SERIES 60 SERVICE MANUAL REPLACING AND REPAIRING In many cases, a technician is justified in replacing parts with new material rather than attempting repair. However, there are times when a slight amount of reworking or reconditioning may save a customer considerable added expense. Exchange assemblies such as injectors, fuel pumps, water pumps and turbochargers are desirable service items. Various factors such as the type of operation of the engine, hours in service and the next overhaul period must be considered when determining whether new parts are installed or used parts are reconditioned to provide trouble-free operation.
For convenience and logical order in disassembly and assembly, the various subassemblies and other related parts mounted on the cylinder block will be treated as separate items in the various sections of the manual. DISASSEMBLY A technician can be severely injured if caught in pulleys, belts or the fan of an engine that is accidentally started. To avoid such a misfortune, take the following precautions before starting to work on an engine. PERSONAL INJURY To avoid injury from accidental engine startup while servicing the engine, disconnect/disable the starting system. PERSONAL INJURY To avoid injury from the sudden release of a high-pressure hose connection, wear a face shield or goggles.
Bleed the air from the air starter system before disconnecting the air supply hose. Before any major disassembly, the engine must be drained of lubricating oil, coolant and fuel. To perform a major overhaul or other extensive repairs, the complete engine assembly, after removal from the engine base and drive mechanism, should be mounted on an engine overhaul stand; then the various subassemblies should be removed from the engine. When only a few items need replacement, it is not always necessary to mount the engine on an overhaul stand. Parts removed from an individual engine should be kept together so they will be available for inspection and assembly.
Those items having machined faces, which might be easily damaged by steel or concrete, should be stored on suitable wooden racks or blocks, or a parts dolly. (Rev. 2005) All information subject to change without notice. 20 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION