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Additional Information SHOP NOTES

Shop notes contains information on checking bearing clearances, the crankshaft remanufacturing procedures and a glossary.

Cylinder Block Liner Boring

Further information will be printed as it is developed.

Machining Cylinder Block Counterbores

Cutter plate assembly (J41063) is used with Porta-Matic boring tool (PT2050D) to machine cylinder block counterbores for the installation of repair bushings. J41063 features a special diameter and taper design which will permit the machining of the counterbore area in accordance with Detroit Diesel specifications. Note: Use the appropriate Detroit Diesel part when installing the counterbore insert (repair bushing). Machine the cylinder block counterbores as follows: 1. Ensure block deck surface and boring tool base plate are clean and burr free. 2. Plug push tube opening, oil galleys and lower liner packing areas to seal out any contaminating particles. Note: Ensure cutter is marked Series 60. Note: Maintain a sharp cutter bit to ensure the cylinder block counterbore is accurately machined. 3. Using cutter (PT2000109) set to the dimensions listed in Table "PT2000 109 Cutter Dimensions" and see Figure "Bushing Repair Area" . Area to be Machined Upper counterbore Cutter Setting Dimensions Depth of Cut 15.29 mm (.602 in.)

161.798 0.0127 mm (6.370 .0005 in. Diameter) 4. Table 1. PT2000109 Cutter Dimensions

5. 6. Figure 1. Bushing Repair Area 7. Assemble Cutter Plate (PT2090) to the Porta-Matic mainshaft. See Figure "Cutter Plate(PT2090) Location" .

Figure 2. Cutter Plate(PT2090) Location 8. Mount Porta-Matic over cylinder to be bored. Open feed valve to lower cutter plate into cylinder bore. Push down firmly while rotating the mainshaft to insure proper alignment of Porta-Matic. 9. With cutter plate centered in the cylinder bore, align base plate with the four cylinder head bolt holes in block deck while maintaining as much base plate to block deck contact as possible. 10. Cross torque all four cylinder head bolts slowly to 67 Nm (50 ftlbs). Rotate mainshaft to insure that the cutter plate is centered and moves freely. Note: If binding occurs loosen the four cylinder head bolts and repeat steps 6 and . 11. Pull up on the mainshaft to retract the cutter plate to the highest position and close the feed valve to lock in position. NOTICE:

Ensure cutter bit is completely inserted into cutter slot. 12. Insert cutter into slot of cutter plate. Hold cutter bit against the main shaft of the boring tool and tighten the cutter plate set screw to secure the cutter. 13. Slowly lower the cutter and allow to rest onto engine block deck surface. Insert a 0.1016 mm (0.004 in.) shim between cutter and engine block. Set the depth of cut using bushing (PT8065). Tighten socket set screw to hold depth collar in place. See Figure "Upper Counterbore Cutting Area." .

Figure 3. Upper Counterbore Cutting Area. 14. Retract cutter plate to the up position and lock machine. 15. Attach a right angle drill (PT7145A) and proceed to bore hole until Porta Matic freewheels. 16. Open feed valve and retract cutter plate upward. Remove cutter bit. 17. Repeat steps 9 to for each of the next five bores. 18. Cut the counterbore ledge depth to 8.966 0.0254 mm (0.353 0.001 in.) using counterbore tool (PT2250B) and the appropriate cutter plates. Follow normal ledge cutting procedures to achieve the finished counterbore depth.

Checking Bearing Clearance

A strip of soft plastic squeezed between the crankshaft journal and the connecting rod bearing or main bearing may be used to measure the bearing clearances. The strip is a specially molded plastic wire manufactured commercially and is available in three sizes and colors. Type PG-1 (green) has a clearance range of 0.0254-0.0762 mm (0.001 -0.003 in.). Type PR-1 (red) has a range of 0.0508-0.1524 mm (0.002 -0.006 in.). Type PB-1 (blue) has a range of 0.1016-0.2286 mm (0.004 -0.009 in.). The plastic strip may be used for checking the bearing clearances as follows: 1. Remove the bearing cap and wipe the oil from the bearing shell and the crankshaft journal to be checked.

Note: Check the main bearing clearances with the weight of the crankshaft supported by a jack under the counterweight adjoining the bearing being checked. If the engine is positioned with the main bearing caps supporting the crankshaft and flywheel, an erroneous reading could result. 2. Place a piece of plastic strip the full width of the bearing shell, about 1/4 inch off center. See Figure "Using Plastic Strip to Measure Bearing-to-Crankshaft Clearance" .

Figure 4. Using Plastic Strip to Measure Bearing-to-Crankshaft Clearance 3. Install the bearing cap. Torque the bolts to 470-530 Nm (347-391 lbft). 4. Remove the bearing cap. The flattened plastic strip will be found adhering to either the bearing shell or the crankshaft. 5. Compare the width of the flattened plastic strip at its widest point with the graduations on the envelope. See Figure "Using Plastic Strip to Measure Bearing-to-Crankshaft Clearance" . The value within the graduation on the envelope indicates the bearing clearance in thousands of an inch. To obtain metric specifications: 1. Multiply the reading obtained (in thousandths) by 25.4. Taper may be indicated when one end of the flattened plastic strip is wider than the other. 2. Measure each end of the plastic strip. The difference between the two readings is the approximate amount of taper.

CRANKSHAFT REMANUFACTURING PROCEDURES

This section describes the procedures used to remanufacture crankshafts.

Crankshaft Grinding
In addition to the standard size main and connecting rod bearings, 0.254 mm, 0.508 mm and 0.762 mm (approximately 0.010 in., 0.020 in., and 0.030 in.), underseas bearings listed in Table "Crankshaft Journal Specifications" are available.

Crankshafts which exhibit surface irregularities may be reground to utilize these bearings. Listed in Table "Crankshaft Journal Specifications" , are guidelines to determine if the crankshaft is suitable for regrinding:

Bearing Size 11 & 12L Connecting Rod Journal Diameter 85.000 - 84.975 mm Standard (3.346 in. - 3.345 in.)

14L Connecting Rod Journal Diameter 95.000 - 94.975 mm (3.740 in. - 3.739 in.)

Main Bearing Journal Diameter 125.000 - 124.975 mm (4.921 in. - 4.920 in.)

0.254 mm (0.010 in.) Undersize 0.508 mm (0.020 in.) Undersize 0.762 mm (0.030 in.) Undersize

*84.750 - 84.775 mm (3.336 in. - 3.337 in.)

94.750 - 94.775 mm (3.730 in. - 3.731 in.)

*124.750 - 124.725 mm (4.911 in. - 4.910 in.)

*84.500 - 84.475 mm (3.327 in. - 3.326 in.)

94.500 - 94.475 mm (3.720 in. - 3.719 in.)

*124.500 - 124.475 mm (4.902 in. - 4.901 in.)

*84.250 - 84.225 mm (3.317 in. - 3.316 in.)

94.250 - 94.225 mm (3.711 in. - 3.709 in.)

*124.250 - 124.225 mm (4.892 in. - 4.891 in.)

Table 3. Crankshaft Journal Specifications Note: * Dimension of reground crankshaft.

Inspection
Perform the following steps for part inspection: 1. Determine if the crankshaft is from an 11.1 liter engine or a 12.7 liter engine. Listed in Table "Crankshaft Part Number History" are the forging number history for Series 60 crankshafts. Series 60 Crankshaft Part Number History Model Forging Part Number 11.1 Liter 12.7 Liter 8929238 8929239 Year Released 1986 1986 Induction Hardened Induction Hardened Fillet Finishing

14 Liter 23522887 1998 Induction Hardened 2. Table 4. Crankshaft Part Number History 3. Inspect connecting rod and main bearing journals for discoloration due to excessive overheating from bearing failure. Note: Crankshafts with discoloration are not acceptable for rework. 4. Inspect keyway conditions using width gages and micrometers. Compare with the specifications. See Figure "Standard Crankshaft Keyway Dimensions" .

Figure 5. Standard Crankshaft Keyway Dimensions 5. Inspect flange bolt holes visually and determine if any necessary repairs can be made by chasing threads or installing heli-coil(s). 6. Regardless of seal area wear condition, a new sleeve and seal must be installed. 7. Read and record all "bearing" total indicator reading (TIR) measurements with the crankshaft mounted in vee blocks. Listed in Table "Bearing Total Indicator Reading (TIR) Specifications" are TIR limits. Note: Run-out tolerance listed in Table "Bearing Total Indicator Reading (TIR) Specifications" are given for guidance when regrinding crankshaft. When the run-out on adjacent journals is in the opposite direction, the sum must not exceed 0.076 mm (0.003 in.) total indicator reading. When the run-out on adjacent journals is in the same direction, the difference must not exceed 0.076 mm (0.003 in.) total indicator reading.

Journals Supported On No. 1 and No. 7 No. 1 and No. 7 No. 1 and No. 7

Journals Measured No. 2 and No. 6 No. 3 and No. 5 No. 4

Maximum Run-Out (Total Indicator Reading) 0.076 mm (0.003 in.) 0.127 mm (0.005 in.) 0.152 mm (0.006 in.)

Table 5. Bearing Total Indicator Reading (TIR) Specifications 8. Whether run-out on adjacent journals is in the same or opposite directions, the sum shall not exceed 0.076 mm (0.003 in.) TIR. 9. When high spots of run-out adjacent journals are at right angles to each other, the sum shall not exceed 0.10 mm (0.004 in.) TIR or 0.05 mm (0.002 in.) on each journal. 10. In the event of bearing seizure, bearing overlay must be removed. Check the width of journals to determine whether the sidewalls can be reground. See Figure "Standard Crankshaft Dimensions" for location of crankshaft dimensions. Crankshaft specifications are listed in Table "Crankshaft Specifications" .

Figure 6. Standard Crankshaft Dimensions

Location A

Diameter, mm (in.) 11.1 L 132.970-133.000 mm (5.235-5.236 in.)

Location

Diameter, mm (in.) 12.7 L 133.670-133.770 mm (5.263-5.264 in.)

B C D E (11 & 12 L) E (14 L) F G H

80.19-80.22 mm (3.157-3.158 in.) 131.72-131.78 mm (5.185-5.188 in.) 49.35-49.65 mm (1.943-1.955 in.) 84.975-85.000 mm (3.345-3.346 in.) 94.975-95.000 mm (3.742-3.743 in.) 49.45-49.55 mm (1.947-1.950 in.) 131.72-131.78 mm (5.186-5.188 in.) 55.77-56.07 mm (2.196-2.208 in.)

Table 6. Crankshaft Specifications 11. Visually inspect the entire crankshaft for any serious deviations from normal wear patterns, cracks, nicks or other damage. 12. If the crankshaft has been ground undersize prior to present receiving inspection, check fillets, thrust, and all widths to determine whether or not enough stock remains to warrant regrinding. See Figure "Standard Crankshaft Dimensions" for location of crankshaft dimensions. Listed in Table "Series 60 Crankshaft Remanufacturing Tolerances" are crankshaft remanufacturing tolerances. Crankshaft Specifications Journal Diameter - Main Bearing Minimum 124.975 mm (4.920 in.) Maximum 125.000 mm (4.921 in.) 85.000 mm (3.346 in.) 95.000 mm (3.743 in.) 0.015 mm (0.0006 in.) Tolerance 0.025 mm (0.001 in.) 0.025 mm (0.001 in.) 0.025 mm (0.001 in.) 0.015 mm (0.0006 in.)

Journal Diameter - Connecting Rod 84.975 mm Bearing (3.345 in.) 14L Journal Diameter - Connecting 94.975 mm Rod Bearing (3.742 in.) Journal Out-of-Round - Main Bearing

Crankshaft Specifications Journal Out-of-Round - Connecting Rod Bearing Journal Taper - Main Bearing - Full Length Journal Taper - Connecting Rod Full Length Journal Taper Connecting Rod Half - Length Gear Fit Run-out TIR (Total Indicated Reading) Journal Alignment - Main and Connecting Rod - Per Length of Pin Axial Profile Slope - Main - Full Length Axial Profile Slope - Mains Per 5.0 mm (0.197 in.) of Length Axial Profile Slope - Connecting Rod Journals - Full Length Axial Profile Slope - Connecting Rod Journals - Per 5.0 mm (0.197 in.) of Length Main and Connecting Rod Fillet Radius Main and Connecting Rod Fillet Radius Surface Finish - Main and Connecting Rod Journals Surface Finish - Thrust Wall Surface Finish - Oil Seal Area

Minimum

Maximum 0.010 mm (0.0004 in.) 0.013 mm (0.0005 in.) 0.010 mm (0.0004 in.) 0.005 mm (0.0002 in.) 0.030 mm (0.0012 in.) 0.012 mm (0.0005 in.) 0.008 mm (0.0003 in.) 0.006 mm (0.00024 in.) 0.006 mm (0.0002 in.) 0.003 mm (0.0001 in.)

Tolerance 0.010 mm (0.0004 in.) 0.013 mm (0.0005 in.) 0.010 mm (0.0004 in.) 0.005 mm (0.0002 in.) 0.030 mm (0.0012 in.) 0.012 mm (0.0005 in.) 0.008 mm (0.0003 in.) 0.006 mm (0.00024 in.)

3.5 mm (0.1378 in.)

4.0 mm (0.1575 in.)

0.3 m 12 AA 0.3 m 12 AA 0.4 m 16 AA 0.4 m 16 AA 2.0 m 80 AA 2.0 m 80 AA

Crankshaft Specifications Journal Hardness (Rockwell C) Crankshaft Dynamic Balance (Ounce - Inch) Main and Connecting Rod Journal Alignment Per Length of Pin Crankshaft - Convex

Minimum 47 Rc

Maximum 55 Rc 1.5 0.012 mm (0.0004 in.) 0.013 mm (0.0005 in.) 0.03 mm (0.0011 in.) 56.07 mm (2.208 in.)

Tolerance 8 Rc 1.5

0.043 mm (0.0017 in.) 0.043 mm (0.0017 in.) 0.30 mm (0.012 in.)

Butt Face Concave

55.77 mm (2.196 in.)

Pin Width

Timing Gear Diameter (must 133.67 (5.263 133.70 mm 0.030 mm maintain 0.003 -0.005 in. press fit) in.) (5.264 in.) (0.0012 in.) 13. Table 7. Series 60 Crankshaft Remanufacturing Tolerances 14. Journal O.D. score marks must be: 1. Circumferential-not axial. 2. Maximum of 0.254 mm (0.010 in.) wide. 3. At least 3.175 mm (0.125 in.) from fillet tangent point. 4. Smooth, no proud metal. 5. Maximum of one mark per journal. 15. No journal dimpling permitted for removal of defects. 16. Nicks, dents or pits in journal O.D. must be 3.175 mm (0.125 in.) maximum diameter, no proud metal, maximum (3) per journal. 17. Pins and bearing journals which exhibit discoloration due to excessive overheating from bearing failure are not acceptable for rework. 18. If one or more main or connecting rod journals require grinding, then grind all of the main journals or all of the connecting rod journals to the same required size. 19. Inspect the hardness of all journals. Crankshafts to be 47-55 Rc. 20. Clean the crankshaft as follows: 1. Clean all oil passages with a brush. Power probing is recommended. 2. Remove all copper, brass and lead, etc., from journal surfaces. Scrub the crankshaft until clean in a detergent bath. 3. Extremely rusted shafts can be soaked in hot rust stripper. 4. Scrub all webs and counterweights with a wire brush to remove all blackened residue. Use industrial detergent at proper ratios or regular hot degreaser.

NOTICE:
A crack in any vital area of the crankshaft cannot be repaired or removed. That is why magnetic particle inspection of the entire crankshaft before regrinding is mandatory. Crankshafts that are cracked MUST BE SCRAPPED. 21. After a visual inspection, the crankshaft should be magnetically inspected using one of the two following methods: 1. Magnetic Particle Method: Refer to "1.7.2.6 Magnetic Particle Method" . 2. Fluorescent Magnetic Particle Method: Refer to "1.7.2.8 Fluorescent Penetrant Method" .

MACHINING OPERATIONS
The following topics cover machining operations:

Main and Connecting Rod Journals

Main and Connecting Rod Journals: 1. Connecting rod and main bearing journal grinding should be performed with crankshaft rotation opposite to actual engine rotation. See Figure "Crankshaft Grinding Rotation" . Note: Crankshaft and main journal grinding should be performed with crankshaft rotation opposite to actual engine rotation. While polishing should be performed with the crankshaft rotation in the same direction as engine rotation.

Figure 7. Crankshaft Grinding Rotation 2. Crankshaft polishing should be performed with the crankshaft rotation in the same direction as engine rotation. 3. All connecting rod journal fillets must have a 5.75 mm (0.226 in.) radius between the crank cheek and the journal.

4. All connecting rod journal fillets must have a 5.75 mm (0.226 in.) radius between the crank cheek and the journal. All main journal fillets must have a 3.75 mm (0.148 in.) radius between the crank cheek and the journal. 5. No journal may have any sharp grind marks. The fillet must blend smoothly into the journal and the crank cheek and must be free of scratches. 6. The radius may be checked with a fillet gage. See Figure "Crankshaft Journal Fillets" .

Figure 8. Crankshaft Journal Fillets 7. Lobing and Chatter: The number of lobes around the journal circumference, times the average peak to valley lobe height in micrometers, shall not exceed 42 micrometers. Peak to valley excursions exceeding 1.0 micrometers shall be considered lobing or chatter. 8. Excursions can be measured on a circular chart of the circumferential profile.

Grinding Connection Rod Journals (Pins)

Perform the following steps for grinding connection rod journals: 1. Grind the pin O.D. surface to the specified undersize. The undersize conditions are 0.254 mm, 0.508 mm or 0.762 mm (approximately 0.010 in., 0.020 in. or 0.030 in.). 2. ALL connecting rod journals must be ground to the same undersize condition. 3. Journal taper on a radial basis shall not exceed 0.008 mm (0.0003 in.) overall, or exceed 0.004 mm (0.00016 in.) on half-length. Note: Avoid localized heating, which often produces grinding cracks. Cool the crankshaft generously with coolant while grinding. Do not crowd the grinding wheel into the work. 4. Grind sidewalls wide enough to clean up the basic face surface, not to exceed pin width allowable. See Figure "Standard Crankshaft Dimensions" . 5. If there are deep interruptions, gouges or nicks that do not extend into fillets, smooth the edges with 120 grit emery cloth.

Grinding Main Bearing Journals

Perform the following steps for grinding main bearing journals: 1. Grind the main bearing O.D. surface to the specified undersize. The undersize conditions are 0.254, 0.508 or 0.762 mm (approximately 0.010, 0.020, or 0.030 in.). Note: Avoid localized heating, which often produces grinding cracks. Cool the crankshaft generously with coolant while grinding. Do not crowd the grinding wheel into the work. 2. ALL main bearing journals must be ground to the same undersize conditions. 3. Journal taper on a radial basis shall not exceed 0.012 (0.0005 in.) overall or exceed 0.006 mm (0.00024 in.) on half-length.

Other Machining Operations:

Perform the following steps for other machining operations: 1. Examine the thrust wall (No. 4 main bearing): 1. If the thrust wall surface is scored, scratched or groove worn, the thrust wall must be "bump ground." 2. The maximum run-out of the thrust wall is 0.038 mm (0.0015 in.) TIR. 3. If wear is 0.0508 mm (0.002 in.) or more, regrind to restore flatness to the thrust wall. See Figure "No. 6 Main Journal Thrust Wall Dimensions" .

Figure 9. No. 6 Main Journal Thrust Wall Dimensions

4. An oversize thrust wall is to be "bump ground" in multiples of 0.127 mm (0.005 in.), with a maximum of 0.250 mm (0.010 in.) to be removed from each side. Record oversize for installations. Note: Avoid localized heating, which often produces grinding cracks. Cool the crankshaft generously with coolant while grinding. Do not crowd the grinding wheel into the work. 2. Chamfer all oil holes to remove grinding burrs to the limit shown on illustrations. See Figure "Oil Hole Specifications - Connecting Rod Journals 11.1 L Crankshaft (139 mm stroke) " . See Figure "Oil Hole Specifications Connecting Rod Journals - 12.7 L Crankshaft (160 mm stroke) " . See Figure "Connecting Rod Journal Oil Hole Chamfer Limits" . See Figure "Main Journal Oil Hole Chamfer Limits" .

Figure 10. Oil Hole Specifications - Connecting Rod Journals - 11.1 L Crankshaft (139 mm stroke)

Figure 11. Oil Hole Specifications - Connecting Rod Journals - 12.7 L Crankshaft (160 mm stroke)

Figure 12. Connecting Rod Journal Oil Hole Chamfer Limits

Figure 13. Main Journal Oil Hole Chamfer Limits 3. Repair the flywheel and pulley contact faces of the crankshaft to clean up the surface of any nicks, gouges or raised metal. The crankshaft face must be 0.013 mm (0.0005 in.) convex to 0.025 mm (0.001 in.) concave.

After-Grinding Inspection
Perform the following steps for after grinding: 1. Inspect the crankshaft by the magnetic particle method after grinding has been completed to determine whether the grinding operation has produced cracks. 2. Re-tap and check all internal threads with plug gages to determine acceptability. If necessary, heli-coil pulley and flywheel flange bolt holes with the following restrictions: Heli-coil 2 holes maximum per crankshaft end (front or rear). Helicoil of two adjacent holes at rear (forward end) is not permitted. 3. Demagnetize the crankshaft. 4. Clean the crankshaft and oil passages thoroughly with clean fuel oil.

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. 5. Dry the crankshaft with compressed air.

GLOSSARY
The following glossary terms support the Series 60 Engine.

Glossary Terms
AA - ARITHMETICAL AVERAGE: The average total sum of the heights and depths of the ridges and valleys above and below the mean reference line. Limits for journal surfaces are 0.3 m (12 AA). AXIAL PROFILE: The deviation of the journal surface from a reference line. Total peak to valley variation per full length of journal. AXIAL PROFILE SLOPE: The amount of variation tolerable from the mean reference line of the journal in a particular distance (example: 0.0025 mm [0.0001 in.] deviation / 2.54 mm [0.100 in.] length maximum). This specification indicates that any deviation in excess of 0.0025 mm (0.0001 in.) inside a 2.54 mm (0.100 in.) length is not acceptable. GOULD 1200: Surfanalyzer 1200 surface texture measuring system is used to determine surface parameters such as profile, roundness and waviness. A diamond stylus having a radius of 0.0025-0.013 mm (0.0001 -0.0005 in.) is moved at a constant speed over the surface. Vertical displacements of this stylus are converted into a voltage signal through a linear variable differential transformer. OIL HOLE WASHOUT: The localized removal of material below the reference surface of an idealized round and straight journal at the trailing edge of the oil hole. This condition is the result of excessive polishing with a soft black apparatus (nut cracker, soft show, rawhide) with lapping paper or cloth in an attempt to improve the surface finish. A depression (washout) extending beyond the oil hole blend out ellipse reduces the effective bearing area appreciably. This type of polishing is not recommended. PIN and CRANKPIN: The cylindrical piece to which the connecting rod is attached. RADIAL CHATTER: This term relates to surface irregularities which are of greater magnitude or spacing than those indicated by the term roughness. Chatter might be the result of vibration or deflection of a cutting tool, of some part of the machine, or the work itself.

ENGINE PLUG AND DOWEL CHARTS

Following figures support the Series 60 Engine plugs and dowels.

1991 Model Year and Later

See Figure "Right Side View" ; see Figure "Left Side View" ; see Figure "Cylinder Head Deck" ; see Figure "Front View " ; see Figure "No. 6 Main Bearing Cap" ; and see Figure "Rear View " for plug and dowel information supporting 1991 model year and later Series 60 Engines.

1. 8922327 1/4 in. Pipe Plug (4 places). Torque to 19-24 Nm (14 -18 lbft). 2. 8929015 Dowel (Round) *

6. 8929163 Dowel (Diamond) *

7. 5139991 Cup Plug (5 places) |

3. 8929594 3/8 in. Pipe Plug (2 8. 8929152 Dowel (Round) * places). Torque to 24-31 Nm (18-23 lbft). 4. 8924140 Draincock 9. 8922327 1/4 in. Pipe Plug (1 place). Opposite Oil Level Dipstick Location. 10. 8929594 3/8 in. Pipe Plug (2 places). Torque to 24-31 Nm (18-23 lbft).

5. 8929022 Dowel (Diamond) (2 places)*

*Installed to a height of 12.0 mm 0.5 mm (0.472 in. 0.002 in.). Use tool (J362441) to install. Use tool (J362242) to install. Refer to illustration for orientation of dowels. | Cup plug 7 are installed 2.5-3.0 mm (0.098 in. -0.118 in.) below the machined surface. Use tool set (J35653) to install the cup plugs. Coat the

outside sealing edge of the cup plugs with a good grade of non-hardening sealant such as Loctite 620 (or equivalent) before installing.

Figure 14. Right Side View

1. 8929022 Dowel (Diamond) (2 places)*

5. 8923916 1/2 in. Pipe Plug (1 place). Torque to 31-39 Nm (23-29 lbft).

2. 8924517 3/8 in. Pipe Plug (2 6. 8929163 Dowel (Diamond) * places). Torque to 24-31 Nm (18-23 lbft). 3. 8922327 1/4 in. Pipe Plug (4 7. 8922327 1/4 in. Pipe Plug (2 places). Torque to 19-24 Nm (14 -18 places) . lbft). 4. 8929152 Dowel (Round) * 8. 8929015 Dowel (Round) *

*Installed to a height of 12.0 mm 0.5 mm (0.472 in. 0.002 in.). Use tool (J36244) to install. Use tool (J362442) to install. Refer to illustration for orientation of dowels.

 Required only for pressure testing of cylinder block. In service, these plugs are replaced by the oil pressure sensor (OPS), refer to "2.25.1 Replacement of the Oil Pressure Sensor" , and the oil temperature sensor (OTS), refer to "2.26.1 Replacement of Oil Temperature Sensor" . Figure 15. Left Side View

Figure 16. Cylinder Head Deck

Figure 17. Front View

Figure 18. No. 6 Main Bearing Cap

1.8929022 Dowel (Diamond-2 Places) 2.5139988 Cup Plug (2 Places) Figure 19. Rear View

3.8929015 Dowel (Round)

Pre-1991 Engines
See Figure "Right Side View" ; see Figure "Left Side View" ; see Figure "Cylinder Head Deck" ; see Figure "Front View " ; see Figure "No. 6 Main Bearing Cap" ; see Figure "Rear View " ; see Figure "Cylinder Head Dowel Chart" ; see Figure "Cylinder Head Cup, Pipe Plug, and Dowel Chart" ; and see Figure "Gear Case Dowel Chart" for plug and dowel information supporting pre-1991 model year Series 60 Engines.

1. 5139991 Cup Plug (6 places) |

6. 8922327 1/4 in. Pipe Plug (4 places). Torque to 19-24 Nm (14-18 lbft).

2. 8929015 Dowel (Round) * 7. 8923312 3/4 in. Pipe Plug (1 place). Torque to 45-56 Nm (31-39 lbft). 3. 8929022 Dowel (Diamond) 8. 8929152 Dowel (Round) * (2 places)* 4. 8929153 Dowel (Diamond) 9. 8922327 1/4 in. Pipe Plug (4 places). Torque to 19-24 Nm (14-18 lbft). 10. 8929594 3/8 in. Pipe Plug (2 places). Torque to 24-31 Nm (18-23 lbft). *Installed to a height of 12.0 mm 0.5 mm (0.472 in. 0.002 in.). Use tool (J362441) to install. Use tool (J362442) to install. Refer to illustration for orientation of dowels. Cup plug 7 are installed 2.5-3.0 mm (0.098 -0.118 in.) below the machined surface. Use tool set (J35653) to install the cup plugs. Coat the outside sealing edge of the cup plugs with a good grade of non-hardening sealant such as Loctite 620 (or equivalent) before installing. 5. 8924140 Draincock

Figure 20. Right Side View

1. 8929022 Dowel 5. 8923916 1/2 in. Pipe Plug (1 place). Torque (Diamond) (2 places)* to 31-39 Nm (23-29 lbft). 2. 8929594 3/8 in. Pipe Plug (2 places) Torque to 24-31 Nm (18-23 lbft). 6. 8929153 Dowel (Diamond) *

3. 8922327 1/4 in. Pipe 7. 8922327 1/4 in. Pipe Plug (2 places). Plug (4 places). Torque to Required only for pressure testing of cylinder 19-24 Nm (14-18 lbft). block. In service, these plugs are replaced by the oil pressure sensor (OPS). 4. 8929152 Dowel (Round) * 8. 8929015 Dowel (Round) *

*Installed to a height of 12.0 mm 0.5 mm (0.472 in. 0.002 in.) Use tool(J362241) to install. Use tool (J362242) to install. Refer to illustration for orientation of dowels.

Figure 21. Left Side View

1. 8929163 Dowel (Diamond) 2. 8929152 Dowel

3. 5151272 Plug (1.0 mm [0.040 in.] below surface)

Figure 22. Cylinder Head Deck

1. 8929022 Dowel (Diamond-2 Places) 2. 8920062 Dowel Pin Figure 23. Front View

3. 5139988 Cup Plug (2 Places) 4. Bull Gear Pilot Bore

Figure 24. No. 6 Main Bearing Cap

1. 8929022 Dowel (Diamond-2 Places) 2. 5139988 Cup Plug (2 Places) Figure 25. Rear View

3. 8929015 Dowel (Round)

1. 5138638 Dowel (Hollow) (7 places). 4. Cylinder Head Dowel Install to a height of 5.000 mm 0.254 mm (0.197 in. 0.010 in.). Bearing Cap 2. Rocker Arm Shaft 3. Camshaft Cap 5. Cylinder Head 6. 5143033 Dowel (Diamond) (3 places). Install to a height of 6.1 mm 0.5 mm (0.240 in. 0.010 in.)

Figure 26. Cylinder Head Dowel Chart

1. 5109157 Cup Plug (11 places) * 2. 5139991 Cup Plug (2 places) *

5. 8926991 Fuse Plug. Torque to 19-24 Nm (14-18 lbft). 6. 8923313 3/4 in. Pipe Plug (2 places). Torque to 45-56 Nm (33-41 lbft).

3. 23513197 3/8 in. Pipe Plug (Square 7. 8924750 1 in. Pipe Plug (1 Drive) (2 places). Torque to 30-33 Nm place). Torque to 102-127 Nm (22-24 lbft). (75-94 lbft). 4. 8923916 1/2 in. Pipe Plug (2 places). Torque to 31-39 Nm (23-29 lbft).

*Cup plugs 1 and 2 are installed 2.5-3.0 mm (0.098 in. -0.118 in.) below the machined surface. Use tool set (J35653) to install the cup plugs. Coat the outside sealing edge of the cup plugs with a good grade of non-hardening sealant such as Loctite 620 (or equivalent) before installing. Figure 27. Cylinder Head Cup, Pipe Plug, and Dowel Chart

Figure 28. Gear Case Dowel Chart

SPECIFICATIONS
Specifications, clearances and wear limits are listed below. It should be specifically noted that the clearances apply only when all new parts are used at the point where the various specifications apply. This also applies to references within the text of the manual. The column entitled "Limits" in this chart lists the amount of wear or increase of clearance which can be tolerated in used engine parts and still ensure satisfactory performance. It should be emphasized that the figures given as "Limits" must be qualified by the judgment of personnel responsible for installing new parts. These wear limits are, in general, listed only for the parts more frequently replaced in engine overhaul work. For additional information, refer to the text.

Specifications, New Clearances, and Wear Limits

These limits also apply to oversize and undersize parts. Refer to the following tables to obtain specifications, new clearances, and wear limits for the Series 60 Engine.

Component Cylinder block

Reference listed in Table "Cylinder Block"

Component Cylinder liner Cross-head piston and piston rings Articulated 14L piston and piston rings Cross-head cast-iron piston pin Articulated 14L piston pin Crankshaft Connecting rod bearing Closed-end connecting rod bushing Main bearing Camshaft Camshaft bearing Camshaft drive gear Idler gear Crankshaft timing gear Bull gear Cylinder head Intake valve (diesel) seat insert Intake valve (natural gas) seat insert

Reference listed in Table "Cylinder Liner" listed in Table "Cross-head Piston and Piston Rings" listed in Table "Articulated 14L Piston and Piston Rings" listed in Table "Cross-head Cast Iron Piston Pin" listed in Table "Articulated Steel Piston Pin" listed in Table "Crankshaft" listed in Table "Connecting Rod Bearing" listed in Table "Closed-End Connecting Rod Bushing" listed in Table "Main Bearing" listed in Table "Camshaft" listed in Table "Camshaft Bearing" listed in Table "Camshaft Drive Gear" listed in Table "Idler Gear" listed in Table "Crankshaft Timing Gear" listed in Table "Bull Gear" listed in Table "Cylinder Head" listed in Table "Intake Valve Seat Inserts (Diesel)" listed in Table "Intake Valve Seat Inserts (Natural Gas)"

Component Exhaust valve (diesel) seat insert Exhaust valve (natural gas) seat insert Intake valves (diesel) Intake valves (natural gas) Exhaust valves (diesel) Exhaust valves (natural gas) Valve guides (diesel) Valve guides (natural gas) Rocker arms and shaft (diesel) Rocker arms and shaft (natural gas) Cam follower roller Exceptions to standard fastener torque specifications Series 60 Diesel valve lash, Jake Brake lash and camshaft timing specifications

Reference listed in Table "Exhaust Valve Seat Inserts (Diesel)" listed in Table "Exhaust Valve Seat Inserts (Natural Gas)" listed in Table "Intake Valves (Diesel)" listed in Table "Intake Valves (Natural Gas)" listed in Table "Exhaust Valves (Diesel)" listed in Table "Exhaust Valves (Natural Gas)" listed in Table "Valve Guides (Diesel)" listed in Table "Valve Guides (Natural Gas)" listed in Table "Rocker Arms and Shafts (Diesel)" listed in Table "Rocker Arms and Shafts (Natural Gas)" listed in Table "Cam Follower Roller" listed in Table "Exceptions to Standard Fastener Torque Specifications (1 of 2)" listed in Tables "Series 60 Diesel Valve Lash, Jake Brake Lash and Camshaft Timing Specifications Table (1 of 3)" , and .

Series 60 Gas valve lash and listed in Table "Series 60 Gas Valve Lash and camshaft timing specifications Camshaft Timing Specifications" Table 20. Engine Component Reference Table Engine Part (Standard Size, New) Block Bore: Diameter - 15.0 mm (0.59 in.) from top of block Minimum 149.050 mm (5.868 in.) Maximum 149.120 mm (5.871 in.) Limits

Engine Part (Standard Size, New) Diameter - 235.0 mm (9.25 in.) from top of block Diameter - 270.0 mm (10.63 in.) from top of block Out-of-round

Minimum 146.050 mm (5.750 in.) 146.050 mm (5.750 in.)

Maximum 146.125 mm (5.753 in.) 146.125 mm (5.753 in.)

Limits 0.076 mm (0.003 in.) 0.076 mm (0.003 in.) 0.0254 mm (0.001 in.) 0.0254 mm (0.001 in.)

Taper (lower bore) Cylinder Liner Counter Bore: Diameter

157.15 mm (6.187 in.) 8.9256 mm (0.3514 in.) 133.00 mm (5.236 in.) 436.50 mm (17.1850 in.)

157.25 mm (6.191 in.) 8.9746 mm (0.3533 in.) 133.020 mm (5.237 in.) 436.62 mm (17.1898 in.)

* Depth Main Bearing Bore: Inside diameter (vertical axis) Top Surface of Block: Center of main bearing bore to top of block Flatness (transverse)

0.076 mm (0.003 in.) 0.127 mm (0.005 in.)

Flatness (longitudinal) Table 21. Cylinder Block

Note: * The bottom of the counterbore must not vary in depth more than 0.04 mm (0.0016 in.). No two adjacent counterbores can vary in depth more than 0.025 mm (0.001 in.) when gaged longitudinally.

Engine Part (Standard Size, New) Outside Diameter (below flange) Outside Diameter (below crevice seal groove)

Minimum

Maximum

Limits

148.95 mm (5.864 149.00 mm (5.866 in.) in.) 145.975 mm (5.747 in.) 146.025 mm (5.749 in.) 146.025 mm (5.749 in.) 9.00 mm

Outside Diameter (between "D" 145.975 mm (5.747 ring grooves) in.) Flange Thickness 8.960 mm (0.3527 in.)

(0.3543 in.)

Inside Diameter

130.00 mm (5.118 130.05 mm (5.120 in.) in.) 133.00 mm (5.236 133.05 mm (5.238 in.) in.) -0.0127 mm (0.0005 in.) 0.0762 mm (0.003 in.)

14 L - Inside Diameter

0.025 mm (0.001 in.) 0.0508 mm (0.002 in.)

Out-of-Round (inside diameter) Taper Height of Flange Above Block Variation in Height between Adjacent Liners Table 22. Cylinder Liner Engine Part (Standard Size, New) At top (above firing ring)

Minimum 128.63 mm (5.064 in.) 129.776 mm (5.1093 in.)

Maximum 128.83 mm (5.072 in.) 129.845 mm (5.112 in.)

Limits

Below (2nd) compression ring Compression Rings

Engine Part (Standard Size, New) Gap (2.5 mm [.0985 in.] chrome fire ring) Gap (3.5 mm plasma [.1379 in.] fire ring) (High sulfur fuel export engines) Gap (No. 2 compression ring) Clearance ring-to-groove:

Minimum 0.40 mm (0.016 in.) 0.51 mm (0.020 in.) 0.79 mm (0.031 in.) must be checked with Piston Ring Land gage (J35884 A)

Maximum 0.87 mm (0.034 in.) 0.87 mm (0.034 in.) 1.30 mm (0.051 in.)

Limits

Top (keystone fire ring)

must be checked with Piston No. 2 (keystone compression ring) Ring Land Gage (J38689 A) Oil Control Rings Gap 0.40 mm (0.016 in.) 0.03 mm Clearance * Piston Pin Bore in Dome (3-piece bushing) (0.001 in.) 51.000 mm (2.0079 in.) 0.050 mm Piston Skirt to Liner Clearance (thrust faces) (0.0020 in.) Table 23. Cross-head Piston and Piston Rings

0.81 mm (0.032 in.) 0.11 mm (0.004 in.) 51.025 mm (2.0089 in.) 0.183 mm (0.0072 in.)

Note: * Both ends must be measured on vertical and horizontal planes.

Engine Part (Standard Size, New) At top (above firing ring)

Minimum 131.60 mm

Maximum 131.70 mm

Limits

Engine Part (Standard Size, New)

Minimum (5.181 in.) 132.685 mm

Maximum (5.185 in.) 132.715 mm (5.2250 in.) 0.80 mm (0.0315 in.) 0.98 mm (0.0386 in.)

Limits

Below (2nd) compression ring Compression Rings Gap (3.0 mm chrome fire ring) Gap (No. 2 compression ring) Clearance ring-to-groove: Top (keystone fire ring) No. 2 (keystone compression ring) Oil Control Rings Gap

(5.2238 in.) 0.60 mm (0.0236 in.) 0.63 mm (0.0248 in.) must be checked with Piston Ring Land Gage(J35884A) must be checked with Piston Ring Land Gage(J38689) 0.21 mm (0.0083 in.) 0.03 mm

0.51 mm (0.0201 in.) 0.11 mm (0.004 in.) 55.065 mm (2.1679 in.) 0.183 mm (0.0072 in.)

Clearance

(0.001 in.) 55.05 mm

* Piston Pin Bore in Dome

(2.1673 in.)

0.050 mm Piston Skirt to Liner Clearance (thrust faces) (0.0020 in.) Table 24. Articulated 14L Piston and Piston Rings

Note: * Both ends must be measured on vertical and horizontal planes.

Engine Part (Standard Size, New)

Minimum

Maximum

Limits

Table 25. Cross-head Cast Iron Piston Pin Engine Part (Standard Size, New) Steel Piston Pin Diameter Minimum Maximum Limits

54.992 mm (2.1650 55.000 mm (2.1653 54.96 mm (2.1638 in.) in.) in.) Table 26. Articulated Steel Piston Pin Engine Part (Standard Size, New) Journal Diameter (main bearing) Minimum 124.968 mm (4.920 in.) 84.963 mm (3.345 in.) 94.975 mm (3.739 in.) Maximum 125.000 mm (4.921 in.) 85.000 mm (3.346 in.) 95.000 mm (3.740 in.) Limits

Journal Diameter (connecting rod bearing) 14L - Journal Diameter (connecting rod bearing) Journal Out-of-Round (ROD)

0.008 mm (0.0003 in.) 0.0127 mm (0.0005 in.) 0.0127 mm (0.0005 in.) 0.008 mm (0.0003 in.) 0.004 mm (0.0002 in.) 0.075 mm (0.003 in.) 0.127 mm (0.005 in.) 0.152 mm (0.006 in.)

Journal Out-of-Round (MAIN)

Journal Taper: Main Bearing

Connecting Rod (full length)

Connecting Rod (half length) * Run-out on Journals-Total Indicator Reading (mounted on No. 1 and 7 Journals): At Journals No. 2 and 6 At Journals No. 3 and 5

At Journal No. 4

Engine Part (Standard Size, New) No. 6 Main Bearing Journal Thrust Width

Minimum 49.45 mm (1.947 in.) 3.48 mm

Maximum 49.53 mm (1.950 in.) 3.56 mm (0.140 in.) 0.419 mm (0.0165 in.)

Limits

Thrust Washer Thickness

(0.137 in.) 0.099 mm (0.0039 in.)

End Play (end thrust clearance) Table 27. Crankshaft

Note: * Run-out tolerance given for guidance when regrinding crankshaft. When the run-out on adjacent journals is in the opposite direction, the sum must not exceed 0.076 mm (0.003 in.) total indicator reading. When the run-out on adjacent journals is in the same direction, the difference must not exceed 0.076 (0.003 in.) total indicator reading.

Engine Part (Standard Size, New) Bearing-to-Journal Clearance Bearing Thickness 90 degrees from Parting Line 14L Bearing Thickness 90 degrees from Parting Line Table 28. Connecting Rod Bearing Engine Part (Standard Size, New) Diameter

Minimum 0.040 mm (0.0016 in.) 3.108 mm (0.1224 in.) 3.111 mm (0.1225 in.)

Maximum 0.127 mm (0.005 in.) 3.125 mm (0.1230 in.) 3.124 mm (0.1230 in.)

Limits 0.152 mm (0.006 in.) 3.086 mm (0.1215 in.)

Minimum

Maximum 55.070 mm (2.16811 in.)

Limits 55.100 mm (2.16929 in.)

55.055 mm (2.16752 in.) Table 29. Closed-End Connecting Rod Bushing Engine Part (Standard Size, New) Bearing-to-Journal Clearance Bearing Thickness 90 degrees from Parting Line Minimum 0.040 mm (0.0016 in.) 3.960 mm (0.1559 in.)

Maximum 0.127 mm (0.005 in.) 3.977 mm (0.1566 in.)

Limits 0.151 mm (0.006 in.) 3.937 mm (0.1550 in.)

Table 30. Main Bearing Engine Part (Standard Size, New) Diameter (bearing journals) Run-out at Center Bearing (when mounted on end bearings should not exceed) End Thrust Table 31. Camshaft Engine Part (Standard Size, New) Bearing-to-Journal Clearance Bearing Thickness (90 degrees from Parting Line) Table 32. Camshaft Bearing Engine Part (Standard Size, New) Camshaft Drive Gear Bore Outside Diameter: Camshaft Hub Minimum 0.089 mm (0.0035 in.) 1.941 mm (0.0764 in.) Maximum 0.166 mm (0.0065 in.) 1.954 mm (0.0769 in.) Limits 0.191 mm (0.0075 in.) Minimum 64.974 mm (2.558 in.) Maximum 65.000 mm (2.5559 in.) Limits

0.381 mm

0.050 mm (0.002 in.)

0.076 mm (0.003 in.)

(0.015 in.)

Minimum

Maximum

Limits

52.00 mm (2.0472 52.03 mm (2.0484 in.) in.)

52.10 mm (2.0511 52.13 mm (2.0523 in.) in.) 0.13 mm 0.07 mm (0.0027 in.)

* Interference (gear-to-hub)

(0.0051 in.) 0.229 mm

0.305 mm (0.012 in.)

Backlash -(cam gear-to0.051 mm (0.002 adjustable idler) in.) Table 33. Camshaft Drive Gear

(0.009 in.)

Engine Part (Standard Size, New) Backlash (adjacent idler-to-cam idler) Table 34. Idler Gear

Minimum

Maximum 0.229 mm

Limits

0.051 mm (0.002 0.305 mm (0.012 in.) (0.009 in.) in.)

Note: * A minimum force of 20.0 kN (4500 lb.) must be obtained when pressing the camshaft drive gear to the drive gear hub.

Engine Part (Standard Size, New) 11.1 Liter Engine

Minimum 132.860 mm (5.2307 in.) 133.561 mm (5.2583 in.)

Maximum

Limits

132.900 mm (5.2322 in.)

12.7 Liter Engine * Interference (gear-tocrankshaft) Backlash: Crank Gear-to-Bull Gear

133.600 mm (5.2598 in.)

0.076 mm (0.003 0.102 mm (press) (0.004 in.) in.) (press) 0.051 mm (0.002 in.) 0.229 mm (0.009 in.) 0.229 mm

0.305 mm (0.012 in.) 0.305 mm (0.012 in.)

Crankshaft Gear-to-Oil 0.051 mm (0.002 Pump Drive Gear in.) Table 35. Crankshaft Timing Gear

(0.009 in.)

Note: *A minimum force of 30 kN (6750 lb) must be obtained when pressing the crankshaft timing gear on the crankshaft.

Engine Part (Standard Size, New) Backlash (Bull Gear-to-Water Pump, Accessory, Fuel Pump or Air Compressor Drive Gears) Table 36. Bull Gear

Minimum 0.051 mm (0.002 in.)

Maximum 0.229 mm

Limits

0.305 mm (0.009 in.) (0.012 in.)

Engine Part (Standard Size, New) Flatness (transverse)

Minimum

Maximum

Limits 0.076 mm (0.003 in.) 0.279 mm (0.011 in.)

Flatness (longitudinal)

Distance between Rail and Fire 164.85 mm (6.490 165.13 mm (6.501 Deck (new) in.) in.) Valve Insert Counterbore: Intake Valve: Diameter

46.12 mm (1.8157 46.15 mm (1.8169 in.) in.) 11.46 mm (0.4511 11.76 mm (0.4629 in.) in.)

Depth Valve Insert Counterbore: Exhaust Valve: Diameter

41.26 mm (1.6244 41.29 mm (1.6255 in.) in.) 10.70 mm (0.4212 11.00 mm (0.4330 in.) in.)

Depth Table 37. Cylinder Head Engine Part (Standard Size, New) Outside Diameter

Minimum 46.20 mm (1.8188 in.) 0.48 mm

Maximum 46.22 mm (1.8196 in.) 2.14 mm (0.084 in.)

Limits

Seat Width

(0.019 in.)

0.05 mm

Valve Seat Run-out

(0.002 in.)

Engine Part (Standard Size, New) Standard Seat Thickness

Minimum 5.55 mm

Maximum 7.256 mm (0.2857 in.)

Limits

(0.282 in.) Table 38. Intake Valve Seat Inserts (Diesel) Engine Part (Standard Size, New) Outside Diameter Minimum 46.20 mm (1.8188 in.) 0.83 mm Seat Width (0.033 in.)

Maximum 46.23 mm (1.820 in.) 4.24 mm (0.167 in.) 6.858 mm

Limits

0.05 mm

Valve Seat Run-out

(0.002 in.)

Standard Seat Thickness

6.756 mm (0.266 in.)

(0.133 in.)

Table 39. Intake Valve Seat Inserts (Natural Gas) Engine Part (Standard Size, New) Outside Diameter Minimum Maximum 41.36 mm 41.34 mm (1.627 in.) 0.67 mm Seat Width (0.026 in.) (1.628 in.) 2.66 mm (0.105 in.) 6.362 mm (0.2505 in.) 0.05 mm Valve Seat Run-out (0.002 in.) Limits

6.261 mm (0.2465 in.) Table 40. Exhaust Valve Seat Inserts (Diesel) Standard Valve Seat Thickness Engine Part (Standard Size, New) Outside Diameter Minimum 41.34 mm (1.627 in.)

Maximum 41.36 mm (1.628 in.)

Limits

Engine Part (Standard Size, New) Seat Width

Minimum 0.92 mm (0.036 in.)

Maximum 3.37 mm (0.133 in.) 6.060 mm

Limits 0.05 mm

Valve Seat Run-out

(0.002 in.)

Standard Valve Seat Thickness 5.958 mm (0.234 in.) Table 41. Exhaust Valve Seat Inserts (Natural Gas) Engine Part (Standard Size, New) Stem Diameter Valve Head-to-Cylinder Head 30 degrees (recess) Table 42. Intake Valves (Diesel) Engine Part (Standard Size, New) Stem Diameter Valve Head-to-Cylinder Head 30 degrees (recess) Table 43. Intake Valves (Natural Gas) Engine Part (Standard Size, New) Minimum

(0.238 in.)

Maximum

Limits

8.679 mm (0.3417 8.699 mm (0.3425 in.) in.) 1.9 mm (0.075 in.) 2.3 mm (0.091 in.)

Minimum 8.725 mm

Maximum

Limits

8.745 mm (0.3443 (0.3435 in.) in.) 0.80 mm (0.031 in.) 1.47 mm (0.058 in.)

Minimum

Maximum

Limits

P/N 23506350 P/N 23506350 8.679 mm (0.3417 in.) Stem Diameter 8.699 mm (0.3425 in.)

P/N 23524521 P/N 23524521 8.701 mm (0.3426 in.) 1.4 mm 8.721 mm (0.3433 in.) 1.8 mm

Valve Head-to-Cylinder Head 30 degrees (recess)

Engine Part (Standard Size, New)

Minimum (0.055 in.)

Maximum (0.071 in.)

Limits

Table 44. Exhaust Valves (Diesel) Engine Part (Standard Size, New) Stem Diameter Valve Head-to-Cylinder Head 20 degrees (recess) Table 45. Exhaust Valves (Natural Gas) Engine Part (Standard Size, New) Height Above Cylinder Head Diameter (inside) Minimum Minimum 8.712 mm 8.732 mm (0.3438 (0.3430 in.) in.) 0.82 mm (0.032 in.) 1.34 mm (0.053 in.) Maximum Limits

Maximum

Limits

37.5 mm (1.476 38.0 mm (1.496 in.) in.) 8.763 mm (0.345 8.785 mm (0.346 in.) in.)

Intake Valve P/N 8929590 0.152 mm (0.006 in.) Exhaust Valve P/N 23506350

Clearance (valve-to-guide, maximum)

0.152 mm (0.006 in.) Exhaust Valve P/N 23524521 0.101 mm (0.004 in.)

Table 46. Valve Guides (Diesel)

Engine Part (Standard Size, New) Height Above Cylinder Head

Minimum 37.5 mm (1.476 in.)

Maximum 38.0 mm (1.496 in.)

Limits

Diameter (inside)

8.759 mm (0.345 8.785 mm (0.346 in.) in.)

0.060 mm (0.002 in.) Intakes

Clearance (valve-to-guide, maximum)

0.073 mm (0.003 in.) Exhaust

Table 47. Valve Guides (Natural Gas) Engine Part (Standard Size, New) Rocker Shaft Diameter Steel Rocker Arm Bushing Diameter (inside) Clearance (shaft to bushing) (maximum): Bronze Bushing Steel Bushing Table 48. Rocker Arms and Shafts (Diesel) Engine Part (Standard Size, New) Rocker Shaft Diameter Minimum 35.992 mm (1.417 in.) Maximum 36.017 mm (1.418 in.) Limits 35.941 mm (1.415 in.) 0.057 mm (0.0022 in.) Minimum 35.992 mm (1.417 in.) 36.017 mm (1.418 in.) Maximum 36.017 mm (1.418 in.) 36.118 mm (1.422 in.) Limits 35.941 mm (1.415 in.) 36.195 mm (1.425 in.) 0.057 mm (0.0022 in.) 0.254 mm (0.010 in.)

Clearance (shaft to bushing) (maximum): Bronze Bushing Table 49. Rocker Arms and Shafts (Natural Gas)

Engine Part (Standard Size, New) Diameter Rollers and Pins: Clearance (pin-to-bushing) (maximum) (horizontal) Side Clearance (roller-to-follower) (maximum) Table 50. Cam Follower Roller

Minimum

Maximum 38.05 mm

Limits 0.08 mm

37.95 mm (1.494 in.) (1.498 in.)

(0.003 in.) 0.40 mm

(0.015 in.)

Exceptions to Standard Fastener Torque Specifications

Listed in Tables "Exceptions to Standard Fastener Torque Specifications (1 of 2)" and are exceptions to standard fastener torque specifications supporting the Series 60 Engine.

Section Refer to "1.6.3.1 Inspection of Two-piece Rocker Cover" Refer to "1.2.5 Installation of Cylinder Head"

Fastener Breather Housing to Rocker Cover Cap

Size

Nm 2.5

(lbft) 22

Cylinder Head Bolt M16 X (torque twice) Prior to 250 - 285 (184 - 210) 2.0 2002

Refer to "1.6.9 Installation of Cylinder Head Bolt Two-Piece and Three-Piece (torque twice) After 2002 Rocker Covers" Refer to "1.2.5 Installation of Cylinder Head" Bolt, Inj. Harness Mounting Flange

298

(220)

M8 X 1.25

10-15

(7-11)

Bolt, Rocker Cover-to Refer to "1.6.8 Installation of Cylinder Head (one piece 3/8-16 One-Piece Rocker Cover" cover) Refer to "1.6.8 Installation of One-Piece Rocker Cover" Bolt, Rocker Cover-to Cylinder Head (two & three piece)

20-25

(15-18)

30-38

(22-28)

Section Refer to "1.9.3 Installation of Main Bearings Shells (Crankshaft Removed)" Refer to "1.12 Gear Case PreExhaust Gas Recirculation (EGR)" Refer to "1.15.3 Installation of Crankshaft Pulley" Refer to "1.18.3 Installation of Flywheel Housing" Refer to "1.18.3 Installation of Flywheel Housing" Refer to "1.16.3 Installation of Flywheel" Refer to "1.22.4 Assembly of Connecting Rod"

Fastener

Size

Nm

(lbft)

Bolt, Main Bearing Cap

M20 X 470-530 (347-391) 2.5

Plug, Gear Case Adj. Idler Oil Hole

5/16-24

15-20

(11-15)

Bolt, Front Pulley Bolt, Flywheel Hsg. Mounting 12 mm Bolt, Flywheel Hsg. Mounting 14 mm Bolt, Flywheel

9/16-18 182-210 (134-155) M12 X 112-126 1.75

(83-93)

160-200 (118-148)

9/16-18 75(+60) (55)(+60) M14 X 160-185 (118-137) 1.5

Nut, Connecting Rod

Refer to "1.28.6 Installation of Bolt, Camshaft Bearing M12 X Camshaft and Camshaft 126-146 Cap 1.75 Bearing" Refer to "1.36.5 Installation of Model 760, 765, or 770 Jake Bolt, Rocker Arm Shaft Brake"

(93-108)

136

100

Refer to "1.28.6 Installation of Nut, Nos. 1&7 Camshaft M12 X Camshaft and Camshaft 126-146 Cap 1.75 Bearing" Refer to "1.28.5 Installation of Camshaft and Camshaft Bearing" Refer to "1.29.4 Installation of Camshaft Drive Gear" Stud, Nos. 1&7 Camshaft Cap M12 X 126-146 1.75 75( + 120)

(93-108)

(93-108)

Bolt (Solid), Camshaft M18 X Drive Gear 1.5

(55 + 120)

Section

Fastener

Size

Nm

(lbft) (42-49)

Refer to "1.24 Gear Train and Nut, Adjustable Idler M12 X 57-67 Engine Timing" Assy. 1.75 Table 51. Exceptions to Standard Fastener Torque Specifications (1 of 2) Refer to "1.33.3 Installation of Bull Gear and Camshaft Idler Gear Assembly" Bolt, Bull Gear Assy-to-Block M12 X 1.75

101(75-86) 116 (694738) (266295)

Refer to "1.33 Bull Gear and Camshaft Nut, Bull Gear Assy 9402-1/2-18 Idler Gear Assembly" (LH thread) 1001 Refer to "1.35.4 Assembly of the Accessory Drive" Nut, Accessory Drive Pulley M24 X 3.0 360400

Refer to "2.3.5 Installation of the N2 Bolt, Injector Hold 58-66 (43-49) Electronic Unit Injector" Down Clamp Table 52. Exceptions to Standard Fastener Torque Specifications (2 of 2) Camshaft Asm P/N Intake Exhaust Jake Jake Cam Injector Valve Valve Brake Brake Timing Height Lash Lash Model Lash Range 4.395.46 mm (0.1730.215 in.)

Model Engine Year DDEC

1988WU 11.1 L 89

II

8929484 / 485

78.2 0.203 0.508 0.660 mm mm mm mm 760A (3.079 (0.008 (0.020 (0.026 in.) in.) in.) in.)

WU 11.1 L

199093

II

8929484 / 485

4.3978.2 0.203 0.660 0.660 5.46 mm mm mm mm mm 760A (3.079 (.008 (0.026 (0.026 (0.173in.) in.) in.) in.) 0.215 in.)

SK

11.1 L

199497

III

4.9578.8 0.203 0.660 0.660 6.53 23518717 / mm mm mm mm mm 71823524899 760A (3.102 (0.008 (0.026 (0.026 (0.195/ 900 in.) in.) in.) in.) 0.257 in.) 23513563 / 78.8 0.203 0.660 760A 0.660 4.95-

WK 11.1 L 1994-

III

97

562 mm mm mm 23524897 / (3.102 (0.008 (0.026 898 in.) in.) in.)

6.53 mm mm 0(.026 (0.195in.) 0.257 in.) 5.466.71 mm (0.2150.264 in.)

EK

11.1 L 1998

IV

23522199 / 81.0 0.203 0.660 0.584 200 mm mm mm mm 760B 23524903 / (3.189 (0.008 (0.026 (0.023 904 in.) in.) in.) in.)

LK

11.1 L 1999

IV

5.2123524654 / 81.0 0.203 0.660 .0584 6.27 655 mm mm mm mm mm 760B 23524913 / (3.189 (0.008 (0.026 (0.023 (0.205914 in.) in.) in.) in.) 0.247 in.) 4.395.46 mm (0.1730.215 in.)

1988 GU 12.7 L / 89

II

8929472 / 473

78.2 0.203 0.508 0.660 mm mm mm mm 760A (3.079 (0.008 (0.020 (0.026 in.) in.) in.) in.)

*GU 12.7 L

1990 / 93

II

78.2 0.203 0.660 23505194 / mm mm mm 195 (3.079 (0.008 (0.026 in.) in.) in.)

4.390.660 5.46 mm mm 765 (0.026 (0.173in.) 0.215 in.) 4.950.660 6.53 mm mm 765 (0.026 (0.195in.) 0.257 in.) 765 0.660 5.36mm 6.76 (0.026 mm in.) (0.2110.266

GK 12.7 L

1994 / 97

III

23513565 / 78.8 0.203 0.660 564 mm mm mm 23524905 / (3.102 (0.008 (0.026 906 in.) in.) in.)

GK 12.7 L 1998

III

23521680 / 80.3 0.203 0.660 681 mm mm mm 23524907 / (3.161 (0.008 (0.026 908 in.) in.) in.)

in.) Table 53. Series 60 Diesel Valve Lash, Jake Brake Lash and Camshaft Timing Specifications Table (1 of 3) *GU40 is equipped with a Model 760A Jake Brake. Use 760A lash specifications when servicing. Jake Camshaf Injecto Intake Exhaus Jake Cam Brake t Asm r Valve t Valve Brake Timing Mode P/N Height Lash Lash Lash Range l 5.362352168 80.3 0.203 0.660 0.584 6.76 0 / 681 mm mm mm mm mm 765A 2352490 (3.161 (0.00 (0.026 (0.02 (0.2117 / 908 in.) 8 in.) in.) 3 in.) 0.266 in.) 5.032352429 81.0 0.203 0.660 0.584 6.10 1 / 292 mm mm mm mm mm 770 2352491 (3.189 (0.00 (0.026 0(.02 (0.1981 / 912 in.) 8 in.) in.) 3 in.) 0.240 in.) 5.032352429 81.0 0.203 0.660 0.660 6.10 1 / 292 mm mm mm mm mm 790 2352491 (3.189 (0.00 (0.026 (0.02 (0.1981 / 912 in.) 8 in.) in.) 6 in.) 0.240 in.) 6.52782.1 0.203 0.660 0.813 7.594 2352830 mm mm mm mm mm 795 8 / 309 (3.232 (0.00 (0.026 (0.03 (0.257in.) 8 in.) in.) 2 in.) 0.299 in.) 5.8930.203 0.660 0.508 6.960 mm mm mm mm 797 (0.00 (0.026 (0.02 (0.2328 in.) in.) 0 in.) 0.274 in.)

Model

Engin DDE Year e C

PK,TK

12.7 L 1998

IV

MK,BK

12.7 L 1999

IV

MK,BK

12.7 L 2000

IV

MK,BK

12.7 L

2000 -02

IV

MK

12.7 L 2002

IV

82.1 2352860 mm 5 / 606 (3.232 in.)

MK_E

12.7 L

2002 -03

IV

82.1 2353113 mm 0 (2.232 in.)

6.4520.203 0.508 0.508 7.214 mm mm mm mm 797 (0.00 (0.020 (0.02 (0.2548 in.) in.) 0 in.) 0.284 in.) 6.6550.203 0.508 0.508 7.214 mm mm mm mm 797 (0.00 (0.020 (0.02 (0.2628 in.) in.) 0 in.) 0.284 in.)

MV_E

12.7 L

2004 -06

See 2353369 Serv. 4 Manua l

5.112352398 80.3 0.203 0.660 0.508 6.17 DAEWOOTK6 2000 2 / 983 mm mm mm mm mm 12.7 L IV 797A K -04 2352491 (3.161 (0.00 (0.026 (0.02 (0.2017 / 918 in.) 8 in.) in.) 0 in.) 0.243 in.) Table 54. Series 60 Diesel Valve Lash, Jake Brake Lash and Camshaft Timing Specifications Table (2 of 3) MK and BK models with 0712 Valve Mechanism are equipped with a model 770 Jake Brake. Use 770 lash specifications when servicing. Intake Exhaust Jake Jake Cam Camshaft Injector Valve Valve Brake Brake Timing Asm P/N Height Lash Lash Model Lash Range 5.030.584 6.10 mm mm 770 (0.023 (0.198in.) 0.240 in.)

Model Engine Year DDEC

HK

14.0 L 1999

IV

23524291 81.0 0.203 0.660 / 292 mm mm mm 23524911 (3.189 (0.008 (0.026 / 912 in.) in.) in.)

HK

14.0 L 2000

IV

5.0323524291 81.0 0.203 0.660 0.660 6.10 / 292 mm mm mm mm mm 790A 23524911 (3.189 (0.008 (0.026 (0.026 (0.198/ 912 in.) in.) in.) in.) 0.240 in.) 23528308 / 309 82.1 mm 0.203 mm 0.660 mm 795 0.813 6.527mm 7.594

HK

14.0 L 200002

IV

(3.232 (0.008 (0.026 in.) in.) in.)

mm (0.032 (0.257in.) 0.299 in.) 6.4520.508 7.214 mm mm 797 (0.020 (0.254in.) 0.284 in.) 6.6550.508 7.214 mm mm 797 (0.020 (0.262in.) 0.284 in.)

HK_E 14.0 L

200003

IV

82.1 0.203 0.508 mm mm mm 23531130 (3.232 (0.008 (0.020 in.) in.) in.)

2004HV_E 14.0 L 06

0.203 0.508 See mm mm 23533694 Serv. (0.008 (0.020 Manual in.) in.)

HK62 14.0 L 2000

IV

5.0381.0 0.203 0.660 0.660 6.10 23524911 mm mm mm mm mm 790C / 912 (3.189 (0.008 (0.026 (0.026 (0.198in.) in.) in.) in.) 0.240 in.) 6.52 0.813 7.594 mm mm 795 (0.032 (0.257in.) 0.299 in.)

2000 HK62 14.0 L 03

IV

82.1 0.203 0.660 23528308 mm mm mm / 309 (3.232 (0.008 (0.026 in.) in.) in.)

6.52 82.1 0.203 0.508 0.508 7.594 200423528308 mm mm mm mm mm HK62 14.0 L IV 797A 06 / 309 (3.232 (0.008 (0.020 (0.020 (0.257in.) in.) in.) in.) 0.299 in.) Table 55. Series 60 Diesel Valve Lash, Jake Brake Lash and Camshaft Timing Specifications (Table 3 of 3) Intake DDEC Camshaft/Asm P/N Valve Lash Exhuast Service Cam Valve Lash Timing Range

Model Engine Year

TKG

12.7

1995III 98

23520286 / 627 23524909 / 910

2.18-2.87 mm 0.279 mm 0.914 mm (0.086-0.113 (0.011 in.) (0.036 in.) in.)

TKG

2.18-2.87 mm 0.279 mm 0.914 mm (0.086-0.113 (0.011 in) (0.036 in.) in.) Table 56. Series 60 Gas Valve Lash and Camshaft Timing Specifications EPA04 Series 60 Workshop Manual (DDC-SVCPrinted Mon Sep 13 14:49:16 MAN-0004) 2010 12.7 1998IV 04 23520286 / 627 23524909 / 910 Copyright 2010 by Detroit Diesel Corporation. All rights reserved. Generated on 09-07-2010