Detroit Diesel Series 92 Workshop Service Repair Manual - 2101-2185

SERIES 92 SERVICE MANUAL
13.22 ENGINE TUNE-UP
There is no scheduled interval for performing an engine tune-up. As long as the engine
performance is satisfactory, no tune-up should be needed. Check the intake and exhaust
valve clearances every 96,000 km (60,000 miles) for vehicle engines. Refer to section 12.2.
Minor adjustments in the valve and injector operating mechanisms, governor, etc. are required
periodically to compensate for normal part wear.
All information subject to change without notice.

6SE379 0303 Copyright © 2003 DETROIT DIESEL CORPORATION 13-71
13.23 BLOWER BYPASS VALVE
13.23 BLOWER BYPASS VALVE
Every 160,000 km (100,000 miles) or approximately 60 months, perform the following:

1. Remove the bypass blower valve.
2. Clean it in solvent, if necessary.
3. Inspect it for free valve operation and piston, piston guide, or sleeve assembly scoring.
4. Repair or replace, as required.

13-72 6SE379 0303 Copyright © 2003 DETROIT DIESEL CORPORATION
13.24 TACHOMETER DRIVE
Lubricate the tachometer drive at the grease fitting every 100 hours or 4,800 km (3,000 miles)
for industrial engines and every 300 hours on marine engines with an all purpose grease.
See Figure 13-10. At temperatures above -1 C (30 F), use a No. 2 grade grease. Use a No. 1
grade grease below this temperature.
1. Tachometer Drive
Figure 13-10 Tachometer Drive

13.25 AIR COMPRESSOR
13.25 AIR COMPRESSOR
Maintain the air compressor as follows:

1. Inspect the air compressor daily for loose or damaged fittings, and coolant leaks.
2. Remove and clean all air compressor air intake parts every 150 hours for stationary and
industrial, or 9,600 km (6,000 miles) for vehicle engines. Refer to section 13.25.
3. Remove and wash all polyurethane sponge strainer parts every 150 operating hours or
8,000 km (5,000 miles).
4. Clean or replace the strainer element.
NOTE:
If cleaning the strainer element, wash in a commercial solvent or a detergent and water
solution.
5. Dip the element in lubricating oil, and squeeze it dry before replacing it in the strainer.
NOTE:
Ensure the air strainer gasket is replaced if the entire air strainer is removed from the
compressor intake.
6. Contact the nearest servicing dealer for air strainer element replacement. Replace with the
polyurethane element, if available.
7. Every 12 months or 32,000 km (20,000 miles), tighten the air compressor mounting bolts.
8. If the air compressor is belt driven, check the belts for proper tension.

13.26 THROTTLE AND CLUTCH CONTROLS
Perform the following procedures for maintenance of throttle and clutch controls:
1. Inspect daily for loose linkage and tighten as required.
2. Every 200 hours or 9,600 km (6,000 miles) lubricate the throttle control mechanism with a
No. 2 grade all purpose grease at temperatures -1 C (30 F) or above.
NOTE:
At temperatures below -1 C (30 F), use a No. 1 grade grease.
To avoid injury from contact with the contaminants in used

engine oil, wear protective gloves and apron.
3. Lubricate all other control mechanisms, as required, with engine oil.

13.27 AIR BOX DRAIN TUBE
13.27 AIR BOX DRAIN TUBE
Maintain the air box drain tube as follows:

1. With the engine running at idle, check for flow of air from the air box drain tube every
1,000 hours or 48,000 km (30,000 miles). See Figure 13-11.
1. Air Box Drain Tube
Figure 13-11 Air Box Drain Tube
2. If the tube is clogged, remove tube.

3. Clean the tube, and install.
NOTE:
The air box drain tube should be cleaned periodically, even if tube is not clogged.
NOTE:
If the engine is equipped with an air box drain tank, drain the sediment periodically.

13.28 AIR BOX CHECK VALVES
Every 160,000 km (100,000 miles) or approximately 3,000 hours maintain the air box check
valves as follows:
1. Remove the air box check valves.
2. Clean with solvent.
To avoid injury from flying debris when using compressed

air, wear adequate eye protection (face shield or safety
goggles) and do not exceed 40 psi (276 kPa) air pressure.
3. Blow out the lines with compressed air.

4. Inspect for air flow after servicing.

13.29 SHUTTER OPERATION
13.29 SHUTTER OPERATION
Check the shutter operation, and clean the linkage and controls every 32.000 km (20,000 miles).

13.30 GOVERNOR, OVERSPEED GOVERNOR
Perform the following maintenance procedures for the governor:

1. Check and record the engine idle speed and no-load speed. Adjust as necessary.
NOTE:
An idle speed lower than recommended will accelerate the engine from a speed lower
than the engine certified speed.
NOTE:
A no-load speed higher than recommended will result in a full-load speed higher than
rated and higher than the engine certified speed.
2. Lubricate the overspeed governor, if equipped with a hinge-type cap oiler or oil cup, with
5 or 6 drops of engine oil every 500 hours or 24,000 km (15,000 miles).
NOTE:
Avoid excessive lubrication and do not lubricate the governor while the engine is running.
All Synchro-Start top switch electric overspeed governors contain sealed ball bearings which
have sufficient grease for their useful life, except Model GT governors. For GT units only, add
Aeroshell® 7A grease (or equivalent) to the open upper shaft bearing every 2,500 operating
hours. Apply grease sparingly with a hand operated low pressure gun. Grease the upper governor
shaft bearing as follows:
1. Remove the governor cap.
2. Apply grease sparingly to the bearing.
NOTICE:
Do not over-grease or use a power gun. Forcing grease onto the
weights and springs will damage bearing seals.
3. Replace the cap.

13.31 THROTTLE DELAY FUEL MODULATOR
13.31 THROTTLE DELAY FUEL MODULATOR
Inspect and adjust, if necessary, every 30 months or 80,000 km (50,000 miles).

The throttle delay system limits the amount of fuel injected during acceleration. It limits the
injector rack movement with a hydraulic cylinder. The initial location of this cylinder must be set
with the proper gage to achieve the appropriate time delay. Refer to section 12.15.
13.31.1 Inspection of Check Valve
Inspect the check valve as follows:

1. Fill the throttle delay cylinder with diesel fuel.
2. Watch for valve leakage while moving the throttle from idle to the full-fuel position.
13.31.2 Inspection of Modulator
Inspect the fuel modulator as follows:

1. Inspect the roller and piston outer diameter and the cylinder bore inner diameter for
wear and free operation.
2. Inspect the lower roller operating surface, the roller pins at the cam pivot, and the cam
attachment to the piston.
3. Replace parts, as required.
NOTE:
The fuel modulator must be set with the proper gage to achieve the correct fuel-to-air
ratio. Refer to section 12.15.

13.32 FAN HUB
If the fan bearing hub assembly has a grease fitting, use a hand grease gun to lubricate the bearings
with one shot of Texaco® Premium RB grease, or an equivalent lithium-based multipurpose
grease every 32,000 km (20,000 miles) for vehicle engines. Care should be taken not to overfill
the housing.
Every 2,500 hours or 120,000 km (75,000 miles) on vehicle engines or 4,000 hours in non-vehicle
engines, the fan bearing hub assembly should be cleaned, inspected and repacked with Texaco
Premium RB grease or equivalent lithium-base multipurpose grease.

13.32 FAN HUB
The bearings in the fan hub assembly should be replaced with new bearings at major engine
overhaul. The hub assembly should be packed with Texaco Premium RB grease or equivalent
lithium-base multipurpose grease before installing. See Figure 13-12. Refer to OEM maintenance
guidelines.
1. Grease Fitting 4. Pulley (3 Groove)

2. Relief Valve 5. Pulley (2 Groove)
3. Fan Hub Cap
Figure 13-12 Location of Fan Hub Grease Fitting and Relief Valve

13.33 FAN (THERMO-MOUNTED)
Inspect the fan drive fluid level as follows:
NOTE:
Current modulated fan drive housings have an inspection plug for checking the fluid
level. Formerly, partial drive disassembly was necessary to check the fluid level. Install a
current drive housing, which includes the fluid inspection plug and a grease fitting for
lubricating the bearings, to update the former units.
1. Check the fan drive fluid level after the unit has been idle for at least a 1/2 hour.
2. Turn the fan drive so that the inspection plug is 19.1 mm (0.75 in.) below the horizontal
center line. Allow the silicone fluid to drain an additional five minutes.
3. Remove the inspection plug.
NOTE:
If fluid flows from the inspection hole, the drive has sufficient fluid.
4. Replace the inspection plug.

5. If the fluid does not flow from the hole, proceed as follows:
[a] Rotate the fan drive downward, and observe when the fluid begins to flow from
the hole.
[b] If the drain hole is more than 50.8 mm (2 in.) below the horizontal center line for
the fluid to flow from the hole, the fan drive should be removed from the engine,
disassembled, and inspected for possible component damage.
[c] Turn the fan drive back so the inspection hole is 19.1 mm (0.75 in.) below the
horizontal center line. Add fluid until reaching the overflow point.
6. Replace the inspection plug. Lubricate the drive bearing as follows:
7. Lubricate the fan drive bearing with a medium consistency silicone grease, such as Dow
Corning® No. 44, or equivalent.The bearing on current fan assemblies is lubricated
through a grease fitting in the drive housing hub. Former bearing assembly lubrication
requires fan assembly, removal and partial disassembly. Install the current housing
to update the former assemblies.

13.34 THERMOSTATS AND SEALS
13.34 THERMOSTATS AND SEALS
The thermostats and seals should be replaced every 384,000 km (240,000 miles) for vehicle
engines. See Figure 13-13. On non-vehicle engines replace every 4,000 engine hours or two
years, whichever comes first and at time of overhaul. Refer to section 4.5.2.2 for thermostat
inspection procedures.
1. Thermostat 6. Washer
2. Seal 7. Gasket
3. Pipe Plug 8. Housing
4. Cover 9. Lock Washer
5. Bolt 10. Short Bolt
Figure 13-13 Typical Thermostat Housing

13.35 BLOWER SCREEN
Maintain the blower screen as follows:

1. Inspect the blower screen and gasket assembly annually on vehicle engines or every 1,000
hours or 48,000 km (30,000 miles) on non-vehicle engines. See Figure 13-14.
1. Blower Screen (Mounted Under Air Intake Manifold)
Figure 13-14 Blower Screen

13.35 BLOWER SCREEN

2. Clean the screen in fuel oil, and dry with compressed air.
3. Install the screen and gasket assembly with the screen side of the assembly toward the
blower.
4. Inspect for blower seal leakage.

13.36 FUEL INJECTORS AND VALVE CLEARANCE
Check the injector timing and exhaust valve clearance every 80,000 km (50,000 miles).
Refer to section 12.2 and refer to section 12.3. Emission control relies primarily on the proper
height adjustment between the injector follower and the injector body.
Replace fuel injectors on pleasure craft marine engines every 1,000 hours of operation. Replace
injectors on commercial marine engines every 5,000 hours of operation.

13.37 VIBRATION DAMPER
13.37 VIBRATION DAMPER
The viscous damper should be inspected periodically and replaced if dented or leaking. Heat
from normal engine operation over a period of time may cause the fluid within the viscous
vibration damper to break down and loose its dampening properties. For this reason, the viscous
vibration damper must be replaced at time of normal major engine overhaul, regardless of
apparent condition.

13.38 STARTING MOTOR
Starting motors which are provided with lubrication fittings should be lubricated every 6 months
or 16,000 km (10,000 miles). See Figure 13-15.
1. Lubrication Fittings
Figure 13-15 Starting Motor Lubrication Fittings
13.38.1 Maintenance of Starter Motor
Maintain a starting motor on vehicle engines as follows:

1. Add 8 to 10 drops of oil (same grade as used in the engine) to hinge cap oilers.
2. If sealed tubes are provided, remove the pipe plugs and add oil.
3. Reseal the tubes.
4. Turn down grease cups one turn.
5. Refill the grease cups, if necessary.
NOTE:
Some starting motors do not require lubrication except during overhaul.

13.38 STARTING MOTOR
13.38.2 Maintenance of Starter Motor (Non-Vehicle Engine)
Maintain a starting motor on non-vehicle engines as follows:
NOTE:
The electrical starting motor is lubricated at the time of original assembly. Oil can be
added to the oil wicks, that extend through each bushing and contact the armature shaft.
1. Remove the pipe plugs on the outside of the motor.

2. Lubricate the wicks.
3. Replace the pipe plugs.
NOTE:
The wicks should be lubricated whenever the starting motor is taken off the engine or
disassembled.
The sprag overrunning clutch drive mechanism should be lubricated with a few drops of
light engine oil whenever the starting motor is overhauled.

13.39 EXHAUST SYSTEM
Inspect the exhaust system as follows:

1. Ensure exhaust manifold retaining nuts and other connections are tight.
2. If equipped, check that the exhaust pipe rain cap is operating properly.

13.40 CRANKCASE BREATHER (EXTERNALLY MOUNTED)
13.40 CRANKCASE BREATHER (EXTERNALLY MOUNTED)
The externally mounted crankcase breather assembly should be removed and the steel mesh
pad cleaned in fuel oil annually on vehicle engines or every 1,000 hours, whichever comes
first. For marine engines every 5,000 hours. The cleaning period may be reduced or lengthened
depending on severity of service.

13.41 CRANKCASE BREATHER (INTERNALLY MOUNTED)
In vehicle engines, remove and clean the internally mounted crankcase breather assembly
annually. See Figure 13-16. Wash the steal mesh pad in clean fuel oil. This cleaning period may
be reduced or lengthened according to the severity of service. On non-vehicle engines, remove
and clean the internally mounted crankcase breather assembly every 1,000 hours.
1. Crankcase Breather
Figure 13-16 Crankcase Breather

13.42 ENGINE (STEAM CLEAN)
13.42 ENGINE (STEAM CLEAN)
Refer to OEM equipment maintenance guidelines.
NOTICE:
Do not apply steam or solvent directly on the battery charging
generator/alternator, starting motor, DDEC components,
sensors, or other electrical components. This could damage the
electrical equipment.
Steam clean the engine and engine compartment only.

13.43 POWER TAKE-OFF
Maintain the power take-off as follows:

1. Lubricate all power take-off bearings with an all purpose grease, such as Shell Alvania
No. 2, or equivalent. Avoid getting grease on the clutch facing. See Figure 13-17.
1. Areas to be Lubricated
Figure 13-17 Power Take-Off Lubrication
2. Lubricate the clutch release bearing, and the disconnect mechanical rear drive shaft
shielded bearing every 8 hours or 400 km (240 miles).
NOTE:
The clutch release bearing in the 457.2 mm (18 in.) diameter clutch is prelubricated and
is not provided with a grease fitting, since no further lubrication is required.

13.43 POWER TAKE-OFF
3. Lubricate the power take-off main bearing and outboard bearing, if equipped, every
50 hours or 2400 km (1,500 miles).
4. Lubricate the front power take-off clutch pilot ball bearing through the fitting in the outer
end of the drive shaft every 50 hours or 2,400 km (1,500 miles).
NOTE:
One or two strokes with a grease gun should be sufficient.
5. Every 500 hours or 24,000 km (15,000 miles), remove the inspection hole cover, and
lubricate the clutch release levers and link pins sparingly.
6. Lubricate the clutch release shaft through the grease fittings on the front of the housing.
7. Check the clutch facing for wear.
8. Adjust the clutch, if necessary.

13.44 TORQMATIC CONVERTER
Maintain the Torqmatic converter as follows:

Check the oil level in the Torqmatic converter and supply tank daily. See Figure 13-18. Check
the oil level while the converter is operating, the engine is idling, and the oil is up to operating
temperature (approximately 93 C or 200 F). If equipped with an input disconnect clutch, the
clutch must be engaged.
Figure 13-18 Torqmatic Converter Lubrication and Oil Level Check
1. Check the oil level after running the unit a few minutes.
NOTICE:
Do not overfill the converter. Too much oil will foam and create
high oil temperatures, leading to potential engine damage.
2. If required, add hydraulic transmission fluid type "C-2" listed in Table 13-7.
Prevailing Ambient Temperature Recommended Oil Specification

Above -23 C (-10 F) Hydraulic Transmission Fluid, Type C-2
Hydraulic Transmission Fluid Type C-2. Auxiliary
Below -23 C (-10 F) preheating required to raise temperature in the sump
to a temperature above -23 C (-10 F).
Table 13-7 Oil Recommendations

13.44 TORQMATIC CONVERTER
The oil should be changed every 1,000 hours or 48,000 km (30,000 miles) for Series 400
through 900 converters. Change the oil if it is dirty, discolored, or contains a strong odor.
If the oil is contaminated with metal, contact an authorized Detroit Diesel Service Outlet.
Change the oil more often under severe operating conditions.

3. Clean the converter oil breather on the dipstick each time the converter oil is changed.
Soak the breather in solvent, and dry with compressed air.
4. Every time the converter oil is changed, remove the full-flow oil filter element.
5. Clean the shell.
6. Install a new element and gasket.
7. Lubricate the input clutch release bearing, ball bearing, and the front disconnect clutch
drive shaft bearing with an all purpose grease every 50 hours or 2,400 km (1,500 miles).
NOTE:
Grease fittings are provided on the clutch housing. Intervals may vary depending on the
operating conditions. Over lubrication will cause grease to be thrown on the clutch
facing, causing the clutch to slip.
8. Replace or clean the strainer in the Torqmatic transmission and the hydraulic system
with each oil change.

13.45 REDUCTION GEAR
Maintain the Rockford® reduction gear as follows:

1. Check the oil level in the reduction gear every 8 hours. Add oil as needed to bring the
oil to the proper level on the dipstick. See Figure 13-19.
Figure 13-19 Reduction Gear Lubrication Fittings and Oil Level Check
2. Drain the oil every 1,000 hours or 48,000 km (30,000 miles).

3. Flush the housing with engine oil.
4. Refill to the proper level with the same grade and viscosity heavy-duty oil as used
in the engine.
NOTE:
Under severe operating conditions, reduce the oil change period.
5. Lubricate the clutch release bearing through the grease fitting on the side of the housing
every 8 hours or 384 km (240 miles).
NOTE:
The clutch release bearing in the 457.2 mm (18 in.) diameter clutch is prelubricated and
is not provided with a grease fitting. No further lubrication is required.
6. Lubricate the front reduction clutch pilot ball bearing through the fitting in the outer end
of the drive shaft every 50 hours or 2,400 km (1,500 miles). One or two strokes with a
grease gun should be sufficient.

13.45 REDUCTION GEAR
7. Remove the inspection hole cover.

8. Oil the clutch release levers and link pins sparingly every 500 hours or 24,000 km
(15,000 miles).
9. Lubricate the clutch release shaft through the grease fittings on the front of the housing
every 500 hours or 24,000 km (15,000 miles).

13.46 TRANSIT COACH CONVERTER MUFFLER
Donaldson® catalytic converter mufflers are used on many transit busses equipped with Detroit
Diesel Series 92 engines. To ensure efficient functioning of these converter systems, the
Donaldson Company and Detroit Diesel Corporation have developed new preventive maintenance
and servicing procedures.
13.46.1 Preventive Maintenance Procedure Details
During normally scheduled vehicle maintenance, inspect the converter muffler, exhaust piping,
and mounting brackets. Look for leaks, structural failures (cracks), or loose or missing fasteners.
Repair or replace defective parts, as required.
Catalytic converter mufflers are subject to plugging under the following conditions:
Engine operation at low load for extended periods of time.
Improper engine maintenance.
Improper engine calibration for the specific fuel type.Use the following procedures to
check and clean catalytic converter mufflers:
NOTE:
To prevent the reoccurrence of plugging, engine performance concerns must be resolved
before operating again with a cleaned converter muffler.
13.46.2 Check Back Pressure
Check back pressure as follows:

1. Remove the plug from the 1/4 in.-18 NPT back pressure tap half coupling located on the
side of the converter muffler, and install a manometer or back pressure gage.
2. Start and run the engine. After thoroughly warm, run at high idle, no load for 2-3 minutes.
3. Record back pressure while the engine is still at no load.
[a] If back pressure is less than 41 in. H2O or 3 in. Hg (10.2 kPa), continue to operate the
converter muffler without further maintenance.
[b] If back pressure is greater than 41 in. H2O or 3 in. Hg (10.2 kPa), use one of the
following procedures to clean out the muffler.
13.46.3 Clean Out Converter (Muffler On Vehicle)
Clean converter on vehicle as follows:

1. Operate the vehicle with a high engine load (maximum highway speed, uphill, on a chassis
dynamometer, for example) for 10-15 minutes, and recheck the high idle, no load back
pressure by repeating step 1 and step 2 of "Check Back Pressure" procedure.
2. If back pressure is less than 41 in. H2O or 3 in. Hg (10.2 kPa), continue to operate the

13.46 TRANSIT COACH CONVERTER MUFFLER
3. If back pressure is greater 41 in. H2O or 3 in. Hg (10.2 kPa), use the procedure under
"Clean Out Converter Muffler Off Vehicle".
13.46.4 Clean Out Converter (Muffler Off Vehicle)
Clean converter off vehicle as follows:

1. Identify and mark the exhaust flow direction on the body of the converter muffler's middle
(core) section between the V-band clamps. This section of the converter muffler contains
the catalyzed ceramic core assembly.
2. Remove the middle (core) section of the converter assembly by removing the V-band
clamps around the body of the converter muffler.
3. Thoroughly vacuum clean both faces of the ceramic core using a non-metallic brush
attachment.
4. Install the middle (core) section into the converter muffler in the opposite direction from
which it was removed so that exhaust gas flow through the core assembly is reversed.
Apply anti-seize lubricant to the inside T-bolts of the V-band, then install the V-band. Tap
the outside of the V-band clamps with a hammer as clamp bolts are tightened. Torque
bolts to a maximum torque of 200 lb·in. (23 N·m).
5. Repeat step 1 and step 2 of "Check Back Pressure" procedure, and check high idle, no
load back pressure.
[a] If back pressure is less than 41 in. H2O or 3 in. Hg (10.2 kPa), continue to operate the
[b] If back pressure is greater than 41 in. H2O or 3 in. Hg (10.2 kPa), use the procedure
under "Clean Out Converter Muffler On Vehicle".

13.47 AIR CLEANER
See Figure 13-20 for illustration of the dry type air cleaner.
1. Dry Type Air Cleaners
Figure 13-20 Dry Type Air Cleaners
NOTICE:
Reusing a damaged air cleaner element or gasket may result in
inadequate air filtration and severe engine damage.
A clogged air cleaner element will cause excessive intake restriction and a reduced air supply to
the engine. This, in turn, can result in increased fuel consumption, inefficient engine operation
and reduced engine life.

13.47 AIR CLEANER
13.47.1 Maintenance of the Dry-Type Air Cleaner
Maintain the dry-type air cleaner as follows:

1. The dry-type air cleaner element should be inspected every 24,000 km (15,000 miles) for
vehicle engines, or more often if the engine is operated under severe dust conditions.
2. Discard and replace elements used in on-highway applications after one year of service or
160,000 km (100,000 miles) or when the maximum allowable air intake restriction has
been reached, whichever comes first. Refer to section 11.5.
NOTE:
Do not attempt to clean or reuse on-highway elements after these intervals.
NOTICE:
Under no engine operating conditions should the air
inlet restriction exceed 6.2 kPa (0.25 in. of water) for
non-turbocharged engines, or 5.0 kPa (0.20 in. of water) for
turbocharged engines. Failure to follow these guidelines will
result in increased fuel consumption, inefficient engine operation
and reduced engine life.
3. Discard and replace elements used in off-highway applications after one year of service or
when the maximum allowable air intake restriction has been reached, whichever comes
first.
4. Check gaskets for deterioration.
[a] If severely deteriorated, replace the gaskets. Refer to section 6.2.3.
[b] If no deterioration is found, continue maintenance check.
NOTE:
Keep air cleaner tight on air intake-to-engine.
5. Ensure air cleaner is properly assembled so joints are oil and air tight.
6. Inspect air cleaner, intake, or connections for damage.
[a] If damage is found, repair at once.
[b] If no damage is found, continue maintenance check.
7. Cleaning and inspection of the air cleaner must be performed per the manufacturer's
recommendations.
8. Cover gasket inspection and replacement of the air cleaner must be performed per
manufacturer's recommendations.
NOTE:
In cases where the air cleaner manufacturer recommends cleaning or washing elements,
the maximum service life is still one year or maximum restriction.

9. If the dry type air cleaner is equipped with an aspirator, check for aspirator damage or
clogging.
10. Clean and repair, if necessary.

13.48 AIR SYSTEM
13.48 AIR SYSTEM
Inspect the air system daily for leaks. Look for torn air inlet piping or boots and loose or
damaged clamps. Have worn or damaged parts repaired or replaced, as required. Tighten any
loose connections.
1. Where rubber hose from air cleaner to blower is employed, remove hose connections and
cement them in place. Use new hose and clamps, if necessary, to obtain an air-tight
connection.
2. After servicing the air cleaner, remove the air inlet housing, and clean accumulated dirt
deposits from the blower screen and air inlet housing. Ensure all air intake passages
and the air box are kept clean.
3. Make a careful, periodic inspection of the entire air system. Enough dust-laden air will
pass through an almost invisible crack to eventually cause serious damage to an engine.
NOTICE:
Paper element overloading will not cause dirt particles to bypass
the filter and enter the engine, but will result in engine air
starvation.

13.49 AIR SEPARATOR FILTER ELEMENT
The closed breather system consists of an air separator assembly mounted to the inlet side of
each turbocharger. See Figure 13-21.
1. Turbine Housing 3. Vacuum Limiter

2. Compressor Housing 4. Air Separator Assembly
Figure 13-21 Typical Air Separator System
To operate efficiently, air separator filters and vacuum limiters must be properly maintained.
Clean and oil the vacuum limiter and filter element every 250 hours of engine operation or
once a year, whichever comes first. Refer to section 13.49.1, refer to section 13.49.2, and
refer to section 13.49.4.
NOTE:
Filter elements and vacuum limiters must also be cleaned and oiled any time the
restriction gage shows red.
Filter elements must be replaced after three cleanings.

Replace vacuum regulator/limiters every 1000 hours of engine operation or every two
years, whichever comes first.

NOTICE:
Failure to properly clean the engine room may allow loose debris
to plug air separator elements. Plugging can lead to high air inlet
restriction, causing reduced engine performance and/or engine
damage caused by engine overheating.
NOTE:
For best cleaning results, and to avoid damaging filter elements, Walker Cleaning and
Re-oiling Kit must be used. Available from Walker Engineering supply distributors or
directly from manufacturer: Walker Engineering Enterprises, 7406 Havenhurst Place
Van Nuys, CA 91406
13.49.1 Pre-Clean Air Separator Filter Element
Perform the following procedures to clean and oil the air separator filter element:
NOTICE:
Failure to clean the air separator filter and the vacuum
regulator/limiter will affect the operation of the air separator and
may cause reduced engine performance and/or engine damage
caused by engine overheating.
NOTE:
A filter that is damaged or clogged with soot due to an exhaust leak may not be able to
be cleaned to maximum air flow condition. Replacement of element may be necessary.
1. Remove filter element from air separator.
NOTE:
Filter elements and vacuum limiters must also be cleaned and oiled when the air inlet
restriction turns red. This indicates the maximum allowable system restriction has been
reached.
2. Tap element to dislodge any large, imbedded particles of dirt.

3. Gently brush outside of element with soft bristle brush, such as a paint brush.
[a] If complete cleaning is impractical at this time, oil and install element.
Refer to section 13.49.2 for oiling procedure.
[b] If complete cleaning is practical at this time, refer to section 13.49.2 and follow
cleaning and oiling procedure.
13.49.2 Cleaning of Air Separator Filter Element
Perform the following procedures to clean air separator:

1. Spray Walker cleaning solution onto element and let soak 10 minutes.

NOTICE:
To avoid filter damage, do not clean with gasoline, steam, high
pressure water or air, caustic solutions, strong detergents, or
parts cleaning solvents.
2. Rinse element with clean, low pressure, fresh (not salt) water. Rinse from clean side
(inside) to dirty side.
NOTICE:
To avoid filter damage, do not use compressed air, open flame,
ovens, or heat dryers. Excess heat will shrink the cotton filter
element, and compressed air will blow holes through it.
3. Shake off excess water and allow element of air dry naturally.
NOTICE:
To avoid filter damage, do not use transmission fluid, motor oil,
diesel fuel, WD-40® or other lightweight oil.
To avoid injury from contact with the contaminants in used

engine oil, wear protective gloves and apron.
4. Squeeze Walker air filter oil out of the bottle and into the valley of each pleat. Make
one pass per pleat.
NOTE:
Filter effectiveness is reduced if the element is used without being oiled.
5. Allow oil to work into element for 20 minutes.

6. Oil any white spots on the element.
7. Install air separator filter element.
13.49.3 Clean Vacuum Regulator Filter Element
The vacuum regulator filter can be cleaned without removing the regulator from the system.
1. Detach filter using a standard blade screwdriver.
2. Refer to section 13.49.1, and follow same preclean procedure.
3. Refer to section 13.49.2, and follow same cleaning procedure.

13.49.4 Clean Vacuum Limiter Filter Element
Clean vacuum limiter filter element as follows:

1. Remove entire vacuum limiter assembly. Do not detach filter element.
2. Refer to section 13.49.1, and follow same preclean procedure.
3. Refer to section 13.49.2, and follow same cleaning procedure.

13.50 AIR SHUTDOWN VALVE
With the engine running at idle speed, check the emergency shutdown operation every 700 hours
or 32,000 km (20,000 miles), or 500 hours on marine, whichever comes first. Reset the air
shutdown valve in the open position after the check has been completed.
To avoid injury from engine run-on when an emergency

shutdown is required, do not use damaged shutdown
devices.
NOTICE:
To avoid engine damage, ensure shutdown valve is properly
adjusted. Failure to do so will prevent valve from closing
completely when activated, thus defeating its intended purpose
to cut off air flow to the engine and shut it down during abnormal
operating conditions.
NOTICE:
Do not use the air shutdown for normal or routine engine
stopping. Failure to observe this precaution can result in serious
engine damage.

13.51 COOLING SYSTEM (MARINE)
13.51 COOLING SYSTEM (MARINE)
When a Detroit Diesel marine engine is put into service at the beginning of boating season, the
following preventive maintenance checks should be made to ensure optimum cooling system
performance:
1. If the raw water pump cover was previously removed or loosened to drain the system for
winter lay-up, remove the cover, and replace the gasket with a new one before operating
the engine.
NOTE:
Failure to use a new gasket when replacing the raw water pump cover may result in
pump leakage at engine start-up. This is a change from the previous recommendation,
which allowed reuse of an undamaged gasket.
2. While the cover is off, check the condition of the raw water pump impeller. Replace
if brittle, damaged, or excessively worn.
NOTICE:
Do not over tighten standard hose clamps or attempt to retorque
constant-torque hose clamps. Hose clamps will break if over
tightened.
3. Check the heat exchanger/raw water pump piping and hose connections for tightness and
serviceability. Replace hoses that show signs of mechanical damage (cuts, crushing)
or deterioration (cracks, bulged areas) or hoses that feel unusually soft or hard when
squeezed. Replace all damaged clamps.
4. If resilient isolators are used to mount the heat exchanger, replace if cracked or brittle.
5. Ensure the inhibited coolant level in the heat exchanger tank is at or near the bottom of the
filler neck and the fill/pressure cap is secure before starting. For coolant recommendations,
refer to section 5.3.1.
6. To avoid impeller damage and ensure a full flow of raw water through the heat exchanger
at engine start-up, remove the pipe plug or "zinc" from the raw water pump inlet, and
prime the pump before starting.
7. Check the condition of the fresh water pump drive belt (if used) and any other drive belts
on the engine. Replace the belt if it is cracked, cut, glazed, or has missing cogs. Tighten
reusable or replacement belt to specifications.

13.52 HEAT EXCHANGER CHANGEOUT INTERVAL
Tube and shell heat exchangers are unitized assemblies with no replaceable components. They
can be identified by the barrel-shaped housing at the bottom of the tank which contains the tube
bundle core. In some installations, the core may be enclosed in a separate barrel-shaped tank
attached to the side of the engine. See Figure 13-22, see Figure 13-23, and see Figure 13-24.
1. Heat Exchanger
Figure 13-22 Heat Exchanger (Tube Bundle Core)

13.52 HEAT EXCHANGER CHANGEOUT INTERVAL
1. Heat Exchanger
Figure 13-23 Typical Heat Exchanger
1. Heat Exchanger
Figure 13-24 Heat Exchanger (Mounted)

NOTICE:
Failure to replace tube and shell heat exchangers on marine
engines at required intervals may permit tube blockage, which
can result in engine overheating and serious engine damage.
Tube and shell heat exchangers used in marine engine installations have a service life of 4,000
hours or four years, whichever comes first. At this interval, they must be replaced.
When heat exchangers are replaced, the antifreeze should also be drained and disposed of in an
environmentally responsible manner, according to state and/or federal (EPA) recommendations.
The cooling system should then be cleaned thoroughly and replenished with ethylene glycol-base
antifreeze solution and Detroit Diesel Selected Product supplemental inhibitors in the required
concentrations.
NOTICE:
Failure to maintain inhibitors at required levels can result
in damage to the cooling system and related components.
Conversely, over-inhibiting antifreeze solutions can cause
"silicate dropout", which can plug oil cooler and aftercooler
cores and/or cause hot spots in the engine. Always follow
Selected Product inhibitor recommendations on usage and
handling.
In extremely hot environments, clean, soft, properly inhibited water may be used if Detroit Diesel
Selected Product supplemental corrosion inhibitors are also added in the right concentration. If
water is used, supplemental coolant additive levels should be increased from 3% to 6% by volume.
For detailed coolant and Selected Product additive information, refer to section 5.3.

13.53 HEAT EXCHANGER ELECTRODES AND CORE (RAW WATER SYSTEM ZINCS)
13.53 HEAT EXCHANGER ELECTRODES AND CORE (RAW WATER SYSTEM

ZINCS)
Heat exchanger "zincs" should be checked initially every 60 hours, then as required or annually.
Clean with a wire brush if serviceable. Replace if badly deteriorated. Electrodes are generally
found in the heat exchanger assembly, raw water pump elbows, fuel and/or boost cooler, and the
engine/marine gear auxiliary coolers.
Maintain the heat exchanger electrodes as follows:
1. Every 500 hours or annually, drain the water from the heat exchanger raw water inlet and
outlet tubes. See Figure 13-25.
1. Raw Water Outlet Tube 2. Raw Water Inlet Tube
Figure 13-25 Heat Exchanger (6V and 8V Marine Pleasurecraft)

2. Remove the zinc electrodes form the inlet side of the raw water pump and the heat
exchanger.
3. Clean the electrodes with a wire brush, or if excessively worn, replace with new electrodes.
NOTE:
To determine the used electrode condition, strike it against a hard surface. A weakened
electrode will break.
Maintain the core as follows:

1. Drain the cooling system. Refer to section 13.12.3.
2. Disconnect the raw water pipes at the outlet side of the heat exchanger.
3. Remove the retaining cover every 1,000 hours or 48,000 km (30,000 miles).
4. Inspect the heat exchanger core.
5. If a considerable amount of scale or deposits are present, contact a Detroit Diesel
Service Outlet.

13.54 RAW WATER PUMP
Water leaking from the pump housing openings indicates a raw water pump seal malfunction. The
pump housing openings, located between the pump mounting flange and the inlet and outlet ports,
must remain open at all times. Leaking seals require replacement. The raw water pump body or
liner should be checked for cracks or wear, and replaced if necessary.

NOTICE:
Always prime the raw water pump before starting the engine.
Since water acts as a lubricant for the impeller, failure to
prime the pump (or at least wet the impeller vanes to induce
a self-priming suction) can result in severe impeller damage
when the engine is started. Insufficient raw water flow into the
heat exchanger caused by a damaged impeller can lead to
overheating and subsequent engine damage.
1. Check the prime on the raw water pump daily. See Figure 13-26. The engine should
not be operated with a dry pump.
1. Outlet Tube 3. Inlet Tube

2. Pipe Plug
Figure 13-26 Raw Water Pump

2. If necessary, prime the water pump as follows:

[a] Remove the pipe plug in the pump inlet elbow.
[b] Add water.
[c] Install the plug.

13.55 FUEL AND BOOST COOLERS
Replace fuel and boost coolers on marine engines every 4 years or 4,000 hours, whichever comes
first. In some applications these are unitized into a single assembly.

13.56 TORQMATIC MARINE GEAR (6V AND 8V)
13.56 TORQMATIC MARINE GEAR (6V AND 8V)
Maintain the Torqmatic marine (6V and 8V) gear as follows:

1. With the controls in neutral and the engine running at idle speed, check the oil level
daily in the marine gear. See Figure 13-27.
Figure 13-27 Marine Gear Oil Level Check
2. Add oil as required to bring it to the proper level on the dipstick, approximately 5.7 liters
(6 quarts) in the M-type and 7.6 liters (8 quarts) in the MH-type gear.
NOTE:
Use the same grade and viscosity heavy-duty oil as used in the engine. Series 3 oil
should not be used in the marine gear.
3. Drain the oil every 200 hours or 9,6000 km (6,000 miles), and flush the gear with light
engine oil.
4. Start and run the engine at light load for three to five minutes.
5. Place the controls in neutral, and run the engine at idle speed.
6. Check the oil level. Bring the oil level to the proper level on the dipstick.
7. Every time the oil is changed, remove the oil strainer element.
8. Rinse it thoroughly in fuel oil.


9. Dry with compressed air.

10. Install the oil strainer element.
11. Replace the full-flow oil filter element every time the marine gear oil is changed.

13.57 MARINE GEAR (TWIN DISC 16V)
13.57 MARINE GEAR (TWIN DISC 16V)
The requirements for Detroit Diesel (Twin Disc) marine gear lube oil and filter change are
listed in Table 13-8.
Sump Temperature, also Oil Sump Temperature, also Oil

Temperature into Heat Exchanger Temperature into Heat Exchanger Recommended Oil Viscosity
(During Start-up) (Steady Operating Conditions)
This operating condition is not
- Below 66 C (150 F)
approved.
SAE viscosity number 40 engine
0 C (32 F) Min. 66-85 C (150-185 F)
oil 1.12:1-2.54:1
0 C (32 F) Min. 66-85 C (150-185 F)
oil 3.10:1-4.95:1
0 C (32 F) Min. 80-99 C (175-210 F)
oil 3.10:1-4.95:1
This operating condition is not
- Above 99 C (210 F)
approved.
Oil Service Class:Use API service classification CD, CD-II, CF-2, CE, or CF-4 engine oil which is certified to pass TO2 or TO4 and
C-4 specifications or meet the requirements of MIL-L-2104E. Engine oil may be used, provided it meets these requirements.
Oil and Filter Change Interval: First oil and filter change should take place after 10 hours and thereafter every 1000 hours of
operation for both filter element and oil, or 6 months, whichever comes first.
Filter Screen: Remove and clean after first 10 hours and thereafter every 1000 hours of operation, or 6 months, whichever
comes first.
Table 13-8 Detroit Diesel (Twin Disc) Marine Gear Lube Oil and Filter Change
Requirements
Maintain the twin disc marine gear (16V) as follows:

1. Check the oil level daily.
NOTE:
The oil should be at operating temperature when checked.
2. With the engine running at low idle speed and the gear in neutral, check the oil level.
NOTE:
Keep oil up to the proper level on the dipstick. Use oil of the same heavy-duty grade
and viscosity that is used in the engine.
3. Change the oil and the oil filter element every 1,000 hours or 48,000 km (30,000 miles).
4. After draining the oil, thoroughly clean the removable oil screen and breather.
5. Install the breather, and refill the marine gear with oil up to the full mark on the dipstick.
6. Start the engine. With the gear in neutral, run the engine at idle speed for three to
five minutes.
7. Stop the engine, and check the oil level.

8. If necessary, add oil to bring it up to the full mark on the dipstick.

13.58 CLUTCH ACTUATOR (DDEC MARINE)
If the engine is equipped with DDEC marine clutch actuator, perform the following instructions:
Daily:
1. Inspect Morse push/pull cable connecting clutch actuator to marine gear selector lever.
2. If cracked, binding, worn, or loose fittings are found, replace the cable.
3. Check plastic cable end connectors daily for cracks or excessive wear.
4. If worn or damaged, replace the connectors.
5. Inspect cable mountings at servo and transmission mount to ensure they are secure.
6. Check servo operation in dry run mode (ignition on, engine not running) for smooth
shifting of selector valve lever.
7. Hit station active button, and observe operating of selector valve when clutches are shifted
ahead, neutral, and astern.
8. Inspect servo mechanical backup solenoid clutch assembly for correct cycle actuation.
9. Release and engage the backup system.
Every Month or 50 Hours or 15,000 hours:
1. Inspect electrical connections for looseness or corrosion.
2. If loose or corroded, replace.
3. Inspect electrical wires for fraying or deterioration.
4. Replace if frayed or deteriorated.
5. Ensure servo base plate fasteners are tight.
NOTE:
The clutch must be mounted securely.
6. Measure actuator servo lever for any change to original setup length.
7. Verify the servo is not over or under stroking the selector valve lever.
8. Adjust as required.
Every 6 Months or 250 Hours:
1. Inspect servo base plate for stress fractures or stress induced deformation.
2. Replace the entire assembly if damaged.
3. Inspect and lubricate cable connector pins with a high quality marine grade grease.
4. Replace pins and connectors if worn.
5. Measure servo valve for any change to the original set up length.

6. Verify that the servo is not over or under stroking the selector valve.
7. Adjust as required.
Every Year or 500 Hours:
1. Replace 33C Red-Jaket® push/pull cables between servo and selector valve.
2. With transmission at operating temperature, verify that the transmission selector valve
shift force does not exceed 67 N (15 lbs.) with cable disconnected and 111 N (25 lbs.)
with the cable connected at the transmission, but disconnected at the clutch actuator.
3. Repair transmission or replace cable if these values are exceeded.


14 STORAGE
Section Page
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) ....................................................................................................... 14-6
14.4 EXTENDED ENGINE STORAGE (MORE THAN 30 DAYS) .................... 14-7
14.5 RESTORING AN EXTENDED STORAGE ENGINE (MORE THAN 30
DAYS) ....................................................................................................... 14-13
14.6 STORAGE OF BATTERY ......................................................................... 14-16
14.1 PREPARING ENGINE FOR STORAGE
When an engine will be stored or removed from operation for a period of time, special precautions
should be taken to protect the interior and exterior of the engine, transmission, and other parts
from rust and corrosion.
Remove all rust or corrosion completely from any exposed part before applying a rust preventive
compound. DDC recommends processing the engine for storage as soon as possible after removal
from operation.
Store the engine in a building which is dry and can be heated during the winter months. Moisture
absorbing chemicals are available commercially for use when excessive dampness prevails in
the storage area.
NOTICE:
Do not use plastic sheeting for outdoor storage. Plastic is fine for
indoor storage. When used outdoors, however, enough moisture
can condense on the inside of the plastic to rust ferrous metal
surfaces and pit aluminum surfaces. If a unit is stored outside
for any extended period of time, severe corrosion can result.
Detroit Diesel Corporation does not recommend storing an engine (or transmission) outdoors.
DDC recognizes that in some cases outdoor storage may be unavoidable. If units must be
kept outdoors, follow the preparation and storage instructions. Protect units with quality,
weather-resistant tarpaulins (or other suitable covers) arranged to provide air circulation.

14.2 TEMPORARY ENGINE STORAGE (30 DAYS OR LESS)
14.2 TEMPORARY ENGINE STORAGE (30 DAYS OR LESS)
To protect an engine for a temporary period of time, proceed as follows:

1. Drain the engine crankcase.
2. Fill the crankcase to the proper level with the recommended viscosity and grade of oil.
3. Fill the fuel tank with the recommended grade of fuel oil. Operate the engine for two
minutes at 1200 RPM. and no load.
NOTE:
Do not drain the fuel system or the crankcase after this run.
4. Check the air cleaner and service it if necessary. Refer to section 6.2.
5. If freezing weather is expected during the storage period, add an ethylene glycol base
antifreeze solution in accordance with the manufacturer recommendations.
6. Drain the raw water system and leave the drain cocks open.
To avoid injury from fire caused by heated diesel-fuel

vapors:
Keep those people who are not directly involved in
servicing away from the engine.
Stop the engine immediately if a fuel leak is detected.
Do not allow open flames or smoke when working on
an operating engine.
Wear adequate protective clothing (face shield,
insulated gloves and apron, etc.).
To prevent a buildup of potentially volatile vapors, keep
the engine area well ventilated during operation.
Diesel fuel is relatively harmless at ambient temperatures.
7. Clean the entire exterior of the engine, except the electrical system, with fuel oil.

8. Dry it with compressed air.

9. Seal all engine openings, use a vapor and water proof material that is resistant to damage
by puncture or expansion.An engine prepared in this manner can be returned to service in

a short time by removing the seals at the engine openings, checking the engine coolant,
fuel oil, lubricating oil, transmission and priming the water pump, if used.

14.3 RESTORING A TEMPORARILY STORED ENGINE (30 DAYS OR LESS)
14.3 RESTORING A TEMPORARILY STORED ENGINE (30 DAYS OR LESS)
Return a temporarily stored engine to service as follows:

1. Remove the seals at the engine openings.
2. Check the engine coolant, fuel oil, lubricating oil, and transmission.
3. Prime the raw water pump, if used.

14.4 EXTENDED ENGINE STORAGE (MORE THAN 30 DAYS)
Prepare an engine for extended storage as follows:

1. Drain the cooling system. Refer to section 13.12.3.
2. Flush with clean, soft water.
3. Fill with clean, soft water, and add a rust inhibitor to the cooling system.
Refer to section 5.3.
4. Remove, check, and recondition the injectors, if necessary, to make sure they will operate
when the engine is restored to service.
5. Install the injectors, time them, and adjust the exhaust valve clearance.
6. Operate the engine until normal operating temperature is reached to circulate the coolant.
Refer to section 11.5.
7. Stop the engine.
8. Drain the engine crankcase. Refer to section 13.5.2.
9. Install and tighten the drain plug.
10. Install new lubricating oil filter elements and gaskets.
11. Fill the crankcase to the proper level with a 30 weight preservative lubricating oil
MIL-L-21260C, Grade 2. Refer to section 13.5.1.
12. Drain the fuel tank.
NOTICE:
If engines in vehicles or marine units are stored where water
condensation in the fuel tank may be a problem, add pure,
waterless isopropyl alcohol (isopropanol) to the fuel at a ratio of
0.5 liter (one pint) to 473 liters (125 gallons) of fuel, or 0.010% by
volume. Where biological fuel contamination may be a problem,
add a biocide such as Biobor JF, or equivalent, to the fuel.
When using a biocide, follow the manufacturer's concentration
recommendations, and observe all cautions and notices.
13. Fill with enough clean No. 1 diesel fuel or pure kerosene to permit the engine to operate
for about ten minutes.
NOTE:
If draining the fuel tank is not convenient, i.e., marine, use a separate portable supply of
the recommended fuel.
14. Drain and disassemble the fuel filter and strainer.

15. Discard the used elements and gaskets.
16. Wash the fuel filter shells in clean No. 1 diesel fuel or pure kerosene.

17. Insert new elements.

18. Fill the cavity between the element and shell with No. 1 diesel fuel or pure kerosene,
and install on the engine.
19. If spin-on fuel filters and strainers are used, discard the used cartridges, fill the new ones
with No. 1 diesel fuel or pure kerosene, and install on the engine.
20. Operate the engine for five minutes to circulate the clean fuel oil throughout the engine.
21. Service the air cleaner. Refer to section 6.2.1.
14.4.1 Marine Gear (More than 30 Days)
Prepare marine gear for extended storage as follows:

1. Drain the oil completely, and refill with clean oil of the recommended grade and viscosity.
Refer to section 13.5.2 and refer to section 13.5.1.
2. Remove and clean or replace the strainer and filter elements.
3. Start and run the engine at 600 RPM. for 10 minutes to coat all internal parts of the
marine gear with clean oil.
4. Engage the clutches alternately to circulate clean oil through all moving parts.
NOTE:
Torqmatic converter preparation is not necessary on torque converter units.
14.4.2 Torqmatic Converter (More than 30 Days)
Prepare the Torqmatic converter for extended storage as follows:

1. Start and operate the engine until the converter oil temperature reaches 66 C (150 F).
2. Stop the engine, remove the converter drain plug and drain the converter.
3. Remove the filter element.
4. Start the engine and stall the converter for twenty seconds at 1000 RPM. to scavenge the
oil from the converter.
NOTE:
Due to lack of lubrication, do not exceed the 20 second limit.
5. Install the drain plug and a new filter element.

6. Fill the converter to the proper operating level with a commercial preservative oil which
meets specification MIL-L-21260C.
NOTE:
Grade 2 oil is available from the major oil companies.

7. Start the engine and operate the converter for at least 10 minutes at a minimum of
1000 RPM.
NOTE:
Do not allow the oil temperature to exceed 107 C (225 F). If the unit does not have a
temperature gage, do not stall the converter for more than thirty seconds.
8. Engage the clutch, and stall the converter to raise the oil temperature to 107 C (225 F).
9. Stop the engine, and allow the converter to cool to a touchable temperature.
10. Seal the breather and all exposed openings with moisture proof tape.
11. Coat all exposed, unpainted surfaces with preservative grease.
12. Position all controls for minimum exposure, and coat them with grease. Coat the external
shafts, flanges, and seals with grease.
14.4.3 Power Take-Off (More than 30 Days)
Prepare the power take-off for extended storage as follows:

1. Use an all purpose grease, such as Shell Alvania No. 2 or equivalent, and lubricate the
clutch throughout bearing, clutch pilot bearing, drive shaft main bearing, clutch release
shaft, and the outboard bearings, if so equipped.
2. Remove the inspection hole cover on the clutch housing, and lubricate the clutch release
lever and link pins with a hand oiler.
NOTE:
Avoid getting oil on the clutch facing.
3. If the unit is equipped with a reduction gear, drain the gear box and flush with light
engine oil.
4. If the unit is equipped with a filter, clean the shell and replace the filter element.
5. Refill the gear box to the proper level with the grade of oil indicated on the name plate.
14.4.4 Turbocharger (More than 30 Days)
Prepare the turbocharger for extended storage as follows:

Since turbocharger bearings are pressure lubricated through the external oil line leading from the
engine cylinder block while the engine is operating, no further attention is required. However, the
turbocharger air inlet and turbine outlet connections should be sealed off with moisture resistant
tape.
14.4.5 Hydrostarter System (More than 30 Days)
Prepare the hydrostarter system for extended storage as follows:

Refer to section 11.2.3 and refer to section 13.38 for the lubrication and preventive maintenance
procedure.
14.4.6 Extended Engine Storage (More Than 30 Days) Continued
Continue preparing the engine for extended storage as follows:
NOTICE:
Do not apply oil, grease, or any wax base compound to the
flywheel. The cast iron will absorb these substances which can
"sweat" out during operation and cause the clutch to slip.
1. Apply a non-friction rust preventive compound to all exposed parts. If convenient,

apply the rust preventive compound to the engine flywheel. If not, disengage the clutch
mechanism to prevent the clutch disc from sticking to the flywheel.
2. Drain the engine cooling system.
NOTICE:
To ensure that all coolant is drained completely from a unit, all
cooling system drains should be opened. Should any entrapped
water in the cylinder block or radiator freeze, it will expand and
may cause damage.
3. When freezing weather is expected, leave all drain cocks open until refilling the cooling
system.
4. Open the drain cocks and remove the cooling system filler cap to drain the engine coolant.
NOTE:
Filler cap removal permits air to enter the cooling passages and the coolant to drain
completely from the system.
NOTE:
On 6V and 8V engines, cylinder block drain cocks are located on each side of the
cylinder block at the rear, below the exhaust manifolds, and at the front of the engine.
NOTE:
On 12V and 16V engines, a drain cock is located on each side of the cylinder block,
below the exhaust manifold, at both the front and the rear of the engine.
In addition to the cylinder block drains, the oil cooler housing has a drain cock at the
bottom. Open a drain cock in the bottom tank to drain the radiator.
5. Drain the preservative oil from the engine crankcase.
6. Install and tighten the drain plug.

To avoid injury from battery explosion or contact with

battery acid, work in a well-ventilated area, wear protective
clothing, and avoid sparks or flames near the battery.
Always establish correct polarity before connecting cables
to the battery or battery circuit. If you come in contact with
battery acid:
Flush your skin with water.
Apply baking soda or lime to help neutralize the acid.
Flush your eyes with water.
Get medical attention immediately.
7. Remove and clean the battery and battery cables with a baking soda solution.
8. Rinse them with fresh water.
9. Add distilled water to the electrolyte, if necessary, and fully charge the battery.


battery acid:

battery acid:
10. Store the battery in a cool (never below 32 F or 0 C) dry place. Keep the battery fully
charged, and check the level and the specific gravity of the electrolyte regularly.
11. Insert heavy paper strips between the pulleys and belts to prevent sticking.
12. Seal all engine openings, including the exhaust outlet, with moisture resistant tape.
NOTE:
Use cardboard, plywood, or metal covers where practical.
13. Clean and dry the exterior painted surfaces of the engine, and spray with a suitable liquid
automobile body wax, a synthetic resin varnish, or a rust preventive compound.
14. Protect the engine with a good weather-resistant tarpaulin, and store it under cover,
preferably in a dry building which can be heated during the winter months.
The stored engine should be inspected periodically. If there is any rust or corrosion, corrective
steps must be taken to prevent damage to the engine parts. Perform a complete inspection at the
end of one year, and apply additional treatment as required.

14.5 RESTORING AN EXTENDED STORAGE ENGINE (MORE THAN 30

DAYS)
Restore an extended storage engine as follows:

1. Remove the covers and tape from all openings of the engine, fuel tank, and electrical
equipment.
NOTE:
Do not overlook the exhaust outlet.
To avoid injury from fire caused by heated diesel-fuel

vapors:
Keep those people who are not directly involved in
servicing away from the engine.
Stop the engine immediately if a fuel leak is detected.
Do not allow open flames or smoke when working on
an operating engine.
Wear adequate protective clothing (face shield,
insulated gloves and apron, etc.).
To prevent a buildup of potentially volatile vapors, keep
the engine area well ventilated during operation.
Diesel fuel is relatively harmless at ambient temperatures.
2. Wash the engine exterior with fuel oil to remove the rust preventive.
3. Remove the rust preventive from the flywheel.
4. Remove the paper strips from between the pulleys and the belts.
5. Remove the drain plug, and drain the preservative oil from the crankcase.
6. Install the drain plug.
7. Fill the crankcase to the proper level with the recommended grade of lubricating oil, using
a pressure prelubricator. Refer to section 13.5.1 and refer to section 5.2.
8. Fill the fuel tank with the fuel specified under Fuel Specifications. Refer to section 5.1.1.5.
9. Close all drain cocks, and fill the engine cooling system with clean soft water and a
rust inhibitor.
NOTE:
If the engine is to be exposed to freezing temperatures, fill the cooling system with
a solution of water and an ethylene glycol base antifreeze. Refer to section 5.3 and
refer to section 13.12.
10. Install and connect the battery.

14.5 RESTORING AN EXTENDED STORAGE ENGINE (MORE THAN 30 DAYS)
11. Service the air cleaner. Refer to section 6.2.1.
14.5.1 Restore Power Generator (More than 30 Days)
Restore power generator from extended storage as follows:

Refer to section 11.1.9 Operating Instructions.
14.5.2 Restore Marine Gear (More than 30 Days)
Restore marine gear from extended storage as follows:

1. Inspect the marine gear.
2. Refill it to the proper level, as necessary, with the correct grade of lubricating oil.
14.5.3 Restore Torqmatic Converter (More than 30 Days)
Restore Torqmatic converter from extended storage as follows:

1. Remove the tape from the breather and all openings.
2. Remove all preservative grease with a suitable solvent.
3. Start the engine, and operate the unit until the temperature reaches 66 C (150 F).
4. Drain the preservative oil, and remove the filter.
NOTE:
A Torqmatic converter containing preservative oil should only be operated enough to
bring the oil temperature up to 66 C (150 F).
5. Start the engine, and stall the converter for twenty seconds at 1000 RPM. to scavenge the
oil from the converter.
6. Install the drain plug and a new filter element.
7. Refill the converter with the recommended oil. Refer to section 13.56.
14.5.4 Restore Power Take-Off (More than 30 Days)
Restore power take-off from extended storage as follows:

1. Remove the inspection hole cover, and inspect the clutch release lever and link pins and
the bearing ends of the clutch release shaft.
2. Apply engine oil sparingly, if necessary, to these areas.
14.5.5 Restore Hydrostarter (More than 30 Days)
Restore hydrostarter from extended storage as follows:

1. Open the relief valve on the side of the hand pump, and release the pressure in the system.

2. Drain, fill, and purge the hydrostarter system. Refer to section 11.2.3 and
refer to section 13.38.
14.5.6 Restore Turbocharger (More than 30 Days)
Restore turbocharger from extended storage as follows:

1. Remove the covers from the turbocharger air inlet and turbine outlet connections.
2. Lubricate the turbocharger. Refer to section 6.6.4.
NOTICE:
Before subjecting the engine to a load or high speed, check the
engine tune-up.
After all of the preparations have been completed, start the engine.

14.6 STORAGE OF BATTERY
The lead-acid storage battery is an electro-chemical device for converting chemical energy into
electrical energy.
The battery has three major functions:
1. Provides a source of current for starting the engine.
2. Acts as a stabilizer to the voltage in the electrical system.
3. Can, for a limited time, furnish current when the electrical demands exceed the output of
the alternator.
When selecting a replacement battery, always select one of an "electrical size" at least equal
to the originally engineered battery for the particular equipment. The specifications are
listed in Table 14-1.
Minimum Battery Rating Minimum Battery Rating

SAE Cold Cranking SAE Cold Cranking
Engine Model System Voltage
AMPS @ -17.8 C (0 F) AMPS @ -17.8 C (0 F)
Above 0 C (32 F) Below 0 C (32 F)
6V, 8V*, 12V* 24V, 32V 950 1250
16V †24V, 32V 950 1250
* Must use Delco-Remy 50MT cranking motor or equivalent.
†Two cranking motors. Battery recommendation is for each motor.
Table 14-1 Battery Recommendations

battery acid:
When batteries are being charged, an explosive gas mixture forms beneath the cover of each cell.
Part of this gas escapes through the holes in the vent plugs. If ventilation is poor, these gases may
form an explosive atmosphere around the battery.
14.6.1 Repair or Replacement of Storage Battery
To determine if repair is possible or replacement is necessary, perform the following procedure.

14.6.2 Removal of Storage Battery
Remove the storage battery as follows:

1. Disconnect and ground the battery terminal.
2. Detach the cable clamps.
3. Loosen the hold-down clamps evenly.
4. Remove the battery.
14.6.2.1 Cleaning of Storage Battery
Prior to inspection, clean the battery as follows:

1. Clean the battery posts, terminals, and connections.

battery acid:
2. Wash the top of the battery with baking soda solution.

3. Rinse with fresh water.
4. Apply a coat of grease to the connections and exposed metal parts.
14.6.2.2 Inspection of Storage Battery
Inspect the battery as follows:

1. Inspect the charge indicator "eyes" periodically for adequate charge.
[a] If there is no charge or weak charge, replace the battery. 14.6.3.
NOTE:
If the battery becomes discharged regularly, inspect the electrical system.
[b] If the battery is sufficiently charged, continue inspection.

2. Inspect the battery posts, terminals, and connections for fraying, loss of insulation covers,
wear, or damage.
[a] If slightly frayed, worn, or damaged, repair the connections, posts, and terminals.
Refer to OEM.
[b] If excessively frayed, worn, or damaged, replace the connections, posts, and
terminals. Refer to OEM.
[c] If not frayed, worn, or damaged, continue inspection.
3. Inspect the electrolyte level frequently if the battery is not the maintenance-free type.
NOTICE:
Do not overfill the battery. Overfilling can cause poor battery
performance or premature battery failure.
[a] If low, add water.

[b] If no water is needed, continue inspection.
4. Inspect the cables, clamps, and hold-down brackets for corrosion or damage.
[a] If corroded or damaged, replace the cables, clamps, or hold-down brackets.
Refer to section 14.6.3.
[b] If not corroded or damaged, reuse the parts.
14.6.3 Installation of Storage Battery
Install the battery as follows:

1. Ensure the battery carrier is clean and the battery rests level when installed.
NOTICE:
Do not over tighten the battery hold-down clamps. The battery
case will distort or crack.
2. Tighten the hold-down clamps evenly until snug.

3. Attach the cable clamps.
4. To make the cable connections as corrosion resistant as possible, place a felt washer at the
base of each terminal beneath the cable clamps.
5. Coat the entire connection with a heavy general-purpose grease.
NOTE:
Ensure the ground cable is clean and tight at the engine block or frame.


battery acid:
6. Check the polarity to ensure the battery is not reversed with respect to the generating
system.
NOTICE:
Connect the grounded battery cable last. This will help prevent
short circuits that may damage the battery.
7. Connect the grounded battery terminal.


INDEX
A
Air Intake System, 6-1
Air Intake System; Air Cleaner, 6-5
Air Intake System; Air Intake System, 6-3
Air Intake System; Air Separator Filter Element, 6-13
Air Intake System; Air Shutdown Housing, 6-15
Air Intake System; Blower, 6-27
Air Intake System; Turbocharger (Airesearch), 6-89
Air Intake System; Turbocharger Aftercooler, 6-128
Air Intake System; Turbocharger Intercooler, 6-120
C
Cooling System, 4-1
Cooling System; Coolant Filter and Conditioner, 4-116
Cooling System; Coolant Pressure Control Cap, 4-63
Cooling System; Cooling System, 4-3
Cooling System; Engine Cooling Fan, 4-66
Cooling System; Heat Exchanger, 4-94
Cooling System; Radiator, 4-50
Cooling System; Raw Water Pump, 4-102
Cooling System; Thermostat, 4-40
Cooling System; Water Manifold, 4-35
Cooling System; Water Pump (12V and 16V Engines), 4-23
Cooling System; Water Pump (6V and 8V Engines), 4-5
E
Electrical Equipment, 8-1
Electrical Equipment; Alarm System, 8-45
Electrical Equipment; Battery-charging Alternator, 8-3
Electrical Equipment; Engine Protective Systems, 8-24
Electrical Equipment; Instruments, 8-20
Electrical Equipment; Overspeed Governor, 8-52
Electrical Equipment; Starting Motor, 8-12
Electrical Equipment; Tachometer Drive, 8-15
Engine, 1-1
Engine; Accessory Drive, 1-445

6SE379 0303 Copyright © 2003 DETROIT DIESEL CORPORATION Index-1
INDEX
Engine; Balance Weight Cover, 1-468

Engine; Blower Drive Gear and Support Assembly, 1-427
Engine; Camshaft Gears, 1-385
Engine; Camshafts and Bearings, 1-356
Engine; Clutch Pilot Bearing, 1-251
Engine; Connecting Rod, 1-308
Engine; Connecting Rod Bearings, 1-326
Engine; Crankshaft, 1-132
Engine; Crankshaft Cap, 1-176
Engine; Crankshaft Main Bearing Shells, 1-180
Engine; Crankshaft Oil Seals (Front and Rear), 1-166
Engine; Crankshaft Outboard Bearing Support (Trunnion), 1-202
Engine; Crankshaft Pulley, 1-238
Engine; Crankshaft Rear Outboard Bearing Support, 1-210
Engine; Crankshaft Timing Gear, 1-416
Engine; Crankshaft Vibration Damper, 1-223
Engine; Cylinder Block, 1-3
Engine; Cylinder Block End Plates, 1-38
Engine; Cylinder Head, 1-47
Engine; Cylinder Liner, 1-333
Engine; Engine Balance and Balance Weights, 1-347
Engine; Engine Drive Shaft Flexible Coupling, 1-256
Engine; Engine Front Cover, 1-197
Engine; Exhaust Valves, 1-102
Engine; Flywheel, 1-243
Engine; Flywheel Housing, 1-264
Engine; Gear Train and Engine Timing, 1-348
Engine; Idler Gear and Bearing Assembly, 1-393
Engine; Piston and Piston Rings, 1-284
Engine; Valve and Injector Operating Mechanism, 1-74
Engine; Valve Rocker Covers, 1-126
Engine Tune-up, 12-1
Engine Tune-up; Engine Tune-up, 12-3
Engine Tune-up; Exhaust Valve Clearance Adjustment, 12-28
Engine Tune-up; Fuel Injector Timing, 12-32
Engine Tune-up; Fuel Modulator, 12-264
Engine Tune-up; Governor Settings, 12-143

Index-2 6SE379 0303 Copyright © 2003 DETROIT DIESEL CORPORATION
Engine Tune-up; Governors With Synchronizing Motor, 12-243

Engine Tune-up; Limiting Speed Mechanical Governor Adjustment (Variable Low-speed),
12-129
Engine Tune-up; Limiting Speed Mechanical Governor and Injector Rack Control Adjustment
(12V and 16V Engines), 12-86
Engine Tune-up; Limiting Speed Mechanical Governor Fast Idle Cylinder, 12-139
Engine Tune-up; Limiting Speed Mechanical Governor Injector Rack Control Adjustment (6V
and 8V Engines), 12-35
Engine Tune-up; Power Control Device, 12-248
Engine Tune-up; Sg Variable Speed Hydraulic Governor Injector Rack Control Adjustment
(12V and 16V), 12-223
Engine Tune-up; Sg Variable Speed Hydraulic Governor Injector Rack Control Adjustment
Engine Tune-up; Static Double Weight Limiting Speed Governor Gap Checking and Setting
Procedure, 12-118
Engine Tune-up; Supplementary Governing Device Adjustment, 12-244
Engine Tune-up; Throttle Delay Mechanism Adjustment, 12-251
Engine Tune-up; Variable Speed Mechanical Governor and Injector Rack Control Adjustment
Engine Tune-up; Variable Speed Mechanical Governor Injector Rack Control Adjustment (6V
and 8V Engines), 12-173
Exhaust System, 7-1
Exhaust System; Exhaust Manifold, 7-5
Exhaust System; Exhaust Manifold (Water-cooled), 7-11
Exhaust System; Exhaust System, 7-3
F
Fuel System, 2-1
Fuel System; Coolant Level Sensor, 2-135
Fuel System; Coolant Pressure Sensor (12V and 16V), 2-143
Fuel System; Coolant Temperature Sensor, 2-141
Fuel System; DDEC II, 2-83
Fuel System; DDEC III, 2-89
Fuel System; DDEC IV, 2-95
Fuel System; Electronic Engine Controls, 2-77
Fuel System; Electronic Foot Pedal Assembly, 2-102
Fuel System; Electronic Governor, 2-416

INDEX
Fuel System; Electronic Unit Injector, 2-55

Fuel System; Fuel Cooler, 2-184
Fuel System; Fuel Injector Control Tube (Non-DDEC Engines), 2-417
Fuel System; Fuel Injector Tube, 2-66
Fuel System; Fuel Pressure Sensor, 2-145
Fuel System; Fuel Pump, 2-151
Fuel System; Fuel Strainer and Fuel Filter, 2-176
Fuel System; Fuel System, 2-3
Fuel System; Fuel Temperature Sensor, 2-148
Fuel System; Hydraulic Governor Drive, 2-376
Fuel System; Hydraulic Governor Synchronizing Motor, 2-413
Fuel System; Limiting Speed Mechanical Governor, 2-187
Fuel System; Limiting Speed Mechanical Governor (Variable High Speed), 2-266
Fuel System; Limiting Speed Mechanical Governor (Variable Low-speed), 2-252
Fuel System; Mechanical Unit Injector, 2-7
Fuel System; Oil Pressure Sensor, 2-106
Fuel System; Oil Temperature Sensor, 2-109
Fuel System; Psg Hydraulic Governor, 2-367
Fuel System; Pulse Wheel (6V and 8V Engines), 2-112
Fuel System; Sg Hydraulic Governors, 2-328
Fuel System; Synchronous Reference Sensor (6V and 8V), 2-119
Fuel System; Timing Reference Sensor, 2-123
Fuel System; Turbo Boost Sensor, 2-103
Fuel System; Variable Speed Mechanical Governor, 2-275
Fuel, Lubricating Oil, and Coolant, 5-1
Fuel, Lubricating Oil, and Coolant; Coolant, 5-28
Fuel, Lubricating Oil, and Coolant; Fuel, 5-3
Fuel, Lubricating Oil, and Coolant; Lubricating Oil Requirements, 5-19
L
Lubricating System, 3-1
Lubricating System; Lubricating Oil Cooler (Plate Type), 3-79
Lubricating System; Lubricating Oil Cooler (Tube Type), 3-93
Lubricating System; Lubricating Oil Cooler Bypass Valve, 3-112
Lubricating System; Lubricating Oil Filters, 3-67
Lubricating System; Lubricating Oil Pressure Regulator Valve, 3-49
Lubricating System; Lubricating Oil Pressure Relief Valve, 3-58

Lubricating System; Lubricating Oil Pump (12V and 16V Engines), 3-35
Lubricating System; Lubricating Oil Pump (6V and 8V Engines), 3-11
Lubricating System; Lubrication System, 3-3
Lubricating System; Oil Level Dipstick, 3-117
Lubricating System; Oil Pan, 3-120
Lubricating System; Ventilating System, 3-126
O
Operation and Verification, 11-1
Operation and Verification; Engine Run-in Procedures, 11-52
Operation and Verification; Operating Conditions, 11-18
Operation and Verification; Preparation, 11-3
Operation and Verification; Running, 11-11
Operation and Verification; Starting, 11-8
Operation and Verification; Stopping, 11-16
P
Power Take-off, 9-1
Power Take-off; Power Take-off Torqmatic Converter, 9-3
Preventive Maintenance, 13-1
Preventive Maintenance; Air Box Check Valves, 13-77
Preventive Maintenance; Air Box Drain Tube, 13-76
Preventive Maintenance; Air Cleaner, 13-103
Preventive Maintenance; Air Compressor, 13-74
Preventive Maintenance; Air Separator Filter Element, 13-107
Preventive Maintenance; Air Shutdown Valve, 13-111
Preventive Maintenance; Air System, 13-106
Preventive Maintenance; Battery, 13-65
Preventive Maintenance; Battery Charging Alternator, 13-68
Preventive Maintenance; Blower Bypass Valve, 13-72
Preventive Maintenance; Blower Screen, 13-85
Preventive Maintenance; Clutch Actuator (DDEC Marine), 13-126
Preventive Maintenance; Coolant Filter, 13-50
Preventive Maintenance; Coolant Filter/inhibitor Precharge Element, 13-51
Preventive Maintenance; Cooling System, 13-36
Preventive Maintenance; Cooling System (Marine), 13-112
Preventive Maintenance; Crankcase Breather, 13-93

INDEX
Preventive Maintenance; Crankcase Pressure, 13-92

Preventive Maintenance; Diesel Fuel Contamination, 13-33
Preventive Maintenance; Drive Belts, 13-58
Preventive Maintenance; Engine (Steam Clean), 13-94
Preventive Maintenance; Engine and Transmission Mounts, 13-70
Preventive Maintenance; Engine Tune-up, 13-71
Preventive Maintenance; Exhaust System, 13-91
Preventive Maintenance; Fan (Thermo-mounted), 13-83
Preventive Maintenance; Fan Hub, 13-81
Preventive Maintenance; Fuel and Boost Coolers, 13-121
Preventive Maintenance; Fuel Injectors and Valve Clearance, 13-87
Preventive Maintenance; Fuel Lines and Flexible Hoses, 13-34
Preventive Maintenance; Fuel Strainer and Filter, 13-29
Preventive Maintenance; Fuel Tank, 13-32
Preventive Maintenance; Governor, Overspeed Governor, 13-79
Preventive Maintenance; Heat Exchanger Changeout Interval, 13-113
Preventive Maintenance; Heat Exchanger Electrodes and Core (Raw Water System Zincs),
13-116
Preventive Maintenance; Lubricating Oil, 13-19
Preventive Maintenance; Lubricating Oil Filter, 13-27
Preventive Maintenance; Maintenance, 13-6, 13-12, 13-16
Preventive Maintenance; Marine Gear (Twin Disc 16V), 13-124
Preventive Maintenance; Oil Pressure, 13-26
Preventive Maintenance; Power Take-off, 13-95
Preventive Maintenance; Preventive Maintenance Items Description, 13-5
Preventive Maintenance; Radiator, 13-53
Preventive Maintenance; Raw Water Pump, 13-118
Preventive Maintenance; Reduction Gear, 13-99
Preventive Maintenance; Shutter Operation, 13-78
Preventive Maintenance; Starting Motor, 13-89
Preventive Maintenance; Tachometer Drive, 13-73
Preventive Maintenance; Thermostats and Seals, 13-84
Preventive Maintenance; Throttle and Clutch Controls, 13-75
Preventive Maintenance; Throttle Delay Fuel Modulator, 13-80
Preventive Maintenance; Torqmatic Converter, 13-97
Preventive Maintenance; Torqmatic Marine Gear (6V and 8V), 13-122
Preventive Maintenance; Transit Coach Converter Muffler, 13-101

Preventive Maintenance; Turbocharger and Exhaust Connections, 13-54

Preventive Maintenance; Vibration Damper, 13-88
Preventive Maintenance; Water Pump, 13-49
S
Special Equipment, 10-1
Special Equipment; Air Compressor, 10-3
Special Equipment; Engine Block Heater, 10-9
Special Equipment; Transmissions, 10-10
Storage, 14-1
Storage; Extended Engine Storage (More Than 30 Days), 14-7
Storage; Preparing Engine, 14-3
Storage; Restoring A Temporarily Stored Engine (30 Days or Less), 14-6
Storage; Restoring an Extended Storage Engine (More Than 30 Days), 14-13
Storage; Storage, 14-16
Storage; Temporary Engine Storage (30 Days or Less), 14-4


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SERIES 92 SERVICE MANUAL

13.22 ENGINE TUNE-UP

All information subject to change without notice.

13.23 BLOWER BYPASS VALVE

Every 160,000 km (100,000 miles) or approximately 60 months, perform the following:

All information subject to change without notice.

13.24 TACHOMETER DRIVE

Figure 13-10 Tachometer Drive

All information subject to change without notice.

13.25 AIR COMPRESSOR

Maintain the air compressor as follows:

All information subject to change without notice.

13.26 THROTTLE AND CLUTCH CONTROLS

To avoid injury from contact with the contaminants in used

3. Lubricate all other control mechanisms, as required, with engine oil.

All information subject to change without notice.

13.27 AIR BOX DRAIN TUBE

Maintain the air box drain tube as follows:

1. Air Box Drain Tube

Figure 13-11 Air Box Drain Tube

2. If the tube is clogged, remove tube.

All information subject to change without notice.

13.28 AIR BOX CHECK VALVES

To avoid injury from flying debris when using compressed

3. Blow out the lines with compressed air.

All information subject to change without notice.

13.29 SHUTTER OPERATION

All information subject to change without notice.

13.30 GOVERNOR, OVERSPEED GOVERNOR

Perform the following maintenance procedures for the governor:

3. Replace the cap.

All information subject to change without notice.

13.31 THROTTLE DELAY FUEL MODULATOR

Inspect and adjust, if necessary, every 30 months or 80,000 km (50,000 miles).

13.31.1 Inspection of Check Valve

Inspect the check valve as follows:

13.31.2 Inspection of Modulator

Inspect the fuel modulator as follows:

All information subject to change without notice.

13.32 FAN HUB

All information subject to change without notice.

1. Grease Fitting 4. Pulley (3 Groove)

All information subject to change without notice.

13.33 FAN (THERMO-MOUNTED)

Inspect the fan drive fluid level as follows:

4. Replace the inspection plug.

All information subject to change without notice.

13.34 THERMOSTATS AND SEALS

Figure 13-13 Typical Thermostat Housing

All information subject to change without notice.

13.35 BLOWER SCREEN

Maintain the blower screen as follows:

1. Blower Screen (Mounted Under Air Intake Manifold)

Figure 13-14 Blower Screen

All information subject to change without notice.

To avoid injury from flying debris when using compressed

All information subject to change without notice.

13.36 FUEL INJECTORS AND VALVE CLEARANCE

All information subject to change without notice.

13.37 VIBRATION DAMPER

All information subject to change without notice.

13.38 STARTING MOTOR

Figure 13-15 Starting Motor Lubrication Fittings