1987-2006 Detroit Series 60 Engine Shop Manual

Covers: Detroit Diesel Series 60 Engine – Pre-EGR through EPA04 emissions (1987-2006)

• 11.1L, 12.7L and 14L
• Diesel and Natural Gas fueled

Pages: 1,685
Format: PDF
File size: 20mb
Compatibility: Windows/Mac/Tablet
Notes: Instant digital download only – no printed copy or CD-ROM media.

This downloadable shop manual contains accurate repair specifications and procedures for Detroit Diesel series 60 engines, 2006 and older (with DDEC I, II, III, IV, V ECMs). With over 1,600 pages of detailed information with illustrations, the workshop manual is recommended for diesel engine mechanics repairing or overhauling the engine to factory standards. View the PDF on your tablet or computer and print off pages at any time to save time and money on repairs. This manual has clickable links in the table of contents and in-text to quickly navigate topics.

Publication dated 2010. DDEC troubleshooting & wiring diagram sold separately.

Topics:

General Information

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 (EGR or Non-EGR)
• Gear Case (EGR or Non-EGR)
• Crankshaft Vibration Damper
• Crankshaft Pulley
• Flywheel
• Ring Gear
• Flywheel Housing
• Piston Assembly and Piston Ring
• Piston and Connecting Rod Assembly
• Connecting Rod
• Cylinder Liner
• Compact Gear Train and Engine Timing
• Camshaft Gear Assembly and Camshaft Bearing
• Adjustable Idler Gear Compact Gear Train
• Bull Gear and Camshaft Idler Gear for the Compact Gear Train
• Crankshaft Timing Gear and Timing Wheel
• Accessory Drive
• Jake Brake

Fuel System

• Diesel Fuel System Overview
• N2/N3 Injector
• N2/N3 Fuel Injector Tube
• Fuel Pump
• Diesel Fuel Filters (Spin-On)
• Fuel Pro 380/380E Fuel Filter System
• Assembly Fuel Filter and Water Separator
• Electronic Engine Control
• DDEC I through V Control Unit
• PROM – DDEC I
• Electronic Distributor Unit – DDEC I
• Electronic Foot Pedal Assy
• Sensors
• Checks

Ignition System

• Overview of Ignition System
• Coil Over Plug System
• Ignition Coil and Boot Assemblies
• Igniter Module
• Spark Plugs

Lubrication System

• Overview of Lubricating System
• Oil Pump
• Oil Pressure Regulator Valve
• Oil Pressure Relief Valve
• Oil Filter
• Oil Filter Adaptor
• Oil Cooler
• Oil Level Dipstick Assembly
• Oil Pan
• Ventilating System

Cooling System

• Cooling System Overview
• Water Pump
• Thermostat
• Coolant Pressure Control Cap
• Engine Cooling Fan
• Coolant Filter and Conditioner
• Radiator

Fuel, Lubricating Oil, and Coolant

• Fuel Type
• Lubricating Oil (Diesel) Type
• Coolant Type

Air Intake System

• Air Intake System Overview
• Air Cleaner
• Intake Manifold
• Crankcase Breather
• Turbocharger
• Recirculation Valve S60G
• Charge Air Cooler
• Throttle Actuator S60G
• Air Dryer

Exhaust System

• Overview of Exhaust Manifold Components
• Three-Piece Exhaust Manifold

EGR Components

• Tube and Shell Bolted Flange
• Hydraulic EGR Valve
• Delivery Pipe
• EGR Rate Measurement System
• DDEC IV-V Variable Pressure Output Devices

Electrical Equipment

• Overview of Electrical System
• Battery Charging Alternator
• Storage Battery
• Cranking Motor
• Tachometer Drive
• Sensor Harness
• Connectors
• Weather Pack Connectors
• Splicing Guidelines

Power Take-Off

• Front Mounted Power Take-Off
• Rear Engine Power Take-Off (REPTO) Assembly

Special Equipment

• Air Compressor

Operation and Verification

• Preparation for a First Time Start
• Starting
• Running
• Stopping
• Engine Run-in Instructions
• Series 60G Operating Conditions

Engine Tune-Up

•  Engine Tune-Up Procedures
•  Valve Lash, Injector Height (Timing) and Jake Brake Lash Adjustments

Preventive Maintenance

• Maintenance Overview
• Daily Maintenance – All Applications
• Maintenance of Vehicle Engines
• Description of Maintenance Items
• Cleaning Contaminated Lubrication Oil System

Storage

• Preparing Engine for Storage
• Restoring An Extended Storage Engine

How does this work?

It’s simple – after purchasing this manual through our secure checkout, a download link will be sent to the email address you specify at checkout. You have up to 90 days to retrieve and save the file. Once saved, the manual is yours for good.

Have any questions or need more details? Contact Us