Service Bulletin No.2984 - Motor Coach Industries

04SUBJECT
CONDITIONS
Nov. 21, 2007J4500 Series Coaches Service Information
PARTS SUPPLEMENT FOR DETROIT DIESEL CORP. ( DDC ) S60 2007 EPA ENGINE EQUIPPED COACH
Service Information Only
Description: Effective with unit number 64455 MCI started production of J4500 model coaches equipped with Detroit Diesel S60 2007 engines. This service information bulletin contains parts pages for the Detroit Diesel S60 engine. The part pages are divided into numbered sections. Each section is divided into subsections, which contain partsbreak---down fora specific installation and/or assembly. Pages and illustrations are numbered consecutively within each section. A table of contents is provided, outlining the numbered sections.
Each section contains only Basic and Option installations.
NOTE The information contained herein is based upon the most recent engineering revision levels pertaining to a basic MCI J4500 model coach equipped with a Detroit Diesel S60 engine.
2007 J4500 DDC S60 Supplement
MOTOR COACH INDUSTRIES, INC.
Section Index
DRYER ASSEMBLY-AIR, HALDEX 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EZ START VALVE INSTALLATION - ZF TRANSMISSION 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PRESSURE PROTECTION VALVE-INSTALLATION 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BRACKET ASSEMBLY-TAG DUMP, J4500 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BRACKET ASSEMBLY-VALVE, TAG UNLOAD 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
JUNCTION BLOCK ASSEMBLY-ACCESSORY, REAR 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MANIFOLD ASSEMBLY-SUSPENSION, AIR 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MANIFOLD ASSEMBLY-SUSPENSION, AIR 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TANK ASSEMBLY-AIR, REAR SERVICE 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TANK ASSEMBLY-EMERGENCY 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TANK ASSEMBLY-AIR, SUPPLY 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COOLANT LINES INSTALLATION - S60, ZF AST 54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FAN DRIVE INSTALLATION - 2007 EPA ENGINE 50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FAN DRIVE GEAR BOX 46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DRIVESHAFT-FAN DRIVE 48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COOLING MODULE 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section 7 - Electrical
BATTERY COMPARTMENT INSTALLATION - MECH W/O CHARGER 104. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BATTERY COMPARTMENT INSTALLATION-ELECTRICAL 106. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CPC INSTALLATION-S60, 2007 94. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation Assembly/Sub -Assembly Page. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DASH HARNESS AND MODULE INSTALLATION 108. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ECU INSTALLATION-B500/B500R TRANSMISSION 100. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE LIGHTING AND FIRE DETECTOR INSTALLATION 58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
IMMERSION HEATER - DETROIT DIESEL S60 66. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTRUMENT PANEL ASSEMBLY, METRIC W/O SMARTWAVE 62. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTRUMENT PANEL ASSEMBLY, IMPERIAL W/O SMARTWAVE 64. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTRUMENT PANEL ASSEMBLY, METRIC W/SMARTWAVE 80. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTRUMENT PANEL ASSEMBLY, IMPERIAL W/SMARTWAVE 82. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
JUNCTION BOX INSTALLATION-FRONT, MUX 72. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BOX ASSEMBLY-JUNCTION, FRONT, MUX 70. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
JUNCTION BOX, REMOTE, W/DUAL BOSCH 76. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
JUNCTION BOX, REMOTE, W/DELCO 50DN 78. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
JUNCTION BOX, REAR - INSTALLATION 84. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BOX ASSEMBLY-JUNCTION, REAR 68. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MANIFOLD ASSEMBLY - AIR, LH SERVICE COMPARTMENT, FRONT 74. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REGEN SWITCH BOX INSTALLATION 96. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section 8 - Engine
CRADLE INSTALLATION-ENGINE 124. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE BUILDUP ASSEMBLY-S60 W/DUAL BOSCH AND ZF AST 120. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE INSTALLATION - DDC S60 W/DUAL BOSCH 118. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DIESEL PARTICULATE FILTER INSTALLATION-S60 132. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DIESEL PARTICULATE FILTER ASSEMBLY, 2007 DDC S60 128. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PANEL INSTALLATION-RADIATOR CLOSING, 2007 ENGINE 126. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PIPE INSTALLATION-EXHAUST, S60 130. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section 9 - Fuel System
AIR INTAKE INSTALLATION - S60, 2007 136. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FUEL INSTALLATION-S60 FUELPRO 138. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section 11 - Steering
Section 12 - Suspension
Installation Assembly/Sub -Assembly Page. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section 13 - Transmission
TRANSMISSION COOLER INSTALLATION-B500, S60 150. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section 16 - Heating and Air Conditioning
AUXILIARY HEATER INSTALLATION-PROHEAT X45, S60 154. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AUXILIARY HEATER - PROHEAT X-45 BLOWER ASSEMBLY 156. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AUXILIARY HEATER - PROHEAT X-45 ELECTRICAL SYSTEM 158. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AUXILIARY HEATER - PROHEAT X-45 HEAT EXCHANGER ASSEMBLY 160. . . . . . . . . . . . . . . . . . . . . . . . . . . .
AUXILIARY HEATER - PROHEAT X-45 COMPRESSOR ASSEMBLY 162. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AUXILIARY HEATER - PROHEAT X-45 MISCELLANEOUS PARTS 164. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BOOST PUMP INSTALLATION-S60 152. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
04 -1
0 -1
02 5A
1 2
Key MCI Part No. Description Qty
04-10-1025 Dryer Assembly-Air, Haldex
04-10-6021 Desiccant Cartridge 1
04-10-6023 Heater Kit w/24V 1
04-10-6024 Check Valve 1
2 19-1-446 Screw-Cap, Hex Head 3
3 19-10-141 Fitting-Pipe, 90 Degree Street Elbow 1
4 19-10-1472 Fitting-Brake, Male Elbow, 3/4 Inch O.D. 1
5 19-10-1496 Adapter 1
7 19-10-2243 Fitting-Str, 1/4T, 1/4NPT, Push In, Brass 1
8 19-10-2283 Fitting-Compression, 3/4 Tube, 1/2MPT 1
9 19-2-10 Washer-Flat, Plain, 1/2 Inch I.D., Steel Zinc 3
10 19-2-29 Washer-Lock, 1/2 Inch, Steel Zinc Plated 3
Sec/GrpPage 3 04.15Date July 2007
04 -1
5 -1
13 4A
04-15-1134 BRAKE VALVE AIRLINE INSTALLATION - J4500
1 04-20-1027 Bracket Assembly-System Fill 1
2 04-22-1032 Decal-System Fill 1
3 19-10-1093 Fitting-Muffler, 1/4 Inch Pipe Thread, 2
4 19-10-1336 Fitting-Brake, Male Elbow, 3/8 Tube OD 1
5 19-10-143 Fitting-Pipe, Street Tee, 1/4 Inch Pipe Thread 1
6 19-10-1962 Fitting-Nipple, Air, 1/4 NPT 2
7 19-10-302 Fitting-Pipe, Bulkhead Coupling, 1/4 4
8 19-10-1337 Fitting-Brake, Male Connector, 3/8 Inch O.D. 1
9 19-10-1394 Fitting-Brake, Male Connector, 1/4 Tube OD 2
10 19-10-1928 Fitting-Brass, Straight, 1/2 NTA, 1/4 NPT 1
11 24-51-0050 Moulding-Edge W/Glue Bead 1
12 04-22-1169 Assy Plate-System Fill 1
13 04-22-1109 Valve Assy-System Fill 1
17 19-10-286 Fitting-Pipe, Male Branch Tee, 1/4 Pipe 3
18 4C-22-17 Valve 2
20 07-13-1634 Manifold Assembly-Air, LH Service Compartment, Front (See 07-13-1634 for service parts)
1
23 19-1-519 Screw-Cap, Hex Hd Flanged 2
24 19-11-259 Tyrap-13.38 Inch Long 17
25 19-13-291 Rivet-Blind, Multi Grip Flush Break Pull 3
26 19-2-62 Washer-Flat, .344IDx.750ODx.046Thk, 3
27 19-4-24 Clamp-Support, Line, Neoprene Covered 1
28 19-4-86 Clamp-Line Support, Vinyl Covered, 2Id, 2
29 19-2-27 Washer-Lock, Spring, Split, 3/8 OD, Steel 1
30 24-54-0027 Loom-Corr, 1/4 Inch ID 2.7
31 24-54-0033 Loom-Coil, 1 Inch O.D. 0.5
32 21-7408-155 Tube-Airline, Nylon, 1/4 Inch OD, Black 29.5
33 24-54-0007 Tube-Airline, Nylon, 1/4 Inch OD, Yellow, Synflex 17
34 24-54-0008 Tube-Airline, Nylon, 3/8 Inch OD, Brown, Synflex 21
35 24-54-0009 Tube-Airline, Nylon 3/8 Inch OD, Green, Synflex 6
36 24-54-0010 Tube-Airline, Nylon, 1/2 Inch OD, Green, Synflex 1
37 24-54-0012 Tube-Airline, Nylon, 1/4 Inch OD, Green 7
38 24-54-0015 Tube-Airline, Nylon, 3/8 Inch OD, Red 4.5
39 24-54-0019 Tube-Airline, Nylon, 1/2 Inch OD, Red, Synflex 1.5
40 21-7404-1 Tube-Airline, Nylon, 1/4 Inch OD, Red 7
41 07-13-1635 Decal -Switches 1
04 -1
9 -1
01 1F
04-19-1011 Tank Assembly-Air, Rear Service
1 04-19-1003 Tank-Air 1
2 19-10-1030 Fitting-Pipe, Male Branch Tee, 1/2 Inch Pipe 1
4 19-10-1520 Fitting-Brass, 45 Deg.Elbow, 3/4 Nta, 2
5 19-10-1535 Fitting-Brass, 45 Deg.Elbow, 5/8 Nta, 1
6 19-10-1930 Fitting-Brass, 90 Deg Elbow, 3/8Nta, 1/2NPT 1
7 19-10-1932 Elbow-Brass, 45 Degree, Street, 1/2 NPT 1
8 19-10-348 Fitting-Pipe, Hex Head Plug, 1/2 Male Pipe 1
9 4R-19-130 Valve Assy-Drain W/Ring, 1/4 NPT 1
10 4R-22-38 Valve Assy-Check 2
04 -1
9 -1
04 0B
04-19-1040 Tank Assembly-Emergency
3 19-10-1929 Fitting-Brass, 45 Deg.Elbow, 1/2NTA, 1/2NPT 1
5 4R-19-130 Valve Assy-Drain W/Ring, 1/4 Npt 1
04 -1
9 -1
15 2A
1 2
04-19-1152 Tank Assembly-Auxiliary Suspension, RH Rear
1 04-19-1005 Tank-Air, Emergency Release 1
2 19-10-1896 Fitting-Elbow, 1/2 Mpt-37’Jic-8 1
4 19-10-22 Fitting-Pipe, 90 Degree Street Elbow, 1
5 19-10-2540 Fitting-45 Deg Elbow 1
7 4R-19-130 Valve Assy-Drain W/Ring, 1/4 Npt 1
04 -1
9 -1
15 6B
04-19-1156 Tank Assembly-Air, Supply
1 04-19-1003 Tank-Air 1
6 19-10-2252 Fitting-90 Degree Elbow, 1/2 T, 1/2 NPT 1
7 4R-19-130 Valve Assembly-Drain W/Ring, 1/4 NPT 1
8 4R-22-38 Valve Assembly-Check 1
04 -2
0 -1
36 9B
04-20-1369 TANK INSTALLATION - AIR, REAR FOR ZF AST TRANSMISSION
1 04-19-1011 Tank Assy-Air, Rear Service (See 04-19-1011 for service parts) 1
2 04-19-1165 Shield-Tank, Emergency 1
3 04-19-1040 Tank Assembly-Emergency (See 04-19-1040 for service parts) 1
4 04-19-1152 Tank Assembly-Auxiliary Suspension, RH Rear (See 04-19-1152 for service parts)
1
5 04-19-1156 Tank Assy-Air, Supply (See 04-19-1156 for service parts) 1
6 04-20-1368 Bracket-Mounting, Air Tank 1
7 04-22-1086 Manifold Assy-Air (See 04-22-1086 for service parts) 1
8 19-01-1570 Screw-Cap, 3/8-16 x 1 Inch Long 20
9 19-03-0535 Locknut - Flanged, 3/8-16 16
10 19-1-376 Screw-Cap, Hexagon Head, 1/4-20Uncx2 1/4, 2
11 19-11-258 Tyrap-7.31 Inch Long 6
13 19-2-37 Washer-Lock, Medium Spring, 1/4 Id, 2
14 19-2-67 Washer-Fender,1/4 ID, 1-1/4 OD, .065 Inch Thick 2
15 19-2-69 Washer-Flat, 1/4”Dia., Steel Zinc Plated 2
16 19-3-469 Nut-Rivnut, 1/4-20 2
17 19-4-144 Clamp-Line Support, Neoprene Covered, 1
18 19-4-24 Clamp-Support, Line, Neoprene Covered 2
19 19-4-32 Clamp-Line Support, Vinyl Covered, 1/2” 15
20 19-4-83 Clamp-Aero 4
22 24-54-0009 Tube-Airline, Nylon 3/8 Inch OD, Green, Synflex 2.1
23 24-54-0010 Tube-Airline, Nylon, 1/2 Inch OD, Green, Synflex 5
24 24-54-0011 Tube-Airline, Nylon, 3/4”Od, Green, Synflex 4.3
25 24-54-0022 Tube-Airline, Nylon, 1/2”Od, Black 12.5
26 24-54-0023 Tube-Airline, Nylon, 1/2”Od, Brown 6.25
27 24-54-0052 Tube-Airline, Nylon, 1/2” Od, Blue 10
28 04-20-1388 Bracket-Mounting Air Tank 1
04 -2
0 -1
41 1C
04-20-1411 AIR SYSTEM INSTALLATION - REAR
1 04-10-1025 Dryer Assembly-Air, Haldex (See 04-10-1025 for service parts) 1
2 04-19-1117 Filter Assembly-Oil, E/J4500 1
3 04-19-1072 Filter-Oil, Bendix QC 1
4 04-19-1116 Plate-Mounting, Oil Filter 1
5 19-01-1970 Screw-Cap, Hex, 5/16-18 x 4 Inch Long 2
6 19-03-0498 Nut- Hex, Flanged, Lock 5/16-18 2
7 19-10-1472 Fitting-Elbow, 90 Deg, 3/4 NTA to 1/2 NPT 2
8 04-19-1148 Bracket Assembly-Mounting, Purge Tank 1
9 04-19-1151 Tank Assembly-Purge, Dryer 1
10 04-19-6018 Tank-Purge 1
11 19-10-2562 Fitting-Brass, 90 Deg Elbow, 1/4 Tube To 1
12 19-10-267 Fitting-Bushing, 1/4 Inch Male Pipe Thread 1
13 19-10-324 Fitting-Pipe, Hex Plug, 1/4 Male Pipe 2
14 4R-19-130 Valve Assembly-Drain W/Ring, 1/4 NPT 1
15 04-20-1291 Angle Assembly 1
16 04-20-1313 Angle 1
17 04-20-1325 Plate 1
18 04-20-1330 Bracket-Teflon 1
20 04-20-1379 Bracket 1
22 04-20-1284 Bracket Assembly 1
23 19-10-1088 Fitting-Pipe, Miscellaneous, Anchor 1
25 19-10-2255 Fitting-45 Degree, 1/2 MPT To JIC-12 1
26 19-10-2283 Fitting-Compression, 3/4 Tube, 1/2MPT 1
27 19-10-2773 Fitting-Str, 37 Deg, Jic-12 To -16 1
28 19-10-418 Fitting-Pipe, Bushing, 1/2 Male Pipe X 1/4 1
29 19-10-535 Fitting-Pipe, Street Tee, 1/2 Male Pipe 1
30 4C-22-17 Valve 1
32 19-03-0535 Locknut - Flanged, 3/8-16 5
33 19-1-40 Screw-Cap, Hex Head, 5/16-24 x2 Inch 2
34 19-11-1031 Conduit-Convoluted, Round, 6MM Slit, Black 2.66
35 19-11-258 Tyrap-7.31 Inch Long 2
36 19-11-259 Tyrap-13.38 Inch Long 3
37 19-2-119 Washer-Fender, 3/8 Inch ID x .406 ID X 1-1/4 Inch 6
38 19-2-26 Washer-Lock,Spring,5/16 Inch ID,Steel Zinc 2
40 19-2-296 Washer-Flat, 5/16 ID, Grade 8 Steel Zn Pl 2
41 19-2-9 Washer-Flat, Zp, 100/Bx 2
42 19-3-15 Nut-Hexagon, Plain, 5/16-24UNF, Grade 5 2
44 19-4-226 Clamp-Line Support Vinyl Covered, 3/8 ID 4
04 -2
0 -1
41 1C
04-20-1411 AIR SYSTEM INSTALLATION REAR
45 19-4-29 Clamp-ID Closed 3
47 21-7411-12 Spirap 1.5
48 24-54-0009 Tube-Airline, Nylon 3/8 Inch OD, Green, Synflex 8
49 24-54-0011 Tube-Airline, Nylon, 3/4 Inch OD, Green, Synflex 5.5
04 -2
0 -1
41 6A
04-20-1416 PRESSURE PROTECTION VALVE-INSTALLATION
2 04-22-1203 Valve Assembly-Pressure Protection 1
3 04-22-1005 Valve-Press Protect, Pr4 1
04-22-1035 No. 10 Hex/Torx 1
04-22-1036 Steel Washer 1
04-22-1037 Brass Shims 1
04-22-1038 Brass Shims 1
04-22-1039 Piston Assembly 1
04-22-1040 Spring Retainer 1
6 19-10-1459 Elbow-Male 1
8 4C-22-17 Valve 1
9 19-1-1012 Screw-Cap, Hexagon Head, 1/4-20UNC x 2-1/2 Inch Long 2
10 19-13-21 Rivet - 3/16, .126-.251 Inch Grip Aluminum 3
11 19-2-23 Washer-Flat, 1/4 ID, Stainless 2
12 19-3-2 Nut-Lock, Nylon Insert, Light, 1/4-20UNC 2
04 -2
0 -1
44 4B
04-20-1444 SUSPENSION INSTALLATION - AIR, REAR w/o TAG AXLE UNLOAD
1 03-36-1030 Pocket -Airlines, Middle 1
2 04-20-1451 Junction Block Assembly-Accessory, Rear (See 04-20-1451 for service parts) 1
3 04-20-1194 Plate-Cover 2
4 04-22-1085 Manifold Assembly-Suspension, Air (See 04-22-1085 for service parts) 2
5 04-22-1098 Bracket Assembly-Tag Dump, J4500 (See 04-22-1098 for service parts) 1
6 04-22-1102 Decal -Dump Valves 1
7 07-12-2085 Harness-Tag Dump 1
8 12-03-1074 Spring Assembly-Air, Tag 2
9 12-03-1029 Spring-Air, Tag Axle 1
10 12-03-1075 Plate-Air Spring, Tag Axle 1
12 19-3-188 Nut-Lock, Hexagon, With Insert, 1/2-13UNC 2
13 12-03-1076 Spring-Air Assembly, Drive 4
14 12-03-1041 Spring-Air, Drive Axle 1
15 12-03-1077 Plate-Air Spring, Drive Axle 1
18 12-06-1027 Valve Assembly-Leveling, LH (See 12-06-1027 for service parts) 1
19 12-06-1028 Valve Assembly-Leveling, RH (See 12-06-1028 for service parts) 1
20 19-01-1641 Screw - No. 10 x 3/4 Inch 8
21 19-1-1095 Screw-Cap, Hex, 5/16-18Unc X 1 Inch, Stainless 24
22 19-1-376 Screw-Cap, Hexagon Head, 1/4-20Uncx2 1/4, 2
23 19-1-655 Screw-Tapping, Thread Cutting, Type T, Pan 6
24 19-11-258 Tyrap-7.31 Inch Long 6
25 19-12-0094 Grommet-11/16 ID, 1/4 Groove, Rubber 4
26 19-2-198 Washer-Lock, 5/16 ID Stainless Steel T304 24
27 19-2-40 Washer-Nylon 2
30 19-12-39 Grommet - 1/2 Inch ID, 1/16 Groove 4
31 19-2-7 Washer-Flat, Zinc 6
34 19-4-50 Clamp-Line Support, Neoprene Covered 1
35 24-54-0030 Loom-Corr, .62 OD 49.7
36 24-54-0052 Tube-Airline, Nylon, 1/2 Inch OD, Blue 79.5
37 21-7210-53 Permastick Tape 1.2
38 19-13-137 Rivet - .187 Inch 6
42 21-7210-21 Tape - Electrical 8
04 -2
0 -1
44 5B
04-20-1445 SUSPENSION INSTL-AIR,REAR
2 04-20-1451 Junction Block Assembly-Accessory, Rear (See 04-20-1451 for service parts) 1
3 04-20-1194 Plate-Cover 2
4 04-22-1085 Manifold Assembly-Suspension, Air (See 04-22-1085 for service parts) 2
5 04-22-1098 Bracket Assembly-Tag Dump, J4500 (See 04-22-1098 for service parts) 1
6 04-22-1102 Decal -Dump Valves 1
7 07-12-2085 Harness-Tag Dump 1
8 12-03-1074 Spring Assembly-Air, Tag 2
9 12-03-1029 Spring-Air, Tag Axle 1
10 12-03-1075 Plate-Air Spring, Tag Axle 1
13 12-03-1076 Spring-Air Assembly, Drive 4
14 12-03-1041 Spring-Air, Drive Axle 1
15 12-03-1077 Plate-Air Spring, Drive Axle 1
18 12-06-1027 Valve Assembly-Leveling, LH (See 12-06-1027 for service parts) 1
19 12-06-1028 Valve Assembly-Leveling, RH (See 12-06-1028 for service parts) 1
20 19-01-1641 Screw - No. 10 x 3/4 Inch 8
21 19-1-1095 Screw-Cap, Hex, 5/16-18UNC X 1 Inch, Stainless 24
22 19-1-376 Screw-Cap, Hexagon Head, 1/4-20UNC x 2-1/4 2
23 19-1-758 Screw - Tapping, No. 10-24 x 1/2 Inch 6
24 19-11-258 Tyrap-7.31 Inch Long 11
25 19-12-0094 Grommet-11/16 ID, 1/4 Groove, Rubber 4
26 19-2-198 Washer-Lock, 5/16 ID Stainless Steel T304 24
29 19-2-69 Washer-Flat, 1/4 Inch Dia., Steel Zinc Plated 11
31 24-54-0033 Loom-Coil, 1 Inch OD 1.6
33 19-4-83 Clamp-Aero 4
35 24-54-0030 Loom-Corr, .62 OD 49.7
37 21-7210-53 Permastick Tape 1.2
38 19-13-137 Rivet - .187 Inch 6
42 21-7210-21 Tape - Electrical 8
43 04-22-1147 Bracket Assembly-Valve 1
04 -2
0 -1
45 1A
04-20-1451 Junction Block Assembly-Accessory, Rear
1 04-20-1004 Block-Junction, Accessory, Rear 1
2 19-10-1250 Fitting-Pipe, 37 Deg Flare, 1/4 NPT to 1
3 19-10-1459 Elbow-Male 1
4 19-10-1681 Fitting-Tube, Sae 37 Degree, Jic 90 Degree 1
5 19-10-1968 Cap-Nut, Jic-4 1
6 19-10-324 Fitting-Pipe, Hex Plug, 1/4 Inch Male Pipe 3
04 -2
2 -1
08 5A
04-22-1085 Manifold Assembly-Suspension, Air
2 19-2-19 Washer-Flat, #8, Zinc Plated 1
3 19-1-602 Screw-Machine, Pan Head Cross Recess 1
4 04-22-1015 Manifold 1
7 19-10-1411 Fitting-Brake, Male Elbow, 1/2 Tube Od, 1
04 -2
2 -1
08 6B
04-22-1086 Manifold Assembly-Air
2 19-10-1411 Fitting-Brake, Male Elbow, 1/2 Tube Od, 3
04 -2
2 -1
09 8F
04-22-1098 Bracket Assembly-Tag Dump, J4500
1 04-22-1097 Bracket-Tag Dump 1
2 04-22-1101 Bracket-Mounting, Valve 1
3 04-22-1125 Valve-Dump, 1/4Npt, 3 Way 2
4 19-01-1532 Capscrew - 5/16-18 x 3/4 Inch Long 3
5 19-03-0498 Nut-Hex, Flanged, Lock 5/16-18 3
6 19-1-261 Screw-Machine, Truss Head Cross Recess 4
9 19-10-2244 Fitting-90 Degree Elbow, Swivel, 1/2T 4
10 19-10-264 Fitting-Pipe, Bushing, 1/4 Inch Male Pipe 2
11 19-2-24 Washer-Lock, Split, 100/Pk 4
12 8F-28-3 Switch-Pressure, Fuel, 9 Lbs 2
04 -2
2 -1
14 7A
04-22-1147 Bracket Assembly-Valve, Tag Unload
1 04-22-1081 Valve Assy-Hold, Tag, Unload 2
2 04-22-1066 Valve-Hold, Tag Unload 1
3 19-10-1996 Fitting-Elbow, 1/2T, 1/4NPT 1
5 04-22-1159 Valve Assembly-Unload, LH 1
6 04-22-1072 Switch-Low Pressure, Tag Unload 1
7 04-22-1146 Valve-Tag Unload 1
11 19-10-2244 Fitting-90 Degree Elbow, Swivel, 1/2T, 1
13 04-22-1160 Valve Assembly-Unload, RH 1
14 04-22-1146 Valve-Tag Unload 1
16 19-10-2244 Fitting-90 Degree Elbow, Swivel, 1/2T, 2
17 04-22-1164 Bracket-Tag Unload 1
18 19-03-0590 Rivet Nut - No. 8-32 6
20 19-1-604 Screw-Machine, Pan Head No.8-32x 1-5/8 Inch 6
21 19-1-609 Screw-Machine, Pan Head No. 10-32 x 1/2 Inch 2
25 19-3-155 Nut-Lock, Hex, Light 4
04 -2
2 -1
21 9A
04-22-1219 EZ START VALVE INSTALLATION - ZF TRANSMISSION
1 04-22-1218 Valve Assembly-EZ Start 1
2 07-12-2162 Harness-Adapter, ZF EZ Start 1
6 19-10-2302 Elbow-Male, 1/4P X 1/2T 45 Deg Elbow 1
7 19-10-2431 Fitting-Adapter, 1/4 Male NPT X 3/8 2
9 19-10-286 Fitting-Pipe, Male Branch Tee, 1/4 Pipe 1
10 19-10-324 Fitting-Pipe, Hex Plug, 1/4 Male Pipe 1
11 24-54-0019 Tube-Airline, Nylon, 1/2 Inch OD, Red, Synflex 0.001
12 4C-22-17 Valve 1
14 8l-28-91 Switch-Pressure 1
16 19-2-26 Washer-Lock,Spring,5/16 Inch ID,Steel Zinc 2
17 19-2-8 Washer-Flat, Zp 4
18 19-3-20 Nut-Hexagon, 5/16-18UNC, Grade 5 Stl Zn Pl 2
19 24-54-0016 Tube-Airline, Nylon, 5/8 Inch OD, Red 1
06 -0
1 -1
14 0A
COOLING MODULE
06-01-1140 COOLING MODULE
2 06-01-1229 Kit-Hardware 9
4 06-01-1231 Core Assembly-Radiator 1
5 06-01-1232 Kit-Bolting Bar And Gasket 1
6 06-01-1233 Channel Assembly-Frame, Top 3
7 06-01-1234 Kit-Module Recirculation Shield Assembly 1
8 06-01-1235 Tank Assembly-Right 1
9 06-01-1236 Tank Assembly-Left 1
10 06-01-1246 Channel Assembly-Top 1
11 06-01-1247 Channel Assembly-Bottom 1
12 06-01-1248 Cable Assembly 1
13 06-01-1250 Kit-Radiator Recirculation Shield Assembly 1
14 06-01-1252 Channel Assembly-Frame, Right 1
15 06-01-1253 Channel Assembly-Frame, Left 1
06 -0
1 -1
14 7D
06-01-1147 RADIATOR AND CHARGE AIR COOLER INSTALLATION
1 06-01-1050 Isolator-Radiator, Lower 2
2 06-01-1140 Cooling Module (See 06-01-1140 for service parts) 1
3 06-01-1142 Bracket-Rear, Rad Mounting 1
4 06-01-1143 Bracket-Front, Rad Mounting 1
5 06-01-1153 Coupler 1
6 06-01-1154 Nipple 1
8 06-01-1157 Seal-Rear, Rad 1
9 06-01-1158 Seal-CAC Outlet 1
10 06-01-1159 Seal-CAC Outlet 2
11 06-01-1160 Bracket-Lower Rad 2
12 06-01-1161 Isolator-Rad, Lower Front 2
13 06-01-1162 Isolator-Rad, Lower Rear 2
14 06-01-1163 Seal-Rear, Rad 1
15 06-01-1165 Hose Assembly-Rad 1
16 06-01-1193 Seal-Lower Rad 1
17 06-01-1226 Seal-Front Rad 1
18 06-05-1033 Shroud-Fan, 40 Inch Dia 1
19 06-05-1034 Seal-Shroud 2
22 06-08-1198 Hose-Radiator 2
24 19-01-1532 Capscrew - 5/16-18 x 3/4 Inch Long 8
25 19-01-1535 Capscrew - 1/2-13 x 1 Inch 4
27 19-03-0497 Nut Flange - 1/2-13 2
29 19-03-0519 Nut Flanged 1/4-20 8
30 19-03-0535 Locknut - Flanged, 3/8-16 11
31 19-1-15 Screw-Cap, Hexagon Head, 1/4-20UNC x 1-3/4 Inch 2
33 19-1-285 Screw-Cap 2
35 19-10-1856 Fitting-1/8 MPT, 37’3 JIC-4 1
36 19-10-279 Nipple-Long 1
38 19-10-622 Fitting-Drain Cock, Internal Seat, 1/4 2
39 19-12-0105 Bumper-Rubber 1
41 19-13-0395 Rivet-Break Mandrel, .188 Dia Lf .25-.38Grip L 36
42 19-13-180 Rivet .187 Inch 8
43 19-2-119 Washer-Fender, 3/8 Inch ID x .406 ID X 1-1/4 Inch 5
06 -0
1 -1
14 7D
06-01-1147 RADIATOR AND CHARGE AIR COOLER INSTALLATION
45 19-3-155 Nut-Lock, Hex, Light 1
46 19-4-210 Clamp 8
47 19-8-74 Plug-Button, Standard, 7/8 Inch Hole Dia. 2
48 6L-2-133 Washer-Flat, .530 Inch ID x 2.88 OD X .125 Thk 6
49 6L-8-353 Hose-Hump, Coolant Instl 2
06 -0
1 -1
16 6B
1 2
06-01-1166 PANEL INSTL-SIDE, RECIRC
2 06-01-1191 Strip-Panel Long, Side 1
3 06-01-1192 Strip-Panel Short, Side 1
4 19-01-2057 Capscrew-1/4-20 x 3 Inch, SST 11
5 19-02-0339 Nut-1/4-20 Stainless Steel Nylock 11
06 -0
6 -1
04 1D
06-06-1041 FAN DRIVE GEAR BOX
06-06-1045 Kit - Seal E-G Box 1
06-06-1046 Kit - Plug and Key E-G Box 1
06-06-1047 Kit - Bearing E-G Box 1
06-06-1048 Kit - Shim E-G Box 1
06-06-1049 Kit - Gear E-G Box 1
06-06-1050 Cap - Open 1
06-06-1051 Housing - Pinion 1
06-06-1052 Shaft - Pinion 1
06-06-1053 Cap - Closed 1
06-06-1054 Shaft - Cross 1
06-06-1055 Hub - Fan 1
06-06-1058 Nut - Lock 1-14 1
06-06-1059 Nut - Jam 7/8-14 1
06-06-1060 Plug - Pipe Socket 1
06-06-1061 Gage - Sight G607 Modified 1
19-02-0324 Washer - Flat, 7/8 x 1-3/8 x 1/8 Inch 1
19-10-2443 Fitting - Vent, 1/8 NPT 1
06 -0
6 -1
23 5A
Driveshaft-Fan Drive
06-06-1235 Driveshaft-Fan Drive
1 06-06-1132 Cross Kit - Driveshaft w/Bearing and Snap Ring 2
2 06-06-1133 Dust Cap Kit - Telescopic Shaft 1
06 -0
6 -1
25 2E
06-06-1252 FAN DRIVE INSTALLATION - 2007 EPA ENGINE
1 06-06-1041 Box-Gear, Fan Drive (See 06-06-1041 for service parts) 1
2 06-06-1070 Plug-Expandable 1
4 06-06-1123 Yoke-End, Fan Drive 1
5 06-06-1124 Kit-Strap, Fan Drive 1
6 06-06-1162 Plate-Clutch 1
7 06-06-1182 Spacer 4
9 06-06-1220 Clutch-Linnig, 3 Speed 1
10 06-06-1221 Bracket Assy-Fan Clutch 1
11 06-06-1227 Frame Assy-Gearbox Mounting 1
12 06-06-1235 Driveshaft-Fan Drive 1
13 06-06-1253 Fan-40 In Dia 1
14 06-06-1259 Hose Assy-Gear Box 1
15 06-06-1368 Guard Assy-Fan Drive Shaft 1
16 06-06-1369 Cover Guard-Assy 1
17 16-02-1145 Tensioner-A/C Belt, 3/4 Balls 1
18 19-01-1523 Capscrew - 1/2-13 x 9 Inch 1
19 19-01-1535 Capscrew - 1/2-13 x 1 Inch 4
21 19-01-1576 Capscrew - 1/2-13 x 3/4 Inch 4
22 19-01-1655 Capscrew - Hex, 5/8-18 x 2-1/2 Inch 2
23 19-01-2078 Capscrew - M12 1.75 x 55 CL 8.8 4
24 19-02-6004 Nut - 5/8-18 4
25 19-03-0495 Nut - Flanged 3/8-16 2
26 19-03-0497 Nut Flange - 1/2-13 5
27 19-03-0507 Nut - M10-1.5, Grade 8.8 4
28 19-03-0509 Nut - 5/8-18 1
29 19-03-0535 Locknut - Flanged, 3/8-16 10
32 19-10-129 Fitting-Compression, Male Elbow, 3/4 Inch OD 1
33 19-10-1877 Fitting-45 Degree Elbow, 1/4 NPT To Jic-4 1
34 19-10-2442 Adapter-Ftg, 1/8 NPT, Jic-4 1
35 19-12-65 Grommet 3/4 Inch ID 1
38 19-4-83 Clamp-Aero 4
40 24-54-0152 Loom-Corr Split, Blk, .413, High Temp 3
41 6F-14-73 Strip-Tying, Mtg Surge Tank 1
42 6L-6-635 Decal -”Do Not Wash Fan Clutch” 1
43 6L-6-637 Decal -Grease Fitting 2
06 -0
8 -1
29 2B
28 25
06-08-1292 COOLANT PIPING INSTALLATION - S60, 2007
1 06-08-1006 Hose-Coolant, 90Deg Elbow 1
2 06-08-1068 Hose Assembly-De-Aeration, Upper Rad 1
3 06-08-1240 Pipe-Surge Tank, Coach Heat Ret 1
4 06-08-1241 Pipe-Coolant, Rad 1
5 06-08-1277 Hose-Silicone, 1-3/8 ID 1
6 06-08-1293 Hose-Boost Pump, S60 1
7 06-08-1294 Pipe-Boost 1
10 08-01-1043 Bracket-Hose Mount 1
11 09-03-1193 Clamp-P, Charge Air Cooler, 4 Inch ID 1
12 13-11-1122 Pipe-Inlet, Pump 1
13 19-01-1516 Capscrew - 3/8-16 x 1-1/4 Inch 1
14 19-01-1543 Capscrew 3/8-16 x 3/4 Inch 3
15 19-03-0495 Nut - Flanged 3/8-16 5
16 19-1-583 Screw-Tapping, Self Drilling, Type Csd 1
17 19-10-1681 Fitting-Tube, Sae 37 Degree, Jic 90 Degree 1
18 19-10-1797 Fitting-1 Inch MPT to 1.38 Inch Hose 1
19 19-10-2747 Fitting-M12 Iso6149 x 7/16 Jic Elbow 1
21 19-10-853 Fitting-Tube, 37 Degree Flare, 1/4 O.D. 1
22 19-4-125 Clamp-Line Support, Rubber Lined 1
25 19-4-205 Clamp-Stepless Spring, Constant Torque 8
26 19-4-210 Clamp 4
28 6J-8-34 Hose-Silicone, Main Evaporator, Baggage 2
29 6L-8-353 Hose-Hump, Coolant Instl 2
30 7L-8-1124 Sensor-Coolant 1
06 -0
8 -1
32 5A
06-08-1325 COOLANT LINES INSTALLATION - S60, ZF AST
1 06-08-1199 Tube-Radiator to Water Pump, ZF 1
2 06-08-1201 Bracket-Tube Mount 2
3 06-08-1324 Pipe - Thermo Bypass, S60 1
5 19-03-0535 Locknut - Flanged, 3/8-16 4
6 19-04-0382 P-Clamp, 2.375 Inch 2
8 19-4-206 Clamp - Stepless Spring 1.94-2 Inch 2
9 19-4-207 Clamp - Stepless Spring 2
10 6J-8-34 Hose-Silicone, Main Evaporator, Baggage 1
11 6L-8-1245 Hose - Straight, 1-3/4 Inch 2
06 -1
4 -1
15 7C
06-14-1157 SURGE TANK INSTALLATION - DDC S60
1 06-14-1068 Bracket-Surge Tank Support 1
2 06-14-1139 Bracket-Surge Tank Support 1
3C 06-14-1143 Filler Neck Assembly 1
3B 06-14-1140 Cap - Radiator, 15PSI 1
3A 06-14-1141 Neck Assembly-Filler 1
4 06-14-1186 Tank-Surge 1
5 16-11-1140 Hose-Silicone 1
6 16-11-1689 Hose-Overflow 1
8 19-04-0384 Clamp-Spring, Uniclamp, 0.59 ID 2
9 19-1-23 Screw-Cap, Hex, 3/8-16UNC x 1 Inch, Grade 5, Ste 1
11 19-10-1681 Fitting-Tube, SAE 37 Degree, Jic 90 Degree 1
12 19-10-2554 Fitting Straight Barbed 1/4 Hose 1
13 19-10-2555 Fitting 90 Deg Elbow Barbed 1
15 19-10-283 Fitting-Pipe, 45 Deg Street Elbow, 1/4 Male 5
17 19-11-258 Tyrap-7.31 Inch Long 1
19 19-2-85 Washer-Lock, Internal/External Tooth 8
21 19-4-35 Clamp-Line Support, U Type Neoprene 5
22 24-54-0160 Hose-Heater, Silicone, 1/4 ID x .60 Inch OD 0.05
23 4G-22-4 Valve-Fill 1
25 19-10-853 Fitting-Tube, 37 Degree Flare, 1/4 OD 3
07 -0
7 -1
25 8B
07-07-1258 ENGINE LIGHTING AND FIRE DETECTOR INSTALLATION
1A 07-07-1028 Lamp Subassembly - Engine Compartment 3
19-11-845 Receptacle-2 Pin 1
19-11-698 Seal-Cable, Weather Pack 2
7L-7-323 Lamp-MDL60 1
4 07-08-1324 Detector-Fire, comes with Connector 2
07 -0
7 -1
30 9A
07-07-1309 BULB AND BELT KIT INSTALLATION-S60, BOSCH
1 08-27-1054 Belt-S60 A/C, 7 Inch Idler 1
2 08-27-1109 Belt-Fan Drive, S60, 1:1.05 Ratio 1
3 08-27-1115 Belt-Alternator, S60, Bosch 1
4 17-01-1036 Key-Toilet Paper Spindle 2
5 17J-5-13 Fitting-On Hose, Chemical Tank (Not Shown) 1
6 19-11-1016 Bulb-Bayonet Basae, Single Contact, 12V 1
7 19-11-1519 Bulb-Headlight, Low 1
8 19-11-1520 Bulb-Headlight, High 1
9 19-11-1521 Bulb-12V T3, 1/4 Wedge 1
10 19-11-1523 Bulb-12V, 21 Watt 1
07 -0
8 -2
31 2A
07-08-2312 INSTRUMENT PANEL ASSEMBLY, METRIC W/O SMARTWAVE
1 07-08-2311 Instrument Panel Assembly, Metric 1
2 07-08-1390 Gauge, Tachometer 3K RPM 1
3 07-08-1393 Gauge, Fuel Level 1
4 07-08-1394 Gauge, Air Pressure, Front 1
5 07-08-1395 Gauge, Air Pressure, Rear 1
6 07-08-1396 Gauge, Voltmeter, 24V 1
7 07-08-2008 Tell Tale Assembly, RH 1
8 07-08-2318 Speedometer, 130 KMPH, SCU 1
9 07-08-2320 Gauge, Water Temperature 250 degress F 1
10 07-08-2321 Gauge, Oil Pressure, 100 PSI 1
11 07-08-2405 Tell Tale Assembly, LH 1
12 07-12-1370 Harness, Daisy 7 Inch 9
13 07-12-2501 Harness, Instrument Panel Interface 1
14 19-1-1264M229 Screw, SEMS, Tapping No. 8-32 x 3/4 Inch 2
07 -0
8 -2
31 7A
07-08-2317 INSTRUMENT PANEL ASSEMBLY, IMPERIAL W/O SMARTWAVE
07 -0
8 -2
32 6A
07-08-2326 IMMERSION HEATER - DETROIT DIESEL S60
1 07-12-2524 Harness - Immersion Heater 1
2 19-11-1032 Wire Loom, 9MM 0.001
3 19-11-259 Tyrap-13.38 Inch Long 11
4 7L-12-206 Cord - Immersion Heater 1
07 -1
3 -1
54 3C
07-13-1543 Box Assembly-Junction, Rear
2 07-08-1932 Panel -Junction Box, Rear 1
4 07-08-1950 Bracket Subassembly-Module, Powertrain 1
5 07-08-1951 Bracket Assembly-Mount, HVAC 1
6 07-08-1974 Panel Assembly-Rear Junction Box 1
7 19-02-0342 Washer - Flat, No. 6 8
8 19-03-0502 Riv Nut - No. 10-32 3
9 19-03-0590 Rivet Nut - No. 8-32 2
10 19-04-0284 Tie Base - Adhesion Mount 10
11 19-13-139 Rivet Domed, HD 1/8 Inch Dia. 20
12 19-13-161 Rivet - 1/4 Inch Dia. 4
14 19-3-469 Nut-Rivnut, 1/4-20 4
15 21-7201-8 Trim Lock 0.001
16 21-7210-2 Tape, Permastick 0.001
07 -1
3 -1
60 2C
07-13-1602 BOX ASSEMBLY-JUNCTION, FRONT, MUX
1 07-08-2113 Nut - Electrical Stud, Black 3/8-16 1
2 07-08-2369 Stud - Electrical, Black, 3/8-16 x 1 Inch 1
3 07-08-2430 Spacer - FJB, Ground Stud 1
4 07-12-2151 Harness - Front Junction Box 1
5 07-13-1591 Panel - Front Junction Box Assembly 1
6 07-18-1164 Module - Multiplex 2
7 19-01-2055 Screw - 1/4-14 x 5/8, Tapping, Single Helix 12
8 19-1-1114 Screw - SEM, No. 10-32 x 3/4 Inch 2
9 19-1-232 Capscrew - 1/4-20 Unc x 3-1/2 Inch 8
10 19-11-1012 Twrap AR
11 19-11-2675 Flange - DRB 102, Key A 1
12 19-11-2682 DRB 48 or DRB 60 Flange, Key A 1
13 19-11-2772 DRB 48 or DRB 60 Flange 1
14 19-11-2829 Flange, Dual Interface, Keys A and B 1
16 19-2-63 Flat Washer 3/8 SST 4
18 19-3-122 Nut - Hex 3/8-16 UNC, Brass 2
07 -1
3 -1
60 3A
07-13-1603 JUNCTION BOX INSTALLATION-FRONT, MUX
1 04-28-1001 Bracket-Override Brake Valve 1
2 07-13-1102 Panel -Rear 1
3 07-13-1602 Box Assembly-Junction, Front, Mux (See 07-13-1602 for service parts) 1
4 19-01-1644 Capscrew No. 8-32 x 3/4 Inch 4
5 19-03-0502 Riv Nut - No. 10-32 2
6 19-13-168 Rivet 3/16 Inch SST 7
9 19-2-25 Washer-Lock, Split 1
11 19-3-184 Nut-Hexagon, Plain, 1/4-20Unc, Brass 1
07 -1
3 -1
63 4B
07-13-1634 Manifold Assembly - Air, LH Service Compartment, Front
1 04-20-1023 Manifold - Front Junction Box 1
2 07-08-1283 Sender-Air Pressure 2
3 19-10-1399 Fitting-Brass, 45 Degree Elbow, 3/8 NTA 4
6 19-10-1734 Elbow-45 Degree 3
7 19-10-211 Fitting-Half Union Type 6
10 4C-13-1 Switch-Stop Light 2
11 7L-8-885 Switch Assembly 1
19-11-870 Connector-Receptacle, Circular Sealed, 1
19-11-871 Pin-Contact, Multimate, 18-14 Awg. 3
7L-8-884 Switch-Low Air Pressure 1
12 4L-22-431 Switch-Park Lamp, 60 Psi, NO/NC 1
07 -1
3 -1
70 2B
07-13-1702 JUNCTION BOX, REAR, w/DUAL BOSCH
1 07-13-1701 Junction Box Assembly, Rear w/Dual Bosch 1
2 19-1-1113 Screw - No. 10-24 x 1 Inch 4
3 19-03-0518 Nut - Flange, No. 4 4
4 19-1-773 Screw - No. 4 x 1/2 Inch 4
5 19-11-1102 DDL Cap 1
6 7L-8-1340 Wire Rope - DDL 1
7 19-3-53 Speed Nut 4
8 07-13-1094 Nameplate - Not Gen. 2
9 7A-8-144 Tell Tale Assembly - Red 2
10 19-11-836 Bulb - 12V 2
11 19-3-223 Nut - Hex w/Washer, No. 10-32 2
12 19-1-1323 Screw-Machine, Pan Head Cross Recess, Sst 2
13 7L-5-53 Relay - 12V 2
14 07-13-1563 Junction Box - Remote 1
15 19-3-489 Riv Nut - 1/4-20 4
16 07-12-2090 Harness - Rear Junction Box for Dual Bosch 1
17 07-13-1700 Junction Box, Rear Cover Assembly 1
18 07-13-1565 Seal - Junction Box Cover, Rear 1
19 19-11-1059 Toggle Switch - DPDT 1
20 7L-8-471 Toggle Switch - SPST 1
21 7L-8-1083 Toggle Switch - DPDT 1
22 7M-8-95 Toggle Switch - DPDT 1
23 7M-8-169 Switch - Engine Compartment Lights 1
24 07-13-1698 Nameplate - Rear Junction Box 1
25 07-13-1699 Cover - Rear Junction Box 1
26 19-1-9 Screw-Cap, Hexagon Head, 1/4-20UNCx1/2, 4
07 -1
3 -1
79 7B
07-13-1797 JUNCTION BOX, REAR, w/DELCO 50DN
1 07-13-1796 Junction Box Assembly, Rear w/Dual Bosch 1
2 19-1-1113 Screw - No. 10-24 x 1 Inch 4
3 19-03-0518 Nut - Flange, No. 4 4
4 19-1-773 Screw - No. 4 x 1/2 Inch 4
5 19-11-1102 DDL Cap 1
6 7L-8-1340 Wire Rope - DDL 1
7 19-3-53 Speed Nut 4
8 07-13-1094 Nameplate - Not Gen. 2
9 7A-8-144 Tell Tale Assembly - Red 2
10 19-11-836 Bulb - 12V 2
11 19-3-223 Nut - Hex w/Washer, No. 10-32 2
13 7L-5-53 Relay - 12V 2
14 07-13-1563 Junction Box - Remote 1
15 19-3-489 Riv Nut - 1/4-20 4
16 07-12-2094 Harness - Rear Junction Box for Delco 50DN 1
17 19-8-14 Plug - 3/4 Inch Hole, Steel Nickel Plated 1
18 07-13-1700 Junction Box, Rear Cover Assembly 1
19 07-13-1565 Seal - Junction Box Cover, Rear 1
20 19-11-1059 Toggle Switch - DPDT 1
21 7L-8-471 Toggle Switch - SPST 1
22 7L-8-1083 Toggle Switch - DPDT 1
23 7M-8-95 Toggle Switch - DPDT 1
24 7M-8-169 Switch - Engine Compartment Lights 1
25 07-13-1698 Nameplate - Rear Junction Box 1
26 07-13-1699 Cover - Rear Junction Box 1
27 19-1-9 Screw-Cap, Hexagon Head, 1/4-20UNCx1/2 4
07 -1
3 -1
82 9A
07-13-1829 INSTRUMENT PANEL ASSEMBLY, METRIC W/SMARTWAVE
14 07-08-1414 Blank Gauge, 2 Inch 1
15 07-08-2358 Buzzer, Smartwave 1
07 -1
3 -1
83 0A
07-13-1830 INSTRUMENT PANEL ASSEMBLY, IMPERIAL W/SMARTWAVE
8 07-08-2347 Speedometer, 80 MPH, SCU 1
14 07-08-1414 Blank Gauge, 2 Inch 1
15 07-08-2358 Buzzer, Smartwave 1
07 -1
4 -2
59 1C
07-14-2591 JUNCTION BOX, REAR - INSTALLATION
1 07-13-1542 Electrical Assembly-Rear Junction Box 1
2 04-31-1012 ECU-ABS/ATC 6S/6M 12VDC, J1939 1
3 07-08-1933 Panel-Connector 1
4 07-08-1965 Bracket-Mount, Rear Junction Box 2
5 07-13-1543 Box Assembly-Junction, Rear (See 07-13-1543 for service parts) 1
7 19-1-9 Screw-Cap, Hexagon Head, 1/4-20UNC x 1/2 Inch 4
8 07-12-2064 Harness - Junction Box, Rear 1
9 19-2-49 Washer-Lock, Internal Tooth, 1/4 Inch ID 4
10 19-11-2681 Flange-DRB48/DRB60, Key A 1
11 03-59-2146 Bracket-Baggage Light 1
12 19-1-787 Screw-Cap, Hexagon Head, 10-24UNC x 1/2 Inch 2
13 19-3-154 Nut-Lock, Nylon Insert, Light, 10-24UNC 2
14 07-12-2069 Harness-J1939, Rear Junction Box 1
15 16-10-1076 Controller-Main, HVAC 1
16 16-10-1077 Board Assembly - Logic 1
17 16-10-6082 Harness - Ribbon Cable 1
18 16-01-6045 Board Assembly - Relay 1
19 07-05-1008 Relay - 24VDC, 20 Amp 1
20 16-10-1034 Relay - 24VDC, SPDT, 40 Amp 11
21 19-11-772 Fuse - 5 Amp 7
22 19-11-773 Fuse - 15 Amp 1
23 19-11-994 Fuse - 7.5 Amp 2
27 19-2-90 Washer-Lock, Internal Tooth, No. 10, Stainless 13
28 07-18-1164 Module-Multiplex 1
29 19-2-69 Washer-Flat, 1/4 Inch Dia., Steel Zinc Plated 8
30 16-17-1175 Hinge-Take Apart 2
31 19-5-208 Latch-Draw, Flexible 2
32 07-08-1981 Cover Assembly-Junction Box, Rear 1
33 16-01-1048 Decal -Micromax, Error Codes 1
07 -1
4 -2
61 9D
07-14-2619 HARNESS, BELOW FLOOR INSTALLATION
1 07-12-1007 Harness, Rear Side Turn 2
2 07-12-2086 Harness, Headlights MUX 1
3 07-12-1359 Cable, Main Feeder 1
4 07-12-2071 Harness, Baggage Compartment 2
5 07-12-2074 Harness, Power Feed 1
6 19-04-0283 Tie Base - ADH MT 75
8 19-11-258 Tyrap-7.31 Inch Long 100
9 19-11-259 Tyrap-13.38 Inch Long 25
10 19-13-0316 Rivet - 5/32 Inch SS Blind 150
07 -1
4 -2
62 7A
07-14-2627 HARNESS INSTALLATION - ENGINE COMPARTMENT
1 07-12-2076 Harness, Engine Compartment 1
2 19-01-1524 Capscrew - 1/4-20 x 3/4 Inch 2
3 19-03-0519 Nut Flanged 1/4-20 2
4 19-1-619 Screw, 10-24 x 3/4 7
6 19-11-258 Tyrap-7.31 Inch Long 7
7 19-11-259 Tyrap-13.38 Inch Long 7
8 19-2-218 Washer, Fender, 3/16 Inch ID x 3/4 Inch OD 7
13 19-4-47 Clamp-Id Closed 7
14 19-4-83 Clamp-Aero 1
07 -1
4 -2
62 9A
07-14-2629 HARNESS INSTALLATION - FRONT BOGIE
1 07-12-6304 Harness Assembly - Front Bogie 1
07 -1
4 -2
63 0A
07-14-2630 HARNESS INSTALLATION - REAR BOGIE
1 07-12-2092 Harness Assembly - Rear Bogie 1
4 19-4-32 Clamp-Line Support, Vinyl Covered, 1/2 ID 4
5 19-4-83 Clamp-Aero 3
07 -1
4 -2
65 0C
1 2
07-14-2650 CPC INSTALLATION-S60, 2007
2 07-14-3192 Assembly-CPC, S60, 2007, E/J Coaches 1
Sec/GrpPage 95May 2007 07.13
Sec/GrpPage 96May 2007 07.13
07-13-2663 REGEN SWITCH BOX INSTALLATION
1 07-14-2662 Assembly-Regen Switch Box 1
2 07-14-3151 Box Subassembly-Regen Switch 1
3 07-08-2295 Nameplate - Switch 1
4 07-12-2493 Harness - Regen Switch 1
5 07-13-1587 Box - Regen 1
6 07-13-1588 Cover - Regen Box 1
7 19-1-808 Screw - No. 6 x .050 4
8 19-2-127 Spring Lock Washer No. 6 4
9 19-12-0121 Grommet - 1/2 Inch ID x 1 Inch OD 1
10 19-3-55 Nut - Speed No. 6-32 4
11 7G-8-249 Switch - Exterior 1
12 07-13-1592 Bracket-Regen Box 1
13 19-13-168 Rivet-Blind, Mandrell Self Plugging 6
14 19-01-1524 Capscrew, Flanged, 1/4-20 x 3/4 Inch, Grade 5 3
15 19-2-25 Washer - Lock 1/4 ID 3
07 -1
4 -2
67 2D
07-14-2672 ROOF HARNESS INSTALLATION MUX
1 07-12-1340 Harness - Power, PDM 2 1
2 07-12-1346 Harness - Power, VMM 3 1
3 07-12-2087 Harness - Front Roof, MUX 1
4 07-12-2528 Harness - Rear Roof 1
5 19-04-0283 Tie Base - ADH MT 10
6 19-1-740 Screw - Tapping, Thread Forming, Type AB 2
7 19-11-259 Tyrap-13.38 Inch Long 7
9 19-13-170 Rivet 3/16 x 1/2, Break Mandrel 5
10 19-2-57 Washer - Fender, 9/32 ID x 3/4 OD x 1/16 Thick 5
07 -1
4 -2
68 4B
07-14-2684 ECU INSTALLATION-B500/B500R TRANSMISSION
2 13-01-1052 Control Module-Transmission 1
3 19-1-10 Screw - Cap, Hex, 1/4-20 UNC x 5/8 Inch 3
07 -1
4 -2
68 7B
6
A
A
B
B
07-14-2687 HARNESS INSTL-EVAPORATOR, MAIN
3 19-11-259 Tyrap-13.38 Inch Long 1
4 19-12-14 Grommet 1
6 19-4-32 Clamp-Line Support, Vinyl Covered, 1/2 Inch 1
07 -1
4 -2
74 1A
COVER REMOVED
07-14-2741 BATTERY COMPARTMENT INSTALLATION - MECH W/O CHARGER
1 03-61-1031 Mount, Switch, Battery Assembly 1
2 03-61-1042 Angle - Cover MTG Assembly 1
3 07-08-1001 Battery Pad 2
4 07-08-1002 Grommet - Battery Enclosure 3
5 07-08-1098 Bracket, Switch Assembly 1
6 07-08-1995 Panel, Circuit Breaker Assembly 1
7 07-09-1031 Pan - Battery 1
8 07-09-1040 Pan - Battery 1
9 07-09-1043 Battery Box Assembly 1
10 07-09-1046 Channel - Battery Spacer 1
11 07-09-1064 Insulation - Circuit Breaker 1
12 19-1-640 Screw - Pan Head No. 10-24 x 1/2 Inch 4
13 07-13-1032 Support S/A, Battery Charger 1
14 07-13-1615 Fuse Box - VEC, Bussmann 1
15 07-08-2176 Fuse - ATM 30 2
16 07-08-1061 Fuse - ATM 20 2
17 07-08-1059 Fuse - ATM 15 1
18 07-08-1058 Fuse - ATM 10 6
19 07-08-2056 Fuse - ATM 7.5A 1
20 07-08-1057 Fuse - ATM 5A 2
21 07-08-2058 Breaker, 30 Amp 12
22 07-08-2059 Breaker, 15 Amp 2
23 07-08-2061 Relay, 24 VDC 2
24 07-16-1034 Switch, Battery 1
25 07-18-1007 Module, Ground Block 1
26 19-01-1979 Bolt - 3/8-16 UNC x 11 Inch 1
27 19-1-1012 Screw-Cap, Hexagon Head, 1/4-20UNC x 2-1/2 Inch Long 4
28 19-1-1595 Screw , Pan HD - No. 10-24 3
29 19-1-688 Screw - Machine Pan HD, 1/4-20 UNC 4
30 19-1-813 Screw, Pan Cross, 1/4-20 4
31 19-12-0092 Grommet - 1/4 Inch Groove, 1 1
32 19-13-168 Rivet 3/16 Inch SST 10
34 19-2-129 Washer 1
07 -1
4 -2
74 3C
07-14-2743 BATTERY COMPARTMENT INSTALLATION-ELECTRICAL
3 07-08-1058 Fuse-Mini, 10A 3
4 07-08-1059 Fuse-Mini, 15 Amp 1
5 07-08-1061 Fuse-Mini, 20A 3
6 07-08-1303 Decal -Equalizer 1
7 07-08-1304 Kit-Fuse Assembly 2
8 07-08-1982 Decal -Main Disc Legend 1
9 07-08-2056 Fuse-7.5A Mini 1
10 07-08-2058 Breaker-Circuit, 30A 3
11 07-08-2059 Breaker-Circuit, 15A 1
12 07-08-2176 Fuse-Mini, 30A 2
13 07-09-1001 Battery-8D 2
19 07-12-1352 Harness-Equalizer 1
21 07-12-2240 Cable-Evap Power 1
22 07-12-2242 Cable-Condenser Power 1
23 07-12-2243 Cable-Fuse Box Feed 1
24 07-12-2248 Cable-24V Power Feed 1
25 19-04-0284 Tie Base - Adhesion Mount 6
26 19-1-10 Screw - Cap, Hex, 1/4-20 UNC x 5/8 Inch 6
28 19-11-1465 Heatshrink-4-1 1
32 19-2-187 Washer-Fender, 5/16 ID, 3/4 OD, Steel 4
33 19-2-21 Washer-Flat, 1/2 ID, Brass 1
36 19-2-29 Washer-Lock, 1/2 Inch, Steel Zinc Plated 1
39 19-2-8 Washer-Flat, Zp 1
40 19-3-12 Nut-Hexagon, Plain, 1/2-13UNC, Brass 1
41 19-3-21 Nut-Hexagon, 3/8-16UNC, Grade 5 Stl Zn Pl 1
42 7B-8-10 Decal -”24 Volts” 1
43 7L-13-1863 Decal -12 Volt 1
44 7L-8-1391 Container-Polyethlene, Round 1
07 -1
4 -3
28 1A
07-14-3281 DASH HARNESS AND MODULE INSTALLATION
1 07-08-2336 Sure Power Wiper Control 1
2 07-08-2247 Pocket Gateway-Module 1
3 07-08-1450 Controller-Vip 1
6 19-1-176 Screw-Tapping, Thread Cutting, Type T 2
8 19-1-696 Screw-Tapping, Thread Cutting, Type T, Pan 13
9 19-1-773 Screw-Machine, Pan Head,Cross Recess, 4-40 4
10 19-11-258 Tyrap-7.31 Inch Long 1
12 19-2-67 Washer-Fender,1/4 ID, 1-1/4 OD, .065 Inch Thick 2
14 19-3-32 Nut-Hexagon,Plain, 1/4-20UNC, Stainless 2
16 21-7201-10 Trim Lock 1/8 Inch Thick .001
17 21-7201-8 Trim Lock .001
18 7L-5-79 Relay-SPDT-24V w/Resistive Suppression 3
19 7L-5-81 Relay-12V 3
07 -1
4 -3
30 5A
07-14-3305 AMEREX FIRE SUPPRESSION INSTALLATION - ELECTRICAL
1 03-15-4096 Bracket - Amerex Contol Panel MTG 1
2 19-2-23 Washer-Flat, 1/4 ID, Stainless 2
3 03-15-4113 Plate - Amerex Warning Decal 1
4 03-15-4272 Bracket - Sensor Standoff 2
5 07-12-2596 Harness - Engine Shutdown 1
6 19-01-1571 Capscrew, Serrated, Flange, 1/4-20 UNC x 1 Inch 4
7 19-01-1608 Screw, No. 10-24 UNC x 1-1/4 Inch 4
9 19-1-621 Screw, Wood No. 6 x 1/2 Inch 4
10 19-1-653 Screw, 8-32 x 1/2 Inch 4
12 19-3-19 Nut - Hex No.1/4-20 UNC, Grade 5 4
14 3L-15-2698 Thermostat - 350 Degree F 3
15 7L-12-3048 Harness - Power, 50 FT 1
16 7L-12-3049 Harness - Thermostat, 50 FT 1
17 7L-12-3051 Harness - Actuator, 30 FT 1
18 19-1-387 Capscrew, 1/4-20 x 3/4 Inch 2
19 7L-12-3053 Harness - Thermostat, 6 FT 4
20 7L-8-3337 Switch - Actuator Kit 1
21 7L-8-3474 Control Panel - Amerex, w/Shutdown 1
22 19-2-37 Washer-Lock, Medium Spring, 1/4 ID 2
23 19-3-32 Nut-Hexagon,Plain, 1/4-20UNC, Stainless 2
07 -1
4 -3
40 0A
07-14-3400 ECU INSTALLATION-ZF TRANS, S60
1 07-08-2003 E Module 1
2 07-08-2426 Adapter-Short Cut (Not shown) 1
3 07-12-2081 Harness-E Module Adapter 1
4 19-1-643 Screw-Machine, Pan Head Cross Recess, 2
5 19-2-37 Washer-Lock, Medium Spring, 1/4 Id, 2
08 -0
1 -1
26 7D
7 67
66 35
08-01-1267 ENGINE BUILDUP ASSEMBLY-S60 w/DUAL Bosch AND B500
1 04-07-1043 Vent-Brass, 1/8 NPT 1
2 04-20-1466 Hose Assembly-Air Cprsr Discharge, S60, E/J 1
3 06-06-1182 Spacer 2
5 07-01-1008 Starter-24V, S60 & C13, Mitsubishi 1
6 07-03-1014 Bracket-Support, Bosch Air Intake 1
7 07-03-1015 Hose-Air Intake, 4”Id, 14”Long 1
8 07-03-1016 Duct-Air Intake, Horizontal 1
9 07-03-1017 Seal-Rubber, Bosch Air Intake 1
10 07-03-1020 Duct-Transition, Bosch Air Intake 1
11 07-03-1021 Spacer-Bosch Air Intake 1
12 07-12-1051 Cable-Ground, Engine 2
13 07-12-1779 Cable-Alternator, Bosch No. 2 1
15 07-12-2051 Cable-Engine Power 1
16 07-12-2075 Harness-Engine Adapter, DDEC VI 1
17 07-12-2089 Harness-Dpf Adapter, DDEC 1
18 07-12-2125 Cable-Alternator, Bosch, Ground No. 1 1
20 08-04-1043 Pulley-Crankshaft, S60, 1:1.05, J4500 1
21 08-11-1001 Decal -Engine Oil Fill 1
22 08-18-1007 Isolator-Front, Engine 2
23 08-18-1008 Isolator-Rear, Engine 2
24 08-18-1018 Spacer-Isolator, Engine 2
25 08-18-1019 Washer-Rebound, Mount 2
26 08-18-1069 Mount-S60, ZF, Rear, RH 1
27 08-18-1070 Mount-S60/ZF Rear LH 1
29 08-27-1055 Pulley Assembly-A/C Idler 1
31 13L-2-125 Kit-Transmission Adaptation 1
32 13L-2-126 Plate-Flex, Capscrew 12
33 13L-2-939 Bracket-Hose, Cooler, Hydraulic 1
34 16-02-1141 Tensioner-A/C, Belt, 3/4 Balls 1
35 17M-2-71 Valve-Rubber, Drain 1
36 19-01-1543 Capscrew 3/8-16 x 3/4 Inch 3
37 19-01-1558 Capscrew - 5/8-11 x 4-1/2 Inch 2
38 19-01-1559 Capscrew - M14-2.0 x 40MM 4
39 19-01-1560 Capscrew - M10-1.5 x 40MM, GR 10.9 8
40 19-01-1563 Capscrew - M10-1.5 x 20MM 1
42 19-01-1648 Capscrew - 7/8-14 x 6. 2
08 -0
1 -1
26 7D
7 67
66 35
08-01-1267 ENGINE BUILDUP ASSEMBLYS60 w/DUAL Bosch AND B500 2
43 19-01-1659 Capscrew - Flanged 3/8-16 x 1/2 Inch 2
44 19-01-1671 Capscrew - Flanged M10x1.5x30MM 3
45 19-01-1695 Capscrew - Flanged 5/8-11 x 2 Inch 8
46 19-01-6136 Screw-Din933-10.9/M12X20X1.75 Hcs Z 2
47 19-02-0365 Washer-Spring, Lock, 6MM, Z&Y 8
48 19-02-6004 Nut - 5/8-18 2
49 19-03-0495 Nut - Flanged 3/8-16 8
50 19-03-0496 Nut - Hex, Flanged, Lock, 5/8-11 GR G 2
51 19-03-0506 Nut - M14-2.0, GR 10.9 4
52 19-03-0507 Nut - M10-1.5, Grade 8.8 8
53 19-03-0509 Nut - 5/8-18 3
54 19-03-0646 Nut-Hex, M6, Z&Y 8
55 19-1-552 Screw-Cap, Hex, 5/8-18UNF X 2-1/4 Inch, Grade 8 2
56 19-1-681 Screw-12 Point Head, 5/8-11 UNC X 1 3/4, 3
57 19-10-1884 Adapter-1/4 Mpt, 3/8 FPT 1
58 19-10-2523 Fitting-Adapter, M14X1/4 NPT 1
59 19-10-2746 Fitting-Drain Valve, 3/8 NPT 1
60 19-11-1568 Boot-Rubber, .9 Id 2
61 19-11-258 Tyrap-7.31 Inch Long 15
62 19-2-107 Washer-Lock, Spring, 1/2 Inch I.D.Stainless 2
63 19-2-28 Washer-Lock, Medium, 5/8 ID, Stainless 4
65 19-3-479 Nut-Stover, Grade 8, 7/8-14UNF 2
66 19-4-109 Clamp-Band, Slotted, Standard, 11/16-1-1/4 1
67 19-4-119 Clamp, Band 3-3/4 Inch to 4 5/8 Inch 3
70 19-4-223 Clamp-Constant Torque 4
74 19-4-83 Clamp-Aero 2
76 7L-13-3910 Cover-Bosch, Air Intake 2
77 8G-18-124 Washer-Rebound 4
79 8L-27-150 Bracket-A/C Idler Pulley 1
08 -0
1 -1
29 4A
1 2
4 5
08-01-1294 DDC S60 ENGINE INSTALLATION - DUAL BOSCH
1 08-01-1270 Engine Assembly - DDC S60 w/Dual Bosch and ZF AST 1
2 08-01-1222 Engine Assembly - DDC S60 w/Dual Bosch and B500 1
5 08-27-1115 Belt-Alternator, S60, Bosch 1
7 08-14-1002 DDC S60 Oil Filter 1
8 04-07-1051 BA922 Air Compressor 1
9 7L-13-3998 Alternator-Bosch, T1 1
10 09-05-1272 Fuel Filter 1
08 -0
1 -1
33 8A
7 67
66 35
08-01-1338 ENGINE BUILDUP ASSEMBLY-S60 w/DUAL BOSCH AND ZF AST
1 04-07-1043 Vent-Brass, 1/8 NPT 1
2 04-20-1466 Hose Assembly-Air Cprsr Discharge, S60, E/J 1
3 06-06-1182 Spacer 2
6 07-03-1014 Bracket-Support, Bosch Air Intake 1
7 07-03-1015 Hose-Air Intake, 4”Id, 14”Long 1
8 07-03-1016 Duct-Air Intake, Horizontal 1
9 07-03-1017 Seal-Rubber, Bosch Air Intake 1
10 07-03-1020 Duct-Transition, Bosch Air Intake 1
11 07-03-1021 Spacer-Bosch Air Intake 1
12 07-12-1051 Cable-Ground, Engine 2
15 07-12-2051 Cable-Engine Power 1
16 07-12-2075 Harness-Engine Adapter, DDEC VI 1
17 07-12-2089 Harness-Dpf Adapter, DDEC 1
21 08-11-1001 Decal -Engine Oil Fill 1
22 08-18-1007 Isolator-Front, Engine 2
23 08-18-1008 Isolator-Rear, Engine 2
24 08-18-1018 Spacer-Isolator, Engine 2
25 08-18-1019 Washer-Rebound, Mount 2
26 08-18-1069 Mount-S60, ZF, Rear, RH 1
27 08-18-1070 Mount-S60/ZF Rear LH 1
29 08-27-1055 Pulley Assembly-A/C Idler 1
31 19-01-1983 Capscrew - 7/16-14 x 3 Inch Long 12
32 13-01-1023 Plate-Clutch 1
34 16-02-1141 Tensioner-A/C, Belt, 3/4 Balls 1
35 17M-2-71 Valve-Rubber, Drain 1
36 19-01-1543 Capscrew 3/8-16 x 3/4 Inch 3
37 19-01-1558 Capscrew - 5/8-11 x 4-1/2 Inch 2
38 19-01-1559 Capscrew - M14-2.0 x 40MM 4
39 19-01-1560 Capscrew - M10-1.5 x 40MM, GR 10.9 8
40 19-01-1563 Capscrew - M10-1.5 x 20MM 1
42 19-01-1648 Capscrew - 7/8-14 x 6. 2
08 -0
1 -1
33 8A
7 67
66 35
08-01-1338 ENGINE BUILDUP ASSEMBLYS60 w/DUAL BOSCH AND ZF
AST
44 19-01-1671 Capscrew - Flanged M10x1.5x30MM 3
45 19-01-1695 Capscrew - Flanged 5/8-11 x 2 Inch 8
46 19-01-6136 Screw-Din933-10.9/M12X20X1.75 Hcs Z 2
47 19-02-0365 Washer-Spring, Lock, 6MM, Z&Y 8
48 19-02-6004 Nut - 5/8-18 2
49 19-03-0495 Nut - Flanged 3/8-16 8
50 19-03-0496 Nut - Hex, Flanged, Lock, 5/8-11 GR G 2
51 19-03-0506 Nut - M14-2.0, GR 10.9 4
52 19-03-0507 Nut - M10-1.5, Grade 8.8 8
53 19-03-0509 Nut - 5/8-18 3
54 19-03-0646 Nut-Hex, M6, Z&Y 8
55 19-1-552 Screw-Cap, Hex, 5/8-18UNF X 2-1/4 Inch, Grade 8 2
56 19-1-681 Screw-12 Point Head, 5/8-11 UNC X 1 3/4, 3
57 19-10-1884 Adapter-1/4 Mpt, 3/8 FPT 1
58 19-10-2523 Fitting-Adapter, M14X1/4 NPT 1
59 19-10-2746 Fitting-Drain Valve, 3/8 NPT 1
60 19-11-1568 Boot-Rubber, .9 ID 2
61 19-11-258 Tyrap-7.31 Inch Long 15
62 19-2-107 Washer-Lock, Spring, 1/2 Inch I.D.Stainless 2
63 19-2-28 Washer-Lock, Medium, 5/8 ID, Stainless 4
65 19-3-479 Nut-Stover, Grade 8, 7/8-14UNF 2
66 19-4-109 Clamp-Band, Slotted, Standard, 11/16-1-1/4 1
70 19-4-223 Clamp-Constant Torque 4
71 19-4-32 Clamp-Line Support, Vinyl Covered, 1/2 Inch 3
73 5G-4-1 Bearing-Flywheel, Clutch Pilot 1
74 19-4-83 Clamp-Aero 2
76 7L-13-3910 Cover-Bosch, Air Intake 2
77 8G-18-124 Washer-Rebound 4
79 8L-27-150 Bracket-A/C Idler Pulley 1
11 -0
8 -1
15 5B
08-18-1155 CRADLE INSTALLATION-ENGINE
3 19-01-1518 Capscrew - Flange 1/2-13 x 9-1/2 Inches 2
4 19-03-0497 Nut Flange - 1/2-13 10
5 08-18-1158 Cradle Assy 1
7 08-18-1156 Crossmember Assembly - Engine Cradle 1
8 08-18-1157 Cradle Rail Assembly - LH 1
9 08-18-1168 Cradle Rail Assembly - RH 1
10 19-01-1521 Capscrew 5/16-18 x 1-1/4 Inch Long 4
11 19-01-1530 Capscrew 1/2-13 x 1-3/4 Inch Long 2
12 19-03-0497 Nut Flange - 1/2-13 2
08 -2
0 -1
18 2B
1 2
08-20-1182 PANEL INSTALLATION-RADIATOR CLOSING, 2007 ENGINE
1 08-20-1181 Panel -Closing Rad, 2007 1
2 19-1-661 Screw-Tapping, Thread Cutting, Type T 17
Sec/GrpPage 127July 2007 08.20
2007 Detroit Diesel S60 Supplement
Sec/GrpPage 128July 2007 08.20
08-20-1194 Filter -Diesel Particulate, 2007 Detroit Diesel S60
1 08-20-1217 Clamp-V-Band 2
3 08-20-1219 Module -DOC- Inlet 1
4 08-20-1220 Module -DPF 1
5 08-20-1221 Module- Exit - Outlet 1
6 08-20-1222 Transducer- Sensor Pressure 2
7 08-20-1223 Connector- Fitting 2
8 08-20-1224 Pipe- DOC Pressure 1
9 08-20-1225 Pigtail- Sensor Gas Temp. 8 Inch Long (Not Shown) 1
10 08-20-1226 Pipe- Exit Pressure 3
11 08-20-1227 Harness Assembly - DPF (Not Shown) 1
08 -2
0 -1
23 0B
08-20-1230 PIPE INSTALLATION-EXHAUST, S60
2 08-20-1204 Insulation-Exhaust Pipe, S60 1
3 08-20-1215 Clamp-V Band, S60 Exhaust 1
4 08-20-1277 Exhaust Gaskete - 4 Inch 1
5 8L-20-101 Clamp-Exhaust, Turbo, V Band 5 1
08 -2
0 -1
23 1E
08-20-1231 DIESEL PARTICULATE FILTER INSTALLATION-S60
1 08-20-1194 Filter-Diesel Particulate, S60, 2007 (See 08-20-1194 for service parts) 1
2 08-20-1195 Mount-DPF, Front Lower, S60 1
3 08-20-1196 Clamp-DPF, Rear, S60 1
4 08-20-1197 Mount-DPF, Front Lower, S60 1
5 08-20-1198 Clamp-DPF, Rear, S60 1
6 08-20-1200 Pipe-Tail, S60 1
7 08-20-1281 Shim-Front 1
9 08-20-1325 Shim-Front 1
14 19-01-1577 Capscrew - Hex Head 1/2-13 x 1 1/4 Inch Long 1
16 19-03-0497 Nut Flange - 1/2-13 1
17 19-03-0527 Nut, Lock Flange 3/8-16 8
18 19-1-25 Capscrew, Hexagon Head, 3/8-16UNCx1-1/2 4
19 8L-20-101 Clamp-Exhaust, Turbo, V Band 5 1
9
09-03-1336 AIR INTAKE INSTALLATION - LOWER
1 07-08-1039 Alarm Assembly - Reverse 1
2 09-03-1411 Insulation - Air Cleaner 1
3 09-03-1040 Hose 1
5 09-03-1153 Hose - 4 Inch ID, Air Intake 2
6 09-03-1164 Muffler - Turbo Noise 1
7 09-03-1379 Air Cleaner w/Sensor 1
8 17L-4-8 Drain Valve 1
10 19-03-0495 Nut - Flanged 3/8-16 3
11 09-03-1412 Insulation - Air Cleaner 2
12 19-04-0279 Clamp, Band 2
14 19-12-25 Grommet - 11/16 Inch ID x 1 5/16 Inch OD 3
15 19-2-119 Washer-Fender, 3/8 Inch I.D. x .406 ID X 1-1/4 Inch 3
16 19-4-110 Clamp, Band, 13/16 - 1 3/4 Inch 1
18 7L-8-1019 Grommet 1
09 -0
3 -1
34 9E
09-03-1349 AIR INTAKE INSTALLATION - S60, 2007
1 04-07-1085 Bracket-Hose Support,Air Compressor 1
2 04-07-1088 Bracket-Hose Support,Air Compressor 1
3 04-07-1108 Hose-1-1/4 Inch Air Intake,Air Compressor 1
4 08-01-1268 Spacer 1
7 09-03-1342 Cac Hose-4 Inch ID,31 Deg Elb 1
8 09-03-1345 Pipe-CAC to S60 1
9 09-03-1348 Pipe-CAC to Intake 1
10 09-03-1358 Pipe-Turbo to CAC 1
11 09-03-1372 Bracket-CAC Pipe 1
12 09-03-1380 Bracket-P/Clamp,Cac 2007 1
13 09-03-1381 Elbow-S60,2007,Turbo 1
14 09-03-1382 Clamp-S60,2007,Turbo 1
15 09-03-1383 Seal-O-Ring,2007,S60,Turbo 1
17 09-03-1392 Insert-4 Inch ID Air Intake 1
18 09-03-1393 Elbow-45 Deg 4 Inch ID Air Intake 1
19 09-03-1403 Sensor-Temperature,Air,Ambient 1
21 09-03-1414 Bracket-Standoff Support 1
22 09-03-1415 Hose-Stand Off,Air Compressor,S60 1
23 09-03-1417 Hose-Air Cleaner Can to Standoff 1
24 19-01-1524 Capscrew - 1/4-20 x 3/4 Inch 2
25 19-01-1560 Capscrew - M10-1.5 x 40MM, GR 10.9 1
27 19-03-0495 Nut - Flanged 3/8-16 2
28 19-03-0503 Nut - Flanged 1/4-20 2
29 19-04-0278 Clamp-Band 6 Inch, SS 2
30 19-04-0345 Clamp - P Clip 1.4375 3
31 19-04-0406 Clamp-Band, 4.31 ID, SST 10
32 19-10-562 Fitting-Tube, Cap, 1 Inch Nominal, Wrot Copper 1
33 19-4-108 Clamp-Band, Slotted, Heavy Duty, 4 3/4- 2
34 19-4-110 Clamp, Band, 13/16 - 1 3/4 Inch 6
36 9L-3-163 Hose-Hump, 4 Inch ID X 6 Inch Long 4
09 -0
5 -1
22 1F
09-05-1221 FUEL INSTALLATION-S60 FUELPRO
3 09-05-1245 Hose Assy-Fuel, S60 1
4 09-05-1276 Hose Assy-Fuel, S60, w/Fuel Cooler 1
5 09-05-1278 Hose Assy-Fuel, Cat W/Fuel Cooler 1
6 09-05-1326 Hose Assembly - Fuel, Supply 1
7 19-01-1516 Capscrew - 3/8-16 x 1-1/4 Inch 5
8 19-01-1543 Capscrew 3/8-16 x 3/4 Inch 1
10 19-03-0535 Locknut - Flanged, 3/8-16 7
11 19-04-0298 Clamp-Hose/Cable, .875 ID, 2 Halves 1
12 19-04-0299 Plate-Cover, Clamp 1
13 19-1-1072 Screw-Cap, Hex 1/4-20UNC x 2 Inch Grade 5 ST 2
14 19-10-2222 Valve-Shut Off, Ball 1
15 19-10-2249 Fitting-Barb, Male Hose 1
16 19-10-2776 Fitting-3/8 MPT to Jic 37-8 1
17 19-10-2804 Reducer, -8 to -6 Jic 37 1
18 19-10-411 Fitting-Pipe, 90 Deg Male Elbow, 1/2- 1
19 19-10-418 Fitting-Pipe, Bushing, 1/2 Male Pipe X 1/4 1
20 19-10-869 Fitting-Cap, Nut-8 1
21 19-10-958 Fitting-Tube, SAE 37 Degree Flare, 90 2
24 19-4-83 Clamp-Aero 2
26 9L-5-643 Fuel Pro (See 9L-5-643 for service parts) 1
9L -5
-6 43
9l-5-643 FUEL PRO FUEL FILTER
1 09-05-1201 O-Ring 1
2 09-05-1202 Kit - Cap and Seal, Fuel Pro 380 1
3 09-05-1203 Spring - Fuel Pro 380 1
4 09-05-1272 Kit - Element and Grommet Assembly w/Seal Rings 1
5 09-05-1205 Cover - Clear, Fuel Pro 1
6 09-05-1206 Collar 2
8 09-05-1208 Kit - Check Valve Repair 1
9 09-05-1209 Drain Valve 1
10A 09-05-1210 Plate Assembly - Bottom, Heated, w/Seal Ring 1
10B 09-05-1212 Plate Assembly - Bottom, No Heat, w/Seal Ring 1
11 09-05-1211 Seal - O-Ring, Bottom Plate 1
11 -0
8 -1
25 5B
11-08-1255 POWER STEERING INSTALLATION-S60, J4500
1 11-07-1047 Bracket Assembly-Mounting Power Steering Pump 1
2 11-08-1185 Hose Assembly-Power Steering, Reservoir 1
3 11-08-1256 Hose Assy-P/S, S60 1
4 11-08-1257 Hose Assy-P/S Suction, S60 1
5 11-08-6043 Reservoir-Steering, Power 1
6 11-08-1230 Ring-Sealing 1
7 11-08-1231 Cover 1
9 11-08-1234 Dipstick 1
11 11-09-1007 Pump-Power Steering, J4500, Lf73 1
12 19-01-1516 Capscrew - 3/8-16 x 1-1/4 Inch 4
13 19-01-1543 Capscrew 3/8-16 x 3/4 Inch 4
14 19-03-0495 Nut - Flanged 3/8-16 14
15 19-04-0387 Clamp-Band, 5 1/8 Dia 1
16 19-04-0392 Clamp Stepless, Spring .75-.94 Inch 1
18 19-10-2215 Fitting-45 Degree Elbow, Orb-12 To Jic-16 1
19 19-10-738 Fitting-Adapter, SAE O Ring(Adj)/37 Deg 1
21 19-4-231 Clamp-Stepless Spring(Constant Torque) 1
24 23-01-0034 Oil Transmission Dexron VI 2
12 -0
6 -1
02 7D
12-06-1027 VALVE ASSEMBLY-LEVELING, LH
1 12-06-1001 Valve-Leveling 1
4 19-10-1459 Elbow-Male 1
12 -0
6 -1
02 8D
12-06-1028 VALVE ASSEMBLY-LEVELING, RH
1 12-06-1001 Valve-Leveling 1
4 19-10-1459 Elbow-Male 1
13 -0
1 -1
04 7G
14 15
7 16
13-01-1047 TRANSMISSION INSTALLATION-ZF AST, 12 SPD, S60
1 04-20-1186 Hose Assy-Clutch, ZF 1
2 04-20-1470 Hose Assy-Shifter, ZF 1
3 07-12-1423 Harness-ZF J1939 Assy (Not shown) 1
4 07-12-1802 Harness-ZF Transmission (Not shown) 1
5 13-01-1048 Transmission-ZF Astronic, 12 Spd, S60 1
6 19-01-1516 Capscrew - 3/8-16 x 1-1/4 Inch 4
9 19-02-0383 Flat Washer, 7/16 12
10 19-03-0535 Locknut - Flanged, 3/8-16 3
11 19-10-2425 Fitting-Connector, M16 Parallel Port X 1
12 19-10-2426 Fitting-Elbow, 90 Degree, M16 Parallel 1
13 19-11-258 Tyrap-7.31 Inch Long 12
B
B
A
A
13-11-1146 TRANSCOOLER INSTALLATION-B500, S60
2 06-08-1272 Pipe-Rad To B500 Cooler 1
4 13-02-1029 Bracket-Hose, Trans Cooler 1
5 13-08-1026 Dipstick Assy-”Z” Bend, S60, B500 1
6 13-11-1011 Isolator-Trans Cooler 4
7 13-11-1021 Washer-Isolator 8
9 13-11-1123 Pipe-Thermo By-Pass 1
10 13-11-1145 Bracket-Thermostat, S60 1
11 13-11-1149 Bracket-Transcooler, S60 1
12 13-11-1150 Spacer-1.06 Long 1
13 13L-11-102 Cooler-Trans, Modine, B500 1
14 13L-2-962 Bracket-Hose, Trans Cooler 1
15 19-01-1516 Capscrew - 3/8-16 x 1-1/4 Inch 3
16 19-01-1531 Capscrew - 3/8-16 x 2-1/4 Inch 4
17 19-01-1536 Capscrew - 1/2-13 x 1-1/2 Inch 2
18 19-01-1543 Capscrew 3/8-16 x 3/4 Inch 2
21 19-03-0495 Nut - Flanged 3/8-16 16
22 19-03-0497 Nut Flange - 1/2-13 2
23 19-10-1444 Fitting-Tube, 90 Degree Adapter, Sae, 4
25 19-4-205 Clamp-Stepless Spring, Constant Torque, 1
26 19-4-206 Clamp - Stepless Spring 1.94-2 Inch 3
27 19-4-207 Clamp - Stepless Spring 2
28 19-4-210 Clamp 2
32 6L-8-1204 Hose-Hump 2
16 -1
1 -1
66 7A
16-11-1667 BOOST PUMP INSTALLATION-S60
2 16-11-1665 Pump-Coolant,Boost 1
4 16-11-1567 Impeller 1
6 16L-16-398 Adapter 1
7 16L-16-392 Housing 1
10 16L-16-393 O-ring, Buna N 1
11 16L-16-399 Drive Magnet 1
12 16-11-1570 Electric Motor 1
13 16-11-1571 Retainer Ring 1
14 16-11-1572 Quad Ring - Viton 1
15 16-11-1573 Capscrew 3/8-16 x 3/4 Inch 4
16 16-11-1666 Suction Flange Assembly 2
17 16L-16-394 Washer - SST 2
18 16L-16-396 Shaft 1/4 Inch Diameter 1
19 16-11-1574 Bushing 1
20 16-11-1575 Shell 1
21 16-11-1576 Magnet 1
25 16-11-1658 Bracket Assembly -Boost Pump Mounting 1
27 19-03-0527 Nut, Lock Flange 3/8-16 4
29 19-4-102 Clamp - Band 2
31 6L-8-1228 Hose-Silicone 1.38 Inch ID 1
16 -1
1 -1
67 0C
VIEW A
VIEW A
16-11-1670 AUXILIARY HEATER INSTALLATION-PROHEAT X45, S60
1 06-08-1101 Bracket-Support, Coolant Line 1
2 07-19-6072 Switch-Auxiliary Heat On/Off 1
4 16-11-1633 Exhaust Pipe-Proheat 1
5 16-11-1642 Bracket-Exhaust Pipe Support 1
6 16-11-1722 Hose-Thermopol, Silicone 3/4 ID 1
7 16-16-1228 Bracket-Proheat Mtg 1
8 16-16-1229 Bracket-Proheat Mount 1
9 16-16-1233 Bracket-Hose 1
11 16-16-1249 Hose Assy-Auxiliary Heater, Supply 1
12 16-16-1250 Aux Heater-Proheat X-45 160-180F Ph9568 (See 16-16-1250 for service parts)
1
14 19-01-1516 Capscrew - 3/8-16 x 1-1/4 Inch 1
15 19-01-1543 Capscr

Service Bulletin No.2984 - Motor Coach Industries

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