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Detroit Diesel

Series S60 Training

Course Outline



Introductions
Basic Engine Operating Principles
Engine Components
System Overview
– Lube
– Air
– Coolant
– Fuel
• Overhaul Procedures
• DDEC Overview
• Mechanical Troubleshooting

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Basic Engine Operating Principles

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Air Rev 3/2/00 25ST0060-2 + Rotary Mechanical Fire Fuel Linear Mechanical .To operate an Diesel Engine you need the following.

Four Stroke Cycle (Continued) Rev 3/2/00 25ST0060-2 .

Four Stroke Cycle Rev 3/2/00 25ST0060-2 .

Heat Balance Exhaust 30-35% Coolant & Radiation 30-35% Engine Horsepower 30-35% Rev 3/2/00 25ST0060-2 Fuel Energy 100% .

Rev 3/2/00 25ST0060-2 .

Series 60 Marine Commercial & Pleasure Craft Marine (2003) Commercial Marine (1997) Truck Model (1987) Rev 3/2/00 25ST0060-2 .

Series 60 Commercial & Pleasure Craft Marine Overview Rev 3/2/00 25ST0060-2 .

92 6V 92 8V 92 Rev 3/2/00 25ST0060-2 .Series 60 Marine vs.

CAT 3196 & 3406E CAT 3196 CAT 3406E Rev 3/2/00 25ST0060-2 .Series 60 Marine v.

Series 60 Marine v. MAN D2840 & D2848 D2840 D2848 Rev 3/2/00 25ST0060-2 .

7 Liters 14.Series 60 Specifications Compression Ratio Aspiration Engine Controls 4-CYCLE Inline 6 Cylinder 12.0:1 Turbocharged / After cooled DDEC Horsepower 400HP (298kW) – 825HP (615kW) Engine Type Configuration Displacement Bore & Stroke Rev 3/2/00 25ST0060-2 .0 Liters 130 mm X 160 mm 133 mm X 168 mm 15.

Series 60 – Marine Engine Rev 3/2/00 25ST0060-2 .

Publications * Rev 3/2/00 25ST0060-2 .

Maintenance Interval Schedules S60 Marine Operators Guide 6SE599 * Rev 3/2/00 25ST0060-2 .

Fuel. and Filters 7SE270 Coolant Selections 7SE298 Fastener Torque Specification 028T6000 (DDC Extranet in General Technical information) Parts Catalogue * Rev 3/2/00 25ST0060-2 6SP161 .Publications Publication Number S60 Application and Installation Manual 7SA747 S60 Marine Operators Guide 6SE559 S60 Service Manual 6SE483 Lubricating Oil.

Commercial Marine Location 2.LOCATIONS OF ENGINE MODEL AND SERIAL NUMBER 1. Engine Model Number 4. Engine Serial Number 3. Pleasure Craft Marine Location Rev 3/2/00 25ST0060-2 .

GENERAL CONSTRUCTION
& SPECIFICATIONS

Series 60 Top View

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Series 60 Front/Rear View

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Right Side Series 60 Block Rev 3/2/00 25ST0060-2 .

Series 60 Left Side Rev 3/2/00 25ST0060-2 .

Main Bearing View 12.7L Rev 3/2/00 25ST0060-2 .

Series 60 Marine Eight Head Bolts Per Cylinder • Provides Uniform Load on Gasket & Liners • Robust “Proven” Head Gasket • Optimal Cylinder Pressure Capability – Low Emissions – Superior Fuel Economy Rev 3/2/00 25ST0060-2 .

Series 60 Head Top View

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Head Components

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Valve Components

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Intake / Exhaust Valves • Chrome Exhaust Valve (MY2K) • Face Change on Valves(MY2K) Rev 3/2/00 25ST0060-2 .

Series 60 Marine Overhead Camshaft • Eliminates Push Rods & Lifters • Reduces Number of Moving Parts – Improves Reliability • Provides Easy Serviceability • Improves Fuel Economy • Allows for High Injector Pressures – Lowers Emissions Rev 3/2/00 25ST0060-2 .

Series 50/60 Camshafts Rev 3/2/00 25ST0060-2 .

Camshaft Components Rev 3/2/00 25ST0060-2 .

Camshaft Components Rev 3/2/00 25ST0060-2 .

Series 60 Marine Ceramic Injector Rollers • Allows Higher Injection Pressures • Improves Fuel Economy • Enhances Performance • Lowers Emission Levels Rev 3/2/00 25ST0060-2 .

Camshaft Rev 3/2/00 25ST0060-2 .

Rocker Arm Assembly Rev 3/2/00 25ST0060-2 .

Exhaust / Intake Rocker Arms Rev 3/2/00 25ST0060-2 .

Injector Rocker Arm

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Series 60 Crankshafts

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Series 50/60
Crankshaft Bearings

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Vibration Damper Rev 3/2/00 25ST0060-2 .

Liner Rev 3/2/00 25ST0060-2 .

Series 60 Marine Top Liner Cooling (TLC) • Reduces Fire Ring Temperature • Reduces Ring and Liner Wear • Extends Ring Life • Reduces Maintenance Costs • Maximizes Life to Overhaul LINER COOLING CHANNEL COOLING CHANNEL INLET NOTCH IN BLOCK COOLING CHANNEL EXIT HOLE MAIN COOLANT STREAM Rev 3/2/00 25ST0060-2 .

Block Bore Liner Rev 3/2/00 25ST0060-2 .

Liner Seals Rev 3/2/00 25ST0060-2 .

Wheep Hole Rev 3/2/00 25ST0060-2 .

Weep Hole/Plug Weep Hole Rev 3/2/00 25ST0060-2 .

Series 60 Marine Cylinder Kit 3mm Fire Ring Lowered Fire Ring Reduced Diameter 2nd Lard Stiffened Piston Pin Rev 3/2/00 25ST0060-2 Sputtered Upper Con Rod Bearings .

Series 60 Steel Forged Piston Rev 3/2/00 25ST0060-2 .

Connecting Rod Rev 3/2/00 25ST0060-2 .

Rod and Main Bearings Sputtered Bearings » Upper Rod Trimetal » Lower Rod » Upper Main & Lower Main Picture of the S60 Bearing Rev 3/2/00 25ST0060-2 .

Trimetal Bearing • Trimetal are the Most Common • The Various Layers of Metal are Typically – Lead/Tin Overlay .Lubricity Under Poor Lube Oil Conditions – Nickel Barrier .Prevents Migration of One Bearing Metal into Another – Copper Lining .Actual Bearing Material – Steel Backing Rev 3/2/00 25ST0060-2 Tin Lead Nickel Copper Steel .

Copper and Aluminum are Mixed and Atomized then Applied to the Steel Backing by a Cathode Process.Sputter Bearing • Sputter Bearings Use the Same Metals as a Trimetal Bearing but are Constructed Differently • Tin. Lubricity and Imbedability of all the Metals Simultaneously • The Adhesion to the Steel Backing is Significantly Greater than the Conventional Rolled Method Rev 3/2/00 25ST0060-2 . in a Vacuum • The Result is a Bearing Surface which Exhibits the Strength.

500 PSI 16000 14000 12000 10000 8000 6000 4000 2000 0 Trimetal Rev 3/2/00 25ST0060-2 Sputtered .Maximum Load Carrying Capacity Trimetal 7.250 PSI Sputtered 14.

Timing Marks Rev 3/2/00 25ST0060-2 .

Cam Gear/ Bolt Rev 3/2/00 25ST0060-2 .

Thrust Plate (Variations) Rev 3/2/00 25ST0060-2 .

Thrust Plate (Variations) Rev 3/2/00 25ST0060-2 .

Thrust Plate (Variations) Rev 3/2/00 25ST0060-2 .

Idler Gear / Retaining Hub Rev 3/2/00 25ST0060-2 .

Bull Gear Assembly Rev 3/2/00 25ST0060-2 .

Bull Gear Rev 3/2/00 25ST0060-2 .

Bull Gear Alignment Rev 3/2/00 25ST0060-2 .

Crank Gear S60 Rev 3/2/00 25ST0060-2 .

Pulse Wheel/Timing Wheel Rev 3/2/00 25ST0060-2 .

Oil Pump Rev 3/2/00 25ST0060-2 .

Oil Pump Rev 3/2/00 25ST0060-2 .

Oil Pump Components Rev 3/2/00 25ST0060-2 .

Oil Cooler Adapter Rev 3/2/00 25ST0060-2 .

Oil Cooler Rev 3/2/00 25ST0060-2 .

Engine Mount & Pulley Rev 3/2/00 25ST0060-2 .

Accessory Drive Rev 3/2/00 25ST0060-2 .

Accessory Drive Rev 3/2/00 25ST0060-2 .

Front Seal Rev 3/2/00 25ST0060-2 .

Rear Seal Rev 3/2/00 25ST0060-2 .

Flywheel Housing • Bolt Change to • 14mm for 1998 Rev 3/2/00 25ST0060-2 .

Flywheel/Scuffplate Rev 3/2/00 25ST0060-2 .

Water Pump Rev 3/2/00 25ST0060-2 .

Water Pump Rev 3/2/00 25ST0060-2 .

Thermostat Housing Rev 3/2/00 25ST0060-2 .

Thermostats and Housing Rev 3/2/00 25ST0060-2 .

Series 60 Marine Complete Package Rev 3/2/00 25ST0060-2 • Water Cooled Pulse Exhaust Manifold • Raw Water Charge Air Cooler • Titanium Plate Heat Exchanger • Marine Transmission With Cooler • AMOT Air Shutdown System • Alternator • Marine Interface Module (MIM) • Engine Mounts and Mounting Brackets • Closed Crankcase Breather System .

and IV) Remote Dual or Single Oil Filter Mount .Series 60 Marine Premium Options • • • • • • Rev 3/2/00 25ST0060-2 Single Rear-Mounted Oil Filter AMOT Air Shutdown (Delete Option) Appearance Package DDEC Control Options Transmission Options (SC. DA.

Series 60 – Marine Engine Rev 3/2/00 25ST0060-2 .

Series 60 – Heat Exchange Cooled Marine Engine (Front View) 1. 7. 6. 11. 3. 10. 12. 5. 4. Rev 3/2/00 25ST0060-2 Engine Oil Fill Engine Oil Dipstick Raw Water Drain Emergency Shutdown Lever Air Inlet Alternator Coolant and Fuel Cooler Accessory Drive Cover Raw Water Inlet Elbow Crankshaft Pulley Front Mount Bracket Oil Filter Fuel Return (Outlet) . 2. 9. 8. 13.

13. 8. 4. 5.Series 60 – Heat Exchange Cooled Marine Engine (Right View) Rev 3/2/00 25ST0060-2 1. 17. 10. 7. Flywheel Housing Raw Water Drain Raw Water Outlet Marine Interface Module (MIM) Marine Gear Oil Cooler Marine Gear Cooler Oil Inlet Marine Gear Cooler Oil Outlet Air Cleaner Lifter Bracket Site Glass Fuel Outlet Alternator Front Mounting Pad Engine Oil Drain Engine Water Pump Oil Pan Engine Oil Filters Block Heater Electrical Junction Box . 18. 15. 3. 9. 12. 16. 6. 2. 11. 14.

Series 60 – Heat Exchange Cooled Marine Engine (Left Side View) 1. 8. 6. 7. Rev 3/2/00 25ST0060-2 9.Cap Lifter Bracket Air Inlet Restriction Indicator Turbocharger Rear Engine Mount Mounting Pad Charge Air Cooler Drain Electronic Control Unit Starter Raw Water Inlet Elbow Raw Water Pump . 3. Oil Pan Front Mounting Pad Raw Water Drain Coolant Fill. 12. Press. 13. 2. 10. 5. 4. 11.

Flywheel 7. 2. 3. Raw Water Inlet Secondary Fuel Filter Lifter Bracket Exhaust Outlet Marine Gear Cooler. 4. 5. Raw Water Outlet 6.Series 60 – Heat Exchange Cooled Marine Engine (Rear View) 1. Flywheel Housing Rev 3/2/00 25ST0060-2 .

Water Cooled Turbine Raw Water Charge Air Cooler Titanium Plate Heat Exchanger Engine Water Pump Fuel Injector Engine Oil Cooler 150 New Components . Pulse.Series 60 Marine Key New Components • Cylinder Kit – Dome (Stiffer Piston Pin) – Fire Ring Location • • • • • • • • Rev 3/2/00 25ST0060-2 Water Cooled. Exhaust Manifold Turbocharger.

Series 60 Marine Cylinder Kit 3mm Fire Ring Lowered Fire Ring Reduced Diameter 2nd Lard Stiffened Piston Pin Rev 3/2/00 25ST0060-2 Sputtered Upper Con Rod Bearings .

Pulsed Exhaust Manifold Rev 3/2/00 25ST0060-2 .

Water Cooled Turbo and Bearing Section Rev 3/2/00 25ST0060-2 .

Charge Air Cooler • Integral Charge Air Cooler and Intake Manifold • Raw Water Cooler • Cast Aluminum Housing • High Efficiency • Sized for Growth Rev 3/2/00 25ST0060-2 .

Series 60 Marine Heat Exchanger • Titanium Cooling Plates • Cast Aluminum Housing and Cover Plate • Stainless Steel Hardware • Flexible Design • Easy to Service • Integral Expansion Tank and Fuel Cooler Rev 3/2/00 25ST0060-2 .

Water Pump • Based on Proven Design • Improved Flow for High Horsepower • Gear Driven Rev 3/2/00 25ST0060-2 .

Series 60 Marine Electronic Unit Injectors • High Injection Pressure • Excellent Fuel Economy • Low Emissions Terminals Solenoid Stator Armature Fuel Manifold Poppet Control Valve Body Forging Rev 3/2/00 25ST0060-2 .

Rear Mount Single Oil Filter Rev 3/2/00 25ST0060-2 .

Series 60 Marine Rear Mounted Single Oil Filter • Inboard Service Points • 250 Hour Change Interval Rev 3/2/00 25ST0060-2 .

Optional Air Shut Down Rev 3/2/00 25ST0060-2 .

Air Sep & Closed Crankcase Standard Rev 3/2/00 25ST0060-2 .

Gear Cooler Rev 3/2/00 25ST0060-2 .

Cold Start Assist Rev 3/2/00 25ST0060-2 .

Cold Start Assist Rev 3/2/00 25ST0060-2 .

Customer Connections Rev 3/2/00 25ST0060-2 .

Overhaul/Safety Precautions • Always Wear Safety Glasses in Lab • Mop Floor when needed while working on engine and around Engine at end of each day • Put all tools and materials back at the end of each class Rev 3/2/00 25ST0060-2 .

OVERHAUL .

OVERHAUL INSPECTION .

Block Flatness Rev 3/2/00 25ST0060-2 .

ID size of Main Journal Rev 3/2/00 25ST0060-2 .

Liner Bore ID size Rev 3/2/00 25ST0060-2 .

Liner Protrusion Rev 3/2/00 25ST0060-2 .

Crankshaft Runout Rev 3/2/00 25ST0060-2 .

Crankshaft End Play Rev 3/2/00 25ST0060-2 .

Camshaft Flatness Check Rev 3/2/00 25ST0060-2 .

Camshaft Runout Rev 3/2/00 25ST0060-2 .

Camshaft End Play Rev 3/2/00 25ST0060-2 .

Plasti-Gage Rev 3/2/00 25ST0060-2 .

Gearlash Rev 3/2/00 25ST0060-2 .

Injector Tube Replacement Rev 3/2/00 25ST0060-2 .

THE SYSTEMS .

FUEL SYSTEM .

Fuel System • • • • • • Rev 3/2/00 25ST0060-2 Engine Requirements Fuel Filters/Fuel Pro 380 Fuel Pump Cold Plate(Optional) Restrictive Fitting Fuel Injectors .

Fuel System schematic Series 60 Rev 3/2/00 25ST0060-2 .

Fuel Filters Rev 3/2/00 25ST0060-2 .

Positive Displacement Fuel Pump Rev 3/2/00 25ST0060-2 .

Fuel Pump Rev 3/2/00 25ST0060-2 .

Restrictive Fittings Rev 3/2/00 25ST0060-2 .

Electronic Control Module (ECM) Rev 3/2/00 25ST0060-2 .

Cold Plate Rev 3/2/00 25ST0060-2 .

Fuel Injector Rev 3/2/00 25ST0060-2 .

Fuel Injector Rev 3/2/00 25ST0060-2 .

Fuel Injector Rev 3/2/00 25ST0060-2 .

Voltage in Rocker Arm Solenoid Poppet Valve Cam Plunger Fuel out Fuel in Needle Valve Series 50/60 Injector Animation .

Injector Cut-Away Voltage in Solenoid Camshaft Poppet Control Valve Fuel Outlet Plunger O-Rings Fuel Inlet O-Ring Needle Valve Rev 3/2/00 25ST0060-2 Spray Tip .

Injector Calibration Codes • DDEC II No Calibration Codes • DDEC III Calibration Codes From 00-99 Part Number Calibration Code Rev 3/2/00 25ST0060-2 .

Injector Cycle Terminology zIRT Injector Response Time .Degrees of Crankshaft Rotation when Fuel is Injected Rev 3/2/00 25ST0060-2 .Length of Time (ms) required to close the Control Valve zPW Pulse Width .

Injector Response Times Rev 3/2/00 25ST0060-2 .

Cylinder Cut-Out Rev 3/2/00 25ST0060-2 .

FUEL SYSTEM TROUBLESHOOTING .

Fuel System Troubleshooting Low Power Inspect the Following • • • • • • • Rev 3/2/00 25ST0060-2 Fuel Supply Restricted Filters Obstructed Fuel Lines Fuel Pump Low Temperature Fuel Blend Fuel Pressure .

Fuel System Troubleshooting Tools • • • • • • • Rev 3/2/00 25ST0060-2 Fuel Priming Pump Fuel Pressure Gage Graduated Bucket Stop Watch Pyrometer Pump Suction Cylinder Cut-Out/ Injector Response Times .

Priming Rev 3/2/00 25ST0060-2 .

Fuel Pump Pressure Rev 3/2/00 25ST0060-2 .

Fuel Spill Back Rev 3/2/00 25ST0060-2 .

Cylinder Cut-Out Rev 3/2/00 25ST0060-2 .

Injector Response Times Rev 3/2/00 25ST0060-2 .

Length of Time (ms) required to close the Control Valve zPW Pulse Width .Degrees of Crankshaft Rotation when Fuel is Injected Rev 3/2/00 25ST0060-2 .Injector Cycle Terminology zIRT Injector Response Time .

AIR SYSTEM .

Series 60 Air Intake Rev 3/2/00 25ST0060-2 .

Air Cleaner System REM: C&I S60 Full 30L and Low 25L Rev 3/2/00 25ST0060-2 .

With low water pressure. WHICHEVER COMES FIRST. . Rinse Off . Re-Oiling The Filter – The effectiveness of the air filter is greatly reduced if it is used without oiling.Air Cleaner System CONTINUED AIR FILTER ELEMENT SHOULD BE CLEANED EVERY 250 HOURS OF OPERATION OR ONCE A YEAR. • • • • Rev 3/2/00 25ST0060-2 Pre-Cleaning – Gently tap and brush element. Spray On Cleaner -Let it stand for 10 minutes.

AIR SYSTEM TROUBLESHOOTING .

Air System Troubleshooting Low Power Inspect the Following • Intake – – – – Air Cleaner Charge Cooler Piping Turbocharger • Exhaust – Faulty Piping – Obstructed Muffler • Turbo Boost Sensor • Low Compression Rev 3/2/00 25ST0060-2 .

Air System Troubleshooting Tools • Water Manometer • Pyrometer/Thermocouple • Pressure Gage – Air Inlet Restriction – Exhaust Back Pressure – Crankcase Pressure Rev 3/2/00 25ST0060-2 .

THE LUBRICATION SYSTEM .

Oil Requirements Rev 3/2/00 25ST0060-2 .

Lube System 9 9 9 9 9 9 9 9 9 9 9 Rev 3/2/00 25ST0060-2 Oil Requirements Oil Pump Regulator Valve Relief Valve Oil Cooler Adapter Oil Cooler Oil Filters Turbo Charger Feed Line Block Passages Head Passages Component Passages .

Series 60 Premium Oil Schematic Rev 3/2/00 25ST0060-2 .

Oil Pump Rev 3/2/00 25ST0060-2 .

Oil Spray Nozzle • All 1998 Blocks have drilled openings into the main oil gallery Rev 3/2/00 25ST0060-2 .

Regulator Valve Rev 3/2/00 25ST0060-2 .

Relief Valve Rev 3/2/00 25ST0060-2 .

Oil Cooler Adapter Rev 3/2/00 25ST0060-2 .

Oil Cooler (with Thermostat) Rev 3/2/00 25ST0060-2 .

Oil Filters Rev 3/2/00 25ST0060-2 .

THE COOLING SYSTEMS .

Cooling System • • • • • • • • Rev 3/2/00 25ST0060-2 Recommendations Water Pump Oil Cooler Housing Block Passages Head Passages Thermostat Housing Thermostats Radiator .

Coolant System Series 60 Rev 3/2/00 25ST0060-2 .

Water Pump Rev 3/2/00 25ST0060-2 .

Oil Cooler Housing Rev 3/2/00 25ST0060-2 .

Coolant Filter (External) Rev 3/2/00 25ST0060-2 .

Thermostat Housing Rev 3/2/00 25ST0060-2 .

Blocking Type Thermostat Operation Rev 3/2/00 25ST0060-2 .

Thermostats / Seals Rev 3/2/00 25ST0060-2 .

THEN EVERY 150 HOURS OR YEARLY. • Electrodes are generally found in the heat exchanger assembly.Raw Water System Zincs RAW WATER SYSTEM “ZINCS” SHOULD BE CHECKED INITIALLY AT 60 HOURS. the fuel cooler and the marine gear auxiliary coolers. • Replace if badly deteriorated. • Clean with a wire brush if serviceable. the raw water pump elbows. Rev 3/2/00 25ST0060-2 .

ENGINE TUNE-UP .

Engine Tune Up
• Injector Height
• Valve Lash
• New Overlap procedure

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Overlap Series 60
Cylinder Overlap
6
2
4
1
5
3

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Valves
1
5
3
6
2
4

Injector
5
3
6
2
4
1

Lash Settings
• Intake Valves
• Exhaust Valves

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Injector Height Setting • Variations in Cam profile will determine setting Rev 3/2/00 25ST0060-2 .

(3.179 .75 . 6062TKXX (2000-2003) = 81.) Rev 3/2/00 25ST0060-2 .3.189 in.81.S60 Marine.0 mm (3.) Tolerance 80. Injector and Valve Lash Setting Models 6062HKXX.199in.25mm.

028 in.) *"H" valves have a machined identification ring above the valve lock groove.711 mm (0.0.) Rev 3/2/00 25ST0060-2 . "U" valves do not.280mm (0.025 -0.011 in.008 in.) 0.787mm (0.) Tolerance 0.635 .S60 Marine Valve Clearance EXHAUST VALVE CLEARANCE .127 .* "H" Models 6062HKXX.031 in.203 mm(0. INTAKE VALVE CLEARANCE 0. 6062TKXX (2000 .0.005 .2003) 0.0.