DD Series 60 Engine Manual.Pdf

ATTENTION This document is a guideline for qualified personnel. It is intended to be used by equipment manufacturers and contains Detroit Diesel Corporation's recommendations for the ancillary systems supporting the Detroit Diesel engines covered by this document. The equipment manufacturer is responsible for developing, designing, manufacturing and installing these systems, including component qualification. The equipment manufacturer is also responsible for furnishing equipment users complete service and safety information for these systems. Detroit Diesel Corporation makes no representations or warranties regarding the information contained in installation of these ancillary systems, or the preparation or distribution to equipment users of preliminary and incomplete and is subject to change without notice. TRADEMARK INFORMATION Series 50®,Series60®, DDEC®, Ether Start®, and Diagnostic Link® are registered trademarks of Detroit Diesel Corporation. Fuel Pro® and Pro-Chek® are registered trademarks of Davco Manufacturing, L.L.C. Viton® is a registered trademark of Dupont Dow Elastomers L.L.C. Loctite® is a registered trademark of Loctite Corporation. Delco Remy® is a registered trademark of Delco Remy America, Inc. Leece-Neville® is a registered trademark of Leece-Neville Company. SERIES 60 AND SERIES 50 CONSTRUCTION AND INDUSTRIAL AND MARINE APPLICATION AND INSTALLATION SERIES 60 AND SERIES 50 CONSTRUCTION AND INDUSTRIAL AND MARINE APPLICATION AND INSTALLATION ABSTRACT This manual discusses the proper application and installation of the Detroit Diesel Series 50 and Series 60 engine. The intention of this manual is to provide information in general terms so that it may be applicable for all applications unless specifically noted or identified. This manual contains the following information: General information on safety precautions and on accessing installation drawings Specific component and accessory information on varius production models Information on the air inlet, exhaust, cooling, fuel, lubrication, electrical, mounting, and starting aid systems. Information on the data to be found in the PowerEvolution Network (PEN), a web based computer system that provides information such as technical data and installation drawings. Distributors may access PEN through the Detroit Diesel extranet. OEMs requiring access to PEN should contact Application Engineering for authorization. All information subject to change without notice. (Rev. 10/04) i 7SA747 0410 Copyright © 2004 DETROIT DIESEL CORPORATION ABSTRACT ii All information subject to change without notice. (Rev. 10/04) 7SA747 0410 Copyright © 2004 DETROIT DIESEL CORPORATION SERIES 60 AND SERIES 50 CONSTRUCTION AND INDUSTRIAL AND MARINE APPLICATION AND INSTALLATION TABLE OF CONTENTS 1 INTRODUCTION ................................................................................................................. 1- 1 2 SAFETY PRECAUTIONS ................................................................................................... 2- 1 2.1 STANDS .......................................................................................................................... 2- 1 2.2 GLASSES ....................................................................................................................... 2- 1 2.3 WELDING ....................................................................................................................... 2- 2 2.4 WORK PLACE ............................................................................................................... 2- 3 2.5 CLOTHING ...................................................................................................................... 2- 4 2.6 ELECTRIC TOOLS ......................................................................................................... 2- 4 2.7 AIR .................................................................................................................................. 2- 5 2.8 FLUIDS AND PRESSURE .............................................................................................. 2- 5 2.9 BATTERIES ..................................................................................................................... 2- 6 2.10 FIRE ................................................................................................................................ 2- 6 2.11 FLUOROELASTOMER ................................................................................................... 2- 7 3 ENGINE AND ACCESSORY IDENTIFICATION ................................................................ 3- 1 3.1 MAJOR COMPONENT LOCATIONS ............................................................................. 3- 8 3.1.1 SERIES 60 CONSTRUCTION AND INDUSTRIAL ENGINE ...................................... 3- 8 3.1.2 SERIES 60 PETROLEUM ENGINE ........................................................................... 3-13 3.1.3 SERIES 60 MARINE ENGINES ................................................................................. 3-18 3.2 ENGINE IDENTIFICATION ............................................................................................. 3-28 4 AIR INLET SYSTEM ........................................................................................................... 4- 1 4.1 AIR INLET SYSTEM DESCRIPTION .............................................................................. 4- 1 4.1.1 SERIES 60 AND SERIES 50 CONSTRUCTION AND INDUSTRIAL ENGINES ........ 4- 2 4.1.2 SERIES 60 MARINE ENGINES ................................................................................. 4- 5 4.2 INSTALLATION REQUIREMENTS ................................................................................. 4- 8 4.2.1 DRY PAPER ELEMENT AIR CLEANERS .................................................................. 4- 8 LIGHT-DUTY AIR CLEANER ............................................................................... 4- 9 MEDIUM-DUTY USE AIR CLEANER ................................................................... 4-10 HEAVY-DUTY USE AIR CLEANER ..................................................................... 4-11 EXTRA HEAVY-DUTY USE ................................................................................. 4-12 FOAM TYPE AIR CLEANERS .............................................................................. 4-13 OIL-BATH AIR CLEANERS .................................................................................. 4-13 AUXILIARY PRECLEANERS ................................................................................ 4-14 INLET SCREENS ................................................................................................. 4-14 RAIN CAPS AND INLET HOODS ........................................................................ 4-15 WATER DRAINS ................................................................................................... 4-15 INLET SILENCERS .............................................................................................. 4-15 AIR CLEANER SELECTION ................................................................................ 4-16 4.2.2 RESTRICTION INDICATOR ....................................................................................... 4-16 4.2.3 PIPEWORK ................................................................................................................ 4-18 PIPEWORK MATERIAL SPECIFICATIONS ......................................................... 4-18 DIFFUSERS ......................................................................................................... 4-18 All information subject to change without notice. (Rev. 10/04) iii 7SA747 0410 Copyright © 2004 DETROIT DIESEL CORPORATION TABLEOFCONTENTS 4.2.4 HOSE CONNECTIONS .............................................................................................. 4-19 4.2.5 MARINE ENGINE DUCTED AIR ................................................................................ 4-20 4.2.6 MARINE ENGINE CHARGE AIR COOLER CONDENSATION DRAIN ...................... 4-21 4.3 DESIGN GUIDELINES .................................................................................................... 4-22 4.3.1 MAXIMUM AIR INLET FLOW .................................................................................... 4-22 4.3.2 AIR INLET SYSTEM RESTRICTION ......................................................................... 4-22 PETROLEUM ENGINE FLAMETRAP .................................................................. 4-23 4.3.3 INLET LOCATION ....................................................................................................... 4-23 4.3.4 AIR-TO-AIR CHARGE AIR COOLER ........................................................................ 4-24 RESTRICTION AND TEMPERATURE REQUIREMENTS ................................... 4-25 PETROLEUM ENGINE COMPRESSOR OUTLET TEMPERATURE CONSIDERATIONS ............................................................................................. 4-26 CLEANLINESS ..................................................................................................... 4-26 LEAKAGE ............................................................................................................. 4-26 SIZE ...................................................................................................................... 4-27 COOLING AIR FLOW RESTRICTION ................................................................. 4-27 MATERIAL ...........................................................................................................

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