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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
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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.
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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)
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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.
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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.
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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
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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.
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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.
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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
CEL CEL1 Flash 3 Flashes 2 Flashes 1 Flash
Short ShortPause Long Pause Pause
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.
CEL CEL1 Flash 3 Flashes 2 Flashes 1 Flash
Short ShortPause Long Pause Pause
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
Codes*See Item in Text I Inspect, Service, Correct, R
Replace
Replace (If Necessary)
SERVICERECOMMENDATIONS
MARINE ENGINES(Continued Next Page)
NOTE: Numbers after each item refer to the lubrication and
preventive maintenance intervals sectionwhich follows.
-
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
Codes*See Item in Text I Inspect, Service, Correct, R
Replace
Replace (If Necessary)
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
Fuel Lines and Flexible Hoses (3) I
Cooling System (4) I
Turbocharger, Exhaust Conns. (5) 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
Lubricating Oil Filter* (9) R
Coolant Filter/Inhibitor Level* (11) I
Codes*See Item in Text I Inspect, Service, Correct, R
Replace
Replace (If Necessary)
SERVICERECOMMENDATIONS
VEHICLE ENGINES(Continued Next Page)
NOTE: Numbers after each item refer to the lubrication and
preventive maintenance intervals sectionwhich follows.
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
Codes*See Item in Text I Inspect, Service, Correct, R
Replace
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
Fuel Lines and Flexible Hoses (3) I
Cooling System (4) I
Turbocharger, Exhaust Conns. (5) I
Air Cleaner (Oil Bath) (7) I
100 HOUR OR 3,000 MILESBattery* (6) I
150 HOUR OR 4,500 MILESLubricating Oil* (1) R
Lubricating Oil Filter* (9) 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
Codes*See Item in Text I Inspect, Service, Correct, R
Replace
Replace (If Necessary)
30
SERVICERECOMMENDATIONS
STATIONARY AND INDUSTRIAL ENGINES(Continued Next Page)
NOTE: Numbers after each item refer to the lubrication and
preventive maintenance intervals sectionwhich follows.
-
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