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

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Rotary
Mechanical

Fire
Fuel

Linear
Mechanical

Four Stroke Cycle (Continued)

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Four Stroke Cycle

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Heat Balance

Exhaust
30-35%
Coolant &
Radiation
30-35%

Engine
Horsepower
30-35%

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Fuel
Energy
100%

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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

Compression Ratio
Aspiration
Engine Controls

4-CYCLE
Inline 6 Cylinder
12.7 Liters
14.0 Liters
130 mm X 160 mm
133 mm X 168 mm
15.0:1
Turbocharged / After cooled
DDEC

Horsepower

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

Engine Type
Configuration
Displacement
Bore & Stroke

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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

*
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6SP161

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
IN BLOCK

COOLING
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
3mm Fire Ring

Lowered Fire Ring

Reduced Diameter
2nd Lard

Stiffened Piston Pin

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Sputtered Upper
Con Rod Bearings

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

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Tin
Lead
Nickel
Copper
Steel

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

Trimetal 7,250 PSI
Sputtered 14,500
PSI

16000
14000
12000
10000
8000
6000
4000
2000
0
Trimetal

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Sputtered

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

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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

Series 60 Marine
Premium Options

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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

Series 60 Marine Engine

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Series 60 Heat Exchange Cooled Marine

Engine (Front View)
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
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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)

Series 60 Heat Exchange Cooled Marine

Engine (Right View)

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1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.

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

Series 60 Heat Exchange Cooled Marine

Engine (Left Side View)
1.
2.
3.
4.
5.
6.
7.
8.

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9.
10.
11.
12.
13.

Oil Pan
Front Mounting Pad
Raw Water Drain
Coolant Fill, Press.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

Series 60 Heat Exchange Cooled Marine

Engine (Rear View)
1.
2.
3.
4.
5.

Raw Water Inlet

Secondary Fuel Filter
Lifter Bracket
Exhaust Outlet
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

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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

Series 60 Marine
Cylinder Kit
3mm Fire Ring

Lowered Fire Ring

Reduced Diameter
2nd Lard

Stiffened Piston Pin

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Sputtered Upper
Con Rod Bearings

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
Excellent Fuel Economy
Low Emissions

Terminals
Solenoid Stator
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

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

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
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
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Spray Tip

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

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Fuel Supply
Restricted Filters
Obstructed Fuel Lines
Fuel Pump
Low Temperature
Fuel Blend
Fuel Pressure

Fuel System
Troubleshooting Tools

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Fuel Priming Pump

Fuel Pressure Gage
Graduated Bucket
Stop Watch
Pyrometer
Pump Suction
Cylinder Cut-Out/ Injector Response Times

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.

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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.

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
9
9
9
9
9
9
9
9
9
9

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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

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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

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

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.

Rev 3/2/00
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ENGINE TUNE-UP

Engine Tune Up
Injector Height
Valve Lash
New Overlap procedure

Rev 3/2/00
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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

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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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