The cylinder block is the basic engine structure, establishing and maintaining the alignment of all engine working parts. In the Series 60 Engine, the cylinder bores are not an integral part of the block casting, but are in the form of replaceable, wet type cylinder liners. See Figure 1-1.
Flanges at the liner upper ends seat in counterbores in the block deck, and project slightly above the deck to compress the head gasket for a good compression seal. Below the water jacket the lower end of the cylinder liner has two D-shaped seal rings and a lipped crevice seal to prevent leakage between the water jacket and crankcase.
An integral coolant inlet manifold is cored into the right side of the block. It distributes the water pump output along the length of the block. Oil galleries are machined into the cooler side of the block. See Figure 1-1.
The integral oil galleries direct the oil pump output through the external oil cooler and filters, to the main oil gallery and to drilled passages in the crankcase webs which supply oil under pressure to each main bearing. In the crankcase, five integral webs plus front and rear bulkheads support the crankshaft in seven main bearings. See Figure 1-2.
An improved cylinder block has replaced the former block on all Series 60 engines. This change took effect with unit serial number 6R210293, built November 30, 1994. The former cylinder block was used on engines built prior to this serial number.
The Series 60 cylinder block was further improved by the addition of a drilled lubrication orifice and bolt hole at the base of each cylinder bore. See Figure 1-2. The orifices are drilled into the main oil gallery and are required for installation of bolt-on oil spray nozzles used with forged steel pistons on premium engines. When blocks are used for non-premium engines with cast-iron pistons, the lubrication orifices are closed with bolt-on steel plates. First usage of the drilled block was on May 2, 1998, effective with engine serial number 6R408505.
The improved block permits installation of adaptorless Bendix and Midland air compressors onto the gear case. The improved block is similar to the former block, except that it has a slightly modified sidewall configuration that eliminates interference between the block and the adaptorless compressor. To compensate for the elimination of the adaptor, air compressor mounting bracket bolt holes have been moved forward 130.3 mm (5.13 in.) on the block. See Figure 1-3. Since these holes have a different spacing than the former holes, an improved compressor mounting bracket is required. A new air compressor coolant supply port has also been added forward of the former supply port. The former port is plugged when the adaptorless compressor is installed.
When replacing a former block with an improved block, it is recommended (but not necessary) that an adaptorless air compressor, improved compressor mounting bracket, and improved compressor coolant supply hose be installed. Refer to section 11.1.3, of this manual for information on installing the adaptorless air compressor.