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PRELIMINARY
PRELIMINARY
To the Operator
SERIES 60 MARINE ENGINE OPERATOR'S GUIDE
TABLE OF CONTENTS
INTRODUCTION .................................................................................. 1
NON-GENUINE AND REBUILT COMPONENT QUALITY ALERT .. 1
MAINTENANCE .................................................................................. 32
MAINTENANCE INTERVAL SCHEDULES ...................................... 32
PREVENTIVE MAINTENANCE INTERVALS .................................. 41
WELDING PRECAUTION ........................................................... 41
ITEM 1 – LUBRICATING OIL ...................................................... 42
ITEM 2 – FUEL AND FUEL TANK ............................................... 42
ITEM 3 – FUEL LINES AND FLEXIBLE HOSES ......................... 43
LEAKS ..................................................................................... 43
HOSES AND FITTINGS .......................................................... 44
HOSE SERVICE LIFE ............................................................. 44
ITEM 4 – COOLING SYSTEM AND COOLANT .......................... 44
COOLANT LEVEL ................................................................... 45
COOLANT INHIBITORS .......................................................... 45
COOLANT DRAIN INTERVAL ................................................. 46
COOLING SYSTEM HOSES .................................................. 47
ITEM 5 – TURBOCHARGER AND EXHAUST CONNECTIONS 47
ITEM 6 – BATTERY ..................................................................... 48
ITEM 7– DRIVE BELTS ............................................................... 49
V-BELTS .................................................................................. 49
This guide is intended for use by the Detroit Diesel Corporation has built
operator of a MTU Detroit Diesel over 650,000 engines with electronic
Series 60 engine used in a pleasure unit injectors — more than anyone
craft marine or commercial marine else in the business. MTU Detroit
application. Diesel cautions that the indiscriminate
rebuilding of precision components,
NON-GENUINE AND without the benefit of specifications,
specialized equipment, and knowledge
REBUILT COMPONENT
of the electronic operating system,
QUALITY ALERT
will jeopardize performance or lead
In recent years, electronic engine to more serious problems, and can
controls have been instrumental take the engine outside of compliance
in aiding engine manufacturers in with U.S. EPA or CARB emissions
meeting the stringent emission standards.
requirements of the U.S.
Environmental Protection Agency
(EPA) and the California Air
Resources Board (CARB) and
also in meeting the ever-increasing
performance demands of the customer.
Electronic controls and components
have significantly increased in
sophistication, but the fundamental
objective remains the same — precise
timing and delivery of fuel. The
very heart of the MTU Detroit Diesel
electronic controls is the Electronic
Unit Injector (EUI). The proper
functioning of the EUI is absolutely
paramount if the benefits of electronic
controls are to be realized.
CAUTION SUMMARY
PERSONAL INJURY
To avoid injury from loss of
vehicle/vessel control, the PERSONAL INJURY
operator of a DDEC equipped To avoid injury from engine
engine must not use or read shutdown in an unsafe situation,
any diagnostic tool while the ensure the operator knows how
vehicle/vessel is moving. to override the stop engine
condition on a DDEC-equipped
unit.
HOT OIL
To avoid injury from hot oil, do
not operate the engine with the FIRE
rocker cover(s) removed. To avoid injury from fire, contain
and eliminate leaks of flammable
fluids as they occur. Failure to
eliminate leaks could result in
fire.
PERSONAL INJURY
To avoid injury from rotating belts
and fans, do not remove and
discard safety guards.
PERSONAL INJURY
USED ENGINE OIL
To avoid injury from hot surfaces,
To avoid injury to skin from
wear protective gloves, or allow
contact with the contaminants in
engine to cool before removing
used engine oil, wear protective
any component.
gloves and apron.
PERSONAL INJURY
PERSONAL INJURY
To avoid injury, use care when
To avoid injury when working
working around moving belts and
on or near an operating engine,
rotating parts on the engine.
wear protective clothing,
eye protection, and hearing
protection.
FIRE
To avoid injury from combustion
PERSONAL INJURY of heated lubricating-oil vapors,
stop the engine immediately if an
To avoid injury when using
oil leak is detected.
caustic cleaning agents, follow
the chemical manufacturers
usage, disposal, and safety
instructions.
FIRE
To avoid injury from fire from a
buildup of volatile vapors, keep
the engine area well ventilated
during operation.
Electrical System
Observe the following cautions when
jump starting an engine, charging ELECTRICAL SHOCK
a battery, or working with the To avoid injury from electrical
vehicle/application electrical system. shock, do not touch battery
terminals, alternator terminals, or
wiring cables while the engine is
operating.
Battery Explosion and Acid Burn
To avoid injury from battery
explosion or contact with battery
acid, work in a well ventilated
area, wear protective clothing,
and avoid sparks or flames near PERSONAL INJURY
the battery. If you come in contact To avoid injury from accidental
with battery acid: engine startup while servicing
□ Flush your skin with water. the engine, disconnect/disable
the starting system.
□ Apply baking soda or lime to
help neutralize the acid.
HOT COOLANT
PERSONAL INJURY
To avoid scalding from the
expulsion of hot coolant, never To avoid injury from contact
remove the cooling system with rotating parts when an
pressure cap while the engine is engine is operating with the air
at operating temperature. Wear inlet piping removed, install an
adequate protective clothing air inlet screen shield over the
(face shield, rubber gloves, turbocharger air inlet. The shield
apron, and boots). Remove the prevents contact with rotating
cap slowly to relieve pressure. parts.
Fuel System
Observe the following cautions when
fueling the vehicle or working with FIRE
the fuel system. To avoid injury from fire caused
by heated diesel-fuel vapors:
□ To prevent a buildup of
FIRE potentially volatile vapors,
To avoid injury from fire, contain keep the engine area well
and eliminate leaks of flammable ventilated during operation.
fluids as they occur. Failure to
eliminate leaks could result in
fire.
FIRE
To avoid increased risk of a fuel
fire, do not mix gasoline and
diesel fuel.
Compressed Air
Observe the following cautions when
using compressed air. FIRE
To avoid injury from fire, do not
smoke or allow open flames when
working on an operating engine.
EYE INJURY
To avoid injury from flying debris
when using compressed air, wear
adequate eye protection (face
shield or safety goggles) and do
not exceed 276 kPa (40 psi) air FIRE
pressure.
To avoid injury from fire from a
buildup of volatile vapors, keep
Lubricating Oil and Filters the engine area well ventilated
during operation.
Observe the following cautions when
replacing the engine lubricating oil
and filters.
PERSONAL INJURY
To avoid injury from slipping and
falling, immediately clean up any
spilled liquids.
FIRE
To avoid injury from combustion
of heated lubricating-oil vapors,
stop the engine immediately if an
oil leak is detected.
The engine serial and model numbers pad near the flywheel housing.
are laser etched on the cylinder block See Figure 1.
in the following locations (as viewed
□ Left side on a machined pad just
from the flywheel end):
below the intake manifold and
□ Pleasure craft marine engine — above the cast-in MTU Detroit
Center, rear on a vertical machined Diesel logo.
System Checks
PERSONAL INJURY
Perform the following system checks
Diesel engine exhaust and some before starting for the first time.
of its constituents are known to
the State of California to cause Cooling System Checks
cancer, birth defects, and other
reproductive harm. Check the cooling system as follows:
NOTICE:
Under no circumstances should
a starting aid such as ether be
used to start the engine. Figure 3 Maintenance-Free
Battery “Eye”
If the engine is equipped with a Sea
Pro® fuel processor or a fuel/water If lead-acid or low-maintenance
separator, drain off any water that batteries are used, make sure battery
has accumulated. Water in fuel can electrolyte level is normal.
seriously affect engine performance
and may cause engine damage.
MTU Detroit Diesel recommends
installation of a Sea Pro fuel processor
NOTE:
oil, exhaust or coolant leaks (if water Pleasure craft marine engines are
cooled). Leaks should be corrected equipped with a Kim Hotstart®
before starting the engine. system for rapid cold weather starting.
Commercial marine engines may
Check engine mounting bolts for
require the use of a cold weather
tightness. Retightened bolts if
starting aid if ambient temperature
necessary.
is below 40°F (4°C). Do not use
ether start systems to start marine
NOTE:
engines.
If engine mounting bolts are loose,
check the engine alignment before
running the engine. Authorized MTU
Detroit Diesel service outlets are
properly equipped and have the
trained technicians to perform this
service.
NOTICE:
The turbocharger may be seriously
damaged if the engine is cranked
with the air shutdown in the closed
position.
Figure 4 EDM
NOTICE:
If the warning lights on the MIM stay
on or if they do not come on mo-
mentarily after turning the ignition
key, consult with a DDEC techni-
cian. In the former case the bridge
displays will show the active fault
codes. Operating the engine under
these circumstances may result in
engine damage.
NOTICE:
Failure to properly fill the cooling sys- Do not restart the engine until
tem and purge it of air can result the cause of the concern has
in serious engine damage. Do not been investigated and corrected.
overfill the coolant recovery bottle, Authorized MTU Detroit Diesel
since this can result in spillage as the service outlets are properly equipped
coolant expands during engine oper- to perform this service.
ation.
NOTICE:
Do not use this procedure if the bat- Jump starting with voltages greater
tery of the disabled vessel will not than those indicated or reversing
accept a charge or is frozen. At- battery polarity may damage the
tempting to start the engine under Electronic Control Module (ECM).
these conditions may result in crank-
ing system damage.
□ Flush your skin with water. Before attempting to jump start the
□ Apply baking soda or lime to engine, make sure the jumper cables
help neutralize the acid. are connected properly (positive to
positive, negative to negative ground)
□ Flush your eyes with water. and in the proper sequence (negative
□ Get medical attention to negative ground last).
immediately.
Marine engines having MTU Detroit sensors (if used). This diagnostic
Diesel Electronic Controls (DDEC) system is connected to the “Check
can be equipped with a display option Engine” and “Stop Engine” lights and
designed to warn the operator of an the bridge displays to provide a visual
engine malfunction. This option is a warning of a system malfunction.
standard LCD panel, the Electronic
In the event a major engine
Display Module (EDM), displaying
malfunction occurs, such as low oil
critical power train parameters.
pressure, high oil temperature, low
See Figure 5.
coolant pressure, or high coolant
temperature, the “Stop Engine” lights
are turned on. The electronic displays
at the bridge present the diagnostic
code numbers and a brief word
description of the fault on the display
screen.
DDEC IV Operation
NOTE:
This engine is equipped with DDEC
Figure 5 Electronic Display software. This software generally
Module assures optimal engine performance.
The installation of software upgrades
may cause minor changes in features
The DDEC engine is equipped with
and engine performance.
an electronically controlled fuel
injection system.
Since the DDEC system is electronic,
DDEC engines have the ability to a battery is required to operate the
perform diagnostics for self-checks computer. The system operates at 12
and continuous monitoring of other or 24 volts. However, in the event of a
system components. Depending on power supply malfunction, the system
the application, DDEC electronics can will continue to operate at reduced
also monitor oil temperature, coolant voltage.
temperature, oil pressure, fuel spill
pressure, coolant level and remote
At voltage less than 10.5 volts, the The Stop Engine malfunction is
electronic control system will detect recorded in the Electronic Control
a malfunction. When this occurs, the Module (ECM) for later retrieval by
“Check Engine” light will come on the service technician. Depending on
and a diagnostic code will show on the ECM DDEC calibration, some or all
bridge display. See Figure 5. You may of the following conditions will cause
notice a change in engine operation, the Stop Engine Light (SEL) to come
because DDEC operates with reduced on:
accuracy below 10.5 volts.
□ Loss of coolant (low coolant level)
You will be able to operate the engine
□ High oil temperature
at reduced voltage until the battery
voltage has reached a point where it □ Low oil pressure
will no longer function and the engine
□ Auxiliary warning
will shut down.
□ High coolant temperature
You can still operate the engine and
proceed to your destination when the □ Low coolant pressure
Check Engine Light (CEL) comes
It is important to point out that
on. However, this condition should
whenever the CEL or the SEL
be reported to an authorized DDEC
illuminate, the DDEC computer will
technician as soon as possible.
determine where the problem is and
will then store this information in its
NOTICE: memory.
When the Stop Engine Light comes If the malfunction is intermittent, the
on, the computer has detected a ma- lights will come on and go off as the
jor malfunction in the engine that re- computer senses the changing engine
quires immediate attention. It is the condition.
operator's responsibility to shut
down the engine to avoid serious
damage.
Flash
DDEC III/IV Description
Code Description Code
43 Coolant level low 53 EEPROM write error
Oil or coolant or intake
44 manifold or air inlet 53 Out of calibration
temp. high
45 Oil pressure low 55 J1939 data link fault
46 ECM battery voltage low 55 Missing other ECM information
RTC backup battery
46 55 Proprietary link fault slave/master
voltage low
46 Sensor supply voltage low 56 J1587 data link fault
Fuel or air inlet or turbo
47 57 J1922 data link fault
boost pressure high
Fuel or air inlet or turbo
48 58 Torque overload
boost pressure low
48 EGR temperature low 61 Injector response time long
48 TCO temperature low 62 Auxiliary output fault
48 EGR delta pressure low 63 PWM fault
TCO temperature
51 64 Turbo speed sensor input fault
failed high
52 ECM A/D conversion fail 64 Turbo overspeed
ECM non-volatile
53 65 Air filter restriction sensor fault
memory fault
The engine systems are the following: into the cylinders, where it mixes with
atomized fuel from the injectors.
Fuel System
Cooling System
The fuel system consists of the DDEC
electronic fuel system controls, fuel Heat exchanger or keel-cooled
injectors, fuel manifolds (integral with systems are used on Series 60 marine
the cylinder head), fuel pump, primary engines.
and secondary fuel filters, and the
These systems have a centrifugal
necessary connecting fuel lines.
type fresh water pump to circulate
The primary filter (marked “P”) or coolant within the engine. The
combination filter and fuel/water flow of coolant is controlled by two
separator removes large impurities full-blocking thermostats located in a
from the fuel. The secondary filter housing attached to the right side of
(marked “S”) removes the smaller the cylinder head.
particles.
Electrical System
Lubrication System
The electrical system consists of
The lubricating oil system consists of a starting motor, starting switch,
an oil pump, oil cooler, two full-flow battery-charging alternator, storage
oil filters or a single high-volume full batteries, and the necessary wiring.
flow oil filter, bypass valves at the oil
pump and oil filter adaptor with an oil Exhaust System
control thermostat, and oil pressure
regulator valve and oil bypass valve in Hot exhaust gas flowing from the
the cylinder block vertical oil gallery. water-cooled exhaust manifold is used
to drive the turbocharger.
Air System
Air is drawn through the air
separator/air silencer or air cleaner
and flows into the turbocharger, where
it is compressed. From here it passes
into the charge air cooler and then into
the air intake manifold. It then flows
MAINTENANCE
Ea. Ea. 2
Hours 150† 250 500 1000 3000
Mon Yr Yrs
Item* Procedure
Change lubricating oil every 250 hours of operation
1. Lubricating Oil
or every year, whichever comes first.
2. Fuel, Fuel Tank – I – – – – I –
3. Fuel Lines,
– – – – – – I –
Flexible Hoses
4. Cooling System,
– I – R – – – R
Coolant
5. Turbocharger,
Exhaust – – I – – – I –
Connections
6. Battery – – – – – I – –
7. Drive Belts – I – – R – – –
9. Lubricating Oil
Replace filters when lubricating oil is changedt.
Filter
10. Fuel Filters – R – – – – – –
11. Water Pump,
– – – – – – I –
Seal
12. Coolant Filter,
– I – – – – I –
Conditioner
13. Cranking Motor Follow Manufacturer's Recommendations
14. Air System –
• Filter Element I – – R‡ – I – –
• Air Separator I – – R – – –
CCV X'r Tube,
• I – – – – I – –
V. L. Valve
• Crankcase
– – – I – – – I
Breather
* All items are described in Preventive Maintenance Intervals.
† Inspect every 150 hours or weekly, whichever comes first.
I – Inspect, service, correct, or replace as necessary.
R – Replace.
Ea. Ea. 2
Hours 150† 250 500 1000 3000
Mon Yr Yrs
Item* Procedure
15. Exhaust System – I‡ – – – – – –
16. Oil Pressure – – I – – – I –
17. Battery-Charging
– I – – – – I –
Alternator
18. Engine, Marine
– – – I – – I –
Gear Mounts
19. Crankcase
– – – I – – – I
Pressure
20. Thermostats,
– – – R – – – R
Seals
21. Engine Tune-Up – – – I&A – – – –
22. Marine Gear – – – I – – – –
23. Marine Gear Oil
I – – R – – – I
Cooler
24. Raw Water
I§ – – – – – I –
System Zincs
25. Raw Water Pump – – I – – – I –
26. Charge Air Cooler I – – I – – I –
27. Heat Exchanger – – – I – – – –
Replace at major engine overhaul or earlier
29. Vibration Damper
if dented or leaking.
30. Flywheel Housing – I – – – – – –
* All items are described in Preventive Maintenance Intervals.
† Inspect every 150 hours or weekly, whichever comes first.
‡ Inspect every 250 hours or once a year, whichever comes first.
§ Replace at 75% usage.
I Inspect, service, correct, or replace as necessary.
R – Replace.
A – Adjust.
Ea. Ea. 2
Hours 150† 250 500 1000 2000 3000 4000
Mon Yr Yrs
Item* Procedure
Change lubricating oil every 250 hours of operation
1. Lubricating Oil
or every year, whichever comes first.
2. Fuel, Fuel Tank – I – – – – – – – –
Fuel Lines, Flex
3. – – I R – – – – R –
Hoses
Cooling Sys,
4. – I – – – – R – – R‡
Coolant
Turbo, Exhaust
5. – I – – – – – I I –
Connections
6. Battery – I – – – – – I I –
7. Drive Belts I – – – R – – I – –
Lubricating Oil
9. Replace filters when lubricating oil is changed.
Filters
10. Fuel Filters – R – – – – – – – –
Water Pump,
11. I – – – – – – I – –
Seal
13. Cranking Motor Follow Manufacturer's Recommendations.
14. Air System –
• Filter Element I – – R§ – – – I – –
Air Separator
• I – – – – R – – – –
Assembly
CCV X'r Tube,
• I – – – – – – I – –
V. L. Valve
Crankcase
• I – – – – – – I – –
Breather
16. Oil Pressure – – – I – – – – – –
Ea. Ea. 2
Hours 150† 250 500 1000 2000 3000 4000
Mon Yr Yrs
Item* Procedures
Battery-Charging
17. – I – – – – – I I –
Alternator
Engine, Marine
18. – – – I – – – – I –
Gear Mounts
Crankcase
19. – – I – – – – – I –
Pressure
Thermostats,
20. – I – – – – R – – –
Seals
21. Engine Tune-Up – – – I&A – – – – – –
22. Marine Gear – I – – – – – – I –
Marine Gear
23. – I – R – – – – – –
Oil Cooler
Raw Water
24. I – – – – – – – – –
System Zincs
26. Charge Air Cooler I – – – – – – I – –
27. Heat Exchanger –
• Core – I – – – – I – – –
• Isolators – I – – – – I – – –
• Radiator Cap – I – – – – I – – –
Replace at major engine overhaul or
29. Vibration Damper – I
earlier if dented or leaking.
30. Flywheel Housing – I – – – – – – – –
* All items are described in Preventive Maintenance Intervals.
† Inspect every 150 hours or weekly, whichever comes first.
Replace at 75% usage.
I – Inspect, service, correct, or replace as necessary.
R – Replace.
A – Adjust.
NOTICE:
Intervals
Do not apply steam or solvent di-
The following is intended as a rectly to the battery-charging alter-
guide for establishing preventive nator, starting motor, DDEC com-
maintenance intervals. The ponents, sensors or other electrical
recommendations given should components, as damage to electrical
be followed as closely as possible equipment may result.
to obtain long life and optimum
performance from your engine.
Maintenance intervals indicated are Welding Precaution
time (hours) of actual operation.
The intervals shown apply only to
the maintenance functions described.
These functions should be coordinated NOTICE:
with other regularly scheduled Failure to isolate the DDEC sys-
maintenance. tem from high current flow can re-
sult in severe Electronic Control
The “Daily” instructions apply to
Module (ECM) damage. To pre-
routine or daily starting of the engine.
vent damage to the ECM and other
For new or stored engines, refer to DDEC components, disconnect bat-
the MTU Detroit Diesel Series 60 tery power and ground cables and
Service Manual (6SE660). Follow the 5–pin power connector at the
instructions under Preparations for ECM before welding.
Starting the Engine the First Time.
Preventive maintenance other than the
“Daily” checks should be performed
by authorized MTU Detroit Diesel
service outlets. These outlets have the
trained personnel and special tools to
properly perform all services.
If it is necessary to clean an area
before performing a service item, keep
the following in mind to avoid engine
damage:
Figure 9 Check Oil Level Daily Item 2 – Fuel and Fuel Tank
Keep the fuel tank filled to reduce
All diesel engines are designed to use condensation. Before adding fuel,
some oil, so the periodic addition of refer to How to Select Fuel Oil in the
oil is normal. HOW-TO SECTION of this guide.
See Figure 10.
NOTICE:
Do not overfill. Oil may be blown out
through the crankcase breather if the
crankcase is overfilled.
NOTICE:
Failure to check and maintain
HOT COOLANT SCA levels at required concentra-
To avoid scalding from the tions will result in severe damage
expulsion of hot coolant, never (corrosion) to the engine cooling
remove the cooling system system and related components.
pressure cap while the engine is Coolant must be inhibited with the
at operating temperature. Wear recommended SCA's listed in this
adequate protective clothing guide. In addition, the engine can
(face shield, rubber gloves, be equipped with a coolant filter/in-
apron, and boots). Remove the hibitor system as an installed option
cap slowly to relieve pressure. or as an after-sale item.
A low coolant level sensor installed Refer to How to Select Coolant in the
in the tank will activate an audible HOW-TO SECTION of this guide
alarm or flashing light on the control for required test intervals and inhibitor
panel. Add coolant as required, but do levels.
not overfill. Before adding coolant,
refer to How to Select Coolant in the
HOW-TO SECTION of this guide.
To avoid injury from accidental Keep the terminal side of the battery
engine startup while servicing clean. When necessary, wash with
the engine, disconnect/disable a solution of baking soda and water.
the starting system. Rinse with fresh water. Do not allow
the soda solution to enter the cells.
If lead-acid or low-maintenance
batteries are used, check the specific
gravity of each cell every 150
operating hours. Check more
frequently in warm weather due to
the more rapid loss of water through
evaporation.
Alternator Drive
Belt New Used
Two 1/2–in. V-Groove 125 lbs (556 N) 100 lbs (445 N)
2–Groove PowerBand 200 lbs (890 N) 150 lbs (667 N)
12–Rib Poly-V 350 lbs (1,557 N) 250 lbs (1,112 N)
6–Rib Poly-V 220 lbs (979 N) 180 lbs (801 N)
PERSONAL INJURY
To avoid injury from slipping and
falling, immediately clean up any Figure 12 Lubricating Oil Filters
spilled liquids.
Table 13 DDC (Twin Disc) Marine Gear Lubricating Oil and Filter
Change Requirements
NOTICE:
Stray current (electrolysis) will cause
accelerated engine raw water sys-
tem corrosion. If electrodes are
badly corroded, the system should
be checked for stray current (elec-
trolysis). Authorized MTU Detroit
Diesel distributors are properly
equipped to perform this service.
Figure 20 Location of Charge
Air Cooler Condensate
Item 25 – Raw Water Pump Drains on Pleasure Craft
and Commercial Marine
A raw water pump seal malfunction Engines
is indicated by leakage of water from
the openings in the pump housing.
These openings, located between Ensure the drains are not plugged,
the pump mounting flange and the fouled or obstructed. Check hoses for
inlet and outlet ports, must remain plugging every 150 hours or once a
open at all times. Leaky seals require year, whichever comes first.
replacement. Worn or brittle flexible
impellers should be replaced. The raw
water pump body or liner should also
be checked for cracks or wear and
replaced, if necessary. Authorized
MTU Detroit Diesel service outlets
NOTICE:
Failure to replace a damaged vibra-
tion damper when required may re-
sult in severe engine damage.
This section covers MTU Detroit Only oils licensed to display the API
Diesel's recommendations on how lubricant service mark should be used.
to select lubricating oil, fuel oil, and See Figure 23.
coolant and includes basic engine
maintenance procedures which can be Lubricant Requirements
performed by the operator.
NOTICE:
The manufacturers warranty appli-
cable to Series 60 engines provides
in part that the provisions of such
warranty shall not apply to any en-
gine unit that has been subject to
misuse, negligence or accident. Ac-
cordingly, malfunctions attributable
to neglect or failure to follow the
manufacturers fuel or lubricating rec-
ommendations may not be within the Figure 23 API Lubricant Service
coverage of the warranty. Mark
API Service Category CI-4 is intended to oil drain intervals. For further
for use with cooled Exhaust Gas information, refer to MTU Detroit
Recirculation (EGR) engines meeting Diesel technical publication, Fluids
2002 and later exhaust emission and Lubricants Specification
regulations. Compared to the older (A001061/29E), available from
API Chi Category, the new API authorized MTU Detroit Diesel
CI-4 engine oils have improved distributors.
performance in wear protection
at higher used oil soot levels Synthetic Oils
and extended oil drain capability.
Lubricants meeting API Service Synthetic oils may be used in MTU
Category CI-4 are required for use Detroit Diesel engines, provided
in 2002 and newer engines, and are they are API licensed and meet
recommended for use in all MTU the performance and chemical
Detroit Diesel Series 60 engines. requirements of non-synthetic oils
outlined in this publication. Synthetic
At ambient temperatures below –20° oils offer improved low-temperature
C (–4° F) when sufficient starter flow properties and high-temperature
speed cannot be achieved with SAE oxidation resistance. However,
15W-40 oils, the use of 5W-XX they are generally more costly than
oils and 10W-XX oils, where XX non-synthetic oils.
is 30 or 40, is allowed to improve
startability, provided they are API Refer to MTU Detroit Diesel technical
CI-4 (October 2002 and later– build publication, Fluids and Lubricants
engines) or API Chi (1998 through Specification (A001061/29E) for
September 2002–build engines) and the recommended synthetic oils for
have demonstrated field performance all MTU Detroit Diesel engines in
in MTU Detroit Diesel engines. marine applications. Synthetic oils
These oils must possess a HT/HS provide maximum performance and
of 3.7 minimum. Monograde oils protection in Series 60 pleasure craft
should not be used in Series 60 marine engines along with superior
engines, regardless of API service cold starting ability, as compared to
classification. conventional SAE 40 oils.
Additives
Lubricants meeting the MTU Detroit FIRE
Diesel specifications outlined in this To avoid injury from combustion
publication already contain a balanced of heated lubricating-oil vapors,
additive treatment. Supplemental stop the engine immediately if an
additives are generally not necessary oil leak is detected.
and can even be harmful. These
additives may be marketed as either
oil treatments or engine treatments
and are discouraged from use in
MTU Detroit Diesel engines. Engine
damage resulting from the use
of such materials is not covered FIRE
by your MTU Detroit Diesel To avoid injury from fire, do not
Corporation warranty. MTU Detroit smoke or allow open flames when
Diesel will not provide statements working on an operating engine.
beyond this publication relative to
their use.
Table 14 Maximum Oil Drain and Filter Change Interval (Fuel Sulfur
0.05 Weight Percent or Less)
NOTICE:
Replace spin-on type oil filters as Do not overtighten filters. Overtight-
follows: ening may crack or distort the filter
adaptor.
Gasoline —
FIRE
To avoid injury from fire caused
by heated diesel-fuel vapors:
FIRE □ Keep those people who are not
To avoid increased risk of a fuel directly involved in servicing
fire, do not mix gasoline and away from the engine.
diesel fuel.
□ Stop the engine immediately if
a fuel leak is detected.
Replace the Sea Pro 152 or 511 6. Dispose of the used element
element(s) as follows: in an environmentally
responsible manner, according
1. Shut down the engine and allow
to federal (EPA) and/or state
it to cool.
recommendations.
2. With the engine at ambient
7. Before installing the new filter
temperature and cool to the touch,
element, wipe the sealing surface
place a suitable container under
on top of the processor body clean
the fuel processor.
with a clean cloth or paper towel.
3. Turn the inlet and outlet valves on
the fuel processor to the closed
position (perpendicular to the
valves) and loosen the vent cap on
the see-through cover. See Figure
27.
4. Remove the plug from the drain
valve at the base of the water
separator bowl, open the valve
and drain the fuel until it is below
the level of the collar holding
the see-through cover. Close the
drain valve and replace the plug.
The drained fuel may be returned
to the tank.
5. Using filter collar/vent cap wrench
(P/N: 232002) supplied with the
fuel processor, remove the collar
by turning counter-clockwise.
Remove the cover, filter spring
and cover seal ring by lifting
straight up and over the filter
element.
The Sea Pro 150 assembly is the single Replace the Sea Pro 150 or 300
processor version of this system. primary fuel filter element as follows:
MTU Detroit Diesel recommends 1. If possible, stop the engine
shutting down the engine and allowing and allow it to cool to ambient
it to cool to engine room temperature temperature.
before replacing the fuel filter
2. Close the fuel inlet and outlet
elements. Where this is not possible or
valves on the fuel processor, if
where filter elements must be changed
installed.
“on the run,” the following cautions
should be observed:
NOTE:
If a Sea Pro 300 assembly is used
and the engine must remain running,
switch fuel flow to the clean filter
FIRE before closing the fuel inlet and outlet
valves on the processor of the filter
To avoid injury from fire caused
being replaced.
by heated diesel-fuel vapors:
□ Keep those people who are not 3. Place a suitable container under
directly involved in servicing the processor body. Open the
away from the engine. vent plug on top of the element
being replaced, then remove the
□ Stop the engine immediately if
plug from the bottom drain valve.
a fuel leak is detected.
Open the valve and allow about
□ Do not smoke or allow open a pint of fuel to drain. This will
flames when working on an remove most of the fuel from the
operating engine. element. Close the drain valve
and replace the valve plug.
□ Wear adequate protective
clothing (face shield, 4. Using a suitable strap type filter
insulated gloves and apron, wrench, remove the element by
etc.). rotating it counter-clockwise.
□ To prevent a buildup of
NOTE:
potentially volatile vapors,
Fuel remaining in the element will be
keep the engine area well
caught in the deep well in which the
ventilated during operation.
element sits and drain back into the
processor.
[e] Replace the vent cap and head and remove the spin-on
tighten by hand until secure. fuel filters. Fill with clean fuel
through the fuel inlet holes (the
[f] Open the fuel inlet and outlet
outer ring of small holes on the
valves on the fuel processor.
element) to ensure the fuel is
[g] Start the engine and check for filtered.
leaks. Shut down the engine.
Correct any leaks with the
engine off. NOTICE:
Do not use a strap wrench or other
Engine Out of Fuel — How tool to tighten the spin-on element.
Overtightening may result in filter el-
to Restart
ement or adaptor head damage.
When an engine has run out of fuel,
there is a definite procedure to follow
when restarting it. 3. Thread the elements onto the
adaptor inserts until the gaskets
NOTICE: make full contact with the adaptor
head and no side movement is
The starting motor and fuel pump evident. Tighten filters by hand,
must never be used to prime the fuel an additional one-half turn or as
filters; this can result in damage to indicated on the filter.
the starter, fuel pump and injectors
and cause erratic running of the en- 4. Open the fuel shutoff valve (if
gine due to the amount of air in the installed), start the engine and
fuel lines and filters. check for leaks. Shut down the
engine before correcting leaks.
Product
Ethylene Glycol & Water +
DDC POWER COOL
Conventional Corrosion Inhibitors *
Commercial Equivalent of DDC Fully Formulated TMC RP-329 Type
POWER COOL A Antifreeze & Water
Propylene Glycol & Water + Fully Formulated TMC RP-330 Type
Conventional Corrosion Inhibitors * A Antifreeze & Water
Ethylene Glycol & Water + OAT
DDC POWER COOL Plus
Inhibitors *
Water Only + Conventional Water + DDC POWER COOL
Corrosion Inhibitors † Plus 3000
Water Only + OAT Inhibitors† DDC POWER COOL Plus 6000
* Preferred Coolants
† Water-only coolant systems offer no freeze protection and should not
be used where ambient temperatures can fall to 32°F (0°C).
Antifreeze Solution
Water Solution Pre-mixed Coolant
with Water
POWER COOL 3000 POWER COOL (P/N
Products
(P/N 23507855) 23518918)
3 % by Volume POWER 100 % by Volume POWER
Initial Fill
COOL 3000 COOL
Monitoring POWER Trac Test Strip
Check for depletion; add
POWER COOL 3000 to Add SCA or dilute coolant
Maintenance
maintain 3 % by volume as needed
concentration
NOTE: The recommended water quality is deionized water as
listed in Table 19 or as specified in DDC publication 7SE298.
For best results make the test while Need Release Coolant Filters
the coolant is between 50 – 140°F (Non-OAT Systems)
(10.0 – 60°C). Wait at least 60, but not
Spin-on coolant filters are available
longer than 75 seconds before reading
for MTU Detroit Diesel engines.
the nitrite level. Use the test strips as
Membranes in the filters release
follows:
SCAs before the coolant approaches
1. Dip the strip into coolant for a corrosive condition, protecting the
one second. Remove and shake engine from corrosion. The elements
briskly to eliminate excess fluid. release the SCA charge as needed,
as opposed to the maintenance SCA
2. Immediately compare the pad end
elements, which instantaneously
(% glycol) to the color chart on
release the SCA charge. Coolant filter
the container.
elements should be replaced after one
3. Sixty seconds (one minute) after (1) year, 2,000 operating hours, or
dipping, compare the nitrite pad anytime the coolant system has been
to the color chart. contaminated, whichever comes first.
4. Color change of the additive
indicator (middle pad) indicates
the presence of inhibitor that is
not approved by MTU Detroit
Diesel.
manufacturers' technologies
Recommendations (brands) could cause cooling
system problems.
4. Maintain the inhibitor at the
prescribed concentration. Test
HOT COOLANT the nitrite concentration by using
To avoid scalding from the
a titration kit or Detroit Diesel
expulsion of hot coolant, never
POWER Trac 3-Way Coolant
remove the cooling system
Test Strips. Add SCA only if
pressure cap while the engine is
the nitrite concentration is below
at operating temperature. Wear
900 PPM. Do not use SCA in
adequate protective clothing
OAT coolant, and do not use
(face shield, rubber gloves,
POWER Trac 3-Way Coolant Test
apron, and boots). Remove the
Strips to test OAT coolant.
cap slowly to relieve pressure. 5. Do not use another manufacturer's
test kit to measure the SCA
concentration of Detroit Diesel
1. Always maintain the engine maintenance products.
coolant to meet MTU Detroit
Diesel specifications. 6. Pre-mix coolant makeup solutions
to the proper concentration before
2. Only use water that meets the adding to the cooling system.
specifications listed in Table 19.
Distilled, de-mineralized (reverse 7. Do not mix OAT and other
osmosis) or de-ionized water is coolants in the same engine.
preferred. 8. Do not use automotive coolants
3. The proper dosage of inhibitors or coolants with phosphates.
must be included in the coolant 9. Where antifreeze/boil over
at initial fill for all MTU Detroit protection is required, use only
Diesel engines. This dosage antifreeze that meets TMC
is usually included in the fully RP-329 “Type A” (EG) or
formulated antifreeze used, TMC RP-330 “Type A” (PG)
or it may need to be added if specifications. Always maintain
water alone or if less than 50% coolant at the proper level.
antifreeze is used. The user is
urged to refer to the full text of this
section to determine the proper
dosage. Mixing of different
10. Do not use the following in MTU a DDC POWER Trac Coolant Test
Detroit Diesel engine cooling Bottle. Required part numbers are
systems: listed in Table 36.
□ Soluble oil
Coolant Life of OAT Coolant —
□ High silicate, automotive-type A properly maintained OAT coolant
antifreeze may be operated four (4) years or
□ Chromate SCAs until overhaul, whichever comes
first. At this time the system must
□ Methoxy propanol-based be completely drained, thoroughly
coolant cleaned, and refilled.
□ Methyl alcohol-based coolant OAT Coolants require the addition of
□ Sealer additives or coolant an extender at two (2) years or 5,000
containing sealer additives. hours, whichever comes first. Use 1
pint of extender for every 20 gallons
□ HVAC coolant of coolant.
□ Phosphated coolants
Coolant Life of Other Coolants —
Coolant Life of Glycol Coolant — Other properly maintained coolants
A properly maintained cooling system, may be operated up to two (2)
filled with phosphate-free coolant years or 4,000 operating hours,
consisting of the required mix of whichever comes first. At this time the
antifreeze and water per TMC RP-329 system must be completely drained,
“Type A” (EG) or TMC RP-330 thoroughly cleaned, and refilled.
“Type A” (PG) specifications can be
operated for the life of the engine until
overhaul.
The proper maintenance involves
periodic evaluation using POWER
Trac 3-Way Coolant Test Strips
and the addition of SCA as needed,
indicated by the strip test. To verify
coolant acceptability, submit a sample
for coolant analysis every one (1) year
or 3,000 operating hours, whichever
comes first. Submit the sample in
Hoses
Cooling system hoses should be
inspected every 250 operating hours
or one (1) year which ever comes first
and any hose that shows obvious signs
of damage or feels abnormally soft or
hard should be replaced. Damaged
clamps should also be replaced. All
external leaks should be corrected as
soon as detected.
Symptoms
Rough
Probable Causes Running
Low Detona-
or
Power tion
Frequent
Stalling
Misfiring cylinder X X –
Insufficient fuel X X –
High return fuel temperature X X –
Low compression X X –
DDEC malfunction X X –
High air inlet restriction/exhaust
– X –
back pressure
Engine application – X –
High air inlet temperature – X –
High altitude operation – X –
Incorrect engine gear train timing – X –
Low coolant temperature – – X
Oil picked up by inlet airstream – – X
Faulty injector operation – – X
Incorrect injector height setting – X X
ENGINE STORAGE
SERVICE PUBLICATIONS
The service manual covering MTU MTU Detroit Diesel distributor in the
Detroit Diesel Series 60 engines and U.S. or Canada. Check the Yellow
various reference works which may be Pages under “Engine, Diesel” or refer
of interest to the owner/operator are to the Distributor and Dealer Directory
listed in Table 21. listed below for the distributor or
service outlet nearest you.
To purchase a copy of any of these
publications, contact an authorize
□ Make sure manual shutoff valve (if □ In many areas, emergency service
installed) on the fuel filter adaptor, 24 hours a day.
fuel processor body or fuel supply □ Complete parts support, including
line is open. reliabilt® remanufactured
□ Check the oil level on the dipstick components.
Warranty Period
Time
Limita- Repair Charge to Be Paid by Owner
Item tions
Repair Engine R &
Months Parts
Labor R Labor
100% of Service
Engine 0 – 24 No Charge No Charge Outlet's Normal
Charge
100% of Service
Major
25 – 60 No Charge No Charge Outlet's Normal
Components*
Charge
100% of Service
Accessories 0 – 12 No Charge No Charge Outlet's Normal
Charge
* Cylinder Block, Crankshaft, Camshaft, Fresh Water Pump Housing,
Flywheel, Flywheel Housing, Oil Cooler Housing/Adapter, Front
Cover, Oil Pan, Connecting Rod Forgings and Exhaust Manifold
Maintenance
MTU Detroit Diesel Inc is not
responsible for the cost of
maintenance or repairs due to
the lack of performance of required
maintenance services as recommended
Other Limitations
THIS LIMITED WARRANTY
IS THE ONLY WARRANTY
APPLICABLE TO THE ENGINE
AND ACCESSORIES AS USED
IN MARINE PLEASURE CRAFT
APPLICATIONS. DETROIT DIESEL
CORPORATION MAKES NO
OTHER WARRANTIES EXPRESS
OR IMPLIED, INCLUDING
ANY IMPLIED WARRANTY
OF MERCHANTABILITY OR
FITNESS FOR A PARTICULAR
PURPOSE. DETROIT DIESEL
CORPORATION SHALL NOT BE
LIABLE FOR ANY INCIDENTAL
OR CONSEQUENTIAL DAMAGES
AS DESCRIBED ABOVE.
Some states do not allow the limitation
of how long this warranty may last
or the limitation or exclusion of
incidental or consequential damages,
so the above may not apply to you.
This warranty gives you specific legal
rights, and you may also have other
rights which may vary from state to
state.
Defects
This warranty covers Engine
REPAIRS to correct any malfunction
occurring during the WARRANTY
PERIOD resulting from defects in
material or workmanship.
Repairs
To obtain warranty repairs, you must
request the needed repairs within
the WARRANTY PERIOD from
Warranty Period
Warranty
Limitations Repair Charge to Be Paid
(Whichever Occurs by Owner
Item
First)
Engine
Months Parts Labor
Hours
Engine 0 – 12 No Limit No Charge No Charge
Accessories 0 – 12 0 – 2,000 No Charge No Charge
Upon expiration of the 12 month warranty coverage, but within 12,000
hours of use, the warranty continues to apply as follows:
Block,
Crankshaft
and 100% of service
13 – 36 0 – 12,000 No Charge
Connecting outlet's normal charge
Rods
(assemblies)
LUBRICATING OIL,
FILTERS, ENGINE OIL
CAPACITY
Lubricating Oil
PRODUCTS
Table 33 POWER COOL Plus Extender for Use with POWER COOL
Plus OAT Coolant