Content

General information

• Scope and use of this manual
• Clearance of new parts and wear limits
• The four cycle principle for diesel engines
• Four cycle principle for natural gas engines
• General description

General specifications

• General specifications for the series 60G engine
• Engine model, serial number and option label
• Replacing and repairing
• Disassembly
• Cleaning
• Safety precautions
• Fluoroelastomer (viton) caution
• Engine views
• English to metric conversion
• Decimal and metric equivalents
• Specifications

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 pre-exhaust gas recirculation
• Gear case cover exhaust gas recirculation
• Gear case pre-exhaust gas recirculation
• Gear case exhaust gas recirculation (EGR) model
• Crankshaft vibration damper
• Crankshaft pulley
• Flywheel
• Ring gear
• Flywheel housing
• Piston and piston ring
• One-piece piston assembly and piston ring
• Piston and connecting rod assembly
• Connecting rod
• Cylinder liner
• Gear train and engine timing
• Compact gear train and engine timing
• Camshaft gear assembly series 60 exhaust gas
• Recirculation (EGR) model
• Thrust plate perimeter seal
• Camshaft and camshaft bearing
• Camshaft drive gear
• Adjustable idler gear assembly
• Adjustable idler gear compact gear train
• Bull gear and camshaft idler gear for the compact gear train
• Bull gear and camshaft idler gear assembly
• Crankshaft timing gear and timing wheel
• Accessory drive
• Jake brake
• Additional information

Fuel system

• Diesel fuel system overview
• Vehicle safety for the natural gas engine
• Electronic unit injector
• Fuel injector tube and o-ring
• Electronic unit injector
• Fuel injector tube
• Fuel pump with separate drive shaft and hub
• Fuel pump with one-piece drive shaft and hub assembly
• Fuel pump drive
• Diesel fuel filters (spin-on)
• Fuel pro 380/380e fuel filter system
• Fuel filter type for the series 60G engine
• Assembly fuel filter and water separator
• Electronic engine control
• DDEC V electronic control unit
• DDEC III/IV electronic control module
• DDEC II electronic control module
• DDEC I
• Programmable read-only memory (prom) DDEC I
• Electronic distributor unit DDEC I
• Electronic foot pedal assembly
• Turbo speed sensor
• Turbo boost pressure sensor
• Air intake pressure sensor
• Pressure sensor
• Oil temperature sensor
• Air temperature sensor
• Air temperature sensor for high pressure fuel system
• Coolant temperature sensor
• Synchronous reference sensor gear case mounted
• Synchronous reference sensor camshaft position sensor camshaft gear cover mounted
• Timing reference sensor
• Coolant level sensor
• Fuel pressure sensor
• Fuel temperature sensor
• Exhaust gas oxygen sensor for series 60G engines
• Exhaust temperature sensor for the series 60G engines
• Knock sensor and signal noise enhancement filter module
• Barometric pressure sensor for the series 60G engine with high pressure fuel system
• Overview of high pressure fuel system for series 60G engines
• Fuel pressure gages for the series 60G engine with a high pressure fuel system
• Venting and leak checking procedures for a natural gas engine (high pressure system)
• High pressure fuel regulator for the series 60G engine
• Pulse width modulated stepper motor valve (psv) for series 60G automotive engines
• Fuel mixer for the series 60G high pressure fuel system
• Fuel shutoff valve for series 60G engine with high pressure fuel system
• Impco low pressure fuel regulator for the series 60G engine high pressure fuel system
• Overview of the low pressure natural gas fuel system
• Low pressure fuel regulator for the series 60G engine
• Fuel mixer for the series 60G low pressure system
• Venting and leak checking procedures for natural gas engine (low pressure system)
• Additional information

Lubrication system

• Overview of lubricating system
• Oil pump
• Pressure regulator valve
• Oil pressure relief valve
• Oil filter
• Oil filter adaptor
• Thermatic oil control valve
• Oil cooler (1991 and later engines)
• Oil cooler (pre-1991 engines)
• Oil level dipstick assembly
• Oil pan
• Ventilating system
• Additional information

Cooling system

• Cooling system overview
• Water pump (gear-case mounted - 1991 and later)
• Water pump (front mounted)
• Thermostat
• Coolant pressure control cap
• Engine cooling fan
• Coolant filter and conditioner
• Radiator
• Additional information

Fuel, lubricating oil, and coolant

• Fuel
• Lubricating oil (diesel)
• Lubricating oil for the series 60G engine
• Coolant

Air intake system

• Air intake system overview
• Air cleaner
• Intake manifold
• Closed crankcase breather for series 60G automotive engines
• Turbocharger (diesel)
• Turbocharger series 60 natural gas (automotive) engine
• Recirculation valve for series 60G automotive engine
• Charge air cooler
• Throttle actuator for the series 60G engine
• Air dryer
• Additional information

Exhaust system

• Overview of exhaust manifold components
• Three-piece exhaust manifold with fey rings
• Three-piece exhaust manifold without fey rings
• Three-piece exhaust manifold with heat shield

Exhaust gas recirulation (EGR) components

• Tube and shell bolted flange EGR cooler
• Hydraulic EGR valve
• Delivery pipe
• EGR rate measurement system
• DDEC v varible pressure output device
• DDEC iv varible pressure output devices

Electrical equipment

• Overview of electrical system
• Battery charging alternator
• Storage battery
• Cranking motor
• Tachometer drive
• DDEC III/IV engine sensor harness
• DDEC II engine sensor harness
• Metri-pack 150 series connectors
• Micro-pack series connectors
• Weather pack and metri-pack 280 series connectors
• Connector tools
• Splicing guidelines
• Additional information

Power take-off

• Front mounted power take-off
• Rear engine power take-off (repto) assembly

Special equipment

• Air compressor (vehicle applications only)
• Air compressor drive hub
• Additional information

Operation and verification

• Preparation for a first time start
• Starting
• Running
• Stopping
• Operating conditions
• Series 60G automotive engine operating conditions
• Engine run-in instructions

Engine tune-up

• Engine tune-up procedures
• Valve lash, injector height (timing) and jake brake® lash adjustments
• Engine tune-up procedures for the series 60G engine
• Valve lash for the series 60G engine

Preventive maintenancep

• Maintenance overview
• Daily maintenance - all applications
• Maintenance of vehicle engines
• Preventive maintenance for the series 60G automotive engine (city transit coach)
• Maintenance of series 60G automotive engines
• Description of maintenance items
• Cleaning contaminated lubrication oil system

Storage

• Preparing engine for storage
• Restoring an extended storage engine

Ignition system

• Overview of ignition system
• Coil over plug ignition system
• Ignition coil assembly
• Ignition boot assembly
• Igniter module
• Igniter module bracket
• Ignition coil harness
• Spark plugs