Detroit Diesel 12V92SEK.pdf

13400 Outer Drive, West / Detroit, Michigan 48239-4001Telephone: 313-592-5000Telex: 4320091 / TWX: 810-221-1649FAX: 313-592-7288

Copyright 1994. Detroit Diesel, reliabilt, and the spinning arrows are registered trademarks of Detroit Diesel Corporation 6SE506 Rev. 06-94 As technical advancements continue, specifications will change. Printed in U.S.A.

Engine Operator's Guide

Series 92

To the OperatorThis guide contains instructions onthe safe operation and preventivemaintenance of your Detroit Dieselengine. Maintenance instructionscover routine engine services suchas lube oil and fi lter changes inenough detail to permit self-servic-ing, if desired.

The operator should become famil-iar with the contents of this manualbefore operating the engine or carry-ing out maintenance procedures.

Power-driven equipment is only assafe as the person operating thecontrols. You are urged, as the oper-ator of this diesel engine, to keep fin-gers and clothing away from therevolving belts, drive shafts, etc. onthe engine installation.

Throughout this guide CAUTIONSregarding personal safety andNOTICES regarding engine perfor-

mance or service life will appear. Toavoid personal injury and ensurelong engine service life, always heedthese instructions.

Whenever possible, it will benefityou to rely on an authorized DetroitDiesel service outlet for all your ser-vice needs from maintenance tomajor parts replacement. Authorizedservice outlets worldwide stock fac-tory original parts and have the spe-cialized equipment and experienced,trained personnel to provide promptpreventive maintenance and skilledengine repairs.

The information and specificationsin this publication are based on theinformation in effect at the time ofapproval for printing. Contact anauthorized Detroit Diesel service out-let for information on the latest revi-sion. The right is reserved to makechanges at any time without obliga-tion.

Table of ContentsSubject Page

Engine Model and Serial Number Designation.................................................1DDEC II/DDEC III Engine Identification ............................................................1Option and Certification Labels ........................................................................1

OPERATING INSTRUCTIONS...........................................................................3Preparations for Starting the Engine the First Time ..........................................3Starting the Engine............................................................................................6Running the Engine...........................................................................................8Stopping the Engine .......................................................................................10Emergency Jump Starting ..............................................................................11

DDEC OPTIONS..............................................................................................12Vehicle, Industrial Engines..............................................................................12Marine Engines ...............................................................................................20

ENGINE SYSTEMS..........................................................................................24Fuel System.....................................................................................................24Lubrication System .........................................................................................24Air System .......................................................................................................24Cooling System ...............................................................................................24Electrical System.............................................................................................24Exhaust System...............................................................................................24

ENGINE MAINTENANCE SCHEDULES.....................................................26-31

LUBRICATION AND PREVENTIVE MAINTENANCE INTERVALS..............32-44

HOW TO SECTION .................................................................................45-60How to Select Lubricating Oil .........................................................................45When to Change Oil ........................................................................................47How to Replace the Lube Oil Filter .................................................................48How to Select Fuel Oil .....................................................................................50How to Replace the Fuel Filter and Strainer ...................................................53Engine Out of FuelHow to Restart ...............................................................54How to Select Coolant.....................................................................................55How to Drain and Flush the Cooling System ..................................................59When to Service the Dry Type Air Cleaner .....................................................60

BASIC TROUBLESHOOTING ....................................................................61-64

ENGINE STORAGE....................................................................................65-69

SERVICE PUBLICATIONS...............................................................................70

CUSTOMER ASSISTANCE ........................................................................71-72

SPECIFICATIONS ......................................................................................73-74

WARRANTY

The applicable engine warranty is contained in the booklet entitled WarrantyInformation for Series 53, 71 and 92 Engines, available from authorized Detroit Diesel service outlets.

Keep this Operators Guide with the engine installation at all times. It con-tains important operating, maintenance, and safety instructions.

iiiii

Copyright 1994 Detroit Diesel Corporation

Information in this guide is for diesel-fueled Series 92 engines. For alcohol-fueled engines refer to publication Alcohol-Fueled Series 92 Engines (Form6SE508), available from authorized Detroit Diesel distributors.

1

ENGINE MODEL ANDSERIAL NUMBER DESIGNATIONThe engine serial number and modelnumber are stamped on the cylinderblock in the following location (asviewed from the front):

6V, 8V-92 Machined pad on theleft side, upper front corner justbelow the fire deck.

12V, 16V-92 Left side of the rearblock, below and between theback airbox covers.

DDEC II/DDEC IIIEngine IdentificationDetroit Diesel Electronic Control(DDEC) systems are available as stan-dard or optional items on many Series92 engine models. Engines equippedwith DDEC II systems are identified bythe letter "B" in the sixth position of themodel number. Example: 80877B28.Engines equipped with DDEC III sys-tems have the letter "K" in the sixthposition Example: 80877K28.

Option LabelsComputerized engine option labels areattached to the valve rocker cover.These labels contain the engine serialnumber and model number and, inaddition, list any optional equipmentused on the engine. Labels alsoinclude required tune-up information(injection timing, valve lash, max. no-load RPM, etc.).

With any order for parts, the enginemodel and serial number must begiven. If a type number is shown onthe option label covering the equip-ment required, this number shouldalso be included on the parts order.

Marine gears, transmissions andpower take-offs generally carry theirown name plates. The model and seri-al number information on these platesis useful when ordering parts for theseassemblies.

Certification LabelIf required, a certification label isattached to the valve rocker cover.This label certifies that the engine con-forms to federal and certain stateemissions regulations for its particularapplication. It also gives the operatingconditions under which certificationwas made.

SERIAL NO.MODEL NO.

08VF15096580877B28

Location of Engine Serial and ModelNumber (8V-92 Shown)

32

OPERATING INSTRUCTIONSPreparations forStarting the Enginethe First TimeWhen preparing to start a new or newlyoverhauled engine or an engine whichhas been in storage, perform all of theoperations listed below. Failure to followthese instructions may result in seriousengine damage. Before a routine start,see Daily checks in the EngineMaintenance schedules (pages 26-31).

Cooling System Checks

1. Make sure all the drain cocks inthe cooling system are installed(drain cocks are often removed forshipping) and are closed tightly.

2. Open the petcock near the top ofthe water-cooled turbocharger (ifused), and any other petcocks, ifso equipped.

3. Remove the radiator or heatexchanger pressure control capand fill with genuine Detroit DieselPower Cool antifreeze or anequivalent ethylene glycol-baseantifreeze solution in the requiredconcentration. In extremely hotenvironments, clean, soft, proper-ly inhibited water may be used inthe summer. Keep the coolantlevel at the bottom of the filler

neck to allow for expansion of thecoolant. For more detailed coolantrecommendations, refer to How toSelect Coolant (page 55).

4. After filling the cooling system,close all petcocks. Fill the coolantrecovery bottle to the "Full Cold"level, if equipped.

5. Entrapped air must be purgedafter filling the cooling system. Todo this refer to "Inspection-CoolingSystem" under "Running theEngine" (page 8).

6. On industrial and off-highwayunits, check to make sure the frontof the radiator is unblocked andfree of debris.

7. On marine units, perform theseadditional steps:

Check sea water strainers andremove any accumulations of sea-weed or debris. Strainers act asfilters between the intake through-hull fittings and the raw waterpump(s) and are easily fouled.Make sure all thru-hull valves,other valves in the cooling system,and raw water sea lines are open.

Remove the cover from the rawwater pump. Visually inspect theimpeller for signs of damaged orbroken vanes. Replace the impellerif damaged. Reinstall the cover witha new gasket.

Before starting the engine, primethe raw water pump by removingthe pipe plug or zinc provided inthe pump outlet elbow and pour-ing at least a pint of water into thepump. Reinstall the plug or zinc.

Typical Engine Option and Certification Labels (8V-92 Labels Shown)

U.S.A.

U.S.A.

0396 C/S PULLEY 0080 C/S PUL BELT 0272 WATER PUMP0458 WAT BYPASS 0426 THERMOSTAT 0462 EXH MANIFOLD0177 FUEL PUMP 0324 INJECTOR 0691 BLOWER1303 TURBOCHARGER 0068 FUEL MAN CONN 0862 FUEL FILTER1995 FUEL LINES 0747 AIR INLT HSG 0341 INJ CONT ELEC0648 ENGINE MOUNTS NONE AIR COMP 0901 CAM/GR TRAIN0384 VALVE MECH JAKE SEE VALV MECH 0425 ROCKER COVER0133 OIL FIL CAP 0727 VENT SYSTEM 0761 VENT SYSTEM0143 ACC DRIVE 0223 ACC DRIVE 0230 ACC DRIVE

UNIT 08VF161310 S.O. 4A42112 MODEL 80877K45 SPEC P0677700

U.S.A.

IMPORTANT ENGINE INFORMATION1994 THIS ENGINE CONFORMS TO U.S. EPAFED REGULATIONS APPLICABLE TO 1994 MODEL YEAR NEW HEAVY DUTY

DIESEL ENGINES. THIS ENGINE HAS A PRIMARY INTENDEDSERVICE APPLICATION AS A HEAVY HEAVY DUTY ENGINE.

FUEL RATE AT ADV. HP 104.7 MM3/STROKE ADV. HP 500 AT 2100 RPMINITIAL INJECTION TIMING 13 DEG. BTC CID 736ENGINE FAMILY RDD736EJ4AR4 MIN. IDLE 600 RPM FEL BSP 0.32MODEL 8V 92TA DDEC MFG. DATE UNIT 08VF161310

U.S.A.

THIS ENGINE IS NOT CERTIFIED FOR USE IN AN URBAN BUS AS DEFINED AT 40 CFR86.093 2. SALE OF THIS ENGINE FOR USE IN AN URBAN BUS IS A VIOLATION OFFEDERAL LAW UNDER THE CLEAN AIR ACT.

THIS ENGINE IS CERTIFIED TO OPERATE ONLOW SULFUR DIESEL FUEL.

UNIT 08VF161310

0483 CYL BLOCK 0161 AIR BOX DRAIN THIS ENGINE WAS0137 CYL HEAD 0247 ENG LIFT BRKT TESTED AT 0450 HP0721 F/W HOUSING 0177 VIB DAMPER AT 02100 RPM0848 FLYWHEEL 0431 CONN ROD/PSTN INJ. TIMING 1.5200810 OIL PAN 0200 OIL PUMP VALVE LASH .0160028 OIL PRESS REG 0203 OIL DIST STARTING AID .0001230 OIL COOLER 1031 DIPSTICK THRTDLY/FMOD .0000591 OIL FILTER 0748 VENT SYSTEM MAX RPM NL 022250048 BAL WT COVER 1689 FAN STDGT DDEC CAMUNIT 08VF161310 S.O. 4A42112 MODEL 80877K45 SPEC P0677700

CAUTION:

When working near the engine,always remove loose items ofclothing or jewelry that could getcaught in a moving part of theengine and cause personal injury.Also wear safety glasses andhearing protection.

NOTICE:

Failure to install a new gasket andtighten cover bolts securely canresult in pump leakage at start-up.

54

Lubricating System Checks

The lubricating oil film on the rotatingparts and bearings of a new or newlyoverhauled engine, or one which hasbeen in storage for six months ormore, may be insufficient when theengine is started for the first time.Insufficient lubrication at start-up cancause serious damage to enginecomponents.

To ensure an immediate flow of oilto all bearing surfaces at init ialengine start-up, the engine lubrica-tion system should be charged with acommercially available pressure pre-lubricator. After pre-lubricating, addadditional oil to bring the level to theproper mark on the dipstick. Refer toHow to Select Lubricating Oil (page45) for lubricant requirements.

Extended StorageAn engine instorage for an extended period of

time (over winter, for example) mayaccumulate water in the oil panthrough normal condensation ofmoisture (always present in the air)on the cold internal surfaces of theengine. Lube oil diluted by watercannot provide adequate bearingprotection at engine startup. For thisreason, Detroit Diesel recommendsreplacing the engine lube oil and fil-ter(s) after extended storage.

Transmission, Marine GearMakesure the transmission or marine gearis filled to the proper level with thefluid recommended by the gear man-ufacturer.

Fuel System Checks

Fill the tank with the recommended fuel.Keeping tanks full reduces water con-densation and helps keep fuel cool,which is important to engine perfor-mance. Full tanks also reduce thechances for microbe (black slime)growth. Refer to How to Select Fuel Oil(page 50) for fuel recommendation.Make sure the fuel supply shutoff valve (ifused) is open.

To ensure prompt starting and evenrunning, the fuel system must be primedif air has entered the fuel system. Primingis done by connecting a manual or elec-tric priming pump to the inlet of the sec-ondary fuel filter. Authorized DetroitDiesel service outlets are properlyequipped to perform this service.

Priming is not normally necessary if thefilter elements are filled with fuel wheninstalled and the fuel manifolds in thecylinder heads are not drained of fuel.

If the engine is equipped with afuel/water separator, drain off anywater that has accumulated. Water infuel can seriously affect engine perfor-mance and may cause engine dam-age. Detroit Diesel recommendsinstallation of a fuel/water separatorwherever water contamination is aconcern.

Check Eye of Maintenance-Free Batteries

Prime the Raw Water Pump (Marine Engines)

L

F

Check Lube Oil Level Before Starting

Eye

Other Checks

Check drive belts to make sure theyare in good condition (not cracked,torn, worn, or glazed) and are properlyadjusted.

Make sure cable connections to thestorage batteries are clean and tight.Check the hydrometer eye of mainte-nance-free batteries for charge. Iflead-acid or low maintenance batteriesare used, make sure battery elec-trolyte level is normal.

Check turbocharger for signs of oilor exhaust leaks. Leaks should be cor-rected before starting the engine.Check engine mounting bolts for tight-ness. Retighten, if necessary.

NOTICE:

Failure to prime the raw waterpump may result in damage to thepump impeller and engine over-heating.

NOTICE:

Failure to eliminate water-dilutedlube oil may lead to serious enginedamage at startup.

NOTICE:

Prolonged use of the starting motorand engine fuel pump to prime the fuelsystem can result in damage to thestarter, fuel pump, and injectors, andcause erratic engine operation due tothe amount of air in the lines and filtersfrom the supply tank to the cylinderhead.

Engines equipped with startingdevices dependent on compressed airor gas reservoirs should always beprimed before initial startup. Otherwise,reserve pressure can be exhaustedand injectors may be damaged fromlack of lubrication and cooling.

Under no circumstances should astarting aid such as ether be used torun the engine until the fuel system isprimed. Injector damage will occur ifthis method is used. The heat generat-ed by the external fuel source will causethe injector tips to be damaged when thefuel cools them. Plunger and bushingassemblies can be scored from runningwithout lubrication.

76

Starting the EngineBefore starting the engine the firsttime, perform the operations listedunder Preparations for Starting theEngine the First Time (pages 3-5).

If the engine has an emergencymanual or automatic shutdown sys-tem, make sure the control is set in theopen position before starting. The tur-bocharger may be seriously damagedif the engine is cranked with the airshutdown in the closed position. Onengines with dual air shutdown, bothair shutoff valves must be in the openposition before starting the engine.

If the unit is located in a closedroom, start the room ventilating fan oropen the windows, as weather condi-tions permit, so ample air is availablefor the engine.

The engine may require the use of acold weather starting aid if the ambienttemperature is below 40F (4C).

Initial Engine StartNon-DDEC Engine

1.Position the transmission or marinegear in park or neutral.

2. Set the speed control lever at partthrottle, then bring it back to thedesired no-load speed. In addi-tion, make sure the stop lever on

the cover of mechanical governors isin the run position.

3. Press the starter switch firmly.

Air StarterBecause of the limitedvolume of most storage tanks and therelatively short duration of the crankingcycle, it is important to make sure theengine is ready to start before acti-vating the air starter. Start an engineequipped with an air starter as follows:

1. Check the pressure in the air stor-age tank. (Most air starter-equippedinstallations have a dash-mountedpressure gauge.) If necessary, addair to bring the pressure up to atleast the recommended minimumfor starting.

2. Press the starter button firmly andhold until the engine starts.

Starting TipNon-DDECElectric Start Engine:

Some white smoke is normal at start-up when the engine is cold and willclear up shortly after the enginewarms. However, if you experienceexcessive smoke at cold start-up,depress the stop button or cable at thesame time you press the starter buttonand crank the engine for a few sec-onds. Release the stop button or cableand continue to crank the engine untilit starts (but not longer than 15 sec-onds). This will preheat the cylindersand reduce white smoke at start-up.

Initial Engine StartDDECVehicle, Industrial Engine

1. With the transmission in neutral orpark, turn the ignition key on.

You wil l notice that both theCheck Engine and Stop Enginelights will come on. This is the resultof the DDEC computer diagnosingthe system to ensure everything isfunctional, including the light bulbsfor the Check Engine and StopEngine warning lights. If everythingis okay, both lights will go out inapproximately five seconds.

2. With foot OFF the foot pedal, startthe engine after the lights go out.Start the engine by pressing thestarter switch firmly.

If the engine fails to start within 15seconds, release the starter switchand allow the starting motor to coolfor 15 seconds before trying again. Ifthe engine fails to start after fourattempts, an inspection should bemade to determine the cause.

Initial Engine StartDDEC Marine Engine

1. With the marine gear in neutral, turnthe ignition key on. You will noticethat both the Check Engine andStop Engine lights on the BoatBuilder Interface Module (BBIM) willcome on. This is the result of theDDEC computer diagnosing thesystem to ensure everything isfunctional, including the light bulbsfor the Check Engine and StopEngine warning lights. If everythingis okay, both lights will go out inapproximately five seconds.

The electronic display panels atthe control bridge also complete adiagnostic check when the ignitionkey is turned on.

The electronic display module or"EDM" (if used) does not contain"Check Engine" and "Stop Engine"lamps, but features the words "STOP"and "CHECK" on the panel face.When the ignition key is turned on,the EDM checks every segment onthe panel face and sets itself for dis-play of engine parameters.

If the vessel is equipped with theDDEC Imaging System, you willnotice that it also does not contain"Check Engine" and "Stop Engine"lamps, but does a self-diagnosticcheck when turned on.

Should a system fault be presentat any time, both display versions willpresent on the screen the diagnosticcode number and a brief worddescription of the fault condition.

Typical Shutdown Override Switch andEngine Lights

NOTICE:

The blower will be seriously dam-aged if operated with the air shutoffvalve in the closed position.

CAUTION:

Starting fluid used in capsules ishighly flammable, toxic, and pos-sesses sleep-inducing properties.

NOTICE:

To prevent serious starting motordamage, do not press the starterswitch again after the engine hasstarted.

NOTICE:

If the warning lights stay on, or if theydo not come on momentarily afterstarting the engine, consult with aDDEC technician. Operating theengine under these circumstancesmay result in engine damage.

NOTICE:

To prevent serious starting motordamage, do not press the starterswitch again after the engine hasstarted.

STOP ENGINE DIAGNOSTIC CHECK STOPSWITCH

OVERRIDE ENGINE ENGINE

ON

OFF

98

2. Start the engine after the lights goout. Start the engine by pressingthe starter switch firmly.

If the engine fails to start within 15seconds, release the starter switchand allow the starting motor to cool for15 seconds before trying again. If theengine fails to start after four attempts,an inspection should be made todetermine the cause.

Running the EngineOil Pressure

Observe the oil pressure gauge or elec-tronic display immediately after startingthe engine. A good indicator that all of themoving parts are getting lubrication iswhen the oil pressure gauge registerspressure (5 psi - 34.5 kPa) at idle speed.If there is no oil pressure indicated within10 to 15 seconds, stop the engine andcheck the lubricating system. The pres-sure should not fall below 28 psi (193kPa) at 1800 rpm, and normal operatingpressure should be higher. If pressuredoes not fall within these guidelines, itshould be checked with a manual gauge.

Warm-up

Run the engine at part throttle for aboutfive (5) minutes to allow it to warm upbefore applying a load.

Inspection

Transmission, Marine GearWhilethe engine is idling, check the transmis-sion or marine gear for proper oil leveland add oil as required. On marine

engines check that water is flowing outthe exhaust pipe or raw water dis-charge pipe. Look for coolant, fuel, orlubricating oil leaks at this time. If anyare found, shut down the engine imme-diately and have leaks repaired after theengine has cooled.

Cooling SystemEntrapped air mustbe purged after the cooling system isfilled. To do this allow the engine towarm up without the pressure capinstalled. With the transmission or marinegear in neutral, increase engine rpmabove 1000 rpm and add coolant asrequired. Vent the petcock on the waterreturn line at the water-jacketed tur-bocharger (if used) until coolant (no air)comes out. Install the pressure cap afterthe coolant level has stabilized at thebottom of the radiator or heat exchangertank filler neck. Refill the recovery bottleas needed if coolant is drawn into theengine while purging the air.

If all of the coolant is drawn out of therecovery bottle when the engine cools,remove the pressure cap from the radi-ator or heat exchanger and check tomake sure the coolant level is at thebottom of the filler neck. Add coolant asrequired, replace the pressure cap,and fill the recovery bottle to the "FullCold" level, or no more than one-quarterof its volume.

CrankcaseIf the engine oil wasreplaced, stop the engine after normaloperating temperature has beenreached. Allow the oil to drain back intothe crankcase for approximately twenty(20) minutes, and check the oil level. Ifnecessary, add oil to bring the level tothe proper mark on the dipstick. Useonly the heavy-duty oils recommendedin How to Select Lubricating Oil (page45) in this guide.

TurbochargerMake a visual inspec-tion of the turbocharger for oil leaks,coolant leaks, exhaust leaks, excessivenoise or vibration. Stop the engine imme-diately if a leak or unusual noise or vibra-tion is noted. Do not restart the engineuntil the cause of the concern hasbeen investigated and corrected.Authorized Detroit Diesel service outletsare properly equipped to perform thisservice.

Avoid Unnecessary IdlingDuring long engine idling periods withthe transmission in neutral, the enginecoolant temperature may fall below thenormal operating range. The incompletecombustion of fuel in a cold engine willcause crankcase oil dilution, formationof lacquer or gummy deposits on thevalves, pistons, and rings, and rapidaccumulation of sludge in the engine.When prolonged idling is necessary,maintain at least 800-1000 rpm.

Electronic Display Module

DDEC Imaging System

NOTICE:

If the warning lights on the BBIM stayon, or if they do not come onmomentarily after turning on the igni-tion key, consult with a DDEC ser-vice technician. In the former casethe bridge displays will show theactive fault codes. Operating theengine under these circumstancesmay result in engine damage.

NOTICE:

To prevent starting motor damage,do not press the starter switch againafter the engine has started.

CAUTION:

To avoid personal injury from thehot oil, do not operate the enginewith rocker covers removed forany reason.

NOTICE:

Failure to properly fill the cooling sys-tem and purge it of air can result inengine overheating and seriousengine damage.

Do not overfill the recovery bottle, sincethis can result in spillage as the coolantexpands during engine operation.

CAUTION:

To avoid personal injury or tur-bocharger damage, do notremove, attach, or tighten tur-bocharger air intake ducting whilethe engine is operating or operatethe engine with the ductingremoved.

NOTE: On coach engines equippedwith Delco 50 DN alternators andmechanical unit injectors the optimumlow idle speed setting with full accessoryload and the transmission in neutral is:

6V-92 650 rpm8V-92 550 rpm

Stopping the EngineNormal Stopping1. Reduce engine speed to normal idle

and put all shift levers in the neutralposition.

2. Allow the engine to run between idleand 1,000 rpm with no load for four(4) or five (5) minutes. This allows theengine to cool and permits the tur-bocharger to slow down. After four orfive minutes, shut down the engine.

Emergency Stopping

The emergency shutdown should beused only when the engine does notrespond to the normal stop engineprocedure.

To shut down the engine, simply acti-vate the emergency shutdown control.This is an electrical switch or mechani-cal lever which is normally identified assuch on the control panel.

The air shutdown, located in the airinlet housing, must be reset by handand the emergency stop knobpushed in before the engine is ready tostart again.

10 11

Emergency JumpStartingUse the following procedure to startthe engine of a vehicle with a low bat-tery or one that will not crank theengine fast enough to start.

The DDEC II electronic control sys-tem operates on 12 volts DC. If aDDEC II engine with an electric start-ing motor requires emergency jumpstarting, do not exceed 16 volts DC.

The DDEC III electronic control sys-tem operates on 12 or 24 volts DC. If aDDEC III engine with an electric start-ing motor requires emergency jumpstarting, do not exceed 32 volts DC.

1. Prevent shorting of the system byremoving metal rings, watches, orjewelry and not allowing metal toolsto contact the positive terminal ofthe battery.

2. Place the transmission of the dis-abled vehicle in neutral, set theparking brake, and turn the ignitionto the off position.

3. Turn off lights, heater, air condition-er, and any other electrical loads inthe disabled vehicle and the boost-er vehicle.

4. Wear eye protection if available, orshield eyes when near either bat-tery.

5. Do not allow vehicle bodies orbumpers to touch.

6. Connect one end of the first jumpercable to the positive (+) terminal ofthe dead battery. Connect the otherend to the positive (+) terminal ofthe booster battery.

7. Connect one end of the secondjumper cable to the negative () ter-minal of the booster battery.Connect the other end to an enginebolt head or good metallic contact(ground) on the disabled vehicle.

NOTICE:

Stopping a turbocharged engineimmediately after high speed opera-tion may cause damage to the tur-bocharger, as it will continue to turnwithout an oil supply to the bearings.

NOTICE:

Jump starting with voltages greaterthan those indicated or reversing bat-tery polarity may damage the ECM(electronic control module).

NOTICE:

Never use the emergency shutdownsystem, except in an emergency.Use of the emergency shutdown cancause lubricating oil to be suckedpast the oil seals and into the blowerand may also cause turbochargerdamage.

NOTICE:

If the emergency air shutdown isused to stop the engine in an emer-gency situation, always have the shut-down checked for damage and forproper operation before the vehicle,vessel, or machine is returned to ser-vice. This is especially important ifshutdown is made at high enginerpm. To ensure positive valve closureshould another emergency shutdownbe required, the shutdown must bechecked and required repairs oradjustments made at this time.Failure to observe this precautionmay permit engine run-on when theemergency shutdown is activated.

NOTICE:

Do not use this procedure if thebattery of the disabled vehicle willnot accept a charge or is frozen.Attempting to start the vehicleunder these conditions may resultin cranking system damage.

CAUTION:

The following procedure must beperformed exactly as outlined.Failure to observe precautionsand/or follow this sequence mayresult in injury to the face, eyes,body, limbs, and respiratory sys-tem caused by fire or acid frombattery explosion. Property dam-age could also result.

CAUTION:

Reversing battery polarity can alsoresult in personal injury caused bythe sudden discharge of elec-trolyte from the battery ventsand/or the sudden rupture of thebattery case caused by explosionof internal hydrogen gas.

major engine malfunction occurs, suchas low oil pressure, high oil tempera-ture, or low coolant level.

DDEC engines may also have anoptional 3-100 minute idle shutdownsystem. The purpose of this system isto conserve fuel by eliminating exces-sive idling and to allow for a tur-bocharger cool down period. Toactivate the shutdown, the transmis-sion must be in neutral, with theengine in idle or PTO mode.

Cruise Control

A DDEC-equipped vehicle enginemay have cruise control. Cruise con-trol is available at either a road speedor engine speed setting. The driverhas switches to activate and deacti-vate the system, and a slight depres-sion of the brake or clutch pedaldeactivates the system as well. Theminimum speed at which cruise con-trol can be used is 30 or 35 mph(depending on vehicle specifications)and 1200 rpm.

The cruise control may also be pro-grammed to permit fast idle using thecruise control switches. With theengine at normal idle, transmission inneutral and service brake on, turn onthe cruise control on/off switch, anduse the set switch. The engine rpm

should increase to a pre-defined rpm.The rpm can be raised or loweredfrom this point using the set andresume switches.

The cruise control option willmaintain the set speed under normalroad and load conditions. It cannotlimit vehicle speeds on down grades ifavailable engine braking effort isexceeded, nor can it maintain speedon upgrades if power requirementsexceed engine power capability.

13

Typical Cruise Control Switches

12

8. Start the engine of the boostervehicle and allow it to run for aminute or two to help charge thebattery of the disabled vehicle.

9. Turn the ignition of the disabledvehicle to the on position andattempt to start the engine.

10. As soon as the engine starts,remove jumper cables in reverseorder of attachment (negativeground cable on newly startedengine first, then negative cable,then positive cable).

11. Allow the engine to warm up beforeputting a load on the vehicle.

DDEC OPTIONSVehicle, IndustrialEnginesEngines having Detroit DieselElectronic Controls (DDEC) can beequipped with a variety of optionsdesigned to warn the operator of anengine malfunction. The options canrange from Check Engine and StopEngine panel lights to automaticreduction in engine power followed byautomatic engine shutdown. Thepower-down/shutdown option may beactivated by low coolant level, low oilpressure or high engine oil or coolanttemperature.

To start a DDEC engine be surethe transmission is in neutral or parkand turn the ignition key on.

You will notice that both the CheckEngine and Stop Engine lights willcome on. This is the result of theDDEC computer diagnosing the sys-tem to ensure everything is functional,including the light bulbs for the CheckEngine and Stop Engine warninglights. If everything is okay, both lightswill go out in approximately fiveseconds.

With foot OFF the foot pedal, startthe engine after the lights go out.

The DDEC engine is equipped withan electronically controlled fuelinjection system.

DDEC engines have the ability toperform diagnostics for self-checksand continuous monitoring of othersystem components. Depending onthe application, DDEC can also moni-tor oil temperature, coolant tempera-ture, oil pressure, fuel spill pressure,coolant level, and remote sensors (ifused). This diagnostic system is con-nected to the Check Engine andStop Engine lights to provide a visualwarning of a system malfunction.

The DDEC engine can beequipped with an engine protectionsystem that features a 30 second,stepped-power shutdown sequenceor an immediate speed reductionwithout shutdown in the event a

NOTICE:

If the warning lights stay on, or if theydo not come on momentarily afterstarting the engine, consult with aDDEC technician. Operating theengine under these circumstancesmay result in engine damage.

NOTICE:

If the engine is equipped with thepower-down/shutdown option, therewill be a system override button orswitch which may be used to allowengine operation for a short period oftime. If the shutdown override buttonis not used, the shutdown will occurin 30 seconds.

NOTICE:

When descending a hill with cruisecontrol on or off, do not allowthe engine to exceed 2300 rpmunder any conditions. Failure toobserve this precaution can resultin overspeeding and seriousengine damage.

CRUISE CONTROL PANEL LIGHTS

SET ON RESUME

OFF

ENGINE STARTACC OFF RUN

CAUTION:

To avoid a spark, do not attachthe cable end to the negative ter-minal of the disabled battery. Aspark could cause explosion ofgases normally present aroundthe battery, resulting in batteryrupture and possible personalinjury and/or property damage.

Stop Engine Override switch, locatedon the instrument panel, until a safestop can be made. The operator onlyneeds to press the override switchevery 15 to 20 seconds to preventengine shutdown from occurring.

An important thing to remember isthat it takes 30 seconds from the timethe automatic shutdown sequencebegins until engine shutdown. There-fore, the operator must press the over-ride switch just prior to engine shutdownand continue to do so until the vehiclecan be brought to a safe stop.

The immediate speed reductionoption will bring engine rpm back to apredetermined speed, but will not shutdown the engine.

The engine should not be restartedafter it has been shut down by theengine protection system unless theproblem has been located and cor-rected.

The conditions that will cause theStop Engine light (SEL) to come onare:

Loss of coolant High oil temperature Low oil pressure Auxiliary shutdown

It is important to point out that when-ever the Check Engine light (CEL) orthe Stop Engine light (SEL) comeson, the DDEC computer will determinewhere the problem is, and will thenstore this information in its memory.

If the malfunction is intermittent, theLights will come on and go off as thecomputer senses the changing enginecondition.

A special diagnostic tool (DiagnosticData Reader, or DDR) is available thatcan be plugged into the engine com-puter memory to extract informationrelated to the cause of the problem.

Once the malfunction has been cor-rected, the DDEC system will returnthe engine to normal operation.

The DDR can distinguish betweencodes now active and those stored inthe ECM memory (inactive).

The diagnostic code recorded in thecomputer memory will remain until it iserased by a technician.

15

On engines equipped with JacobsEngine Brakes, the Jake Brake cir-cuit can be activated by releasingthe EFPA (Electronic Foot PedalAssembly) completely to the idleposition. The Jake Brake will thenoperate the same as on engines withmechanical governors. To return thevehicle to cruise speed after brake orclutch application, simply activatethe Resume switch. Each subse-quent touch of the Resume switchwill increase cruise speed by 1 mile(1.6 km) per hour.

DDEC Operation

Since the DDEC system is electronic, abattery is required to operate the com-puter.

The system operates at 12 volts.However, in the event of a power sup-ply malfunction, the system will contin-ue to operate at reduced voltage.

At reduced voltage, the electroniccontrol system will detect a malfunction.When this occurs the Check Enginelight (CEL) will come on.

At this point, the Electronic ControlModule will go into Back Up Control.You should then notice a change inengine operation, and at this time cer-tain DDEC options, such as cruise con-trol, smoke control, and automaticshutdown, will not function.

The engine will operate only atreduced rpm. You will be able to oper-ate the vehicle at reduced voltage untilthe battery voltage has reached a pointwhere it will no longer function and theengine will shut down.

You can still operate the vehicle andproceed to your designation when theCheck Engine light (CEL) comes on.However, a report should be made to aDDEC technician as soon as possible.

The Stop Engine malfunction isrecorded in the Electronic ControlModule. With the 30 second shutdownoption, the engine will begin a 30 sec-ond, stepped, power down sequenceuntil it shuts down completely.

To allow for the possibility of theStop Engine automatic shutdownfunction being activated while thevehicle is operating in a critical situa-tion, an override is provided.NOTE: In some applications the StopEngine Override and DiagnosticRequest switches can be the same.

In this situation the operator mayelect to override the automatic stopengine sequence by pressing the

14

CAUTION:

To avoid the possibility of vehicledamage and/or personal injury,Detroit Diesel does not recom-mend using cruise control underthe following conditions:

When it is not possible to keepthe vehicle at a constant speed(on winding roads, in heavy traf-fic, in traffic that varies in speed,etc.).

On slippery roads (wet pave-ment, ice or snow-covered roads,loose gravel, etc.).

NOTICE:

When the Stop Engine l ightcomes on, the computer hasdetected a major malfunction in theengine that requires immediateattention. It is the operator'sresponsibility to shut down theengine to avoid serious damage.

NOTICE:

For some applications, holding theStop Engine Override switch in willnot prevent the engine shutdownsequence. You must continue toreset the automatic shutdown sys-tem by pressing the Stop EngineOverride switch at intervals ofapproximately 15 to 20 seconds.

STOP ENGINE DIAGNOSTIC CHECK STOPSWITCH

OVERRIDE ENGINE ENGINE

ON

OFF

Typical Shutdown Override Switch andEngine Lights

The diagnostic code can also beobtained by the operator:

DDEC II EnginesA DiagnosticRequest switch is provided which,when pressed, will cause the CheckEngine light (CEL) to flash a codenumber. It will, for example, flashtwice...pause...flash five times...pause.In other words a code 25.

Code 25 indicates all systems areworking satisfactorily.

DDEC III EnginesThe active codeswill be flashed on the Stop Enginelight (SEL) in the order of most recentto least recent occurrence based onengine hours. If there are no activecodes, a code 25 will be flashed.

The inactive codes will be flashedon the Check Engine light (CEL) inthe order of most recent to least recentoccurrence based on engine hours. Ifthere are no inactive codes, a code25 will be flashed.

Diagnostic Data Reader J38500

Note that only one lamp will beflashing codes at any time. Whencode flashing is initiated, the activecodes (or code 25) will be flashed onthe SEL. Then the inactive codes (orcode 25) will be flashed on the CEL.When all the inactive codes (or code25) have been flashed, the processof flashing all the active codes fol-lowed by all the inactive codes willrepeat until the conditions for codeflashing are no longer satisfied.

The codes will continue to flash andrepeat as long as the DiagnosticRequest switch is held in the Onposition with the ignition on. Otherdiagnostic codes are shown in thecharts (pages 18-19).

NOTICE: If a DDEC II vehicle engineis equipped with an OEM-supplieddiagnostic switch, the switch mustNOT be switched on when operatingthe vehicle. If this is done, the diag-nostic mode line will be grounded,and the throttle will be forced to idle,affecting vehicle operation. Thethrottle will also go to idle if pins Aand M in the Diagnostic DataReader (DDR) connector arejumpered together. This conditionwill not occur when the DiagnosticData Reader is used.

Welding Precaution

16 17

NOTICE:

To prevent damage to the DDECelectronic control system, discon-nect battery power and groundcables and the 6-pin power connec-tor at the ECM (electronic controlmodule) before welding. Failure toisolate the DDEC system fromhigh current flow can result insevere ECM damage.

CAUTION:

The operator of a DDEC-equippedengine should know the extent ofthe warning system on his vehicle,in order to bring it to a safe stop inthe event of an engine malfunc-tion. A description of the warningsystem and detailed instructionsregarding its operation should beobtained from the owner, the selleror the manufacturer of the vehicle.This information may also beobtained at any authorized DetroitDiesel service outlet.

To be confronted with a power-down/shutdown situation withoutknowing how the system workscould cause the vehicle to stop inan unsafe location, posing thepossibility of damage to the vehi-cle and a threat to the safety of theoperator.

CAUTION:

The operator of a DDEC-equippedvehicle must not attempt to use orread a diagnostic data reader ofany kind while the vehicle is oper-ating. Doing so can result in lossof control, which may cause vehi-cle damage and may result in per-sonal injury.

When engine or electronics sys-tem diagnosis is required on aDDEC-equipped vehicle, this mustbe done by a person other thanthe operator. The operator mustmaintain control of the movingvehicle while the assistant per-forms the diagnosis.

Diagnostic CodesDDEC IIOn-Highway and Industrial Engines

Diagnostic Connector

Error ErrorCode # Description Code # Description

11 Power Take-off Sensor Lo Volt 43 Low Coolant Level12 Power Take-off Sensor Hi Volt 44 Engine Overtemperature13 Coolant Sensor Lo Volt 45 Low Oil Pressure14 Eng Temp Sensor Hi Volt 46 Low Battery Voltage15 Eng Temp Sensor Lo Volt 47 Hi Fuel Pressure16 Coolant Sensor Hi Volt 48 Lo Fuel Pressure21 Throttle Pos Sensor Hi Volt 51 EEPROM Error22 Throttle Pos Sensor Lo Volt 52 ECM - A/D Failure23 Fuel Temp Sensor Hi Volt 53 EEPROM Memory Fails24 Fuel Temp Sensor Lo Volt 54 Vehicle Speed Sensor25 No Codes 55 Proprietary Comm. Link26 Power Control Enabled 56 ECM - A/D Failure31 Fault on Auxiliary Output 58 Cruise Ctl/Press Gov Ctl Switch32 ECM Backup System Failure 61-68 Inj Response Time Long33 Turbo Boost Sensor Hi Volt 71-78 Inj Response Time Short34 Turbo Boost Sensor Lo Volt 84 Crankcase Pressure Hi35 Oil Pressure Sensor Hi Volt 85 Engine Overspeed36 Oil Pressure Sensor Lo Volt 86 Press Gov Ctl - Hi Volt37 Fuel Pressure Sensor Hi Volt 87 Press Gov Ctl - Lo Volt38 Fuel Pressure Sensor Lo Volt41 Timing Reference Sensor42 Synchronous Ref Sensor

F E D C B A

G H J K L M

Diagnostic CodesDDEC IIIOn-Highway and Industrial Engines

Flash FlashCode DDEC Description Code DDEC Description

11 PTO input low 46 Battery voltage low12 PTO input high 47 Fuel pressure high13 Coolant level circuit low 48 Fuel pressure low14 Intercooler, coolant or oil temp. circuit high 52 A/D conversion fail15 Intercooler, coolant or oil temp. circuit low 53 EEPROM write or nonvolatile fail16 Coolant level circuit high 54 Vehicle speed sensor fault17 Bypass position circuit high 55 J1939 data link fault18 Bypass position circuit low 56 J1587 data link fault21 TPS circuit high 57 J1922 data link fault22 TPS circuit low 58 Torque overload23 Fuel temp. circuit high 61 Injector response time long24 Fuel temp. circuit low 62 Digital output open or short to battery25 No codes 63 PWM open or short to battery26 Aux. shutdown #1 or #2 active 64 Turbo speed circuit failed27 Air temp. circuit high 67 Coolant pressure circuit high or low28 Air temp. circuit low 68 IVS switch fault, open or grounded circuit31 Aux. output short or open circuit (high side) 71 Injector response time short32 SEL short or open circuit 72 Vehicle overspeed33 Boost pressure circuit high 75 Battery voltage high34 Boost pressure circuit low 76 Engine overspeed with engine brake35 Oil pressure circuit high 81 Oil level or crankcase pressure circuit high36 Oil pressure circuit low 82 Oil level or crankcase pressure circuit low37 Fuel pressure circuit high 83 Oil level or crankcase pressure high38 Fuel pressure circuit low 84 Oil level or crankcase pressure low41 Too many SRS (missing TRS) 85 Engine overspeed42 Too few SRS (missing SRS) 86 Water pump or baro. pressure circuit high43 Coolant level low 87 Water pump or baro. pressure circuit low44 Intercooler, coolant or oil temp. high 88 Coolant pressure low45 Oil pressure low

SEL/CEL EXAMPLES

NOTE: The SEL flashing gives active codes. The CEL flashing gives inactive codes.

NOTE: DDEC II-equipped engines are designatedby the letter B in the sixth position of the modelnumber. Example: 80877B28.TO READ CODES: Use diagnostic data reader orshort pin A to pin M. The latter method will flashcodes at the CEL.

NOTE: DDEC III-equipped engines are designated by the letter K in the sixth position of the enginemodel number. Example: 80877K28.TO READ CODES: Use the diagnostic data reader or depress and hold the diagnostic request switchwith the ignition on, engine at idle or not running. Press and hold the switch. Active codes will beflashed on the Stop Engine light (SEL) followed by the inactive codes being flashed on the CheckEngine light (CEL). The cycle will repeat until the operator releases the diagnostic request switch.

RED = SEL YELLOW = CELCEL EXAMPLES

NOTE: The CEL flashing gives both active and historic codes.

CEL CEL1 Flash 3 Flashes 2 Flashes 1 Flash

Short ShortPause Long Pause Pause

Code 13 Code 21



Code 13 Code 21

1918

DDEC II Operation

Since the DDEC system is electronic, abattery is required to operate the com-puter.

The system operates at 12 volts.However, in the event of a power sup-ply malfunction, the system will contin-ue to operate at reduced voltage.

At voltage less than 10.5V, the elec-tronic control system will detect a mal-function. When this occurs, the "CheckEngine" light will come on and a diag-nostic code will show on the bridgedisplay. You may notice a change inengine operation, because DDECoperates with reduced accuracybelow 10.5 volts.

You will be able to operate theengine at reduced voltage until thebattery voltage has reached a pointwhere it will no longer function and theengine will shut down.

You can still operate the engineand proceed to your destinationwhen the "Check Engine" light (orCEL) comes on. However, a reportshould be made to a DDEC techni-cian as soon as possible.

DDEC II OPTIONSMarine EnginesMarine engines having Detroit DieselElectronic Controls (DDEC) can beequipped with two display optionsdesigned to warn the operator of anengine malfunction. The options are anelectronic display module panel dis-playing critical powertrain parametersor a DDEC imaging system displaythat includes many vessel functions aswell.

The DDEC engine is equippedwith an electronically controlled fuelinjection system.

DDEC engines have the ability toperform diagnostics for self-checksand continuous monitoring of othersystem components. Depending onthe application, DDEC can also moni-tor oil temperature, coolant tempera-ture, oil pressure, fuel spill pressure,coolant level, and remote sensors (ifused). This diagnostic system is con-nected to the "Check Engine" and"Stop Engine" lights and the bridgedisplays to provide a visual warning ofa system malfunction.

In the event a major engine malfunc-tion occurs, such as low oil pressure,high oil temperature, low coolant level,or high coolant temperature, the StopEngine and Check Engine lights areturned on. The electronic displays atthe bridge present the diagnostic codenumbers and a brief word descriptionof the fault on the display screen.

20

Diagnostic CodesDDEC II Marine Engines

Diagnostic Connector

Error ErrorCode # Description Code # Description

11 Hand Throttle Speed Adj Lo Volt 42 Synchronous Ref Sensor12 Hand Throttle Speed Adj Hi Volt 43 Low Coolant Level13 Coolant Sensor Lo Volt 44 Engine Overtemperature14 Eng Temp Sensor Hi Volt 45 Low Oil Pressure15 Eng Temp Sensor Lo Volt 46 Low Battery Voltage16 Coolant Sensor Hi Volt 47 Hi Fuel Pressure23 Fuel Temp Sensor Hi Volt 48 Lo Fuel Pressure24 Fuel Temp Sensor Lo Volt 51 ECM Calibration Memory Failure25 No Codes 52 ECM A/D Failure26 External Warning Switch Enabled 53 ECM Nonvolatile Memory Failure31 Fault on Auxiliary Output 54 Tach Sync Circuit Fault32 ECM Backup Failure 55 Proprietary Data Link Circuit Fault33 Turbo Boost Sensor Hi Volt 56 ECM A/D Failure34 Turbo Boost Sensor Lo Volt 57 To Be Determined35 Oil Pressure Sensor Hi Volt 58 Auxiliary Switch Circuit Failure36 Oil Pressure Sensor Lo Volt 61-68 Inj Response Time Long37 Fuel Pressure Sensor Hi Volt 71-78 Inj Response Time Short38 Fuel Pressure Sensor Lo Volt 84 Crankcase Pressure - Hi41 Timing Reference Sensor 85 Engine Overspeed

A

F B

CD

E

NOTE: DDEC II-equipped engines are designatedby the letter B in the sixth position of the enginemodel number. Example: 80627B00.TO READ CODES: Use diagnostic data reader orpress and hold the diagnostic switch on the BBIM.The latter method will flash codes at the CEL.

CEL EXAMPLES

NOTE: The CEL flashing gives both active and historic codes.



Code 13 Code 21

21

NOTICE:

When the "Stop Engine" light comeson or the word STOP appears onthe screen, the computer has detect-ed a major malfunction in the enginethat requires immediate attention. Itis the operator's responsibility to shutdown the engine to avoid seriousdamage.

Welding Precaution

The "Stop Engine" malfunction isrecorded in the Electronic ControlModule for later retrieval by the servicetechnician.

The conditions that will cause the"Stop Engine" light to come on are:

Loss of coolant High oil temperature Low oil pressure Auxiliary warning

It is important to point out that when-ever the "Check Engine" light or the"Stop Engine" light comes on, theDDEC computer will determine wherethe problem is, and will then store thisinformation in its memory.

If the malfunction is intermittent, the"Lights" will come on and go off as thecomputer senses the changing enginecondition.

A special diagnostic tool(Diagnostic Data Reader, or "DDR") isavailable that can be plugged into theengine computer data link to extractinformation related to the cause of theproblem.

Diagnostic Data Reader J 38500

Once the malfunction has been cor-rected, the DDEC system will returnthe engine to normal operation.

The DDR can distinguish betweencodes now active and those stored inthe historic code memory.

The malfunction code recorded inthe computer memory will remain untilit is erased by a technician.

The historic malfunction codes canalso be obtained by the operator. A"Diagnostic Request" switch is locatedat the BBIM which, when pressed, willcause the "Check Engine" light (orCEL) to flash a code number. It will, forexample, flash twice...pause...flashfive times....pause. In other words, acode 25.

Code 25 indicates all systems areworking satisfactorily.

The codes will continue to flash andrepeat as long as the DiagnosticRequest switch is held in the "On"position with the ignition on. Otherdiagnostic codes are shown in thechart (page 21).

22

NOTICE:

The diagnostic switch on the BBIMmust NOT be switched on whenoperating the vessel. If this is done,the diagnostic mode line will begrounded, and fuel injection timingwill be altered, affecting engineoperation.

CAUTION:

The operator of a DDEC-equipped vessel must notattempt to use or read a diagnos-tic data reader of any kind whilethe vessel is operating. Doing socan result in loss of control,which may cause vessel damageand may result in personal injury.

When engine or electronicssystem diagnosis is required ona DDEC-equipped vessel, thismust be done by a person otherthan the operator. The operatormust maintain control of themoving vessel while the assistantperforms the diagnosis.

NOTICE:

To prevent damage to the DDECelectronic control system, discon-nect the following before welding:battery power and ground cablesand the 6-pin power connector at theECM (electronic control module).Failure to isolate the DDEC sys-tem from high current flow canresult in severe ECM damage.

CAUTION:

The operator of a DDEC-equippedengine should know the extent ofthe warning system on his vessel,in order to bring it to a safe stop inthe event of an engine malfunc-tion. A description of the warningsystem and detailed instructionsregarding its operation should beobtained from the owner, the selleror the manufacturer of the vessel.This information may also beobtained at any authorized DetroitDiesel service outlet.

23

AIR COMPRESSOR BLOWER

OIL COOLER

OIL FILTERFLYWHEEL HOUSING

FLYWHEEL

25

TURBOCHARGER

BREATHER

OIL PAN

FAN

DIPSTICK

ROCKER COVER

STARTER MOTOR

OILFILLER

EXHAUSTMANIFOLD

THERMOSTATHOUSING

ELECTRONICCONTROL

MODULE (ECM)

CRANKSHAFTPULLEY

TYPICAL SERIES 92 ENGINE(6V-92 TURBOCHARGED-AFTERCOOLED ENGINE SHOWN)

ENGINE SYSTEMSFuel SystemThe fuel system consists of the fuelinjectors, fuel pipes, fuel manifolds(integral with the cylinder head), fuelpump, fuel strainer, fuel filter, and thenecessary connecting fuel lines. Thefuel system on DDEC engines alsoincludes electronic fuel system con-trols and a cooling plate for the elec-tronic control module (ECM).

The primary filter (marked "P") orcombination filter and fuel/water sep-arator removes large impurities fromthe fuel. The secondary filter (markedS) removes the smaller particles.

Lubrication SystemThe lubricating oil system consists ofan oil pump, oil cooler, full flow oil fil-ter(s), bypass valves at the oil coolerand filter(s), and pressure relief andregulator valves at the lube oil pump.

Air SystemIn the air system used on Series 92engines, outside air drawn into theengine passes through the air filter,air silencer, or air separator and ispulled into the turbocharger, where itis compressed. It then movesthrough the blower, where it is furthercompressed. An intercooler beforethe blower, an aftercooler beneaththe blower or a charge air cooler infront of the radiator (vehicle engines)may be used to further increase thedensity of the charge. The air thenflows into the cylinders, where itmixes with atomized fuel from theinjectors.

Dry type air cleaners are used onthe majority of Detroit Diesel engines.For optimum protection of the enginefrom dust and other airborne contam-inants, service these air cleanerswhen the maximum allowable airrestriction has been reached, orannually, whichever occurs first.

Cooling SystemRadiator/fan cooling systems areused on engines in on-highway, off-highway, industrial, and generatorset applications. Heat exchanger/rawwater pump systems and keel cool-ing systems are used on marineengines. Certain generator set appli-cations may also use heat exchang-ers. Each system has a centrifugaltype fresh water pump to circulatecoolant within the engine. Each sys-tem also incorporates thermostats tomaintain normal engine operatingtemperature.

Electrical SystemThe electrical system generally con-sists of a starting motor, startingswitch, battery-charging alternator,storage batteries, and the necessarywiring.

Exhaust SystemHot exhaust gas flowing from theexhaust manifold into the exhaust riseris used to drive the turbocharger.

24

HOURS 150 300 500 1,000 4,000Fuel Tank (2)Fuel Lines and Flexible Hoses* (3) I ICooling System (4) I IDrive Belts* (8) IAir Cleaner* (7) IAir Separators* (7) RFuel Filters* (10) RWater Pump, Seal* (11)Tachometer Drive (22) IAir System (7)Turbocharger, Exhaust Connections (5)*Engine (Steam Clean) (34)*Oil Pressure (13)* IBattery Charging Alternator* (14) IEngine & Transmission Mounts (15)* IClosed Crankcase Collectors* (16) IThermostats & Seals* (31) RCrankcase Breather* (16) ICrankcase Pressure* (16) IBlower Screen (32)Blower Bypass Valve (21)Coolant Filter/Conditioner* (11)Fuel Lines and Flexible Hoses* (3)Air Box Drain Tube* (25) IAir Shutdown Valve* (12) IGovernor, Overspeed Governor (28) IRaw Water System Zincs (18)Throttle Delay/Fuel Modulator* (29)Air Box Check Valves (25)* IMarine Gear* (20) IMarine Gear Oil Cooler* (20) RFuel and Boost Coolers* (35) RHeat Exchanger* (36) RFuel Injectors* (37) REngine Tune-Up* (17) AS REQUIRED

Codes*See Item in Text I Inspect, Service, Correct, R Replace

Replace (If Necessary)

27

MARINE ENGINE MAINTENANCE

NOTE: Numbers after each item refer to the lubrication and preventive maintenance intervals sectionwhich follows.

26

MARINE ENGINE MAINTENANCE

DAILYLubricating Oil (1) I

Fuel Tank (2) I

Fuel Lines and Flexible Hoses (3) I

Cooling System (4) I

Turbocharger, Exhaust Conns. (5) I

Air System, Cleaners* (7) I

Fuel/Water Separator and Filter* (10) I

Oil Pressure* (13) I

Marine Gear* (20) I

Raw Water Pump* (19) I

150 HOURLubricating Oil* (1) R

Lubricating Oil Filter* (9) R

Drive Belts (Marine) (8) I

Cooling System* (4) I

Fuel/Water Separator and Filter (10) R

200 HOURCoolant Filter/Inhibitor Level* (11) I



SERVICERECOMMENDATIONS

MARINE ENGINES(Continued Next Page)


MONTHS 6 12 18 24 30 36 42 48 54 60 120 MILES 1000 x 10 20 30 40 50 60 70 80 90 100 200 240Fuel Filters (10) R R R R R R R R R R

Water Pump* (11) I I I I I I I I I I I

Fuel Tank* (2) I I I I I

Cooling System* (4) I I I I I

Air Compressor* (23) I I I I I

Air System, Cleaners (7)* I I I I I

Turbochargers, Exhaust Conns.* (5) I I I I I

Engine (Steam Clean)* (34) I I I I I

Radiator* (26) I I I I I

Oil Pressure* (13) I I I I I

Battery Charging Alternator* (14) I I I I I

Thermostats and Seals* (31) I I I I I R

Engine and Transmission Mounts* (15) I

Crankcase Pressure* (16) I

Crankcase Breather* (16) I I I I I

Blower Bypass Valve* (21) I

Coolant Filter/Inhibitor Level* (11)

Fuel Lines, Flex Hoses* (3) I I I I R

Air Box Drain Tube* (25) I I I

Air Shutdown Valve* (12) I I I I I

Shutter Operation* (27) I I I I I

Throttle Delay/Fuel Modulator* (29) I I

Air Box Check Valves* (25) I

Fan Hub* (30) I I I I I

Blower Screen* (32) I

Engine Tune-Up* (17) AS REQUIRED



VEHICLE ENGINE MAINTENANCE

29

NOTE: Numbers after each item refer to the lubrication and preventive maintenance intervals section whichfollows.

VEHICLE ENGINE MAINTENANCEDAILYLubricating Oil (1) I

Fuel Tank (2) I




3000 MILE INTERVALBattery* (6) I

6000 MILE INTERVALDrive Belts* (8) I

Air Compressor (23) I

Throttle Controls (24) I

15,000 MILE INTERVALFuel Tank (2) I

Overspeed Governor (28) I

Dry Type Air Cleaner (7) I

Lubricating Oil* (1) R


Coolant Filter/Inhibitor Level* (11) I




VEHICLE ENGINES(Continued Next Page)


28

STATIONARY AND INDUSTRIALENGINE MAINTENANCE

31

MONTHS 6 9 12 18 36 60 120HOURS 300 500 700 1,000 2,000 3,000 6,000Fuel Tank* (2) I I

Fuel Lines and Flexible Hoses* (3) I R

Cooling System* (4) I

Drive Belts* (8)

Air Compressor* (23) I

Air Cleaner* (7) I R

Fuel Filters* (10)

Water Pump, Seal* (11) R

Tachometer Drive* (22) I

Air System* (7) I

Turbocharger, Exhaust Connections* (5) I

Engine (Steam Clean)* (34) I

Radiator* (26) I

Oil Pressure* (13) I

Battery Charging Alternator* (14) I

Engine & Transmission Mounts* (15) I

Thermostats & Seals* (31) I

Crankcase Breather* (16) I

Crankcase Pressure* (16) I

Blower Screen* (32) I

Blower Bypass Valve* (21) I

Coolant Filter/Inhibitor Level* (11)

Fuel Lines and Flexible Hoses* (3) R

Air Box Drain Tube* (25) I

Air Shutdown Valve* (12) I I

Governor, Overspeed Governor* (28) I

Shutter Operation* (27) I

Raw Water System Zincs* (18)

Throttle Delay/Fuel Modulator* (29)

Air Box Check Valves* (25) I

Fan Hub* (30) I

Fuel and Boost Coolers* (35)

Heat Exchanger* (36)

Fuel Injectors* (37)

Engine Tune-Up* (17) AS REQUIRED


Replace (If Necessary)NOTE: Numbers after each item refer to the lubrication and preventive maintenance intervals section

which follows.

STATIONARY AND INDUSTRIALENGINE MAINTENANCE

DAILYLubricating Oil (1) I

Fuel Tank (2) I




Air Cleaner (Oil Bath) (7) I

100 HOUR OR 3,000 MILESBattery* (6) I

150 HOUR OR 4,500 MILESLubricating Oil* (1) R


150 HOUR OR 5,000 MILESAir Compressor* (23) I

200 HOUR OR 6,000 MILESCoolant Filter/Inhibitor Level* (11) I

Drive Belts* (8) I

Throttle Controls* (24) I

600 HOURS OR 18,000 MILESWater Pump (11)* I



30


STATIONARY AND INDUSTRIAL ENGINES(Continued Next Page)


Refill the tank at the end of eachdays operation to prevent condensa-tion from contaminating the fuel.Condensation formed in a partiallyfilled tank promotes the growth ofmicroorganisms that can clog fuel fil-ters and restrict fuel flow. To preventmicrobe growth add a biocide to thefuel tank or primary fuel supply. Followmanufacturers usage, handling, andsafety recommendations.

Water accumulation can be con-trolled by mixing isopropyl alcohol (drygas) into the fuel oil at a ratio of onepint (0.5 liter) per 125 gallons (473liters) fuel (or 0.10% by volume).

Detroit Diesel does not recom-mend adding alcohol to fuel used inmarine engines.

Open the drain at the bottom of thefuel tank every 30,000 miles or 48,000km (300 hours for industrial applica-tions) to drain off any water and/orsediment.

Every 12 months or 120,000 miles(192,000 km) (600 hours for industrialapplications) tighten all fuel tankmountings and brackets. At the sametime, check the seal in the fuel tankcap, the breather hole in the cap andthe condition of the flexible fuel lines.Repair or replace the parts, as neces-sary.

Item 3 Fuel Lines, FlexibleHoses

Pre-Start InspectionMake a visualcheck for fuel leaks at all engine-mounted fuel lines and connections,and at the fuel tank suction and returnlines. Since fuel tanks are susceptibleto road hazards, leaks in this area maybest be detected by checking foraccumulation of fuel under the tanks.Check hoses daily as part of the pre-start inspection. Examine hoses forleaks, and check all fittings, clamps,and ties carefully. Make sure thathoses are not resting on or touchingshafts, couplings, heated surfacesincluding exhaust manifolds, anysharp edges, or other obviously haz-ardous areas. Since all machineryvibrates and moves to a certain extent,clamps and ties can fatigue with age.To ensure continued proper support,inspect fasteners frequently and tight-en or replace them as necessary.

If fittings have loosened or crackedor if hoses have ruptured or wornthrough, take corrective action imme-diately. Leaks are not only potentiallydetrimental to machine operation, butthey can also result in added expensecaused by the need to replace lostfluids.

Service lifeA hose has a finite ser-vice life. With this in mind, all hosesshould be thoroughly inspected atleast every 500 operating hours (1,000hours for fire-resistant fuel and lubri-cating oil hoses) and/or annually. Look

33

NOTICE:

A galvanized steel tank should neverbe used for fuel storage, becausethe fuel oil reacts chemically with thezinc coating to form powdery flakeswhich can quickly clog the fuel filtersand damage the fuel pump andinjectors.

CAUTION:

Personal injury and/or propertydamage may result from fire dueto the leakage of flammable fluidssuch as fuel or lube oil.

LUBRICATION ANDPREVENTIVE MAINTE-NANCE INTERVALSThe following is intended as a guidefor establishing preventive mainte-nance intervals. The recommenda-tions given should be followed asclosely as possible to obtain long lifeand optimum performance fromSeries 92 engines. Intervals indicatedon the chart are t ime (hours ormileage) of actual operation.

The intervals shown apply only tothe maintenance functions de-scribed. These functions should becoordinated with other regularlyscheduled maintenance.

The daily instructions apply toroutine or daily starting of an engine.They do not apply to a new engine orone that has not been operated for aconsiderable period of time. For newor stored engines, refer to the engineservice manual (6SE379). Followinstructions given under Prepar-ations for Starting the Engine theFirst Time (section 13.1).

Preventive maintenance other thanthe daily checks should be per-formed by authorized Detroit Dieselservice outlets. These outlets havethe trained personnel and specialtools to properly perform all services.

Item 1 - Lubricating Oil

Check the oil level daily with theengine stopped. On coach enginesequipped with running level dip-sticks, this may be done with theengine at idle and at operating tem-perature. If necessary, add sufficientoil to raise the level to the propermark on the dipstick. All dieselengines are designed to use some

oil, so the periodic addition of oil isnormal.

For lubricating oil change intervals,refer to When to Change Oil in theHow To section of this guide. Beforeadding lube oil, refer to How toSelect Lubricating Oil in the How Tosection.

Item 2 Fuel and Fuel Tank

Keep the fuel tank filled to reduce con-densation. Before adding fuel, refer toHow to Select Fuel Oil in the How Tosection of this guide.

L

F

Check Oil Level Daily

32

Keep Tank Filled to Reduce Condensation

NOTICE:

If the oil level is constantly abovenormal and excess lube oil has notbeen added to the crankcase, con-sult with an authorized Detroit Dieselservice outlet for the cause. Fuel orcoolant dilution of lube oil can resultin serious engine damage.

or 200,000 miles (320,000 km),whichever comes first. At this interval,the coolant must be drained and thecooling system cleaned thoroughly.The cooling system should then bereplenished with Power Cool or anequivalent quality ethylene glycol baseantifreeze/ water solution in therequired concentration. If Power Coolor equivalent fully formulated pre-charged inhibited ethylene glycol(IEG) antifreeze is not used, requiredDetroit Diesel Maintenance Productcooling system inhibitors must beadded at initial fill. Inhibitor levels mustbe checked at regular intervals and anew maintenance element installed, ifrequired. Refer to Inhibitor TestProcedures under How to SelectCoolant and use the required coolantfilter/conditioner elements shown onthe Specifications chart (pages 73-74).

Cooling System HosesAll coolingsystem hoses should be inspected atleast every 500 hours for signs of dete-rioration and replaced, if necessary.

Raw Water Cooling System- Drain atthe end of each boating season.

Sea Strainers- Inspect sea strainersdaily. Clean sea strainers at least annu-ally. Clean more often if surface sea-weed growth or water contaminationlevels are fairly high.

Item 5 - Turbocharger, ExhaustConnections

Visually inspect the mountings, intakeand exhaust ducting and connectionsfor leaks daily. Check the oil inlet andoutlet lines for leaks or restrictions to oilflow. Check for unusual noise or vibra-tion and, if excessive, stop the engineand do not operate until the cause isdetermined.

Every 12 months, 700 hours or20,000 miles (32,000 km), the exhaust

manifold retaining nuts, exhaust flangeclamp and other connections should bechecked for tightness. Check for properoperation of the exhaust pipe rain cap, ifone is used.

Check heat-insulating exhaust sys-tem blankets for damage daily. Torn,matted, crushed, oil-soaked, or other-wise damaged insulation blankets mustbe replaced immediately.

Item 6 - Battery

Check "Eye" of Maintenance-Free Batteries35

Eye

CAUTION:

To avoid personal injury or tur-bocharger damage, do not remove,attach, or tighten turbocharger airintake ducting while the engine isoperating or operate the enginewith the ducting removed.

CAUTION:

To avoid possible personal injuryand/or engine damage from acci-dental engine startup, always dis-connect the battery beforeservicing the electrical system. Toavoid alternator damage whenremoving battery connections,disconnect the negative () termi-nal first. Reconnect the negativeterminal last.

for cover damage and/or indications oftwisted, worn, crimped, brittle,cracked, or leaking lines. Hoses withtheir outer cover worn through or dam-aged metal reinforcement should beconsidered unfit for further service.

All hoses in and out of machineryshould be replaced during majoroverhaul and/or after a maximum offive years of service.

EXCEPTION: Replace all coolingsystem hoses on pleasure craftmarine engines after 1,000 hours ofservice, regardless of apparent con-dition. Cooling system hoses oncommercial marine engines do notrequire automatic replacement after1,000 hours, but should be replacedat overhaul.

Fire resistant fuel and lube oil hoseassemblies do not require automaticreplacement after five years service orat major overhaul, but should beinspected carefully before being putback into service.

Item 4 - Cooling System

Check the coolant level daily andmaintain it near the bottom of the fillerneck on the radiator or heat exchang-er. On some installations this is doneby checking an overflow bottle or sightglass. Add coolant as necessary, butdo not overfill. Before adding coolant,refer to How to Select Coolant in theHow To section of this guide.

Make a daily visual check for cool-ing system leaks. Look for an accumu-lation of coolant when the engine isrunning and when it is stopped. Cool-ant leaks may be more apparent on anengine when it is cold.

The inhibitors in antifreeze solutionsshould be replenished with a non-chromate corrosion inhibitor supple-ment when indicated by testing thecoolant. Refer to How to SelectCoolant for required test intervals andinhibitor levels.

Coolant Drain IntervalDetroitDiesel recommends replacing cool-ant with genuine Detroit DieselPower Cool antifreeze or equivalentquality ethylene glycol-base perma-nent type antifreeze annually.However, a cooling system properlymaintained and protected with supple-mental corrosion inhibitors can beoperated up to two years, 4000 hours,

Remove Radiator or Heat ExchangerPressure Control Cap with Caution

34

CAUTION:

Do not remove the pressure con-trol cap from the radiator or heatexchanger or attempt to drain thecoolant until the engine hascooled. Once the engine hascooled, use extreme caution whenremoving the cap. The suddenrelease of pressure from a heatedcooling system can result in a lossof coolant and possible personalinjury (scalding, eye injury, etc.)from the hot liquid.

Under no engine operating condi-tions should the air inlet restrictionexceed 20 inches of water (5.0 kPa). Aclogged air cleaner element will causeexcessive intake restriction and areduced air supply to the engine. This,in turn, can result in increased fuel con-sumption, inefficient engine operationand reduced engine life.

Inspect the entire air system for leaksdaily. Look especially for torn air inletpiping or boots and loose or damagedclamps. Have worn or damaged partsrepaired or replaced, as required.Retighten any loose connections.

Air Silencers. Inspect mountingbands and clamps for t ightnessdaily. Clean or replace polyurethanefoam elements (socks ) annually.

Air Separators (Closed CrankcaseVapor Collectors). Clean and reoil thevacuum limiter and filter element every250 hours of engine operation. Filterelements and vacuum limiters mustalso be cleaned and reoiled when theair inlet restriction indicator turns red.This indicates the maximum allowablesystem restriction has been reached.

Replace filter elements after oneyear or 500 hours of engine operation,whichever comes first. Replace

vacuum limiters every 1000 hours ofengine operation or every two years,whichever comes first.

Cleaning. If cleaned, filters must becleaned and reoiled with fluids spe-cially designed for this purpose.Authorized Detroit Diesel service out-lets are properly equipped to performthese services.

Item 8 Drive Belts

New standard V-belts will stretch afterthe first few hours of operation. Run theengine for 10 to 15 minutes at 1200 rpmto seat the belts, then readjust the ten-sion. Check the belts and tighten thefan drive, battery-charging alternatorand other accessory drive belts after1/2 hour or 15 miles and again after 8hours or 250 miles (402 km) of opera-tion. Thereafter, check the tension of thedrive belts every 200 hours (150 hourson marine units) or 6,000 miles (9,600km) and adjust, if necessary.

Belts should be neither too tight nortoo loose. Belts that are too tightimpose excess loads on thecrankshaft, fan and/or alternator bear-ings, shortening both belt and bearinglife. Excessively overtightened beltscan result in crankshaft breakage. Aloose belt will slip and may causedamage to accessory components.

37

Typical Air Silencer Installation

Typical Air Separator Installation

Check the hydrometer eye of mainte-nance-free batteries for charge. If lead-acid or low maintenance batteries areused, check the specific gravity ofeach cell every 150 hours. Check morefrequently in warm weather due to themore rapid loss of water through evap-oration. Maintain the electrolyte levelaccording to the battery manufacturersrecommendations, but do not overfill.Overfilling can cause poor perfor-mance or early failure.

Keep the terminal side of the batteryclean. When necessary, wash with asolution of baking soda and water.Rinse with fresh water. Do not allow thesoda solution to enter the cells.

Inspect the cables, clamps, andhold-down brackets regularly. Cleanand reapply a light coating ofpetroleum jelly when needed. Havecorroded or damaged parts replaced.

If the engine is to be out of servicefor more than 30 days, remove the bat-teries and store in a cool, dry place.Keep batteries fully charged, if possi-ble. Replace any battery that fails tohold a charge.

Periodically check battery connec-tions for corrosion and tightness. If nec-essary, remove connections and wirebrush any corrosion from terminals andcable ends. Replace damaged wiring.

Item 7 - Air Cleaners

A clogged air cleaner element willcause excessive intake restriction anda reduced air supply to the engine.This, in turn, can result in increasedfuel consumption, inefficient engineoperation and reduced engine life.

Do not allow air inlet restriction toexceed 20 inches of water (5.0 kPa)under any operating conditions.

Oil Bath Type. Air cleaner cups andcenter tubes should be removed,cleaned, and refilled with clean engine

oil every 8 hours (or less, if operatingconditions warrant). The frequency ofservicing may be adjusted to suit localdust conditions. If heavy rain or snow isencountered, check the air cleaner foran accumulation of water.

The air cleaner element and baffleshould be removed and cleaned annu-ally. The body and fixed element in theheavy duty oil bath air cleaner shouldbe serviced every 500 hours or as con-ditions warrant.

Dry Type. The air cleaner elementshould be inspected every 15,000miles (24,000 km) for vehicle engines,150 hours for non-vehicle engines, ormore often if the engine is operatedunder severe dust conditions. Replacethe element if necessary. Check thegaskets for deterioration and replace, ifnecessary. If the dry type air cleaner isequipped with an aspirator, check foraspirator damage or clogging. Cleanand repair as necessary.

Dry-type air cleaner elementsshould be replaced when the maxi-mum allowable air inlet restriction(20 inches of water or 5.0 kPa) hasbeen reached or annually, whichevercomes first. Refer to When to Servicethe Dry Type Air Cleaner (page 60).

36

Oil Bath Air Cleaner (Light Duty)

Item 11 - Water Pump andCoolant Filter/Conditioner

Water Pump. The water pump drainhole should be inspected for plug-ging every 600 hours and cleanedout, if necessary. Authorized DetroitDiesel service outlets are properlyequipped to perform this service. Thewater pump seal should be replacedat engine overhaul or earlier, if leak-ing is found.

Coolant Filter. If the cooling systemis protected by a coolant filter/condi-tioner, the coolant must be tested atrequired intervals and the elementreplaced, if required. Refer to Cool-ant Test Intervals and Inhibitor TestProcedures under How to SelectCoolant for required test intervalsand inhibitor levels. Use the coolantfilter/conditioner element part numbershown on the Specifications chart(page 74).

Item 12 - Air Shutdown Valve

Air shutdown assemblies, whetherelectrical or manual (pull cable-actuat-ed), must be tested for proper opera-tion (with the engine at idle) at leastonce a year or after 700 hours ofengine operation (500 hours on marineunits), whichever comes first. The airshutdown valve should be reset in theopen position after the check hasbeen made.

39Typical Air Shutdown Cam, Latch, and Solenoid

Typical Coolant Filter/Conditioner Element

NOTICE:

If not adjusted properly, the valvemay not close completely whenactivated, thus defeating its intend-ed purpose to cut off air flow to theengine and shut it down duringabnormal operating conditions.

NOTICE:

Do not use the air shutdown for nor-mal or routine engine stopping.Failure to observe this precautioncan result in serious engine damage.

NOTICE:

If the emergency air shutdown isused to stop the engine in an emer-gency situation, always have theshutdown checked for damage andfor proper operation before theengine is returned to service. This isespecially important if shutdown ismade at high engine rpm. To ensurepositive valve closure should anotheremergency shutdown be required,the shutdown must be checked andrequired repairs or adjustmentsmade at this time. Failure toobserve this precaution may per-mit engine run-on when the emer-gency shutdown is activated.

Drive belts (V and Poly-V) shouldbe replaced every 2,000 hours or100,000 miles (160,000 km).

EXCEPTION: Replace belts onpleasure craft marine engines every1,000 hours of operation, regardlessof condition.

Replace ALL belts in a set whenone is worn. Single belts of similarsize should not be used as a substi-tute for a matched belt set. Prematurebelt wear can result because of beltlength variation. All belts in a matchedbelt set are within .032 of their speci-fied center distances.

Use a Belt Tension Gage, such asKent-Moore tool J 23600-B, (V Belt) or J 23586 (Poly-V Belt) or equivalent, andadjust the belt tension as outlined below.

FAN DRIVEENGINE ONE BELT 2 OR 3 BELTS6V, 8V-92 80-100 lbs 60-80 lbs12V-92 70-90 lbs16V-92 90-120 lbs16V-92 10 Rib Poly-V 310-360 lbs

ALTERNATOR DRIVETwo 3/8" or One 1/2" 8 Rib1/2" Belts Belt Poly-V Belt40-50 lbs 50-70 lbs 110-130 lbs

AIR COMPRESSORBelt tension is 60 lbs ( 10 lbs) for a single premium

high capacity belt (.785" wide) used to drive a 12CFM air compressor.

If a belt tension gage is not available,adjust the belt tension so that a firmpush with the thumb, at a point midwaybetween the two pulleys, will depressthe belt .500"-.750" (12.70-19.05 mm).

When installing or adjusting anaccessory drive belt, be sure thebolt at the accessory adjusting pivotpoint is properly tightened, as wellas the bolt in the adjusting slot.

Item 9 - Lubricating Oil Filter

Lubricating oil f i l ters should bechanged whenever the engine oil ischanged. For oil change intervals,refer to When to Change Oil in theHow To section of this guide. Beforechanging filters, refer to How toReplace the Lube Oil Filter in theHow To section of this guide. Referto the Specifications section of thisguide for required filter part number.

Item 10 - Fuel/WaterSeparator, Filters

Drain water from fuel/water separatordaily or as required. Primary andsecondary fuel f i l ters should bereplaced every 10,000 miles (16,000km) or 6 months, whichever comesfirst (or sooner if plugging is indicat-ed). Refer to the Specifications sec-tion of this guide for required partnumbers. Before changing filters,refer to How to Replace the FuelFilter and Strainer in the How Tosection of this guide.

38

Typical Lubricating Oil Filter Installation

Typical Secondary Fuel Filter Installation

first. Replace vacuum limiters every1000 hours of engine operation orevery two years, whichever comes first.If cleaned, filters must be cleaned andreoiled with fluids especially designedfor this purpose. Authorized DetroitDiesel service outlets are properlyequipped to perform these services.

Crankcase pressure should bechecked and recorded every 2,000hours or 60,000 miles (96,000 km). Ifan additional crankcase breather col-lection device is used, crankcasepressure should be recorded with theunit attached and removed.

NOTE: Crankcase pressure of up to6" H2O is normal for marine enginesequipped with closed crankcasecollectors.

Item 17 - Engine Tune-up

There is no scheduled interval for per-forming an engine tune-up. As long asthe engine performance is satisfactory,no tune-up should be needed. Minoradjustments in the valve and injectoroperating mechanisms, governor, etc.may be required periodically to com-pensate for normal wear on parts.

Item 18 - Raw Water SystemZincs

Heat exchanger zincs should bechecked initially every 60 hours, thenas required or annually. Clean with awire brush if serviceable. Replace ifbadly deteriorated. Electrodes are gen-erally found in the heat exchangerassembly, the raw water pump elbows,the fuel and/or boost cooler, and theengine/marine gear auxiliary coolers.

Item 19 - Raw Water Pump

A raw water pump seal malfunction isindicated by leakage of water from theopenings in the pump housing. Theseopenings, located between the pumpmounting flange and the inlet and outletports, must remain open at all times.Leaky seals require replacement. Wornor brittle flexible impellers should bereplaced. The raw water pump body orliner should also be checked for cracksor wear and replaced, if necessary.Authorized Detroit Diesel service outletsare properly equipped to perform theseservices.

Item 20 - Marine Gear

Check marine gear oil level daily.Replace DDC (Twin Disc) marine gearoil, filter, and screen at intervals shownon the chart (page 42). Replacemarine gear oil coolers every 4 yearsor 4,000 hours, whichever comesfirst.

Item 21 - Blower Bypass Valve

The blower bypass valve should beremoved, cleaned in solvent (if nec-essary), and inspected every100,000 miles (160,000 km) or 3,000hours. The valve should be checkedfor free operation and for scoring onthe piston, piston guide, or sleeve

41

Crankcase Breather Assembly

Item 13 - Oil Pressure

Under normal operation, oil pressure isnoted each time the engine is started.If the engine is equipped with a warn-ing light instead of a pressure gauge,have the oil pressure checked andrecorded every 700 hours or 20,000miles (32,000 km). On marine enginescheck every 500 hours.

Item 14 - Battery ChargingAlternator

Terminals should be checked for cor-rosion and loose connections andwiring inspected for damaged orfrayed insulation. Have wiringrepaired or replaced, as required.

Precautions must be taken whenworking on or around the alternator.The diodes and transistors in thealternator circuit are very sensitiveand can be easily destroyed.

1. Avoid grounding the output terminal.Grounding an alternators outputwire or terminal (which is alwayshot, regardless of whether or not theengine is running) and accidentallyreversing the battery polarity willresult in equipment damage.

2. Do not reverse battery connections.This can also cause damage.

3. Never disconnect the battery whilethe alternator is operating. Dis-connecting the battery can result indamage to the alternator diodes. Inmarine applications which have twosets of batteries, switching from oneset to the oth

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