GENERAL INFORMATION ...................................................................... 1
SCOPE AND USE OF THIS MANUAL ..................................................... 3
SAFETY PRECAUTIONS ........................................................................ 3
FLUOROELASTOMER (VITON) CAUTION ............................................. 10
SERVICE PARTS AVAILABILITY ............................................................. 11
CLEARANCE AND TORQUE SPECIFICATIONS .................................... 11
THE TWO CYCLE PRINCIPLE FOR DIESEL ENGINES ........................ 12
GENERAL DESCRIPTION ..................................................................... 13
DDEC DIAGNOSTIC READER CAUTION ............................................... 15
DDEC I ..................................................................................................... 16
DDEC II .................................................................................................... 17
DDEC III .................................................................................................. 17
GENERAL SPECIFICATIONS ................................................................ 18
ENGINE MODEL, SERIAL NUMBER AND OPTION LABEL ................... 21
REPAIR AND REPLACE .......................................................................... 24
DISASSEMBLY ....................................................................................... 25
CLEANING ............................................................................................... 25
INSPECTION .......................................................................................... 26
ASSEMBLY .............................................................................................. 27
GASKETS ................................................................................................ 27
ENGLISH TO METRIC CONVERSION .................................................... 28
DECIMAL AND METRIC EQUIVALENTS ................................................ 30
SPECIFICATIONS ................................................................................... 30
1.1 CYLINDER BLOCK ................................................................................. 1-3
1.2 CYLINDER BLOCK END PLATES ........................................................... 1-38
1.3 CYLINDER HEAD ................................................................................... 1-47
1.4 VALVE AND INJECTOR OPERATING MECHANISM .............................. 1-74
1.5 EXHAUST VALVES ................................................................................. 1-102
1.6 VALVE ROCKER COVERS ...................................................................... 1-126
1.7 CRANKSHAFT ........................................................................................ 1-132
1.8 CRANKSHAFT OIL SEALS (FRONT AND REAR) .................................. 1-166
1.9 CRANKSHAFT CAP ................................................................................ 1-176
1.10 CRANKSHAFT MAIN BEARING SHELLS ............................................... 1-180
1.11 ENGINE FRONT COVER ........................................................................ 1-197
1.12 CRANKSHAFT OUTBOARD BEARING SUPPORT (TRUNNION) .......... 1-202
1.13 CRANKSHAFT REAR OUTBOARD BEARING SUPPORT ..................... 1-210
1.14 CRANKSHAFT VIBRATION DAMPER ..................................................... 1-223
1.15 CRANKSHAFT PULLEY .......................................................................... 1-238
1.16 FLYWHEEL ............................................................................................. 1-243
1.17 CLUTCH PILOT BEARING ...................................................................... 1-251
1.18 ENGINE DRIVE SHAFT FLEXIBLE COUPLING ..................................... 1-256
1.19 FLYWHEEL HOUSING ............................................................................ 1-264
1.20 PISTON AND PISTON RINGS ................................................................. 1-284
1.21 CONNECTING ROD ................................................................................ 1-308
1.22 CONNECTING ROD BEARINGS ............................................................. 1-326
1.23 CYLINDER LINER .................................................................................. 1-333
1.24 ENGINE BALANCE AND BALANCE WEIGHTS ..................................... 1-347
1.25 GEAR TRAIN AND ENGINE TIMING ...................................................... 1-348
1.26 CAMSHAFTS AND BEARINGS ............................................................... 1-356
1.27 CAMSHAFT GEARS ............................................................................... 1-385
1.28 IDLER GEAR AND BEARING ASSEMBLY .............................................. 1-393
1.29 CRANKSHAFT TIMING GEAR ................................................................ 1-416
1.30 BLOWER DRIVE GEAR AND SUPPORT ASSEMBLY ............................ 1-427
1.31 ACCESSORY DRIVE ............................................................................... 1-445
1.32 BALANCE WEIGHT COVER ................................................................... 1-468
1.A ADDITIONAL INFORMATION .................................................................. 1-473
2 FUEL SYSTEM
2.1 FUEL SYSTEM ....................................................................................... 2-3
2.2 MECHANICAL UNIT INJECTOR ............................................................. 2-7
2.3 ELECTRONIC UNIT INJECTOR .............................................................. 2-55
2.4 FUEL INJECTOR TUBE ........................................................................... 2-66
2.5 ELECTRONIC ENGINE CONTROLS ...................................................... 2-77
2.6 DDEC II .................................................................................................... 2-83
2.7 DDEC III .................................................................................................. 2-89
2.8 DDEC IV .................................................................................................. 2-95
2.9 ELECTRONIC FOOT PEDAL ASSEMBLY ............................................... 2-102
2.10 TURBO BOOST SENSOR ...................................................................... 2-103
2.11 OIL PRESSURE SENSOR ..................................................................... 2-106
2.12 OIL TEMPERATURE SENSOR ............................................................... 2-109
2.13 PULSE WHEEL DDEC III AND II (6V AND 8V ENGINES) ...................... 2-112
2.14 SYNCHRONOUS REFERENCE SENSOR (6V AND 8V) ........................ 2-119
2.15 TIMING REFERENCE SENSOR ............................................................. 2-123
2.16 COOLANT LEVEL SENSOR ................................................................... 2-135
2.17 COOLANT TEMPERATURE SENSOR .................................................... 2-141
2.18 COOLANT PRESSURE SENSOR (12V AND 16V) ................................. 2-143
2.19 FUEL PRESSURE SENSOR ................................................................... 2-145
2.20 FUEL TEMPERATURE SENSOR ............................................................ 2-148
2.21 FUEL PUMP ............................................................................................ 2-151
2.22 FUEL STRAINER AND FUEL FILTER ..................................................... 2-176
2.23 FUEL COOLER ....................................................................................... 2-184
2.24 LIMITING SPEED MECHANICAL GOVERNOR ...................................... 2-187
2.25 LIMITING SPEED MECHANICAL GOVERNOR (VARIABLE
LOW-SPEED) ........................................................................................... 2-252
2.26 LIMITING SPEED MECHANICAL GOVERNOR (VARIABLE HIGH
SPEED) .................................................................................................... 2-266
2.27 VARIABLE SPEED MECHANICAL GOVERNOR .................................... 2-275
2.28 SG HYDRAULIC GOVERNORS .............................................................. 2-328
2.29 PSG HYDRAULIC GOVERNOR .............................................................. 2-367
2.30 HYDRAULIC GOVERNOR DRIVE ........................................................... 2-376
2.31 HYDRAULIC GOVERNOR SYNCHRONIZING MOTOR .......................... 2-413
2.32 ELECTRONIC GOVERNOR .................................................................... 2-416
2.33 FUEL INJECTOR CONTROL TUBE (NON-DDEC ENGINES) ................ 2-417
2.A ADDITIONAL INFORMATION .................................................................. 2-431
3 LUBRICATING SYSTEM
3.1 LUBRICATION SYSTEM .......................................................................... 3-3
3.2 LUBRICATING OIL PUMP (6V AND 8V ENGINES) ................................ 3-11
3.3 LUBRICATING OIL PUMP (12V AND 16V ENGINES) ............................ 3-35
3.4 LUBRICATING OIL PRESSURE REGULATOR VALVE ........................... 3-49
3.5 LUBRICATING OIL PRESSURE RELIEF VALVE .................................... 3-58
3.6 LUBRICATING OIL FILTERS ................................................................... 3-67
3.7 LUBRICATING OIL COOLER (PLATE TYPE) .......................................... 3-79
3.8 LUBRICATING OIL COOLER (TUBE TYPE) ........................................... 3-93
3.9 LUBRICATING OIL COOLER BYPASS VALVE ........................................ 3-112
3.10 OIL LEVEL DIPSTICK .............................................................................. 3-117
3.11 OIL PAN ................................................................................................... 3-120
3.12 VENTILATING SYSTEM .......................................................................... 3-126
3.A ADDITIONAL INFORMATION .................................................................. 3-131
4 COOLING SYSTEM
4.1 COOLING SYSTEM ................................................................................ 4-3
4.2 WATER PUMP (6V AND 8V ENGINES) .................................................. 4-5
4.3 WATER PUMP (12V AND 16V ENGINES) .............................................. 4-23
4.4 WATER MANIFOLD ................................................................................ 4-35
4.5 THERMOSTAT ........................................................................................ 4-40
4.6 RADIATOR .............................................................................................. 4-50
4.7 COOLANT PRESSURE CONTROL CAP ................................................ 4-63
4.8 ENGINE COOLING FAN .......................................................................... 4-66
4.9 HEAT EXCHANGER ............................................................................... 4-94
4.10 RAW WATER PUMP ................................................................................ 4-102
4.11 COOLANT FILTER AND CONDITIONER ................................................ 4-116
4.A ADDITIONAL INFORMATION .................................................................. 4-123
5 FUEL, LUBRICATING OIL, AND COOLANT
5.1 FUEL ........................................................................................................ 5-3
5.2 LUBRICATING OIL REQUIREMENTS ..................................................... 5-19
5.3 COOLANT ................................................................................................ 5-28
6 AIR INTAKE SYSTEM
6.1 AIR INTAKE SYSTEM ............................................................................. 6-3
6.2 AIR CLEANER ........................................................................................ 6-5
6.3 AIR SEPARATOR FILTER ELEMENT ...................................................... 6-13
6.4 AIR SHUTDOWN HOUSING ................................................................... 6-15
6.5 BLOWER .................................................................................................. 6-27
6.6 TURBOCHARGER (AIRESEARCH) ........................................................ 6-89
6.7 TURBOCHARGER INTERCOOLER ........................................................ 6-120
6.8 TURBOCHARGER AFTERCOOLER ....................................................... 6-128
6.A ADDITIONAL INFORMATION .................................................................. 6-139
7 EXHAUST SYSTEM
7.1 EXHAUST SYSTEM ................................................................................ 7-3
7.2 EXHAUST MANIFOLD ............................................................................ 7-5
7.3 EXHAUST MANIFOLD (WATER-COOLED) ............................................. 7-11
8 ELECTRICAL EQUIPMENT
8.1 BATTERY-CHARGING ALTERNATOR .................................................... 8-3
8.2 STARTING MOTOR ................................................................................. 8-12
8.3 TACHOMETER DRIVE ............................................................................. 8-15
8.4 INSTRUMENTS ...................................................................................... 8-20
8.5 ENGINE PROTECTIVE SYSTEMS ......................................................... 8-24
8.6 ALARM SYSTEM .................................................................................... 8-45
8.7 OVERSPEED GOVERNOR ..................................................................... 8-52
8.A ADDITIONAL INFORMATION .................................................................. 8-59
9 POWERTAKE-OFF
9.1 POWER TAKE-OFF TORQMATIC CONVERTER .................................... 9-3
10 SPECIAL EQUIPMENT
10.1 AIR COMPRESSOR ............................................................................... 10-3
10.2 ENGINE BLOCK HEATER ....................................................................... 10-9
10.3 TRANSMISSIONS .................................................................................. 10-10
11 OPERATION AND VERIFICATION
11.1 PREPARATION FOR A FIRST TIME START ........................................... 11-3
11.2 STARTING ............................................................................................... 11-8
11.3 RUNNING ................................................................................................. 11-11
11.4 STOPPING .............................................................................................. 11-16
11.5 OPERATING CONDITIONS ..................................................................... 11-18
11.6 ENGINE RUN-IN PROCEDURES ............................................................ 11-52
12 ENGINE TUNE-UP
12.1 ENGINE TUNE-UP ................................................................................. 12-3
12.2 EXHAUST VALVE CLEARANCE ADJUSTMENT .................................... 12-28
12.3 FUEL INJECTOR TIMING ........................................................................ 12-32
12.4 LIMITING SPEED MECHANICAL GOVERNOR INJECTOR RACK
CONTROL ADJUSTMENT (6V AND 8V ENGINES) ............................... 12-35
12.5 LIMITING SPEED MECHANICAL GOVERNOR AND INJECTOR RACK
CONTROL ADJUSTMENT (12V AND 16V ENGINES) ............................ 12-86
12.6 STATIC DOUBLE WEIGHT LIMITING SPEED GOVERNOR GAP
CHECKING AND SETTING PROCEDURE ............................................. 12-118
12.7 LIMITING SPEED MECHANICAL GOVERNOR ADJUSTMENT
(VARIABLE LOW-SPEED) ....................................................................... 12-129
12.8 LIMITING SPEED MECHANICAL GOVERNOR FAST IDLE CYLINDER 12-139
12.9 GOVERNOR SETTINGS FOR "TT" ENGINES ........................................ 12-143
12.10 VARIABLE SPEED MECHANICAL GOVERNOR INJECTOR RACK
CONTROL ADJUSTMENT (6V AND 8V ENGINES) ............................... 12-173
12.11 VARIABLE SPEED MECHANICAL GOVERNOR AND INJECTOR RACK
CONTROL ADJUSTMENT (12V AND 16V ENGINES) ............................ 12-186
12.12 SG VARIABLE SPEED HYDRAULIC GOVERNOR INJECTOR RACK
CONTROL ADJUSTMENT (6V AND 8V ENGINES) ............................... 12-204
12.13 SG VARIABLE SPEED HYDRAULIC GOVERNOR INJECTOR RACK
CONTROL ADJUSTMENT (12V AND 16V) ............................................. 12-223
12.14 GOVERNORS WITH SYNCHRONIZING MOTOR ................................... 12-243
12.15 SUPPLEMENTARY GOVERNING DEVICE ADJUSTMENT .................... 12-244
12.16 POWER CONTROL DEVICE ................................................................... 12-248
12.17 THROTTLE DELAY MECHANISM ADJUSTMENT .................................. 12-251
12.18 FUEL MODULATOR ................................................................................ 12-264
13 PREVENTIVE MAINTENANCE
13.1 PREVENTIVE MAINTENANCE ITEMS DESCRIPTION .......................... 13-5
13.2 MAINTENANCE OF VEHICLE ENGINE .................................................. 13-6
13.3 MAINTENANCE OF STATIONARY AND INDUSTRIAL ENGINE ............ 13-12
13.4 MAINTENANCE OF PLEASURE CRAFT MARINE ENGINES ................ 13-16
13.5 LUBRICATING OIL ................................................................................... 13-19
13.6 OIL PRESSURE ...................................................................................... 13-26
13.7 LUBRICATING OIL FILTER ...................................................................... 13-27
13.8 FUEL STRAINER AND FILTER ............................................................... 13-29
13.9 FUEL TANK ............................................................................................. 13-32
13.10 FUEL CONTAMINATION .......................................................................... 13-33
13.11 FUEL LINES AND FLEXIBLE HOSES ..................................................... 13-34
13.12 COOLING SYSTEM ................................................................................ 13-36
13.13 WATER PUMP ........................................................................................ 13-49
13.14 COOLANT FILTER .................................................................................. 13-50
13.15 COOLANT FILTER/INHIBITOR PRECHARGE ELEMENT ...................... 13-51
13.16 RADIATOR .............................................................................................. 13-53
13.17 TURBOCHARGER AND EXHAUST CONNECTIONS ............................. 13-54
13.18 DRIVE BELTS ......................................................................................... 13-58
13.19 BATTERY ................................................................................................. 13-65
13.20 BATTERY CHARGING ALTERNATOR ..................................................... 13-68
13.21 ENGINE AND TRANSMISSION MOUNTS .............................................. 13-70
13.22 ENGINE TUNE-UP ................................................................................. 13-71
13.23 BLOWER BYPASS VALVE ....................................................................... 13-72
13.24 TACHOMETER DRIVE ............................................................................. 13-73
13.25 AIR COMPRESSOR ............................................................................... 13-74
13.26 THROTTLE AND CLUTCH CONTROLS ................................................. 13-75
13.27 AIR BOX DRAIN TUBE ............................................................................ 13-76
13.28 AIR BOX CHECK VALVES ....................................................................... 13-77
13.29 SHUTTER OPERATION ......................................................................... 13-78
13.30 GOVERNOR, OVERSPEED GOVERNOR .............................................. 13-79
13.31 THROTTLE DELAY FUEL MODULATOR ................................................ 13-80
13.32 FAN HUB .................................................................................................. 13-81
13.33 FAN (THERMO-MOUNTED) ................................................................... 13-83
13.34 THERMOSTATS AND SEALS .................................................................. 13-84
13.35 BLOWER SCREEN ................................................................................. 13-85
13.36 FUEL INJECTORS AND VALVE CLEARANCE ....................................... 13-87
13.37 VIBRATION DAMPER .............................................................................. 13-88
13.38 STARTING MOTOR ................................................................................. 13-89
13.39 EXHAUST SYSTEM ................................................................................ 13-91
13.40 CRANKCASE BREATHER (EXTERNALLY MOUNTED) ......................... 13-92
13.41 CRANKCASE BREATHER (INTERNALLY MOUNTED) .......................... 13-93
13.42 ENGINE (STEAM CLEAN) ....................................................................... 13-94
13.43 POWER TAKE-OFF ................................................................................ 13-95
13.44 TORQMATIC CONVERTER ..................................................................... 13-97
13.45 REDUCTION GEAR ................................................................................. 13-99
13.46 TRANSIT COACH CONVERTER MUFFLER ........................................... 13-101
13.47 AIR CLEANER ........................................................................................ 13-103
13.48 AIR SYSTEM .......................................................................................... 13-106
13.49 AIR SEPARATOR FILTER ELEMENT ...................................................... 13-107
13.50 AIR SHUTDOWN VALVE ......................................................................... 13-111
13.51 COOLING SYSTEM (MARINE) ............................................................... 13-112
13.52 HEAT EXCHANGER CHANGEOUT INTERVAL ...................................... 13-113
13.53 HEAT EXCHANGER ELECTRODES AND CORE (RAW WATER
SYSTEM ZINCS) ..................................................................................... 13-116
13.54 RAW WATER PUMP ................................................................................ 13-118
13.55 FUEL AND BOOST COOLERS ............................................................... 13-121
13.56 TORQMATIC MARINE GEAR (6V AND 8V) ............................................ 13-122
13.57 MARINE GEAR (TWIN DISC 16V) .......................................................... 13-124
13.58 CLUTCH ACTUATOR (DDEC MARINE) .................................................. 13-126
14 STORAGE
14.1 PREPARING ENGINE FOR STORAGE ................................................... 14-3
14.2 TEMPORARY ENGINE STORAGE (30 DAYS OR LESS) ....................... 14-4
14.3 RESTORING A TEMPORARILY STORED ENGINE (30 DAYS OR
LESS) ....................................................................................................... 14-6
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
INDEX ................................................................................................. Index-1