SERIES 60 SERVICE MANUAL 8 EXHAUST GAS RECIRULATION (EGR) COMPONENTS 8.1 TUBE AND SHELL BOLTED FLANGE EGR COOLER ........................... 8-3 8.2 HYDRAULIC EGR VALVE ........................................................................ 8-19 8.3 DELIVERY PIPE ...................................................................................... 8-28 8.4 EGR RATE MEASUREMENT SYSTEM .................................................. 8-40 8.5 DDEC V VARIBLE PRESSURE OUTPUT DEVICE ................................. 8-44 8.6 DDEC IV VARIBLE PRESSURE OUTPUT DEVICES .............................
8-48 9 ELECTRICAL EQUIPMENT 9.1 OVERVIEW OF ELECTRICAL SYSTEM ................................................. 9-3 9.2 BATTERY CHARGING ALTERNATOR .................................................... 9-4 9.3 STORAGE BATTERY .............................................................................. 9-24 9.4 CRANKING MOTOR ................................................................................ 9-26 9.5 TACHOMETER DRIVE ............................................................................ 9-31 9.6 DDEC III/IV ENGINE SENSOR HARNESS ............................................. 9-37 9.7 DDEC II ENGINE SENSOR HARNESS ...................................................
9-47 9.8 METRI-PACK 150 SERIES CONNECTORS ............................................ 9-53 9.9 MICRO-PACK SERIES CONNECTORS .................................................. 9-58 9.10 WEATHER PACK AND METRI-PACK 280 SERIES CONNECTORS ...... 9-60 9.11 CONNECTOR TOOLS ............................................................................. 9-63 9.12 SPLICING GUIDELINES ......................................................................... 9-64 9.A ADDITIONAL INFORMATION .................................................................. 9-69 10 POWER TAKE-OFF 10.1 FRONT MOUNTED POWER TAKE-OFF .................................................
10-3 10.2 REAR ENGINE POWER TAKE-OFF (REPTO) ASSEMBLY ................... 10-8 11 SPECIAL EQUIPMENT 11.1 AIR COMPRESSOR (VEHICLE APPLICATIONS ONLY) ........................ 11-3 11.2 AIR COMPRESSOR DRIVE HUB ............................................................ 11-19 11.A ADDITIONAL INFORMATION .................................................................. 11-25 12 OPERATION AND VERIFICATION 12.1 PREPARATION FOR A FIRST TIME START ........................................... 12-3 12.2 STARTING ...............................................................................................
12-7 12.3 RUNNING ................................................................................................ 12-8 12.4 STOPPING ............................................................................................... 12-11 12.5 OPERATING CONDITIONS ..................................................................... 12-12 12.6 SERIES 60G AUTOMOTIVE ENGINE OPERATING CONDITIONS ....... 12-14 12.7 ENGINE RUN-IN INSTRUCTIONS .......................................................... 12-16 13 ENGINE TUNE-UP 13.1 ENGINE TUNE-UP PROCEDURES ........................................................
13-3 13.2 VALVE LASH, INJECTOR HEIGHT (TIMING) AND JAKE BRAKE® LASH ADJUSTMENTS ....................................................................................... 13-5 13.3 ENGINE TUNE-UP PROCEDURES FOR THE SERIES 60G ENGINE .. 13-24 13.4 VALVE LASH FOR THE SERIES 60G ENGINE ...................................... 13-26 14 PREVENTIVE MAINTENANCE 14.1 MAINTENANCE OVERVIEW .................................................................. 14-3 All information subject to change without notice. (Rev. 2005) 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION ix