Detroit Diesel 92 Series Manuel

13400 Outer Drive, West / Detroit, Michigan 48239-4001

Telephone: 313-592-5000

Telex: 4320091 / TWX: 810-221-1649

FAX: 313-592-7288

6SE506 Rev. 06-94 As technical advancements continue, specifications will change. Printed in U.S.A.

Engine Operator's Guide

Series 92

To the Operator

This guide contains instructions on

the safe operation and preventive

maintenance of your Detroit Diesel

engine. Maintenance instructions

cover routine engine services such

as lube oil and filter changes in

enough detail to permit self-servic-

ing, if desired.

The operator should become famil-

iar with the contents of this manual

before operating the engine or carry-

ing out maintenance procedures.

Power-driven equipment is only as

safe as the person operating the

controls. You are urged, as the oper-

ator of this diesel engine, to keep fin-

gers and clothing away from the

revolving belts, drive shafts, etc. on

the engine installation.

Throughout this guide CAUTIONS

regarding personal safety and

NOTICES regarding engine perfor-

mance or service life will appear. To

avoid personal injury and ensure

long engine service life, always heed

these instructions.

Whenever possible, it will benefit

you to rely on an authorized Detroit

Diesel service outlet for all your ser-

vice needs from maintenance to

major parts replacement. Authorized

service outlets worldwide stock fac-

tory original parts and have the spe-

cialized equipment and experienced,

trained personnel to provide prompt

preventive maintenance and skilled

engine repairs.

The information and specifications

in this publication are based on the

information in effect at the time of

approval for printing. Contact an

authorized Detroit Diesel service out-

let for information on the latest revi-

sion. The right is reserved to make

changes at any time without obliga-

tion.

Table of Contents

Subject Page

Engine Model and Serial Number Designation.................................................1

DDEC II/DDEC III Engine Identification ............................................................1

Option and Certification Labels ........................................................................1

OPERATING INSTRUCTIONS...........................................................................3

Preparations for Starting the Engine the First Time ..........................................3

Starting the Engine............................................................................................6

Running the Engine...........................................................................................8

Stopping the Engine .......................................................................................10

Emergency Jump Starting ..............................................................................11

DDEC OPTIONS..............................................................................................12

Vehicle, Industrial Engines..............................................................................12

Marine Engines ...............................................................................................20

ENGINE SYSTEMS..........................................................................................24

Fuel System.....................................................................................................24

Lubrication System .........................................................................................24

Air System.......................................................................................................24

Cooling System...............................................................................................24

Electrical System.............................................................................................24

Exhaust System...............................................................................................24

ENGINE MAINTENANCE SCHEDULES.....................................................26-31

LUBRICATION AND PREVENTIVE MAINTENANCE INTERVALS..............32-44

“HOW TO” SECTION .................................................................................45-60

How to Select Lubricating Oil .........................................................................45

When to Change Oil........................................................................................47

How to Replace the Lube Oil Filter .................................................................48

How to Select Fuel Oil.....................................................................................50

How to Replace the Fuel Filter and Strainer ...................................................53

Engine Out of Fuel—How to Restart ...............................................................54

How to Select Coolant.....................................................................................55

How to Drain and Flush the Cooling System ..................................................59

When to Service the Dry Type Air Cleaner .....................................................60

BASIC TROUBLESHOOTING ....................................................................61-64

ENGINE STORAGE....................................................................................65-69

SERVICE PUBLICATIONS...............................................................................70

CUSTOMER ASSISTANCE ........................................................................71-72

SPECIFICATIONS ......................................................................................73-74

WARRANTY

The applicable engine warranty is contained in the booklet entitled “Warranty

Information for Series 53, 71 and 92 Engines,” available from authorized

Detroit Diesel service outlets.

Keep this Operators Guide with the engine installation at all times. It con-

tains important operating, maintenance, and safety instructions.

iiiii

Information in this guide is for diesel-fueled Series 92 engines. For alcohol-

fueled engines refer to publication “Alcohol-Fueled Series 92 Engines” (Form

6SE508), available from authorized Detroit Diesel distributors.

ENGINE MODEL AND

SERIAL NUMBER

DESIGNATION

The engine serial number and model

number are stamped on the cylinder

block in the following location (as

viewed from the front):

• 6V, 8V-92 Machined pad on the

left side, upper front corner just

below the fire deck.

• 12V, 16V-92 Left side of the rear

block, below and between the

back airbox covers.

DDEC II/DDEC III

Engine Identification

Detroit Diesel Electronic Control

(DDEC) systems are available as stan-

dard or optional items on many Series

92 engine models. Engines equipped

with DDEC II systems are identified by

the letter "B" in the sixth position of the

model number. Example: 80877B28.

Engines equipped with DDEC III sys-

tems have the letter "K" in the sixth

position Example: 80877K28.

Option Labels

Computerized engine option labels are

attached to the valve rocker cover.

These labels contain the engine serial

number and model number and, in

addition, list any optional equipment

used on the engine. Labels also

include required tune-up information

(injection timing, valve lash, max. no-

load RPM, etc.).

With any order for parts, the engine

model and serial number must be

given. If a type number is shown on

the option label covering the equip-

ment required, this number should

also be included on the parts order.

Marine gears, transmissions and

power take-offs generally carry their

own name plates. The model and seri-

al number information on these plates

is useful when ordering parts for these

assemblies.

Certification Label

If required, a certification label is

attached to the valve rocker cover.

This label certifies that the engine con-

forms to federal and certain state

emissions regulations for its particular

application. It also gives the operating

conditions under which certification

was made.

SERIAL NO.

MODEL NO.

08VF150965

80877B28

Location of Engine Serial and Model

Number (8V-92 Shown)

OPERATING

INSTRUCTIONS

Preparations for

Starting the Engine

the First Time

When preparing to start a new or newly

overhauled engine or an engine which

has been in storage, perform all of the

operations listed below. Failure to follow

these instructions may result in serious

engine damage. Before a routine start,

see “Daily” checks in the Engine

Maintenance schedules (pages 26-31).

Cooling System Checks

1. Make sure all the drain cocks in

the cooling system are installed

(drain cocks are often removed for

shipping) and are closed tightly.

2. Open the petcock near the top of

the water-cooled turbocharger (if

used), and any other petcocks, if

so equipped.

3. Remove the radiator or heat

exchanger pressure control cap

and fill with genuine Detroit Diesel

Power Cool antifreeze or an

equivalent ethylene glycol-base

antifreeze solution in the required

concentration. In extremely hot

environments, clean, soft, proper-

ly inhibited water may be used in

the summer. Keep the coolant

level at the bottom of the filler

neck to allow for expansion of the

coolant. For more detailed coolant

recommendations, refer to How to

Select Coolant (page 55).

4. After filling the cooling system,

close all petcocks. Fill the coolant

recovery bottle to the "Full Cold"

level, if equipped.

5. Entrapped air must be purged

after filling the cooling system. To

do this refer to "Inspection-Cooling

System" under "Running the

Engine" (page 8).

6. On industrial and off-highway

units, check to make sure the front

of the radiator is unblocked and

free of debris.

7. On marine units, perform these

additional steps:

■Check sea water strainers and

remove any accumulations of sea-

weed or debris. Strainers act as

filters between the intake through-

hull fittings and the raw water

pump(s) and are easily fouled.

Make sure all thru-hull valves,

other valves in the cooling system,

and raw water sea lines are open.

■Remove the cover from the raw

water pump. Visually inspect the

impeller for signs of damaged or

broken vanes. Replace the impeller

if damaged. Reinstall the cover with

a new gasket.

■Before starting the engine, prime

the raw water pump by removing

the pipe plug or zinc provided in

the pump outlet elbow and pour-

ing at least a pint of water into the

pump. Reinstall the plug or zinc.

Typical Engine Option and Certification Labels (8V-92 Labels Shown)

U.S.A.

0396 C/S PULLEY 0080 C/S PUL BELT 0272 WATER PUMP

0458 WAT BYPASS 0426 THERMOSTAT 0462 EXH MANIFOLD

0177 FUEL PUMP 0324 INJECTOR 0691 BLOWER

1303 TURBOCHARGER 0068 FUEL MAN CONN 0862 FUEL FILTER

1995 FUEL LINES 0747 AIR INLT HSG 0341 INJ CONT ELEC

0648 ENGINE MOUNTS NONE AIR COMP 0901 CAM/GR TRAIN

0384 VALVE MECH JAKE SEE VALV MECH 0425 ROCKER COVER

0133 OIL FIL CAP 0727 VENT SYSTEM 0761 VENT SYSTEM

0143 ACC DRIVE 0223 ACC DRIVE 0230 ACC DRIVE

UNIT 08VF161310 S.O. 4A42112 MODEL 80877K45 SPEC P0677700

U.S.A.

IMPORTANT ENGINE INFORMATION

1994 THIS ENGINE CONFORMS TO U.S. EPA

FED REGULATIONS APPLICABLE TO 1994 MODEL YEAR NEW HEAVY DUTY

DIESEL ENGINES. THIS ENGINE HAS A PRIMARY INTENDED

SERVICE APPLICATION AS A HEAVY HEAVY DUTY ENGINE.

FUEL RATE AT ADV. HP 104.7 MM3/STROKE ADV. HP 500 AT 2100 RPM

INITIAL INJECTION TIMING 13 DEG. BTC CID 736

ENGINE FAMILY RDD736EJ4AR4 MIN. IDLE 600 RPM FEL BSP 0.32

MODEL 8V 92TA DDEC MFG. DATE

UNIT 08VF161310

U.S.A.

THIS ENGINE IS NOT CERTIFIED FOR USE IN AN URBAN BUS AS DEFINED AT 40 CFR

86.093 2. SALE OF THIS ENGINE FOR USE IN AN URBAN BUS IS A VIOLATION OF

FEDERAL LAW UNDER THE CLEAN AIR ACT.

THIS ENGINE IS CERTIFIED TO OPERATE ON

LOW SULFUR DIESEL FUEL.

UNIT 08VF161310

0483 CYL BLOCK 0161 AIR BOX DRAIN THIS ENGINE WAS

0137 CYL HEAD 0247 ENG LIFT BRKT TESTED AT 0450 HP

0721 F/W HOUSING 0177 VIB DAMPER AT 02100 RPM

0848 FLYWHEEL 0431 CONN ROD/PSTN INJ. TIMING 1.520

0810 OIL PAN 0200 OIL PUMP VALVE LASH .016

0028 OIL PRESS REG 0203 OIL DIST STARTING AID .000

1230 OIL COOLER 1031 DIPSTICK THRTDLY/FMOD .000

0591 OIL FILTER 0748 VENT SYSTEM MAX RPM NL 02225

0048 BAL WT COVER 1689 FAN STDGT DDEC CAM

UNIT 08VF161310 S.O. 4A42112 MODEL 80877K45 SPEC P0677700

CAUTION:

When working near the engine,

always remove loose items of

clothing or jewelry that could get

caught in a moving part of the

engine and cause personal injury.

Also wear safety glasses and

hearing protection.

NOTICE:

Failure to install a new gasket and

tighten cover bolts securely can

result in pump leakage at start-up.

Lubricating System Checks

The lubricating oil film on the rotating

parts and bearings of a new or newly

overhauled engine, or one which has

been in storage for six months or

more, may be insufficient when the

engine is started for the first time.

Insufficient lubrication at start-up can

cause serious damage to engine

components.

To ensure an immediate flow of oil

to all bearing surfaces at initial

engine start-up, the engine lubrica-

tion system should be charged with a

commercially available pressure pre-

lubricator. After pre-lubricating, add

additional oil to bring the level to the

proper mark on the dipstick. Refer to

How to Select Lubricating Oil (page

45) for lubricant requirements.

Extended Storage—An engine in

storage for an extended period of

time (over winter, for example) may

accumulate water in the oil pan

through normal condensation of

moisture (always present in the air)

on the cold internal surfaces of the

engine. Lube oil diluted by water

cannot provide adequate bearing

protection at engine startup. For this

reason, Detroit Diesel recommends

replacing the engine lube oil and fil-

ter(s) after extended storage.

Transmission, Marine Gear—Make

sure the transmission or marine gear

is filled to the proper level with the

fluid recommended by the gear man-

ufacturer.

Fuel System Checks

Fill the tank with the recommended fuel.

Keeping tanks full reduces water con-

densation and helps keep fuel cool,

which is important to engine perfor-

mance. Full tanks also reduce the

chances for microbe (black slime)

growth. Refer to How to Select Fuel Oil

(page 50) for fuel recommendation.

Make sure the fuel supply shutoff valve (if

used) is open.

To ensure prompt starting and even

running, the fuel system must be primed

if air has entered the fuel system. Priming

is done by connecting a manual or elec-

tric priming pump to the inlet of the sec-

ondary fuel filter. Authorized Detroit

Diesel service outlets are properly

equipped to perform this service.

Priming is not normally necessary if the

filter elements are filled with fuel when

installed and the fuel manifolds in the

cylinder heads are not drained of fuel.

If the engine is equipped with a

fuel/water separator, drain off any

water that has accumulated. Water in

fuel can seriously affect engine perfor-

mance and may cause engine dam-

age. Detroit Diesel recommends

installation of a fuel/water separator

wherever water contamination is a

concern.

Check “Eye” of Maintenance-Free Batteries

Prime the Raw Water Pump (Marine Engines)

Check Lube Oil Level Before Starting

Eye

Other Checks

Check drive belts to make sure they

are in good condition (not cracked,

torn, worn, or glazed) and are properly

adjusted.

Make sure cable connections to the

storage batteries are clean and tight.

Check the hydrometer “eye” of mainte-

nance-free batteries for charge. If

lead-acid or low maintenance batteries

are used, make sure battery elec-

trolyte level is normal.

Check turbocharger for signs of oil

or exhaust leaks. Leaks should be cor-

rected before starting the engine.

Check engine mounting bolts for tight-

ness. Retighten, if necessary.

NOTICE:

Failure to prime the raw water

pump may result in damage to the

pump impeller and engine over-

heating.

NOTICE:

Failure to eliminate water-diluted

lube oil may lead to serious engine

damage at startup.

NOTICE:

Prolonged use of the starting motor

and engine fuel pump to prime the fuel

system can result in damage to the

starter, fuel pump, and injectors, and

cause erratic engine operation due to

the amount of air in the lines and filters

from the supply tank to the cylinder

head.

Engines equipped with starting

devices dependent on compressed air

or gas reservoirs should always be

primed before initial startup. Otherwise,

reserve pressure can be exhausted

and injectors may be damaged from

lack of lubrication and cooling.

Under no circumstances should a

starting aid such as ether be used to

run the engine until the fuel system is

primed. Injector damage will occur if

this method is used. The heat generat-

ed by the external fuel source will cause

the injector tips to be damaged when the

fuel cools them. Plunger and bushing

assemblies can be scored from running

without lubrication.

Starting the Engine

Before starting the engine the first

time, perform the operations listed

under Preparations for Starting the

Engine the First Time (pages 3-5).

If the engine has an emergency

manual or automatic shutdown sys-

tem, make sure the control is set in the

open position before starting. The tur-

bocharger may be seriously damaged

if the engine is cranked with the air

shutdown in the closed position. On

engines with dual air shutdown, both

air shutoff valves must be in the open

position before starting the engine.

If the unit is located in a closed

room, start the room ventilating fan or

open the windows, as weather condi-

tions permit, so ample air is available

for the engine.

The engine may require the use of a

cold weather starting aid if the ambient

temperature is below 40°F (4°C).

Initial Engine Start

Non-DDEC Engine

1.Position the transmission or marine

gear in park or neutral.

2. Set the speed control lever at part

throttle, then bring it back to the

desired no-load speed. In addi-

tion, make sure the stop lever on

the cover of mechanical governors is

in the run position.

3. Press the starter switch firmly.

Air Starter—Because of the limited

volume of most storage tanks and the

relatively short duration of the cranking

cycle, it is important to make sure the

engine is ready to start before acti-

vating the air starter. Start an engine

equipped with an air starter as follows:

1. Check the pressure in the air stor-

age tank. (Most air starter-equipped

installations have a dash-mounted

pressure gauge.) If necessary, add

air to bring the pressure up to at

least the recommended minimum

for starting.

2. Press the starter button firmly and

hold until the engine starts.

Starting Tip—Non-DDEC

Electric Start Engine:

Some white smoke is normal at start-

up when the engine is cold and will

clear up shortly after the engine

warms. However, if you experience

excessive smoke at cold start-up,

depress the stop button or cable at the

same time you press the starter button

and crank the engine for a few sec-

onds. Release the stop button or cable

and continue to crank the engine until

it starts (but not longer than 15 sec-

onds). This will preheat the cylinders

and reduce white smoke at start-up.

Initial Engine Start—DDEC

Vehicle, Industrial Engine

1. With the transmission in neutral or

park, turn the ignition key on.

You will notice that both the

“Check Engine” and “Stop Engine”

lights will come on. This is the result

of the DDEC computer diagnosing

the system to ensure everything is

functional, including the light bulbs

for the “Check Engine” and “Stop

Engine” warning lights. If everything

is okay, both lights will go out in

approximately five seconds.

2. With foot OFF the foot pedal, start

the engine after the lights go out.

Start the engine by pressing the

starter switch firmly.

If the engine fails to start within 15

seconds, release the starter switch

and allow the starting motor to cool

for 15 seconds before trying again. If

the engine fails to start after four

attempts, an inspection should be

made to determine the cause.

Initial Engine Start—

DDEC Marine Engine

1. With the marine gear in neutral, turn

the ignition key on. You will notice

that both the “Check Engine” and

“Stop Engine” lights on the Boat

Builder Interface Module (BBIM) will

come on. This is the result of the

DDEC computer diagnosing the

system to ensure everything is

functional, including the light bulbs

for the “Check Engine” and “Stop

Engine” warning lights. If everything

is okay, both lights will go out in

approximately five seconds.

The electronic display panels at

the control bridge also complete a

diagnostic check when the ignition

key is turned on.

The electronic display module or

"EDM" (if used) does not contain

"Check Engine" and "Stop Engine"

lamps, but features the words "STOP"

and "CHECK" on the panel face.

When the ignition key is turned on,

the EDM checks every segment on

the panel face and sets itself for dis-

play of engine parameters.

If the vessel is equipped with the

DDEC Imaging System, you will

notice that it also does not contain

"Check Engine" and "Stop Engine"

lamps, but does a self-diagnostic

check when turned on.

Should a system fault be present

at any time, both display versions will

present on the screen the diagnostic

code number and a brief word

description of the fault condition.

Typical Shutdown Override Switch and

Engine Lights

NOTICE:

The blower will be seriously dam-

aged if operated with the air shutoff

valve in the closed position.

CAUTION:

Starting fluid used in capsules is

highly flammable, toxic, and pos-

sesses sleep-inducing properties.

NOTICE:

To prevent serious starting motor

damage, do not press the starter

switch again after the engine has

started.

NOTICE:

If the warning lights stay on, or if they

do not come on momentarily after

starting the engine, consult with a

DDEC technician. Operating the

engine under these circumstances

may result in engine damage.

NOTICE:

To prevent serious starting motor

damage, do not press the starter

switch again after the engine has

started.

STOP ENGINE DIAGNOSTIC CHECK STOP

SWITCH

OVERRIDE ENGINE ENGINE

OFF

2. Start the engine after the lights go

out. Start the engine by pressing

the starter switch firmly.

If the engine fails to start within 15

seconds, release the starter switch

and allow the starting motor to cool for

15 seconds before trying again. If the

engine fails to start after four attempts,

an inspection should be made to

determine the cause.

Running the Engine

Oil Pressure

Observe the oil pressure gauge or elec-

tronic display immediately after starting

the engine. A good indicator that all of the

moving parts are getting lubrication is

when the oil pressure gauge registers

pressure (5 psi - 34.5 kPa) at idle speed.

If there is no oil pressure indicated within

10 to 15 seconds, stop the engine and

check the lubricating system. The pres-

sure should not fall below 28 psi (193

kPa) at 1800 rpm, and normal operating

pressure should be higher. If pressure

does not fall within these guidelines, it

should be checked with a manual gauge.

Warm-up

Run the engine at part throttle for about

five (5) minutes to allow it to warm up

before applying a load.

Inspection

Transmission, Marine Gear—While

the engine is idling, check the transmis-

sion or marine gear for proper oil level

and add oil as required. On marine

engines check that water is flowing out

the exhaust pipe or raw water dis-

charge pipe. Look for coolant, fuel, or

lubricating oil leaks at this time. If any

are found, shut down the engine imme-

diately and have leaks repaired after the

engine has cooled.

Cooling System–Entrapped air must

be purged after the cooling system is

filled. To do this allow the engine to

warm up without the pressure cap

installed. With the transmission or marine

gear in neutral, increase engine rpm

above 1000 rpm and add coolant as

required. Vent the petcock on the water

return line at the water-jacketed tur-

bocharger (if used) until coolant (no air)

comes out. Install the pressure cap after

the coolant level has stabilized at the

bottom of the radiator or heat exchanger

tank filler neck. Refill the recovery bottle

as needed if coolant is drawn into the

engine while purging the air.

If all of the coolant is drawn out of the

recovery bottle when the engine cools,

remove the pressure cap from the radi-

ator or heat exchanger and check to

make sure the coolant level is at the

bottom of the filler neck. Add coolant as

required, replace the pressure cap,

and fill the recovery bottle to the "Full

Cold" level, or no more than one-quarter

of its volume.

Crankcase—If the engine oil was

replaced, stop the engine after normal

operating temperature has been

reached. Allow the oil to drain back into

the crankcase for approximately twenty

(20) minutes, and check the oil level. If

necessary, add oil to bring the level to

the proper mark on the dipstick. Use

only the heavy-duty oils recommended

in How to Select Lubricating Oil (page

45) in this guide.

Turbocharger—Make a visual inspec-

tion of the turbocharger for oil leaks,

coolant leaks, exhaust leaks, excessive

noise or vibration. Stop the engine imme-

diately if a leak or unusual noise or vibra-

tion is noted. Do not restart the engine

until the cause of the concern has

been investigated and corrected.

Authorized Detroit Diesel service outlets

are properly equipped to perform this

service.

Avoid Unnecessary Idling

During long engine idling periods with

the transmission in neutral, the engine

coolant temperature may fall below the

normal operating range. The incomplete

combustion of fuel in a cold engine will

cause crankcase oil dilution, formation

of lacquer or gummy deposits on the

valves, pistons, and rings, and rapid

accumulation of sludge in the engine.

When prolonged idling is necessary,

maintain at least 800-1000 rpm.

Electronic Display Module

DDEC Imaging System

NOTICE:

If the warning lights on the BBIM stay

on, or if they do not come on

momentarily after turning on the igni-

tion key, consult with a DDEC ser-

vice technician. In the former case

the bridge displays will show the

active fault codes. Operating the

engine under these circumstances

may result in engine damage.

NOTICE:

To prevent starting motor damage,

do not press the starter switch again

after the engine has started.

CAUTION:

To avoid personal injury from the

hot oil, do not operate the engine

with rocker covers removed for

any reason.

NOTICE:

Failure to properly fill the cooling sys-

tem and purge it of air can result in

engine overheating and serious

engine damage.

Do not overfill the recovery bottle, since

this can result in spillage as the coolant

expands during engine operation.

CAUTION:

To avoid personal injury or tur-

bocharger damage, do not

remove, attach, or tighten tur-

bocharger air intake ducting while

the engine is operating or operate

the engine with the ducting

removed.

NOTE: On coach engines equipped

with Delco 50 DN alternators and

mechanical unit injectors the optimum

low idle speed setting with full accessory

load and the transmission in neutral is:

6V-92 — 650 rpm

8V-92 — 550 rpm

Stopping the Engine

Normal Stopping

1. Reduce engine speed to normal idle

and put all shift levers in the neutral

position.

2. Allow the engine to run between idle

and 1,000 rpm with no load for four

(4) or five (5) minutes. This allows the

engine to cool and permits the tur-

bocharger to slow down. After four or

five minutes, shut down the engine.

Emergency Stopping

The emergency shutdown should be

used only when the engine does not

respond to the normal stop engine

procedure.

To shut down the engine, simply acti-

vate the emergency shutdown control.

This is an electrical switch or mechani-

cal lever which is normally identified as

such on the control panel.

The air shutdown, located in the air

inlet housing, must be reset by hand

and the “emergency stop”knob

pushed in before the engine is ready to

start again.

10 11

Emergency Jump

Starting

Use the following procedure to start

the engine of a vehicle with a “low bat-

tery” or one that will not crank the

engine fast enough to start.

The DDEC II electronic control sys-

tem operates on 12 volts DC. If a

DDEC II engine with an electric start-

ing motor requires emergency jump

starting, do not exceed 16 volts DC.

The DDEC III electronic control sys-

tem operates on 12 or 24 volts DC. If a

DDEC III engine with an electric start-

ing motor requires emergency jump

starting, do not exceed 32 volts DC.

1.Prevent shorting of the system by

removing metal rings, watches, or

jewelry and not allowing metal tools

to contact the positive terminal of

the battery.

2. Place the transmission of the dis-

abled vehicle in neutral, set the

parking brake, and turn the ignition

to the off position.

3. Turn off lights, heater, air condition-

er, and any other electrical loads in

the disabled vehicle and the boost-

er vehicle.

4. Wear eye protection if available, or

shield eyes when near either bat-

tery.

5.Do not allow vehicle bodies or

bumpers to touch.

6. Connect one end of the first jumper

cable to the positive (+) terminal of

the dead battery. Connect the other

end to the positive (+) terminal of

the booster battery.

7. Connect one end of the second

jumper cable to the negative (–) ter-

minal of the booster battery.

Connect the other end to an engine

bolt head or good metallic contact

(ground) on the disabled vehicle.

NOTICE:

Stopping a turbocharged engine

immediately after high speed opera-

tion may cause damage to the tur-

bocharger, as it will continue to turn

without an oil supply to the bearings.

NOTICE:

Jump starting with voltages greater

than those indicated or reversing bat-

tery polarity may damage the ECM

(electronic control module).

NOTICE:

Never use the emergency shutdown

system, except in an emergency.

Use of the emergency shutdown can

cause lubricating oil to be sucked

past the oil seals and into the blower

and may also cause turbocharger

damage.

NOTICE:

If the emergency air shutdown is

used to stop the engine in an emer-

gency situation, always have the shut-

down checked for damage and for

proper operation before the vehicle,

vessel, or machine is returned to ser-

vice. This is especially important if

shutdown is made at high engine

rpm. To ensure positive valve closure

should another emergency shutdown

be required, the shutdown must be

checked and required repairs or

adjustments made at this time.

Failure to observe this precaution

may permit engine run-on when the

emergency shutdown is activated.

NOTICE:

Do not use this procedure if the

battery of the disabled vehicle will

not accept a charge or is frozen.

Attempting to start the vehicle

under these conditions may result

in cranking system damage.

CAUTION:

The following procedure must be

performed exactly as outlined.

Failure to observe precautions

and/or follow this sequence may

result in injury to the face, eyes,

body, limbs, and respiratory sys-

tem caused by fire or acid from

battery explosion. Property dam-

age could also result.

CAUTION:

Reversing battery polarity can also

result in personal injury caused by

the sudden discharge of elec-

trolyte from the battery vents

and/or the sudden rupture of the

battery case caused by explosion

of internal hydrogen gas.

major engine malfunction occurs, such

as low oil pressure, high oil tempera-

ture, or low coolant level.

DDEC engines may also have an

optional 3-100 minute idle shutdown

system. The purpose of this system is

to conserve fuel by eliminating exces-

sive idling and to allow for a tur-

bocharger cool down period. To

activate the shutdown, the transmis-

sion must be in neutral, with the

engine in idle or PTO mode.

Cruise Control

A DDEC-equipped vehicle engine

may have cruise control. Cruise con-

trol is available at either a road speed

or engine speed setting. The driver

has switches to activate and deacti-

vate the system, and a slight depres-

sion of the brake or clutch pedal

deactivates the system as well. The

minimum speed at which cruise con-

trol can be used is 30 or 35 mph

(depending on vehicle specifications)

and 1200 rpm.

The cruise control may also be pro-

grammed to permit fast idle using the

cruise control switches. With the

engine at normal idle, transmission in

neutral and service brake on, turn on

the cruise control “on/off” switch, and

use the “set” switch. The engine rpm

should increase to a pre-defined rpm.

The rpm can be raised or lowered

from this point using the “set” and

“resume” switches.

The cruise control option will

maintain the set speed under normal

road and load conditions. It cannot

limit vehicle speeds on down grades if

available engine braking effort is

exceeded, nor can it maintain speed

on upgrades if power requirements

exceed engine power capability.

Typical Cruise Control Switches

8. Start the engine of the booster

vehicle and allow it to run for a

minute or two to help charge the

battery of the disabled vehicle.

9. Turn the ignition of the disabled

vehicle to the on position and

attempt to start the engine.

10.As soon as the engine starts,

remove jumper cables in reverse

order of attachment (negative

ground cable on newly started

engine first, then negative cable,

then positive cable).

11. Allow the engine to warm up before

putting a load on the vehicle.

DDEC OPTIONS

Vehicle, Industrial

Engines

Engines having Detroit Diesel

Electronic Controls (DDEC) can be

equipped with a variety of options

designed to warn the operator of an

engine malfunction. The options can

range from “Check Engine” and “Stop

Engine” panel lights to automatic

reduction in engine power followed by

automatic engine shutdown. The

power-down/shutdown option may be

activated by low coolant level, low oil

pressure or high engine oil or coolant

temperature.

To start a DDEC engine be sure

the transmission is in neutral or park

and turn the ignition key on.

You will notice that both the “Check

Engine” and “Stop Engine” lights will

come on. This is the result of the

DDEC computer diagnosing the sys-

tem to ensure everything is functional,

including the light bulbs for the “Check

Engine” and “Stop Engine” warning

lights. If everything is okay, both lights

will go out in approximately five

seconds.

With foot OFF the foot pedal, start

the engine after the lights go out.

The DDEC engine is equipped with

an electronically controlled fuel

injection system.

DDEC engines have the ability to

perform diagnostics for self-checks

and continuous monitoring of other

system components. Depending on

the application, DDEC can also moni-

tor oil temperature, coolant tempera-

ture, oil pressure, fuel spill pressure,

coolant level, and remote sensors (if

used). This diagnostic system is con-

nected to the “Check Engine” and

“Stop Engine” lights to provide a visual

warning of a system malfunction.

The DDEC engine can be

equipped with an engine protection

system that features a 30 second,

stepped-power shutdown sequence

or an immediate speed reduction

without shutdown in the event a

NOTICE:

If the warning lights stay on, or if they

do not come on momentarily after

starting the engine, consult with a

DDEC technician. Operating the

engine under these circumstances

may result in engine damage.

NOTICE:

If the engine is equipped with the

power-down/shutdown option, there

will be a system override button or

switch which may be used to allow

engine operation for a short period of

time. If the shutdown override button

is not used, the shutdown will occur

in 30 seconds.

NOTICE:

When descending a hill with cruise

control “on” or “off,” do not allow

the engine to exceed 2300 rpm

under any conditions. Failure to

observe this precaution can result

in overspeeding and serious

engine damage.

CRUISE CONTROL

PANEL LIGHTS

SET ON RESUME

OFF

ENGINE START

ACC OFF RUN

CAUTION:

To avoid a spark, do not attach

the cable end to the negative ter-

minal of the disabled battery. A

spark could cause explosion of

gases normally present around

the battery, resulting in battery

rupture and possible personal

injury and/or property damage.

“Stop Engine Override” switch, located

on the instrument panel, until a safe

stop can be made. The operator only

needs to press the override switch

every 15 to 20 seconds to prevent

engine shutdown from occurring.

An important thing to remember is

that it takes 30 seconds from the time

the automatic shutdown sequence

begins until engine shutdown. There-

fore, the operator must press the over-

ride switch just prior to engine shutdown

and continue to do so until the vehicle

can be brought to a safe stop.

The immediate speed reduction

option will bring engine rpm back to a

predetermined speed, but will not shut

down the engine.

The engine should not be restarted

after it has been shut down by the

engine protection system unless the

problem has been located and cor-

rected.

The conditions that will cause the

“Stop Engine” light (SEL) to come on

are:

• Loss of coolant

• High oil temperature

• Low oil pressure

• Auxiliary shutdown

It is important to point out that when-

ever the “Check Engine” light (CEL) or

the “Stop Engine” light (SEL) comes

on, the DDEC computer will determine

where the problem is, and will then

store this information in its memory.

If the malfunction is intermittent, the

“Lights” will come on and go off as the

computer senses the changing engine

condition.

A special diagnostic tool (Diagnostic

Data Reader, or “DDR”) is available that

can be plugged into the engine com-

puter memory to extract information

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