Detroit Diesel 60, Service Manual

Page 1: ...ON Series 60 2002 Engines are equipped with a new Compact Gear Train Assembly Camshaft Camshaft Drive Gear and Camshaft Gear Cover will be installed and removed as a assembly For engines equipped with a Compact Gear Train Assembly remove camshaft assembly as follows 1 Rotate the engine by hand to get the No 1 piston at TDC Do this by installing the crankshaft timing pin J 45947 into its bracket an...

Page 2: ...shaft gear cover inspection plate and remove the plate To verify camshaft timing proceed as follows a Look at the timing hole in the camshaft gear b The timing hole should be aligned with the timing hole in the back of the gear cover located at the 5 o clock position See Figure 2 ...

Page 3: ...e the crankshaft timing pin and rotate the engine one more complete revolution When the timing pin drops back into the hole in the crankshaft check the timing of the camshaft Refer to step 2 1 Camshaft Gear Cover 2 Timing Hole Figure 2 Timing Verification ...

Page 4: ...Cover Bolt NOTE If timing is correct and the repair being made does not require that the engine is turned over clean off an area where the camshaft gear and idler gear teeth mesh and mark the teeth with a suitable marker for a reference point when reassembling the camshaft This procedure will make assembly easier ...

Page 5: ...4 Remove four camshaft gear cover bolts See Figure 4 1 Bolt Figure 4 Camshaft Gear Cover Bolts ...

Page 6: ...5 Remove three bolts inside of camshaft gear cover See Figure 5 1 Bolt Figure 5 Camshaft Gear Cover Bolts ...

Page 7: ...aft cap bolts and camshaft caps To avoid injury when removing or installing a heavy engine component ensure the component is properly supported and securely attached to an adequate lifting device to prevent the component from falling 8 Lift camshaft and camshaft gear cover assembly from camshaft bearings and gear case Use lifting tool J 46305 to assist in lifting camshaft gear cover assembly ...

Page 8: ...lding 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 Install the camshaft gear on the camshaft as follows 1 Using a suitable press support the camshaft securely on the press The bottom of camshaft must be firmly secured to prevent any movement 2 Install the cams...

Page 9: ...ssembly on engine as follows 1 Install camshaft alignment tool J 45946 on the camshaft gear cover and through the camshaft gear making sure the pin on the tool is entered into the timing hole in the backside of the camshaft gear cover See Figure 7 Figure 7 Camshaft Alignment Tool ...

Page 10: ...kshaft locator hole See Figure 8 1 Timing Pin Figure 8 Crankshaft Timing Pin 3 If the adjustable idler gear was removed or replaced remove the cover plate and loosen the three hub retaining nuts so the gear hub can be easily moved Install tool to J 46306 hold idler gear hub at the middle of travel this procedure will assist in correctly installing the camshaft gear ...

Page 11: ...4 Ensure two seals are properly installed in camshaft gear cover See Figure 9 Figure 9 Camshaft Seals ...

Page 12: ... 10 Apply RTV Sealant along Split line NOTE Camshaft gear cover assembly must be installed promptly to avoid the setting of the RTV To avoid injury when removing or installing a heavy engine component ensure the component is properly supported and securely attached to an adequate lifting device to prevent the component from falling ...

Page 13: ...ar of the camshaft gear cover does not catch on the edge of the cylinder head 7 After the assembly is in position remove the alignment tool and guide studs and install the camshaft gear cover bolts by hand The timing hole in the back of the camshaft gear cover should be visible in the center of the hole in the gear Install and tighten the four attachment bolts to the gear case until the camshaft g...

Page 14: ...fy alignment tool is installed correctly Incorrect installation will result in gear not being in time and the procedure will need to be repeated 1 Camshaft Gear Cover 2 Timing Hole Figure 11 Timing Verification ...

Page 15: ...ply RTV to grooves in camshaft cap No 1 and Gasket Eliminator to camshaft cap No 7 See Figure 12 Figure 12 Sealant Application Notice If the camshaft gear cover bolts and or the camshaft cap bolts are tightened down with the camshaft gear out of time damage to the camshaft gear cover and timing pin will result ...

Page 16: ...in each and tighten See Figure 13 1 Bolt 2 Stud Bolt Figure 13 Camshaft Bearing Cap Bolt and Stud Bolt 10 Install the remaining five camshaft caps onto cylinder head with one bolt for each camshaft cap 11 Torque all camshaft cap bolts and stud bolts to 126 146 N m 93 108 lb ft ...

Page 17: ...12 Install three bolts inside camshaft gear cover and torque to 10 N m 7 lb ft See Figure 14 1 Bolt Figure 14 Camshaft Gear Cover Bolts ...

Page 18: ...13 Install four camshaft gear cover bolts torque to 56 66 N m 44 48 lb ft using torque sequence as shown in Figure 15 Figure 15 Bolt Torque Sequence ...

Page 19: ...14 Torque the three bolts previously installed inside camshaft gear cover to 56 66 N m 44 48 lb ft See Figure 16 1 Bolt Figure 16 Camshaft Gear Cover Bolts ...

Page 20: ...gnment tool from gearcase cover 18 Check camshaft gear lash and adjust if necessary Refer to section 1 21 ADDITIONAL SERVICE INFORMATION Additional service information is available in the Detroit Diesel Series 60 Service Manual 6SE483 The next revision to this manual will include the revised information As a convenience to holders of the Series 60 Service Manual information in service manual forma...

Page 21: ...0 Service Manual dated April 2002 Service manuals are available from authorized Detroit Diesel distributors If this bulletin was obtained from the Internet service manual page s are available by returning to the screen SIB Index selecting attachment pages and printing the page s ...

Page 22: ...Detroit Diesel DDC Series 60 and the spinning arrows design are registered trademarks of Detroit Diesel Corporation Copyright 2002 Detroit Diesel Corporation All rights reserved Printed in U S A ...