Detroit Diesel Engine Series 60 Service Manual 6SE483 2004 EN

Description

Contents:
General Information
Scope And Use Of This Manual
Clearance Of New Parts And Wear Limits
The Four Cycle Principle For Diesel Engines
Four Cycle Principle For Natural Gas Engines
General Description
General Specifications
General Specifications For The Series 60g Engine
Engine Model, Serial Number And Option Label
Engine Model, Serial Number And Option Label (Series
60g Engine)
Replacing And Repairing
Disassembly
Cleaning
Safety Precautions
Fluoroelastomer (Viton) Caution
Engine Views
English To Metric Conversion
Decimal And Metric Equivalents
Specifications
1 Engine
1.1 Cylinder Block And Cylinder Liner
1.2 Cylinder Head
1.3 Valve And Injector Operating Mechanism
1.4 Valves, Springs, Guides, Inserts, Seals And Rotators
1.5 Engine Lifter Brackets
1.6 Rocker Cover
1.7 Crankshaft
1.8 Crankshaft Oil Seals
1.9 Crankshaft Main Bearings
1.10 Gear Case Cover
1.11 Gear Case
1.12 Crankshaft Vibration Damper
1.13 Crankshaft Pulley
1.14 Flywheel
1.15 Ring Gear
1.16 Flywheel Housing
1.17 Piston And Piston Ring
1.18 Forged Steel One Piece Piston Assembly And Piston
Ring
1.19 Piston And Connecting Rod Assembly
1.20 Connecting Rod
1.21 Cylinder Liner
1.22 Gear Train And Engine Timing
1.23 Thrust Plate Perimeter Seal
1.24 Camshaft And Camshaft Bearing
1.25 Camshaft Drive Gear
1.26 Adjustable Idler Gear Assembly
1.27 Bull Gear And Camshaft Idler Gear Assembly
1.28 Crankshaft Timing Gear And Timing Wheel
1.29 Accessory Drive
1.30 Jake Brake®
1.A Additional Information
2 Fuel System
2.1 Diesel Fuel System Overview
2.2 Vehicle Safety For The Natural Gas Engine
2.3 Electronic Unit Injector
2.4 Fuel Injector Tube And O-Ring
2.5 N3 Electronic Unit Injector
2.6 Fuel Injector Tube
2.7 Fuel Pump With Separate Drive Shaft And Hub
2.8 Fuel Pump With One-Piece Drive Shaft And Hub Assembly
2.9 Fuel Pump Drive
2.10 Diesel Fuel Filters (Spin-On)
2.11 Fuel Pro 380/380e Fuel Filter System
2.12 Sea Pro 150/300 Diesel Fuel Processor System (Marine)
2.13 Sea Pro 152 Fuel Filter System (Marine Engine)
2.14 Fuel Filter Type For The Series 60g Engine
2.15 Fuel Cooler (Heat Exchanger-Cooled Marine Engine)
2.16 Assembly Fuel Filter And Water Separator
2.17 Electronic Engine Control
2.18 Ddec V Electronic Control Unit
2.19 Ddec Iii/Iv Electronic Control Module
2.20 Ddec Ii Electronic Control Module
2.21 Ddec I
2.22 Programmable Read-Only Memory (Prom) Ddec I
2.23 Electronic Distributor Unit Ddec I
2.24 Electronic Foot Pedal Assembly
2.25 Turbo Boost Pressure Sensor
2.26 Air Intake Pressure Sensor
2.27 Oil Pressure Sensor
2.28 Oil Temperature Sensor
2.29 Air Temperature Sensor
2.30 Air Temperature Sensor For High Pressure Fuel
System
2.31 Coolant Temperature Sensor
2.32 Synchronous Reference Sensor
2.33 Timing Reference Sensor
2.34 Coolant Level Sensor
2.35 Fuel Pressure Sensor
2.36 Fuel Temperature Sensor
2.37 Exhaust Gas Oxygen Sensor For Series 60g Engines
2.38 Exhaust Temperature Sensor For The Series 60g
Engines
2.39 Knock Sensor And Signal Noise Enhancement Filter
Module
2.40 Barometric Pressure Sensor For The Series 60g Engine
With High Pressure Fuel System
2.41 Overview Of High Pressure Fuel System For Series 60g
Engines
2.42 Fuel Pressure Gages For The Series 60g Engine With A
High Pressure Fuel System
2.43 Venting And Leak Checking Procedures For A Natural
Gas Engine (High Pressure System)
2.44 High Pressure Fuel Regulator For The Series 60g
Engine
2.45 Pulse Width Modulated Stepper Motor Valve (Psv) For
Series 60g Automotive Engines
2.46 Fuel Mixer For The Series 60g High Pressure Fuel System
2.47 Fuel Shutoff Valve For Series 60g Engine With High
Pressure Fuel System
2.48 Impco Low Pressure Fuel Regulator For The Series 60g
Engine High Pressure Fuel System
2.49 Overview Of The Low Pressure Natural Gas Fuel
System
2.50 Low Pressure Fuel Regulator For The Series 60g
Engine
2.51 Fuel Mixer For The Series 60g Low Pressure System
2.52 Venting And Leak Checking Procedures For Natural Gas
Engine (Low Pressure System)
2.A Additional Information
3 Lubrication System
3.1 Overview Of Lubricating System
3.2 Oil Pump
3.3 Oil Pressure Regulator Valve
3.4 Oil Pressure Relief Valve
3.5 Oil Filter
3.6 Oil Filter Adaptor
3.7 Thermatic Oil Control Valve
3.8 Oil Cooler (1991 And Later Engines)
3.9 Oil Cooler (Pre-1991 Engines)
3.10 Oil Level Dipstick Assembly
3.11 Oil Pan
3.12 Ventilating System
3.A Additional Information
4 Cooling System
4.1 Cooling System Overview
4.2 Water Pump (Gear Case Mounted – 1991 And Later) (Gcm)
4.3 Water Pump (Front Mounted) (Fm)
4.4 Charge Air Cooler Raw Water Pump (Keel-Cooled
Commercial Marine)
4.5 Thermostat
4.6 Coolant Pressure Control Cap
4.7 Engine Cooling Fan
4.8 Coolant Filter And Conditioner
4.9 Radiator
4.10 Keel Cooling System (Commercial Marine)
4.11 Heat Exchanger Cooling System (Pleasure Craft
Marine)
4.12 Heat Exchanger (Pleasure Craft Marine)
4.13 Jabsco® Engine Cooling Raw Water Pump (Marine)
4.A Additional Information
5 Fuel, Lubricating Oil, And Coolant
5.1 Fuel
5.2 Lubricating Oil (Diesel)
5.3 Lubricating Oil For The Series 60g Engine
5.4 Coolant
6 Air Intake
6.1 Air Intake System Overview
6.2 Air Cleaner
6.3 Air Separator
6.4 Intake Manifold
6.5 Closed Crankcase Breather For Series 60g Automotive
Engines
6.6 Turbocharger (Diesel)
6.7 Turbocharger Series 60 Gas Engines (Genset)
6.8 Turbocharger Series 60 Natural Gas (Automotive)
Engine
6.9 Recirculation Valve For Series 60g Automotive Engine
6.10 Charge Air Cooler
6.11 Throttle Actuator For The Series 60g Engine
6.12 Air Dryer
6.A Additional Information
7 Exhaust System
7.1 Overview Of Exhaust System
7.2 Exhaust Manifold
8 Electrical Equipment
8.1 Overview Of Electrical System
8.2 Battery Charging Alternator
8.3 Storage Battery
8.4 Cranking Motor
8.5 Tachometer Drive
8.6 Ddec Iii/Iv Engine Sensor Harness
8.7 Ddec Ii Engine Sensor Harness
8.8 Metri-Pack 150 Series Connectors
8.9 Micro-Pack Series Connectors
8.10 Weather Pack And Metri-Pack 280 Series Connectors
8.11 Connector Tools
8.12 Splicing Guidelines
8.A Additional Information
9 Power Take-Off
9.1 Front Mounted Power Take-Off
9.2 Rear Engine Power Take-Off (Repto) Assembly
10 Special Equipment
10.1 Air Compressor (Vehicle Applications Only)
10.2 Air Compressor Drive Hub
10.3 Air Compressor/Raw Water Pump Drive Assembly
10.4 Kim Hot Start Starting Aid System (Marine)
10.A Additional Information
11 Operation And Verification
11.1 Preparation For A First Time Start
11.2 Starting
11.3 Running
11.4 Stopping
11.5 Operating Conditions
11.6 Series 60g Genset Engine Operating Conditions
11.7 Series 60g Automotive Engine Operating Conditions
11.8 Engine Run-In Instructions
12 Engine Tune-Up
12.1 Engine Tune-Up Procedures
12.2 Valve Lash, Injector Height (Timing) And Jake Brake® Lash
Adjustments
12.3 Engine Tune-Up Procedures For The Series 60g Engine
12.4 Valve Lash For The Series 60g Engine
13 Preventive Maintenance
13.1 Maintenance Overview
13.2 Daily Maintenance – All Applications
13.3 Daily Maintenance – Marine Applications
13.4 Maintenance Of Marine Engines
13.5 Maintenance Of Vehicle Engines
13.6 Maintenance Of Engines Used In Stationary And
Industrial Applications
13.7 Maintenance Of Series 60 Diesel Engines For Generator
Set
13.8 Maintenance Of Series 60g Engines For Generator Set
13.9 Lubricating Oil And Filter Change Intervals For Genset
13.10 Preventive Maintenance For The Series 60g Automotive
Engine (City Transit Coach)
13.11 Maintenance Of Series 60g Automotive Engines
13.12 Lubricating Oil And Filter Change Intervals For Genset
(With High Sulfur Fuels)
13.13 Description Of Maintenance Items
13.14 Air Separator Filter Element (Marine)
13.15 Detecting Internal Fuel Leaks
13.16 Cleaning Contaminated Lubrication Oil System
14 Storage
14.1 Preparing Engine For Storage
14.2 Restoring An Extended Storage Engine
14.3 Winter Storage For Marine Engine
15 Ignition System
15.1 Overview Of Ignition System
15.2 Coil Over Plug Ignition System
15.3 Ignition Boot Assembly
15.4 Igniter Module
15.5 Igniter Module Bracket
15.6 Ignition Coil Harness
15.7 Spark Plugs
16 Misfiring Cylinder
16.1 Poor Vehicle Ground
16.2 Aerated Fuel
16.3 Improper Injector Calibration Setting (Ddec Iii/Iv
Engines Only)
16.4 Improper Valve Clearance Or Injector Height, Worn Or
Damaged Camshaft Lobes And Rollers
16.5 Faulty Fuel Injector
16.6 Faulty Electronic Control Module
16.7 Worn Or Damaged Valve Or Cylinder Kit
17 Starting Difficulty (Engine Rotates)
17.1 Electronic Control Module Wiring Harness
17.2 Empty Fuel Tank
17.3 Low Battery Voltage
17.4 Corroded Or Damaged Battery Terminals
17.5 Defective Magnetic Switch
17.6 Defective Starter
17.7 Low Cranking Speed
17.8 Fuel Supply Valve
17.9 Plugged Fuel Filter(S)
17.10 Fuel Pump
17.11 Aerated Fuel
17.12 Restrictive Air Filter
17.13 Low Compression
18 No Start (Engine Will Not Rotate)
18.1 Discharged Battery
18.2 Defective Magnetic Switch
18.3 Defective Starter
18.4 Internal Engine Damage
19 Excessive Oil Consumption
19.1 Miscalibrated Dipstick
19.2 External Oil Leaks
19.3 Leaking Oil Cooler Core
19.4 Defective Air Compressor
19.5 Defective Turbocharger
19.6 Worn Or Damaged Valve Or Cylinder Kit
20 Excessive Crankcase Pressure
20.1 Obstruction Or Damage To Rocker Cover Breather
20.2 Defective Air Compressor
20.3 Defective Turbocharger
20.4 Worn Or Damaged Valve Or Cylinder Kit
21 Excessive Exhaust Smoke (Black Or Gray)
21.1 Improper Grade Of Fuel Oil
21.2 Restricted Air Cleaner Element
21.3 Restricted Or Cracked Charge Air Cooler
21.4 Faulty Exhaust System
21.5 Faulty Fuel Injector
21.6 Defective Turbocharger
22 Excessive Blue Smoke
22.1 Defective Turbocharger
22.2 Worn Or Damaged Valve Or Cylinder Kit
23 Excessive White Smoke
23.1 Improper Grade Of Fuel
23.2 Defective Fuel Pump
23.3 Aerated Fuel
23.4 Improper Injector Calibration Setting (Ddec Iii/Iv
Engines Only)
23.5 Improper Valve Clearance Or Injector Height, Worn Or
Damaged Camshaft Lobes And Rollers
23.6 Faulty Fuel Injector
23.7 Faulty Electronic Control Module
24 Rough Running Or Stalling
24.1 Low Battery Voltage
24.2 Aerated Fuel Oil
24.3 Insufficient Fuel Oil Flow
24.4 High Fuel Oil Temperature Return
24.5 Improper Injector Calibration Setting (Ddec Iii/Iv
Engines Only)
24.6 Low Compression Pressure
25 Lack Of Power
25.1 Aerated Fuel
25.2 High Fuel Pressure
25.3 High Fuel Oil Temperature Return
25.4 Restricted Air Cleaner Element
25.5 Restricted Or Cracked Charge Air Cooler Or Leaking
Intake Manifold
25.6 Faulty Exhaust System
25.7 High Inlet Air Temperature
25.8 High Altitude Operation
25.9 Incorrect Camshaft Timing
26 Low Oil Pressure
26.1 Improper Engine Oil Level
26.2 Improper Lubricating Oil Viscosity
26.3 Lubricating Oil Diluted With Fuel Oil Or Engine Coolant
26.4 Faulty Oil Pressure Gauge Sensor
26.5 Oil Pressure Gauge Line Obstructed
26.6 Rocker Arm Shaft Plugs Missing (New Or Rebuilt Engines
Only)
26.7 Restricted Oil Cooler
26.8 Nonfunctional Or Sticking Oil Pressure Regulator
Valve
26.9 Defective Bypass Valve
26.10 Defective Pressure Relief Valve
26.11 Defective Pickup Screen Tube And Screen Assembly
26.12 Defective Crankshaft Main Bearing Shells
26.13 Defective Oil Pump Assembly
27 High Engine Coolant Temperature
27.1 Improper Engine Coolant Level
27.2 Insufficient Radiator Air Circulation
27.3 Faulty Pressure Control Cap
27.4 Defective Coolant Hoses
27.5 Fan Belts Are Incorrectly Adjusted
27.6 Inoperative Thermo-Modulated Fan
27.7 Faulty Thermostats
27.8 Faulty Water Pump
27.9 Combustion Gases In Coolant
27.10 Abnormal Radiator Coolant Flow
28 Low Coolant Temperature
28.1 Faulty Thermostats
28.2 Insufficient Radiator Air Circulation
29 Poor Fuel Economy
29.1 Probable Cause #1
Index