Series 53, 71, 92 And 149 Engines

3.5 million two-cycle engines
built since 1940
Nearly 500,000 still in operation
around the world
$100 million in parts inventory to
cover your needs
Series 53, 71, 92
and 149 Engines
Over 2,500 factory trained technicians
Nearly 2,000 service locations to keep
you up and running
13400 Outer Drive, West
Detroit, MI 48239-4001
313.592.5000
www.detroitdiesel.com
© 2005 Detroit Diesel Corporation. All rights reserved. Detroit Diesel, DDEC, POWER GUARD, POWER
Trac, POWER COOL and Spinning Arrows Design are registered trademarks of Detroit Diesel Corporation.
6SA0072 0501 As technical advancements continue, specifications will change. Printed in U.S.A.
Maintenance, Repair, Overhaul and
Replace/Repower Solutions
2 Cycle Engine
Maintenance, Repair, Overhaul
and Replace/Repower Options
Our name stands above all others in the industry
for quality, dependability and performance...
Whether you’re...
n
n
Always choose genuine Detroit Diesel products.
n
changing the oil in your 6V92
replacing the blower on your 4-71
replacing the 8V71 engine in your bus
Detroit Diesel has you covered
with quality genuine DDC parts.
Maintenance
PERFORMANCE PRODUCTS
Repair
ENGINE COMPONENTS
Overhaul
OVERHAUL & LONG BLOCKS
Replace/Repower
REMANUFACTURED ENGINES
Genuine DDC 2-Cycle new and reliabilt® remanufactured
parts and engines are built to the latest Detroit Diesel
engineering specifications, so you can be assured of
exacting quality and a great value. Best of all, DDC genuine
parts are backed by a Detroit Diesel warranty and serviced
by the vast network of authorized distributors and dealers.
Maintenance
Detroit Diesel maintenance products are engineered
specifically for DDC engines to maximize engine
performance. A full line of preventative maintenance
products assist you in prolonging engine life.
POWER GUARD®
Oil And Fuel Filters
POWER COOL®
Antifreeze/Coolant
POWER GUARD®
Oil
POWER Trac®
Coolant Analysis
POWER Trac®
Oil Analysis
POWER Trac®
Coolant Test Strips
Oil and fuel filters designed for
your Detroit Diesel engine offer
maximum engine protection
Heavy duty engine coolant that is
pre-charged with supplemental
coolant additives to help prevent
inhibitor dropout, scale deposits
and gel problems
Designed for heavy duty 2-cycle
commercial on-highway and
off-highway equipment to satisfy
the critical lubrication needs of
diesel engines in low-emission
highway applications
Forty percent of engine downtime is related to coolant maintenance. POWER Trac helps
prevent cooling system repairs.
Monitors your engine lubricating oil
and helps to identify a problem prior
to a catastrophic engine failure
Each Power Trac coolant test
strip checks for freeze point (EG
& PG Coolants), nitrite levels and
molybdate contamination
n Computer controlled double-lock
seams prevent leaks
n Formulated with high efficiency materials
to ensure proper filtering
n Engineered gasket material for top
performance in all environmental
conditions with easy installation
and removal
n Pre-charged with supplemental coolant
additives saving you labor time
n Can be recharged with POWER COOL
Supplemental Coolant Additives
n Prevents inhibitor dropout, scale deposits
and gel problems frequently associated
with diesel engine cooling systems
n Low ash formula minimizes exhaust
deposits and valve burning which lead
to premature failure
n Minimizes engine rust and oil foaming
which helps you get the most out of
your engine
n Reduces slipper bushing wear and
prevents liner and ring scuffing – that
translates to longer component life and
a higher return on your equipment dollar.
n Measures coolant condition, inhibitor
strength, water quality, and
corrosion products
n Provides extensive evaluation of
coolant and factory recommendations
for correction
n Digital spectrometer measures the
quantities of 21 wear metals to help
extend engine life by detecting and
correcting lubricant contamination
n Tests on your oil sample are also
conducted to detect oil dilution, soot
loading and viscosity breakdown –
conditions that could contribute to
equipment and oil degradation
n Extended oil drain intervals require
mandatory oil analysis and DDC
pre-approval
n Oil analysis available from regional
labs – Quick Results!
n Easy 1 minute field test ensures your
engine is properly protected
n Designed exclusively for POWER COOL
chemistry to guarantee
proper cooling
n Available as single, foil wrapped strips,
in a 10 count bottle or 50 count bottle
for use in the field or in the shop
Repair
reliabilt® Engine Components
reliabilt® goes beyond the
remanufacturing process. While
the reliabilt® process closely
parallels the remanufacturing
process, there are some distinct
differences in the reliabilt®
methodology.
n reliabilt®
products are fully
remanufactured to Detroit Diesel’s
current standards. Updates and
specification modifications are
incorporated into the assembly,
making them comparable to new
replacement parts.
n When cores are received with
non-genuine parts attached, the
non-genuine parts are scrapped
and destroyed.
n Wear items are replaced with
genuine Detroit Diesel parts and
salvageable items are restored
to factory specifications.
n After the component is reassembled, it is subjected to rigorous
functional testing and a thorough
inspection to assure quality.
n When you purchase a reliabilt®
product you are assured of
restored, predictable service life.
n No other remanufacturer has
access to current Detroit Diesel
specifications, quality audits or
insight on progressive modifications.
n When you choose reliabilt®
products you get factory quality,
optimum performance and more
value for your money.
Injectors
All water pumps are available with the
unitized seal to reduce the likelihood of
leaks. The carbon seal pump core will be
accepted at no charge and updated when
upgrading to the unitized seal pump. The
older style Gitts pump is automatically
upgraded to newer standards. Water
pumps are supplied with appropriate
mounting gaskets and seals (except
Series 149).
are manufactured for consistent performance
n All nozzles are replaced with new parts
n Calibrated at full rack and at idle
n Opening pressures set to factory specifications
Crankshafts
Subjected to a series of rigorous
tests on our Coordinate Measuring
Machine. This “state-of-the-art”
computer driven robot, which measures in forty millionths resolution,
runs a complex battery of tests on
every crankshaft. Its proven
repeatability offers the ultimate
verification of crankshaft blueprint
specifications compliance. The
comprehensive steps ensure
trouble-free performance.
Turbochargers are completely remanufactured to exacting OEM specifications,
ensuring performance and uptime. Both
the turbine and compressor wheels are
balanced separately and together. Radial
and axial endplay are checked to ensure
compliance to critical tolerances.
Conversion programs are available to
upgrade former turbocharger designs to a
different turbocharger type.
n Bushings are replaced 100%
n Turbine wheels CNC machined to
blueprint specifications
Connecting Rods
Maximum life–ensured quality
n Honed and gauged to current blueprint
specification
n Checked for bend and twist in accordance
to the latest blueprint specifications
n 100% new bushings
Fuel Pumps
Rotors and housings remanufactured
to new OEM specifications utilizing the
latest metal recovery technologies to
ensure reliable performance.
Remanufactured and flow tested to
Detroit Diesel specifications. Gear pockets and gears are matched to ensure
maximum performance.
Starters And
Alternators
Maximum durability
reliabilt heads are offered in a number of
different configurations. The product that is
right for you will depend on your current head
casting and your engine application.
n Magnetic particle tested for cracks
n 100% vacuum tested for leaks
n Valve seats machined to OEM specifications
These processes ensure the highest quality
cylinder heads.
®
n Remanufactured and tested to
OEM specifications
All With A12 Month Warranty
Overhaul
reliabilt® Long Blocks
Only genuine Detroit Diesel new
and reliabilt® remanufactured
parts can guarantee the right fit
and function when you overhaul
your engine. No matter what level
overhaul your engine needs – from
inframe to complete - Detroit
Diesel has the parts you need to
perform your overhaul correctly.
All Detroit Diesel reliabilt® parts
come with a 12 month warranty
against defects in material and
workmanship and are guaranteed
to meet/exceed all DDC factory
specifications.
Detroit Diesel knows that no one
can visually inspect an engine and
know for sure what condition the
major castings are in. Or even in
instances where catastrophic damage is visible, it can still be
difficult to measure the extent of
damage that has occurred.
The solution -- a reliabilt® remanufactured long block assembly.
How It Works
As long as your long block has no
visible damage to the major castings,
you will not be charged back for any
non-rebuildable castings that are discovered when we disassemble the
core. Simply put, if the damage is
hidden, you will not be charged back
regardless of what is found.
Furthermore, if the core does
have visible damage to any of the
major castings, you pay only the
unacceptable core charge no matter how extensive the damage.
This means, for the first time, you
can accurately calculate your cost
to overhaul...even in instances
where an engine has suffered visible damage.
The Choice
A reliabilt® remanufactured long
block assembly includes:
n Cylinder Block
n Gear Train
n Cylinder Kits
n Rear End Plate
n Crankshaft (.020 max)
n Camshaft(s)
n Front Cam Weights
n Oil Pump Drive Gear (53 Series)
n Cylinder Heads with operating
mechanism
A reliabilt® “plus” remanufactured long block assemblies are an
excellent choice when the application demands additional new part
content. They come equipped with
the same content as the reliabilt®
long block, plus:
n New crankshaft
n New cylinder head castings (equipped
with new valves and springs)
n Cylinder block with a maximum oversized cylinder bore of .010
These quality long block
assemblies are remanufactured
using genuine DDC parts to Detroit
Diesel Corporation's exacting
specifications.
A reliabilt® long block assembly
carries our full one-year warranty.
This warranty is honored by all
Detroit Diesel distributors and
authorized service dealers.
Replace/Repower
reliabilt® Remanufactured Engines
Remanufactured
Engines
Many rebuilders replace only failed
components and a short list of
wear items. That’s fine if you can
carry the risk of unpredictable service life. Restoring your engine to
the latest performance specification is a fundamental requirement
of our remanufacturing process.
That’s where the reliabilt® engine
differs from competitive rebuilt
engines in the marketplace.
The Detroit Diesel remanufacturing
process starts with the complete
disassembly of the engine core.
When engine cores are received
with non-genuine part content, the
non-genuine parts are scrapped.
Each constituent part is cleaned,
inspected, tested, qualified and
restored to Detroit Diesel “blueprint”
standards. Wear items are replaced
with genuine Detroit Diesel parts. All
reliabilt® engine components are
upgraded to include the latest
design improvements.
Every reliabilt® engine is
dynamometer tested to validate
performance and ensure customer
satisfaction. All engines are tested
on Detroit Diesel factory specified
dynamometers using Detroit Diesel
new engine test protocol.
No other remanufacturer or
rebuilder has access to Detroit
Diesel specifications or insight into
ongoing product modifications.
Only with reliabilt® can you be
assured that the product performs
to Detroit Diesel specifications.
Warranty Coverage
reliabilt® remanufactured engines
are covered by a 1 year/100,000
mile warranty serviced at any
authorized DDC location around
the world.
Protecting Your
Investment: Extended
Power Protection Plans
(P3) Are Also Available:
Extended service coverages up to
5 year/300,000 miles are available
for purchase with a reliabilt®
remanufactured engine. Should you
ever require service inside or outside of the warranty or P3 period,
there are over 2,000 trained factory
authorized locations to serve you.