Diesel Engine, Truck, Heavy Equipment Service Manuals

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

$19.99

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Product Description

 High definition, searchable, printable PDF  Instant download

Covers: Detroit/MTU Series 60 Off-Highway and Marine Diesel Engine (engines with DDEC I, II, III/IV, V controls)

  • 11.1L
  • 12.7L
  • 14.0L
  • Includes natural gas variants

Pages: 1,648
Format: PDF file (zipped)
Features: Linked table of contents, searchable, printable
Compatibility: Windows/Mac computers
File size: 15mb

This manual provides service and repair instructions for off-highway applications of the Detroit MTU Series 60 off-highway diesel engine. Example applications include marine engines, genset engines, industrial truck engines and more. 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. DDEC electronic troubleshooting manuals sold separately.

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
3.2 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)
4.3 FRONT MOUNTED WATER PUMP
4.4 THERMOSTAT
4.5 COOLANT PRESSURE CONTROL CAP
4.6 ENGINE COOLING FAN
4.7 COOLANT FILTER AND CONDITIONER
4.8 RADIATOR .
4.9 HEAT EXCHANGER COOLING SYSTEM
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
5.5 DETROIT DIESEL ENGINE INITIAL FILL COOLANTS
5.6 COOLANTS AND ADDITIVES NOT RECOMMENDED
5.7 MAINTENANCE
5.8 POWER COOL ENGINE PRODUCTS
6 AIR INTAKE SYSTEM
6.1 AIR INTAKE SYSTEM OVERVIEW
6.2 AIR CLEANER
6.3 INTAKE MANIFOLD .
6.4 CLOSED CRANKCASE BREATHER FOR SERIES 60G ENGINES
6.5 TURBOCHARGER (DIESEL)
6.6 TURBOCHARGER SERIES 60 GAS ENGINES (GENSET)
6.7 CHARGE AIR COOLER
6.8 THROTTLE ACTUATOR FOR THE SERIES 60G ENGINE
6.9 AIR DRYER
6.A ADDITIONAL INFORMATION
7 EXHAUST SYSTEM
7.1 OVERVIEW OF EXHAUST MANIFOLD COMPONENTS
7.2 THREE-PIECE EXHAUST MANIFOLD WITH FEY RINGS
7.3 THREE-PIECE EXHAUST MANIFOLD WITHOUT FEY RINGS
7.4 THREE-PIECE EXHAUST MANIFOLD WITH HEAT SHIELD
7.5 HEAT EXCHANGER-COOLED EXHAUST MANIFOLD
8 ELECTRICAL EQUIPMENT
8.1 OVERVIEW OF ELECTRICAL SYSTEM
8.2 BATTERY CHARGING ALTERNATOR
8.3 STORAGE BATTERY
8.4 STARTING 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 ASSEMBLY
10 SPECIAL EQUIPMENT
10.1 AIR COMPRESSOR
10.2 AIR COMPRESSOR DRIVE HUB
10.3 AIR COMPRESSOR DRIVE ASSEMBLY
10.4 KIM HOTSTART STARTING AID SYSTEM
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 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 (EXCEPT MARINE)
13.3 MAINTENANCE OF ENGINES USED IN STATIONARY AND INDUSTRIAL APPLICATIONS
13.4 MAINTENANCE OF SERIES 60 DIESEL ENGINES FOR GENERATOR SET
13.5 MAINTENANCE OF SERIES 60G ENGINES FOR GENERATOR SET
13.6 LUBRICATING OIL AND FILTER CHANGE INTERVALS FOR GENSET
13.7 FUEL FILTER CHANGE INTERVALS
13.8 LUBRICATING OIL AND FILTER CHANGE INTERVALS FOR GENSET (WITH HIGH SULFUR FUELS)
13.9 DESCRIPTION OF MAINTENANCE ITEMS
13.10 AIR SEPARATOR FILTER ELEMENT
13.11 DETECTING INTERNAL FUEL LEAKS
13.12 CLEANING CONTAMINATED LUBRICATION OIL SYSTEM

14 STORAGE
14.1 PREPARING ENGINE FOR STORAGE
14.2 RESTORING AN EXTENDED STORAGE 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 HIGH ENGINE COOLANT TEMPERATURE
26.1 IMPROPER ENGINE COOLANT LEVEL
26.2 INSUFFICIENT RADIATOR AIR CIRCULATION
26.3 FAULTY PRESSURE CONTROL CAP
26.4 DEFECTIVE COOLANT HOSES
26.5 FAN BELTS ARE INCORRECTLY ADJUSTED
26.6 INOPERATIVE THERMO-MODULATED FAN
26.7 FAULTY THERMOSTATS
26.8 FAULTY WATER PUMP
26.9 COMBUSTION GASES IN COOLANT
26.10 ABNORMAL RADIATOR COOLANT FLOW

27 LOW COOLANT TEMPERATURE
27.1 FAULTY THERMOSTATS
28 POOR FUEL ECONOMY
28.1 PROBABLE CAUSE #1
28.2 PROBABLE CAUSE #2

29 AIR COMPRESSOR

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