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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 To operate an Diesel Engine you need the
following;

Air
+ Fuel
Fire

Rotary
Linear
Mechanical
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Mechanical
 Four Stroke Cycle (Continued)

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 Four Stroke Cycle

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 Heat Balance

Fuel
Exhaust
30-35%
Energy
100%
Coolant &
Radiation
30-35%

Engine
Horsepower
30-35%

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Rev 3/2/00
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 Series 60 Marine

Commercial & Pleasure Craft

Marine
(2003)
Commercial
Marine
(1997)
Truck Model
(1987)
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 Series 60 Commercial & Pleasure Craft
Marine Overview

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 Series 60 Marine
vs. 92

6V 92
8V 92
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 Series 60 Marine
v. CAT 3196 & 3406E

CAT 3196
CAT 3406E
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 Series 60 Marine
v. MAN D2840 & D2848

D2840
D2848
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 Series 60 Specifications

Engine Type 4-CYCLE

Configuration Inline 6 Cylinder
Displacement 12.7 Liters
14.0 Liters
Bore & Stroke 130 mm X 160 mm
133 mm X 168 mm
Compression Ratio 15.0:1
Aspiration Turbocharged / After cooled
Engine Controls DDEC

Horsepower 400HP (298kW) 825HP (615kW)

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 Series 60 Marine Engine

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 Publications

*
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 Maintenance Interval Schedules
S60 Marine Operators Guide 6SE599

*
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 Publications
Publication Number

S60 Application and Installation Manual 7SA747

S60 Marine Operators Guide 6SE559
S60 Service Manual 6SE483
Lubricating Oil, Fuel, and Filters 7SE270
Coolant Selections 7SE298
Fastener Torque Specification 028T6000
(DDC Extranet in General Technical information)

Parts Catalogue 6SP161

*
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 LOCATIONS OF ENGINE MODEL AND
SERIAL NUMBER

1. Commercial Marine Location

2. Engine Serial Number
3. Engine Model Number
4. Pleasure Craft Marine Location

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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

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 Series 60 Left Side

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 Main Bearing View 12.7L

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 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

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 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)

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 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

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 Series 50/60
Camshafts

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 Camshaft Components

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 Camshaft Components

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 Series 60 Marine
Ceramic Injector Rollers
Allows Higher Injection
Pressures
Improves Fuel Economy
Enhances Performance
Lowers Emission Levels

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 Camshaft

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 Rocker Arm Assembly

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 Exhaust / Intake
Rocker Arms

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 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

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 Liner

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 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 COOLING
IN BLOCK CHANNEL
EXIT HOLE

MAIN COOLANT
STREAM

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 Block Bore Liner

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 Liner Seals

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 Wheep Hole

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 Weep Hole/Plug

Weep Hole

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 Series 60 Marine
Cylinder Kit
Lowered Fire Ring
3mm Fire Ring

Reduced Diameter
2nd Lard

Stiffened Piston Pin

Sputtered Upper
Con Rod Bearings

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 Series 60
Steel Forged Piston

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 Connecting Rod

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 Rod and Main Bearings

Sputtered Bearings
Upper Rod

Trimetal
Lower Rod
Upper Main & Lower Main Picture of the S60 Bearing

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 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
Tin
One Bearing Metal into Another
Lead
Copper Lining - Actual Nickel
Bearing Material Copper
Steel
Steel Backing

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

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 Maximum Load Carrying Capacity
16000
Trimetal 7,250 PSI
14000
Sputtered 14,500
PSI 12000
10000
8000
6000
4000
2000
0
Trimetal Sputtered

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 Timing Marks

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 Cam Gear/ Bolt

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 Thrust Plate (Variations)

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 Thrust Plate (Variations)

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 Thrust Plate (Variations)

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 Idler Gear / Retaining Hub

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 Bull Gear Assembly

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 Bull Gear

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 Bull Gear Alignment

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 Crank Gear S60

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 Pulse Wheel/Timing Wheel

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 Oil Pump

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 Oil Pump

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 Oil Pump Components

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 Oil Cooler Adapter

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 Oil Cooler

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 Engine Mount & Pulley

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 Accessory Drive

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 Accessory Drive

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 Front Seal

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 Rear Seal

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 Flywheel Housing

Bolt Change to
14mm for 1998

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 Flywheel/Scuffplate

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 Water Pump

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 Water Pump

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 Thermostat Housing

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 Thermostats and Housing

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 Series 60 Marine
Complete Package
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

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 Series 60 Marine
Premium Options
Single Rear-Mounted Oil Filter
AMOT Air Shutdown (Delete Option)
Appearance Package
DDEC Control Options
Transmission Options (SC, DA, and IV)
Remote Dual or Single Oil Filter Mount

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 Series 60 Marine Engine

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 Series 60 Heat Exchange Cooled Marine
Engine (Front View)
1. Engine Oil Fill
2. Engine Oil Dipstick
3. Raw Water Drain
4. Emergency Shutdown Lever
5. Air Inlet
6. Alternator
7. Coolant and Fuel Cooler
8. Accessory Drive Cover
9. Raw Water Inlet Elbow
10. Crankshaft Pulley
11. Front Mount Bracket
12. Oil Filter
13. Fuel Return (Outlet)
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 Series 60 Heat Exchange Cooled Marine
Engine (Right View)
1. Flywheel Housing
2. Raw Water Drain
3. Raw Water Outlet
4. Marine Interface Module (MIM)
5. Marine Gear Oil Cooler
6. Marine Gear Cooler Oil Inlet
7. Marine Gear Cooler Oil Outlet
8. Air Cleaner
9. Lifter Bracket
10. Site Glass
11. Fuel Outlet
12. Alternator
13. Front Mounting Pad
14. Engine Oil Drain
15. Engine Water Pump
16. Oil Pan
17. Engine Oil Filters
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 Series 60 Heat Exchange Cooled Marine
Engine (Left Side View)
1. Oil Pan
2. Front Mounting Pad
3. Raw Water Drain
4. Coolant Fill, Press.Cap
5. Lifter Bracket
6. Air Inlet Restriction
Indicator
7. Turbocharger
8. Rear Engine Mount
Mounting Pad
9. Charge Air Cooler Drain
10. Electronic Control Unit
11. Starter
12. Raw Water Inlet Elbow
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13. Raw Water Pump
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 Series 60 Heat Exchange Cooled Marine
Engine (Rear View)
1. Raw Water Inlet
2. Secondary Fuel Filter
3. Lifter Bracket
4. Exhaust Outlet
5. Marine Gear Cooler, Raw
Water Outlet
6. Flywheel
7. Flywheel Housing

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 Series 60 Marine
Key New Components
Cylinder Kit
Dome (Stiffer Piston Pin)
Fire Ring Location
Water Cooled, Pulse, Exhaust Manifold
Turbocharger, Water Cooled Turbine
Raw Water Charge Air Cooler
Titanium Plate Heat Exchanger
Engine Water Pump
Fuel Injector
Engine Oil Cooler
150 New Components

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 Series 60 Marine
Cylinder Kit
Lowered Fire Ring
3mm Fire Ring

Reduced Diameter
2nd Lard

Stiffened Piston Pin

Sputtered Upper
Con Rod Bearings

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 Pulsed Exhaust Manifold

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Water Cooled Turbo and Bearing Section

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 Charge Air Cooler

Integral Charge Air

Cooler and Intake
Manifold
Raw Water Cooler
Cast Aluminum
Housing
High Efficiency
Sized for Growth

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 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
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 Water Pump

Based on Proven
Design
Improved Flow for
High Horsepower
Gear Driven

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 Series 60 Marine
Electronic Unit Injectors
High Injection Pressure Terminals
Excellent Fuel Economy Solenoid Stator
Low Emissions
Armature

Fuel Manifold

Poppet Control Valve

Body Forging

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 Rear Mount Single Oil Filter

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 Series 60 Marine
Rear Mounted Single Oil Filter
Inboard Service Points
250 Hour Change Interval

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 Optional Air Shut Down

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 Air Sep & Closed Crankcase Standard

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 Gear Cooler

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 Cold Start Assist

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 Cold Start Assist

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 Customer Connections

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 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

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OVERHAUL
OVERHAUL INSPECTION
 Block Flatness

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 ID size of Main Journal

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 Liner Bore ID size

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 Liner Protrusion

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 Crankshaft Runout

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 Crankshaft End Play

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 Camshaft Flatness Check

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 Camshaft Runout

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 Camshaft End Play

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 Plasti-Gage

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 Gearlash

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 Injector Tube
Replacement

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THE SYSTEMS
FUEL SYSTEM
 Fuel System

Engine Requirements
Fuel Filters/Fuel Pro 380
Fuel Pump
Cold Plate(Optional)
Restrictive Fitting
Fuel Injectors

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 Fuel System schematic
Series 60

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 Fuel Filters

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 Positive Displacement Fuel Pump

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 Fuel Pump

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 Restrictive Fittings

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 Electronic Control Module
(ECM)

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 Cold Plate

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 Fuel Injector

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 Fuel Injector

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 Fuel Injector

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 Voltage in Series 50/60
Rocker Arm Injector
Solenoid
Cam
Animation
Poppet
Valve
Plunger

Fuel out

Fuel in

Needle Valve
 Injector Cut-Away
Voltage in

Solenoid

Camshaft

Plunger
Poppet Control Valve

Fuel Outlet O-Rings

Fuel Inlet
O-Ring

Needle Valve Spray Tip

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 Injector Calibration
Codes
DDEC II No Calibration Codes
DDEC III Calibration Codes From 00-99

Part Number

Calibration Code
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 Injector Cycle Terminology

zIRT Injector Response Time - Length of Time (ms)

required to close the Control Valve

zPW Pulse Width - Degrees of Crankshaft Rotation

when Fuel is Injected

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 Injector Response Times

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 Cylinder Cut-Out

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 FUEL SYSTEM
TROUBLESHOOTING
 Fuel System Troubleshooting
Low Power
Inspect the Following

Fuel Supply
Restricted Filters
Obstructed Fuel Lines
Fuel Pump
Low Temperature
Fuel Blend
Fuel Pressure
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 Fuel System
Troubleshooting Tools
Fuel Priming Pump
Fuel Pressure Gage
Graduated Bucket
Stop Watch
Pyrometer
Pump Suction
Cylinder Cut-Out/ Injector Response Times

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 Priming

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 Fuel Pump Pressure

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 Fuel Spill Back

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 Cylinder Cut-Out

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 Injector Response Times

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 Injector Cycle Terminology

zIRT Injector Response Time - Length of Time (ms)

required to close the Control Valve

zPW Pulse Width - Degrees of Crankshaft Rotation

when Fuel is Injected

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AIR SYSTEM
 Series 60 Air Intake

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 Air Cleaner System

REM: C&I S60 Full 30L and Low 25L

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 Air Cleaner System CONTINUED

AIR FILTER ELEMENT SHOULD BE CLEANED

EVERY 250 HOURS OF OPERATION OR ONCE
A YEAR, WHICHEVER COMES FIRST.

Pre-Cleaning Gently tap and brush element.

Spray On Cleaner -Let it stand for 10 minutes.
Rinse Off - With low water pressure.
Re-Oiling The Filter The effectiveness of the air filter
is greatly reduced if it is used without oiling.

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 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
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 Air System
Troubleshooting Tools
Water Manometer
Pyrometer/Thermocouple
Pressure Gage
Air Inlet Restriction
Exhaust Back Pressure
Crankcase Pressure

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THE LUBRICATION SYSTEM
 Oil Requirements

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 Lube System
9 Oil Requirements
9 Oil Pump
9 Regulator Valve
9 Relief Valve
9 Oil Cooler Adapter
9 Oil Cooler
9 Oil Filters
9 Turbo Charger Feed Line
9 Block Passages
9 Head Passages
9 Component Passages

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 Series 60 Premium
Oil Schematic

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 Oil Pump

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 Oil Spray Nozzle

All 1998 Blocks have drilled openings into the

main oil gallery

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 Regulator Valve

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 Relief Valve

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 Oil Cooler Adapter

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 Oil Cooler (with Thermostat)

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 Oil Filters

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THE COOLING SYSTEMS
 Cooling System

Recommendations
Water Pump
Oil Cooler Housing
Block Passages
Head Passages
Thermostat Housing
Thermostats
Radiator

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 Coolant System Series 60

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 Water Pump

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 Oil Cooler Housing

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 Coolant Filter (External)

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 Thermostat Housing

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 Blocking Type Thermostat Operation

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 Thermostats / Seals

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 Raw Water System Zincs

RAW WATER SYSTEM ZINCS SHOULD BE

CHECKED INITIALLY AT 60 HOURS, THEN
EVERY 150 HOURS OR YEARLY.

Electrodes are generally found in the heat exchanger

assembly, the raw water pump elbows, the fuel cooler
and the marine gear auxiliary coolers.
Clean with a wire brush if serviceable.
Replace if badly deteriorated.

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ENGINE TUNE-UP
 Engine Tune Up

Injector Height
Valve Lash
New Overlap procedure

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 Overlap Series 60

Cylinder Overlap Valves Injector

6 1 5
2 5 3
4 3 6
1 6 2
5 2 4
3 4 1

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 Lash Settings

Intake Valves
Exhaust Valves

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 Injector Height Setting

Variations in Cam profile

will determine setting

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 S60 Marine, Injector and Valve Lash Setting

Models
6062HKXX, 6062TKXX (2000-2003) = 81.0 mm (3.189 in.)

Tolerance
80.75 - 81.25mm, (3.179 - 3.199in.)

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 S60 Marine Valve Clearance

EXHAUST VALVE CLEARANCE - * "H" Models

6062HKXX, 6062TKXX (2000 - 2003) 0.711 mm (0.028 in.)
Tolerance 0.635 - 0.787mm (0.025 -0.031 in.)
*"H" valves have a machined identification ring above the
valve lock groove. "U" valves do not.
INTAKE VALVE CLEARANCE
0.203 mm(0.008 in.) 0.127 - 0.280mm (0.005 - 0.011 in.)

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