……………………………………………………………… 28-3
28.2 INSUFFICIENT RADIATOR AIR CIRCULATION ………………………………. 28-5
29 POOR FUEL ECONOMY
29.1 PROBABLE CAUSE #1 …………………………………………………………………. 29-3
INDEX ……………………………………………………………………………………. Index-1
All

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