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*Detroit Diesel Series 60 Service Manual Espa Ol Latino
*Detroit Series 60 Service Manual
*Detroit Series 60 Service Manual
*Detroit Diesel Series 60 Service Manual Espa Ol 2017
50 and 60 series Detroit diesel 50 and 60 series Construction & Industrial, and Marine Engines - Application and Installation Guide. 176196 50 and 60 series DDEC IV ON-HIGHWAY - EGR Application and Installation (include sensor failure CODE). 176197 60 series The 2007 version of the Detroit Series 60 Emissions. Table 35 Fuel Filters – Series 60 Regular Service Lubricating Oil Filters Filter Type Detroit Diesel Part Number Full Flow. Page 168: Power Cool Engine Products 1 Gallon Jug – 6 Per Case Pre-Blended 4923 55 Gallon Drum 23524924 Bulk Delivery – 1,000 Gallon Minimum Table 38 POWER COOL Latin American Coolant All information. DETROIT diesel engines Spare parts catalogs, Service & Operation Manuals. Spare parts for MTU and Detroit marine engines. Since March 2011 the Off-Highway division of Detroit Diesel Corporation, MTU Friedrichshafen, Bergen Marine, Rolls-Royce are under control Rolls-Royce Group PLC, Daimler AG and Tognum AG. For Series 50 and Series 60 engine brake installation and service procedures, refer to Detroit Diesel engine Service Manuals for Series 50 P/N 6SE50 and Series 60 P/N 6SE483. For Jacobs Engine Brake service parts, refer to Detroit Diesel Parts Catalogs. Series 60 engines with serial numbers below are not engine brake ready.Section 1.28 Camshaft and Camshaft Bearing
The Series 60 camshaft is located on top of the cylinder head, just below the valve cover. The camshaft actuates the intake and exhaust valves and injector operating mechanism. See Figure ’Camshaft and Related Parts’ .
Figure 1. Camshaft and Related Parts
Note: The Series 60G camshaft has no injector lobe on the cam.Detroit Diesel Series 60 Service Manual Espa Ol Latino
The camshaft is supported by seven bearing assemblies, consisting of precision-type, replaceable bearing shell inserts that are split at their center lines. Current non-tin-plated production bearing shells are identified by their shiny aluminum color. Current tin-plated service bearing shells have a dull gray sheen. The lower bearing shell is positioned in a saddle that is integral with the cylinder head. The upper bearing shell is held in place by a machined camshaft cap. Upper and lower bearing shells are identical and have locating tangs and oil holes. Only the upper bearing shell oil holes index with oil supply holes in the camshaft caps. See Figure ’Camshaft and Related Parts’ . These camshaft caps are precision line-bored after assembly to the cylinder head. Caps are NOT interchangeable once the head is finished. Caps are numbered and must NOT be interchanged with other caps of the same part number from stock or from a different cylinder head.
1. Dowel
6. Stud, Camshaft Cap (2)
2. Bearing Shells
7. Camshaft Cap
3. Bolt, Camshaft Cover
8. Camshaft
4. Rear, Camshaft Access Cover
9. O-ring
5. Bolt, Camshaft Cap (13)
10. Cylinder Head
Figure 2. Camshaft and Related Parts
The No. 4 camshaft cap is secured to the cylinder head with three bolts; cap numbers 2, 3, 5, and 6 use two bolts each. Caps one and seven have a stud and one bolt each. The stud and nut arrangement on the end caps (1 and 7) allows rocker arm shaft removal without disturbing the gasket eliminator seal from the end camshaft caps to the cylinder head. There are four different camshaft cap configurations. Only the intermediate caps No. 2, 3, 5, and 6 are identical but must not be interchanged during re-assembly. See Figure ’Camshaft Bolt and Cap Location’ .
1. Camshaft Cap Bolt (13)
2. Camshaft Cap Stud and Nut (2)
Figure 3. Camshaft Bolt and Cap Location
The camshaft is driven by a camshaft drive gear, located in the gear case at the front of the engine and is driven, through a series of intermediate gears, by the crankshaft timing gear. Refer to ’1.24.2.1 Check Engine Timing’ for gear train information and camshaft drive gear lash measurement and adjustment procedures. See Figure ’Engine Gear Train’ .
Figure 4. Engine Gear Train
The camshaft drive gear is indexed to the camshaft drive gear hub by a Woodruff key and retained by a bolt which goes through the camshaft drive gear and hub and threads into the end of the camshaft. The camshaft has a dowel which indexes and fits into the mating hole in the camshaft hub. See Figure ’Cross-Section of Camshaft Drive Gear and Related Parts’ .
1. Woodruff Key
5. Seal Groove
2. Camshaft Drive Gear Hub
6. Camshaft Dowel Hole
3. Camshaft Drive Gear
7. Camshaft Thrust Plate
4. O-ring Groove
Figure 5. Cross-Section of Camshaft Drive Gear and Related Parts
The camshaft hub is located in the camshaft thrust plate, which is positioned in an opening in the gear case housing. See Figure ’Camshaft Thrust Plate and Related Parts’ .
1. Bolt, Thrust Plate Retaining (2) or (3)
6. Gear Case
2. Bolt, Camshaft Hub Retaining
7. Seal, Thrust Plate
3. Drive Gear, Camshaft
8. Camshaft
4. Thrust Plate, Camshaft
9. Key
5. O-ring
10. Hub
Figure 6. Camshaft Thrust Plate and Related Parts
Access openings are provided in the gear case cover for camshaft drive gear lash adjustment and camshaft retaining bolt removal. See Figure ’Camshaft Drive Gear Access Cover and Adjustable Idler Gear Access’ .
Figure 7. Camshaft Drive Gear Access Cover and Adjustable Idler Gear Access
A cover is provided at the rear end of the camshaft and is secured to the No. 7 camshaft bearing cap and the cylinder head by three bolts.See Figure ’Rear Camshaft Access Cover’ .
Figure 8. Rear Camshaft Access Cover
Vertical oil passages at the front and rear of the cylinder head deliver oil from the cylinder block front and rear oil galleries to the No. 1 and 7 lower camshaft bearing saddles. From there, the oil is directed up ward ( through the enlarged stud hole) to the No. 1 and 7 upper bearing caps. A drilled passage in each of these caps exits at the rocker arm shaft seat area, where it indexes with a hole in each rocker arm shaft. The rocker arm shafts have internal oil passages that deliver oil to the rocker arm bushings and intermediate upper camshaft bearings. Some of the oil supplied to the rocker arm bushing passes through the oil hole in the bushing to the rocker arm. The rocker is drilled to supply oil to the camshaft follower, roller pin, and bushing. The rocker is also drilled to supply oil to the valve adjusting screw, valve button, retainer clip, intake, and exhaust valve stems and the fuel injector follower. The No. 4 camshaft cap is “Y” drilled, forming an oil path connection between the front and rear rocker arm shafts, to ensure complete lubrication. See Figure ’Cylinder Head Lubrication Schematic’ .
1. Rocker Arm, Exhaust Valve
4. Rocker Arm Shaft
2. Rocker Arm, Fuel Injector
5. Cylinder Head
3. Camshaft Cap
6. Rocker Arm, Intake Valve
Figure 9. Cylinder Head Lubrication SchematicSection 1.28.1 Repair or Replacement of Camshaft and Camshaft Bearing
To determine if repair or replacement of the camshaft and camshaft bearings is necessary, perform the following procedure. See Figure ’Flowchart for Repair or Replacement of Camshaft and Related Parts’ .
Figure 10. Flowchart for Repair or Replacement of Camshaft and Related PartsSection 1.28.2 Removal of Camshaft and Camshaft Bearing
Removal of camshaft and camshaft bearings as follows:
*Remove the valve rocker cover. Refer to ’1.6.2 Removal and Cleaning of One-piece Rocker Cover For Diesel Engines Only’ (one-piece), refer to ’1.6.3 Removal and Cleaning of Two-piece Rocker Cover For Diesel Engines Only’ (two-piece), refer to ’1.6.5 Removal and Cleaning of Three-piece Rocker Cover’ (three-piece).
*Remove the five bolts that secure the camshaft drive gear access cover to the gear case. See Figure ’Camshaft Drive Gear Access Cover and Adjustable Idler Gear Access’ .
*Remove both rocker arm shaft assemblies. Refer to ’1.3.2 Removal of Rocker Arm Assembly’ .NOTICE:
Only retaining tool (J–35652–B) , should be used to hold the camshaft drive gear stationary while loosening or tightening the camshaft drive gear-to-camshaft bolt. Other tools or devices can cause engine damage.
*Insert the shoe of the camshaft drive gear torque retaining tool (J–35652–B) through a lightening hole of the camshaft drive gear.
*Bar the engine over slightly to position the camshaft drive gear holding tool so that the bolt holes in the holding tool align with the access cover bolt holes in the gear case cover, using the 3/4 in. square hole in the center of the crankshaft pulley.
*Install retaining tool (J–35652–B) to the gear case, engaging one of the lightening holes in the camshaft drive gear. Use two of the access cover bolts to secure the tool to the gear case. See Figure ’Camshaft Drive Gear Torque Holding Tool Installation’ .
Figure 11. Camshaft Drive Gear Torque Holding Tool Installation
*Use a long 3/4 in. drive breaker bar and a 27 mm impact socket to remove the camshaft drive gear-to-camshaft bolt.
*Remove the camshaft drive gear torque holding tool from the gear case.
*Rotate the crankshaft, using the square hole in the middle of the crankshaft pulley, to align the lightening holes in the camshaft drive gear to the camshaft thrust plate mounting bolts.
*Remove the camshaft thrust plate mounting bolts carefully, to avoid dropping them into the gear case. The current plate uses three bolts, the former plate requires two bolts. See Figure ’Camshaft Thrust Plate Mounting Bolt Locations’ .
Note: A clean shop towel may be inserted into the gear case opening to trap the bolts in case they are dropped. Do not allow the shop towel to drop into the gear case.
1. Camshaft Thrust Plate Mounting Bolt Locations
Figure 12. Camshaft Thrust Plate Mounting Bolt Locations
*Install pilot tool (J–35906) to the camshaft drive gear access opening using three of the access cover bolt holes. Engage the puller screw in the threads of the camshaft drive gear hub, until the screw is tight. See Figure ’Camshaft Thrust Plate Remover’ .
Figure 13. Camshaft Thrust Plate Remover
*Continue turning the puller screw to pull the camshaft drive gear hub and thrust plate forward approximately 6-7 mm (1/4 in.) until the thrust plate seal is clear of the camshaft front bearing cap and cylinder head. See Figure ’Camshaft Thrust Plate Clearance’ .
Figure 14. Camshaft Thrust Plate Clearance
*Remove the three bolts that secure the rear camshaft cover to the engine and remove the cover.
*Remove the remaining seven camshaft cap bolts. Remove the No. 1 and 7 studs using socket tool (J–44706) . See Figure ’Camshaft Cap Stud Removal’ .
Figure 15. Camshaft Cap Stud Removal
*Remove the seven camshaft bearing caps and the upper bearing shells. Keep the caps and shells together for possible later installation. Tag the bearing cap location, as they must always be installed in the same location.
*The camshaft gear pilot tool will remain in place, holding the camshaft drive gear in contact with the adjustable idler gear, to prevent accidental disengagement. This arrangement makes it unnecessary to re-time the gear train.
Note: The camshaft gear can go out of time if the pilot tool is removed.
*Slide the camshaft rearward to completely disengage the dowel from the hub. Lift out the camshaft.
*Remove the lower camshaft bearing shells, and group them with the upper shells and caps for possible reuse.Section 1.28.3 Disassembly of Camshaft and Camshaft Bearing
Refer to ’1.29.2 Removal of Camshaft Drive Gear’ for disassembly of camshaft drive gear, camshaft hub and thrust plate assembly.
Note: Disassembly of camshaft and drive gear assembly is not required for inspection. Disassembly will require timing of the camshaft gear again.
For Series 60 engines equipped with Compact Gear Train Assembly disassemble camshaft from the camshaft gear as follows.
*Use suitable fixture to secure the camshaft assembly from movement.
*Install a heavy duty gear puller capable of withstanding the 48260 kPa (7000 psi) required to remove the gear from the camshaft. Support the backside of the camshaft gear cover as close to the camshaft as possible to prevent damaging the gear cover and gently press the camshaft off the gear holding the camshaft as it is pressed through the gear. Removing the camshaft gear and cover together.
NOTICE
Extreme care must be taken not to support the camshaft gear cover at the outer edges.Section 1.28.3.1 Inspection of Camshaft and Camshaft BearingDetroit Series 60 Service Manual
Inspect camshaft and camshaft bearings as follows:
*Clean all of the removed parts in clean fuel oil.
*Ensure all oil passages are clear.
EYE INJURY
To avoid injury from flying debris when using compressed air, wear adequate eye protection (face shield or safety goggles) and do not exceed 276 kPa (40 psi) air pressure.
*Dry with compressed air.
*Inspect the rocker arm components for scoring. Refer to ’1.3.2.2 Inspection of Rocker Arm Assemblies and Camshaft Lobes’ .
*Replace damaged rocker arm components.
*Inspect the camshaft lobes and journals for scoring, pitting, or flat spots.
Note: Camshafts may exhibit surface pits on the exhaust lobes. See Figure ’Camshafts Acceptable for Reuse’ . Extensive durability and field testing has shown that surface pits on the exhaust lobes can occur early in the operation of the engine. These blemishes do not adversely affect engine performance or the durability of the camshaft and followers. Camshafts with this condition may be reused.
Figure 16. Camshafts Acceptable for Reuse
Note: Camshafts exhibiting extensive wear and pitting must be replaced. See Figure ’Camshafts Not Acceptable for Reuse’ .
Figure 17. Camshafts Not Acceptable for Reuse
*If the camshaft is scored, inspect the camshaft follower rollers.
*Replace damaged camshaft followers.
*If there is a doubt as to the acceptability of the camshaft for further service, determine the extent of camshaft lobe wear as follows:
Note: The camshaft can be in or out of the engine during this procedure.
*Using a feeler gage, 0.038-0.254 mm (0.0015 -0.010 in.) and a piece of square, hard material 3 x 10 x 25 mm (1/8 in. x 3/8 in. x 1 in.), measure the flat on the injector rise side of the camshaft lobes and nose of valve lobes. See Figure ’Checking Camshaft Lobe Wear’ .
Figure 18. Checking Camshaft Lobe Wear
*If the flats measure greater than 0.076 mm (0.003 in.) in depth and there are no other camshaft defects, replace the camshaft.
*Inspect the camshaft bearings for signs of excessive wear, scoring or pitting.
*Replace camshaft bearings as necessary.
Note: If one camshaft bearing needs to be replaced, replace both of the camshaft bearing shells.
*Check the camshaft bearing clearance using plastic gaging material under each upper shell.
Note: Check camshaft bearing clearance with bearing shells, camshaft, bearing caps and rocker arm shafts (without rocker assemblies in place) installed, and cap bolts, studs and nuts tightened to specification.
*Allowable clearance is 0.09 - 0.166 mm (0.0035 -0.0065 in.) or a maximum of 0.191 mm (0.0075 in.) with used parts.
*Replace excessively worn or scored parts.
*After completing the camshaft bearing clearance measurements, remove the rocker arm shafts, bearing caps, camshaft, and camshaft bearings. Keep the caps and shells together for possible reuse.
*Clean all of the plastic gaging material from the bearing shells and camshaft journals if used parts are to be reused.
*Remove all of the Gasket Eliminator from both the cylinder head and camshaft caps. Refer to ’Cleaning’ in the ’General Information’ section at the beginning of this manual.
*Coat the No. 1 and 7 bearing shell inserts with clean engine oil and install them to their respective locations in the cylinder head and camshaft caps.
*Install the camshaft to its normal position in the bearing saddles. Install the No. 1 and 7 camshaft caps to the cylinder head.
*Install the No. 1 and 7 camshaft cap outboard bolts and inboard studs and torque, using socket tool (J–44706) to the studs to 126–146 N·m (93–108 lb·ft).
*Using a dial indicator with magnetic base, check the run-out of the camshaft at the No. 4 bearing journal. See Figure ’Camshaft Run-out Measurement’ . If camshaft run-out exceeds 0.050 mm (0.002 in.), replace the camshaft
Figure 19. Camshaft Run-out MeasurementSection 1.28.4 Assembly of Camshaft and Camshaft Bearing
Refer to ’1.29.3 Installation of Camshaft Drive Gear’ for assembly of camshaft drive gear, camshaft hub and thrust plate assembly.Section 1.28.5 Installation of Camshaft and Camshaft Bearing
Install the camshaft and camshaft bearings as follows:
*Coat the lower camshaft bearing shells with clean engine lubricating oil, and install them to their original positions. Note the position of oil holes and locating tangs.
Note: If new bearings are to be installed, the upper and lower shells MUST be replaced as a set.
EYE INJURY
To avoid injury from flying debris when using compressed air, wear adequate eye protection (face shield or safety goggles) and do not exceed 276 kPa (40 psi) air pressure.
*When installing a new camshaft, steam clean it to remove the rust preventive and blow dry with compressed air.
*Before installing the camshaft dowel into the camshaft hub, ensure that the dimple in the thrust plate is located at the 12 o’clock position to properly position bolt holes to cam cap and cylinder head. See Figure ’Indexing Camshaft Dowel’ .
Figure 20. Indexing Camshaft Dowel
*Coat the lobes and journals of the camshaft with clean engine lubricating oil. Index the dowel pin in the camshaft with the dowel hole in the camshaft hub.
*Lower the camshaft into position and slide the camshaft forward, making certain that the camshaft dowel indexes with its mating hole in the camshaft thrust plate hub.
*Install the upper bearing shells to the No. 1, 4 and 7 camshaft caps, noting the position of the oil holes and locating tangs.NOTICE:
Do not apply oil to the number 1 or number 7 camshaft bearing shells. These shells must be clean and dry for proper sealant application. Applying oil to the number 1 or number 7 shells may result in oil leakage from the camshaft bearing caps. NOTE: The camshaft will still have adequate clearance from the number 1 and number 7 shells due to the oil film thickness on bearings 2 through 6.
*Coat the number 2 through number 6 bearing shells with clean engine lubricating oil.
*For engines built after May 1999, a race track seal is used on the Number 1 bearing cap. For bearing cap Number 7, use one rubber O-ring in the counterbore in the cylinder head. Before assembling the camshaft cap to the cylinder head, ensure the O-ring is in place on the cylinder head.
*For engines built prior to May 1999, install the two rubber O-rings to the counterbores in the cylinder head at the Number 1 and 7 camshaft cap locations. Bef
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*Detroit Diesel Series 60 Service Manual Espa Ol Latino
*Detroit Series 60 Service Manual
*Detroit Series 60 Service Manual
*Detroit Diesel Series 60 Service Manual Espa Ol 2017
50 and 60 series Detroit diesel 50 and 60 series Construction & Industrial, and Marine Engines - Application and Installation Guide. 176196 50 and 60 series DDEC IV ON-HIGHWAY - EGR Application and Installation (include sensor failure CODE). 176197 60 series The 2007 version of the Detroit Series 60 Emissions. Table 35 Fuel Filters – Series 60 Regular Service Lubricating Oil Filters Filter Type Detroit Diesel Part Number Full Flow. Page 168: Power Cool Engine Products 1 Gallon Jug – 6 Per Case Pre-Blended 4923 55 Gallon Drum 23524924 Bulk Delivery – 1,000 Gallon Minimum Table 38 POWER COOL Latin American Coolant All information. DETROIT diesel engines Spare parts catalogs, Service & Operation Manuals. Spare parts for MTU and Detroit marine engines. Since March 2011 the Off-Highway division of Detroit Diesel Corporation, MTU Friedrichshafen, Bergen Marine, Rolls-Royce are under control Rolls-Royce Group PLC, Daimler AG and Tognum AG. For Series 50 and Series 60 engine brake installation and service procedures, refer to Detroit Diesel engine Service Manuals for Series 50 P/N 6SE50 and Series 60 P/N 6SE483. For Jacobs Engine Brake service parts, refer to Detroit Diesel Parts Catalogs. Series 60 engines with serial numbers below are not engine brake ready.Section 1.28 Camshaft and Camshaft Bearing
The Series 60 camshaft is located on top of the cylinder head, just below the valve cover. The camshaft actuates the intake and exhaust valves and injector operating mechanism. See Figure ’Camshaft and Related Parts’ .
Figure 1. Camshaft and Related Parts
Note: The Series 60G camshaft has no injector lobe on the cam.Detroit Diesel Series 60 Service Manual Espa Ol Latino
The camshaft is supported by seven bearing assemblies, consisting of precision-type, replaceable bearing shell inserts that are split at their center lines. Current non-tin-plated production bearing shells are identified by their shiny aluminum color. Current tin-plated service bearing shells have a dull gray sheen. The lower bearing shell is positioned in a saddle that is integral with the cylinder head. The upper bearing shell is held in place by a machined camshaft cap. Upper and lower bearing shells are identical and have locating tangs and oil holes. Only the upper bearing shell oil holes index with oil supply holes in the camshaft caps. See Figure ’Camshaft and Related Parts’ . These camshaft caps are precision line-bored after assembly to the cylinder head. Caps are NOT interchangeable once the head is finished. Caps are numbered and must NOT be interchanged with other caps of the same part number from stock or from a different cylinder head.
1. Dowel
6. Stud, Camshaft Cap (2)
2. Bearing Shells
7. Camshaft Cap
3. Bolt, Camshaft Cover
8. Camshaft
4. Rear, Camshaft Access Cover
9. O-ring
5. Bolt, Camshaft Cap (13)
10. Cylinder Head
Figure 2. Camshaft and Related Parts
The No. 4 camshaft cap is secured to the cylinder head with three bolts; cap numbers 2, 3, 5, and 6 use two bolts each. Caps one and seven have a stud and one bolt each. The stud and nut arrangement on the end caps (1 and 7) allows rocker arm shaft removal without disturbing the gasket eliminator seal from the end camshaft caps to the cylinder head. There are four different camshaft cap configurations. Only the intermediate caps No. 2, 3, 5, and 6 are identical but must not be interchanged during re-assembly. See Figure ’Camshaft Bolt and Cap Location’ .
1. Camshaft Cap Bolt (13)
2. Camshaft Cap Stud and Nut (2)
Figure 3. Camshaft Bolt and Cap Location
The camshaft is driven by a camshaft drive gear, located in the gear case at the front of the engine and is driven, through a series of intermediate gears, by the crankshaft timing gear. Refer to ’1.24.2.1 Check Engine Timing’ for gear train information and camshaft drive gear lash measurement and adjustment procedures. See Figure ’Engine Gear Train’ .
Figure 4. Engine Gear Train
The camshaft drive gear is indexed to the camshaft drive gear hub by a Woodruff key and retained by a bolt which goes through the camshaft drive gear and hub and threads into the end of the camshaft. The camshaft has a dowel which indexes and fits into the mating hole in the camshaft hub. See Figure ’Cross-Section of Camshaft Drive Gear and Related Parts’ .
1. Woodruff Key
5. Seal Groove
2. Camshaft Drive Gear Hub
6. Camshaft Dowel Hole
3. Camshaft Drive Gear
7. Camshaft Thrust Plate
4. O-ring Groove
Figure 5. Cross-Section of Camshaft Drive Gear and Related Parts
The camshaft hub is located in the camshaft thrust plate, which is positioned in an opening in the gear case housing. See Figure ’Camshaft Thrust Plate and Related Parts’ .
1. Bolt, Thrust Plate Retaining (2) or (3)
6. Gear Case
2. Bolt, Camshaft Hub Retaining
7. Seal, Thrust Plate
3. Drive Gear, Camshaft
8. Camshaft
4. Thrust Plate, Camshaft
9. Key
5. O-ring
10. Hub
Figure 6. Camshaft Thrust Plate and Related Parts
Access openings are provided in the gear case cover for camshaft drive gear lash adjustment and camshaft retaining bolt removal. See Figure ’Camshaft Drive Gear Access Cover and Adjustable Idler Gear Access’ .
Figure 7. Camshaft Drive Gear Access Cover and Adjustable Idler Gear Access
A cover is provided at the rear end of the camshaft and is secured to the No. 7 camshaft bearing cap and the cylinder head by three bolts.See Figure ’Rear Camshaft Access Cover’ .
Figure 8. Rear Camshaft Access Cover
Vertical oil passages at the front and rear of the cylinder head deliver oil from the cylinder block front and rear oil galleries to the No. 1 and 7 lower camshaft bearing saddles. From there, the oil is directed up ward ( through the enlarged stud hole) to the No. 1 and 7 upper bearing caps. A drilled passage in each of these caps exits at the rocker arm shaft seat area, where it indexes with a hole in each rocker arm shaft. The rocker arm shafts have internal oil passages that deliver oil to the rocker arm bushings and intermediate upper camshaft bearings. Some of the oil supplied to the rocker arm bushing passes through the oil hole in the bushing to the rocker arm. The rocker is drilled to supply oil to the camshaft follower, roller pin, and bushing. The rocker is also drilled to supply oil to the valve adjusting screw, valve button, retainer clip, intake, and exhaust valve stems and the fuel injector follower. The No. 4 camshaft cap is “Y” drilled, forming an oil path connection between the front and rear rocker arm shafts, to ensure complete lubrication. See Figure ’Cylinder Head Lubrication Schematic’ .
1. Rocker Arm, Exhaust Valve
4. Rocker Arm Shaft
2. Rocker Arm, Fuel Injector
5. Cylinder Head
3. Camshaft Cap
6. Rocker Arm, Intake Valve
Figure 9. Cylinder Head Lubrication SchematicSection 1.28.1 Repair or Replacement of Camshaft and Camshaft Bearing
To determine if repair or replacement of the camshaft and camshaft bearings is necessary, perform the following procedure. See Figure ’Flowchart for Repair or Replacement of Camshaft and Related Parts’ .
Figure 10. Flowchart for Repair or Replacement of Camshaft and Related PartsSection 1.28.2 Removal of Camshaft and Camshaft Bearing
Removal of camshaft and camshaft bearings as follows:
*Remove the valve rocker cover. Refer to ’1.6.2 Removal and Cleaning of One-piece Rocker Cover For Diesel Engines Only’ (one-piece), refer to ’1.6.3 Removal and Cleaning of Two-piece Rocker Cover For Diesel Engines Only’ (two-piece), refer to ’1.6.5 Removal and Cleaning of Three-piece Rocker Cover’ (three-piece).
*Remove the five bolts that secure the camshaft drive gear access cover to the gear case. See Figure ’Camshaft Drive Gear Access Cover and Adjustable Idler Gear Access’ .
*Remove both rocker arm shaft assemblies. Refer to ’1.3.2 Removal of Rocker Arm Assembly’ .NOTICE:
Only retaining tool (J–35652–B) , should be used to hold the camshaft drive gear stationary while loosening or tightening the camshaft drive gear-to-camshaft bolt. Other tools or devices can cause engine damage.
*Insert the shoe of the camshaft drive gear torque retaining tool (J–35652–B) through a lightening hole of the camshaft drive gear.
*Bar the engine over slightly to position the camshaft drive gear holding tool so that the bolt holes in the holding tool align with the access cover bolt holes in the gear case cover, using the 3/4 in. square hole in the center of the crankshaft pulley.
*Install retaining tool (J–35652–B) to the gear case, engaging one of the lightening holes in the camshaft drive gear. Use two of the access cover bolts to secure the tool to the gear case. See Figure ’Camshaft Drive Gear Torque Holding Tool Installation’ .
Figure 11. Camshaft Drive Gear Torque Holding Tool Installation
*Use a long 3/4 in. drive breaker bar and a 27 mm impact socket to remove the camshaft drive gear-to-camshaft bolt.
*Remove the camshaft drive gear torque holding tool from the gear case.
*Rotate the crankshaft, using the square hole in the middle of the crankshaft pulley, to align the lightening holes in the camshaft drive gear to the camshaft thrust plate mounting bolts.
*Remove the camshaft thrust plate mounting bolts carefully, to avoid dropping them into the gear case. The current plate uses three bolts, the former plate requires two bolts. See Figure ’Camshaft Thrust Plate Mounting Bolt Locations’ .
Note: A clean shop towel may be inserted into the gear case opening to trap the bolts in case they are dropped. Do not allow the shop towel to drop into the gear case.
1. Camshaft Thrust Plate Mounting Bolt Locations
Figure 12. Camshaft Thrust Plate Mounting Bolt Locations
*Install pilot tool (J–35906) to the camshaft drive gear access opening using three of the access cover bolt holes. Engage the puller screw in the threads of the camshaft drive gear hub, until the screw is tight. See Figure ’Camshaft Thrust Plate Remover’ .
Figure 13. Camshaft Thrust Plate Remover
*Continue turning the puller screw to pull the camshaft drive gear hub and thrust plate forward approximately 6-7 mm (1/4 in.) until the thrust plate seal is clear of the camshaft front bearing cap and cylinder head. See Figure ’Camshaft Thrust Plate Clearance’ .
Figure 14. Camshaft Thrust Plate Clearance
*Remove the three bolts that secure the rear camshaft cover to the engine and remove the cover.
*Remove the remaining seven camshaft cap bolts. Remove the No. 1 and 7 studs using socket tool (J–44706) . See Figure ’Camshaft Cap Stud Removal’ .
Figure 15. Camshaft Cap Stud Removal
*Remove the seven camshaft bearing caps and the upper bearing shells. Keep the caps and shells together for possible later installation. Tag the bearing cap location, as they must always be installed in the same location.
*The camshaft gear pilot tool will remain in place, holding the camshaft drive gear in contact with the adjustable idler gear, to prevent accidental disengagement. This arrangement makes it unnecessary to re-time the gear train.
Note: The camshaft gear can go out of time if the pilot tool is removed.
*Slide the camshaft rearward to completely disengage the dowel from the hub. Lift out the camshaft.
*Remove the lower camshaft bearing shells, and group them with the upper shells and caps for possible reuse.Section 1.28.3 Disassembly of Camshaft and Camshaft Bearing
Refer to ’1.29.2 Removal of Camshaft Drive Gear’ for disassembly of camshaft drive gear, camshaft hub and thrust plate assembly.
Note: Disassembly of camshaft and drive gear assembly is not required for inspection. Disassembly will require timing of the camshaft gear again.
For Series 60 engines equipped with Compact Gear Train Assembly disassemble camshaft from the camshaft gear as follows.
*Use suitable fixture to secure the camshaft assembly from movement.
*Install a heavy duty gear puller capable of withstanding the 48260 kPa (7000 psi) required to remove the gear from the camshaft. Support the backside of the camshaft gear cover as close to the camshaft as possible to prevent damaging the gear cover and gently press the camshaft off the gear holding the camshaft as it is pressed through the gear. Removing the camshaft gear and cover together.
NOTICE
Extreme care must be taken not to support the camshaft gear cover at the outer edges.Section 1.28.3.1 Inspection of Camshaft and Camshaft BearingDetroit Series 60 Service Manual
Inspect camshaft and camshaft bearings as follows:
*Clean all of the removed parts in clean fuel oil.
*Ensure all oil passages are clear.
EYE INJURY
To avoid injury from flying debris when using compressed air, wear adequate eye protection (face shield or safety goggles) and do not exceed 276 kPa (40 psi) air pressure.
*Dry with compressed air.
*Inspect the rocker arm components for scoring. Refer to ’1.3.2.2 Inspection of Rocker Arm Assemblies and Camshaft Lobes’ .
*Replace damaged rocker arm components.
*Inspect the camshaft lobes and journals for scoring, pitting, or flat spots.
Note: Camshafts may exhibit surface pits on the exhaust lobes. See Figure ’Camshafts Acceptable for Reuse’ . Extensive durability and field testing has shown that surface pits on the exhaust lobes can occur early in the operation of the engine. These blemishes do not adversely affect engine performance or the durability of the camshaft and followers. Camshafts with this condition may be reused.
Figure 16. Camshafts Acceptable for Reuse
Note: Camshafts exhibiting extensive wear and pitting must be replaced. See Figure ’Camshafts Not Acceptable for Reuse’ .
Figure 17. Camshafts Not Acceptable for Reuse
*If the camshaft is scored, inspect the camshaft follower rollers.
*Replace damaged camshaft followers.
*If there is a doubt as to the acceptability of the camshaft for further service, determine the extent of camshaft lobe wear as follows:
Note: The camshaft can be in or out of the engine during this procedure.
*Using a feeler gage, 0.038-0.254 mm (0.0015 -0.010 in.) and a piece of square, hard material 3 x 10 x 25 mm (1/8 in. x 3/8 in. x 1 in.), measure the flat on the injector rise side of the camshaft lobes and nose of valve lobes. See Figure ’Checking Camshaft Lobe Wear’ .
Figure 18. Checking Camshaft Lobe Wear
*If the flats measure greater than 0.076 mm (0.003 in.) in depth and there are no other camshaft defects, replace the camshaft.
*Inspect the camshaft bearings for signs of excessive wear, scoring or pitting.
*Replace camshaft bearings as necessary.
Note: If one camshaft bearing needs to be replaced, replace both of the camshaft bearing shells.
*Check the camshaft bearing clearance using plastic gaging material under each upper shell.
Note: Check camshaft bearing clearance with bearing shells, camshaft, bearing caps and rocker arm shafts (without rocker assemblies in place) installed, and cap bolts, studs and nuts tightened to specification.
*Allowable clearance is 0.09 - 0.166 mm (0.0035 -0.0065 in.) or a maximum of 0.191 mm (0.0075 in.) with used parts.
*Replace excessively worn or scored parts.
*After completing the camshaft bearing clearance measurements, remove the rocker arm shafts, bearing caps, camshaft, and camshaft bearings. Keep the caps and shells together for possible reuse.
*Clean all of the plastic gaging material from the bearing shells and camshaft journals if used parts are to be reused.
*Remove all of the Gasket Eliminator from both the cylinder head and camshaft caps. Refer to ’Cleaning’ in the ’General Information’ section at the beginning of this manual.
*Coat the No. 1 and 7 bearing shell inserts with clean engine oil and install them to their respective locations in the cylinder head and camshaft caps.
*Install the camshaft to its normal position in the bearing saddles. Install the No. 1 and 7 camshaft caps to the cylinder head.
*Install the No. 1 and 7 camshaft cap outboard bolts and inboard studs and torque, using socket tool (J–44706) to the studs to 126–146 N·m (93–108 lb·ft).
*Using a dial indicator with magnetic base, check the run-out of the camshaft at the No. 4 bearing journal. See Figure ’Camshaft Run-out Measurement’ . If camshaft run-out exceeds 0.050 mm (0.002 in.), replace the camshaft
Figure 19. Camshaft Run-out MeasurementSection 1.28.4 Assembly of Camshaft and Camshaft Bearing
Refer to ’1.29.3 Installation of Camshaft Drive Gear’ for assembly of camshaft drive gear, camshaft hub and thrust plate assembly.Section 1.28.5 Installation of Camshaft and Camshaft Bearing
Install the camshaft and camshaft bearings as follows:
*Coat the lower camshaft bearing shells with clean engine lubricating oil, and install them to their original positions. Note the position of oil holes and locating tangs.
Note: If new bearings are to be installed, the upper and lower shells MUST be replaced as a set.
EYE INJURY
To avoid injury from flying debris when using compressed air, wear adequate eye protection (face shield or safety goggles) and do not exceed 276 kPa (40 psi) air pressure.
*When installing a new camshaft, steam clean it to remove the rust preventive and blow dry with compressed air.
*Before installing the camshaft dowel into the camshaft hub, ensure that the dimple in the thrust plate is located at the 12 o’clock position to properly position bolt holes to cam cap and cylinder head. See Figure ’Indexing Camshaft Dowel’ .
Figure 20. Indexing Camshaft Dowel
*Coat the lobes and journals of the camshaft with clean engine lubricating oil. Index the dowel pin in the camshaft with the dowel hole in the camshaft hub.
*Lower the camshaft into position and slide the camshaft forward, making certain that the camshaft dowel indexes with its mating hole in the camshaft thrust plate hub.
*Install the upper bearing shells to the No. 1, 4 and 7 camshaft caps, noting the position of the oil holes and locating tangs.NOTICE:
Do not apply oil to the number 1 or number 7 camshaft bearing shells. These shells must be clean and dry for proper sealant application. Applying oil to the number 1 or number 7 shells may result in oil leakage from the camshaft bearing caps. NOTE: The camshaft will still have adequate clearance from the number 1 and number 7 shells due to the oil film thickness on bearings 2 through 6.
*Coat the number 2 through number 6 bearing shells with clean engine lubricating oil.
*For engines built after May 1999, a race track seal is used on the Number 1 bearing cap. For bearing cap Number 7, use one rubber O-ring in the counterbore in the cylinder head. Before assembling the camshaft cap to the cylinder head, ensure the O-ring is in place on the cylinder head.
*For engines built prior to May 1999, install the two rubber O-rings to the counterbores in the cylinder head at the Number 1 and 7 camshaft cap locations. Bef
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