Detroit Diesel 92 Series User manual

•
•
SERIES9e™
Service
Manual
Detroit Diesel
Series 92
Engine
DETRDIT DIESEL
NOTE:
CCIRPGRATION
6SE379 September 1999
•
1MOO OUterOrl\19, WestIDetroit. Mtchigan ~1
Telephone: 31:s-592-SOCIO
Fax:: [phone]
http:llwww.detrottdlesel.com
Additional copies of this service manual may be
purchased from Detroit Diesel Corporation
Distributors. See your yellow pages- under
Engines, Diesel.
Detroit DieseP, .OOC- and the spinning arrows design areregistered trademarks of DetroitDiesel Corporation.
Series
12 Tll is atrademark of DetroitDieselCorporation.
All information subjectto change withoutnotice.
8SE379 9909 Copyright C> 1999DETROIT DIESEL CORPORATION. Al rightsreserved.
Printed in U.S.A.

CALIFORNIA
Proposition 65 Warning
Diesel engine exhaust and some of its
constituents are known to the State of
California to cause cancer, birth
defects, and other reproductive harm.

•
•
•
SERIES 92 SERVICE MANUAL
A CAUTION:
Engine
exhaust
may
be
harmful
to
your
health
if
inhaled. To
reduce
the
chance
of
personal
injury
and/or
property
damage,
the
following
instructions
must
be
carefully
observed.
Proper
service
and
repair
are
important
to
the
safety
of
the
service
technician
and
the
safe, reliable operation
of
the
engine.
If
part
replacement
is
necessary, the
part
must
be replaced
with
one
of
the
same
part
number
or
with
an equivalent
part
number. Do
not
use a replacement
part
of
lesser
quality.The
service
procedures
recommended
and
described
in
this
manual are effective
methods
of
performing
repair.
Some
of
these
procedures
require
the
use
of
specially
designed
tools.Accordingly,
anyone
who
intends
to
use
a replacement
part, procedure
or
tool
which
is
not
recommended,
must
first
determine
that
neither
personal safety
nor
the
safe
operation
of
the
engine
will
be jeopardized
by
the
replacement part,
procedure
or
tool
selected.It
is
important
to
note
that
this
manual
contains
various
"Cautions"
and
"Notices"
that
must
be
carefully
observed
in
order
to
reduce
the
risk
of
personal
injury
during
repair
or
the
possibility
that
improper
repair
may
damage
the
engine
or
render
it
unsafe.
It
is
also
important
to
understand
that
these
"Cautions"
and
"Notices"
are
not
exhaustive, because
it
is
impossible
to
warn
personnel
of
the
possible
hazardous
consequences
that
might
result
from
failure
to
follow
these
instructions.
___
___.
ABSTRACT
This manual provides instruction for servicing on-highway, industrial, generator set, and marine
applications
of
the Detroit Diesel Series 92 Engines.
Specifically a basic overview
of
each major component and system along with recommendations
for removal, cleaning, inspection, criteria for replacement, repair and installation and mechanical
troubleshooting are contained in this manual.
DDEC
III/IV troubleshooting concerns are contained in the DDEC III/IV Single
ECM
Troubleshooting Guide, 6SE497.
All
~
.subject
to
chanr,s
without
noJice.
6SE379
9909
Copyright
Q
1999DETROIT DIESEL CORPORATION

SERIES 92 SERVICEMANUAL
REVISION NOTIFICATION
Modifications to this manual are announced in the form
of
Service Information
Bulletins. The bulletins include attachment pages and are posted on the World Wide Web
(www.detroitdiesel.com/svc/sibindex.htm).
Revisions to this manual will be sent marked with a revision bar (see Example 2). Sections
containing revisions will have a third line in the page footer (compare Examples I and 2).
ii
AJflrdolmaOoff
~fOC,-..
lllllilncMlf---.
6SE379 9905
01990
DETROIT OIESEL CORPORATION
Example
1 -
Unchanged
Pages
I
The
active switchinput
repiesents
alow (grounded) exlemal input
cin:uit
to
theECM.
NI,,,,,,,,,__,
sllbJ,,dlOchange
wfltJwfnadce.
6SE319
990$
01989
DETROIT
DIESEL
CORPORATION
Example
2 -
Changed
Pages
From
BuHatin
1-92-00
AH
inlormatiOn
sutJjl1ct
to
Changs
without
notJcs.
6SE379
9909
CopyrightO 1999 DETROIT DIESEL CORPORATION
•
•
•

•
•
SER/ES 92 SERVICE MANUAL
TABLE OF CONTENTS
1 ENGINE
1.1 CYLINDER BLOCK .................................................................................
1.2 CYLINDER BLOCK END PLATES .........................................................
..
1.3 CYLINDER HEAD ...................................................................................
1.4 VALVE AND INJECTOR OPERATING MECHANISM ..............................
1.5 EXHAUST VALVES .................................................................................
1.6
VALVE ROCKER COVERS .................................................................... ..
1.7 CRANKSHAFT ........................................................................................
1.8 CRANKSHAFT OIL SEALS (FRONT AND REAR) ..................................
1.9 CRANKSHAFT CAP ................................................................................
1.10 CRANKSHAFT MAIN BEARING SHELLS ...............................................
1. 11 ENGiNE FRONT COVER ........................................................................
1.12 CRANKSHAFT OUTBOARD BEARING SUPPORT (TRUNNION) ........
..
1.13 CRANKSHAFT REAR OUTBOARD BEARING SUPPORT .....................
1.14 CRANKSHAFT VIBRATION DAMPER .....................................................
1.15 CRANKSHAFT PULLEY ..........................................................................
1.16 FLYWHEEL .............................................................................................
1.17 CLUTCH PILOT BEARING ....................................................................
..
1.18 ENGINE DRIVE SHAFT FLEXIBLE COUPLING ................................... ..
1.19 FLYWHEEL HOUSING ............................................................................
1.20 PISTON AND PISTON RINGS .................................................................
1.21 CONNECTING ROD ................................................................................
1.22 CONNECTING ROD BEARINGS .............................................................
1.23 CYLINDER LINER ..................................................................................
1.24 ENGINE BALANCE AND BALANCE WEIGHTS .....................................
1.25 GEAR TRAIN AND ENGINE TIMING ....................................................
..
1.26 CAMSHAFTS AND BEARINGS ...............................................................
1.27 CAMSHAFT GEARS ...............................................................................
1.28 IDLER GEAR AND BEARING ASSEMBLY ..............................................
1.29 CRANKSHAFT TIMING GEAR ..............................................................
..
1.30 BLOWER DRIVE GEAR AND SUPPORTASSEMBLY ............................
1.31 ACCESSORY DRIVE ...............................................................................
1.32 BALANCE WEIGHT COVER ...................................................................
1.A ADDITIONAL INFORMATION ..................................................................
2 FUEL SYSTEM
2.1 FUEL SYSTEM ..................................................................................... ..
2.2 MECHANICAL UNIT INJECTOR .............................................................
2.3 ELECTRONIC UNIT INJECTOR ............................................................
..
2.4 FUEL INJECTOR TUBE ...........................................................................
2.5 ELECTRONIC ENGINE CONTROLS ......................................................
2.6 DDEC
II ....................................................................................................
Al intxmstion subject to~ without. notice.
6SE379 9909 Copyright© l999 DETROIT DIESELCORPORATION
1-3
1-45
1-55
1-84
1-113
1-137
1-144
1-179
1-190
1-194
1-212
1-218
1-227
1-240
1-256
1-261
1-269
1-274
1-283
1-306
1-335
1-354
1-364
1-381
1-382
1-390
1-419
1-427
1-451
1-462
1-480
1-503
1-507
2-3
2-7
2-57
2-69
2-80
2-85
iii

SERIES
92
SERVICEMANUAL
2.7 DDEC Ill ................................................•.................................................
2-91
2.8 DDEC IV ....................
..
....
..
..
....
..
..
...
..
..
..
..
..
...
.
...
....
..
...........
..
..........
...
.
...
.... 2-97 •
2.9 ELECTRONIC FOOT PEDAL ASSEMBLY ............................................... 2-104
2.10 TURBO BOOST SENSOR ...................................................................... 2-105
2.11
Oil
PRESSURE SENSOR ..................................................................... 2-108
2.12
Oil
TEMPERATURE SENSOR ...............................................................
2-111
2.13 PULSE WHEEL DDEC Ill AND
II
(6V AND
av
ENGINES} ...................... 2-114
2.14 SYNCHRONOUS REFERENCE SENSOR (6V AND 8V) ........................ 2-121
2.15 TIMING REFERENCE SENSOR ............................................................. 2-126
2.16 COOLANT LEVEL SENSOR ................................................................... 2-140
2.17 COOLANT TEMPERATURE SENSOR .................................................... 2-146
2.18 COOLANT PRESSURE SENSOR (12Vand 16V) ................................... 2-148
2.19 FUEL PRESSURE SENSOR ................................................................... 2-150
2.20 FUEL TEMPERATURE SENSOR ............................................................ 2-153
2.21
FUEL PUMP ............................................................................................ 2-156
2.22 FUEL STRAINER AND FUEL FILTER ..................................................... 2-180
2.23 FUEL COOLER ....................................................................................... 2-188
2.24 LIMITING SPEED MECHANICAL GOVERNOR ...................................... 2-191
2.25 LIMITING SPEED MECHANICAL GOVERNOR (VARIABLE
LOW-SPEED}
..
.............
...
.
...
....................
..
......................
..
...
....
..
..
.....
...
.... 2-254
2.26 LIMITING SPEED MECHANICAL GOVERNOR (VARIABLE HIGH
SPEED) .................................................................................................... 2-268
2.27 VARIABLE SPEED MECHANICAL GOVERNOR .................................... 2-277
2.28 SG HYDRAULIC GOVERNORS .............................................................. 2-330 •
2.29 PSG HYDRAULIC GOVERNOR ..
...
..
..
..
..
...
..
.
..
..
..
...........
...
...
..
.
..
..
.
..
...
...
..
.. 2-369
2.30 HYDRAULIC GOVERNOR DRIVE ........................................................... 2-379
2.31
HYDRAULIC GOVERNOR SYNCHRONIZING MOTOR .......................... 2-421
2.32 ELECTRONIC GOVERNOR .................................................................... 2-424
2.33 FUEL INJECTOR CONTROL TUBE (NON-DDEC ENGINES) ................ 2-425
2.A ADDITIONAL INFORMATION .................................................................. 2-439
3 LUBRICATING SYSTEM
4
iv
3.1
LUBRICATION SYSTEM .......................................................................... 3-3
3.2 LUBRICATING
Oil
PUMP (6V AND
av
ENGINES) ................................
3-11
3.3 LUBRICATING OIL PUMP (12V AND 16V ENGINES) ............................ 3-36
3.4 LUBRICATING OIL PRESSURE REGULATOR
VALVE
........................... 3-50
3.5 LUBRICATING OIL PRESSURE RELIEF
VALVE
.................................... 3-59
3.6 LUBRICATING OIL FILTERS ................................................................... 3-68
3.7 LUBRICATING OIL COOLER (PLATE TYPE)..........................................
3-81
3.8 LUBRICATING OIL COOLER (TUBE TYPE) ........................................... 3-95
3.9 LUBRICATING OIL COOLER BYPASS
VALVE
........................................ 3-114
3.10 OIL LEVEL DIPSTICK .............................................................................. 3-119
3.11
OILPAN ................................................................................................... 3-123
3.12 VENTILATING SYSTEM .......................................................................... 3-130
3.A ADDITIONAL INFORMATION .................................................................. 3-135
4.1
COOLING SYSTEM
COOLING SYSTEM 4-3
All
information subjf1ct
to
change
witllout
notk:e.
6SE379
9909
Copyright© 1999 DETROITDIESEL CORPORATION
•

SERIES 92 SERVICE MANUAL
4.2
• 4.3
4.4
WATER PUMP (6V AND
av ENGINES) ·················································· 4-5
WATER PUMP (12V AND 16V ENGINES) .............................................. 4-24
WATER MANIFOLD ................................................................................ 4-37
4.5 THERMOSTAT ........................................................................................ 4-43
4.6 RADIATOR .
.. ......... .. .... ... . ... .. .. .. ... .. .. ................. .. ................................. ... . 4-54
4.7 COOLANT PRESSURE CONTROL CAP ...........................
.. .. ... . .. ........... 4-67
4.8 ENGINE COOLING
FAN .......................................................................... 4-70
4.9 HEAT EXCHANGER ............................................................................... 4-98
4.10 RAW WATER PUMP ................................................................................ 4-107
4.11 COOLANT FILTER AND CONDITIONER ................................................ 4-121
4.A ADDITIONAL INFORMATION .................................................................. 4-127
5 FUEL, LUBRICATING OIL, AND COOLANT
5.1 FUEL ........................................................................................................ 5-3
5.2 LUBRICATING OIL REQUIREMENTS ..................................................... 5-23
5.3 COOLANT ..
.. ......... .. ........... .. .... .. . .. ... .. ............. .. .. .. ........ .. .... .. ................. .. 5-34
6 AIR INTAKE SYSTEM
6.1 AIR INTAKE SYSTEM ............................................................................. 6-3
6.2 AIR CLEANER ........................................................................................ 6-5
6.3 AIR SEPARATOR FILTER ELEMENT ...................................................... 6-13
6.4 AlR SHUTDOWN HOUSING ...
... .. .......... .. ...................... .. ....................... 6-15
6.5 BLOWER .....
... . .. .. .. . ... .. .... ... ........ ... ............................... .. ......... .. .... .. .. ... .... 6-26
6.6 TURBOCHARGER (AIRESEARCH) ........................................................ 6-83
6.7 TURBOCHARGER INTERCOOLER ........................................................ 6-119
6.8 TURBOCHARGER AFTERCOOLER ....................................................... 6-127
6.A ADDITIONAL INFORMATION .................................................................. 6-139
7 EXHAUST SYSTEM
7.1 EXHAUST SYSTEM ................................................................................ 7-3
7.2 EXHAUST MANIFOLD ............................................................................ 7-5
7.3 EXHAUST MANIFOLD (WATER-COOLED).............................................
7-11
8 ELECTRICAL EQUIPMENT
8.1 BATTERY-CHARGING ALTERNATOR .................................................... 8-3
8.2 STARTING MOTOR ................................................................................. 8-12
8.3 TACHOMETER DRIVE ............................................................................. 8-15
8.4 INSTRUMENTS ......................................................................................
8-21
8.5 ENGINE PROTECTIVE SYSTEMS ......................................................... 8-25
8.6 ALARM SYSTEM ..
.. .... ... . ... ........... .. ........................... .. .. .. ....................... 8-49
8.7 OVERSPEED GOVERNOR ..................................................................... 8-56
8.A ADDITIONAL INFORMATION .................................................................. 8-63
9 POWER TAKE-OFF
9.1 POWER TAKE-OFF TORQMATIC CONVERTER .................................... 9-3
10 SPECIAL EQUIPMENT
10.1 AIR COMPRESSOR ............................................................................... 10-3
• 10.2 ENGINE BLOCK HEATER ...
.. . .. .... ............................................... ... ...... .. . 10-9
10.3 TRANSMISSIONS .................................................................................. 10-10
Alt mtirmatiOn StJbject to change wilhoUt notlctit.
6SE379 9909 Copyright© 1999 DETROITDIESEL CORPORATION V

SERIES 92 SERVICE MANUAL
11 OPERATION AND VERIFICATION
11.1 PREPARATION FOR A FIRST TIME START ......... ... ............................... 11-3
11.2 STARTING ............................................................................................... 11-8
11.3 RUNNING.................................................................................................
11-11
11.4 STOPPING .............................................................................................. 11-18
11.5 OPERATING CONDITIONS
.. ............. .... ...... .... ........................................ 11-20
11.6 ENGINE RUN-IN PROCEDURES .........................:.................................. 11-54
12 ENGINE TUNE-UP
12.1 ENGINE TUNE-UP ................................................................................. 12-3
12.2 EXHAUST
VALVE CLEARANCE ADJUSTMENT .................................... 12-29
12.3 FUEL INJECTOR TIMING ........................................................................ 12-33
12.4 LIMITING SPEED MECHANICAL GOVERNOR INJECTOR RACK
CONTROL ADJUSTMENT (6V AND
av ENGINES) ............................... 12-37
12.5 LIMITING SPEED MECHANICAL GOVERNOR AND INJECTOR RACK
CONTROL ADJUSTMENT (12V AND 16V ENGINES) ............................ 12-89
12.6
STATIC DOUBLE WEIGHT LIMITING SPEED GOVERNOR GAP
CHECKING AND SETTING PROCEDURE ............................................. 12-121
12.7 LIMITING SPEED MECHANICAL GOVERNOR ADJUSTMENT
(VARIABLE LOW-SPEED) ....................................................................... 12-133
12.8 LIMITING SPEED MECHANICAL GOVERNOR FAST IDLE CYLINDER 12-145
12.9 GOVERNOR SETTINGS FOR
"Tr ENGINES ........................................ 12-149
12.10 VARIABLE SPEED MECHANICAL GOVERNOR INJECTOR RACK
CONTROL ADJUSTMENT (6V AND
av ENGINES) ··························..... 12-180
12.11 VARIABLE SPEED MECHANICAL GOVERNOR AND INJECTOR RACK
CONTROL ADJUSTMENT (12V AND 16V ENGINES) ............................ 12-193
. 12.12
SG VARIABLE SPEED HYDRAULIC GOVERNOR INJECTOR RACK
CONTROL ADJUSTMENT (6V AND
av ENGINES) ··························..... 12-211
12.13 SG VARIABLE SPEED HYDRAULIC GOVERNOR INJECTOR RACK
CONTROL ADJUSTMENT (12V AND 16V) ............................................. 12-230
12.14 GOVERNORS WITH SYNCHRONIZING MOTOR ................................... 12-251
12.15 SUPPLEMENTARY GOVERNING DEVICE ADJUSTMENT .................... 12-252
12.16 POWER CONTROL DEVICE ................................................................... 12-256
12.17 THROTTLE DELAY MECHANISM ADJUSTMENT .................................. 12-259
12.18 FUEL MODULATOR ................................................................................ 12-273
13 PREVENTIVE MAINTENANCE
vi
13.1 PREVENTIVE MAINTENANCE ITEMS DESCRIPTION ..........................
13.2 MAINTENANCE OF VEHICLE ENGINE ..................................................
13.3 MAINTENANCE OF STATIONARY AND INDUSTRIAL ENGINE ............
13.4 MAINTENANCE OF PLEASURE CRAFT MARINE ENGINES ..............
..
13.5 LUBRICATING OIL ...................................................................................
13.6 OIL PRESSURE ......................................................................................
13.7 LUBRICATING OIL FILTER ......................................................................
13.8 FUEL STRAINER AND FILTER ...............................................................
13.9 FUEL TANK .............................................................................................
13.10 FUEL CONTAMINATION ..........................................................................
13.11 FUEL LINES AND FLEXIBLE HOSES .....................................................
13-5
13-6
13-12
13-16
13-19
13-28
13-29
13-31
13-34
13-35
13-36
Alt inbtmation subjtK:t to change tvilhoutnotice.
6SE379 9909 Copyright© 1999 DETROIT DIESEL CORPORATION
•
•
•

SERIES 92 SERVICE MANUAL
13.12 COOLING SYSTEM ................................................................................ 13-38
• 13.13 WATER PUMP ........................................................................................ 13-51
13.14 COOLANT FILTER .....
... .... ... .... .. . .. .... .. .. ... ........ .... .................... ... .. ...... .. .. 13-52
13.15 COOLANT FILTER/INHIBITOR PRE-CHARGE ELEMENT ..................... 13-53
13.16 RADIATOR
.. ... . ... ........ ... .. .................. .... ... . ... . .. . .. .. .. .... .. . ... . ... ................... 13-55
13.17 TURBOCHARGER AND EXHAUST CONNECTIONS ............................. 13-56
13.18 DRIVE BELTS
.. ....................................................................................... 13-60
13.19 BATTERY ................................................................................................. 13-67
13.20 BATTERY CHARGING ALTERNATOR ..................................................... 13-69
13.21 ENGINE AND TRANSMISSION MOUNTS .............................................. 13-71
13.22 ENGINE TUNE-UP ................................................................................. 13-72
13.23 BLOWER BYPASS VALVE ....................................................................... 13-73
13.24 TACHOMETER DRIVE ............................................................................. 13-74
13.25 AIR COMPRESSOR ............................................................................... 13-75
13.26 THROTTLE AND CLUTCH CONTROLS ................................................. 13-76
13.27 AIR BOX DRAIN TUBE ............................................................................ 13-77
13.28 AIR BOX CHECK VALVES ....................................................................... 13-78
13.29 SHUTTER OPERATION ......................................................................... 13-79
13.30 GOVERNOR, OVERSPEED GOVERNOR .............................................. 13-80
13.31 THROTTLE DELAY FUEL MODULATOR ................................................ 13-81
13.32
FAN HUB .................................................................................................. 13-82
13.33 FAN (THERMO-MOUNTED) ................................................................... 13-84
13.34 THERMOSTATS AND SEALS ...
... .. .... .. .. ... .... ... . ... .... .... .... .... ........ ... . ... ..... 13-85
• 13.35 BLOWER SCREEN ................................................................................. 13-86
13.36 FUEL INJECTORS AND VALVE CLEARANCE ....................................... 13-88
13.37 VIBRATION DAMPER .............................................................................. 13-89
13.38 STARTING MOTOR ................................................................................. 13-90
13.39 EXHAUST SYSTEM ................................................................................ 13-92
13.40 CRANKCASE BREATHER (EXTERNALLY MOUNTED) ......................... 13-93
13.41 CRANKCASE BREATHER (INTERNALLY MOUNTED) .......................... 13-94
13.42 ENGINE (STEAM CLEAN) ....................................................................... 13-95
13.43 POWER TAKE-OFF ................................................................................ 13-96
13.44 TORQMATIC CONVERTER..................................................................... 13-98
13.45 REDUCTION GEAR ................................................................................. 13-100
13.46 TRANSIT COACH CONVERTER MUFFLER ........................................... 13-102
13.47 AIR CLEANER ........................................................................................ 13-104
13.48 AIR SYSTEM .......................................................................................... 13-107
13.49 AIR SEPARATOR FILTER ELEMENT ...................................................... 13-108
13.50 AIR SHUTDOWN VALVE ......................................................................... 13-112
13.51 COOLING SYSTEM (MARINE) ............................................................... 13-113
13.52 HEAT EXCHANGER CHANGEOUT INTERVAL ...................................... 13-114
13.53 HEAT EXCHANGER ELECTRODES AND CORE (RAW WATER
SYSTEM ZINCS) ..................................................................................... 13-117
13.54 RAW WATER PUMP ................................................................................ 13-119
13.55 FUEL AND BOOST COOLERS ............................................................... 13-121
• 13.56 TORQMATIC MARINE GEAR (6V AND 8V) ............................................ 13-122
13.57 MARINE GEAR (TWIN DISC 16V) .......................................................... 13-124
AR lnbtmaticnsubjeCt fO Change without notice.
6SE379 9909 Copyright © 1999DETROIT DIESEL CORPORATION vii

SERIES 92 SERVICE MANUAL
13.58 CLUTCH ACTUATOR (DDEC MARINE) ................................................ ..
13-126
14 STORAGE
14.1 PREPARING ENGINE FOR STORAGE ................................................... 14-3
14.2 TEMPORARY ENGINE STORAGE (30
DAYS OR LESS) ....................... 14-4
14.3 RESTORING A TEMPORARILY STORED ENGINE (30
DAYS OR
LESS) ...........................................................................··························
··
14-5
14.4 EXTENDED ENGINE STORAGE (MORE THAN 30
DAYS) .................. ..
14-6
14.5 RESTORING
AN EXTENDED STORAGE ENGINE (MORE THAN 30
DAYS) ....................................................................................................... 14-12
14.6 STORAGE OF BATTERY ......................................................................... 14-15
15 SERIES 92 SERVICE TOOLS
15.1 Series 92 Service Tools ........................................................................ ..
15-3
viii
All information subjed tochtmge wflhout nolics.
6SE379 9909 Copyright© 1999 DETROITDIESEL CORPORATION
•

•
•
SERIES 92 SERVICE MANUAL
ENGINE EXHAUST
Consider the following before servicing engines:
A. CAUTION:
Engine exhaust may be harmful to your health if inhaled.
Please note this caution and remember:
□ Always start and operate the engine in a well ventilated area.
□ If in an enclosed area, vent the exhaust to the outside.
□ Do not modify or tamper with the exhaust system.For accurate dynamometer readings
during a engine run-in, the chassis dynamometer room must be properly ventilated.
See Figure
l.
Figure 1
CALIFORNIA
Proposition 65 Warning
Diesel engine exhaust and some of its
constituents are known to the State
of
California to cause cancer, birth
defects, and other reproductive harm.
California Proposition
65 Warning
All inbrmation sut)ject to change vdthout notice.
6SE379 9909 Copyright © 1999 DETROITDIESELCORPORATION ix

•
GENERAL INFORMATION
Section Page
SCOPE AND USE OF THIS MANUAL ....................................................... 3
SAFETY PRECAUTIONS ........................................................................... 3
FLUOROELASTOMER (VITON) CAUTION ................................................
11
SERVICE PARTS AVAILABILITY ................................................................ 11
CLEARANCE AND TORQUE SPECIFICATIONS ....................................... 11
• THE TWO CYCLE PRINCIPLE FOR DIESEL ENGINES ........................... 12
GENERAL DESCRIPTION ........................................................................ 14
DDEC DIAGNOSTIC READER CAUTION ........
... . .. .... ... . ... ....... .. ........ ... ..... 16
DDEC I
.. ............... .. .. ... .. .. .. ...................... ... ....... .. ........................................ 17
DDEC
11 .. .•• •••• ••• • •• . •• .. •••••. ••• •. ••••••••• •••• ••• •.•• •• . ••• . ••• •• . ••• •••• ••• • ••• •••• ••• •• . •. •..• •••• ••... 18
DDEC Ill ..................................................................................................... 19
GENERAL SPECIFICATIONS ...................................................................
20
ENGINE MODEL, SERIAL NUMBER AND OPTION LABEL ..................... 22
REPAIR AND REPLACE .
.. ... .... ........ ...... .............................................. .. ... .. 26
DISASSEMBLY .......................................................................................... 26
CLEANING . .. .... .. .. ..... .. ............. ... . ... .... ... ............................................... ... ... 27
INSPECTION .. . ... .. .... .. ...... .. ............ .. ............. ... ................ ... ............ .. ... .. . .. 29
ASSEMBLY
.. .... ... ............... .. ............... ...... ............ ... .. ............................. .. .. 29
FABRICATING, ALTERING, REMOVING AND DISPOSING OF
GASKETS ............................................................................................ 30
ENGLISH TO METRIC CONVERSION ...................................................... 31
•

SERIES 92 SERVICE MANUAL
DECIMAL AND METRIC EQUIVALENTS ...................................................
33
34
2
SPECIFICATIONS .....................................................................................
AN fnkxmation subjact to change without notice.
6SE379 9909 Copyright © 1999 DETROIT DIESEL CORPORATION
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SERIES 92 SERVICE MANUAL
SCOPE AND USE OF THIS MANUAL
This manual covers the basic V-92 diesel engines built by the Detroit Diesel Corporation.
Complete instructions on operation, adjustment (tune-up), preventive maintenance, and
lubrication and repair(including complete overhaul) are covered. Basic maintenance andoverhaul
procedures are common to all V-92 engines and apply to all engine models.
The manual is divided into numbered sections.
The first section covers the engine (less major
assemblies). The following sections cover a complete system such as the fuel system, lubrication
system
or air system. Each section is divided into subsections containing complete maintenance
and operating instructions for a specific subassembly on the engine. Each section begins with a
table
of contents. Pages and illustrations are numbered consecutively within each section.
Information can be located using the table
of contents at the front of the manual or the table of
contents at the beginning of each section. Information on specific sub-assemblies within the
major section is listed immediately following the section title.
SAFETY PRECAUTIONS
The following safety measures are essential when working on the Series 92 engine.
Please note this caution and remember:
D Always start and operate the engine in a well ventilated area.
□ If in an enclosed area, vent the exhaust outside.
□ Do not modify or tamper with the exhaust system.
A CAUTION:
The exhaust products of an internal combustion engine are
toxic. They may cause injury or death if inhaled. All engine
installations, especially those within enclosed spaces, should
be equipped with an exhaust discharge pipe so that exhaust
gases
are delivered into the outside air. An enclosed space
must be adequately vented. Some means
of providing fresh
air into an enclosed space must be ensured.
Stands
Safety stands are required in conjunction with hydraulic jacks or hoists. Do not rely on either
the
jack or the hoist to carry the load. When lifting an engine, ensure lifting device is fastened
securely. Ensure that the item to be lifted does not exceed thecapacity
of the lifting device.
Glasses
Select appropriate safety glasses for the job. It is especially important to wear safety glasses when
• using tools such as hammers, chisels, pullers,
or punches.
AJ! lnformatJon subject 1o chBnf}fl wttl'IOu1 noticie.
6SE379 -Copyright Cl 1999 DETROIT DIESELCORPORATION 3

SERIES 92 SERVICE MANUAL
Welding
Wear welding goggles and gloves when welding or using an acetylene torch. Ensure that a metal
shield separates the acetylene and oxygen that must be chained to a cart.
4
A CAUTION:
To avoid possible personal injury when arc welding, gas
welding or cutting, wear required safety equipment such
as arc welder's faceplate or gas welder's goggles, plus
welding gloves and protective apron, long sleeve shirt,
head protection, and safety shoes. Always perform welding
or cutting operations in a well-ventilated area. The gas in
oxygen/acetylene cylinders used in gas welding and cutting
is under high pressure. If a cylinder should fall due to
careless handling, the gage end could strike an obstruction
and fracture, resulting in a gas leak which could lead to fire or
an explosion, both of which could cause personal injury or
property damage or both. If a fall should result in the gage
end breaking off, the sudden release of high pressure gas
could turn the cylinder into a dangerous projectile, which
could cause severe personal injury or property damage
or both. Observe the following precautions when using
oxygen/acetylene gas cylinders: 1. To avoid possible foot
injury, always wear required safety-toed shoes. 2 . Do not
handle tanks in a careless manner or with greasy gloves or
slippery hands. 3. Use a chain, bracket, or other restraining
device at all times to prevent gas cylinders from falling. 4. Do
not drop, drag, roll, or strike a cylinder violently. 5. Always
close valves completely when finished welding or cutting.
A CAUTION:
Do not weld or heat areas near fuel tanks or lines. An
explosion could result if heat buildup inside the tank is
· sufficient. Utilize proper shielding around hydraulic lines.
All inkumation subject to change wllfKNt notice.
6SE379 9909 Copyright© 1999 DETROIT DIESEL CORPORATION
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SERIES 92 SERVICE MANUAL
Work
Place
Organize your work area, and keep it clean. A fall could result in a serious injury. Eliminate
the possibility
of
a fall by:
D Wiping up oil spills.
0 Keeping tools and parts off the floor.
After servicing or adjusting the engine:
D Install all safety devices, guards,
or
shields.
□ Ensure that all tools and service equipment are removed from the engine.
Clothing
Wear safe work clothes that fit and are
in
good condition. Work shoes are sturdy and rough-soled.
Bare feet, sandals,
or
sneakers are not acceptable foot wear when adjusting and/or servicing an
engine.
Do
not wear the following when working on
an
engine:
A
CAUTION:
To avoid personal injury when working near the engine,
do not wear jewelry or loose fitting clothing. Any of these
items could catch on moving parts and cause serious injury.
Safety glasses and hearing protection must be worn.
0 Rings
D Wrist watches
D Loose fitting clothing
0 Any
of
these items could catch on moving parts causing serious injury.
AH
inbrmatioo subjecl
to
change
without
notice.
6SE379 9909
Copyrighl © 1999DETROIT DIESELCORPORATION
5

SERIES 92 SERVICE MANUAL
Power
Tools
Do
not use defective portable power tools. Checkfor frayed cords prior to usingthe tool. Ensure
that all electric tools are grounded. Defective electrical equipment and improper use
of
electrical
equipment can cause severe injury.
Air
A CAUTION:
To avoid personal injury, do not use defective portable
power tools. Check for frayed cords prior
to
use. Ensure
all electric tools are grounded. Using defective electrical
equipment can cause severe injury. Improper use of electrical
equipment can result in electrical shock, fire, or explosion
under certain conditions which may cause severe injury.
Recommendations regarding the use
of
compressed air are indicated throughout the manual
with the following: A
CAUTION:
To
avoid personal injury when blow drying, wear adequate
eye protection (safety glasses or faceplate) and do not
exceed 276 kPa (40 lb/in.
2)
air pressure.
Too much air can rupture
or
in some other way damage a component and create a hazardous
situation that can lead to personal injury. Use only approved air blow guns that
do
not exceed
276
kPa (40 lb/in.
2
).
Wear safety glasses
or
goggles. Use proper shielding
to
protect everyone in
the work area.
6
All
irmrmation
subjed
to change 'Mlhout nolics.
6SE379
9909
Copyright©
1999
DETROIT
DIESEL
CORPORATION
•
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•
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SERIES 92 SERVICE MANUAL
Fluids
and
Pressure
Be extremely careful when dealing with fluids under pressure.
A CAUTION:
Do
not
put
your
hands
in
front
of
fluid
under
pressure.
Fluids
under
pressure
can penetrate
skin
and
clothing
and
cause injury.
A CAUTION:
To
avoid
personal injury,
use
care
when
dealing
with
fluids
under
pressure.
Fluids
under
pressure
have
enough
force
to
penetrate
the
skin.
These
fluids
can cause a
minor
cut
or
opening
in
the
skin.
If
injured
by
escaping
fluid,
see a
doctor
immediately.
Serious
infection
or
adverse reaction
to
the
fluid
can
result
if
not
treated immediately•
Fluids under pressure can penetrate the skin. These fluids can infect a minor cut or opening in
the skin.
If
injured, see a doctor immediately.
/tD
lnformatioo
subject
to
change without
notioe.
6SE379
9909
Copyright©
1999
DETROITDIESELCORPORATION
7

SERIES
92
SERVICE MANUAL
Fuel
Keep the hose and nozzle
or
the funnel and container in contact with the metal
of
the fuel tank
when refueling to avoid the possibility
of
an electric spark igniting the fuel.
The following cautions should be followed when filling a fuel tank:
8
A
CAUTION:
To
avoid personal injury, do not overfill the fuel tank. Overflow
will release flammable liquid and create a fire hazard.
A CAUTION:
Do not smoke when refueling. Do not refuel when
the engine is hot or running.
AH
infonnation
Subj8C(
lo
change
without
notict,.
6SE379 9909 Copyright © I
999
DETROIT
DIESEL
CORPORATION
•
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•

•
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•
SERIES
92
SERVICE MANUAL
Batteries
Electrical storage batteries
emit
highly flammable hydrogen gas when charging
and
continue to
do
so
for some time after receiving a steady charge.
A CAUTION:
Electrical
storage
batteries
emit
highly
flammable hydrogen
gas
when
charging. They
continue
to
do
so
for
some
time
after
receiving
a steady charge.
To
avoid personal injury,
do
not
under
any
circumstances
allow
an
electric
spark
or
open flame near
the
battery.
An
explosion
may occur.
Always disconnect the battery cable before working on the electrical system.
A CAUTION:
Disconnect
the
battery
or
batteries
from
the
starting
system
by
removing
one
or
both
of
the
battery cables
from
each
system
battery. With
the
electrical
circuit
disrupted,
accidental
contact
with
the
starter
button
will
not
produce
an
engine
start.
In
addition,
the
Electronic
Unit
Injectors
(EUI)
will
be
disabled, preventing
any
fuel
delivery
to
the
injector
tips.
If
the
engine
is
equipped
with
an
air
starter,
drain
the
air
storage
tank
and
disconnect
the
air
supply
to
the
starter
before
beginning
engine
disassembly.
A CAUTION:
To
prevent
accidental
starting
which
could
result
in
personal injury,
disconnect
the
batteries
or
disable
the
air
starter
(if
so
equipped}.
Disconnect the batteries or disable an air starter when working on the engine to prevent
accidental starting.
All
fn.tlnn8#on
subjsa
to
change Without
nota.
6SE379
9909
Copyright© 1999 DETROIT DIESEL CORPORATION
9