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Series 60 Service Manual - 6SE483 |
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General Information |
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1 Engine |
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1.1 Cylinder Block and Cylinder Liner |
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1.2 Cylinder Head |
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1.3 Valve and Injector Operating Mechanism |
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1.4 Valves, Springs, Guides, Inserts, Seals and Rotators |
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1.5 Engine Lifter Brackets |
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1.6 Rocker Cover |
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1.7 Crankshaft |
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1.8 Crankshaft Oil Seals |
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1.9 Crankshaft Main Bearings |
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1.10 Gear Case Cover Pre-Exhaust Gas Recirculation (EGR) |
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1.11 Gear Case Cover Exhaust Gas Recirculation (EGR) Model |
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1.12 Gear Case Pre-Exhaust Gas Recirculation (EGR) |
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1.13 Gear Case Exhaust Gas Recirculation (EGR) Model |
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1.14 Crankshaft Vibration Damper |
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1.15 Crankshaft Pulley |
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1.16 Flywheel |
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1.17 Ring Gear |
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1.18 Flywheel Housing |
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1.19 Piston and Piston Ring |
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1.20 One-Piece Piston Assembly and Piston Ring |
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1.21 Piston and Connecting Rod Assembly |
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1.22 Connecting Rod |
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1.23 Cylinder Liner |
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1.24 Gear Train and Engine Timing |
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1.25 Compact Gear Train and Engine Timing |
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1.26 Camshaft Gear Assembly Series 60 Exhaust Gas Recirculation (EGR) Model |
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1.27 Thrust Plate Perimeter Seal |
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1.28 Camshaft and Camshaft Bearing |
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1.29 Camshaft Drive Gear |
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1.30 Adjustable Idler Gear Assembly |
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1.31 Adjustable Idler Gear Compact Gear Train |
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1.32 Bull Gear and Camshaft Idler Gear for the Compact Gear Train |
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1.33 Bull Gear and Camshaft Idler Gear Assembly |
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1.34 Crankshaft Timing Gear and Timing Wheel |
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1.35 Accessory Drive |
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1.36 Jake Brake |
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Additional Information |
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2 Fuel System |
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2.1 Diesel Fuel System Overview |
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2.2 Vehicle Safety for the Natural Gas Engine |
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2.3 N2 Electronic Unit Injector |
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2.4 N2 Fuel Injector Tube and O-Ring |
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2.5 N3 Electronic Unit Injector |
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2.6 N3 Fuel Injector Tube |
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2.7 Fuel Pump With Separate Drive Shaft and Hub |
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2.8 Fuel Pump With One-Piece Drive Shaft and Hub Assembly |
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2.9 Fuel Pump Drive |
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2.10 Diesel Fuel Filters (Spin-On) |
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2.11 Fuel Pro 380/380E Fuel Filter System |
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2.12 Fuel Filter Type for the Series 60G Engine |
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2.13 Assembly Fuel Filter and Water Separator |
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2.14 Electronic Engine Control |
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2.15 DDEC V Electronic Control Unit |
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2.16 DDEC III/IV Electronic Control Module |
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2.17 DDEC II Electronic Control Module |
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2.18 DDEC I |
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2.19 Programmable Read-Only Memory (PROM) DDEC I |
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2.20 Electronic Distributor Unit DDEC I |
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2.21 Electronic Foot Pedal Assembly |
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2.22 Turbo Speed Sensor (TSS) |
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2.23 Turbo Boost Pressure Sensor |
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2.24 Air Intake Pressure Sensor |
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2.25 Oil Pressure Sensor |
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2.26 Oil Temperature Sensor |
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2.27 Air Temperature Sensor |
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2.28 Air Temperature Sensor for High Pressure Fuel System |
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2.29 Coolant Temperature Sensor |
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2.30 Synchronous Reference Sensor Gear Case Mounted |
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2.31 Synchronous Reference Sensor Camshaft Position Sensor Camshaft Gear Cover Mounted |
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2.32 Timing Reference Sensor |
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2.33 Coolant Level Sensor |
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2.34 Fuel Pressure Sensor |
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2.35 Fuel Temperature Sensor |
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2.36 Exhaust Gas Oxygen Sensor for Series 60G Engines |
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2.37 Exhaust Temperature Sensor for the Series 60G Engines |
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2.38 Knock Sensor and Signal Noise Enhancement Filter Module |
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2.39 Barometric Pressure Sensor for the Series 60G Engine With High Pressure Fuel System |
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2.40 Overview of High Pressure Fuel System for Series 60G Engines |
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2.41 Fuel Pressure Gages for the Series 60G Engine With a High Pressure Fuel System |
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2.42 Venting and Leak Checking Procedures for a Natural Gas Engine (High Pressure System) |
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2.43 High Pressure Fuel Regulator for the Series 60G Engine |
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2.44 Pulse Width Modulated Stepper Motor Valve (Psv) for Series 60G Automotive Engines |
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2.45 Fuel Mixer for the Series 60G High Pressure Fuel System |
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2.46 Fuel Shutoff Valve for Series 60G Engine With High Pressure Fuel System |
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2.47 Impco Low Pressure Fuel Regulator for the Series 60G Engine High Pressure Fuel System |
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2.48 Overview of the Low Pressure Natural Gas Fuel System |
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2.49 Low Pressure Fuel Regulator for the Series 60G Engine |
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2.50 Fuel Mixer for the Series 60G Low Pressure System |
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2.51 Venting and Leak Checking Procedures for Natural Gas Engine (Low Pressure System) |
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Additional Information |
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3 Lubrication System |
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3.1 Overview of Lubricating System |
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3.2 Oil Pump |
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3.3 Oil Pressure Regulator Valve |
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3.4 Oil Pressure Relief Valve |
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3.5 Oil Filter |
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3.6 Oil Filter Adaptor |
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3.7 Thermatic Oil Control Valve |
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3.8 Oil Cooler (1991 and Later Engines) |
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3.9 Oil Cooler (Pre-1991 Engines) |
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3.10 Oil Level Dipstick Assembly |
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3.11 Oil Pan |
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3.12 Ventilating System |
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Additional Information |
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4 Cooling System |
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4.1 Cooling System Overview |
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4.2 Water Pump (Gear-Case Mounted - 1991 and Later) (GCM) |
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4.3 Water Pump (Front Mounted) (Fm) |
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4.4 Thermostat |
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4.5 Coolant Pressure Control Cap |
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4.6 Engine Cooling Fan |
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4.7 Coolant Filter and Conditioner |
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4.8 Radiator |
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Additional Information |
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5 Fuel, Lubricating Oil, and Coolant |
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5.1 Fuel |
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5.2 Lubricating Oil (Diesel) |
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5.3 Lubricating Oil for the Series 60G Engine |
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5.4 Coolant |
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6 Air Intake System |
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6.1 Air Intake System Overview |
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6.2 Air Cleaner |
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6.3 Intake Manifold |
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6.4 Closed Crankcase Breather for Series 60G Automotive Engines |
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6.5 Turbocharger (Diesel) |
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6.6 Turbocharger Series 60 Natural Gas (Automotive) Engine |
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6.7 Recirculation Valve for Series 60G Automotive Engine |
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6.8 Charge Air Cooler |
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6.9 Throttle Actuator for the Series 60G Engine |
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6.10 Air Dryer |
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Additional Information |
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7 Exhaust System |
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7.1 Overview of Exhaust Manifold Components |
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7.2 Three-Piece Exhaust Manifold With Fey Rings |
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7.3 Three-Piece Exhaust Manifold Without Fey Rings |
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7.4 Three-Piece Exhaust Manifold With Heat Shield |
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8 Exhaust Gas Recirulation (EGR) Components |
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8.1 Tube and Shell Bolted Flange EGR Cooler |
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8.2 Hydraulic EGR Valve |
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8.3 Delivery Pipe |
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8.4 EGR Rate Measurement System |
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8.5 DDEC V Varible Pressure Output Device |
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8.6 DDEC IV Varible Pressure Output Devices |
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9 Electrical Equipment |
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9.1 Overview of Electrical System |
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9.2 Battery Charging Alternator |
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9.3 Storage Battery |
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9.4 Cranking Motor |
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9.5 Tachometer Drive |
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9.6 DDEC III/IV Engine Sensor Harness |
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9.7 DDEC II Engine Sensor Harness |
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9.8 Metri-Pack 150 Series Connectors |
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9.9 Micro-Pack Series Connectors |
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9.10 Weather Pack and Metri-Pack 280 Series Connectors |
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9.11 Connector Tools |
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9.12 Splicing Guidelines |
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Additional Information |
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10 Power Take-Off |
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10.1 Front Mounted Power Take-Off |
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10.2 Rear Engine Power Take-Off (REPTO) Assembly |
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11 Special Equipment |
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11.1 Air Compressor (Vehicle Applications Only) |
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11.2 Air Compressor Drive Hub |
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Additional Information |
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12 Operation and Verification |
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12.1 Preparation for a First Time Start |
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12.2 Starting |
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12.3 Running |
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12.4 Stopping |
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12.5 Operating Conditions |
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12.6 Series 60G Automotive Engine Operating Conditions |
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12.7 Engine Run-in Instructions |
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13 Engine Tune-Up |
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13.1 Engine Tune-Up Procedures |
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13.2 Valve Lash, Injector Height (Timing) and Jake Brake® Lash Adjustments |
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13.3 Engine Tune-Up Procedures for the Series 60G Engine |
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13.4 Valve Lash for the Series 60G Engine |
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14 Preventive Maintenance |
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14.1 Maintenance Overview |
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14.2 Daily Maintenance - All Applications |
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14.3 Maintenance of Vehicle Engines |
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14.4 Preventive Maintenance for the Series 60G Automotive Engine (City Transit Coach) |
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14.5 Maintenance of Series 60G Automotive Engines |
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14.6 Description of Maintenance Items |
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14.7 Cleaning Contaminated Lubrication Oil System |
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15 Storage |
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15.1 Preparing Engine for Storage |
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15.2 Restoring An Extended Storage Engine |
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16 Ignition System |
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16.1 Overview of Ignition System |
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16.2 Coil Over Plug Ignition System |
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16.3 Ignition Coil Assembly |
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16.4 Ignition Boot Assembly |
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16.5 Igniter Module |
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16.6 Igniter Module Bracket |
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16.7 Ignition Coil Harness |
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16.8 Spark Plugs |