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Rev 3/2/00
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Basic Engine Operating Principles
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To operate an Diesel Engine you need the
following;
Air
+ Fuel
Fire
Rotary
Linear
Mechanical
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Mechanical
Four Stroke Cycle (Continued)
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Four Stroke Cycle
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Heat Balance
Fuel
Exhaust
30-35%
Energy
100%
Coolant &
Radiation
30-35%
Engine
Horsepower
30-35%
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Series 60 Marine
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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
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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
*
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LOCATIONS OF ENGINE MODEL AND
SERIAL NUMBER
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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
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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
Rev 3/2/00
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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
COOLING
CHANNEL
INLET NOTCH COOLING
IN BLOCK 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
Lowered Fire Ring
3mm Fire Ring
Reduced Diameter
2nd Lard
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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
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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
16000
Trimetal 7,250 PSI
14000
Sputtered 14,500
PSI 12000
10000
8000
6000
4000
2000
0
Trimetal Sputtered
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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
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
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Series 60 Marine
Premium Options
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
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Series 60 Marine Engine
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Series 60 Heat Exchange Cooled Marine
Engine (Front View)
1. Engine Oil Fill
2. Engine Oil Dipstick
3. Raw Water Drain
4. Emergency Shutdown Lever
5. Air Inlet
6. Alternator
7. Coolant and Fuel Cooler
8. Accessory Drive Cover
9. Raw Water Inlet Elbow
10. Crankshaft Pulley
11. Front Mount Bracket
12. Oil Filter
13. Fuel Return (Outlet)
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Series 60 Heat Exchange Cooled Marine
Engine (Right View)
1. Flywheel Housing
2. Raw Water Drain
3. Raw Water Outlet
4. Marine Interface Module (MIM)
5. Marine Gear Oil Cooler
6. Marine Gear Cooler Oil Inlet
7. Marine Gear Cooler Oil Outlet
8. Air Cleaner
9. Lifter Bracket
10. Site Glass
11. Fuel Outlet
12. Alternator
13. Front Mounting Pad
14. Engine Oil Drain
15. Engine Water Pump
16. Oil Pan
17. Engine Oil Filters
Rev 3/2/00
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Series 60 Heat Exchange Cooled Marine
Engine (Left Side View)
1. Oil Pan
2. Front Mounting Pad
3. Raw Water Drain
4. Coolant Fill, Press.Cap
5. Lifter Bracket
6. Air Inlet Restriction
Indicator
7. Turbocharger
8. Rear Engine Mount
Mounting Pad
9. Charge Air Cooler Drain
10. Electronic Control Unit
11. Starter
12. Raw Water Inlet Elbow
Rev 3/2/00
13. Raw Water Pump
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Series 60 Heat Exchange Cooled Marine
Engine (Rear View)
1. Raw Water Inlet
2. Secondary Fuel Filter
3. Lifter Bracket
4. Exhaust Outlet
5. Marine Gear Cooler, Raw
Water Outlet
6. Flywheel
7. Flywheel Housing
Rev 3/2/00
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Series 60 Marine
Key New Components
Cylinder Kit
Dome (Stiffer Piston Pin)
Fire Ring Location
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
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Series 60 Marine
Cylinder Kit
Lowered Fire Ring
3mm Fire Ring
Reduced Diameter
2nd Lard
Rev 3/2/00
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Pulsed Exhaust Manifold
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Water Cooled Turbo and Bearing Section
Rev 3/2/00
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Charge Air Cooler
Rev 3/2/00
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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
Rev 3/2/00
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Water Pump
Based on Proven
Design
Improved Flow for
High Horsepower
Gear Driven
Rev 3/2/00
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Series 60 Marine
Electronic Unit Injectors
High Injection Pressure Terminals
Excellent Fuel Economy Solenoid Stator
Low Emissions
Armature
Fuel Manifold
Body Forging
Rev 3/2/00
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Rear Mount Single Oil Filter
Rev 3/2/00
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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
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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
Rev 3/2/00
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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
Rev 3/2/00
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THE SYSTEMS
FUEL SYSTEM
Fuel System
Engine Requirements
Fuel Filters/Fuel Pro 380
Fuel Pump
Cold Plate(Optional)
Restrictive Fitting
Fuel Injectors
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Fuel System schematic
Series 60
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Fuel Filters
Rev 3/2/00
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Positive Displacement Fuel Pump
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Fuel Pump
Rev 3/2/00
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Restrictive Fittings
Rev 3/2/00
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Electronic Control Module
(ECM)
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Cold Plate
Rev 3/2/00
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Fuel Injector
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Fuel Injector
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Fuel Injector
Rev 3/2/00
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Voltage in Series 50/60
Rocker Arm Injector
Solenoid
Cam
Animation
Poppet
Valve
Plunger
Fuel out
Fuel in
Needle Valve
Injector Cut-Away
Voltage in
Solenoid
Camshaft
Plunger
Poppet Control Valve
Fuel Inlet
O-Ring
Part Number
Calibration Code
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Injector Cycle Terminology
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Injector Response Times
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Cylinder Cut-Out
Rev 3/2/00
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FUEL SYSTEM
TROUBLESHOOTING
Fuel System Troubleshooting
Low Power
Inspect the Following
Fuel Supply
Restricted Filters
Obstructed Fuel Lines
Fuel Pump
Low Temperature
Fuel Blend
Fuel Pressure
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Fuel System
Troubleshooting Tools
Fuel Priming Pump
Fuel Pressure Gage
Graduated Bucket
Stop Watch
Pyrometer
Pump Suction
Cylinder Cut-Out/ Injector Response Times
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Priming
Rev 3/2/00
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Fuel Pump Pressure
Rev 3/2/00
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Fuel Spill Back
Rev 3/2/00
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Cylinder Cut-Out
Rev 3/2/00
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Injector Response Times
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Injector Cycle Terminology
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AIR SYSTEM
Series 60 Air Intake
Rev 3/2/00
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Air Cleaner System
Rev 3/2/00
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Air Cleaner System CONTINUED
Rev 3/2/00
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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
Rev 3/2/00
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Air System
Troubleshooting Tools
Water Manometer
Pyrometer/Thermocouple
Pressure Gage
Air Inlet Restriction
Exhaust Back Pressure
Crankcase Pressure
Rev 3/2/00
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THE LUBRICATION SYSTEM
Oil Requirements
Rev 3/2/00
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Lube System
9 Oil Requirements
9 Oil Pump
9 Regulator Valve
9 Relief Valve
9 Oil Cooler Adapter
9 Oil Cooler
9 Oil Filters
9 Turbo Charger Feed Line
9 Block Passages
9 Head Passages
9 Component Passages
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Series 60 Premium
Oil Schematic
Rev 3/2/00
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Oil Pump
Rev 3/2/00
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Oil Spray Nozzle
Rev 3/2/00
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Regulator Valve
Rev 3/2/00
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Relief Valve
Rev 3/2/00
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Oil Cooler Adapter
Rev 3/2/00
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Oil Cooler (with Thermostat)
Rev 3/2/00
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Oil Filters
Rev 3/2/00
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THE COOLING SYSTEMS
Cooling System
Recommendations
Water Pump
Oil Cooler Housing
Block Passages
Head Passages
Thermostat Housing
Thermostats
Radiator
Rev 3/2/00
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Coolant System Series 60
Rev 3/2/00
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Water Pump
Rev 3/2/00
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Oil Cooler Housing
Rev 3/2/00
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Coolant Filter (External)
Rev 3/2/00
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Thermostat Housing
Rev 3/2/00
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Blocking Type Thermostat Operation
Rev 3/2/00
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Thermostats / Seals
Rev 3/2/00
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Raw Water System Zincs
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
Rev 3/2/00
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Lash Settings
Intake Valves
Exhaust Valves
Rev 3/2/00
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Injector Height Setting
Rev 3/2/00
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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.)
Rev 3/2/00
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S60 Marine Valve Clearance
Rev 3/2/00
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