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Detroit MTU Series 60 Off-Highway & Marine Diesel Engine Service Manual

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Covers: Detroit/MTU Series 60 Off-Highway and Marine Diesel Engine (engines with DDEC I, II, III/IV, V)
Pages: 1,648
Format: PDF (zipped)
Compatibility: Windows/Mac computers

This manual provides service and repair instructions for off-highway applications of the Detroit Series 60 Off-Highway Diesel engine. Specifically 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 contained in this service manual.

Topics in the Detroit MTU Series 60 Off-Highway & Marine Diesel Engine Service Manual:

GENERAL INFORMATION
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 N2 ELECTRONIC UNIT INJECTOR
2.4 N2 FUEL INJECTOR TUBE AND O-RING
2.5 N3 ELECTRONIC UNIT INJECTOR
2.6 N3 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 FUEL FILTER TYPE FOR THE SERIES 60G ENGINE
2.13 ASSEMBLY FUEL FILTER AND WATER SEPARATOR
2.14 ELECTRONIC ENGINE CONTROL
2.15 DDEC V ELECTRONIC CONTROL UNIT
2.16 DDEC III/IV ELECTRONIC CONTROL MODULE
2.17 DDEC II ELECTRONIC CONTROL MODULE .
2.18 DDEC I
2.19 PROGRAMMABLE READ-ONLY MEMORY DDEC I
2.20 ELECTRONIC DISTRIBUTOR UNIT DDEC I .
2.21 ELECTRONIC FOOT PEDAL ASSEMBLY
2.22 TURBO BOOST PRESSURE SENSOR
2.23 AIR INTAKE PRESSURE SENSOR
2.24 OIL PRESSURE SENSOR
2.25 OIL TEMPERATURE SENSOR
2.26 AIR TEMPERATURE SENSOR
2.27 AIR TEMPERATURE SENSOR FOR HIGH PRESSURE FUEL SYSTEM
2.28 COOLANT TEMPERATURE SENSOR
2.29 SYNCHRONOUS REFERENCE SENSOR
2.30 TIMING REFERENCE SENSOR
2.31 COOLANT LEVEL SENSOR
2.32 FUEL PRESSURE SENSOR

2.33 FUEL TEMPERATURE SENSOR
2.34 EXHAUST GAS OXYGEN SENSOR FOR SERIES 60G ENGINES
2.35 EXHAUST TEMPERATURE SENSOR FOR THE SERIES 60G ENGINES
2.36 KNOCK SENSOR AND SIGNAL NOISE ENHANCEMENT FILTER MODULE
2.37 BAROMETRIC PRESSURE SENSOR FOR THE SERIES 60G ENGINE WITH HIGH PRESSURE FUEL SYSTEM
2.38 OVERVIEW OF HIGH PRESSURE FUEL SYSTEM FOR SERIES 60G ENGINES
2.39 FUEL PRESSURE GAGES FOR THE SERIES 60G ENGINE WITH A HIGH PRESSURE FUEL SYSTEM
2.40 VENTING AND LEAK CHECKING PROCEDURES FOR A NATURAL GAS ENGINE (HIGH PRESSURE SYSTEM)
2.41 HIGH PRESSURE FUEL REGULATOR FOR THE SERIES 60G ENGINE
2.42 PULSE WIDTH MODULATED STEPPER MOTOR VALVE FOR SERIES 60G AUTOMOTIVE ENGINES
2.43 FUEL MIXER FOR THE SERIES 60G HIGH PRESSURE FUEL SYSTEM
2.44 FUEL SHUTOFF VALVE FOR SERIES 60G ENGINE WITH HIGH PRESSURE FUEL SYSTEM
2.45 IMPCO LOW PRESSURE FUEL REGULATOR FOR THE SERIES 60G ENGINE HIGH PRESSURE FUEL SYSTEM
2.46 OVERVIEW OF THE LOW PRESSURE NATURAL GAS FUEL SYSTEM
2.47 LOW PRESSURE FUEL REGULATOR FOR THE SERIES 60G ENGINE
2.48 FUEL MIXER FOR THE SERIES 60G LOW PRESSURE SYSTEM
2.49 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 ……………………………………….. 3-3
3.2 OIL PUMP …………………………………………………………………………………… 3-7
3.3 OIL PRESSURE REGULATOR VALVE …………………………………………… 3-20
3.4 OIL PRESSURE RELIEF VALVE ……………………………………………………. 3-25
3.5 OIL FILTER …………………………………………………………………………………. 3-30
3.6 OIL FILTER ADAPTOR …………………………………………………………………. 3-33
3.7 THERMATIC OIL CONTROL VALVE ………………………………………………. 3-38
3.8 OIL COOLER (1991 AND LATER ENGINES) …………………………………… 3-44
3.9 OIL COOLER (PRE-1991 ENGINES) ……………………………………………… 3-53
3.10 OIL LEVEL DIPSTICK ASSEMBLY ………………………………………………… 3-62
3.11 OIL PAN ……………………………………………………………………………………… 3-67
3.12 VENTILATING SYSTEM ……………………………………………………………….. 3-75
3.A ADDITIONAL INFORMATION ………………………………………………………… 3-83
4 COOLING SYSTEM
4.1 COOLING SYSTEM OVERVIEW ……………………………………………………. 4-3
4.2 WATER PUMP (GEAR CASE MOUNTED — 1991 AND LATER) ………. 4-8
4.3 FRONT MOUNTED WATER PUMP ……………………………………………….. 4-35
4.4 THERMOSTAT ……………………………………………………………………………. 4-62
4.5 COOLANT PRESSURE CONTROL CAP ………………………………………… 4-72
4.6 ENGINE COOLING FAN ……………………………………………………………….. 4-75
4.7 COOLANT FILTER AND CONDITIONER ………………………………………… 4-85
4.8 RADIATOR ………………………………………………………………………………….. 4-87
4.9 HEAT EXCHANGER COOLING SYSTEM ……………………………………….. 4-88
4.A ADDITIONAL INFORMATION ………………………………………………………… 4-89
5 FUEL, LUBRICATING OIL, AND COOLANT
5.1 FUEL ………………………………………………………………………………………….. 5-3
5.2 LUBRICATING OIL (DIESEL) ………………………………………………………… 5-12
5.3 LUBRICATING OIL FOR THE SERIES 60G ENGINE ……………………….. 5-17
5.4 COOLANT …………………………………………………………………………………… 5-19
5.5 DETROIT DIESEL ENGINE INITIAL FILL COOLANTS ……………………… 5-20
5.6 COOLANTS AND ADDITIVES NOT RECOMMENDED …………………….. 5-27
5.7 MAINTENANCE …………………………………………………………………………… 5-28
5.8 POWER COOL ENGINE PRODUCTS …………………………………………… 5-34
6 AIR INTAKE SYSTEM
6.1 AIR INTAKE SYSTEM OVERVIEW ………………………………………………… 6-3
6.2 AIR CLEANER …………………………………………………………………………….. 6-6
6.3 INTAKE MANIFOLD ……………………………………………………………………… 6-8
6.4 CLOSED CRANKCASE BREATHER FOR SERIES 60G ENGINES ……. 6-17
6.5 TURBOCHARGER (DIESEL) ………………………………………………………… 6-19
6.6 TURBOCHARGER SERIES 60 GAS ENGINES (GENSET) ………………. 6-39
6.7 CHARGE AIR COOLER ………………………………………………………………… 6-53
6.8 THROTTLE ACTUATOR FOR THE SERIES 60G ENGINE ……………….. 6-63
6.9 AIR DRYER …………………………………………………………………………………. 6-66
6.A ADDITIONAL INFORMATION ………………………………………………………… 6-67
7 EXHAUST SYSTEM
7.1 OVERVIEW OF EXHAUST MANIFOLD COMPONENTS …………………… 7-3
7.2 THREE-PIECE EXHAUST MANIFOLD WITH FEY RINGS ………………… 7-7
7.3 THREE-PIECE EXHAUST MANIFOLD WITHOUT FEY RINGS …………. 7-17
7.4 THREE-PIECE EXHAUST MANIFOLD WITH HEAT SHIELD …………….. 7-24
7.5 HEAT EXCHANGER-COOLED EXHAUST MANIFOLD …………………….. 7-30
8 ELECTRICAL EQUIPMENT
8.1 OVERVIEW OF ELECTRICAL SYSTEM …………………………………………. 8-3
8.2 BATTERY CHARGING ALTERNATOR ……………………………………………. 8-4
8.3 STORAGE BATTERY …………………………………………………………………… 8-11
8.4 STARTING MOTOR ……………………………………………………………………… 8-13
8.5 TACHOMETER DRIVE …………………………………………………………………. 8-18
8.6 DDEC III/IV ENGINE SENSOR HARNESS ……………………………………… 8-24
8.7 DDEC II ENGINE SENSOR HARNESS …………………………………………… 8-34
8.8 METRI-PACK 150 SERIES CONNECTORS …………………………………….. 8-40
8.9 MICRO-PACK SERIES CONNECTORS ………………………………………….. 8-45
8.10 WEATHER PACK AND METRI-PACK 280 SERIES CONNECTORS …… 8-47
8.11 CONNECTOR TOOLS ………………………………………………………………….. 8-50
8.12 SPLICING GUIDELINES ………………………………………………………………. 8-51
8.A ADDITIONAL INFORMATION ………………………………………………………… 8-55
9 POWER TAKE-OFF
9.1 FRONT MOUNTED POWER TAKE-OFF …………………………………………. 9-3
9.2 REAR ENGINE POWER TAKE-OFF ASSEMBLY …………………………….. 9-8
10 SPECIAL EQUIPMENT
10.1 AIR COMPRESSOR …………………………………………………………………….. 10-3
10.2 AIR COMPRESSOR DRIVE HUB …………………………………………………… 10-16
10.3 AIR COMPRESSOR DRIVE ASSEMBLY ………………………………………… 10-21
10.4 KIM HOTSTART STARTING AID SYSTEM ……………………………………… 10-41
10.A ADDITIONAL INFORMATION ………………………………………………………… 10-43
11 OPERATION AND VERIFICATION
11.1 PREPARATION FOR A FIRST TIME START ……………………………………. 11-3
11.2 STARTING ………………………………………………………………………………….. 11-6
11.3 RUNNING …………………………………………………………………………………… 11-7
11.4 STOPPING ………………………………………………………………………………….. 11-10
11.5 OPERATING CONDITIONS …………………………………………………………… 11-11
11.6 SERIES 60G GENSET ENGINE OPERATING CONDITIONS ……………. 11-15
11.7 ENGINE RUN-IN INSTRUCTIONS …………………………………………………. 11-17
12 ENGINE TUNE-UP
12.1 ENGINE TUNE-UP PROCEDURES ……………………………………………….. 12-3
12.2 VALVE LASH, INJECTOR HEIGHT (TIMING) AND JAKE BRAKE LASH
ADJUSTMENTS …………………………………………………………………………… 12-5
12.3 ENGINE TUNE-UP PROCEDURES FOR THE SERIES 60G ENGINE .. 12-20
12.4 VALVE LASH FOR THE SERIES 60G ENGINE ……………………………….. 12-22
13 PREVENTIVE MAINTENANCE
13.1 MAINTENANCE OVERVIEW …………………………………………………………. 13-3
13.2 DAILY MAINTENANCE — ALL APPLICATIONS (EXCEPT MARINE) …. 13-4
13.3 MAINTENANCE OF ENGINES USED IN STATIONARY AND
INDUSTRIAL APPLICATIONS ……………………………………………………….. 13-5
13.4 MAINTENANCE OF SERIES 60 DIESEL ENGINES FOR GENERATOR
SET ……………………………………………………………………………………………. 13-13
13.5 MAINTENANCE OF SERIES 60G ENGINES FOR GENERATOR SET .. 13-16
13.6 LUBRICATING OIL AND FILTER CHANGE INTERVALS FOR GENSET 13-18
13.7 FUEL FILTER CHANGE INTERVALS ……………………………………………… 13-19
13.8 LUBRICATING OIL AND FILTER CHANGE INTERVALS FOR GENSET
(WITH HIGH SULFUR FUELS) ………………………………………………………. 13-20
13.9 DESCRIPTION OF MAINTENANCE ITEMS ……………………………………. 13-22
13.10 AIR SEPARATOR FILTER ELEMENT …………………………………………….. 13-53
13.11 DETECTING INTERNAL FUEL LEAKS …………………………………………… 13-56
13.12 CLEANING CONTAMINATED LUBRICATION OIL SYSTEM ……………… 13-63
14 STORAGE
14.1 PREPARING ENGINE FOR STORAGE ………………………………………….. 14-3
14.2 RESTORING AN EXTENDED STORAGE ENGINE ………………………….. 14-9
15 IGNITION SYSTEM
15.1 OVERVIEW OF IGNITION SYSTEM ………………………………………………. 15-3
15.2 COIL OVER PLUG IGNITION SYSTEM ………………………………………….. 15-4
15.3 IGNITION BOOT ASSEMBLY ………………………………………………………… 15-9
15.4 IGNITER MODULE ……………………………………………………………………… 15-10
15.5 IGNITER MODULE BRACKET ………………………………………………………. 15-11
15.6 IGNITION COIL HARNESS …………………………………………………………… 15-12
15.7 SPARK PLUGS …………………………………………………………………………… 15-15
16 MISFIRING CYLINDER
16.1 POOR VEHICLE GROUND …………………………………………………………… 16-3
16.2 AERATED FUEL …………………………………………………………………………. 16-5
16.3 IMPROPER INJECTOR CALIBRATION SETTING (DDEC III/IV
ENGINES ONLY) …………………………………………………………………………. 16-6
16.4 IMPROPER VALVE CLEARANCE OR INJECTOR HEIGHT, WORN OR
DAMAGED CAMSHAFT LOBES AND ROLLERS ……………………………. 16-9
16.5 FAULTY FUEL INJECTOR …………………………………………………………….. 16-19
16.6 FAULTY ELECTRONIC CONTROL MODULE ………………………………….. 16-21
16.7 WORN OR DAMAGED VALVE OR CYLINDER KIT ………………………….. 16-22
17 STARTING DIFFICULTY (ENGINE ROTATES)
17.1 ELECTRONIC CONTROL MODULE WIRING HARNESS …………………. 17-3
17.2 EMPTY FUEL TANK …………………………………………………………………….. 17-5
17.3 LOW BATTERY VOLTAGE ……………………………………………………………. 17-6
17.4 CORRODED OR DAMAGED BATTERY TERMINALS ………………………. 17-7
17.5 DEFECTIVE MAGNETIC SWITCH …………………………………………………. 17-8
17.6 DEFECTIVE STARTER …………………………………………………………………. 17-10
17.7 LOW CRANKING SPEED ……………………………………………………………… 17-12
17.8 FUEL SUPPLY VALVE ………………………………………………………………….. 17-13
17.9 PLUGGED FUEL FILTER(S) ………………………………………………………….. 17-14
17.10 FUEL PUMP ……………………………………………………………………………….. 17-15
17.11 AERATED FUEL …………………………………………………………………………. 17-16
17.12 RESTRICTIVE AIR FILTER …………………………………………………………… 17-17
17.13 LOW COMPRESSION …………………………………………………………………. 17-18
18 NO START (ENGINE WILL NOT ROTATE)
18.1 DISCHARGED BATTERY ……………………………………………………………… 18-3
18.2 DEFECTIVE MAGNETIC SWITCH …………………………………………………. 18-4
18.3 DEFECTIVE STARTER …………………………………………………………………. 18-6
18.4 INTERNAL ENGINE DAMAGE ………………………………………………………. 18-8
19 EXCESSIVE OIL CONSUMPTION
19.1 MISCALIBRATED DIPSTICK …………………………………………………………. 19-3
19.2 EXTERNAL OIL LEAKS ………………………………………………………………… 19-4
19.3 LEAKING OIL COOLER CORE ……………………………………………………… 19-5
19.4 DEFECTIVE AIR COMPRESSOR ………………………………………………….. 19-7
19.5 DEFECTIVE TURBOCHARGER ……………………………………………………. 19-9
19.6 WORN OR DAMAGED VALVE OR CYLINDER KIT ………………………….. 19-10
20 EXCESSIVE CRANKCASE PRESSURE
20.1 OBSTRUCTION OR DAMAGE TO ROCKER COVER BREATHER …….. 20-3
20.2 DEFECTIVE AIR COMPRESSOR ………………………………………………….. 20-4
20.3 DEFECTIVE TURBOCHARGER ……………………………………………………. 20-6
20.4 WORN OR DAMAGED VALVE OR CYLINDER KIT ………………………….. 20-7
21 EXCESSIVE EXHAUST SMOKE (BLACK OR GRAY)
21.1 IMPROPER GRADE OF FUEL OIL ………………………………………………… 21-3
21.2 RESTRICTED AIR CLEANER ELEMENT ……………………………………….. 21-4
21.3 RESTRICTED OR CRACKED CHARGE AIR COOLER …………………….. 21-5
21.4 FAULTY EXHAUST SYSTEM ………………………………………………………… 21-7
21.5 FAULTY FUEL INJECTOR …………………………………………………………….. 21-9
21.6 DEFECTIVE TURBOCHARGER ……………………………………………………. 21-11
22 EXCESSIVE BLUE SMOKE
22.1 DEFECTIVE TURBOCHARGER ……………………………………………………. 22-3
22.2 WORN OR DAMAGED VALVE OR CYLINDER KIT ………………………….. 22-5
23 EXCESSIVE WHITE SMOKE
23.1 IMPROPER GRADE OF FUEL ………………………………………………………. 23-3
23.2 DEFECTIVE FUEL PUMP …………………………………………………………….. 23-4
23.3 AERATED FUEL …………………………………………………………………………. 23-6
23.4 IMPROPER INJECTOR CALIBRATION SETTING (DDEC III/IV
ENGINES ONLY) …………………………………………………………………………. 23-7
23.5 IMPROPER VALVE CLEARANCE OR INJECTOR HEIGHT, WORN OR
DAMAGED CAMSHAFT LOBES AND ROLLERS ……………………………. 23-8
23.6 FAULTY FUEL INJECTOR …………………………………………………………….. 23-9
23.7 FAULTY ELECTRONIC CONTROL MODULE ………………………………….. 23-10
24 ROUGH RUNNING OR STALLING
24.1 LOW BATTERY VOLTAGE ……………………………………………………………. 24-3
24.2 AERATED FUEL OIL ……………………………………………………………………. 24-4
24.3 INSUFFICIENT FUEL OIL FLOW …………………………………………………… 24-5
24.4 HIGH FUEL OIL TEMPERATURE RETURN ……………………………………. 24-6
24.5 IMPROPER INJECTOR CALIBRATION SETTING (DDEC III/IV
ENGINES ONLY) …………………………………………………………………………. 24-8
24.6 LOW COMPRESSION PRESSURE ……………………………………………….. 24-10
25 LACK OF POWER
25.1 AERATED FUEL …………………………………………………………………………. 25-3
25.2 HIGH FUEL PRESSURE ………………………………………………………………. 25-4
25.3 HIGH FUEL OIL TEMPERATURE RETURN ……………………………………. 25-7
25.4 RESTRICTED AIR CLEANER ELEMENT ……………………………………….. 25-8
25.5 RESTRICTED OR CRACKED CHARGE AIR COOLER OR LEAKING
INTAKE MANIFOLD ……………………………………………………………………… 25-9
25.6 FAULTY EXHAUST SYSTEM ………………………………………………………… 25-10
25.7 HIGH INLET AIR TEMPERATURE …………………………………………………. 25-11
25.8 HIGH ALTITUDE OPERATION ………………………………………………………. 25-12
25.9 INCORRECT CAMSHAFT TIMING ………………………………………………… 25-14
26 HIGH ENGINE COOLANT TEMPERATURE
26.1 IMPROPER ENGINE COOLANT LEVEL …………………………………………. 26-3
26.2 INSUFFICIENT RADIATOR AIR CIRCULATION ………………………………. 26-4
26.3 FAULTY PRESSURE CONTROL CAP ……………………………………………. 26-5
26.4 DEFECTIVE COOLANT HOSES ……………………………………………………. 26-6
26.5 FAN BELTS ARE INCORRECTLY ADJUSTED ………………………………… 26-7
26.6 INOPERATIVE THERMO-MODULATED FAN ………………………………….. 26-8
26.7 FAULTY THERMOSTATS …………………………………………………………….. 26-9
26.8 FAULTY WATER PUMP ………………………………………………………………… 26-10
26.9 COMBUSTION GASES IN COOLANT ……………………………………………. 26-12
26.10 ABNORMAL RADIATOR COOLANT FLOW …………………………………….. 26-18
27 LOW COOLANT TEMPERATURE
27.1 FAULTY THERMOSTATS …………………………………………………………….. 27-3
28 POOR FUEL ECONOMY
28.1 PROBABLE CAUSE #1 ………………………………………………………………… 28-3
28.2 PROBABLE CAUSE #2 ………………………………………………………………… 28-4
29 AIR COMPRESSOR
29.1 AIR COMPRESSOR …………………………………………………………………….. 29-3
INDEX ……………………………………………………………………………………. Index-1

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