Detroit Series 60 Marine Diesel Engine Service Manual

$39.99

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Covers: Detroit Series 60 Marine Diesel Engine

  • 11.1L
  • 12.7L
  • 14.0L
  • Pre-EPA07

Pages: 2,117
Format: PDF files
File size: 27mb
Features: Searchable, printable
Compatibility: Windows/Mac computers

This manual provides service and repair instructions for marine applications of the Detroit Series 60 diesel engine (with DDEC I, II, III/IV, V controls). In this service manual a basic overview of each major component and system along with recommendations for removal, cleaning, inspection, criteria for replacement, repair and installation and mechanical troubleshooting are included. View the service manual on your computer or print off pages as needed.

Includes Application and Installation Manual. DDEC electronic troubleshooting manuals & wiring diagrams sold separately.

Topics in the Detroit Series 60 Marine Diesel Engine Service Manual:

GENERAL INFORMATION

ENGINE
CYLINDER BLOCK AND CYLINDER LINER
CYLINDER HEAD
VALVE AND INJECTOR OPERATING MECHANISM
VALVES SPRINGS GUIDES INSERTS SEALS AND ROTATORS
ENGINE LIFTER BRACKETS
ROCKER COVER
CRANKSHAFT
CRANKSHAFT OIL SEALS
CRANKSHAFT MAIN BEARINGS
GEAR CASE COVER
GEAR CASE
CRANKSHAFT VIBRATION DAMPER
CRANKSHAFT PULLEY
FLYWHEEL
RING GEAR
FLYWHEEL HOUSING
PISTON AND PISTON RING
FORGED STEEL ONE PIECE PISTON ASSEMBLY AND PISTON RING
PISTON AND CONNECTING ROD ASSEMBLY
CONNECTING ROD
CYLINDER LINER
GEAR TRAIN AND ENGINE TIMING
THRUST PLATE PERIMETER SEAL
CAMSHAFT AND CAMSHAFT BEARING
CAMSHAFT DRIVE GEAR
ADJUSTABLE IDLER GEAR ASSEMBLY
BULL GEAR AND CAMSHAFT IDLER GEAR ASSEMBLY
CRANKSHAFT TIMING GEAR AND TIMING WHEEL
ACCESSORY DRIVE
JAKE BRAKE

FUEL SYSTEM
DIESEL FUEL SYSTEM OVERVIEW
VEHICLE SAFETY FOR THE NATURAL GAS ENGINE
ELECTRONIC UNIT INJECTOR
FUEL INJECTOR TUBE AND ORING
N3 ELECTRONIC UNIT INJECTOR
FUEL INJECTOR TUBE
FUEL PUMP WITH SEPARATE DRIVE SHAFT AND HUB
FUEL PUMP WITH ONEPIECE DRIVE SHAFT AND HUB ASSEMBLY
FUEL PUMP DRIVE
DIESEL FUEL FILTERS SPINON
FUEL PRO 380380E FUEL FILTER SYSTEM
SEA PRO 150300 DIESEL FUEL PROCESSOR SYSTEM MARINE
SEA PRO 152 FUEL FILTER SYSTEM MARINE ENGINE
FUEL FILTER TYPE FOR THE SERIES 60G ENGINE
FUEL COOLER HEAT EXCHANGERCOOLED MARINE ENGINE
ASSEMBLY FUEL FILTER AND WATER SEPARATOR
ELECTRONIC ENGINE CONTROL
DDEC V ELECTRONIC CONTROL UNIT
DDEC IIIIV ELECTRONIC CONTROL MODULE
DDEC II ELECTRONIC CONTROL MODULE
DDEC I
PROGRAMMABLE READONLY MEMORY PROM DDEC I
ELECTRONIC DISTRIBUTOR UNIT DDEC I
ELECTRONIC FOOT PEDAL ASSEMBLY
TURBO BOOST PRESSURE SENSOR
AIR INTAKE PRESSURE SENSOR
OIL PRESSURE SENSOR
OIL TEMPERATURE SENSOR
AIR TEMPERATURE SENSOR
AIR TEMPERATURE SENSOR FOR HIGH PRESSURE FUEL SYSTEM
COOLANT TEMPERATURE SENSOR
SYNCHRONOUS REFERENCE SENSOR
TIMING REFERENCE SENSOR
COOLANT LEVEL SENSOR
FUEL PRESSURE SENSOR
FUEL TEMPERATURE SENSOR
EXHAUST GAS OXYGEN SENSOR FOR SERIES 60G ENGINES
EXHAUST TEMPERATURE SENSOR FOR THE SERIES 60G ENGINES
KNOCK SENSOR AND SIGNAL NOISE ENHANCEMENT FILTER MODULE
BAROMETRIC PRESSURE SENSOR FOR THE SERIES 60G ENGINE WITH HIGH PRESSURE FUEL SYSTEM
OVERVIEW OF HIGH PRESSURE FUEL SYSTEM FOR SERIES 60G ENGINES
FUEL PRESSURE GAGES FOR THE SERIES 60G ENGINE WITH A HIGH PRESSURE FUEL SYSTEM
VENTING AND LEAK CHECKING PROCEDURES FOR A NATURAL GAS ENGINE HIGH PRESSURE SYSTEM
HIGH PRESSURE FUEL REGULATOR FOR THE SERIES 60G ENGINE
PULSE WIDTH MODULATED STEPPER MOTOR VALVE PSV FOR SERIES 60G AUTOMOTIVE ENGINES
FUEL MIXER FOR THE SERIES 60G HIGH PRESSURE FUEL SYSTEM
FUEL SHUTOFF VALVE FOR SERIES 60G ENGINE WITH HIGH PRESSURE FUEL SYSTEM
IMPCO LOW PRESSURE FUEL REGULATOR FOR THE SERIES 60G ENGINE HIGH PRESSURE FUEL SYSTEM
OVERVIEW OF THE LOW PRESSURE NATURAL GAS FUEL SYSTEM
LOW PRESSURE FUEL REGULATOR FOR THE SERIES 60G ENGINE
FUEL MIXER FOR THE SERIES 60G LOW PRESSURE SYSTEM
VENTING AND LEAK CHECKING PROCEDURES FOR NATURAL GAS ENGINE LOW PRESSURE SYSTEM

LUBRICATION SYSTEM
OVERVIEW OF LUBRICATING SYSTEM
OIL PUMP
OIL PRESSURE REGULATOR VALVE
OIL PRESSURE RELIEF VALVE
OIL FILTER
OIL FILTER ADAPTOR
THERMATIC OIL CONTROL VALVE
OIL COOLER 1991 AND LATER ENGINES
OIL COOLER PRE1991 ENGINES
OIL LEVEL DIPSTICK ASSEMBLY
OIL PAN
VENTILATING SYSTEM

COOLING SYSTEM
COOLING SYSTEM OVERVIEW
WATER PUMP GEAR CASE MOUNTED 1991 AND LATER GCM
WATER PUMP FRONT MOUNTED FM
CHARGE AIR COOLER RAW WATER PUMP KEELCOOLED
COMMERCIAL MARINE
THERMOSTAT
COOLANT PRESSURE CONTROL CAP
ENGINE COOLING FAN
COOLANT FILTER AND CONDITIONER
RADIATOR
KEEL COOLING SYSTEM COMMERCIAL MARINE 4109
HEAT EXCHANGER COOLING SYSTEM PLEASURE CRAFT MARINE
HEAT EXCHANGER PLEASURE CRAFT MARINE
JABSCO® ENGINE COOLING RAW WATER PUMP MARINE

FUEL LUBRICATING OIL AND COOLANT
FUEL
LUBRICATING OIL DIESEL
LUBRICATING OIL FOR THE SERIES 60G ENGINE
COOLANT
AIR INTAKE SYSTEM
AIR INTAKE SYSTEM OVERVIEW
AIR CLEANER
AIR SEPARATOR
INTAKE MANIFOLD
CLOSED CRANKCASE BREATHER FOR SERIES 60G AUTOMOTIVE ENGINES
TURBOCHARGER DIESEL
TURBOCHARGER SERIES 60 GAS ENGINES GENSET
TURBOCHARGER SERIES 60 NATURAL GAS AUTOMOTIVE ENGINE
RECIRCULATION VALVE FOR SERIES 60G AUTOMOTIVE ENGINE
CHARGE AIR COOLER
THROTTLE ACTUATOR FOR THE SERIES 60G ENGINE
AIR DRYER
ADDITIONAL INFORMATION
EXHAUST SYSTEM
OVERVIEW OF EXHAUST SYSTEM
EXHAUST MANIFOLD
ELECTRICAL EQUIPMENT
OVERVIEW OF ELECTRICAL SYSTEM
BATTERY CHARGING ALTERNATOR
STORAGE BATTERY
CRANKING MOTOR
TACHOMETER DRIVE
DDEC IIIIV ENGINE SENSOR HARNESS
DDEC II ENGINE SENSOR HARNESS
METRIPACK 150 SERIES CONNECTORS
MICROPACK SERIES CONNECTORS
WEATHER PACK AND METRIPACK 280 SERIES CONNECTORS
CONNECTOR TOOLS
SPLICING GUIDELINES
ADDITIONAL INFORMATION
POWER TAKEOFF
FRONT MOUNTED POWER TAKEOFF
REAR ENGINE POWER TAKEOFF REPTO ASSEMBLY
SPECIAL EQUIPMENT
AIR COMPRESSOR VEHICLE APPLICATIONS ONLY
AIR COMPRESSOR DRIVE HUB
AIR COMPRESSORRAW WATER PUMP DRIVE ASSEMBLY
KIM HOT START STARTING AID SYSTEM MARINE
ADDITIONAL INFORMATION
OPERATION AND VERIFICATION
PREPARATION FOR A FIRST TIME START
STARTING
RUNNING
STOPPING
OPERATING CONDITIONS
SERIES 60G GENSET ENGINE OPERATING CONDITIONS
SERIES 60G AUTOMOTIVE ENGINE OPERATING CONDITIONS
ENGINE RUNIN INSTRUCTIONS
ENGINE TUNEUP
ENGINE TUNEUP PROCEDURES
VALVE LASH INJECTOR HEIGHT TIMING AND JAKE BRAKE LASH ADJUSTMENTS
ENGINE TUNEUP PROCEDURES FOR THE SERIES 60G ENGINE
VALVE LASH FOR THE SERIES 60G ENGINE
PREVENTIVE MAINTENANCE
MAINTENANCE OVERVIEW
DAILY MAINTENANCE ALL APPLICATIONS
DAILY MAINTENANCE MARINE APPLICATIONS
MAINTENANCE OF MARINE ENGINES
MAINTENANCE OF VEHICLE ENGINES
MAINTENANCE OF ENGINES USED IN STATIONARY AND INDUSTRIAL APPLICATIONS
MAINTENANCE OF SERIES 60 DIESEL ENGINES FOR GENERATOR SET
MAINTENANCE OF SERIES 60G ENGINES FOR GENERATOR SET
LUBRICATING OIL AND FILTER CHANGE INTERVALS FOR GENSET
PREVENTIVE MAINTENANCE FOR THE SERIES 60G AUTOMOTIVE ENGINE CITY TRANSIT COACH 1328
MAINTENANCE OF SERIES 60G AUTOMOTIVE ENGINES
LUBRICATING OIL AND FILTER CHANGE INTERVALS FOR GENSET WITH HIGH SULFUR FUELS
DESCRIPTION OF MAINTENANCE ITEMS
AIR SEPARATOR FILTER ELEMENT MARINE
DETECTING INTERNAL FUEL LEAKS
CLEANING CONTAMINATED LUBRICATION OIL SYSTEM
STORAGE
PREPARING ENGINE FOR STORAGE
RESTORING AN EXTENDED STORAGE ENGINE
WINTER STORAGE FOR MARINE ENGINE
IGNITION SYSTEM
OVERVIEW OF IGNITION SYSTEM
COIL OVER PLUG IGNITION SYSTEM
IGNITION BOOT ASSEMBLY
IGNITER MODULE
IGNITER MODULE BRACKET
IGNITION COIL HARNESS
SPARK PLUGS
MISFIRING CYLINDER
POOR VEHICLE GROUND
AERATED FUEL
IMPROPER INJECTOR CALIBRATION SETTING DDEC III IV ENGINES ONLY
IMPROPER VALVE CLEARANCE OR INJECTOR HEIGHT WORN OR DAMAGED CAMSHAFT LOBES AND ROLLERS
FAULTY FUEL INJECTOR
FAULTY ELECTRONIC CONTROL MODULE
WORN OR DAMAGED VALVE OR CYLINDER KIT
STARTING DIFFICULTY ENGINE ROTATES
ELECTRONIC CONTROL MODULE WIRING HARNESS
EMPTY FUEL TANK
LOW BATTERY VOLTAGE
CORRODED OR DAMAGED BATTERY TERMINAL
DEFECTIVE MAGNETIC SWITCH
DEFECTIVE STARTER
LOW CRANKING SPEED
FUEL SUPPLY VALVE
PLUGGED FUEL FILTERS
FUEL PUMP
AERATED FUEL
RESTRICTIVE AIR FILTER
LOW COMPRESSION
NO START ENGINE WILL NOT ROTATE
DISCHARGED BATTERY
DEFECTIVE MAGNETIC SWITCH
DEFECTIVE STARTER
INTERNAL ENGINE DAMAGE
EXCESSIVE OIL CONSUMPTION
MISCALIBRATED DIPSTICK
EXTERNAL OIL LEAKS
LEAKING OIL COOLER CORE
DEFECTIVE AIR COMPRESSOR
DEFECTIVE TURBOCHARGER
WORN OR DAMAGED VALVE OR CYLINDER KIT
EXCESSIVE CRANKCASE PRESSURE
OBSTRUCTION OR DAMAGE TO ROCKER COVER BREATHER
DEFECTIVE AIR COMPRESSOR
DEFECTIVE TURBOCHARGER
WORN OR DAMAGED VALVE OR CYLINDER KIT
EXCESSIVE EXHAUST SMOKE BLACK OR GRAY
IMPROPER GRADE OF FUEL OIL
RESTRICTED AIR CLEANER ELEMENT
RESTRICTED OR CRACKED CHARGE AIR COOLER
FAULTY EXHAUST SYSTEM
FAULTY FUEL INJECTOR
DEFECTIVE TURBOCHARGER
EXCESSIVE BLUE SMOKE
DEFECTIVE TURBOCHARGER
WORN OR DAMAGED VALVE OR CYLINDER KIT
EXCESSIVE WHITE SMOKE
IMPROPER GRADE OF FUEL
DEFECTIVE FUEL PUMP
AERATED FUEL
IMPROPER INJECTOR CALIBRATION SETTING DDEC IIIIV ENGINES ONLY
IMPROPER VALVE CLEARANCE OR INJECTOR HEIGHT WORN OR DAMAGED CAMSHAFT LOBES AND ROLLERS
FAULTY FUEL INJECTOR
FAULTY ELECTRONIC CONTROL MODULE
ROUGH RUNNING OR STALLING
LOW BATTERY VOLTAGE
AERATED FUEL OIL
INSUFFICIENT FUEL OIL FLOW
HIGH FUEL OIL TEMPERATURE RETURN
IMPROPER INJECTOR CALIBRATION SETTING DDEC IIIIV ENGINES ONLY
LOW COMPRESSION PRESSURE
LACK OF POWER
AERATED FUEL
HIGH FUEL PRESSURE
HIGH FUEL OIL TEMPERATURE RETURN
RESTRICTED AIR CLEANER ELEMENT
RESTRICTED OR CRACKED CHARGE AIR COOLER OR LEAKING INTAKE MANIFOLD
FAULTY EXHAUST SYSTEM
HIGH INLET AIR TEMPERATURE
HIGH ALTITUDE OPERATION
INCORRECT CAMSHAFT TIMING
LOW OIL PRESSURE
IMPROPER ENGINE OIL LEVEL
IMPROPER LUBRICATING OIL VISCOSITY
LUBRICATING OIL DILUTED WITH FUEL OIL OR ENGINE COOLANT
FAULTY OIL PRESSURE GAUGE SENSOR
OIL PRESSURE GAUGE LINE OBSTRUCTED
ROCKER ARM SHAFT PLUGS MISSING NEW OR REBUILT ENGINES ONLY
RESTRICTED OIL COOLER
NONFUNCTIONAL OR STICKING OIL PRESSURE REGULATOR VALVE
DEFECTIVE BYPASS VALVE
DEFECTIVE PRESSURE RELIEF VALVE
DEFECTIVE PICKUP SCREEN TUBE AND SCREEN ASSEMBLY
DEFECTIVE CRANKSHAFT MAIN BEARING SHELLS
DEFECTIVE OIL PUMP ASSEMBLY
HIGH ENGINE COOLANT TEMPERATURE
IMPROPER ENGINE COOLANT LEVEL
INSUFFICIENT RADIATOR AIR CIRCULATION
FAULTY PRESSURE CONTROL CAP
DEFECTIVE COOLANT HOSES
FAN BELTS ARE INCORRECTLY ADJUSTED
INOPERATIVE THERMOMODULATED FAN
FAULTY THERMOSTATS
FAULTY WATER PUMP
COMBUSTION GASES IN COOLANT
ABNORMAL RADIATOR COOLANT FLOW
LOW COOLANT TEMPERATURE
FAULTY THERMOSTATS
INSUFFICIENT RADIATOR AIR CIRCULATION
POOR FUEL ECONOMY
PROBABLE CAUSE

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