A1 - DDCSN
Contents
1. 2001 DETROIT DIESEL CORPORATION From Bulletin 10 60 01 1 249 1 11 GEAR CASE NOTE Bolts attaching bracket to the gear case are torqued first then the bolt to cylinder head is torqued next g Install the two bolts securing the former right side gear case stiffening bracket to the cylinder head or one bolt securing the current right side bracket Torque the former bracket bolts to 58 73 N m 43 54 lb ft or torque the current gear case bracket bolt to 74 81 N m 53 60 lb ft See Figure 1 201b RIGHT SIDE RIGHT SIDE BRACKET BRACKET FORMER BRACKET CURRENT BRACKET Figure 1 201b Gear Case Stiffening Bracket Right Side 22 Refer to section 1 23 5 Installation of Camshaft Bearing and perform the necessary steps 23 For bull gear to accessory drive gear lash measurement perform step 10 Refer to section 1 21 2 1 24 Continue engine assembly Rev 07 01 All information subject to change without notice 1 249a From Bulletin 10 60 01 6SE483 0010 Copyright 2001 DETROIT DIESEL CORPORATION SERIES 60 SERVICE MANUAL This page intentionally left blank All information subject to change without notice Rev 0 01 6SE483 0010 Copyright 2001 DETROIT DIESEL CORPORATION From Bulletin 10 60 01 1 249b 1 12 CRANKSHAFT VIBRATION DAMPER 1 12 CRANKSHAFT VIBRATION DAMPER A viscous type vibration damper is mounted on the front end of the crankshaft to reduce torsional vibrations to a safe value See2. Drive Assembly Rev 07 01 All information subject to change without notice 1 228 From Bulletin 10 60 01 6SE483 0010 Copyright 2001 DETROIT DIESEL CORPORATION SERIES 60 SERVICE MANUAL 1 Drive Housing 8 2 Washers 9 3 Drive Housing Short Bolt 10 4 Drive Ball Bearing 11 5 Snap Ring 12 6 Spacer 13 7 Drive Hub 14 Drive Hub Flange Nut Drive Housing Long Bolt Drive Shaft Drive Gear Drive Gear Bolt Drive Housing Gasket Gear Case Housing Figure 1 183 Air Compressor or Raw Water Pump Drive Assembly All information subject to change without notice Rev 07 01 6SE483 0010 Copyright 2001 DETROIT DIESEL CORPORATION From Bulletin 10 60 01 1 229 1 11 GEAR CASE k Retaining Bolt Washer Water Pump Drive Gear Snap ring Bearing Race Bearing Spacer Rings 2 Bearing Bearing Race Drive Shaft SO MNDRA RHO DHN e Figure 1 184 Water Pump Assembly 1 230 From Bulletin 10 60 01 Oil Seal Water Pump Housing O ring Drain Cock Water Pump Housing Water Pump Housing Pipe Plug Water Seal Impeller Water Pump Cover O ring Water Pump Cover Water Pump Cover Snap Ring Rev 07 01 All information subject to change without notice 6SE483 0010 Copyright 2001 DETROIT DIESEL CORPORATION SERIES 60 SERVICE MANUAL To eliminate the possibility of oil leakage at the adjustable idler gear stud location Detroit Diesel recommends the following When reb
3. Figure 1 196 DIAMOND Figure 1 196 Cylinder Block Locating Diamond Dowel All information subject to change without notice Rev 07 01 6SE483 0010 Copyright 2001 DETROIT DIESEL CORPORATION From Bulletin 10 60 01 1 243 1 11 GEAR CASE 4 With the gear case alignment plug fully seated the gear case centered on the alignment plug and the diamond dowel in the cylinder block indexed with its mating hole in the gear case the gear case is positioned properly for bolt installation See Figure 1 197 GEAR CASE HOUSING Figure 1 197 Gear Case Positioning NOTE Gasket Eliminator cures with the absence of air The time between the installation of the gear case and torquing of the bolts that secure the gear case to the cylinder block should be kept to a minimum Rev 07 01 All information subject to change without notice 1 244 From Bulletin 10 60 01 6SE483 0010 Copyright 2001 DETROIT DIESEL CORPORATION SERIES 60 SERVICE MANUAL 5 Install the 12 gear case to cylinder block retaining bolts finger tight 6 Torque the gear case to cylinder block bolts to 58 73 N m 43 54 lb ft See Figure 1 198 TORQUE SPECIFICATION 58 73 N m 43 54 lb ft Figure 1 198 Gear Case Housing Bolt Torque Sequence 7 Remove the gear case alignment plug from the gear case Install the air compressor Refer to section 10 1 8 9 Install the air compressor drive assembly Refer to section 10 3 6 10 Install the fuel pump drive as
4. Figure 1 202 VISCOUS CRANKSHAFT MERTON PULLEY SPINDLE WASHER BOLT CRANKSHAFT PULLEY AND HUB ASSEMBLY 40206 Figure 1 202 Viscous Vibration Damper Mounting with Crankshaft Pulley or Crankshaft Pulley and Hub Assembly with Spindle Prior to April 1993 11 1 liter engines with less than 320 hp 238 kW were equipped with a 313 4 mm 12 34 in damper and 11 1 liter engines with 320 hp 238 kW or more were equipped with a 342 9 mm 13 5 in damper and all 12 7 liter engines were equipped with a 342 9 mm 13 5 in damper Beginning in April 1993 all Series 60 engines are built with a 342 9 mm 13 5 in damper Rev 07 01 All information subject to change without notice 1 250 From Bulletin 10 60 01 6SE483 0010 Copyright 2001 DETROIT DIESEL CORPORATION
5. or equivalent to the cylinder block See Figure 1 194 Carefully smooth the bead around the block to gear case oil passage to avoid contamination NOTE The installation of Gasket Eliminator to the gear case to block mating surfaces at the top of the block is critical Excess gasket eliminator material can extrude into the oil passage between the block and gear case causing early failure of components In addition the bull gear recess area MUST be cleaned of any and all foreign material after installation of the gear case to the engine block OIL PASSAGE SQUARE CUT O RING Figure 1 194 Gasket Eliminator Application All information subject to change without notice Rev 07 01 6SE483 0010 Copyright 2001 DETROIT DIESEL CORPORATION From Bulletin 10 60 01 1 241 1 11 GEAR CASE 2 Insert gear case alignment plug J 35651 into the bull gear and camshaft idler gear hub recess in the cylinder block See Figure 1 195 J 35651 Figure 1 195 Gear Case Alignment Plug Rev 07 01 All information subject to change without notice 1 242 From Bulletin 10 60 01 6SE483 0010 Copyright 2001 DETROIT DIESEL CORPORATION SERIES 60 SERVICE MANUAL 3 Using a suitable lifting sling made of cloth or leather position the bull gear and camshaft idler gear opening of the gear case over the gear case alignment plug Index the hole in the gear case mating surface with the diamond dowel at the lower left corner of the cylinder block See
6. Bull Gear and Camshaft Idler Gear Assembly All information subject to change without notice Rev 07 01 6SE483 0010 Copyright 2001 DETROIT DIESEL CORPORATION From Bulletin 10 60 01 1 233 1 11 GEAR CASE An access cover is provided at the rear of the gear case on the cooler right side of the engine This access cover provides an opening for inspection of the accessory drive assembly drive gear See Figure 1 188 NOTE This access cover opening may be cast closed on the rear of the gear case ACCESSORY DRIVE GEAR ACCESS COVER Figure 1 188 Accessory Drive Gear Access Cover Pre 1991 Engines Rev 07 01 All information subject to change without notice 1 234 From Bulletin 10 60 01 6SE483 0010 Copyright 2001 DETROIT DIESEL CORPORATION SERIES 60 SERVICE MANUAL For gear lash measurement and adjustment procedures for the gears in the engine gear train Refer to section 1 21 2 1 An oil gallery is drilled in the gear case casting for lubrication of the adjustable idler gear assembly A hole in the front of the cylinder block indexes with the gear case gallery At the edge of the gear case the gallery is threaded for insertion of a plug An exit hole feeds the adjustable idler gear assembly See Figure 1 189 NOTE Do not use the oil plug location for an oil supply or for checking oil pressure PLUG 15 20 N m 11 15 lb ft COPPER WASHER LUBRICATION GALLERY LUBRICATION OIL HOLE Figure 1 189 Adjust
7. Inspection of Gear Case Clean all of the old gasket sealer from the mating surfaces of the gear case gear case cover and engine block Refer to Gasket Eliminator Removal in the General Information section at the beginning of this manual Clean the gasket material from the mating surfaces of any components or access covers that were removed from the gear case cover or gear case Clean all of the parts with clean fuel oil and dry with compressed air Remove the oil gallery plug at the edge of the gear case See Figure 1 189 To avoid injury from flying debris when using compressed air wear adequate eye protection face shield or safety goggles and do not exceed 40 psi 276 kPa air pressure Use compressed air to ensure the oil gallery is completely free of blockage If necessary use a wire brush to clean the gear case oil gallery Inspect the gear case for stress cracks breaks or other damage Repair or replace as necessary Inspect the adjustable idler gear studs for signs of galling or scoring Replace as necessary Inspect all the individual components as outlined under the appropriate section Rev 07 01 All information subject to change without notice 1 240 From Bulletin 10 60 01 6SE483 0010 Copyright 2001 DETROIT DIESEL CORPORATION SERIES 60 SERVICE MANUAL 1 11 3 Installation of Gear Case Use the following instructions for gear case installation 1 Apply a thin film of gasket eliminator PT 7276 Loctite 518
8. SERIES 60 SERVICE MANUAL 1 Gear Case Cover 5 Bolt 2 Gear Case 6 Acoustical Cover 3 Acoustical Cover Snap 7 Acoustical Cover 4 Acoustical Cover Clip 8 Nut Figure 1 179 Typical Group D Rear Acoustical Cover Installation All information subject to change without notice Rev 07 01 6SE483 0010 Copyright 2001 DETROIT DIESEL CORPORATION From Bulletin 10 60 01 1 225 1 11 GEAR CASE 1 11 GEAR CASE The gear case housing is constructed of cast iron with machined mating surfaces and is bolted to the front of the engine cylinder block The gear case and gear case cover are bolted together to provide a sealed compartment for the engine gear train See Figure 1 180 1 Lifting Bracket 3 Gear Case Housing 2 Gear Case Cover Figure 1 180 Gear Case and Gear Case Cover Several components are mounted to the gear case including the adjustable idler gear assembly see Figure 1 181 the fuel pump drive assembly see Figure 1 182 the air compressor drive assembly or raw water pump drive assembly see Figure 1 183 the water pump assembly 1991 and later engines see Figure 1 184 and the camshaft thrust plate and drive gear assembly see Figure 1 199 Rev 07 01 All information subject to change without notice 1 226 From Bulletin 10 60 01 6SE483 0010 Copyright 2001 DETROIT DIESEL CORPORATION SERIES 60 SERVICE MANUAL In July 2001 new right and left side gear case stiffening brackets were added to provide reduce e
9. able Idler Gear Lubrication Gallery All information subject to change without notice Rev 07 01 6SE483 0010 Copyright 2001 DETROIT DIESEL CORPORATION From Bulletin 10 60 01 1 235 1 11 GEAR CASE 1 11 1 Repair or Replacement of Gear Case To determine if repair is possible or replacement is necessary perform the following procedure See Figure 1 190 REMOVE GEAR CASE COVER REMOVE GEAR CASE INSPECT GEAR CASE CRACKS BREAKS GALLED OR SCORED IDLER OR OTHER GEAR STUDS DAMAGE REPLACE REPLACE IDLER GEAR STUDS l INSTALL Figure 1 190 Flowchart for Repair or Replacement of Gear Case Rev 07 01 All information subject to change without notice 1 236 From Bulletin 10 60 01 6SE483 0010 Copyright 2001 DETROIT DIESEL CORPORATION SERIES 60 SERVICE MANUAL 1 11 2 Removal of Gear Case Perform the following steps to remove the gear case 1 Remove the SRS Refer to section 2 29 2 2 Remove the TRS Refer to section 2 30 2 3 Remove the rocker arm assemblies Refer to section 1 3 2 4 On heat exchanger cooled marine engines remove the water cooled charge air cooler Refer to section 4 4 2 Or remove the heat exchanger tank Refer to section 2 13 1 on Perform all of the steps for camshaft removal Refer to section 1 23 2 Remove the 3 bolts that secure the camshaft gear pilot tool J 35906 to the gear case and remove
10. assembly mounting bolts Torque the bolts to 101 126 N m 75 93 lb ft Tighten in a clockwise sequence Check the timing marks on the gears to ensure the gear train is properly timed See Figure 1 200 Rev 07 01 All information subject to change without notice From Bulletin 10 60 01 6SE483 0010 Copyright 2001 DETROIT DIESEL CORPORATION SERIES 60 SERVICE MANUAL 21 Perform the following a For crankshaft timing gear to oil pump gear lash measurement Perform step 2 refer to section 1 21 2 1 b For crankshaft timing gear to bull gear lash measurement Perform step 3 refer to section 1 21 2 1 c To install the gear case cover Refer to section 1 10 3 d Install the two bolts and nuts securing the left side gear case stiffening bracket to the gear case Torque to 75 81 N m 55 60 lb ft See Figure 1 201a LEFT SIDE BRACKET Figure 1 201a Gear Case Stiffening Bracket Left Side e Install the bolt securing the left side gear case stiffening bracket to the cylinder head Torque to 58 73 N m 43 54 lb ft See Figure 1 201a f Install the bolt securing the right side gear case stiffening bracket to the gear case Torque the former bracket bolt to 58 73 N m 43 54 lb ft or torque the current gear case bracket bolt to 74 81 N m 53 60 lb ft See Figure 1 201b All information subject to change without notice Rev 07 01 6SE483 0010 Copyright
11. ngine noise increase belt driven accessory life reduce gear case vibration amplitude and reduce wear on the cam thrust plate perimeter seal See Figure 1 180A and see Figure 1 180B LEFT SIDE BRACKET Figure 1 180A Gear Case Stiffening Bracket Left Side RIGHT SIDE BRACKET Figure 1 180B Gear Case Stiffening Bracket Right Side All information subject to change without notice Rev 07 01 6SE483 0010 Copyright 2001 DETROIT DIESEL CORPORATION From Bulletin 10 60 01 1 226a 1 11 GEAR CASE This page intentionally left blank Rev 07 01 All information subject to change without notice 1 226b From Bulletin 10 60 01 6SE483 0010 Copyright 2001 DETROIT DIESEL CORPORATION SERIES 60 SERVICE MANUAL 2 3 4 Fi All information subject to change without notice 6SE483 0010 Copyright 2001 DETROIT DIESEL CORPORATION Gear Case Diamond Dowel Adjustable Idler Gear Locknut 3 Adjustable Idler Gear Hub Retainer 5 Adjustable Idler Gear 6 7 8 Adjustable Idler Hub Adjustable Idler Gear Stud 3 Round Dowel gure 1 181 Adjustable Idler Gear Assembly Rev 07 01 From Bulletin 10 60 01 1 227 1 11 GEAR CASE e Fuel Pump Drive Gear 5 Shaft and Bearing Assembly 2 Snap Ring 6 Fuel Pump Drive Hub 3 O ring 7 Fuel Pump Drive Coupling 4 Fuel Pump Drive Housing 8 Fuel Pump Assembly Figure 1 182 Fuel Pump
12. nkshaft seal surface when removing the bull gear and camshaft idler gear assembly See Figure 1 191 J 35994 Figure 1 191 Crankshaft Protector Installation 14 Remove the bull gear and camshaft idler gear assembly from the engine Refer to section 1 26 2 15 Remove the adjustable idler gear assembly from the gear case Refer to section 1 25 2 16 Using a plastic hammer or fiber mallet tap the rear face of the camshaft thrust plate to remove the thrust plate camshaft drive gear hub and camshaft drive gear from the gear case All information subject to change without notice Rev 07 01 6SE483 0010 Copyright 2001 DETROIT DIESEL CORPORATION From Bulletin 10 60 01 1 237b 1 11 GEAR CASE 17 Remove the 12 bolts that secure the gear case to the engine block See Figure 1 192 Figure 1 192 Gear Case Mounting Bolt Locations Rev 07 01 All information subject to change without notice 1 238 From Bulletin 10 60 01 6SE483 0010 Copyright 2001 DETROIT DIESEL CORPORATION SERIES 60 SERVICE MANUAL 18 Using a leather or cloth wrapped strap support the gear case See Figure 1 193 GEAR CASE Figure 1 193 Gear Case Removal 19 Use a rubber hammer or plastic mallet to loosen the gear case from the cylinder block dowels All information subject to change without notice Rev 07 01 6SE483 0010 Copyright 2001 DETROIT DIESEL CORPORATION From Bulletin 10 60 01 1 239 1 11 GEAR CASE 1 11 2 1
13. nspect the bull gear and camshaft idler gear access opening in the gear case and remove any foreign material All information subject to change without notice Rev 07 01 6SE483 0010 Copyright 2001 DETROIT DIESEL CORPORATION From Bulletin 10 60 01 1 247 1 11 15 GEAR CASE Install two bull gear guide studs J 35785 to the cylinder block See Figure 1 201 EAN a Sy Figure 1 201 Bull Gear Guide Stud Installation 16 17 18 19 20 1 248 NOTICE Always install crankshaft protector when installing the bull gear and camshaft idler gear assembly to prevent damaging the crankshaft oil seal contact surface Install the crankshaft protector J 35994 to the oil seal contact area of the crankshaft This will help to protect the crankshaft seal surface when installing the bull gear and camshaft idler gear assembly Install the bull gear and camshaft idler gear assembly to the guide studs Align the timing marks on the bull gear and the crankshaft timing gear and the camshaft idler gear and adjustable idler gear see Figure 1 200 and slide the bull gear and camshaft idler gear assembly forward to seat it in the recess in the gear case and cylinder block Working through the lightening holes in the bull gear install two of the bull gear assembly mounting bolts through the hub and into the cylinder block Finger tighten the bolts Remove the two bull gear guide studs Install the remaining two bull gear
14. sembly to the gear case if so equipped Refer to section 2 6 5 or refer to section 2 6 6 11 Install the fuel pump to the fuel pump drive assembly or air compressor Refer to section 2 7 3 NOTE For 1991 and later model year engines refer to section 4 2 8 or refer to section 4 3 7 and install the water pump assembly All information subject to change without notice Rev 07 01 6SE483 0010 Copyright 2001 DETROIT DIESEL CORPORATION From Bulletin 10 60 01 1 245 1 11 GEAR CASE 12 Lubricate the rubber O ring on the camshaft thrust plate with clean engine oil Install the camshaft thrust plate assembly with the camshaft drive gear and hub in place to the gear case using a plastic hammer or fiber mallet to tap the thrust plate rearward in the gear case just enough to start it in the gear case See Figure 1 199 CAMSHAFT THRUST PLATE ASSEMBLY Figure 1 199 Camshaft Thrust Plate Installation Rev 07 01 All information subject to change without notice 1 246 From Bulletin 10 60 01 6SE483 0010 Copyright 2001 DETROIT DIESEL CORPORATION SERIES 60 SERVICE MANUAL 13 Install the adjustable idler gear assembly to the gear case Refer to section 1 25 3 Align the timing marks of the adjustable idler gear and camshaft drive gear See Figure 1 200 1 Camshaft Idler Gear 4 Bull Gear 2 Adjustable Idler Gear 5 Crankshaft Timing Gear 3 Camshaft Drive Gear Figure 1 200 Engine Gear Train Timing Marks 14 I
15. the tool 7 Remove the three bolts securing the former right side gear case stiffening bracket or two bolts securing the current right side gear case stiffening bracket See Figure 1 190A RIGHT SIDE RIGHT SIDE BRACKET BRACKET FORMER BRACKET CURRENT BRACKET Figure 1 190A Gear Case Stiffening Bracket Right Side All information subject to change without notice Rev 07 01 6SE483 0010 Copyright 2001 DETROIT DIESEL CORPORATION From Bulletin 10 60 01 1 237 1 11 GEAR CASE 8 Remove the three bolts securing the left side gear case stiffing bracket See Figure 1 190B LEFT SIDE BRACKET Figure 1 190B Gear Case Stiffening Bracket Left Side 9 Remove gear case cover Refer to section 1 10 2 for step 1 through step 13 Supporting the gear case cover with a suitable lifting device but don t remove it 10 Remove the fuel pump from the fuel pump drive assembly or air compressor Refer to section 2 6 2 11 Remove the air compressor Refer to section 10 1 5 12 Remove the air compressor drive assembly Refer to section 10 3 2 Rev 07 01 All information subject to change without notice 1 237a From Bulletin 10 60 01 6SE483 0010 Copyright 2001 DETROIT DIESEL CORPORATION SERIES 60 SERVICE MANUAL 13 Install the crankshaft protector J 35994 to the oil seal contact area of the crankshaft This will help to protect the cra
16. uilding a Series 60 engine or if the gear case is removed for any reason the three original adjustable idler gear studs should be removed and replaced with new studs Before pressing studs into the gear case coat the shanks and underside of the stud heads with Loctite No 242 Sealant This will prevent any oil leakage around the studs during engine operation The Timing Reference Sensor TRS is an electronic component that is bolted to the side of the gear case on the intake left side of the engine just above the oil pan See Figure 1 185 TIMING REFERENCE SENSOR Figure 1 185 Timing Reference Sensor TRS All information subject to change without notice Rev 07 01 6SE483 0010 Copyright 2001 DETROIT DIESEL CORPORATION From Bulletin 10 60 01 1 231 1 11 GEAR CASE The Synchronous Reference Sensor SRS is an electronic component that is bolted to the gear case at the lower intake left side of the engine See Figure 1 186 GEAR CASE SYNCHRONOUS REFERENCE SENSOR Figure 1 186 Synchronous Reference Sensor Rev 07 01 All information subject to change without notice 1 232 From Bulletin 10 60 01 6SE483 0010 Copyright 2001 DETROIT DIESEL CORPORATION SERIES 60 SERVICE MANUAL An opening is provided in the center of the gear case for the bull gear and camshaft idler gear assembly which bolts directly to the engine block See Figure 1 187 BULL GEAR AND CAMSHAFT IDLER GEAR ASSEMBLY Figure 1 187
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