Detroit Diesel 60 User manual

SECTION 01: ENGINE
01-1
CONTENTS
1. ENGINE.............................................................................................................................................01-3
2. ENGINE-MOUNTED COMPONENTS .............................................................................................. 01-3
2.1 ELECTRONIC CONTROL MODULE ...................................................................................................01-4
2.2 ELECTRONIC UNIT INJECTOR.........................................................................................................01-4
3. SYNCHRONOUS REFERENCE SENSOR ...................................................................................... 01-4
3.1 TIMING REFERENCE SENSOR ........................................................................................................01-5
3.2 TURBO BOOST PRESSURE SENSOR...............................................................................................01-5
3.3 COOLANT TEMPERATURE SENSOR ................................................................................................01-6
3.4 FUEL TEMPERATURE SENSOR.......................................................................................................01-6
3.5 AIR TEMPERATURE SENSOR..........................................................................................................01-6
3.6 OIL PRESSURE SENSOR ...............................................................................................................01-6
3.7 OIL TEMPERATURE SENSOR..........................................................................................................01-6
4. ENGINE-RELATED COMPONENTS ...............................................................................................01-6
4.1 COOLANT LEVEL SYSTEM (CLS)...................................................................................................01-7
4.2 ELECTRONIC FOOT PEDAL ASSEMBLY (EFPA) &THROTTLE POSITION SENSOR ..............................01-7
4.3 CRUISE CONTROL SWITCHES (CCS).............................................................................................01-7
4.4 DIAGNOSTIC SYSTEM ACCESSORIES (DSA)...................................................................................01-8
4.4.1 Check Engine Telltale Light................................................................................................01-8
4.4.2 Stop Engine Warning Light.................................................................................................01-8
4.4.3 Stop Engine Override Switch..............................................................................................01-8
4.4.4 Diagnostic Data Link (DDL) Connectors.............................................................................01-8
5. DDEC IV DIAGNOSTIC CODES ...................................................................................................... 01-8
5.1 READING DIAGNOSTIC CODES,FLASH METHOD:............................................................................01-8
6. ENGINE OIL LEVEL.......................................................................................................................01-11
7. ENGINE OIL AND FILTER CHANGE ............................................................................................01-11
8. RECOMMENDED ENGINE OIL TYPE...........................................................................................01-12
9. WELDING PRECAUTIONS............................................................................................................01-12
10. POWER PLANT ASSEMBLY REMOVAL..................................................................................01-12
11. POWER PLANT ASSY. INSTALLATION...................................................................................01-15
12. VALVE COVER REMOVAL........................................................................................................ 01-16
13. JAKE BRAKE .............................................................................................................................01-16
14. ENGINE MOUNTS ......................................................................................................................01-16
15. SPECIFICATIONS.......................................................................................................................01-17

Section 01: ENGINE
01-2
ILLUSTRATIONS
FIGURE 1: DETROIT DIESEL SERIES 60 ENGINE (TYPICAL)..............................................................01-3
FIGURE 2: ELECTRONIC CONTROL MODULE (ECM)..........................................................................01-4
FIGURE 3: UNIT INJECTOR CROSS SECTION .....................................................................................01-4
FIGURE 4: SRS LOCATION.....................................................................................................................01-5
FIGURE 5: BULL GEAR ...........................................................................................................................01-5
FIGURE 6: TIMING GEAR........................................................................................................................01-5
FIGURE 7: TURBO BOOST PRESSURE SENSOR ................................................................................01-6
FIGURE 8: FUEL TEMPERATURE SENSOR..........................................................................................01-6
FIGURE 9: CYLINDER BLOCK................................................................................................................01-6
FIGURE 10: ELECTRONIC FOOT PEDAL ASSEMBLY ..........................................................................01-7
FIGURE 11: ENGINE OIL LEVEL DIPSTICK .........................................................................................01-11
FIGURE 12: ENGINE COMPARTMENT ................................................................................................01-11
FIGURE 13: UNDER VEHICLE VIEW....................................................................................................01-12
FIGURE 14: ENGINE COMPARTMENT ................................................................................................01-13
FIGURE 15: ENGINE COMPARTMENT ................................................................................................01-13
FIGURE 16: ENGINE COMPARTMENT ................................................................................................01-14
FIGURE 17: RUBBER DAMPER TOLERANCE.....................................................................................01-16
FIGURE 18: POWER PLANT CRADLE INSTALLATION.......................................................................01-17

Section 01: ENGINE
01-3
1. ENGINE
This vehicle is powered by a 6-cylinder, four-
cycle, Detroit Diesel series 60 engine, equipped
with an electronic control system (DDEC IV).
Series 60 engines come in either of two
displacement volumes: 11 liters or 12.7 liters.
Summary information on the Electronic Control
System is given in this section.
Complete maintenance and repair information on
the engine will be found in the current DDEC IV
Service Manual #6SE483. This maintenance
manual covers engine accessories, controls and
related components.
Procedures for engine removal and installation
are given at the end of this section. The DDEC
system is self-diagnostic. It can identify faulty
components and other engine-related problems
by providing the technician with a diagnostic
code. Refer to DDEC Troubleshooting Guide
#6SE492 published by Detroit Diesel for more
complete information on diagnosis of
components and system problems.
DDEC IV (Detroit Diesel Electronic Control)
controls the timing and amount of fuel injected
by the electronic unit injectors (EUI). The system
also monitors several engine functions using
electrical sensors, which send electrical signals
to the Electronic Control Module (ECM). The
ECM computes the electrical signals and
determines the correct fuel output and timing for
optimum power, fuel economy and emissions.
The ECM also has the ability to display warnings
or shut down the engine completely (depending
on option selection) in the event of damaging
engine conditions, such as low oil pressure, low
coolant level, or high oil temperature.
Two categories divide system components:
engine-mounted components and engine-related
components.
2. ENGINE-MOUNTED COMPONENTS
FIGURE 1: DETROIT DIESEL SERIES 60 ENGINE (TYPICAL) 01015
Engine-mounted components are as follows:
• Electronic Control Module
• Electronic Unit Injector
• Synchronous Reference Sensor
• Timing Reference Sensor
• Turbo Boost Pressure Sensor
• Coolant Temperature Sensor
• Fuel Temperature Sensor
• Air Temperature Sensor
• Oil Pressure Sensor
• Oil Temperature Sensor

Section 01: ENGINE
01-4
2.1 ELECTRONIC CONTROL MODULE
The Electronic Control Module is mounted, on
the starter side of the engine (Fig. 2).
Considered the "Brain" of the DDEC IV system,
it provides overall monitoring and control of the
engine. It does so by comparing input data from
the various sensors to a set of calibration data
stored in the EEPROM (Electrically Erasable,
Programmable, Read-Only Memory) within the
Electronic Control Module. After comparing the
input data with the calibration data, the ECM
sends high-current command pulses to the
Electronic Unit Injectors (EUI) to initiate fuel
injection. The ECM also receives feedback
regarding the start and end of injection for a
given cylinder. The EEPROM within the
Electronic Control Module is factory programmed
by Detroit Diesel. Reprogramming must be done
at a Detroit Diesel authorized service center.
However, some changes may be performed to
the cruise control and road speed limiter using a
diagnostic data reader (see paragraph "DDEC IV
Diagnostic Codes" in this section).
FIGURE 2: ELECTRONIC CONTROL MODULE (ECM)
2.2 ELECTRONIC UNIT INJECTOR
The Electronic Unit Injector is a compact device
that injects diesel fuel directly into the
combustion chamber (Fig. 3). The amount of
fuel injected and the Electronic Control Module
(ECM) determines the beginning of injection
timing. The ECM sends a command pulse, which
activates the injector solenoid. The EUI performs
four functions:
•Creates the high-fuel pressure required for
efficient injection;
• Meters and injects the exact amount of fuel
required to handle the load;
• Atomizes the fuel for mixing with the air in the
combustion chamber;
• Permits continuous fuel flow for component
cooling.
FIGURE 3: UNIT INJECTOR CROSS SECTION 01019
3. SYNCHRONOUS REFERENCE SENSOR
The Synchronous Reference Sensor (SRS) is an
electronic component, mounted to the rear of the
gear case (Fig. 4). The SRS senses a raised
metal pin on the rear of the bull gear and sends
a signal to the ECM via a black connector wire.
The SRS sensor extends through a hole in the
gear case. It is positioned near the rear of the
bull gear. A bolt, inserted through a hole in the
SRS bracket, secures the SRS assembly to the
gear case.

Section 01: ENGINE
01-5
FIGURE 4: SRS LOCATION 01020
FIGURE 5: BULL GEAR 01021
The bull gear pin passes by the SRS as piston
number one crank pin reaches 45°before Top-
Dead-Center. The ECM uses this information to
determine engine speed.
The SRS is non-serviceable and must be
replaced as a unit. No adjustment is required.
3.1 TIMING REFERENCE SENSOR
The Timing Reference Sensor (TRS) is an
electronic component mounted on the left side of
the gear case (right side of coach), near the
crankshaft centerline. The TRS sensor,
positioned near the timing wheel gear teeth,
extends through an opening in the gear case. A
bolt, inserted through a hole in the TRS bracket,
secures the TRS assembly to the gear case.
The TRS connector is gray. The TRS sensor
sends a signal to the ECM. The TRS senses a
series of evenly spaced special teeth on the
timing wheel. A tooth passes by the TRS as
each cylinder crank pin reaches 10°before Top-
Dead-Center.
The ECM uses these signals to determine
injector solenoid operation time. The TRS is
non-serviceable and must be replaced as a unit.
No adjustment is required.
FIGURE 6: TIMING GEAR 01022
3.2 TURBO BOOST PRESSURE SENSOR
Two bolts mount the Turbo Boost Pressure
Sensor to the intake manifold. A rubber O-ring
seals the sensor to the manifold (Fig. 7). This
device is a pressure sensor that sends an
electrical signal to the ECM. The ECM uses this
information to compute the amount of air
entering the engine. Turbo boost sensor
information regulates fuel supply to control
engine exhaust.
The turbo boost sensor is non-serviceable and
must be replaced as an assembly. No
adjustment is required.