Detroit Diesel Troubleshooting Diagrams

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Series 60 DDEC II Engine Sensor Harness

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An improved vehicle engine sensor harness which virtually eliminates the potential for wire chafing damage has replaced the former harness on all Detroit Diesel Series 60 DDEC II engines. This change took effect approximately October 30, 1992

Detroit Diesel has found instances of chafing on the sensor connector harness (part number 8929468) used on DDEC II engines. The chafing can occur at the end of the plastic tee-coupling where the wires from the 30-way connector enter the coupling.  The chafing results from the absence of abrasion-resistant, convoluted tubing around the wires. Installing convoluted tubing is impractical due to the shortness of the wires at this point. With no abrasion-resistant material surrounding the wires, the rough plastic ridges inside the leg of the tee-coupling can cut through the wire coatings, exposing the wires to moisture and potential shorting. Shorting can result in the logging of false DDEC trouble codes. ‪

Series 60 DDEC II Engine Sensor Harness Series 60 DDEC II Engine Sensor Harness

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October 19th, 2011 at 3:35 am

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Series 60 DDEC III/IV Engine Sensor Harness

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The DDEC III/IV engine sensor harness for vehicle engines was originally equipped with five metal retaining clips and was secured to the engine cylinder block with bolts. Effective with engines built in May of 1995, three of the metal clips were replaced by three plastic push-in clips.

Due to a hardware change made in October of 1995 to the DDEC ® III ECM, a path to ground can arise during ECM powerdown which may allow unintended engine cranking. ‪

Unintended engine cranking can occur if all of the following conditions exist: ‪

  • The engine has an ECM manufactured between October of 1995 and September of 1996.
  • The engine is equipped with the Optimized Idle feature.
  • The ignition remains turned on while battery power is removed from the ECM during servicing.

Note: This condition will not occur on engines manufactured after September of 1996.

To address this concern and eliminate the potential for unintended engine cranking under the conditions listed above, an Optimized Idle Starter Relay Harness Overlay Service Kit was released for engines with ECM’s manufactured between October of 1995 and September of 1996. ‪

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October 19th, 2011 at 3:32 am

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Series 60 Tachometer Drive Adaptor

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October 17th, 2011 at 3:00 am

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Series 60 Tachometer Drive Parts

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The Series 60 engine can be configured with or without a mechanical tachometer drive. A camshaft drive gear access cover mounted to the gear case cover and a slotted head camshaft bolt must be used with the mechanical tachometer drive option.

Series 60 Tachometer Drive Parts Series 60 Tachometer Drive Parts

1. Attaching Bolts ‪ 4. Camshaft Drive Gear Access Cover ‪
2. Tachometer Drive Adaptor ‪ 5. Tachometer Drive Shaft ‪
3. Tachometer Drive Unit ‪

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October 17th, 2011 at 2:46 am

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Series 60 Cranking Circuit

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The cranking circuit may contain a key start switch or push switch (or both), a relay, magnetic switches, solenoids, oil pressure switch, fuel pressure switch, and other protective devices. For the complete cranking circuit, refer to the vehicle manufacturer’s wiring diagram.

A solenoid, mounted on the cranking motor housing, operates the over-running clutch drive by linkage and a shift lever. When the start switch is closed, the magnetic switch contacts close, and the solenoid windings are connected to the battery. The resulting plunger and shift lever movement causes the pinion to engage the engine flywheel ring gear and the solenoid main contacts to close, and the cranking takes place.

Series 60 Cranking Circuit Series 60 Cranking Circuit

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October 17th, 2011 at 2:32 am

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Series 60 Cranking Motor Parts

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When the cranking circuit is closed, a drive pinion on the armature shaft engages with the teeth on the engine flywheel ring gear to crank the engine. When the engine starts, it is necessary to disengage the drive pinion to prevent the armature from overspeeding and damaging the cranking motor. To accomplish this, the cranking motor is equipped with an over-running clutch within the drive pinion. The cranking motor drive pinion and the engine flywheel ring gear must be matched to provide positive engagement and to avoid clashing of the gear teeth. ‪

Note: Some engines may be equipped with air starters. Contact starter manufacturer for operating characteristics and rebuilding procedures.

The 42 MT cranking motor typically used on the engine has a nose housing that can be rotated to obtain a number of different solenoid positions with respect to the mounting flange. The commutator end cap can be removed to inspect the brushes, in most cases, without removing the cranking motor from the vehicle. ‪

Note: The 50 MT cranking motor is used on heat exchanger-cooled pleasure craft marine engines.

The cranking motor armature is supported by three sintered bronze bearings located, one each, in the nose and intermediate housings, with one in the commutator end cap.

Series 60 Cranking Motor Parts Series 60 Cranking Motor Parts

1. O-ring ‪ 10. Shift Mechanism (Totally Enclosed) ‪
2. End Cap (Removal for Inspection) ‪ 11. Two-piece Housing ‪
3. Bronze Bearing ‪ 12. O-ring ‪
4. Connector Strap ‪ 13. Shaft ‪
5. Gasket ‪ 14. Heavy-duty Drive Overrunning Clutch ‪
6. Low Friction Bushing ‪ 15. Shaft ‪
7. Seamless, One-piece Solenoid Case ‪ 16. O-ring ‪
8. O-ring ‪ 17. Shaft Seal ‪
9. Sealing Boot ‪ 18. One-piece Brush ‪

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October 17th, 2011 at 2:30 am

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Series 60 Cranking Motor Mounting

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The cranking motor is bolted to the flywheel housing.

Series 60 Cranking Motor Mounting Series 60 Cranking Motor Mounting

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October 17th, 2011 at 2:26 am

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Tensioner Parts Series 60 2002 Engine

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Tensioner Parts Series 60 2002 Engine Tensioner Parts Series 60 2002 Engine

1. Alternator Bracket ‪ 2. Bolts ‪
3. Tensioner ‪

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October 17th, 2011 at 2:25 am

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Alternator Mounting Bracket for Series 60 2002 Engine

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October 17th, 2011 at 2:22 am

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Series 60 Alternator Parts

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The battery charging alternator provides a source of electrical current for maintaining the storage battery in a charged condition and supplies sufficient current to carry any other electrical load requirements up to the rated capacity of the alternator. ‪

The battery charging circuit consists of an alternator, with an integral voltage regulator, a battery(s) and the connecting wiring.

Series 60 Alternator Parts Series 60 Alternator Parts

1. Nut (2) ‪ 8. Bolt, Adjusting Rod-to-Engine ‪
2. Nut ‪ 9. Pulley, Alternator Drive ‪
3. Alternator ‪ 10. Locknut ‪
4. Bolt, Alternator-to-Adjusting Rod ‪ 11. Bolt, Alternator-to-Mounting Bracket ‪
5. Washer ‪ 12. Mounting Bracket ‪
6. Alternator Adjusting Rod ‪ 13. Bolt, Mounting Bracket-to-Engine (2) ‪
7. Nut ‪ 14. Drive Belts ‪

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October 15th, 2011 at 7:50 am

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