Detroit Diesel 92 Series Manual

®
13400 Outer Drive, West / Detroit, Michigan 48239-4001
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Telex: 4320091 / TWX: 810-221-1649
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©Copyright 1994. Detroit Diesel®, reliabilt®, and the spinning arrows are registered trademarks of Detroit Diesel Corporation
6SE506 Rev. 06-94 As technical advancements continue, specifications will change. Printed in U.S.A.
Engine Operator's Guide
Series 92

To the Operator
This guide contains instructions on
the safe operation and preventive
maintenance of your Detroit Diesel
engine. Maintenance instructions
cover routine engine services such
as lube oil and filter changes in
enough detail to permit self-servic-
ing, if desired.
The operator should become famil-
iar with the contents of this manual
before operating the engine or carry-
ing out maintenance procedures.
Power-driven equipment is only as
safe as the person operating the
controls. You are urged, as the oper-
ator of this diesel engine, to keep fin-
gers and clothing away from the
revolving belts, drive shafts, etc. on
the engine installation.
Throughout this guide CAUTIONS
regarding personal safety and
NOTICES regarding engine perfor-
mance or service life will appear. To
avoid personal injury and ensure
long engine service life, always heed
these instructions.
Whenever possible, it will benefit
you to rely on an authorized Detroit
Diesel service outlet for all your ser-
vice needs from maintenance to
major parts replacement. Authorized
service outlets worldwide stock fac-
tory original parts and have the spe-
cialized equipment and experienced,
trained personnel to provide prompt
preventive maintenance and skilled
engine repairs.
The information and specifications
in this publication are based on the
information in effect at the time of
approval for printing. Contact an
authorized Detroit Diesel service out-
let for information on the latest revi-
sion. The right is reserved to make
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 Engines..............................................................................12
Marine Engines ...............................................................................................20
ENGINE SYSTEMS..........................................................................................24
Fuel System.....................................................................................................24
Lubrication System .........................................................................................24
Air System.......................................................................................................24
Cooling System...............................................................................................24
Electrical System.............................................................................................24
Exhaust System...............................................................................................24
ENGINE MAINTENANCE SCHEDULES.....................................................26-31
LUBRICATION AND PREVENTIVE MAINTENANCE INTERVALS..............32-44
“HOW TO” SECTION .................................................................................45-60
How to Select Lubricating Oil .........................................................................45
When to Change Oil........................................................................................47
How to Replace the Lube Oil Filter .................................................................48
How to Select Fuel Oil.....................................................................................50
How to Replace the Fuel Filter and Strainer ...................................................53
Engine Out of Fuel—How to Restart ...............................................................54
How to Select Coolant.....................................................................................55
How to Drain and Flush the Cooling System ..................................................59
When 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 “Warranty
Information 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” (Form
6SE508), available from authorized Detroit Diesel distributors.

1
ENGINE MODEL AND
SERIAL NUMBER
DESIGNATION
The engine serial number and model
number are stamped on the cylinder
block in the following location (as
viewed from the front):
• 6V, 8V-92 Machined pad on the
left side, upper front corner just
below the fire deck.
• 12V, 16V-92 Left side of the rear
block, below and between the
back airbox covers.
DDEC II/DDEC III
Engine Identification
Detroit Diesel Electronic Control
(DDEC) systems are available as stan-
dard or optional items on many Series
92 engine models. Engines equipped
with DDEC II systems are identified by
the letter "B" in the sixth position of the
model number. Example: 80877B28.
Engines equipped with DDEC III sys-
tems have the letter "K" in the sixth
position Example: 80877K28.
Option Labels
Computerized engine option labels are
attached to the valve rocker cover.
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 be included on the parts order.
Marine gears, transmissions and
power take-offs generally carry their
own name plates. The model and seri-
al number information on these plates
is useful when ordering parts for these
assemblies.
Certification Label
If required, a certification label is
attached to the valve rocker cover.
This label certifies that the engine con-
forms to federal and certain state
emissions regulations for its particular
application. It also gives the operating
conditions under which certification
was made.
SERIAL NO.
MODEL NO.
08VF150965
80877B28
Location of Engine Serial and Model
Number (8V-92 Shown)

32
OPERATING
INSTRUCTIONS
Preparations for
Starting the Engine
the First Time
When preparing to start a new or newly
overhauled engine or an engine which
has been in storage, perform all of the
operations listed below. Failure to follow
these instructions may result in serious
engine damage. Before a routine start,
see “Daily” checks in the Engine
Maintenance schedules (pages 26-31).
Cooling System Checks
1. Make sure all the drain cocks in
the cooling system are installed
(drain cocks are often removed for
shipping) and are closed tightly.
2. Open the petcock near the top of
the water-cooled turbocharger (if
used), and any other petcocks, if
so equipped.
3. Remove the radiator or heat
exchanger pressure control cap
and fill with genuine Detroit Diesel
Power Cool antifreeze or an
equivalent ethylene glycol-base
antifreeze solution in the required
concentration. In extremely hot
environments, clean, soft, proper-
ly inhibited water may be used in
the summer. Keep the coolant
level at the bottom of the filler
neck to allow for expansion of the
coolant. For more detailed coolant
recommendations, refer to How to
Select Coolant (page 55).
4. After filling the cooling system,
close all petcocks. Fill the coolant
recovery bottle to the "Full Cold"
level, if equipped.
5. Entrapped air must be purged
after filling the cooling system. To
do this refer to "Inspection-Cooling
System" under "Running the
Engine" (page 8).
6. On industrial and off-highway
units, check to make sure the front
of the radiator is unblocked and
free of debris.
7. On marine units, perform these
additional steps:
■Check sea water strainers and
remove any accumulations of sea-
weed or debris. Strainers act as
filters between the intake through-
hull fittings and the raw water
pump(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 raw
water pump. Visually inspect the
impeller for signs of damaged or
broken vanes. Replace the impeller
if damaged. Reinstall the cover with
a new gasket.
■Before starting the engine, prime
the 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 0068 FUEL MAN CONN 0862 FUEL FILTER
1995 FUEL LINES 0747 AIR INLT HSG 0341 INJ CONT ELEC
0648 ENGINE MOUNTS NONE AIR COMP 0901 CAM/GR TRAIN
0384 VALVE MECH JAKE SEE VALV MECH 0425 ROCKER COVER
0133 OIL FIL CAP 0727 VENT SYSTEM 0761 VENT SYSTEM
0143 ACC DRIVE 0223 ACC DRIVE 0230 ACC DRIVE
UNIT 08VF161310 S.O. 4A42112 MODEL 80877K45 SPEC P0677700
U.S.A.
IMPORTANT ENGINE INFORMATION
1994 THIS ENGINE CONFORMS TO U.S. EPA
FED REGULATIONS APPLICABLE TO 1994 MODEL YEAR NEW HEAVY DUTY
DIESEL ENGINES. THIS ENGINE HAS A PRIMARY INTENDED
SERVICE APPLICATION AS A HEAVY HEAVY DUTY ENGINE.
FUEL RATE AT ADV. HP 104.7 MM3/STROKE ADV. HP 500 AT 2100 RPM
INITIAL INJECTION TIMING 13 DEG. BTC CID 736
ENGINE FAMILY RDD736EJ4AR4 MIN. IDLE 600 RPM FEL BSP 0.32
MODEL 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 CFR
86.093 2. SALE OF THIS ENGINE FOR USE IN AN URBAN BUS IS A VIOLATION OF
FEDERAL LAW UNDER THE CLEAN AIR ACT.
THIS ENGINE IS CERTIFIED TO OPERATE ON
LOW SULFUR DIESEL FUEL.
UNIT 08VF161310
0483 CYL BLOCK 0161 AIR BOX DRAIN THIS ENGINE WAS
0137 CYL HEAD 0247 ENG LIFT BRKT TESTED AT 0450 HP
0721 F/W HOUSING 0177 VIB DAMPER AT 02100 RPM
0848 FLYWHEEL 0431 CONN ROD/PSTN INJ. TIMING 1.520
0810 OIL PAN 0200 OIL PUMP VALVE LASH .016
0028 OIL PRESS REG 0203 OIL DIST STARTING AID .000
1230 OIL COOLER 1031 DIPSTICK THRTDLY/FMOD .000
0591 OIL FILTER 0748 VENT SYSTEM MAX RPM NL 02225
0048 BAL WT COVER 1689 FAN STDGT DDEC CAM
UNIT 08VF161310 S.O. 4A42112 MODEL 80877K45 SPEC P0677700
CAUTION:
When working near the engine,
always remove loose items of
clothing or jewelry that could get
caught in a moving part of the
engine and cause personal injury.
Also wear safety glasses and
hearing protection.
NOTICE:
Failure to install a new gasket and
tighten cover bolts securely can
result in pump leakage at start-up.

5
4
Lubricating System Checks
The lubricating oil film on the rotating
parts and bearings of a new or newly
overhauled engine, or one which has
been in storage for six months or
more, may be insufficient when the
engine is started for the first time.
Insufficient lubrication at start-up can
cause serious damage to engine
components.
To ensure an immediate flow of oil
to all bearing surfaces at initial
engine start-up, the engine lubrica-
tion system should be charged with a
commercially available pressure pre-
lubricator. After pre-lubricating, add
additional oil to bring the level to the
proper mark on the dipstick. Refer to
How to Select Lubricating Oil (page
45) for lubricant requirements.
Extended Storage—An engine in
storage for an extended period of
time (over winter, for example) may
accumulate water in the oil pan
through normal condensation of
moisture (always present in the air)
on the cold internal surfaces of the
engine. Lube oil diluted by water
cannot provide adequate bearing
protection at engine startup. For this
reason, Detroit Diesel recommends
replacing the engine lube oil and fil-
ter(s) after extended storage.
Transmission, Marine Gear—Make
sure the transmission or marine gear
is filled to the proper level with the
fluid 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 the
chances for microbe (black slime)
growth. Refer to How to Select Fuel Oil
(page 50) for fuel recommendation.
Make sure the fuel supply shutoff valve (if
used) is open.
To ensure prompt starting and even
running, the fuel system must be primed
if air has entered the fuel system. Priming
is done by connecting a manual or elec-
tric priming pump to the inlet of the sec-
ondary fuel filter. Authorized Detroit
Diesel service outlets are properly
equipped to perform this service.
Priming is not normally necessary 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 contamination is a
concern.
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 they
are in good condition (not cracked,
torn, worn, or glazed) and are properly
adjusted.
Make sure cable connections to the
storage batteries are clean and tight.
Check the hydrometer “eye” of mainte-
nance-free batteries for charge. If
lead-acid or low maintenance batteries
are used, make sure battery elec-
trolyte level is normal.
Check turbocharger for signs of oil
or 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 water
pump may result in damage to the
pump impeller and engine over-
heating.
NOTICE:
Failure to eliminate water-diluted
lube oil may lead to serious engine
damage at startup.
NOTICE:
Prolonged use of the starting motor
and engine fuel pump to prime the fuel
system can result in damage to the
starter, fuel pump, and injectors, and
cause erratic engine operation due to
the amount of air in the lines and filters
from the supply tank to the cylinder
head.
Engines equipped with starting
devices dependent on compressed air
or gas reservoirs should always be
primed before initial startup. Otherwise,
reserve pressure can be exhausted
and injectors may be damaged from
lack of lubrication and cooling.
Under no circumstances should a
starting aid such as ether be used to
run the engine until the fuel system is
primed. Injector damage will occur if
this method is used. The heat generat-
ed by the external fuel source will cause
the injector tips to be damaged when the
fuel cools them. Plunger and bushing
assemblies can be scored from running
without lubrication.

76
Starting the Engine
Before starting the engine the first
time, perform the operations listed
under Preparations for Starting the
Engine the First Time (pages 3-5).
If the engine has an emergency
manual or automatic shutdown sys-
tem, make sure the control is set in the
open position before starting. The tur-
bocharger may be seriously damaged
if the engine is cranked with the air
shutdown in the closed position. On
engines with dual air shutdown, both
air shutoff valves must be in the open
position before starting the engine.
If the unit is located in a closed
room, start the room ventilating fan or
open the windows, as weather condi-
tions permit, so ample air is available
for the engine.
The engine may require the use of a
cold weather starting aid if the ambient
temperature is below 40°F (4°C).
Initial Engine Start
Non-DDEC Engine
1.Position the transmission or marine
gear in park or neutral.
2. Set the speed control lever at part
throttle, then bring it back to the
desired no-load speed. In addi-
tion, make sure the stop lever on
the cover of mechanical governors is
in the run position.
3. Press the starter switch firmly.
Air Starter—Because of the limited
volume of most storage tanks and the
relatively short duration of the cranking
cycle, it is important to make sure the
engine is ready to start before acti-
vating the air starter. Start an engine
equipped with an air starter as follows:
1. Check the pressure in the air stor-
age tank. (Most air starter-equipped
installations have a dash-mounted
pressure gauge.) If necessary, add
air to bring the pressure up to at
least the recommended minimum
for starting.
2. Press the starter button firmly and
hold until the engine starts.
Starting Tip—Non-DDEC
Electric Start Engine:
Some white smoke is normal at start-
up when the engine is cold and will
clear up shortly after the engine
warms. However, if you experience
excessive smoke at cold start-up,
depress the stop button or cable at the
same time you press the starter button
and crank the engine for a few sec-
onds. Release the stop button or cable
and continue to crank the engine until
it starts (but not longer than 15 sec-
onds). This will preheat the cylinders
and reduce white smoke at start-up.
Initial Engine Start—DDEC
Vehicle, Industrial Engine
1. With the transmission in neutral or
park, turn the ignition key on.
You will notice that both the
“Check Engine” and “Stop Engine”
lights will come on. This is the result
of 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
seconds, release the starter switch
and allow the starting motor to cool
for 15 seconds before trying again. If
the engine fails to start after four
attempts, an inspection should be
made to determine the cause.
Initial Engine Start—
DDEC Marine Engine
1. With the marine gear in neutral, turn
the ignition key on. You will notice
that both the “Check Engine” and
“Stop Engine” lights on the Boat
Builder Interface Module (BBIM) will
come on. This is the result of 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.
The electronic display panels at
the control bridge also complete a
diagnostic check when the ignition
key 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 on
the panel face and sets itself for dis-
play of engine parameters.
If the vessel is equipped with the
DDEC Imaging System, you will
notice that it also does not contain
"Check Engine" and "Stop Engine"
lamps, but does a self-diagnostic
check when turned on.
Should a system fault be present
at any time, both display versions will
present on the screen the diagnostic
code number and a brief word
description of the fault condition.
Typical Shutdown Override Switch and
Engine Lights
NOTICE:
The blower will be seriously dam-
aged if operated with the air shutoff
valve in the closed position.
CAUTION:
Starting fluid used in capsules is
highly flammable, toxic, and pos-
sesses sleep-inducing properties.
NOTICE:
To prevent serious starting motor
damage, do not press the starter
switch again after the engine has
started.
NOTICE:
If the warning lights stay on, or if they
do not come on momentarily after
starting the engine, consult with a
DDEC technician. Operating the
engine under these circumstances
may result in engine damage.
NOTICE:
To prevent serious starting motor
damage, do not press the starter
switch again after the engine has
started.
STOP ENGINE DIAGNOSTIC CHECK STOP
SWITCH
OVERRIDE ENGINE ENGINE
ON
OFF

98
2. 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
seconds, release the starter switch
and allow the starting motor to cool for
15 seconds before trying again. If the
engine fails to start after four attempts,
an inspection should be made to
determine the cause.
Running the Engine
Oil Pressure
Observe the oil pressure gauge or elec-
tronic display immediately after starting
the engine. A good indicator that all of the
moving parts are getting lubrication is
when the oil pressure gauge registers
pressure (5 psi - 34.5 kPa) at idle speed.
If there is no oil pressure indicated within
10 to 15 seconds, stop the engine and
check the lubricating system. The pres-
sure should not fall below 28 psi (193
kPa) at 1800 rpm, and normal operating
pressure should be higher. If pressure
does not fall within these guidelines, it
should be checked with a manual gauge.
Warm-up
Run the engine at part throttle for about
five (5) minutes to allow it to warm up
before applying a load.
Inspection
Transmission, Marine Gear—While
the engine is idling, check the transmis-
sion or marine gear for proper oil level
and add oil as required. On marine
engines check that water is flowing out
the exhaust pipe or raw water dis-
charge pipe. Look for coolant, fuel, or
lubricating oil leaks at this time. If any
are found, shut down the engine imme-
diately and have leaks repaired after the
engine has cooled.
Cooling System–Entrapped air must
be purged after the cooling system is
filled. To do this allow the engine to
warm up without the pressure cap
installed. With the transmission or marine
gear in neutral, increase engine rpm
above 1000 rpm and add coolant as
required. Vent the petcock on the water
return line at the water-jacketed tur-
bocharger (if used) until coolant (no air)
comes out. Install the pressure cap after
the coolant level has stabilized at the
bottom of the radiator or heat exchanger
tank filler neck. Refill the recovery bottle
as needed if coolant is drawn into the
engine while purging the air.
If all of the coolant is drawn out of the
recovery bottle when the engine cools,
remove the pressure cap from the radi-
ator or heat exchanger and check to
make sure the coolant 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 level. If
necessary, add oil to bring the level to
the proper mark on the dipstick. Use
only the heavy-duty oils recommended
in How to Select Lubricating Oil (page
45) in this guide.
Turbocharger—Make a visual inspec-
tion of the turbocharger for oil leaks,
coolant leaks, exhaust leaks, excessive
noise or vibration. Stop the engine imme-
diately if a leak or unusual noise or vibra-
tion is noted. Do not restart the engine
until the cause of the concern has
been investigated and corrected.
Authorized Detroit Diesel service outlets
are properly equipped to perform this
service.
Avoid Unnecessary Idling
During long engine idling periods with
the transmission in neutral, the engine
coolant temperature may fall below the
normal operating range. The incomplete
combustion of fuel in a cold engine will
cause crankcase oil dilution, formation
of lacquer or gummy deposits on the
valves, pistons, and rings, and rapid
accumulation 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 stay
on, or if they do not come on
momentarily after turning on the igni-
tion key, consult with a DDEC ser-
vice technician. In the former case
the bridge displays will show the
active fault codes. Operating the
engine under these circumstances
may result in engine damage.
NOTICE:
To prevent starting motor damage,
do not press the starter switch again
after the engine has started.
CAUTION:
To avoid personal injury from the
hot oil, do not operate the engine
with rocker covers removed for
any reason.
NOTICE:
Failure to properly fill the cooling sys-
tem and purge it of air can result in
engine overheating and serious
engine damage.
Do not overfill the recovery bottle, since
this can result in spillage as the coolant
expands during engine operation.
CAUTION:
To avoid personal injury or tur-
bocharger damage, do not
remove, attach, or tighten tur-
bocharger air intake ducting while
the engine is operating or operate
the engine with the ducting
removed.

NOTE: On coach engines equipped
with Delco 50 DN alternators and
mechanical unit injectors the optimum
low idle speed setting with full accessory
load and the transmission in neutral is:
6V-92 — 650 rpm
8V-92 — 550 rpm
Stopping the Engine
Normal Stopping
1. Reduce engine speed to normal idle
and put all shift levers in the neutral
position.
2. Allow the engine to run between idle
and 1,000 rpm with no load for four
(4) or five (5) minutes. This allows the
engine to cool and permits the tur-
bocharger to slow down. After four or
five minutes, shut down the engine.
Emergency Stopping
The emergency shutdown should be
used only when the engine does not
respond to the normal stop engine
procedure.
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 as
such on the control panel.
The air shutdown, located in the air
inlet housing, must be reset by hand
and the “emergency stop”knob
pushed in before the engine is ready to
start again.
10 11
Emergency Jump
Starting
Use the following procedure to start
the engine of a vehicle with a “low bat-
tery” or one that will not crank the
engine fast enough to start.
The DDEC II electronic control sys-
tem operates on 12 volts DC. If a
DDEC II engine with an electric start-
ing motor requires emergency jump
starting, do not exceed 16 volts DC.
The DDEC III electronic control sys-
tem operates on 12 or 24 volts DC. If a
DDEC III engine with an electric start-
ing motor requires emergency jump
starting, do not exceed 32 volts DC.
1.Prevent shorting of the system by
removing metal rings, watches, or
jewelry and not allowing metal tools
to contact the positive terminal of
the battery.
2. Place the transmission of the dis-
abled vehicle in neutral, set the
parking brake, and turn the ignition
to the off position.
3. Turn off lights, heater, air condition-
er, and any other electrical loads in
the disabled vehicle and the boost-
er vehicle.
4. Wear eye protection if available, or
shield eyes when near either bat-
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 vehicle.
NOTICE:
Stopping a turbocharged engine
immediately after high speed opera-
tion may cause damage to the tur-
bocharger, as it will continue to turn
without an oil supply to the bearings.
NOTICE:
Jump starting with voltages greater
than those indicated or reversing bat-
tery polarity may damage the ECM
(electronic control module).
NOTICE:
Never use the emergency shutdown
system, except in an emergency.
Use of the emergency shutdown can
cause lubricating oil to be sucked
past the oil seals and into the blower
and may also cause turbocharger
damage.
NOTICE:
If the emergency air shutdown is
used to stop the engine in an emer-
gency situation, always have the shut-
down checked for damage and for
proper operation before the vehicle,
vessel, or machine is returned to ser-
vice. This is especially important if
shutdown is made at high engine
rpm. To ensure positive valve closure
should another emergency shutdown
be required, the shutdown must be
checked and required repairs or
adjustments made at this time.
Failure to observe this precaution
may permit engine run-on when the
emergency shutdown is activated.
NOTICE:
Do not use this procedure if the
battery of the disabled vehicle will
not accept a charge or is frozen.
Attempting to start the vehicle
under these conditions may result
in cranking system damage.
CAUTION:
The following procedure must be
performed exactly as outlined.
Failure to observe precautions
and/or follow this sequence may
result in injury to the face, eyes,
body, limbs, and respiratory sys-
tem caused by fire or acid from
battery explosion. Property dam-
age could also result.
CAUTION:
Reversing battery polarity can also
result in personal injury caused by
the sudden discharge of elec-
trolyte from the battery vents
and/or the sudden rupture of the
battery case caused by explosion
of internal hydrogen gas.

major engine malfunction occurs, such
as low oil pressure, high oil tempera-
ture, or low coolant level.
DDEC engines may also have an
optional 3-100 minute idle shutdown
system. The purpose of this system is
to conserve fuel by eliminating exces-
sive idling and to allow for a tur-
bocharger cool down period. To
activate the shutdown, the transmis-
sion must be in neutral, with the
engine in idle or PTO mode.
Cruise Control
A DDEC-equipped vehicle engine
may have cruise control. Cruise con-
trol is available at either a road speed
or engine speed setting. The driver
has switches to activate and deacti-
vate the system, and a slight depres-
sion of the brake or clutch pedal
deactivates the system as well. The
minimum 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 the
cruise control switches. With the
engine at normal idle, transmission in
neutral and service brake on, turn on
the cruise control “on/off” switch, and
use the “set” switch. The engine rpm
should increase to a pre-defined rpm.
The rpm can be raised or lowered
from this point using the “set” and
“resume” switches.
The cruise control option will
maintain the set speed under normal
road and load conditions. It cannot
limit vehicle speeds on down grades if
available engine braking effort is
exceeded, nor can it maintain speed
on upgrades if power requirements
exceed engine power capability.
13
Typical Cruise Control Switches
12
8. Start the engine of the booster
vehicle and allow it to run for a
minute or two to help charge the
battery of the disabled vehicle.
9. Turn the ignition of the disabled
vehicle to the on position and
attempt to start the engine.
10.As soon as the engine starts,
remove jumper cables in reverse
order of attachment (negative
ground cable on newly started
engine first, then negative cable,
then positive cable).
11. Allow the engine to warm up before
putting a load on the vehicle.
DDEC OPTIONS
Vehicle, Industrial
Engines
Engines having Detroit Diesel
Electronic Controls (DDEC) can be
equipped with a variety of options
designed to warn the operator of an
engine malfunction. The options can
range from “Check Engine” and “Stop
Engine” panel 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 is the result of the
DDEC computer diagnosing the sys-
tem 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.
With foot OFF the foot pedal, start
the engine after the lights go out.
The DDEC engine is equipped with
an electronically controlled fuel
injection system.
DDEC engines have the ability to
perform diagnostics for self-checks
and continuous monitoring of other
system components. Depending on
the application, DDEC can also moni-
tor oil temperature, coolant tempera-
ture, oil pressure, fuel spill pressure,
coolant level, and remote sensors (if
used). This diagnostic system is con-
nected to the “Check Engine” and
“Stop Engine” lights to provide a visual
warning of a system malfunction.
The DDEC engine can be
equipped with an engine protection
system that features a 30 second,
stepped-power shutdown sequence
or an immediate speed reduction
without shutdown in the event a
NOTICE:
If the warning lights stay on, or if they
do not come on momentarily after
starting the engine, consult with a
DDEC technician. Operating the
engine under these circumstances
may result in engine damage.
NOTICE:
If the engine is equipped with the
power-down/shutdown option, there
will be a system override button or
switch which may be used to allow
engine operation for a short period of
time. If the shutdown override button
is not used, the shutdown will occur
in 30 seconds.
NOTICE:
When descending a hill with cruise
control “on” or “off,” do not allow
the engine to exceed 2300 rpm
under any conditions. Failure to
observe this precaution can result
in overspeeding and serious
engine damage.
CRUISE CONTROL
PANEL LIGHTS
SET ON RESUME
OFF
ENGINE START
ACC OFF RUN
CAUTION:
To avoid a spark, do not attach
the cable end to the negative ter-
minal of the disabled battery. A
spark could cause explosion of
gases normally present around
the battery, resulting in battery
rupture and possible personal
injury and/or property damage.

“Stop Engine Override” switch, located
on the instrument panel, until a safe
stop can be made. The operator only
needs to press the override switch
every 15 to 20 seconds to prevent
engine shutdown from occurring.
An important thing to remember is
that it takes 30 seconds from the time
the automatic shutdown sequence
begins until engine shutdown. There-
fore, the operator must press the over-
ride switch just prior to engine shutdown
and continue to do so until the vehicle
can be brought to a safe stop.
The immediate speed reduction
option will bring engine rpm back to a
predetermined speed, but will not shut
down the engine.
The engine should not be restarted
after it has been shut down by the
engine protection system unless the
problem has been located and cor-
rected.
The conditions that will cause the
“Stop Engine” light (SEL) to come on
are:
• 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) or
the “Stop Engine” light (SEL) comes
on, the DDEC computer will determine
where the problem is, and will then
store this information in its memory.
If the malfunction is intermittent, the
“Lights” will come on and go off as the
computer senses the changing engine
condition.
A special diagnostic tool (Diagnostic
Data Reader, or “DDR”) is available that
can be plugged into the engine com-
puter memory to extract information
related to the cause of the problem.
Once the malfunction has been cor-
rected, the DDEC system will return
the engine to normal operation.
The DDR can distinguish between
codes now active and those stored in
the ECM memory (inactive).
The diagnostic code recorded in the
computer memory will remain until it is
erased by a technician.
15
On engines equipped with Jacobs
Engine Brakes, the “Jake Brake” cir-
cuit can be activated by releasing
the EFPA (Electronic Foot Pedal
Assembly) completely to the idle
position. The “Jake Brake” will then
operate the same as on engines with
mechanical governors. To return the
vehicle to cruise speed after brake or
clutch application, simply activate
the “Resume” switch. Each subse-
quent touch of the “Resume” switch
will increase cruise speed by 1 mile
(1.6 km) per hour.
DDEC Operation
Since the DDEC system is electronic, a
battery 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 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 operation, and at this time cer-
tain DDEC options, such as cruise con-
trol, smoke control, and automatic
shutdown, will not function.
The engine will operate only at
reduced rpm. You will be able to oper-
ate the vehicle at reduced voltage until
the battery voltage has reached a point
where it will no longer function and the
engine will shut down.
You can still operate the vehicle and
proceed to your designation when the
“Check Engine” light (CEL) comes on.
However, a report should be made to a
DDEC technician as soon as possible.
The “Stop Engine” malfunction is
recorded in the Electronic Control
Module. With the 30 second shutdown
option, the engine will begin a 30 sec-
ond, stepped, power down sequence
until it shuts down completely.
To allow for the possibility of the
“Stop Engine” automatic shutdown
function being activated while the
vehicle is operating in a critical situa-
tion, an override is provided.
NOTE: In some applications the “Stop
Engine Override” and “Diagnostic
Request” switches can be the same.
In this situation the operator may
elect to override the automatic stop
engine sequence by pressing the
14
CAUTION:
To avoid the possibility of vehicle
damage and/or personal injury,
Detroit Diesel does not recom-
mend using cruise control under
the following conditions:
•When it is not possible to keep
the 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” light
comes on, the computer has
detected a major malfunction in the
engine that requires immediate
attention. It is the operator's
responsibility to shut down the
engine to avoid serious damage.
NOTICE:
For some applications, holding the
“Stop Engine Override” switch in will
not prevent the engine shutdown
sequence. You must continue to
reset the automatic shutdown sys-
tem by pressing the “Stop Engine
Override” switch at intervals of
approximately 15 to 20 seconds.
STOP ENGINE DIAGNOSTIC CHECK STOP
SWITCH
OVERRIDE ENGINE ENGINE
ON
OFF
Typical Shutdown Override Switch and
Engine Lights

The diagnostic code can also be
obtained by the operator:
DDEC II Engines—A “Diagnostic
Request” switch is provided which,
when pressed, will cause the “Check
Engine” light (CEL) to flash a code
number. It will, for example, flash
twice...pause...flash five times...pause.
In other words a code 25.
Code 25 indicates all systems are
working satisfactorily.
DDEC III Engines—The active codes
will be flashed on the “Stop Engine”
light (SEL) in the order of most recent
to least recent occurrence based on
engine hours. If there are no active
codes, a code “25” will be flashed.
The inactive codes will be flashed
on the “Check Engine” light (CEL) in
the order of most recent to least recent
occurrence based on engine hours. If
there are no inactive codes, a code
“25” will be flashed.
Diagnostic Data Reader J38500
Note that only one lamp will be
flashing codes at any time. When
code flashing is initiated, the active
codes (or code “25”) will be flashed on
the SEL. Then the inactive codes (or
code “25”) will be flashed on the CEL.
When all the inactive codes (or code
“25”) have been flashed, the process
of flashing all the active codes fol-
lowed by all the inactive codes will
repeat until the conditions for code
flashing are no longer satisfied.
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
charts (pages 18-19).
NOTICE: If a DDEC II vehicle engine
is equipped with an OEM-supplied
diagnostic switch, the switch must
NOT be switched on when operating
the vehicle. If this is done, the diag-
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 power and ground
cables and the 6-pin power connec-
tor at the ECM (electronic control
module) before welding. Failure to
isolate the DDEC system from
high current flow can result in
severe ECM damage.
CAUTION:
The operator of a DDEC-equipped
engine should know the extent of
the warning system on his vehicle,
in order to bring it to a safe stop in
the event of an engine malfunc-
tion. A description of the warning
system and detailed instructions
regarding its operation should be
obtained from the owner, the seller
or the manufacturer of the vehicle.
This information may also be
obtained at any authorized Detroit
Diesel service outlet.
To be confronted with a power-
down/shutdown situation without
knowing how the system works
could cause the vehicle to stop in
an unsafe location, posing the
possibility of damage to the vehi-
cle and a threat to the safety of the
operator.
CAUTION:
The operator of a DDEC-equipped
vehicle must not attempt to use or
read a diagnostic data reader of
any kind while the vehicle is oper-
ating. Doing so can result in loss
of control, which may cause vehi-
cle damage and may result in per-
sonal injury.
When engine or electronics sys-
tem diagnosis is required on a
DDEC-equipped vehicle, this must
be done by a person other than
the operator. The operator must
maintain control of the moving
vehicle while the assistant per-
forms the diagnosis.

Diagnostic Codes—DDEC II
On-Highway and Industrial Engines
Diagnostic Connector
Error Error
Code # Description Code # Description
11 Power Take-off Sensor Lo Volt 43 Low Coolant Level
12 Power Take-off Sensor Hi Volt 44 Engine Overtemperature
13 Coolant Sensor Lo Volt 45 Low Oil Pressure
14 Eng Temp Sensor Hi Volt 46 Low Battery Voltage
15 Eng Temp Sensor Lo Volt 47 Hi Fuel Pressure
16 Coolant Sensor Hi Volt 48 Lo Fuel Pressure
21 Throttle Pos Sensor Hi Volt 51 EEPROM Error
22 Throttle Pos Sensor Lo Volt 52 ECM - A/D Failure
23 Fuel Temp Sensor Hi Volt 53 EEPROM Memory Fails
24 Fuel Temp Sensor Lo Volt 54 Vehicle Speed Sensor
25 No Codes 55 Proprietary Comm. Link
26 Power Control Enabled 56 ECM - A/D Failure
31 Fault on Auxiliary Output 58 Cruise Ctl/Press Gov Ctl Switch
32 ECM Backup System Failure 61-68 Inj Response Time Long
33 Turbo Boost Sensor Hi Volt 71-78 Inj Response Time Short
34 Turbo Boost Sensor Lo Volt 84 Crankcase Pressure Hi
35 Oil Pressure Sensor Hi Volt 85 Engine Overspeed
36 Oil Pressure Sensor Lo Volt 86 Press Gov Ctl - Hi Volt
37 Fuel Pressure Sensor Hi Volt 87 Press Gov Ctl - Lo Volt
38 Fuel Pressure Sensor Lo Volt
41 Timing Reference Sensor
42 Synchronous Ref Sensor
FEDCBA
GHJ KLM
Diagnostic Codes—DDEC III
On-Highway and Industrial Engines
Flash Flash
Code DDEC Description Code DDEC Description
11 PTO input low 46 Battery voltage low
12 PTO input high 47 Fuel pressure high
13 Coolant level circuit low 48 Fuel pressure low
14 Intercooler, coolant or oil temp. circuit high 52 A/D conversion fail
15 Intercooler, coolant or oil temp. circuit low 53 EEPROM write or nonvolatile fail
16 Coolant level circuit high 54 Vehicle speed sensor fault
17 Bypass position circuit high 55 J1939 data link fault
18 Bypass position circuit low 56 J1587 data link fault
21 TPS circuit high 57 J1922 data link fault
22 TPS circuit low 58 Torque overload
23 Fuel temp. circuit high 61 Injector response time long
24 Fuel temp. circuit low 62 Digital output open or short 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 circuit high 75 Battery voltage high
34 Boost pressure circuit low 76 Engine overspeed with engine brake
35 Oil pressure circuit high 81 Oil level or crankcase pressure circuit high
36 Oil pressure circuit low 82 Oil level or crankcase pressure circuit low
37 Fuel pressure circuit high 83 Oil level or crankcase pressure high
38 Fuel pressure circuit low 84 Oil level or crankcase pressure low
41 Too many SRS (missing TRS) 85 Engine overspeed
42 Too few SRS (missing SRS) 86 Water pump or baro. pressure circuit high
43 Coolant level low 87 Water pump or baro. pressure circuit low
44 Intercooler, coolant or oil temp. high 88 Coolant pressure low
45 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 designated
by the letter “B”in the sixth position of the model
number. Example: 80877B28.
TO READ CODES: Use diagnostic data reader or
short pin A to pin M. The latter method will flash
codes at the CEL.
NOTE: DDEC III-equipped engines are designated by the letter “K”in the sixth position of the engine
model number. Example: 80877K28.
TO READ CODES: Use the diagnostic data reader or depress and hold the diagnostic request switch
with the ignition on, engine at idle or not running. Press and hold the switch. Active codes will be
flashed on the “Stop Engine”light (SEL) followed by the inactive codes being flashed on the “Check
Engine”light (CEL). The cycle will repeat until the operator releases the diagnostic request switch.
RED = SEL YELLOW = CEL
CEL EXAMPLES
NOTE: The CEL flashing gives both active and historic codes.
CEL CEL
1 Flash 3 Flashes 2 Flashes 1 Flash
Short Short
Pause Long Pause Pause
Code 13 Code 21
CEL CEL
1 Flash 3 Flashes 2 Flashes 1 Flash
Short Short
Pause Long Pause Pause
Code 13 Code 21
19
18

DDEC II Operation
Since the DDEC system is electronic, a
battery 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 "Check
Engine" light will come on and a diag-
nostic code will show on the bridge
display. You may notice a change in
engine operation, because DDEC
operates with reduced accuracy
below 10.5 volts.
You will be able to operate the
engine at reduced voltage until the
battery voltage has reached a point
where it will no longer function and the
engine will shut down.
You can still operate the engine
and proceed to your destination
when the "Check Engine" light (or
CEL) comes on. However, a report
should be made to a DDEC techni-
cian as soon as possible.
DDEC II OPTIONS
Marine Engines
Marine engines having Detroit Diesel
Electronic Controls (DDEC) can be
equipped with two display options
designed to warn the operator of an
engine malfunction. The options are an
electronic display module panel dis-
playing critical powertrain parameters
or a DDEC imaging system display
that includes many vessel functions as
well.
The DDEC engine is equipped
with an electronically controlled fuel
injection system.
DDEC engines have the ability to
perform diagnostics for self-checks
and continuous monitoring of other
system components. Depending on
the application, DDEC can also moni-
tor oil temperature, coolant tempera-
ture, oil pressure, fuel spill pressure,
coolant level, and remote sensors (if
used). This diagnostic system is con-
nected to the "Check Engine" and
"Stop Engine" lights and the bridge
displays to provide a visual warning of
a 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 “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
12 Hand Throttle Speed Adj Hi Volt 43 Low Coolant Level
13 Coolant Sensor Lo Volt 44 Engine Overtemperature
14 Eng Temp Sensor Hi Volt 45 Low Oil Pressure
15 Eng Temp Sensor Lo Volt 46 Low Battery Voltage
16 Coolant Sensor Hi Volt 47 Hi Fuel Pressure
23 Fuel Temp Sensor Hi Volt 48 Lo Fuel Pressure
24 Fuel Temp Sensor Lo Volt 51 ECM Calibration Memory Failure
25 No Codes 52 ECM A/D Failure
26 External Warning Switch Enabled 53 ECM Nonvolatile Memory Failure
31 Fault on Auxiliary Output 54 Tach Sync Circuit Fault
32 ECM Backup Failure 55 Proprietary Data Link Circuit Fault
33 Turbo Boost Sensor Hi Volt 56 ECM A/D Failure
34 Turbo Boost Sensor Lo Volt 57 To Be Determined
35 Oil Pressure Sensor Hi Volt 58 Auxiliary Switch Circuit Failure
36 Oil Pressure Sensor Lo Volt 61-68 Inj Response Time Long
37 Fuel Pressure Sensor Hi Volt 71-78 Inj Response Time Short
38 Fuel Pressure Sensor Lo Volt 84 Crankcase Pressure - Hi
41 Timing Reference Sensor 85 Engine Overspeed
A
FB
C
D
E
NOTE: DDEC II-equipped engines are designated
by the letter “B”in the sixth position of the engine
model number. Example: 80627B00.
TO READ CODES: Use diagnostic data reader or
press 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 CEL
1 Flash 3 Flashes 2 Flashes 1 Flash
Short Short
Pause Long Pause Pause
Code 13 Code 21
21
NOTICE:
When the "Stop Engine" light comes
on or the word “STOP” appears on
the screen, the computer has detect-
ed a major malfunction in the engine
that requires immediate attention. It
is the operator's responsibility to shut
down the engine to avoid serious
damage.

Welding Precaution
The "Stop Engine" malfunction is
recorded in the Electronic Control
Module for later retrieval by the service
technician.
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, the
DDEC computer will determine where
the problem is, and will then store this
information in its memory.
If the malfunction is intermittent, the
"Lights" will come on and go off as the
computer senses the changing engine
condition.
A special diagnostic tool
(Diagnostic Data Reader, or "DDR") is
available that can be plugged into the
engine computer data link to extract
information related to the cause of the
problem.
Diagnostic Data Reader J 38500
Once the malfunction has been cor-
rected, the DDEC system will return
the engine to normal operation.
The DDR can distinguish between
codes now active and those stored in
the historic code memory.
The malfunction code recorded in
the computer memory will remain until
it is erased by a technician.
The historic malfunction codes can
also be obtained by the operator. A
"Diagnostic Request" switch is located
at the BBIM which, when pressed, will
cause the "Check Engine" light (or
CEL) to flash a code number. It will, for
example, flash twice...pause...flash
five times....pause. In other words, a
code 25.
Code 25 indicates all systems are
working 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, affecting engine
operation.
CAUTION:
The operator of a DDEC-
equipped vessel must not
attempt to use or read a diagnos-
tic data reader of any kind while
the vessel is operating. Doing so
can result in loss of control,
which may cause vessel damage
and may result in personal injury.
When engine or electronics
system diagnosis is required on
a DDEC-equipped vessel, this
must be done by a person other
than the operator. The operator
must maintain control of the
moving vessel while the assistant
performs the diagnosis.
NOTICE:
To prevent damage to the DDEC
electronic control system, discon-
nect the following before welding:
battery power and ground cables
and the 6-pin power connector at the
ECM (electronic control module).
Failure to isolate the DDEC sys-
tem from high current flow can
result in severe ECM damage.
CAUTION:
The operator of a DDEC-equipped
engine should know the extent of
the warning system on his vessel,
in order to bring it to a safe stop in
the event of an engine malfunc-
tion. A description of the warning
system and detailed instructions
regarding its operation should be
obtained from the owner, the seller
or the manufacturer of the vessel.
This information may also be
obtained at any authorized Detroit
Diesel service outlet.
23

AIR COMPRESSOR BLOWER
OIL COOLER
OIL FILTER
FLYWHEEL HOUSING
FLYWHEEL
25
TURBOCHARGER
BREATHER
OIL PAN
FAN
DIPSTICK
ROCKER COVER
STARTER MOTOR
OIL
FILLER
EXHAUST
MANIFOLD
THERMOSTAT
HOUSING
ELECTRONIC
CONTROL
MODULE (ECM)
CRANKSHAFT
PULLEY
TYPICAL SERIES 92 ENGINE
(6V-92 TURBOCHARGED-AFTERCOOLED ENGINE SHOWN)
ENGINE SYSTEMS
Fuel System
The fuel system consists of the fuel
injectors, fuel pipes, fuel manifolds
(integral with the cylinder head), fuel
pump, fuel strainer, fuel filter, and the
necessary connecting fuel lines. The
fuel system on DDEC engines also
includes electronic fuel system con-
trols and a cooling plate for the elec-
tronic control module (ECM).
The primary filter (marked "P") or
combination filter and fuel/water sep-
arator removes large impurities from
the fuel. The secondary filter (marked
“S”) removes the smaller particles.
Lubrication System
The lubricating oil system consists of
an oil pump, oil cooler, full flow oil fil-
ter(s), bypass valves at the oil cooler
and filter(s), and pressure relief and
regulator valves at the lube oil pump.
Air System
In the air system used on Series 92
engines, outside air drawn into the
engine passes through the air filter,
air silencer, or air separator and is
pulled into the turbocharger, 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 are used on
the majority of Detroit Diesel engines.
For optimum protection of the engine
from dust and other airborne contam-
inants, service these air cleaners
when the maximum allowable air
restriction has been reached, or
annually, whichever occurs first.
Cooling System
Radiator/fan cooling systems are
used on engines in on-highway, off-
highway, industrial, and generator
set applications. Heat exchanger/raw
water pump systems and keel cool-
ing systems are used on marine
engines. Certain generator set appli-
cations may also use heat exchang-
ers. Each system has a centrifugal
type fresh water pump to circulate
coolant within the engine. Each sys-
tem also incorporates thermostats to
maintain normal engine operating
temperature.
Electrical System
The electrical system generally con-
sists of a starting motor, starting
switch, battery-charging alternator,
storage batteries, and the necessary
wiring.
Exhaust System
Hot exhaust gas flowing from the
exhaust manifold into the exhaust riser
is used to drive the turbocharger.
24

HOURS 150 300 500 1,000 4,000
Fuel Tank (2)
Fuel Lines and Flexible Hoses* (3) II
Cooling System (4) II
Drive Belts* (8) I
Air Cleaner* (7) I
Air Separators* (7) R
Fuel Filters* (10) R
Water Pump, Seal* (11)
Tachometer Drive (22) I
Air System (7)
Turbocharger, Exhaust Connections (5)*
Engine (Steam Clean) (34)*
Oil Pressure (13)* I
Battery Charging Alternator* (14) I
Engine & Transmission Mounts (15)* I
Closed Crankcase Collectors* (16) I
Thermostats & Seals* (31) R
Crankcase Breather* (16) I
Crankcase Pressure* (16) I
Blower Screen (32)
Blower Bypass Valve (21)
Coolant Filter/Conditioner* (11)
Fuel Lines and Flexible Hoses* (3)
Air Box Drain Tube* (25) I
Air Shutdown Valve* (12) I
Governor, Overspeed Governor (28) I
Raw Water System Zincs (18)
Throttle Delay/Fuel Modulator* (29)
Air Box Check Valves (25)* I
Marine Gear* (20) I
Marine Gear Oil Cooler* (20) R
Fuel and Boost Coolers* (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) 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 HOUR
Lubricating 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 HOUR
Coolant Filter/Inhibitor Level* (11) I
Codes
*See Item in Text I Inspect, Service, Correct, R Replace
Replace (If Necessary)
SERVICE
RECOMMENDATIONS
MARINE ENGINES
(Continued Next Page)
NOTE: Numbers after each item refer to the lubrication and preventive maintenance intervals section
which follows.

MONTHS 6 12 18 24 30 36 42 48 54 60 120 —
MILES 1000 x 10 20 30 40 50 60 70 80 90 100 200 240
Fuel Filters (10) R R R R R R R R R R
Water Pump* (11) IIIIIIIIII I
Fuel Tank* (2) II I I I
Cooling System* (4) III I I
Air Compressor* (23) III I I
Air System, Cleaners (7)* III I I
Turbochargers, Exhaust Conns.* (5) III I I
Engine (Steam Clean)* (34) III I I
Radiator* (26) III I I
Oil Pressure* (13) III I I
Battery Charging Alternator* (14) III I I
Thermostats and Seals* (31) III I I R
Engine and Transmission Mounts* (15) I
Crankcase Pressure* (16) I
Crankcase Breather* (16) III I I
Blower Bypass Valve* (21) I
Coolant Filter/Inhibitor Level* (11)
Fuel Lines, Flex Hoses* (3) III IR
Air Box Drain Tube* (25) III
Air Shutdown Valve* (12) III I I
Shutter Operation* (27) III I I
Throttle Delay/Fuel Modulator* (29) II
Air Box Check Valves* (25) I
Fan Hub* (30) III 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 Flexible Hoses (3) I
Cooling System (4) I
Turbocharger, Exhaust Conns. (5) I
3000 MILE INTERVAL
Battery* (6) I
6000 MILE INTERVAL
Drive Belts* (8) I
Air Compressor (23) I
Throttle Controls (24) I
15,000 MILE INTERVAL
Fuel 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 IInspect, Service, Correct, R Replace
Replace (If Necessary)
SERVICE
RECOMMENDATIONS
VEHICLE ENGINES
(Continued Next Page)
NOTE: Numbers after each item refer to the lubrication and preventive maintenance intervals section
which follows.
28

STATIONARY AND INDUSTRIAL
ENGINE MAINTENANCE
31
MONTHS 6 9 12 18 36 60 120
HOURS 300 500 700 1,000 2,000 3,000 6,000
Fuel Tank* (2) II
Fuel Lines and Flexible Hoses* (3) IR
Cooling System* (4) I
Drive Belts* (8)
Air Compressor* (23) I
Air Cleaner* (7) IR
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) II
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 INDUSTRIAL
ENGINE MAINTENANCE
DAILY
Lubricating 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 MILES
Battery* (6) I
150 HOUR OR 4,500 MILES
Lubricating Oil* (1) R
Lubricating Oil Filter* (9) R
150 HOUR OR 5,000 MILES
Air Compressor* (23) I
200 HOUR OR 6,000 MILES
Coolant Filter/Inhibitor Level* (11) I
Drive Belts* (8) I
Throttle Controls* (24) I
600 HOURS OR 18,000 MILES
Water Pump (11)* I
Codes
*See Item in Text I Inspect, Service, Correct, R Replace
Replace (If Necessary)
30
SERVICE
RECOMMENDATIONS
STATIONARY AND
INDUSTRIAL ENGINES
(Continued Next Page)
NOTE: Numbers after each item refer to the lubrication and preventive maintenance intervals section
which follows.

Refill the tank at the end of each
day’s operation to prevent condensa-
tion from contaminating the fuel.
Condensation formed in a partially
filled tank promotes the growth of
microorganisms that can clog fuel fil-
ters and restrict fuel flow. To prevent
microbe growth add a biocide to the
fuel tank or primary fuel supply. Follow
manufacturer’s usage, handling, and
safety recommendations.
Water accumulation can be con-
trolled by mixing isopropyl alcohol (dry
gas) into the fuel oil at a ratio of one
pint (0.5 liter) per 125 gallons (473
liters) fuel (or 0.10% by volume).
Detroit Diesel does not recom-
mend adding alcohol to fuel used in
marine engines.
Open the drain at the bottom of the
fuel tank every 30,000 miles or 48,000
km (300 hours for industrial applica-
tions) to drain off any water and/or
sediment.
Every 12 months or 120,000 miles
(192,000 km) (600 hours for industrial
applications) tighten all fuel tank
mountings and brackets. At the same
time, check the seal in the fuel tank
cap, the breather hole in the cap and
the condition of the flexible fuel lines.
Repair or replace the parts, as neces-
sary.
Item 3 — Fuel Lines, Flexible
Hoses
Pre-Start Inspection—Make a visual
check for fuel leaks at all engine-
mounted fuel lines and connections,
and at the fuel tank suction and return
lines. Since fuel tanks are susceptible
to road hazards, leaks in this area may
best be detected by checking for
accumulation of fuel under the tanks.
Check hoses daily as part of the pre-
start inspection. Examine hoses for
leaks, and check all fittings, clamps,
and ties carefully. Make sure that
hoses are not resting on or touching
shafts, couplings, heated surfaces
including exhaust manifolds, any
sharp edges, or other obviously haz-
ardous areas. Since all machinery
vibrates 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 cracked
or if hoses have ruptured or worn
through, take corrective action imme-
diately. Leaks are not only potentially
detrimental to machine operation, but
they can also result in added expense
caused by the need to replace lost
fluids.
Service life—A hose has a finite ser-
vice life. With this in mind, all hoses
should be thoroughly inspected at
least every 500 operating hours (1,000
hours for 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 flammable fluids
such as fuel or lube oil.
LUBRICATION AND
PREVENTIVE MAINTE-
NANCE INTERVALS
The following is intended as a guide
for establishing preventive mainte-
nance intervals. The recommenda-
tions given should be followed as
closely as possible to obtain long life
and optimum performance from
Series 92 engines. Intervals indicated
on the chart are time (hours or
mileage) of actual operation.
The intervals shown apply only to
the maintenance functions de-
scribed. These functions should be
coordinated with other regularly
scheduled maintenance.
The “daily” instructions apply to
routine or daily starting of an engine.
They do not apply to a new engine or
one that has not been operated for a
considerable period of time. For new
or stored engines, refer to the engine
service manual (6SE379). Follow
instructions given under Prepar-
ations for Starting the Engine the
First Time (section 13.1).
Preventive maintenance other than
the “daily” checks should be per-
formed by authorized Detroit Diesel
service outlets. These outlets have
the trained personnel and special
tools to properly perform all services.
Item 1 - Lubricating Oil
Check the oil level daily with the
engine stopped. On coach engines
equipped with running level dip-
sticks, this may be done with the
engine at idle and at operating tem-
perature. If necessary, add sufficient
oil to raise the level to the proper
mark on the dipstick. All diesel
engines are designed to use some
oil, so the periodic addition of oil is
normal.
For lubricating oil change intervals,
refer to “When to Change Oil” in the
How To section of this guide. Before
adding lube oil, refer to “How to
Select Lubricating Oil” in the How To
section.
Item 2 — Fuel and Fuel Tank
Keep the fuel tank filled to reduce con-
densation. Before adding fuel, refer to
How to Select Fuel Oil in the How To
section of this guide.
L
F
Check Oil Level Daily
32
Keep Tank Filled to Reduce Condensation
NOTICE:
If the oil level is constantly above
normal and excess lube oil has not
been added to the crankcase, con-
sult with an authorized Detroit Diesel
service outlet for the cause. Fuel or
coolant dilution of lube oil can result
in serious engine damage.

or 200,000 miles (320,000 km),
whichever comes first. At this interval,
the coolant must be drained and the
cooling system cleaned thoroughly.
The cooling system should then be
replenished with Power Cool or an
equivalent quality ethylene glycol base
antifreeze/ water solution in the
required concentration. If Power Cool
or equivalent fully formulated pre-
charged inhibited ethylene glycol
(IEG) antifreeze is not used, required
Detroit Diesel Maintenance Product
cooling system inhibitors must be
added at initial fill. Inhibitor levels must
be checked at regular intervals and a
new maintenance element installed, if
required. Refer to “Inhibitor Test
Procedures” under How to Select
Coolant and use the required coolant
filter/conditioner elements shown on
the Specifications chart (pages 73-74).
Cooling System Hoses—All cooling
system hoses should be inspected at
least every 500 hours for signs of dete-
rioration and replaced, if necessary.
Raw Water Cooling System- Drain at
the end of each boating season.
Sea Strainers- Inspect sea strainers
daily. Clean sea strainers at least annu-
ally. Clean more often if surface sea-
weed growth or water contamination
levels are fairly high.
Item 5 - Turbocharger, Exhaust
Connections
Visually inspect the mountings, intake
and exhaust ducting and connections
for leaks daily. Check the oil inlet and
outlet lines for leaks or restrictions to oil
flow. Check for unusual noise or vibra-
tion and, if excessive, stop the engine
and do not operate until the cause is
determined.
Every 12 months, 700 hours or
20,000 miles (32,000 km), the exhaust
manifold retaining nuts, exhaust flange
clamp and other connections should be
checked for tightness. Check for proper
operation of the exhaust pipe rain cap, if
one is used.
Check heat-insulating exhaust sys-
tem blankets for damage daily. Torn,
matted, crushed, oil-soaked, or other-
wise damaged insulation blankets must
be replaced immediately.
Item 6 - Battery
Check "Eye" of Maintenance-Free Batteries
35
Eye
CAUTION:
To avoid personal injury or tur-
bocharger damage, do not remove,
attach, or tighten turbocharger air
intake ducting while the engine is
operating or operate the engine
with the ducting removed.
CAUTION:
To avoid possible personal injury
and/or engine damage from acci-
dental engine startup, always dis-
connect the battery before
servicing the electrical system. To
avoid 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 during major
overhaul and/or after a maximum of
five years of service.
EXCEPTION: Replace all cooling
system hoses on pleasure craft
marine engines after 1,000 hours of
service, regardless of apparent con-
dition. Cooling system hoses on
commercial marine engines do not
require automatic replacement after
1,000 hours, but should be replaced
at overhaul.
Fire resistant fuel and lube oil hose
assemblies do not require automatic
replacement after five years service or
at major overhaul, but should be
inspected carefully before being put
back into service.
Item 4 - Cooling System
Check the coolant level daily and
maintain it near the bottom of the filler
neck on the radiator or heat exchang-
er. On some installations this is done
by checking an overflow bottle or sight
glass. Add coolant as necessary, but
do not overfill. Before adding coolant,
refer to How to Select Coolant in the
How 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 is
running and when it is stopped. Cool-
ant leaks may be more apparent on an
engine when it is cold.
The inhibitors in antifreeze solutions
should be replenished with a non-
chromate corrosion inhibitor supple-
ment when indicated by testing the
coolant. Refer to How to Select
Coolant for required test intervals and
inhibitor levels.
Coolant Drain Interval—Detroit
Diesel recommends replacing cool-
ant with genuine Detroit Diesel
Power Cool antifreeze or equivalent
quality ethylene glycol-base perma-
nent type antifreeze annually.
However, a cooling system properly
maintained and protected with supple-
mental corrosion inhibitors can be
operated up to two years, 4000 hours,
Remove Radiator or Heat Exchanger
Pressure Control Cap with Caution
34
CAUTION:
Do not remove the pressure con-
trol cap from the radiator or heat
exchanger or attempt to drain the
coolant until the engine has
cooled. Once the engine has
cooled, use extreme caution when
removing the cap. The sudden
release of pressure from a heated
cooling system can result in a loss
of coolant and possible personal
injury (scalding, eye injury, etc.)
from the hot liquid.