Detroit Diesel 92 Series, Operator'S Manual

Page 1: ...091 TWX 810 221 1649 FAX 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 ...

Page 2: ...e changes at any time without obliga tion Table of Contents Subject Page Engine Model and Serial Number Designation 1 DDEC II DDEC III Engine Identification 1 Option and Certification Labels 1 OPERATING INSTRUCTIONS 3 Preparations for Starting the Engine the First Time 3 Starting the Engine 6 Running the Engine 8 Stopping the Engine 10 Emergency Jump Starting 11 DDEC OPTIONS 12 Vehicle Industrial ...

Page 3: ...These labels contain the engine serial number and model number and in addition list any optional equipment used on the engine Labels also include required tune up information injection timing valve lash max no load RPM etc With any order for parts the engine model and serial number must be given If a type number is shown on the option label covering the equip ment required this number should also ...

Page 4: ...raw water pump by removing the pipe plug or zinc provided in the pump outlet elbow and pour ing at least a pint of water into the pump 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 PUMP 0458 WAT BYPASS 0426 THERMOSTAT 0462 EXH MANIFOLD 0177 FUEL PUMP 0324 INJECTOR 0691 BLOWER 1303 TURBOCHARGER 0...

Page 5: ...ssary if the filter elements are filled with fuel when installed and the fuel manifolds in the cylinder heads are not drained of fuel If the engine is equipped with a fuel water separator drain off any water that has accumulated Water in fuel can seriously affect engine perfor mance and may cause engine dam age Detroit Diesel recommends installation of a fuel water separator wherever water contami...

Page 6: ... the DDEC computer diagnosing the system to ensure everything is functional including the light bulbs for the Check Engine and Stop Engine warning lights If everything is okay both lights will go out in approximately five seconds 2 With foot OFF the foot pedal start the engine after the lights go out Start the engine by pressing the starter switch firmly If the engine fails to start within 15 seco...

Page 7: ...olant level is at the bottom of the filler neck Add coolant as required replace the pressure cap and fill the recovery bottle to the Full Cold level or no more than one quarter of its volume Crankcase If the engine oil was replaced stop the engine after normal operating temperature has been reached Allow the oil to drain back into the crankcase for approximately twenty 20 minutes and check the oil...

Page 8: ...tery 5 Do not allow vehicle bodies or bumpers to touch 6 Connect one end of the first jumper cable to the positive terminal of the dead battery Connect the other end to the positive terminal of the booster battery 7 Connect one end of the second jumper cable to the negative ter minal of the booster battery Connect the other end to an engine bolt head or good metallic contact ground on the disabled...

Page 9: ...anel lights to automatic reduction in engine power followed by automatic engine shutdown The power down shutdown option may be activated by low coolant level low oil pressure or high engine oil or coolant temperature To start a DDEC engine be sure the transmission is in neutral or park and turn the ignition key on You will notice that both the Check Engine and Stop Engine lights will come on This ...

Page 10: ... 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 electronic control system will detect a malfunction When this occurs the Check Engine light CEL will come on At this point the Electronic Control Module will go into Back Up Control You should then notice a change in engine operat...

Page 11: ...ag nostic mode line will be grounded and the throttle will be forced to idle affecting vehicle operation The throttle will also go to idle if pins A and M in the Diagnostic Data Reader DDR connector are jumpered together This condition will not occur when the Diagnostic Data Reader is used Welding Precaution 16 17 NOTICE To prevent damage to the DDEC electronic control system discon nect battery p...

Page 12: ...ort to battery 25 No codes 63 PWM open or short to battery 26 Aux shutdown 1 or 2 active 64 Turbo speed circuit failed 27 Air temp circuit high 67 Coolant pressure circuit high or low 28 Air temp circuit low 68 IVS switch fault open or grounded circuit 31 Aux output short or open circuit high side 71 Injector response time short 32 SEL short or open circuit 72 Vehicle overspeed 33 Boost pressure c...

Page 13: ...nt level or high coolant temperature the Stop Engine and Check Engine lights are turned on The electronic displays at the bridge present the diagnostic code numbers and a brief word description of the fault on the display screen 20 Diagnostic Codes DDEC II Marine Engines Diagnostic Connector Error Error Code Description Code Description 11 Hand Throttle Speed Adj Lo Volt 42 Synchronous Ref Sensor ...

Page 14: ...king satisfactorily The codes will continue to flash and repeat as long as the Diagnostic Request switch is held in the On position with the ignition on Other diagnostic codes are shown in the chart page 21 22 NOTICE The diagnostic switch on the BBIM must NOT be switched on when operating the vessel If this is done the diagnostic mode line will be grounded and fuel injection timing will be altered...

Page 15: ...rbocharger where it is compressed It then moves through the blower where it is further compressed An intercooler before the blower an aftercooler beneath the blower or a charge air cooler in front of the radiator vehicle engines may be used to further increase the density of the charge The air then flows into the cylinders where it mixes with atomized fuel from the injectors Dry type air cleaners ...

Page 16: ...rs 35 R Heat Exchanger 36 R Fuel Injectors 37 R Engine 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 section which follows 26 MARINE ENGINE MAINTENANCE DAILY Lubricating Oil 1 I Fuel Tank 2 I Fuel Lines and Flexible Hoses 3...

Page 17: ...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 which follows VEHICLE ENGINE MAINTENANCE DAILY Lubricating Oil 1 I Fuel Tank 2 I Fuel Lines and Flexibl...

Page 18: ...ub 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 INDUSTRIAL ENGINE MAINTENANCE DAILY Lubricating Oil 1 I Fuel Tank 2 I Fuel Lines and Flexibl...

Page 19: ... fire resistant fuel and lubri cating oil hoses and or annually Look 33 NOTICE A galvanized steel tank should never be used for fuel storage because the fuel oil reacts chemically with the zinc coating to form powdery flakes which can quickly clog the fuel filters and damage the fuel pump and injectors CAUTION Personal injury and or property damage may result from fire due to the leakage of flamma...

Page 20: ...d alternator damage when removing battery connections disconnect the negative termi nal first Reconnect the negative terminal last for cover damage and or indications of twisted worn crimped brittle cracked or leaking lines Hoses with their outer cover worn through or dam aged metal reinforcement should be considered unfit for further service All hoses in and out of machinery should be replaced du...

Page 21: ... check the specific gravity of each cell every 150 hours Check more frequently in warm weather due to the more rapid loss of water through evap oration Maintain the electrolyte level according to the battery manufacturer s recommendations but do not overfill Overfilling can cause poor perfor mance or early failure Keep the terminal side of the battery clean When necessary wash with a solution of b...

Page 22: ...ctivated Drive belts V and Poly V should be replaced every 2 000 hours or 100 000 miles 160 000 km EXCEPTION Replace belts on pleasure craft marine engines every 1 000 hours of operation regardless of condition Replace ALL belts in a set when one is worn Single belts of similar size should not be used as a substi tute for a matched belt set Premature belt wear can result because of belt length var...

Page 23: ...ted 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 and recorded every 700 hours or 20 000 miles 32 000 km On marine engines check every 500 hours Item 14 Battery Charging Alternator Terminals should be checked for cor rosion and loose connections and wiring inspected for damaged or frayed insulation Have wir...

Page 24: ...equently if the engine is operated in extremely dusty or dirty areas CAUTION To avoid personal injury wear adequate eye protection and do not exceed 40 psi 276 kPa air pressure assembly Have components repaired or replaced as needed Item 22 Tachometer Drive The tachometer drive should be lubricated every 300 hours at the grease fitting Use an all purpose grease No 2 grade at tempera tures above 30...

Page 25: ...ons of such warranty shall not apply to any engine unit that has been sub ject to misuse negligence or acci dent Accordingly malfunctions attributable to neglect or failure to follow the manufacturer s fuel or lubricating recommendations may not be within the coverage of the warranty Every 2 500 hours or 75 000 miles 120 000 km vehicle engines or 4 000 hours non vehicle engines the fan bearing hub...

Page 26: ...46 Total Base Number is important to neutralize the effects of high sulfur fuel in all diesel engines For two stroke cycle engines Detroit Diesel recommends lubricants with sulfated ash contents below 1 0 mass and TBN s between 6 and 10 for engines operating on less than 0 5 sulfur fuel When the use of a high ash oil is required such as with high sulfur fuel the oil selected should have the highes...

Page 27: ...erious engine damage NOTICE Overtightening may distort or crack the filter adaptor The disposal of waste oil may be best addressed by the engine oil supplier who may accept responsi bility for proper disposal of this mate rial as part of the business of providing lubricant C How to Replace the Lube Oil Filter Filters are an integral part of the lubri cating oil system Proper filter selec tion and ...

Page 28: ...t of the fuel should be as low as possible to avoid pre mature wear of piston rings and lin ers avoid excessive deposit formation and minimize sulfur diox ide exhausted into the atmosphere Limited amounts of sulfur can be tol erated but the amount in the fuel and engine operating conditions can influence corrosion and deposit for mation tendencies The use of fuel containing greater than 0 5 mass p...

Page 29: ...of liquid or vapor ized diesel fuel 3 Engine or vehicle fuel systems service operations should be performed in a well ventilated area that is kept free of bystanders Gasoline The presence of gasoline in diesel fuel will reduce fuel cetane number and increase combustion tempera tures Tanks which contain such mixtures should be drained and cleaned as soon as possible Detroit Diesel Corporation will ...

Page 30: ...from 6 by Volume or 1 Quart Specifications Page per 4 Gallons Such as Detroit Diesel Power Cool antifreeze or equivalent Maintenance SCA Dosage Coolant Element Liquid Select Element from Specifications Page 0 6 by Volume or 1 Pint per 20 Gallons Proper SCA Dosage for Initial Fill and Maintenance Requirements state and or federal EPA recom mendations 2 Fill a new replacement cartridge about two thi...

Page 31: ...ing with supplemental coolant additives or coolant concen trate can cause additive dropout Always follow the coolant manufactur er s recommendations on usage and handling fluoroelastomer seals found in the cooling system Glycol based coolants formulated for heating ventilation air condition ing HVAC are not recommended These generally contain very high levels of phosphates which can deposit on hot...

Page 32: ... tions before draining coolant may result in damage to the block heater element if the heater is switched on without coolant in the system Inhibitor Test Procedures Engine coolant must be tested for required inhibitor levels at the intervals shown on the Coolant Test Intervals chart Test kits and test strips are com mercially available to check engine coolant for nitrite concentration Inhibitor le...

Page 33: ...hever comes first Some air cleaners are equipped with a restriction indicator which aids in determining the service interval Cleaning and or reusing dry paper type air cleaner elements is not recom mended unless the cleaning method used removes clogging without dam age to the element Inspection and cleaning of elements must be done in accordance with the air cleaner manu facturers recommendations ...

Page 34: ... for gage X Plugged oil orifice X Obstructed oil line X 63 OBJECTIONABLE EXHAUST Black or Gray Smoke Probable Causes Blue Smoke White Smoke Damaged or dirty air cleaner X Improper grade of fuel X Excessive exhaust back pressure X Misfiring cylinders X Lubricating oil not burned in cylinder being burned in exhaust manifold or turbocharger X Faulty injector setting X Faulty oil control rings X Exces...

Page 35: ...rage period check the antifreeze coolant for required freeze and inhibitor protection Add an ethylene glycol base antifreeze solution to the cooling system to provide required freeze and inhibitor protection NOTE If an antifreeze solution is not required during storage flush the cooling system with a good rust inhibitor to prevent rusting of the out side diameter of the cylinder liners 6 Clean the...

Page 36: ... and rotate the tur bine compressor shaft without an adequate flow of lubricating oil to the center housing bearings This can result in severe bearing damage Extended Storage More than 30 Days To prepare an engine for extended storage more than 30 days follow this procedure 1 Drain the cooling system and flush with clean soft water Refill with clean soft water and add a rust inhibitor to the cooli...

Page 37: ...f rust or corrosion correc tive steps must be taken to prevent damage to the engine parts Perform a complete inspection at the end of one year and apply additional treatment as required Procedure for Restoring to Service an Engine that Has Been in Extended Storage 1 Remove the covers and tape from all of the openings of the engine fuel tank and electrical equipment Do not overlook the exhaust outl...

Page 38: ... REGION Singapore 7 Jurong Pier Rd Singapore 2261 Phone 65 265 4697 Fax 65 265 9530 PACIFIC REGION Australia 13 Lynette Ave Beaumaris Victoria 3193 Australia Phone 61 3 5895181 Fax 61 3 5893424 EUROPE MIDDLE EAST AFRICA EMA REGION The Netherlands Ridderpoort 9 2980 GD Ridderkerk The Netherlands Phone 31 1804 10388 Fax 31 1804 62062 MEXICO Detroit Diesel Allison de Mexico S A Reforma 2977 Colonia C...

Page 39: ... has not been handled satisfactorily Step One Discuss your problem with a member of management from the authorized service outlet Frequently complaints are the result of a breakdown in com munication and can quickly be resolved by a member of manage ment If you have already discussed the problem with the Sales or Service Manager contact the General Manager If your complaint originates with a deale...

Page 40: ...MIXTURES COOLING SYSTEM CAPACITY DDC PART NALCOOL PART GALLONS QTY NUMBER NUMBER 5 8 1 23507545 DDF 3000 9 12 1 23507545 DDF 3000 13 16 1 23507545 DDF 3000 24 32 1 23508425 DDF 3000 8 47 52 1 23508426 DDF 3000 12 COOLANT INHIBITOR ELEMENT SIZE REQUIREMENTS INITIAL DOSAGE FOR WATER ONLY SYSTEMS COOLING DETROIT SYSTEM SCA DIESEL NALCOOL ADDITIONAL CAPACITY ELEMENT SCA ELEMENT ELEMENT SCA LIQUID GALL...

Page 41: ...NOTES 77 NOTES 76 ...

Page 42: ...NOTES 78 ...