DETROIT DIESEL SERIES 92 ENGINES 6 8 12 & 16 CYLINDER SERVICE REPAIR MANUAL

DETROIT DIESEL SERIES 92 ENGINES 6, 8, 12 & 16 CYLINDER SERVICE REPAIR MANUAL

Loaded with illustrations, instructions, photos, and diagrams, complete to service and repair your engine. Read and print pages or copy the entire manual to your hard drive.

 828 Pages

This manual covers the basic V-92 Diesel Engines built by the Detroit Diesel Corporation.

Complete instructions on operation, adjustment (tune-up), preventative maintenance and lubrication

and repair (including complete overhaul) are covered.

This manual primarily was written for mechanics servicing and overhauling these engines.

Basic maintenance and overhaul procedures for all the V-92 engines v6 v8 v12 v16 cylinders.

MANUAL COVERS:

• Engine (6, 8, 12 & 16 cylinder Diesel engines)
• Fuel System and Governors
• Air Intake System
• Lubrication System
• Cooling System
• Exhaust System
• Electrical Equipment and Instruments
• Power Take Off – Torqmatic Converter
• Transmissions
• Special Equipment
• Operating Instructions
• Engine Tune-Up
• Preventative Maintenance
• Updates

SECTION 1

CONTENTS

Cylinder Block 1.1

Cylinder Block End Plates 1.1.1

Air Box Drains 1.1.2

Cylinder Head 1.2

Valve and Injector Operating Mechanism 1.2.1

Exhaust Valves 1.2.2

Valve Rocker Cover 1.2.4

Crankshaft 1.3

Crankshaft Oil Seals 1.3.2

Crankshaft Cap 1.3.3

Crankshaft Main Bearings 1.3.4

Engine Front Cover (Lower) 1.3.5

Crankshaft Outboard Bearing Support 1.3.5.1

Crankshaft Vibration Damper 1.3.6

Crankshaft Pulley 1.3.7

Flywheel 1.4

Clutch Pilot Bearing 1.4.1

Engine Drive Shaft Flexible Coupling 1.4.2

Flywheel Housing 1.5

Piston and Piston Rings 1.6

Connecting Rod 1.6.1

Connecting Rod Bearings 1.6.2

Cylinder Liner 1.6.3

Engine Balance and Balance Weights 1.7

Gear Train and Engine Timing 1.7.1

Camshafts and Bearings 1.7.2

Camshaft Gears 1.7.3

Idler Gear and Bearing Assembly 1.7.4

Crankshaft Timing Gear 1.7.5

Blower Drive Gear and Support Assembly 1.7.6

Accessory Drives 1.7.7

Balance Weight Cover 1.7.8

Shop Notes – Troubleshooting – Specifications – Service Tools 1.0

SECTION 2

FUEL SYSTEM AND GOVERNORS

CONTENTS

Fuel System 2

Fuel Injector 2.1.1

Fuel Injector Tube 2.1.4

Fuel Pump 2.2

Fuel Strainer and Fuel Filter 2.3

Fuel Cooler 2.5.1

Mechanical Governors 2.7

Limiting Speed Mechanical Governor 2.7.1

Limiting Speed Mechanical Governor (Variable Low-Speed) 2.7.1.3

Limiting Speed Mechanical Governor (Variable High-Speed) 2.7.1.5

Variable Speed Mechanical Governor 2.7.2

Hydraulic Governors 2.8

SG Hydraulic Governor (Variable Speed) 2.8.1

PSG Hydraulic Governor 2.8.2

Hydraulic Governor Drive 2.8.3

Hydraulic Governor Synchronizing Motor 2.8.4

Fuel Injector Control Tube 2.9

Shop Notes – Trouble Shooting – Specifications – Service Tools 2.0

SECTION 3

AIR INTAKE SYSTEM

CONTENTS

Air Intake System 3

Air Cleaner 3.1

Air Silencer 3.2

Air Shutdown Housing 3.3

Blower 3.4

Turbocharger 3.5

Turbocharger Intercooler 3.5.2

Turbocharger Aftercooler 3.5.3

Shop Notes – Trouble Shooting – Specifications – Service Tools 3.0

SECTION 4

LUBRICATION SYSTEM

CONTENTS

Lubrication System 4

Lubricating Oil Pump 4.1

Lubricating Oil Pressure Regulator and Relief Valves 4.1.1

Lubricating Oil Filters 4.2

Lubricating Oil Cooler 4.4

Oil Level Dipstick 4.6

Oil Pan 4.7

Ventilating System 4.8

Specifications – Service Tools 4.0

SECTION 5

COOLING SYSTEM

CONTENTS

Cooling System 5

Water Pump 5.1

Water Manifold 5.2

Thermostat 5.2.1

Radiator 5.3

Coolant Pressure Control Cap 5.3.1

Engine Cooling Fan 5.4

Heat Exchanger 5.5

Raw Water Pump (Jabsco) 5.6

Coolant Filter and Conditioner 5.7

Shop Notes – Specifications – Service Tools 5.0

SECTION 6

EXHAUST SYSTEM

CONTENTS

Exhaust System 6

Exhaust Manifold (Air-Cooled) 6.1

Exhaust Manifold (Water-Cooled) 6.1.1

EXHAUST SYSTEM

SECTION 7

ELECTRICAL EQUIPMENT, INSTRUMENTS AND

PROTECTIVE SYSTEMS

CONTENTS

Electrical System 7

Battery-Charging Alternator 7.1

Storage Battery 7.2

Starting Motor 7.3

Instruments and Tachometer Drive 7.4

Engine Protective Systems 7.4.1

Alarm System 7.4.2

Overspeed Governors 7.4.3

Shop Notes – Trouble Shooting – Specifications Service Tools 7.0

SECTION 14

ENGINE TUNE-UP

CONTENTS

Engine Tune-Up Procedures and Emission Regulations 14

Exhaust Valve Clearance Adjustment 14.1

Fuel Injector Timing 14.2

Limiting Speed Mechanical Governor and Injector Rack Control Adjustment:

6V and 8V Engines 14.3

12V and 16V Engines 14.3.1

Variable Low-Speed 14.3.3

Fast Idle Cylinder 14.3.4

Governor Settings for “TT” Engines 14.3.5

Variable Speed Mechanical Governor:

6V and 8V Engines 14.4

12V and 16V Engines 14.4.1

Hydraulic Governor and Injector Rack Control Adjustment:

Hydraulic Governor (6V and 8V) 14.7.2

Hydraulic Governor (12V and 16V) 14.7.3

Supplementary Governing Device Adjustment:

Engine Load Limit Device 14.14

Power Control Device 14.14

Throttle Delay Mechanism 14.14

Governor Shutdown Solenoid 14.14

Fuel Modulator 14.14

Starting Aid Screw (see Section 14.3 and 14.3.1) 14.14

This manual is the same as the manual used by workshops. Service Manual contains detailed instructions and step by step diagrams for all workshop procedures. 

Language: English 
Format: PDF – Indexed and Searchable

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