Updated gear lash procedures for the compact gear train assembly have been added to the Series 60 Service Manual.

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1 NUMBER: S.M. REF.: 1.21 ENGINE: 60 DATE: November 2003 SUBJECT: GEAR TRAIN AND CAMSHAFT GEAR LASH PROCEDURES FOR THE COMPACT GEAR TRAIN ASSEMBLY INTRODUCTION Updated gear lash procedures for the compact gear train assembly have been added to the Series 60 Service Manual. DETAILS AND REASON Procedures for measuring and adjusting gear lash for the compact gear train assembly have been updated. This procedure is now shown in a separate step to avoid confusion with engines that are not equipped with a compact gear train assembly. 1. The gear lash procedures for the compact gear train are as follows: [a] Install the gear lash pedestal tool, J onto the center of the camshaft drive gear. See Figure 1. Bar the engine over until the tool is at the three o clock position. [b] Attach the magnetic base on dial indicator to the gear case cover. Adjust it so the dial indicator is positioned at a 90 angle to the measuring bar and is at the scribe line on the bar. See Figure 1.

2 1. Adjustable Idler Gear Retaining Nut 3. Dial Indicator 2. Magnetic Base Figure 1 Compact Gear Train Gear Lash Measurement NOTE: Since the teeth of the camshaft drive gear are not accessible, the gear lash measuring adaptor has a predetermined spot where the lash measurement must be taken. The measurement bar must be installed into the magnetic base correctly and the dial indicator positioned between the marks at the end of the bar. [c] [d] [e] Adjust the stem of the dial indicator to rest on the flat of the pedestal between the scribed marksontheendbarata90 angle. If the adjustable idler gear has been removed, torque the three flanged nuts that retain the adjustable idler gear hub to the gear case to N m (42-49 lb ft) to seat the assembly before proceeding. Loosen the three locknuts that retain the adjustable idler gear hub to the gear case until they are hand tight.

3 [f] Insert the dowel portion of the gear lash adjusting tool, J through the hole in the adjustable idler gear retaining plate and into the adjustable idler gear hub, using the bottom two adjustable idler gear cover bolt holes. See Figure 1. Figure 2 Compact Gear Train Lash Adjustment NOTE: For Series 60 engines equipped with the compact gear train, tool J needs to be modified to fit the four bolt pattern of the idler gear cover. A simple modification to the mounting plate will allow it to be securely bolted to the cover. [g] [h] [i] Hold the adjustable idler gear by inserting a screwdriver through the access hole provided in the gear case cover. Engage between two of the idler gear teeth and apply upward pressure on the screwdriver to move the gear in a counterclockwise direction. This will prevent the gear from moving. See Figure 2. Rotate the camshaft by hand and watch the dial indicator pointer. Turn the adjusting screw of the gear lash adjusting tool J 35596, approximately 1-1/2 turns. Gear lash should be mm ( in.). Hold the adjustable idler gear with screwdriver refer to step [g]. Repeat steps [h] and [i] until proper lash is obtained.

4 NOTE: If there is zero lash between the two gears, the dial indicator pointer will not move from zero. [j] Check the gear lash with the pedestal at the 3, 6, 9, and 12 o clock positions, exactly as previously performed. [k] When the proper readings of mm ( in.) are obtained at all four positions, hold the idler gear and torque the three adjustable idler gear flanged nuts to N m (76-83 lb ft.). [l] Remove the gear lash adjusting tool and check the gear lash again. Refer to step [j]. If gear lash is not correct repeat steps [e] through [j]. [m] If proper lash measurement cannot be obtained, replace gear(s) with new part(s). [n] Remove the dial indicator and pedestal from the gear case. [o] Before installing the rocker arm shaft assemblies, check the torque on the end studs to ensure they were not loosened at the time of removal. The torque specification is N m (75-86 lb ft). [p] Install the rocker arm shaft assemblies to the cylinder head. Refer to section [q] Adjust the intake and exhaust valve clearances, and fuel injector heights. Refer to section [r] Install the valve rocker cover. Refer to section for a one-piece valve rocker cover and refer to section for two piece and three piece rocker covers. [s] Install the camshaft drive gear access cover and the gear case cover. Refer to section

5 ADDITIONAL SERVICE INFORMATION Additional service information is available in the Detroit Diesel Series 60 Service Manual, 6SE483. The next revision to this manual will include the revised information. As a convenience to holders of the Series 60 Service Manual, information in service manual format is attached. The page(s) may be inserted into the manual. NOTE: Manual insert pages are numbered for insertion into the current Series 60 Service Manual dated March Service manuals are available from authorized Detroit Diesel distributors. If this bulletin was obtained from the Internet, service manual page(s) are available by returning to the screen SIB Index, selecting attachment pages, and printing the page(s).

6 Detroit Diesel, DDC,Series60 and the spinning arrows design are registered trademarks of Detroit Diesel Corporation. Copyright 2003 Detroit Diesel Corporation. All rights reserved. Printed in U.S.A.