Detroit Diesel Engine 50 Service Manual

SERIES 50 OPERATOR'S GUIDE

To the Operator

This guide contains instructions on the safe operation and preventive maintenance of your Detroit Diesel Series 50 stationary, construction/industrial, agricultural, generator set or fire fighting apparatus applications. Maintenance instructions cov er routine engine services such as lube oil and filter changes in enough detail to permit self-servicing, if desired.

The operator should become familiar with the con tents of this guide before operating the engine or carrying out maintenance procedures.

Power-driven equipment is only as safe as the person operating the controls. You are urged, as the operator of this diesel engine, to keep fingers and clothing away from the revolving belts, drive shafts, pulleys, etc. on the engine installation.

engine used in vehicle,

Whenever possible, it will benefit youtorelyonanauthorized Detroit Diesel service outlet for all your service needs from maintenance to major parts replacement. Authorized service outlets worldwide stock factory-original parts and have the specialized 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 outlet fo r information on the latest revision. The right is reserved to make changes at any time without obligation.

Throughout this guide CAUTION S regarding personal safety and NOTICES regarding engine performance or service life will appear. To avoid personal injury and ensure long engine service life, always heed these instructions.

All information subject to change without not ice. (Rev. 01/ 04) i

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NOTICE:

Trademark Information

Failure to check and maintain SCA (supplemental coolant additive) levels at required concentrations will result in severe damage (corrosion) to the engine cooling system and related components.Coolant must

be inhibited with the recommended SCAslistedinthisengineoperator's guide.Refer to section How to Select Coolant. In addition, the engine can be equipped with a coolant filter/inhibitor system as an installed option or as an after-sale item.

WARRANTY

The limited warranties for each engine application are covered in the Limited Warranty pages of this guide and in the booklet, “Warranty Information for Series 50 Engines,” available f rom authorized Detroit Diesel service outlets.

Detroit Diesel®,DDC®,DDEC®, Series 50 ProManager

Trac Guard

, Optimized Idle®,

, Power Cool®,andPower

, reliabilt®, Power

are registered t radem a rks of

DetroitDieselCorporation. Delco

Remy Delco Remy America, Inc. Bosch

is a registered trademark of

is a registered trademark of Ro bert Bosch Company N.A. Fuel Pro

Pro

and Mega Filter®are registered

,Sea

trademarks of Davco Manufacturing, L.L.C. The PowerBand

is a registered trademark of Gates Rubber Company. Tectyl

is a reg ister e d trademark of Daubert Chemical Company, Inc. Biobor

is a registered trademark of United States Borax and Chemical Corporation. DuPont

is a registered trademark of E.I. DuPont de Nemours and Company, Inc. All other trad emarks used are the property of their respective owners.

p this Operator's Guide

Kee

ith the engine installation at

w all times. It contains important operating, maintenance, and safety instructions.

ii All information subject to change without notic e . (Rev. 01/ 04)

SEL CORPORATION

SERIES 50 OPERATOR'S GUIDE

TABLE OF CONTENTS

INTRODUCTION .................................................................................. 1

NON-GENUINE AND REBUILT COMPONENT QUALITY ALERT .. 1

CAUTION SUMMARY .......................................................................... 3

ENGINE OPERATION ............................. ....................................... .. 3

PREVENTIVE MAINTENANCE ....................................................... 4

ELECTRICAL SYSTEM ................................................................... 7

COOLING SYSTEM ...................................... ................................... 8

AIR INTAKE SYSTEM ...................................................................... 8

FUEL SYSTEM ................................................................................ 9

STARTING AIDS .............................................................................. 1 0

COMPRESSED AIR ......................................................................... 11

LUBRICATING OIL AND FILTERS ................................................... 11

ENGINE MODEL AND SERIAL NUMBER DESIGNATION ................ 12

OPTION LABELS ....................................... ...................................... 13

CERTIFICATION LABELS ............................................................... 14

OPERATING INSTRUCTIONS FOR A FIRST TIME START .............. 15

PREPARATIONS FOR S TARTING THE ENGINE THE FIRST

TIME ................................................................................................. 15

COOLING SYSTEM CHECKS ........... ......................................... 15

LUBRICATION SYSTEM CHECKS ............................................. 16

EXTENDED STORAGE ................................................... ........ 16

FUEL SYSTEM CHECKS ............................................................ 17

OTHER CHECKS ........................................................................ 18

STARTING THE ENGINE ................................................................ 18

INITIAL ENGINE START .............................................................. 19

ELECTRIC STARTER ............................................................. 19

AIR STARTER ......................................................................... 20

RUNNING THE ENGINE ............... .................................................. 20

OIL PRESSURE ............................................................... ........... 20

WARM-UP ................................................................................... 20

INSPECTION ................. ....................................... ....................... 20

AVOID UNNECESSARY IDLING ................................................. 21

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STOPPING THE ENGINE ................................... ............................. 21

EMERGENCY JUMP STARTING .................................................... 22

DDEC IV SYSTEM ............................................ ................................... 23

DDEC SYSTEM .............................................................................. 23

ENGINE PROTECTION ............................................................... 24

IDLE SHUT DOWN TIMER ................................................... ........ 2 4

CRUISE CONTROL .................................................... ................. 24

ENGINE BRAKES ....................................................................... 26

DATA RECORDING C APABILITY ....... ... ...................................... 27

DDEC IV OPERATION .......................................................... ........... 27

IMMEDIATE SPEED RE DUC TION OPTION ............................... 28

STOP ENGINE LIGHT ................................................................. 28

DIAGNOSTIC DATA READER ..................................................... 28

DIAGNOSTIC CODE LIST ........................................................... 30

DDEC IV ENGINE DRIVING TIPS ....................................................... 37

ACCELERATING THE VEHICLE ..................................................... 37

CRUISE CONTROL .............................................................. ........... 37

ENGINE BRAKES AND CRUISE CONTROL ................. ... .............. 39

SHIFTING ........................................................................................ 39

IDLING .................................. ........................................................... 40

WINTER F RONTS ............................................................ ........... 40

ENGINE BRAKE SYSTEM .................................................................. 41

DRIVER CONTROL SWITCHES ..................................................... 41

LOW/HIGH SWITCH ................................. ................................... 41

LOW/MED/HIGH SWITCH ................................. .......................... 41

CLUTCH PEDAL AND THROTTLE POSITION CONTROLS .......... 41

ENGINE BRAKE OPERATION .................................... .................... 42

ANTI-LOCK BRAKING SYSTEMS ................................................... 43

DRIVING ON FLAT, DRY PAVEMENT ............................................. 43

DESCENDING A LONG, STEEP GRADE ....................................... 43

DRIVING ON WET OR SLIPPERY PAVEMENT .............................. 45

ENGINE SYSTEMS .................. .................................... ....................... 46

FUEL SYSTEM ................................................................................ 46

LUBRICATION SYSTEM ............. ..................................................... 46

AIR SYSTEM ................................................................................... 46

COOLING SYSTEM ...................................... ................................... 46

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SERIES 50 OPERATOR'S GUIDE

ELECTRICAL SYSTEM ................................................................... 46

EXHAUST SYSTEM ......................................................................... 46

EXHAUST GAS RECIRCULATION SYSTEM .................................. 46

MAINTENANCE ................................................................................... 47

PREVENTIVE MAINTEN A NCE INTERVALS ................................... 63

ITEM 1 – LUBRICATING OIL ...................................... ................. 63

ITEM 2 – FUEL AND FUEL TANK ............................................... 65

ITEM 3 – FUEL LINES, F LEXIBLE HOSES ................................ 66

LEAKS ..................................................... ................................ 66

HOSES AND FITT INGS .............. ............................................ 67

HOSE SERVICE LIFE ............................................... .............. 67

ITEM 4 – COOLING SYSTEM ..................................................... 67

COOLANT LEVEL ........................................................ ........... 67

COOLANT INHIBITORS .......................................................... 68

COOLANT DRAIN INTERVAL ............................. .................... 68

ITEM 5 – TURBOCHARGER, AIR-TO-AIR CHARGE COOLER . 70

WASTEGATE D TURBOCHARGERS ......... ... .......................... 70

ITEM 6 – B ATTERY ....................................................... .............. 71

ITEM 7 – TACHOMETER DRIVE ........ ....................................... .. 72

ITEM 8 – DRIVE BELTS ............................................. ................. 72

V-BELTS ........................................................ .......................... 73

2-GROOVE POWERBAND ........................ ............................. 73

12–RIB POLY-V BELT ............................................................. 74

BELT REPLACEMENT ..................................... ....................... 74

ITEM 9 – AIR COMPRESSOR ................................ ... ................. 74

ITEM 10 – AIR CLEANER ........................................................... 75

ITEM 11 – LUBRICATING OIL FILTERS ........ ... .......................... 75

ITEM 12 – FUEL FILTERS ........................................................... 76

FUEL PRO

382 FILTERS ...................................................... 76

SPIN-ON FILTERS .................................................................. 76

ITEM 13 – WATER PUMP AND COOLANT INHIBITOR

ELEMENT .......................................................... .......................... 77

WATER PUMP DRAIN HOLE .................................................. 77

COOLANT INHIBITOR ELEMENT .................................. ........ 7 7

ITEM 14 – CRANKING MOTOR .................................................. 78

ITEM 15 – AIR SYSTEM ............................................................. 78

ITEM 16 – EXHAUST SYSTEM ................................................... 78

ITEM 17 – ENGINE (STE AM CLEAN) .................................... ..... 78

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ITEM 18 – RADIATOR ................................................................. 78

ITEM 19 – O IL PRESSURE ........................................ ................. 79

ITEM 20 – B ATTERY-CHARGING ALTERNATOR ................. ..... 79

BOSCH GENERAL SERVICE REQUIREMENTS – BOSCH DELCO REMY

T1 ALTERNATOR SERVICE REQUIREMENTS ...... 80

ALTERNATORS .......................................... .. 80

AND

ITEM 21 – ENGINE AND TRANSMISSION MOUNTS ................ 80

ITEM 22 – CRANKCASE PRESSURE ........................................ 80

ITEM 23 – FAN HUB .................................................................... 81

ITEM 24 – THERMOSTATS AND SEALS . ... ................................ 81

ITEM 25 – CRANKCASE BREATHER ......................................... 81

ITEM 26 – ENGINE TUNE -UP ........ .......................................... .. 82

ITEM 27 – VIBRATION DAMPER ................................................ 82

HOW-TO SECTION .............................................................................. 83

HOW TO SELECT LUBRICATING OIL ............................................ 83

LUBRICANT REQUIREMENTS .................................................. 83

EGR-EQUIPPED ENGINES .................................................... 83

NON-EGR ENGINES ...... ........................................................ 83

ENGINES BU ILT PRIOR TO 1 998 .......................................... 83

COLD WEATHER STARTING ...................................................... 84

SYNTHETIC OILS ........................ ............................................... 84

THE USE OF SUPPLEMENTAL ADD IT IVES .............................. 85

WHEN TO CHANGE OIL ................................................................. 85

DISPOSING OF WASTE OIL ...................... ................................ 86

HOW TO REPLACE THE LUBE OIL FILTERS ................................ 86

REPLACE SPIN-ON TYPE OIL FILTER ...................................... 86

HOW TO SELECT FUEL OIL ..................... ...................................... 88

QUALITY .................................... .................................................. 88

FUEL CONTAMINATION ................................... .......................... 88

PROHIBITED ADDITIVES ........................................................... 88

USED LUBRI CATING OIL ....................................................... 89

GASOLINE ............................................................................. 89

HOW TO REPLACE THE FUE L FILTERS ....................................... 89

REPLACE SPIN-ON FILTER EL EMENTS ................................... 89

REPLACE FUEL/WATER SEPARATOR ELEMENT .................... 91

REPLACE FUEL PRO FILTER ELEMENT .................................. 92

ENGINE OUT OF FUEL — HOW TO RESTART ............................. 94

ENGINES W ITH SPIN-ON FILTERS ........................................... 95

vi All information subjec t to change without notice. (Rev. 01/ 04)

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SERIES 50 OPERATOR'S GUIDE

ENGINES WITH FUEL PRO FILTERS ........... ............................. 95

HOW TO SELECT COOLANT .... ....................................... .............. 96

DEFINITIONS ......................................................................... ..... 96

ANTIFREEZE .......................................................................... 96

COOLANT ............................................................................... 96

DROP-OUT ........................................................................... .. 96

FULLY FORMULATED ANT IFREEZE ..................................... 96

INITIAL–FILL COOLANT ......................................................... 96

OAT .... ...................................................................................... 96

SCA ......................................................................................... 96

APPROVED COOLANTS ........................................... ................. 97

EG OR PG & WATER + S CA INHIBITOR ............................... 98

MIXING EG OR PG ANTIFREEZ E AND WATER ......... ... ... ... .. 98

RECYCLED ANTIFREEZE ...................................... .............. 100

EG OR PG & WATER + OAT INHIBITOR ............... ................. 100

WATER ONLY + SCA OR WATER ONLY + OAT INHIBITOR . 101

WATER REQUIREMENTS ..................................................... 102

COOLANTS NOT RECOMMENDED ................................... ........ 102

ALL ANTIFREEZES AND COOLANTS CONTAINING

PHOSPHATE . .......................................................................... 102

AUTOMOTIVE TYPE COOLANTS .......................................... 102

METHYL ALCOHOL-BASED ANTIFREEZE ........................... 103

METHOXY PROPANOL-BASED ANTIFR EEZE .................... .. 103

GLYCOL-BASED COOLANTS FORMULATED FOR HVAC .... 103

ADDITIVES NOT RECOMMENDED .......................... ................. 103

SOLUBLE OIL ADDITIVES ..................................................... 103

CHROMATE ADDITIVES ....................................... ................. 103

COOLANT MAINTENANCE .................. ...................................... 103

COOLANT I NHI BITOR TEST INT E RVALS ............................ 103

SUPPLEMENTAL ADDITIVES ................................................ 104

COOLANT M AI NTENANCE INTERVALS ............................... 105

SCA TES T PROCEDURES ........................................ ................. 107

NEED-RELEASE F ILTERS (NON-OAT SYSTEMS) .................... 108

DROPOUT ................................................................................... 108

EXTENDER ADDITIVE FOR OAT COOLANT ............................. 109

OAT COOLANT DRAIN INTERVAL ............... .......................... 109

CHRONIC COOLANT SYSTEM PROBLEMS ............................. 109

MAINTENANCE PRODUCTS ........................ ............................. 109

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POWER COOL SCAS ..... ....................................... ................. 109

POWER COOL COOLANT FILTER ELEMENTS .................... 110

POWER COOL CL EANERS ................................................... 110

SUMMARY OF COOLANT RECOMMENDATIONS .................... 110

HOW TO DRAIN AN D FLUSH THE COOLING SYSTEM ............... 112

WHEN TO SERVICE TH E DRY TYPE AIR CLEANER .................... 114

BASIC TROUBLESHOOTING ................................ ............................. 115

ENGINE STORAGE ............................................................................. 120

PREPARING THE ENGINE FOR STORAGE .................................. 120

TEMPORARY STORAGE (30 DAYS OR LESS) .......................... 120

EXTENDED STORAGE (MORE THAN 30 DAYS) ...... ... .............. 121

RESTORING ENGINE TO SERVICE .......................................... 124

SERIES 50 SERVICE PUBLICATIONS ......... .................................... .. 126

CUSTOMER ASSISTANCE ................................................................. 127

IN U.S. AND CANADA CALL 1–800–445–1980 .............................. 130

WORKING WITH DDC SERVICE OUTLETS .................................. 130

ON-HIGHWAY VEHICLE ENGINE WARRANTY ................................. 133

TERMS OF COVERAGE: ON-HIGHWAY VEHICLE ENGINE

APPLICATIONS ................ .............................................................. 133

USES ...................................... ..................................................... 133

DEFECTS ........................................... ......................................... 133

REPAIRS ..................................................................................... 133

WARRANTY PERIOD ........................................... ....................... 133

LIKE REPLACEMENT ENGINE .................................................. 134

SERVICE SUPPLIES ................................................................... 134

ENGINE REM OVAL AND REINSTALLATION ...................... ... ... .. 135

THIS WARRANTY DOES NOT COVER: ......................................... 135

REPAIRS DUE TO ACCIDENTS, MISUSE, STORAGE DAMAGE,

NEGLIGENCE OR CERTAIN MODIFICATIONS ......................... 135

BRAKING DEVICES .................................................................... 135

FUEL INJECTORS AFTER 100,000 MILES/160,000

KILOMETERS .............................................................................. 135

MAINTENANCE ........................................................................... 135

INCIDENTAL OR CONSEQUENTIAL DAMAGE ......................... 1 3 5

OTHER LIMITATIONS .................................................................. 136

viii All information subject to change without notic e . (Rev. 01/ 04)

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SERIES 50 OPERATOR'S GUIDE

URBAN BUS, MOTOR COACH OR MOTOR HOME ENGINE

WARRANTY ....................................... .................................................. 137

TERMS OF COVERAGE: URBAN BUS, MOTOR COACH OR

MOTOR HOME ENGINE APPLICATIONS ...................................... 137

USES ...................................... ..................................................... 137

DEFECTS ........................................... ......................................... 137

REPAIRS ..................................................................................... 137

WARRANTY PERIOD ........................................... ....................... 137

SERVICE SUPPLIES ................................................................... 138

LIKE REPLACEMENT ENGINE .................................................. 138

ENGINE REM OVAL AND REINSTALLATION ...................... ... ... .. 139

THIS WARRANTY DOES NOT COVER: ......................................... 139

REPAIRS DUE TO ACCIDENTS, MISUSE, ALTERATION, STORAGE DAMAGE, NEGLIGENCE OR CERTAIN

MODIFICATIONS .. ....................................................................... 139

BRAKING DEVICES .................................................................... 139

FUEL INJECTORS AFTER 200,000 MILES/320,000

KILOMETERS .............................................................................. 139

MAINTENANCE ........................................................................... 139

INCIDENTAL OR CONSEQUENTIAL DAMAGE ......................... 1 3 9

OTHER LIMITATIONS .................................................................. 139

CONSTRUCTION/ INDUSTRIAL ENGINE WARRANTY .................... 141

TERMS OF COVERAGE: CONSTRUCTION/INDUSTRIAL ENGINE

APPLICATIONS ......................................... ...................................... 141

USES ...................................... ..................................................... 141

DEFECTS ........................................... ......................................... 141

REPAIRS ..................................................................................... 141

WARRANTY PERIOD ........................................... ....................... 141

SERVICE SUPPLIES ................................................................... 141

ENGINE REMOVAL AND REINSTALLATION –

CONSTRUCTION/INDUSTRIAL APPLICATIONS ....................... 142

MECHANIC'S TRAVEL EXPENSES ........................................... 142

LIKE REPLACEMENT ENGINE .................................................. 142

THIS WARRANTY DOES NOT COVER: ......................................... 143

REPAIRS DUE TO ACCIDENTS, MISUSE, STORAGE DAMAGE,

NEGLIGENCE OR CERTAIN MODIFICATIONS ......................... 143

ENGINE REMOVAL AND REINSTALLATION – AGRICULTU RAL

MACHINERY AND STAND-BY PUMP APPLICATIONS .............. 143

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NON-DDC SUPPLIED/MANUFACTURED C OMPONEN T S ....... 143

MAINTENANCE ........................................................................... 143

INCIDENTAL OR CONSEQUENTIAL DAMAGE ......................... 1 4 3

OTHER LIMITATIONS .................................................................. 144

AGRICULTURAL MACHINERY ENGINE WARRANTY ...................... 145

TERMS OF COVERAGE: AGRICULTURAL MACHINERY ENGINE

APPLICATIONS ......................................... ...................................... 145

USES ...................................... ..................................................... 145

DEFECTS ........................................... ......................................... 145

REPAIRS ..................................................................................... 145

WARRANTY PERIOD ........................................... ....................... 146

THIS WARRANTY DOES NOT COVER: ......................................... 146

REPAIRS DUE TO ACCIDENTS, MISUSE, STORAGE DAMAGE,

NEGLIGENCE OR CERTAIN MODIFICATIONS ......................... 146

ENGINE REM OVAL AND REINSTALLATION ...................... ... ... .. 146

NON-DDC SUPPLIED/MANUFACTURED C OMPONEN T S ....... 146

MAINTENANCE ........................................................................... 146

INCIDENTAL OR CONSEQUENTIAL DAMAGE ......................... 1 4 7

OTHER LIMITATIONS .................................................................. 147

PRIME POWER GENERATOR SET ENGINE WARRANTY ............... 148

TERMS OF COVERAGE: PRIME POWER GENERATOR SET

ENGINE APPLICATIONS ................................................................. 148

USES ...................................... ..................................................... 148

DEFECTS ........................................... ......................................... 148

REPAIRS ..................................................................................... 148

WARRANTY PERIOD ........................................... ....................... 148

LIKE REPLACEMENT ENGINE .................................................. 148

SERVICE SUPPLIES ................................................................... 149

MECHANIC'S TRAVEL EXPENSES ........................................... 149

THIS WARRANTY DOES NOT COVER: ......................................... 149

REPAIRS DUE TO ACCIDENTS, MISUSE, STORAGE DAMAGE,

NEGLIGENCE OR CERTAIN MODIFICATIONS ......................... 149

ENGINE REM OVAL AND REINSTALLATION ...................... ... ... .. 149

NON-DDC SUPPLIED/MANUFACTURED C OMPONEN T S ....... 150

MAINTENANCE ........................................................................... 150

INCIDENTAL OR CONSEQUENTIAL DAMAGE ......................... 1 5 0

OTHER LIMITATIONS .................................................................. 150

x All information subject to change without notice. (Rev. 01/ 04)

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SERIES 50 OPERATOR'S GUIDE

STAND-BY GENERATOR SET ENGINE WARRANTY ....................... 151

TERMS OF COVERAGE: STAND-BY GENERATOR SET ENGINE

APPLICATIONS ......................................... ...................................... 151

USES ...................................... ..................................................... 151

DEFECTS ........................................... ......................................... 151

REPAIRS ..................................................................................... 151

WARRANTY PERIOD ........................................... ....................... 152

LIKE REPLACEMENT ENGINE .................................................. 152

SERVICE SUPPLIES ................................................................... 152

MECHANIC'S TRAVEL EXPENSES ........................................... 152

THIS WARRANTY DOES NOT COVER: ......................................... 152

REPAIRS DUE TO ACCIDENTS, MISUSE, STORAGE DAMAGE,

NEGLIGENCE OR CERTAIN MODIFICATIONS ......................... 152

ENGINE REM OVAL AND REINSTALLATION ...................... ... ... .. 152

NON-DDC SUPPLIED/MANUFACTURED C OMPONEN T S ....... 152

MAINTENANCE ........................................................................... 153

INCIDENTAL OR CONSEQUENTIAL DAMAGE ......................... 1 5 3

OTHER LIMITATIONS .................................................................. 153

SPECIFICATIONS ................................................................................ 154

FUEL AND LUBRICATING OIL FILTER REQUIREMENTS ............. 154

OIL PAN ...................................................................... ................. 154

OIL PAN CAPACITY ............................................ .................... 154

TOTAL OI L CAPACITY OF THE ENGINE ............................... 154

POWER COOL ENGINE PRODUCTS ............................................. 155

FULLY FORMULATED IEG COOLANT ....................................... 155

LATIN AMERICAN COOLANT ..................................................... 155

2000 SUPPLEM ENTAL COOLANT ADDITIVE .... ... ... ... ... ........... 156

3000 SUPPLEM ENTAL COOLANT ADDITIVE .... ... ... ... ... ........... 156

3000 SUPPLEMENTAL ADDITIVE COOLANT FILTERS ............ 157

SUPPLEMENTAL ADDITIVE NEED RELEASE FILTERS ........... 157

PLUS EXTENDED LIFE OAT COOLANT .................................... 158

PLUS EXTENDER FOR USE WITH POWER COOL PLUS OAT

COOLANT .................................................................. ................. 158

PLUS 6000 OAT INHIBITOR FOR WATER-O NLY SYSTEMS ..... 159

COOLING SYSTEM CLEANERS ............................ .................... 159

COOLANT TESTING AND ANALYSIS PRODUCTS ................... 160

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xii All information subject to change without notice . (Rev. 01/ 04)

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INTRODUCTION

SERIES 50 OPERATOR'S GUIDE

This guide is intended for use by the operator of a Detroit Diesel Series

engine used in the f ollow ing

applications:

On-Highway Vehicles

Construction/Industrial

Agricultural Machinery

Generator Drive Engines

Operators of Series 50 engines used in prime power or stand-by generator set applications should also refer to the Detroit Diesel Generator Set Operator's Guide, 6SE513. Guides are available from authorized Detroit Diesel distributors.

NON-GENUINE AND REBUILT COMPONENT QUALITY ALERT

In recent years, electronic engine controls have been instrumental in aid ing engine manufacturers in meeting the stringent emission requirements of the U.S. Environmental P rotection Agency (U.S. E PA) and the California Air Resources Board (CARB) and also in meeting the ever-increasing performance demands of the customer.

Maintenance procedures are to be followed in order to continue satisfactory performance and

durability and to ensure coverage of the engine under th e manufacturer's warranty. M any of these main tenance procedures also ensure that the engine continues to comply with applicable emissions standards. The U.S. E PA specifically defines an engine's “useful emission life” — currently established as 290,000 miles (464,000 kilometers) for on-highway engines. Proper maintenance procedures, using specific components engineered to comply with emissions regulations, may be performed by an authorized Detroit Diesel distributor or dealer, an independent o utlet or the operator or owner. The owner is responsible for determining the suitability of components to maint a in emissions compliance during the engine's useful emission life.

Electronic controls and components have significantly increased in sophistication, but the fundamental objective remains the same — precise timing and delivery of fuel. The very heart of the Detroit Diesel electro nic controls is the electronic unit injector (EUI). The pro per functioning of the EUI is absolutely paramount if the benefits of electronic controls are to be realized. Detroit Diesel Corporation has built over 650,000 engines with electronic unit injectors — more than anyone else in the business.

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INTRODUCTION

Detroit Diesel cauti ons that the indiscriminate rebuilding of precision components, without the benefit of specifications, specialized equipment, and knowledge of the electronic operating system, will jeopardize performance or lead to more serious problems, and can take the engine outside of compliance with U.S. EPA or CARB emissions standards.

There are other components in an engine, such as turbocharger, camshaft, piston, etc., which are specifically designed and manufactured to exacting standards for emissions compliance. It is important that these components, if replaced, modified or substituted, can be verified to ensure that the engine remains in compliance with emissions standards. The use of inadequately engineered, manufactured or tested components in repair or rebuild of the engine may be in violation of the federal Clean Air Act and applicable U.S. EPA or CARB regulations.

Furthermore, modern engines exhibit operating parameters which require the use of proper fluids, such as fuel, coolant and lubricating oil, to maintain long engine life. The use of fluids that do not meet Detroit D iesel Corporation specifications may result in early wear out or engine failure.

2 All information subject to change without notice. (Rev. 01/ 04)

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CAUTION SUMMARY

The following cautions must be observed by the operator of the vehicle or equipment in which th is engine is installed an d/ or by those performing basic engine preventive maintenance. Failure to read and heed these cautions and exercise reasonable care for personal safety and the safety of others when operating the vehicle/equipment or performing basic engine preventive maintenance may result in personal injury and engine and/or vehicle/equipment damage.

Engine Operation

Observe the fo llowing cautions when operating the engine.

SERIES 50 OPERATOR'S GUIDE

Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth d efects, and other reproductive harm.

Always start and operate an

engine in a well ventilated area.

If operating an engine in

an enclosed area, vent the exhaust to the outside.

Do not modify or tamper

with the exhaust system or emission control system.

To avoid injury from loss of vehicle/vessel control, the operator of a DDEC equipped engine must not attempt to use or read the Diagnostic Data Reader when the vehicle/vessel is moving.

All information subject to change without not ice. (Rev. 01/ 04) 3

To avoid injury from engine shutdown in an unsafe situation, ensure the operator knows how to override the stop engine condition on a DDEC-equipped unit.

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CAUTION SUMMARY

To avoid injury from loss of vehicle control, do not activate the Engine Brake system under the following conditions:

On wet or slippery pavement,

unless the vehicle is equipped with ABS (anti-lock braking system) and you have had prior experience driving under these conditions.

When driving without a trailer

(bobtailing) or pulling and empty trailer.

If the tractor drive wheels

begin to lock or there is fishtail motion after the Engine Br ake is activated.

Deactivate the brake system immediately, if this occurs.

Failure to observe these precautions may result in loss of vehicle control and/or personal injury.

To avoid injury from the loss of vehicle control, do not use cruise control under these conditions:

When it is not possible to

keep the vehicle at a con stant speed (on winding roads, in heavy traffic, in traffic that varies in speed, etc.).

On slippery roads

(wet pavement, ice-or snow-covered roads, loose gravel, etc.).

Preventive Maintenance

Observe the following cautions when performing preventative maintenance.

To avoid injury when working near or on an operating engine, remove loose items of clothing, jewelry, tie back or contain long hair that could be caught in any moving part causing injury.

4 All information subject to change without notice. (Rev. 01/ 04)

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SERIES 50 OPERATOR'S GUIDE

To avoid injury when working on or near an operating engine, wear protective clothing, eye protection, and hearing protection.

To avoid injury from hot oil, do not operate the engine with the rocker cover(s) removed.

To avoid injury from fire, contain and eliminate leaks o f flammable fluids as they occur. Failure to eliminate lea ks could result in fire.

To avoid injury from slipping and falling, immediately clean up any spilled liquids.

To avoid injury from the expulsion of hot coolant, never remove the cooling system pressure cap whiletheengineisatoperating temperature. Remove the cap slowly to reliev e pressure. Wear adequate protective clothing (face shield or safety goggles, rubber gloves, apron, and boots).

To avoid injury from hot surfaces, allow engine to c ool before removing any component. Wear protective gloves.

To avoid injury from contact with the contaminants in used engine oil, wear protective gloves and apron.

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CAUTION SUMMARY

To avoid injury, use care when working around moving belts and rotating parts on the engine.

To avoid injury from fire caused by heated lubricating-oil vapors:

Keep those people who

are not directly involved in servicing away from the engine.

Stop the engine immediately

if an oil leak is detected.

Do not allow open flames or

smoke whe n working on an operating engine.

Wear adequate protective

clothing (face shield, insulated gloves, ap ron, etc.) to avoid burns.

To prevent a b uildup of

potentially volatile vapors, keep the engine area well ventilated during operation.

To avoid injury from rotating belts and fans, do not remove and discard safety guards.

To avoid injury from contact with rotating parts when an engine is operating with the air inlet piping removed, install an air inlet screen shield over the turbocharger air inlet. The shield prevents contact with rotating parts.

To avoid injury when using caustic cleaning agents, follow the chemical manufacturers usage, disposal, and safety instructions.

Lubricating oil is relatively harmless at ambient temperatures.

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SEL CORPORATION

Electrical System

Observe the fo llowing cautions when jump starting an engine, charging a battery, or working with the vehicle/application electrical system.

To avoid injury from accidental engine startup while servicing the engine, disconnect/disable the starting system.

To avoid injury from electrical shock, do not touch battery terminals, alternator terminals, or wiring cables while the engine is operating.

SERIES 50 OPERATOR'S GUIDE

To avoid injury from battery explosion or contact with battery acid, w ork in a well-ventilated area, wear pr otective clothing, and avoid sparks or flames near th e 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.

Applybakingsodaorlimeto

help neutralize the acid.

Flush your eyes with water.

Get medical attention

immediately.

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SEL CORPORATION

CAUTION SUMMARY

Cooling System

Observe the fo llowing cautions when servicing the coolin g system.

To avoid injury from the expulsion of hot coolant, never remove the cooling system pressure cap while the engine is at operating temperature. Remove the c ap slowly to relieve pressure. Wear adequate protective clothing (face shield or safety goggles, rubber gloves, apron, and boots).

To avoid injury from slipping and falling, immediately clean up any spilled liquids.

Air Intake System

Observe the following cautions when working on the air intake system.

To avoid injury from hot surfaces, allow engine to c ool before removing any component. Wear protective gloves.

8 All information subject to change without notice. (Rev. 01/ 04)

SEL CORPORATION

Fuel System

Observe the fo llowing cautions when fueling the vehicle or working with the fuel system.

To avoid injury from fire, keep all potential ignition sources away from diesel fuel, open flames, sparks, and electrical resistance heating elements. Do not smoke when refueling .

To avoid injury from fire, contain and eliminate leaks o f flammable fluids as they occur. Failure to eliminate lea ks could result in fire.

SERIES 50 OPERATOR'S GUIDE

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

ifafuelleakisdetected.

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, keeptheengineareawell ventilated during operation.

Diesel fuel is relatively harmle ss at ambient temperatures.

To avoid increased risk of a fuel fire, do not mix gasoline and diesel fuel.

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SEL CORPORATION

CAUTION SUMMARY

Starting Aids

Observe the fo llowing cautions when using starting aids.

To avoid injury from flames, explosion, and toxicants when using ether, the following precautions must be taken:

Always wear goggles when

testing.

If fluid enters the eyes or if

fumes irritate the eyes, wash eyes with large quantities of clean water for 15 minutes. A physician, preferably an eye specialist, should be contacted.

Contents of cylinder are

under pressure. Store cylinders in a co ol dry area. Do not incinerate, puncture or attempt to remove cores from cylinders.

Do not smoke when servicing

ether system.

Work in well-ventilated area.

Do not work near open

flames, pilot flames (gas or oil heaters), or sparks.

Do not weld or carry an open

flame near the ether system if you smell ether or otherwise suspect a leak.

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SEL CORPORATION

Compressed Air

Observe the fo llowing cautions when using compressed air.

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 k Pa) air pressure.

Lubricating Oil and Filters

Observe the fo llowing cautions when replacing the engine lubricating oil and filters.

SERIES 50 OPERATOR'S GUIDE

To avoid injury from fire caused by heated lubricating-oil vapors:

Keep those people who

are not directly involved in servicing away from the engine.

Stop the engine immediately

if an oil lea k is detected.

Do not allow open flames or

smoke when working on an operating engine.

Wear adequate protective

clothing (face shield, insulated gloves, apron, etc.) to avoid burns.

To prevent a buildup of

potentially volatile vapors, keeptheengineareawell ventilated during operation.

To avoid injury from slipping and falling, immediately clean up any spilled liquids.

All information subject to change without not ice. (Rev. 01/ 04) 11

Lubricating oil is relatively harmless at ambient temperatures.

SEL CORPORATION

ENGINE MODEL AND SERIAL NUMBER DESIGNATION

The engine serial number and model number are laser etched on the cylinder block on the left side just

the cast- in Detroit Diesel logo (as viewed from the flywheel end). SeeFigure1

below the intake manifold and above

Figure 1 Location of Engine Serial and Model Numbers

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SERIES 50 OPERATOR'S GUIDE

Option Labels

Computerized en gin e 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 timin g, valve lash, maximum no-load rpm, etc.).

With any order for parts, the engine model and serial num ber m ust be

given. If a type number is shown on the option label covering the equipment required, this number should also be included on the parts order. See Figure 2.

Transmissions and power take-o ffs generally carry their own name plates. The model a n d serial number information on these plates is useful when ordering parts for these assemblies.

Figure 2 Typical Option Labels

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ENGINE MODEL AND SERIAL NUMBER DESIGNATION

Certification Labels

If required, a certification label is attached to the valve rocker cover. This label certifi es that the engine conforms to federal and certain state

emissions regulations for its particular application. It also gives the operating conditions under which certification was made. See Figure 3.

Figure 3 Typical Engine Certification Labels

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SERIES 50 OPERATOR'S GUIDE

OPERATING INSTRUCTIONS FOR A FIRST TIME START

When preparing to start a new or newly overhauled engine which has been in storage, perform a ll of the operations listed below. Failure to follow these instructions may result in serious engine damage. Before a routine start, see the “Daily” checks for your engine in the MAINTENANCE section.

To avoid injury when working near or on an operating engine, remove loose items of clothing, jewelry, tie back or contain long hair that could be caught in any moving part causing injury.

System Checks

Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.

Always start and operate an

engine in a well ventilated area.

If operating an engine in

an enclosed area, vent the exhaust to the outside.

Do not modify or tamper

with the exhaust system or emission control system.

Perform the following system checks before starting for the first time.

Cooling System Checks

Check the cooling system as follows:

1. Make sure all drain cocks in the cooling system are installed (drain cocks are often removed for shipping) and are closed tightly.

2. Remove the radiator pressure control cap and fill with genuine Detroit Diesel Power Cool antifreeze or an equivalent quality ethylene glycol or propylene glycol-base antifreeze solution in the required concentration. In extremely hot environments, properly inhibited water may be used in the summer. Keep the coolant level at the bo ttom of the fill er neck to allow for

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OPERATING INSTRUCTIONS FOR A FIRST TIME START

expansion of the coolant. For more detailed reco mmendations, refer to the How to Select Coolant section in this guide.

3. Entrapped air m ust be purged after filling the cool ing system. To do this, allow the engine to warm up with the pressure cap removed. With the transmission in neutral, increase engine speed above 1,000 rpm and add coolant to the radiator as required.

4. Check to make sure the front of the radiator and air-to -air charge cooler (if equipped) are unblocked and free of debris.

Lubrication System C hecks

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.

NOTICE:

Insufficient lubrication at startup can cause serious damage to engine components.

To insure an immediate flow of oil to all bearing surfaces at initial engine startup, the engine lubrication system should be charged with a commercially available pressure

pre-lubricator. If this is impractical, rocker covers should be removed and clean lubricating oil should be poured over the rocker arms. The oil should be the same weight and viscosity as that used in the crankcase. After pre-lubricating, add additional oil to bring the level to the proper mark on the dipstick. See Figure 4.

Figure 4 Check Lube Oil Level

Before Starting

For lubricant recomm endation , refer to the How to Select Lubricating Oil section in this guide.

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

16 All information subject to change without notice. (Rev. 01/ 04)

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SERIES 50 OPERATOR'S GUIDE

replacing the engine lubricating oil and filters after extended storage.

NOTICE:

Failure to eliminate water-diluted lubricating oil may lead to serious engine damage at startup.

Fuel System Checks

Fill the tanks with the recommended fuel. Keeping tanks full reduces water condensation and helps keep fuel cool, which is important to engine performance. Full tanks also reduce the chance for microbe (black slime) growth. For fuel recommendations, refer to the How to Select Fuel Oil section in this guide. Make sure the fuel shutoff valve (if used) is open.

To insure 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 electric priming pump to the secondary fuel filter adaptor. Authorized Detroit Diesel service outlets are properly eq uip ped and have the trained technicians to perform this service.

NOTICE:

Prolonged use of the starting motor andenginefuelpumptoprimethe fuel system can result in damage to the starter, fuel pump and injectors and may cause erratic engine operation due to the amount of air in the line s and filters from the fuel 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 result if this method is used. The heat generated by the

external fuel source will cause the injector tips to be damaged when the fuel cools them. The injector plunger and bushing can be scored from running without lubrication.

Priming is not normally required if the filter elements are filled with clean fuel when installed and the manifolds are not drained of fuel.

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OPERATING INSTRUCTIONS FOR A FIRST TIME START

If the engine is equipped with a fuel/water separator, drain off any water that has accumulated. Water in fuel can seriously affect engine performance and may cause engine damage. Detroit Diesel recommends installation of a fuel/water separator wherever water contamina tio n is a concern.

Other Checks

Make sure the transmission is filled to the proper level with the fluid recommended by the gear manufacturer. Do not ov erfill.

Make sure cable connections to the storage batteries are clean and tight. Check the hydrometer “eye” of maintenance-free batteries for charge. SeeFigure5.

Check drive belts to m ake sure they are in good condition (not cracked, torn, worn or glazed) and are properly adjusted.

If lead-acid or low-maintenance batteries are used, make sure battery electrolyte level is normal.

Check the turbocharger for signs of oil or exhaust leaks. Leaks should be corrected before starting the engine.

Check engine mounting bolts for tightness. Bolts should be retightened, if necessary.

Starting the Engine

Before starting the engine the first time, refer to the System Checks section and perform the operations listed.

NOTICE:

The turbocharger may be seriously damaged if the engine is cranked with the air shutdown in the closed position.

If the engine has an emergency manual or automatic shutdown system, make sure the control is set in th e open position before starting.

Figure 5 Check “Eye” of

Maintenance-Free Batteries

18 All information subject to change without notice. (Rev. 01/ 04)

Theenginemayrequiretheuseofa cold weather star ting aid if the ambient temperature is below 40

F(4 C).

SEL CORPORATION

To avoid injury from flames, explosion, and toxicants when using ether, the following precautions must be taken:

SERIES 50 OPERATOR'S GUIDE

warning lights. If everything is OK, both lights will go out in approximately five seconds.

Start the engine after the lights go out. If starting a vehicle, start the engine with foot off the foot pedal.

Do not smoke when servicing

ether system.

Work in well-ventilated area.

Do not work near open

flames, pilot flames (gas or oil heaters), or sparks.

Do not weld or carry an open

flame near the ether system if you smell ether or otherwise suspect a leak.

Initial Engine Start

To start a Series 50 engine, make sure the transmission is in neutral and turn the ignition key on.

You will notice t hat both t he yellow Check Engin Light (CEL) and the red Stop Engine Light (SEL) will come on.

This is the result of theDetroit Diesel Electronic Control (DDEC

) computer diagnosing the system to ensure everything is functional, including the light bulbs for the

NOTICE:

If the operating lights stay on, consult with DDC Technical Service. Operating the engine under these circumstances may result in engine damage.

Electric Starter — Start an engine equipped with an electric starting motor as follows:

1. With foot OFF the foot pedal, press the starter switch firmly.

NOTICE:

To prevent serious starting motor damage, d o not press the starter switch again after the engine has started.

2. If the engine fails to start within 15 seconds, release the starter switch and allow the starter to cool for 15 seconds before trying again. If the engine fails to start after four attempts, an inspection should be m a de to determine the cause.

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OPERATING INSTRUCTIONS FOR A FIRST TIME START

Air Starter — Because of the limited volume of most compressed air 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 vati ng the air starter. Start an en gin e equipped with

an air starter as follows:

1. Check the pressure in the air storage tank. If necessary, add air to b ri ng the pressure up to at least the recommended minimum for starting.

2. With foot OFF the foot pedal, press the starter button firmly and hold until the engine starts.

Running the Engine

While the engine is operating, monitor the battery charge indicator light, the oil pressure and avoid excessive idling.

operating pressure should be higher. If oil pressure does not fall within these guidelines, it should be checked with a manual gage.

To avoid injury from hot oil, do not operate the engine with the rocker cover(s) removed.

Warm-up

Run the engine at part throttle for about five minutes to allow it to warm up before applying a loa d.

Inspection

While the engine is idling, inspect the transmission, check for fluid leaks, check the crankcase and turbocharger.

Oil Pressure

Observe the oil pressure gage immediately after starting the engine. A good indicator that all m oving parts are getting lubrication is when the oil pressure gage registers pressure (5 psi or 35 kPa at idle speed). If no pressure is indicated within 10

is idling, check the automatic transmission (if equipp e d) for proper oil level and add oil as required.

Fluid Leaks – Lo ok for coolant, fuel or lubricating oil leaks. If any are found, shut down the engine immediately and have the leaks repaired after the engine has cooled.

to 15 seconds, stop the engine and check the lubrication system. The pressure should not drop below 28 psi or 193 kPa at 1800 rpm, an d normal

Transmission – While the engine

20 All information subject to change without notice. (Rev. 01/ 04)

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SERIES 50 OPERATOR'S GUIDE

Crankcase – Iftheengineoilwas replaced, stop the engine after normal operating temperature has been reached. Allow the oil to drain back into the crankcase for about twenty minutes, then 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. Refer to the How to Select Lubricating Oil section in this guide.

Turbocharger – Makeavisual inspection of the turb ocharger for oil leaks, exhaust leaks, excessive noise or vibration. Stop the engine immediately if a leak or unusual noise or vibration is noted. Do not restart

the engine until the cause of the concern has been investigated and corrected. Autho rized Detroit Diesel

service outlets are properly equipped to perform this service.

sludge in the engine. When prolonged idling is necessary, maintain at least 850 rpm spring/summer and 1200 rpm fall/winter.

Stopping the Engine

Stop an engine under normal operating conditions as follows:

1. Reduce engine speed to idle and put all shift levers in the n e utr al position.

NOTICE:

Stopping a turbocha rged engine immediately after high-speed operation without allowing a sufficient cool-down peri od may cause damage to the turbocharger, as it will continue to turn without an oil supply to the bearings.

Avoid Unnecessary Idling

Whenever possible, avoid unnecessary idling.

During long engine idling periods with the transmission in neutral, the engine coolant temperature may fall

2. Allow the engine to run between idle and 1000 rpm with no load for four or five minutes. This allows the engine to cool and permits the turbo charger to slow down. After four or five minutes, shut down th e engine.

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

All information subject to change without not ice. (Rev. 01/ 04) 21

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OPERATING INSTRUCTIONS FOR A FIRST TIME START

Emergency Jump Starting

The DDEC IV system operates on 12 or 24 volts DC. If an engine with an electric starting motor requires emergency jump starting, do not

exceed 32 volts DC.

NOTICE:

Jump starting with voltages greater than those indicated or reversing battery polarity may damage the Electronic Control Module.

To avoid injury from battery explosion when jump starting the engine, do not attach the cable end to the negative terminal of the disabled battery.

and in the proper sequence (negative to negative g ro und last).

Flush your skin with water.

Applybakingsodaorlimeto

help neutralize the acid.

Flush your eyes with water.

Get medical attention

immediately.

NOTICE:

Failure to connect jumper cables in the proper sequence can result in alternator and/or equipment damage.

Before att e mpting to jump start the engine, make sure the jumper cables are connected properly (positive to positive, negative to negative ground)

22 All information subject to change without notice. (Rev. 01/ 04)

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DDEC IV SYSTEM

SERIES 50 OPERATOR'S GUIDE

The DDEC sytem's engine-mounted Electronic Control Module (ECM) includes control logic to provide overall engine m anagement. The ECM co ntinuo usly performs self-diagnostic checks and monitors other system components. System diagnostic checks are made at ignition-on and continue throughout all engine-operating modes.

Detroit Diesel Series 50 engines equipped with DDEC IV are identified by the letter “K” in the sixth position of the model number. Example: 6047GK27.

The DDEC engine is equipped with an electronically controlled fuel injection system. There are no

control racks or mechanical linkages to adjust. This system not only helps to improve fuel economy and vehicle performance, it also helps to reduce cold starting time and increase initial idle speed for fast engine wa rm-up and virtual elimination of cold smoke.

The DDEC engine has no mechanical governor. Engine

horsepower, torque, idle, and engine speed are contained in the internal electronics. Therefore, there are no mechanical governor spring adjustments for idle and high-speed control.

There is no need for a throttle delay.

Emission control is performed through the electronic control module (ECM).

The Electronic Foot Pedal Assembly (EFPA) eliminates the need for any throttle linkage.

DDEC Features

DDEC offers a variety of options designed to warn the operator of an engine malfunction. Options can range from the CEL and SEL panel lightstoautomaticreductioninengine power followed by automatic engine shutdown.

The pow er-down/shutdown option may be activated by a low coolant level, low oil pressure or high engine oil or coolant temperature.

The DDEC engine has the ability to perform diagnostics for self-checks and continuous monitoring of other system components. Depending

on the application, DDEC can also monitor oil temperature, coolant temperature, oil pressure, fuel pressure, coolant level and remote sensors (if used). This diagnostic system is connected to the CEL and the SEL to provide a visual warning of a system malfunction.

All information subject to change without not ice. (Rev. 01/ 04) 23

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DDEC IV SYSTEM

Engine Protection

The DDE C engine protection system monitors all engine sensors and electronic components, and recognizes system malfunctions. If a critical fault is detected, the CEL and SEL illumin ate. The malfunction codes are logged into the ECM's memory.

The standard parameters which are monitored for engine protection are: low coolant level, high coolant temperature, low oil pressure, and high oil temperature

This system features a 30-second, stepped-power shutdown sequence or an immediate speed reduction without shutdown in the event a major engine malfunction occurs, such as low oil pressure, high oil or coolant temperature, or low coolant level.

NOTICE:

Engines equipped w ith the power-down/shutdown option have a system override button or switch to allow engine operation for a short period of time. Using the override button so the engine does not shutdown in 30 seconds but operates for an extended period may result in engine damage

Idle Shutdown Timer

The DDEC engine may also have an optional 1 to 100 minute idle shutdown system. The purpose of

this system is to conserve fuel by eliminating excessive idling and to allow for a turbocharger cool-down period. To activate the shutdown, the transmission must be in neutral with the vehicle parking brakes set and the engine in idle or fast-idle mode.

Cruise Control

To avoid injury from engine shutdown in an unsafe situation, ensure the operator knows how to override the stop engine condition on a DDEC-equipped unit.

Cruise Control is available with any DDEC engine. Cruise Control maintains a set vehicle or engine speed settin g. The driver/operator has switches to set, activate and deactivate the system . See Figure 6. A slight pressure on the brake or clutch deactivates the system, as well. The minimum speed at which cruise control can be used is programmable.

24 All information subject to change without notice. (Rev. 01/ 04)

SEL CORPORATION

Figure 6 Typical Cruise Control

Switches

SERIES 50 OPERATOR'S GUIDE

To avoid injury from the loss of vehicle control, do not use cruise control under these conditions:

When it is not possible to

keep the vehicle at a con stant speed (on winding roads, in heavy traffic, in traffic that varies in speed, etc.).

On slippery roads

(wet pavement, ice-or snow-covered roads, loose gravel, etc.).

Cruise Control may a lso be programmed to permit fast idle using the cruise control switches.

With the engine at normal idle, transmission in neutral and service brakes on, turn on the cruise control “ON/OFF” switch, and use the “Resume” switch. The engine rpm should increase to a pre-defined

When descending a hill with cruise control OFF, do not allow the eng ine to exceed 2,500 rpm under any conditions. Failure to observe this precaution can result in overspeeding and serious engine damage.

NOTICE:

speed. The engine rpm can be raised or lowered from this point using the “Set” and “Resume” switches.

Cruise Control will main tain the set speed under normal road and load conditions.

Cruise Control 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.

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DDEC IV SYSTEM

When the Cruise Control switch is in the O N position, cruise control is engaged by momentarily contacting the “Set/Coast” switch to the ON position. Holding the switch in the ON position allows the vehicle to slow to a lower speed. Toggling t he switch will result in a one mile-per-hour (1.6 kph) decrease in vehicle speed. If cruise control has been disabled, toggling the “Resume/Accel” switch restores the vehicle to the previously set cruise speed.

Using either the brake or the clutch will disable cruise control.

To avoid injury from loss of vehicle control, do not activate the Engine Brake system under the following conditions:

On wet or slippery pavement,

unless the vehicle is equipped with ABS (anti-lock braking system) and you have had prior experience driving under these conditions.

When driving without a trailer

(bobtailing) or pulling and empty trailer.

Engine Brakes

Engine brakes are enabled by an ON/OFF switch mounted on the dash. A separate intensity switch is used to select low, medium or high braking power. Th e engine brakes will only operate when the electronic foot pedal assembly (EFPA) is fully released. Disengaging the clutch will prevent the engine brakes from operating.

Ifthetractordrivewheels

begin to lock or there is fishtail motion after the EngineBrakeisactivated.

Deactivate the brake system immediately, if this occurs.

Failure to observe these precautions may result in loss of vehicle control and/or personal injury.

Engine b rakes will supply braking power even when in cruise control. The electronic control module (ECM) will control the amount of engine braking with respect to the cruise control set speed. The maximum amount of braking (low, medium, high) is selected with the dash switches.

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SERIES 50 OPERATOR'S GUIDE

Data Recording Capability

DDEC Reports is a data recording capability that is standard on all DDEC IV engines. DDEC Reports contains information on driver activities, engine performance and critical incidence reporting. The information can be extracted with Detroit Diesel Diagnostic Link

2.1 (DDDL 2.1) or later software. To perform the extraction, at least a 486 computer with a 16-MB RAM is required.

DDEC IV Operation

NOTE:

This engine is equipped with DDEC software. This software generally assures optimal en gine performance. The installation of software upgrades may cause minor changes in features and engine performance.

Since the DDEC system is electronic, a battery is required to operate the computer. The system operates at 12 or 24 volts. However, in the event of a power supply malfunction, the system will continue to operate at reduced voltage. When this occurs, the CEL will come on.

The engine will only operate at reduced rpm until the battery voltage reaches a point where t he ECM w ill no longer function and the engine shuts down.

Should the CEL come on for any reason, the vehicle can still be operated and the driver can proceed to the required destination. This

conditionshouldbereportedtoan authorized Detroit Diesel di stributor or dealer.

NOTICE:

When the SEL comes on, the computer has detected a major malfunction in the engine that requires immediate attention. It is

the operator's responsibility to shut down the engine to avoid serious damage.

The engine can be configured to give a warning only, to ramp down (reduce power) or to shut down. Ramp down will red uce engine rpm to a pre-determined speed, but will not shut down the engin e . With the 30-second shutdown option, the engine will begin a 30-second, stepped power-down sequence until it shuts down completely.

Stop Engine Override can be supplied in case the vehicle is to operate in a critical location.

NOTE:

The Stop Engine Override switch and the Diagnostic Request switch are the same.

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DDEC IV SYSTEM

In this situation the operator may elect to override the automatic stop engine sequence by pressing the Stop Engine Override switch every 15 to 20 seconds to prevent engine shutdown from occurring.

NOTE:

For some applications, holding down the Stop Engine Override switch will not prevent the engine shutdown sequence. You must continue to reset the automatic shutdown system by pressing the S top Engi ne Overrid e switch at intervals of approximately 15 to 20 seconds.

It takes 30 seconds from the time the automatic shutdown sequence begins until engine shutdown. Therefore, the operator must press the override switch just prior to engine shutdown and continue to do so until the vehicle can be b ro ught to a stop in a safe location.

Immediate Speed Reduction Option

The immediate speed reduction option will bring engine rpm back to a predetermined speed, but will not shut down the engine.

Stop Engine Light

The conditions that will cause theSEL to come on are:

High coolant temperature

Loss of coolant

High oil temperature

Low oil pressure

Auxiliary shutdown

It is important to point out that whenever the CEL or the SEL comes on, the DDEC computer will determine wh e re 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.

Diagnostic Data Reader

The Diagnostic Data Reader (DD R) is a special diagnostic tool that can be plugged into the engine computer memory to extract information related to the cau se of the problem. See Figure 7.

The engine should not be restarted after it has been shut down by the engine protection system, unless the problem has been located and corrected.

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Figure 7 Diagnostic Data Reader

J 38500

Once the malfunction has been corrected, the DDEC system will return the engine to normal operation.

The DDR can distinguish between codes now active and th ose stored in the ECM memory (inactive).

SERIES 50 OPERATOR'S GUIDE

The malfunction code recorded in the computer memory will remain until it is erased by a technician.

The malfunction code can also be obtained by the operator. A “Diagnostic Request” switch is provided which, when pressed, will cause the “Check Engine” light (CEL) to flash a code number. It will, for example, flash twice. . . pause . . . flashonce...pause.Inotherwords,a code 21. Code 21 indicates the throttle position sensor input voltage is high. See Figure 8.

NOTE:

A code 25 (two flashes followed by 5 flashes) indicates all systems are working satisfactorily.

Figure 8 SEL/CEL Flashing Code Examples

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DDEC IV SYSTEM

Active Codes – The active codes will be flashed on the SEL in the order of most recent to least recent occurrence based on engine hours. If there are no active codes, a code 25 will be flashed.

Inactive Codes – The inactive codes willbeflashedontheCELinthe order of most recent to least recent occurrence based on engine hours. If there are no inactive codes, a code 25 will be flashed.

Only One Light Flashes at a Time –

Only one light will be flashing codes at any time. When code flashing is initiated, the active cod es (or code

25) will be flashed on the SEL. Then the inactive codes (or code 25) will be flashed on the CEL. When all the inactive codes (or code 25) have been flashed, the process of flashing all the active codes followed by all the inactive codes will repeat until the conditions for code flashing are no longer satisfied.

To Read Codes: Use the diagnostic data reader (DDR) or depress and hold the diagn ostic request switch with the ignition ON and the engine AT IDLE or NOT RUNNING. Press and hold the switc h. Active codes will be flashed on the SEL first, followed by inactive codes flashed on the CEL.

Diagnostic Code List

Diagnostic codes are listed in the next several pages.

To avoid injury from engine shutdown in an unsafe situation, ensure the operator knows how to override the stop engine condition on a DDEC-equipped unit.

To avoid injury from loss of vehicle/vessel contr ol, the operator of a DDEC equipped engine must not attempt to use or read the Diagnostic Data Reader when the vehicle/vessel is moving.

The codes will continue to flash and repeat as long as the diagnostic request switchisheldintheONpositionwith the ignition on.

30 All information subject to change without notice. (Rev. 01/ 04)

SEL CORPORATION

SERIES 50 OPERATOR'S GUIDE

Flash

Code

Description

11 Variable Speed Governor Sensor Voltage Low

11 Variable Speed Governor Switch System Not Responding

12 Variable Speed Governor Sensor Voltage High

13 Coolant Level Sensor Input Voltage Low

13 Add Coolant L evel Sensor Input Voltage Low

14 Intercooler Coolant Temperature Sensor Input Voltage High

14 Coolant Temperature Sensor Input Voltage High

14 Oil Temperature Sensor Input Voltage High

15 Intercooler Coolant Temperature Sensor Input Voltage Low

15 Coolant Temperature Sensor Input Voltage Low

15 Oil Temperature Sensor Input Voltage Low

16 Coolant Level Sensor Input Voltage High

16 Add Coolant Le vel Sensor Input Voltage High

17 Throttle Plate Position Sensor Input Voltage High

17 Blower Bypass Position Input Voltage High

17 Relative Humidity Sensor Circuit Failed High

18 Throttle Plate Position Sensor Input Voltage Low

18 Blower Bypass Position Input Voltage Low

18 Relative Humidity Sensor Circuit Failed Low

21 Throttle Position Sensor Input Voltage High

22 Throttle Position Sensor Input Voltage Low

23 Fuel Temperature Sensor Input Voltage High

23 Oxygen Content Circuit Input Voltage High

24 Fuel Temperature S ensor Input Voltage Low

24 Oxygen Content Circuit Input Voltage Low

25 Reserved for ‘‘No Codes"

26 Aux. Shutdown #1 Active

26 Aux. Shutdown #2 Active

27 Intake Manifold Temperature Sensor Input Voltage High

All information subject to change without not ice. (Rev. 01/ 04) 31

SEL CORPORATION

DDEC IV SYSTEM

Flash Code

27 Ambient Air Temperature Sensor Input Voltage High

27 Air Temperature Sensor Input Voltage High

28 Intake Manifold Temperature Sensor Input Voltage Low

28 Ambient Air Temperature Sensor Input Voltage Low

28 Air Temperature Sensor Input Voltage Low

29 TCI Temperature Circuit Failed Low

Turbo Compressor Temperature Out Sensor Input Voltage

Low

31 Aux. Output #3 or #4 Open Circuit (High Side)

31 Aux. Output #3 or #4 Short To Ground (High Side)

31 Aux. Output #3 or #4 Mechanical System Failure

32 SEL or CEL Short to Battery (+)

32 SEL or CEL O pen Circuit

33 Turbo Bo ost Pressure Sensor Input Voltage Hig h

34 Turbo Boost Pressure Sensor Input Voltage Low

35 High Range Oil Pressure Sensor Input Voltage High

35 Oil Pressure Sensor Input Voltage Low

36 High Range Oil Pressure Sensor Input Voltage High

36 Oil Pressure Sensor Input Voltage Low

37 High Range Fuel P ressure Sensor Input Voltage High

37 Fuel Restriction or Fuel Pressure Sensor Input Voltage High

38 High Range Fuel Pressure Sensor Input Voltage Low

38 Fuel Restriction or Fuel Pressure Sensor Input Voltage Low

39 EGR Leak — Boo st Power

39 EGR Leak — Boost Jake

39 EGR Valve Not Re sponding

39 VNT Vanes No t Responding — Boost Power

39 VNT Vanes at Max — Jake

39 VNT Vanes Not Responding — Boost Jake

Description

32 All information subject to change without notice. (Rev. 01/ 04)

SEL CORPORATION

SERIES 50 OPERATOR'S GUIDE

Flash

Code

Description

39 EGR Flow too Low

39 VNT Vanes Not Responding — EG R

41 Too Many SRS (missing TRS)

42 Too few SRS (missing SRS)

43 Coolant Level Low

44 Intercooler Coolant Temperature High

44 Engine Derate Due to Intake Manifold Temp or Coolant Temp

Intake Manifold Temp, Coolant Temp, Air Inlet Temp, or Oil

Tem p Hi gh

45 High Range Oil Pressure Low

45 Oil Pressure Low

46 ECM Battery Voltage Low

46 RTCBackupBatteryVoltageLow

46 Sensor Supply Voltage Low

High Range F uel Pressure, Fuel Pressure, Turbo Boost

Pressure, Air Inlet Pressure, or Injection Control Pressure High

High Range Fuel Pressure, Fuel Pressure, Air Inlet Pressure,

or Injection Control Pressure Low

48 TCI Temperature Below Range

48 Turbo Compressor Temperature Out High

48 EGR Differential Pressure or EGR Temperature Low

49 TCI Temperature Above Range

49 Turbo Compressor Out Temperature High

49 Engine Derate Due to TCO Temperature

51 TCI Temperature Circuit F ailed High

Turbo Compressor Out Temperature Sensor Input Voltage

High

52 A/D Conversion Fail

53 Nonvolatile Checksum Incorrect

All information subject to change without not ice. (Rev. 01/ 04) 33

SEL CORPORATION

DDEC IV SYSTEM

Flash Code

53 EEPROM Write Error

53 OutofCalibration

54 Vehicle Speed Sensor Fault

55 Missing information from another ECU

J1939 Data Link, Proprietary Data Li nk (Master), or

Proprietary Data Link (Receiver) Fault

56 J1587 Data Link or J1922 Data Link Fault

58 Torque Overload

61 Injector xxx Response Time Long

Aux. Output #1, #2, #5, #6, #7, or #8 Short to Battery (+), Open Circuit, or Mechanical System Not R esp onding

Properly PWM #1, #2, #3, or #4 Above Normal Range, Below Normal

Range, Short to Battery (+), or Open Circuit

64 Turbo Overspeed

64 Turbo Speed Sensor Input Failure — Abnormal Period

Throttle Plate Position Ab ove Normal Range, Below Normal

Range, Erratic, or No t Responding

65 Air Filter Restriction Sensor Voltage High or Low

66 Oil Filter Restriction Sensor Voltage High or Low

66 Engine Knock Le v el Above Normal Range

Engine Knock Level Sensor Input Voltage High, Low, or Not

Responding

67 High Range Coolant Pre ssure Sensor Input Voltage High

67 High Range Coolant Pressure Sensor Input Voltage Low

67 Air Inlet Pressure Senso r Input Voltage High or Low

67 Coolant Pressure Sensor Input Voltage High or Low

TPS Idle Validation Circuit Fault (open circuit or short to

ground)

71 Injector xxx Response Time Short

72 Vehicle Overspeed

Description

34 All information subject to change without notice. (Rev. 01/ 04)

SEL CORPORATION

SERIES 50 OPERATOR'S GUIDE

Flash

Code

Description

72 Vehicle O verspeed (Absolute)

72 Oxygen Content Too High or Too Low

73 AirFilterRestrictionHigh

73 Gas Valve Position Above or Below Normal Range

73 Gas Valve Position Input Voltage High or Low

73 Gas Metering Valve Not Responding

73 ESS Transmission Stuck in Gear

73 Transmission Neutral Switch Failure (ESS Transmission)

Aux Analog Input Data Erratic, Intermittent, or Incorrect

(ESS Transmission)

73 Aux Analog Input #1 Voltage High or Low (ESS Transmission)

74 Optimized Idle Safety Loop Short to Ground

74 Oil Filter Restriction High

75 ECM Battery Voltage High

75 RTC Backup Battery Voltage High

75 Sensor Supply Voltage High

76 Engine Overspeed With Engine Brake

Miscellaneous Faults – Refer to BASIC TROUBLESHOOT-

ING

78 Cruise Control/Adaptive Cruise Control Fault

Oil Level Sensor Input or Crankcase Pressure Sensor Input

Voltage High

81 Extended Crankcase Pressure Input Voltage Hig h

Injection Control Pressure or Exhaust Temperature Sensor

Input Voltage High EGR Differential Pressure Sensor Circuit or EGR

Temperature Circuit Failed High

81 Timing Actuator Failed High or Low

Exhaust Port Temperature #1, #2, #3, #4, #5, #6, #7, #8, #9,

#10, #11, #12, #13, #14, #15 or #16 Sensor Voltage High

81 EGR Mass Flow Smart Sensor not Responding or Failed

All information subject to change without not ice. (Rev. 01/ 04) 35

SEL CORPORATION

DDEC IV SYSTEM

Flash Code

Oil Level Sensor or Crankcase Pressure Sensor Input

Voltage Low

82 Extended Crankcase Pressure Input Voltage Low

Injection Control Pressure Sensor or Exhaust Temperature

Sensor Input Voltage Low EGR Temperature Circuit or EGR Diffferential Pressure

Sensor Circuit Failed Low Exhaust Port Temperature #1, #2, #3, #4, #5, #6, #7, #8, #9,

#10, #11, #12, #13, #14, #15 or #16 Sensor Voltage Low

82 EGR Temperature Smart Senso r not Responding or Failed

83 Oil Level, Pump Pressure, or Crankcase Pressure High

83 Extended Crankcase Pressure High

83 Exhaust Temperature High

83 EGR Differential Pressure or EGR Temperature High

83 Exhaust Port Temperature #1 — #16 Sensor Voltage High

84 Oil Level or Crankcase Pressure Low

84 Extended Crankcase Pressure Low

85 Engine Overspeed

85 Engine Overspee d Signal

Pump Pressure Sensor or Barometric Pressure Se nsor Input

Voltage High Pump Pressure Sensorr or Barometric Pressure Sensor

Input Voltage Low

88 High Range Coolant Pressure or Coolant Pressure Low

89 Fuel Restriction High

89 Maintenance Alert Coolant Level Fault

Description

36 All information subject to change without notice. (Rev. 01/ 04)

SEL CORPORATION

DDEC IV ENGINE DRIVING TIPS

SERIES 50 OPERATOR'S GUIDE

Driving with an electronically controlled engine feels different from driving with a mechancially governed engine.

Accelerating the Vehicle

Engine response versus pedal movement may feel different from the mechanical-governed engine you were driving. The electronic foot pedal assembly (EFPA) was designed to communicate “percentage” foot pedal travel to the engine's electronic control module (ECM). The engine will respond accordingly to the driver's demand.

Another thro ttle or governor characteristic you may need time to get used to is the DDEC limiting speed governor. This allows the driver to command total en g ine response between idle and rated speed, such as accelerating at half throttle — an advantage when driving under slippery conditions.

Cruise Control

For added driver convenience and comfort, DDEC IV also features a cruise control option that works just like the system in your car. It can be operated in any gear above 1000 rpm or road speed faster than 20 mph (32 kph), up to the r ated engine speed. And it can be programmed to hold your road speed at or below the maximum vehicle speed. The switch to energize cruise control is usually mounted on the instrument panel. See Figure 9.

If you require wide-open throttle engine response, either accelerating or just plain pulling hard, the throttle (EFPA) will have to be held to the floor. To obtain 100% fueling at any speed, the foot pedal will have to be maintained at the fully depressed position.

All information subject to change without not ice. (Rev. 01/ 04) 37

Figure 9 Typical Cruise Control

Switches

SEL CORPORATION

DDEC IV ENGINE DRIVING TIPS

Turn the switch ON to energize the system. When you reach your road speed, press the “Set” switch to activate cruise control. The cruise light will come on. To increase road speed in one mile-per-hour (1.6 kilometer-per-hour) increments, press the “Resume/Accel” switch. To reduce road speed, press and hold the “Set/Coast” switch until the lower speed is reached.

Cruise control is deactivated by slightly depressing the service brakes, clutch ped al, or trailer brake. The “On/Off” switch will also d eactivate cruise control.

Cruise control will maintain vehicle speed even on up grades, unless power requirements dem and a downshift. And, of course, cruise control does not limit your speed on dow n grades. Most likely, cruise control will feel stronger than driving with the foot pedal because of the instantaneous and wide-open throttle response. That's why cruise control use is not suggested during slippery driving conditions.

Usecruisecontrolafterdown shifting on a hill to pull the hill. Hitting the “Resume” switch (not the “Set” switch) will keep the truck accelerating in the lower gears up to the rated engine speed.

Cruise control will disengage below 1100 rpm or 20 mph (32 kph) road speed. When using cruise control, if you want to pull the engine below 1100 rpm, remember to hold the throttle pedal to the floor to keep the engine pulling at wide-open throttle. Realistically, the engine will pull to about 1050 rpm.

Remember: The electronic data programmed into th e ECM will not allow you to hurt or overfuel theengineatlowor“lug”engine speeds. There is enough oil pressure to withstand hard pulls at low engine speeds.

38 All information subject to change without notice. (Rev. 01/ 04)

SEL CORPORATION

SERIES 50 OPERATOR'S GUIDE

Engine Brakes and Cruise Control

If your engine is equipped with both cruise control and engine brake retarders, the engine retarders can operate automatically while you are in cruise control. If the cruise control/engine brake function is turned ON in the ECM (electronic control module) programming, the engine retarders will come on “low” when your set road speed increases a few miles-per-hour (kilometers per hour) above your cruise set speed. If your speed continues to increase, the ECM will increase the engine retarders' braking power progressively. When the vehicle returns to the set cruise speed, the engine retarders will “turn off” until you need them.

For safety reasons, don't use cruise control when it is not possible to keep the vehicle at constant speed due to:

Winding roads

Heavy traffic

Shifting

Depending on your transmission model, the gear split may vary from 500 to 300 rpm. The electronic governor provides almost no overrun capability; and, if the transmission is downshifted too early, you will experience a temporary loss of pulling power until the en gine speed falls below rated speed.

In general, when using a 7- or 9-speed transmission, you should alway s downshift between 1250 and 1300 rpm. This is true even on steep grades with heav y loads. When using an 18-, 15- or 13-speed transmission, youwillneedtodownshiftatan rpm that allows “less than rated” rpm before throttle application in the next gear down. You may want to limit engine speed to 1900 rpm in all gears. The S eries 50 provides constant horsepower from 1800 rpm through 2100 rpm, but fuel economy is not as efficient above 1800 rpm.

Slippery pavement

Descending grades that call for engine brake assistance.

For an explanation of the engine brake retarder system and recommendations for pro per operation, refer to section ENGINE BRAKE SYSTEM.

All information subject to change without not ice. (Rev. 01/ 04) 39

SEL CORPORATION

DDEC IV ENGINE DRIVING TIPS

If you decide to drive at lower rpm's for improved fuel economy, don't let different engine noises throw you off guard. The Series 50 sounds quiet at 1400 rpm, almost as if it had quit pulling . Don't believe it! If you had a boost gage to look at while driving, you would notice the turbocharger maintaining steady intake manifold pressure, even as rpm's fall. Depen ding on the air intake arrangement, you may also experience a “chuffing” sound as the engine starts to pu ll hard at lower rpm's. This is caused by the velocity changes of the air flow w ithin the air intake plumbing. Electronic engines can actually deliver more fuel at lower engine speeds than at rated speed.

Idling

The com m on belief that idling a diesel engine causes no engine damage is wrong. Idling produces sulfuric acid, which breaks down the oil and eats into bearings, rings, valve stems and engine surfaces. If you must idle the engine for cab heat or cooling, the high idle function of the cruise control switches should be used. An idle speed of 1100 rpm should be enough to provide cab heat in above 32

C) ambients.

F(0

Winter Fronts

Awinterfrontmaybeusedtoimprove cab heating while idling, bu t it should never cover more than 3/4 of the grille while driving. Winter fronts should only be used when the ambient temperature remains below 10 (-12.2

C).

40 All information subject to change without notice. (Rev. 01/ 04)

SEL CORPORATION

ENGINE BRAKE SYSTEM

SERIES 50 OPERATOR'S GUIDE

Certain Series 50 v ehicle engines are equipped with engine brakes, commonly referred to as retarders. Before operating the vehicle, you must familiarize yourself with the retarder system to obtain optimum benefit from it. Engine brake control systems may vary slightly, depending on the engine brake configuration and cab design. However, basic operator controls are similar for all m odels.

Driver Control Switches

Vehicles with manual transmissions allow t he driver to turn the engine brake on and off and select a low, medium or high level of braking. Two types of switches are available.

Low/High Switch

The “Low” setting on this switch activates three (3) brake cylinders, supplying approximately 50% of normal engine braking horsepower. The “High” setting activates all six (6) cylinders, providing full engine braking horsepower.

about two-thirds engine braking horsepower. The “High” setting activates all six (6) cylinders, providing full braking horsepower.

Clutch Pedal and Throttle Position Controls

Engine brakes have two additional controls, one activated by the position of the clutch pedal and the other activated by the position of the throttle. These controls permit fully automatic operation of the engine braking system.

Low/Med/High Switch

The “Low” setting on this switch activates two (2) brake cylinders, yielding about one-third engine braking horsepower. The “Medium” activates four (4) cylinders, supplying

All information subject to change without not ice. (Rev. 01/ 04) 41

SEL CORPORATION

ENGINE BRAKE SYSTEM

Engine Brake Operation

NOTICE:

Proper operation of the engine brake retarder system depends o n the free flow of engine oil. To ensure positive engine brake engagement when required, allow the engine to warm to normal operating temperature before activating the engine brake system.

The engine brake retarder system depends on a full-pressure flow of warm engine lubricating oil for proper lubrication of moving parts and optimum performance. That's why it's important to allow the engine to reach full operating temperature before switching on the engine brake system.

Under normal driving conditions the engine brake system is left in the ON position. However, t his should change if roads become wet or slippery.

After it is switched on, the engine brake system is automatically activated each time you remove your feet completely from the clutch pedal and throttle. The engine brake automatically deactivates itself when you depress the clutch pedal while shifting gears.

To avoid injury from loss of vehicle control, do not activate the Engine Brake system under the following conditions:

On wet or slippery pavement,

unless the vehicle is equipped with ABS (anti-lock braking system) and you have had prior experience driving under these conditions.

When driving without a trailer

(bobtailing) or pulling and empty trailer.

Ifthetractordrivewheels

begin to lock or there is fishtail motion after the EngineBrakeisactivated.

Deactivate the brake system immediately, if this occurs.

Failure to observe these precautions may result in loss of vehicle control and/or personal injury.

NOTE:

Some systems may be programmed to activate themselves only when the brake pedal is depressed, so read your vehicle owner's manual thoroughly to find out if you have this option.

42 All information subject to change without notice. (Rev. 01/ 04)

SEL CORPORATION

SERIES 50 OPERATOR'S GUIDE

NOTICE:

Do not attempt to “double clutch” the transmission while the engine brake system is turned on. Shifting gears without depressing the clutch or using the engine brake to reduce engine rpm may result in seriou s powertrain damage.

Anti-Lock Braking Systems

Vehicles equipped with A BS (anti-lock braking systems) have the ability to turn the engine brake retarder OFF if a wheel-slip condition is detected. The engine brake will automatically turn itself ON once the wheel slip is no longer detected. The DDEC system will deactivate theenginebrakesystemwhenthe engine speed falls below 1000 rpm or when the vehicle slows down to a pre-set speed, depending on DDEC programming. This prevents stalling the engine. Engine brakes can also be used with vehicle cruise control TURNED ON.

DrivingonFlat,Dry Pavement

Use the following guidelines when driving on flat, dry pavement:

1. If driving on f lat, dry, o pen stretches w it h a light load and greater slowing power is not

required, place the progressive brakingswitchintheLOW position.

2. If you find you are still u sing the service brakes, move the switch to a higher position until you do not need to use the service brakes to slow the vehicle down.

3. If you are carrying a heavier load and road traction is good, move the progressive braking switch to the “High” position.

4. Check your progressive braking switch often for proper position, since road conditions can change quickly. Never skip a step when

operating the progressive braking switch. Always go from OFF

to LOW, and then to a higher position.

Descending a Long, Steep Grade

An explanation of “control speed” may be helpful in understanding h ow to use the engine brake system while descending a grade. Control Speed is the constant speed at which the forces pushing the veh icle forward on a grade are equal to the forces holding it back, without using the vehicle service brakes. In other words, this

is the speed the vehicle will maintain without using the service brakes or fueling.

All information subject to change without not ice. (Rev. 01/ 04) 43

SEL CORPORATION

ENGINE BRAKE SYSTEM

To avoid personal injury, do not over apply the vehicle service brakes when descending a long, steep grade. Excessive use of the vehicle brakes will cause them to heat up, r educing their stopping ability. This condition, referred to as “brake fade”, may result in loss of braking , which couldleadtopersonalinjuryor vehicle/property damage or both.

switch is in the appropriate power position.

Failure to keep the vehicle within safe control speed limits while descending a grade may result in loss of vehicle control, which could cause personal injury.

You could descend a 6% grade under controlonlyat10mph(16kph) without an engine brake, but at 25 mph (40 kph) with an engine brake. You could not descend that same hill at 50 mph (80 kph) and still expect to remain under control. Know how much slowing power your engine brake can provide. K now your engine brake system before climbing hills and do not exceed a safe control speed.

Use the following guidelines when descending a long, steep grade:

1. Before beginn ing a long, steep descent, first determine if your engine brake sys tem is operating properly by lifting your foot briefly off the throttle. You should feel the system activate.

2. When descending the grade, make sure the progressive braking

NOTICE:

Failure to keep the vehicle within safe control speed limits while descending a grade may result in vehicle or property damage or both.

3. When descending a grade, do not exceed the safe control speed of your vehicle.

4. Check your progressive braking switch often for proper position, since road conditions can change quickly. Never skip a step when

operating the progressive braking switch. Always go from OFF

to LOW and then to a higher position when on slippery roads.

44 All information subject to change without notice. (Rev. 01/ 04)

SEL CORPORATION

SERIES 50 OPERATOR'S GUIDE

DrivingonWetorSlippery Pavement

Do no t attempt to use the engine brake system on wet or slippery roads until you have some experience with it on dry pavement.

To avoid injury from loss of vehicle control, do not activate the Engine Brake system under the following conditions:

On wet or slippery pavement,

unless the vehicle is equipped with ABS (anti-lock braking system) and you have had prior experience driving under these conditions.

When driving without a trailer

(bobtailing) or pulling and empty trailer.

If the tractor drive wheels

begin to lock or there is fishtail motion after the Engine Br ake is activated.

Deactivate the brake system immediately, if this occurs.

Failure to observe these precautions may result in loss of vehicle control and/or personal injury.

NOTE:

On single trailers or combinations, a light air application of the trailer brakes may be desirable to help keep the trailer stretched out. Follow the manufacturer's recommended operating procedure when using your trailer brakes.

On wet or slippery p avem ent, start with the master switch in the OFF position and use the gear you would normally use under these conditions.

If the vehicle is maintaini ng traction, place the selective braking switch in the LOW position and t urn ON the engine brake s ystem . If the drive wheels are maintaining traction and you desire greater slowing power, move the braking swi tch to the next highest position.

However, if the tractor drive wheels begintolockorthereisafishtail motion, turn the engine brake system OFF immediately and do not activate it until road conditions improve.

Check your progressive braking switch often for proper position, since road conditions can change quickly. Never skip a step when operating the progressive braking system. Always gofromOFFtoLOWandthentoa higher position

All information subject to change without not ice. (Rev. 01/ 04) 45

SEL CORPORATION

ENGINE SYSTEMS

The engine system are the following:

Fuel System

The fuel system consists of the DDEC, fuel injectors, fuel manifolds (integral with the cylinder head), fuel pump, a cooling plate for the ECM on non-automotive engines, p rim a ry and secondary fuel filters, and the necessary connecting fuel lines.

Lubrication System

The lubricating oil system consists of an oil pump, oil cooler, two full-flow oil filters, bypass valves at the oil pump and oil filter adaptor, and oil p ressure regulator valve in the cylinder block vertical oil gallery.

Air S ystem

The outside air drawn into the engine passes through the air filter and is pulled into the turbocharger and compressed. It then moves to the air-to-air charge cooler (heat exchanger) and is cooled. Next it flows to the intake manifold and into the c ylinders, where it mixes with atomized fuel from the injectors.

For optimum protection of the engine from dust and other airborne contaminants, servicethedrytypeair

cleaners when th e maximum allo wable

air restriction has been reached, or annually, whichever occurs first.

Cooling System

A radiator/thermo-modulated fan cooling system is used on Series 50 engines. This system has a centrifugal type fresh water pump to circulate coolant within the engine. Two full-blocking type thermostats located in a housing attached to the right side of the c ylinder head control the flow of coolant.

Electrical System

The electrical system consists of a starting motor, starting switch, battery-charging alternator, storage batteries, and the necessary wiring.

Exhaust System

Hot exhaust gas flowing from the exhaust manifold into the exhaust riser is used to dri ve the turbocharger.

Exhaust Gas Recirculation System

The purpose of the Exhaust G as Recirculation System (EGR) is to reduce engine exhaust gas emissions in accordance with EPA regulations.

46 All information subject to change without notice. (Rev. 01/ 04)

SEL CORPORATION

MAINTENANCE

SERIES 50 OPERATOR'S GUIDE

The following is intended as a guide for establishing preventive maintenance intervals. The recommendations given should be followed as closely as possible to obtain long life and optimum performance from y our engine. Maintenance intervals indicated are time (hours) of actual operation. The intervals shown a pp ly only to the maintenance functions described. These fun ctio ns should be coordinated with other regularly scheduled maintenance.

A description of the maintenanc e to be performed for each item in the following tables can be found in the PREVENTIVE MA IN TEN ANCE INTERVALS section

Recommended maintenance intervals for Series 50 on-highway truck and parlor coach engines are listed in Table 1, Table 2 and Table3. Recommended maintenance intervals for Series 50 transit coach engines are listed in Table 4 , Table 5, an d Table 6. Recommended maintenance intervals for Series 50 construction/industrial and stationary engines are listed in Table 7, Table 8, an d Table 9. Recommended maintenance intervals for Series 50 fire fighting, crash/rescue, and emergency vehicle engines are listed in Table 10, Table 11,

and Table 12. Recommended maintenance intervals for Series 50 generator drive engines are listed in Table 13, Table 14, and Table 15.

NOTICE:

Failure to check and maintain SCA (supplemental coolant additive) levels at required concentrations will re sult in severe damage (corrosion) to the engine cooling system and related compo nents.

Coolant must be inhibited with the recommendedSCAslistedinthis guide. Refer to section How to Select Coolant. In addition, the engine can be equipped with a coolant filter/inhibitor system as an installed option or as an after-sale item.

All information subject to change without not ice. (Rev. 01/ 04) 47

SEL CORPORATION

MAINTENANCE

Item

1. Lubricating Oil I R

2. Fuel Tank I

3. Fuel Lines & Flex Hoses I

4. Cooling System I

5. Turbocharger I I

6. Battery I

8. Drive Belts I

9. Air Compressor I

10. Air Cleaner I

11. Lube Oil Filters R

12. Fuel Filters R

13. Coolant/Inhibitor Level I

All items are described in PREVENTIVE MAINTENANCE INTERVALS.

I – Inspect, service, correct or replace as necessary. R –Replace.

Daily

Checks

7,500 Miles

(12,000 Km)

15,000 Miles (24,000 Km)

Table 1 On-Highway Truck, Motor Coach, Urban Bus and Motor

Home Daily, 7,500 Mile, and 15,000 Mile Checks

48 All information subject to change without notice. (Rev. 01/ 04)

SEL CORPORATION

SERIES 50 OPERATOR'S GUIDE

Months 6 12 18 24 30 36 42 48 54 60

Item

1. Lubricating Oil Replace lubricating oil every 15,000 miles (24,000 km).

2. Fuel Tank I I I I I

4. Cooling System I I

5. Turbocharger I I I I I I I I I I

8. Drive Belts I I I I I I I R I I

9. Air Compressor I I I I I I I I I I

11. Lube Oil Filters Replace when lubricating oil is changed.

12. Fuel Filters R R R R R R R R R R

13.

14. Cranking Motor

15. Air System I I I I I I I I I I

16. Exhaust System I I I I I I I I I I

All items are described in PREVENTIVE MAINTENANCE INTERVALS.

I – Inspect, service, correct or replace as necessary. R –Replace.

Miles/Km

( X 1000)

Coolant Pump/ Inhibitor Level

15/2430/4845/7260/9675/

120

90/ 144

105/ 168

120/ 192

135/ 216

I I I I I I I I I I

Follow manufacturer's recommendations.

150/ 240

Table 2 On-Highway Truc

Home Reg

All information subject to change without not ice. (Rev. 01/ 04) 49

ular Maintenance Intervals

k, Motor Coach, Urban Bus and Motor

SEL CORPORATION

MAINTENANCE

Months 6 12 18 24 30 36 42 48 54 60

Item

Engine

17. (Steam Clean)

18. Radiator & A/A Charge Cooler

19. Oil Pressure I I

20. Battery Charging Alternator

21. Engine & Transmission Mounts

22. Crankcase Pressure I I

23. Fan Hub I

24. Thermostats & Seals I

25. Crankcase Breather I

26. Engine Tune-Up I

27. Vibration Damper

ms are described in PREVENTIVE MAINTENANCE INTERVALS.

All ite

I – Inspect, service, correct or replace as necessary. R –Replace.

Miles/Km ( X 100 0)

15/2430/4845/7260/9675/

I I

I I I I I

I I I I I I I I I I

I I

Replace a t major engine overhaul or earlier

if dented or leaking.

120

90/ 144

105/ 168

120/ 192

135/ 216

150/ 240

Table 3 On-Highway Truck, Motor Coach, Urban Bus and Motor

Home Regular Maintenance Intervals (continued)

50 All information subject to change without notice. (Rev. 01/ 04)

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SERIES 50 OPERATOR'S GUIDE

Item

Daily

Checks

6,000 Miles

(9,600 Km)

7,500 Miles

(12,000 Km)

15,000 Miles

(24,000 Km)

1. Lubricating Oil I R

2. Fuel Tank I

Fuel Lines &

3. Flexible Hoses

4. Cooling System I

5. Turbocharger I I

6. Battery I

8. Drive Belts I

9. Air Compressor I

10. Air Cleaner I

11. Lube Oil Filters R

12. Fuel Filters R

Coolant/ Inhibitor

13. Level

All items are described in PREVENTIVE MAINTENANCE INTERVALS.

I – Inspect, service, correct or replace as necessary. R –Replace.

Table 4 Transit Coach, Pick-Up and Delivery, Stop-and-Go and

Short Trip Daily, 6,000 Mile, 7,500 Mile , and 15,000 Mile Checks

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MAINTENANCE

Months 6 12 18 24 30 36 42 48 54 60

Item

1. Lubricating Oil

2. Fuel Tank I I I I I

4. Cooling System I I

5. Turbocharger I I I I I I I I I I

8. Drive Belts I I I I I I I R I I

9. Air Compressor I I I I I I I I I I

11. Lube Oil Filters Replace when lubricating oil is changed.

12. Fuel Filters R R R R R R R R R R

13. Coolant Pump/

14. Cranking Motor

15. Air System I I I I I I I I I I

All items are described in PREVENTIVE MAINTENANCE INTERVALS.

I – Inspect, service, correct or replace as necessary. R –Replace.

Miles/Km ( X 1000)

Tachometer Drive

Inhibitor Level

15/2430/4845/7260/9675/

Replace lubricating oil every 6,000 miles (9,600 km)

or every three months, whichever comes first.

n transit coach mo del 6047MK1E only,replace

oil every 3,000 miles (4,800 km).

I I I I I I I I I I

Follow man ufacturer's recommend ations.

120

90/

144

105/ 168

120/ 192

135/ 216

150/ 240

Table 5 Transit Coach, Pick-Up and Delivery, Stop-and-Go and

Short Trip Regular Maintenance Intervals

52 All information subject to change without notice. (Rev. 01/ 04)

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SERIES 50 OPERATOR'S GUIDE

Months 6 12 18 24 30 36 42 48 54 60

Item

16. Exhaust System I I I I I I I I I I

17. Engine

(Steam Clean)

18. Radiator & A/A

Cooler

19. Oil Pressure

20. Battery Charging

Alternator

21. Engine &

Transmission Mounts

22. Crankcase Pressure I I

23. Fan Hub I

24. Thermostats & Seals I

25. Crankcase Breather I

26. Engine Tune-Up I

27. Vibration Damper

All items are described in PREVENTIVE MAINTENANCE INTERVALS.

I – Inspect, service, correct or replace as necessary. R –Rep

lace.

Miles/Km

( X 1000)

15/2430/4845/7260/9675/

I I

I I I I I

I I

I I I I I I I I I I

I I

Replace at major engine overhaul or earlier

if dented or leaking.

120

90/ 144

105/ 168

120/ 192

135/ 216

150/ 240

able 6

ransit Coach, Pick-Up and Delivery, Stop-and-Go and

T Short Trip Maintenance Intervals (continued)

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MAINTENANCE

Item

1. Lubricating Oil I R

2. Fuel Tank I I

Fuel Lines &

3. Flexible Hoses

4. Cooling System I

5. Turbocharger I

6. Battery* I

7. Tachometer Drive

8. Drive Belts I

9. Air Compressor I

10. Air Cleaner I

11. Lube Oil Filters R

12. Fuel Filters R

13. Coolant/ Inhibitor Level

18. Radiator I

20. Battery Charging Alternator

All items are described in PREVENTIVE MAINTENANCE INTERVALS.

I – Inspect, service, correct or replace as necessary. R –Replace.

Daily

Checks

100 Hr

3,000 Mi

150 Hr

4,500 Mi

200 Hr

6,000 Mi

9,000 Mi

300 Hr

Table 7 Stationary or Construction/Industrial Engine Daily, 100

Hour, 150 Hour, 200 Hour, and 300 Hour Checks

54 All information subject to change without notice. (Rev. 01/ 04)

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SERIES 50 OPERATOR'S GUIDE

Hours 150 300 450 600 750 900 1050 1200 1350 1500

Item

1. Lubricating Oil

2. Fuel Tank I I I I I

4. Cooling

5. Turbocharger I I I I I I I I I I

7. Tachometer

8. Drive Belts I I I I I I I R I I

9. Air

11. Lube Oil Filters Replac e when lubricatin g oil is changed.

12. Fuel Filters R R R R R R R R R R

13. Coolant Pump/

14. Cranking

15. Air System I I I I I I I I I I

All items are described in PREVENTIVE MAINTENANCE INTERVALS.

I – Inspect, service, correct or replace as necessary. R –Replace.

Miles/Km ( X 1000)

System

Drive

Compressor

Inhibitor Level

Motor

4.5/

9.0/

13.5/

18/

7.2

14.4

21.6

22.5/3627/

28.8

43.2

31.5/

50.4

36/

57.6

40.5/

64.6

Replace lubricating oil every 150 hours or 4,500

miles (7, 200 km), whichever comes first.

I I

I I I I I I I I I I

Follow manufacturer's recommendations.

45/

Table 8 Stationary or Construction/Industrial Regular

Maintenance Intervals

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Hours 150 300 450 600 750 900 1050 1200 1350 150 0

Item

16. Exhaust

17. Engine

18. Radiator & A/A

19.

20. Battery

21. Engine &

22. Crankcase

23. Fan Hub I

24. Thermostats &

25. Crankcase

26. Engine

27. Vibration

All items are described in PREVENTIVE MAINTENANCE INTERVALS.

I – Inspect, service, correct or replace as necessary. R –Replace.

Miles/Km ( X 1000)

System

(Steam Clean)

Charge Cooler

Oil Pressure

Charging Alternator

Transmission Mounts

Pressure

Seals

Breather

Tune-Up

Damper

4.5/

9.0/

13.5/

18/

22.5/3627/

7.2

14.4

21.6

28.8

I I I I I I I I I I

I I I I I

I I

I I I I I

I I

Replace at major engine overhaul or earlier

if dented or leaking.

43.2

31.5/

50.4

36/

57.6

40.5/

64.6

45/

Table 9 Stationary or Construction/Industrial Regular Maintenance

Intervals (continued)

56 All information subject to change without notice. (Rev. 01/ 04)

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SERIES 50 OPERATOR'S GUIDE

Item

Daily

Checks

100 Hours or

3,000 Miles ( 4,800 Km)

300 Hours or

6,000 Miles

(9,600Km)

1. Lubricating Oil I R

2. Fuel Tank I

3. Fuel Lines & Flexi ble Hoses I

4. Cooling System I

5. Turbocharger I

6. Battery I

7. Tachometer Drive I

8. Drive Belts I

9. Air Compressor I

10. Air Cleaner I

11. Lube Oil Filter R

12. Fuel Filters R

13. Coolant/ Inhibitor Level I

18. Radiator I

20. Battery Charging Alternator I

All items are described in PREVENTIVE MAINTENANCE INTERVALS.

I – Inspect, service, correct or replace as necessary. R –Replace.

Table 10 Fire Fighting, Crash/Rescue and Emergency Vehicle

Engine Daily, 100 Hour and 300 Hour Checks

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Hours 300 600 900 1,200 1,500

Item

1. Lubricating Oil

2. Fuel Tank I I I I I

4. Cooling System I I

5. Turbocharger I I I I I

7. Tachometer Drive I I I I I

9. Air Compressor I I I I I

11. Lube Oil Filters Replace when lubricating oil is changed.

12. Fuel Filters R R R R R

13. Coolant Pump/ Inhibitor

Level

14. Cranking Motor*

15. Air System I I I I I

16. Exhaust System I I I I I

All items are described in PREVENTIVE MAINTENANCE INTERVALS.

I – Inspect, service, correct or replace as necessary. R –Replace.

Miles/Km

(X 1000)

6/1.6 12/9.6 18/28.8 24/38.4 30/48

Replace lubricating oil every 300 hours or

6,000 miles (1,600 km), whichever comes first.

I I I I I

Follow manufacturer's recommendations.

Table 11 Fire Fighting, Crash/Rescue and Emergency Vehicle

Engine Regular Maintenance Intervals

58 All information subject to change without notice. (Rev. 01/ 04)

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SERIES 50 OPERATOR'S GUIDE

Hours 300 600 900 1,200 1,500

Item

17. Engine (Steam Clean)

18. Radiato r & A/A Charge Cooler

19. Oil Pressure I I

20. Battery Charging Alternator*

21. Engine & Transmission Mounts

22. Crankcase Pressure I I

23. Fan Hub I

24. Thermostats & Seals

25. Crankcase Breather I

26. Engine Tune-Up I

27. Vibration Damper

All items are described in PREVENTIVE MAINTENANCE INTERVALS.

I – Inspect, service, correct or replace as necessary. R –Replace.

Miles/Km

(X 1000)

6/1.6 12/9.6 18/28.8 24/38.4 30/48

I I I I I

I I

Replace at major engine overhaul or

earlier if dented or leaking.

Table 12 Fire Fighting, Crash/Rescue and Emergency Vehicle

Engine Regular Maintenance Intervals (continued)

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Item

1. Lubricating Oil I I*

2. ]Fuel Tank I I

3. Fuel Lines & Flexible Hoses I

4. Cooling System I I*

5. Turbocharger I

6. Battery I

8. Drive Belts I I

10. Air System, Cleaner I I

12. Fuel Filters, Water Separator I I*

16. Exhaust System I

19. Oil Pressure I I*

Load Test P

All items are described in PREVENTIVE MAINTENANCE INTERVALS.

I – Inspect, service, correct or replace as necessary. P –Perform * Perform these items at time of load test. Load test should be at

least 35% of the uni t's full rated output. Refer to generator set manufacturer's instructions.

Prime

Daily

Standby

Monthly

Table 13 Generator Set Engine Prime Daily and Standby Monthly

Maintenance Intervals

60 All information subject to change without notice. (Rev. 01/ 04)

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SERIES 50 OPERATOR'S GUIDE

Item

150 300 600 1,000 1,500 2,000 3,000 4,000

Hours

Standby: Replace every 150 hours or 1 year,

1. Lubricating Oil

rime: Replace every 250 hours or 3 months,

whichever comes first.

2. Fuel Tank I

3. Fuel Lines &

Flexible Hoses

I R

4. Cooling System R

6. Battery I

7. Tachometer

Drive

8. Drive Belts I

10. Air Cleaner I

11.

Lube Oil Filters

Replace when lubricating oil is changed.

Standby: Replace every 150 hours or 1 year,

12. Fuel Filters

rime: Replace every 150 hours or 3 months,

whichever comes first.

13. Coolant Pump/

Inhibitor Level

14.

Cranking Motor

Follow manufacturer's recommendations.

All items are described in PREVENTIVE MAINTENANCE INTERVALS.

I – Inspect, service, correct or replace as necessary. R – Replace

Table 14 Generator Set Engine Regular Maintenance Intervals

All information subject to change without not ice. (Rev. 01/ 04) 61

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Item

16. Exhaust System I

17. Engine (Steam Clean)

18. Radiator I

19. Oil Pressure I

20. Battery Charging Alternator

21. Engine & Generator Mounts

22. Crankcase Pressure

23. Fan Hub I

24. Thermostats & Seals

25. Crankcase Breather

26. Engi ne Tune-Up I

27. Vibration Damper

All items are described in PREVENTIVE MAINTENANCE INTERVALS.

I – Inspect, service, correct or replace as necessary. R – Replace

150 300 600 1,000 1,500 2,000 3,000 4,000

Replace at major engine overhaul or earlier

Hours

I I

I R

if dented or leaking.

Table 15 Generator Set Engine Regular Maintenance Intervals

(continued)

62 All information subject to change without notice. (Rev. 01/ 04)

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SERIES 50 OPERATOR'S GUIDE

PREVENTIVE MAINTENANCE INTERVALS

The intervals shown apply only to the maintenance functions described and should be coordinated with other regularly scheduled maintenance.

The “Daily” instructions apply to routine or daily starting of the en g ine. They do not apply to a new engine or one that has been operated for a considerable period of time.

For new or stored engines, refer to Section 13.1, “Prep arations for Starting the Engine the First Time,” in the Series 50 Service Manual (6SE50).

Item 1 – Lubric ating Oil

Check the oil lev e l daily with the engine stopped. If the engine has just been stopped and is warm, wait approximately 20 m inutes to allow the oil to drain back into the oil pan before checking. Add the proper grade of oil to mainta in the correct level on the dipstick. See Figure 10.

Figure 10 Check Oil Level Daily

NOTICE:

When adding lubricating oil, do not overfill. Oil may be blown out through the crankcase breather if the crankcase is overfilled.

Preventive maintenance other than the “Daily” checks should be performed by authorized Detroit Diesel service outlets. These outlets have the trained personnel and special tools to properly perform all services.

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Figure 11 Engine Oil Consumption Guidelines

All diesel engines are designed to use some oil, so the periodic addition of oil is normal. See Figure 11 to determine the degree of oil usage.

NOTICE:

If the oil level is constantly above normal and excess oil has not been added to the crankcase, consult with an authorized Detroit Diesel service outlet. Fuel or coolant dilution of lubricating oil can result in s erious engine damage.

Before adding lubricating oil, refer to How to Select Lubricating Oil in this guide. Change lubricating oil and filters a t the intervals listed in Table 16 when using fuel with a sulfur conten t of less than 0.05 mass percent. When using fuel with a higher sulfur content, refer to When to Change Oil in this guide.

64 All information subject to change without notice. (Rev. 01/ 04)

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SERIES 50 OPERATOR'S GUIDE

Service Application Lube Oil and Filter Change Interval*

Highway Truck & Motor Coach 15,000 Miles (24,000 Kilometers)

City Transit Coach except model 6047MK1E

City Transit Coach Model 6047MK1E 3,000 Miles (4,800 Kilometers)

Fire Fighting, Crash/Rescue, & Emergency Vehicles

Construction, Industrial & Agricul tural 250 Hours or 1 Year, whichever comes

Stationary Generator – Prime Power or Continuous

Stationary Generator – Standby 150 Hours or 1 Year, whichever comes

* Change both full-flow filter s when lube oil is changed.

6,000 Miles (9,600 Kilometers), 300 Hours or 3 Months, whichever comes first

6,000 Miles (9,600 Kilometers), 300 Hours or 1 Year, whichever comes first

first 300 Hours or 3 Months, whichever

comes first

first

Table 16 Recommended Engine Oil Drain and Filter Change

Intervals (Diesel Fuel Sulfur Content Less Than 0.05 Mass %)

Item 2 – Fuel and Fuel Tank

Keep the fuel tank filled to reduce condensation. See Figure 12.

Before adding fuel, refer to section How to Select Fuel Oil in the How To section of this guide.

Refill the tank at the end of each day's operation to prevent conden sation from contaminating the fuel. Condensation formed in a partially filled tank promotes the growth of microorganisms that can clog fuel filters and restrict fuel flow.

To prevent microbe growth, add a biocide to the fuel tank or primary fuel supply.

Figure 12 Filled Fuel Tank

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Water accumulation can be controlled by using additives containing methyl carbitol or butyl cel lusolve. Follow manufacturer's usage, handling and safety precautions.

Open the drain at the bottom of the fuel tank every 30,000 miles (48,000 kilometers) or 300 hours for construction/industrial applications to drain off any water and/or sediment.

To avoid injury from improper use of chemicals, follow the chemical manufacturer’s usage, handling, and disposal instructions. Observe all manufacturer’s cautions.

Every 120,000 miles (192,000 kilometers), 12 months, or 600 hours for construction/industrial applications tighten all fuel tank mountings and brackets. At the same time, check the seal in the fuel tank cap, the breather hole in the cap and the condition of the flexible fuel lines. Repair or replace the parts, as necessary.

NOTICE:

Galvanized steel fuel tanks, fittings, pipes or supply lines should never be used, because the fuel reacts chemically with the zinc coating to form powdery flakes that can quickly clog the fuel filters and damage the fuel pump and injectors.

Item 3 – Fuel Lines, Flexible Hoses

A pre-start inspectio n for leaks and of hosese and fittings must be made.

Leaks — Makeavisualcheckfor fuel leaks at all engine-mounted fuel lines and connections, and at the fuel tank suction and return lines. Since fuel tanks are susceptible to road hazards, leaks in this area may best be detected by checking for an accumulation of fuel under the tank.

To avoid inj ury from fire, contain and eliminate leaks of flammable fluids as they occur. Failure to eliminate leaks could result in fire.

66 All information subject to change without notice. (Rev. 01/ 04)

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SERIES 50 OPERATOR'S GUIDE

Leaks are no t only detrimental to machine operation, but they can also result in added expen se caused by the need to replace lost fluids.

Hoses and Fittings — Check hoses daily as part of the pre-start inspection. Examine hoses for leaks, and check all fittings, clamps and ties carefully. Make sure hoses are not resting on or touching shafts, couplings, heated surfaces including exhaust manifolds, any sharp edges, or other obviously hazardous areas. Since all machinery vibrates and moves to a certain extent, clamps and ties can fatigue with age. To ensure continued proper support, inspect fasteners frequently and tighten or replace them as necessary. If fittings have loosened or cracked or if hoses have ruptured or worn through, take corrective action immediately.

Hose Service Life — A hose has a finite service life. With this in mind, all hoses should be thoroughly inspected at least every 500 operating hours (1,000 hours for fire-resistant fuel and lubricating oil hoses) and/or annually. Look for cover damage and/or indications of twisted, worn, crimped, brittle, cracked or leaking lines. Hoses with their outer cover worn through or with dam a ged metal reinforcements should be considered unfit for fu rther service.

All hoses in and out of machinery should be replaced during major overhaul and/or after a maximum of five (5) years of service.

NOTE:

Fire-resistant fuel and lube oil hose assemblies do not require automatic replacement after five years of service or at major overhaul, but should be inspected carefully before being put back into service.

Item 4 – Cooling System

The cooling system must be full for proper operation of the engine.

Coolant Level — Check the coolant

level daily and m aintain it near the bottom of the filler neck on the radiator. On so me installations this is done by checking an overflow bottle or sight glass. Add coolant as

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MAINTENANCE

required, but do not overfill. Before adding coolant, refer to section How to Select Coolant in this guide.

Make a daily visual check for cooling system leaks. Look for an accumulation of coolant when the engine is running and when it is stopped. Coolant leaks may be more apparent on a engine when it is cold.

Coolant Inhibito rs — The inhibitors in antifreeze solutions must be replenished with a non-chromate corrosion inhibitor supplement when indicated by testing the coolant. Refer to section How to Select Coolant for required test intervals and inhibitor levels.

NOTICE:

must be inhibited with the recommended SCA's listed in this guide. In addition, the engine can be equipped with a coolant filter/inhibitor system as an installed option or as an after-sale item.

Coolant Drain Interval —

Detroit Diesel recommends replacing coolant at the intervals listed in Table 1 7.

A coolant system properly maintained and protected with supplemental coolant inhibitors can be operated up to the intervals listed. At these intervals the coolant must be drained and disposed of in an environmentally responsible manner according to state and/or federal (EPA) recommendations.

68 All information subject to change without notice. (Rev. 01/ 04)

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SERIES 50 OPERATOR'S GUIDE

Coolant Type Coolant Replacement Interval

A 50/50 mix of PowerCool®fully formulated, inhibited ethylene glycol antifreeze and water or a 50/50 mix of fully formulated, inhibited propylene glycol antifreeze and water

A 50/50 mix of phosphate-free TMC RP-329 “Type A“ (propylene glycol) antifreeze and water.

A 50/50 mix of OAT (organic acid technology) coolant and water.

Proper maintenance involves periodic evaluation using PowerTrac

3-Way Coolant Test Strips and the addition of required SCA, as indicated by the test strip.

To verify coolant acceptability, submit a sample to DD C for coolant

analysis every 3 years, 300,000 miles (480,000 km) or 6,000 operating hours, whichever comes first. Submit sample using PowerTrac coolant analysis kit, part number 23516921 (IEG/IPG coolant) or 23523398 (organic coolant).

OAT coolants require the addition of an extender every 2 years,

300,000 miles (480,000 km), or 5,000 hours, whichever comes first. Use 1 pint to 20 gallons of OAT coolant.

With proper mainten an ce1coolant can be operated 2 years, 300,000 miles (480,000 km), or 4,000 hours, whichever comes first. At this time the cooling system must be completely drained and cleaned before refill. With proper maintenance1coolant can be operated for the life of the engine until overhaul.

Forlifetooverhaul, pre-charged c oolant in combination with a need-release filter must be used. At this time the cooling system must be completely drained and cleaned before refill. With proper mainte nance coolant can be operated 4 years, 600,000 miles (960,000 k m), or 10,000 operating hours, whichever comes first. this time the cooling system must be completely drained and cleaned before refill.

Table 17 Coolant Drain Intervals

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Item 5 – Turbocharger, Air-to-Air Charge Cooler

Visually inspect the turbocharger mountings, intake and exhaust ductin g and connections for leaks daily. Check the lube oil inlet and outlet lines fo r leaks or restrictions to oil f low. Check for unusual noise or vibration and, if excessive, stop the engine and do not operate until the cause is determined.

To avoid injury from hot surfaces, allow engine to cool before removing any component. Wear protective gloves.

Periodically inspect the air-to-air charge cooler (if used) for buildup of dirt,mud,etc. andwashoff. Check the charge cooler, ductwork, and flexible connections for leaks and have repaired or replaced, as required.

Wastegated Turbochargers —

The turbocharger wastegate actuator is factory-calibrated and is not adjustable. Check actuator operation at the intervals shown in the maintenance schedule.

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.

NOTICE:

Do not exceed 30 psi (207 kPa) air pressure when checking wastegate actuator operation. Excessive air pressure can damage the actuato r.

Check turbocharger heat-insulating exhaust system blankets (if used) for damage on a daily basis. Torn, matted, crushed, oil-soaked or otherwise

To verify correct wastegate actuator operation, apply 30 psi (20 7 kPa) of regulated shop air and watch for

actuator rod movement. damaged insulation blankets must be replaced immediately.

70 All information subject to change without notice. (Rev. 01/ 04)

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SERIES 50 OPERATOR'S GUIDE

Item6–Battery

Check the hydrometer “eye” of maintenance-free batteries for charge. See Figure 13.

Figure 13 Check “Eye” of

Maintenance-Free Batteries

To avoid injury from accidental engine startup while servicing the engine, disconnect/disable the starting system.

Maintain the electrolyte level according to the battery manufacturer's recommendations, but do not overfill. Overfilling can cause poor battery performance or early failure.

Keep the terminal side of the b a tter y clean. When necessary, wash with a solution of baking soda and water. Rinse with fresh water. Do not allow the soda solution to enter the cells.

Inspect the cables, clamps and hold-down brackets regularly. Clean andreapplyalightcoatingof petroleum jelly when needed. Have corroded or damaged parts replaced.

If the engine is to be out of service formorethan30days,removethe batteries and store in a cool, dry place. Keep batteries fully charged, if possible. Replace any battery that fails to hold a charge.

Periodically check battery connections for corrosion an d tightness. If necessary, remove connections and wire brush any corrosion from terminals and cable ends. Replace damaged wiring.

If lead-acid or low-maintenance batteries are used, check the specific gravity of each cell every 150 operating hours. Check more frequently in warm weather due to the more rapid loss of water through evaporation.

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Item 7 – Tachometer Drive

A typical tachometer drive take-off location is the camshaft drive gear

result in crankshaft breakage. A loose

belt will slip and may cause damage

to accessory components.

access cover on the front of the gear case cover. Lubricate t he tachometer drive (if so equipped) every 150 hours or 15,000 miles (24,000 km) with an all-purpose grease. At temperatures above – 1

C(+30 F) use a No. 2

grade g rease. Use a N o. 1 grade

To avoid injury from rotating belts and fans, do not remove and discard safety guards.

grease below this temperature.

Item 8 – Drive Belts

Belts should be n either too tight nor too loose. Belts that are too tight impose extra loads on the crankshaft, fan and/or alternator bear ings, shortening both belt and bearing life.

Use a belt tension gage, such

as Kent-Moore

(V-belt), J 23600–B (poly-V belt),

J 41251 (Po w erBand

poly-V belt), or equivalent, when

tensioning drive belts. Tension belts

to the values listed in Table 18. Excessively overtightened belts can

Fan Drive

Single Belt

80–100lbs(356–445N) 60–80lbs(267–356N)

Alternator Drive

Belt New Used

Two 1/2–in. V-Groove

2–Groove PowerBand

12–Rib Poly-V (50 DN Alternator)

125 lbs (556 N) 100 lbs (445 N)

200 lbs (890 N) 150 lbs (667 N)

350 lbs (1,557 N) 250 lbs (1,112 N)

2or3Belts

tool J 23586–B

and 12–rib

Table 18 Drive Belt Tensioning

72 All information subject to change without notice. (Rev. 01/ 04)

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SERIES 50 OPERATOR'S GUIDE

V-Belts — New standard V-belts will stretch after the first few hours of operation. Tighten V-belts as listed in Table 18. Run the engine for 10 to 15 minutes to seat the belts, then readjust tension. Check and retension belts after 1/2 hour and again after 8 hours or 250 miles (400 km) of operation. Thereafter, check the tension of the drive belts every 100 hours or 6,000 miles (10,000 km) and adjust, if necessary.

If a belt tension gage is not available, adjust the belt tension so that a firm push with the thumb, at a point midway between the two pulleys, will depress the belt .50 in. – .75 in. (13 – 19 mm).

2-Groove PowerBand — The 2-groove PowerBand

is used with the 50 DN alternator. To provide proper running tension for the belt, current Series 50 engines use an auto belt tensioner, which requires no adjustment. See Figure 14.

tensioning, measure belt tension every month or every 7,500 miles (12,000 km), whichever comes first. Retension belt to 150 lbs (667 N) at these intervals.

Figure 14 Auto Belt Tensioner

Assembly with 50 DN Alternator

Earlier-built Seri e s 50 engines have a m anual belt tensioner assembly. See Figure 15.

Tighten a new PowerBand

drive belt

Figure 15 Manual Tensioner

Assembly with 50 DN Alternator

to 200 lbs (890 N), then run the engine for 10 minutes at 1200 rpm. Stop the engineandallowa10–15minute cool down period. Check tension. If less than 150 lbs (667 N), retension to 150 lbs (667 N). Following initial

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12–Rib Poly-V Belt — Tighten a 12–rib poly-V belt to 350 lbs (1,557 N), then run the engine at high idle for 30 minutes. Stop the en gine and allow a 10 – 15 m inute cool down period. Check tension with tool J 41251–B or equivalent. If tension is 250 lbs (1,112 N) or more, no retensioning is required. If tension is less than 250 lbs (1,112 N), retension to 250 lbs (1,112 N). Measure belt tension every month or every 7,500 miles (12,000 k m), whichever comes first. Retension to 250 lbs (1,112 N) as required.

Belt Replacement — Drive belts (V and poly-V) should be replaced every 2,000 hours or 100,000 miles (160,000 km).

Replace all belts in a set when one is worn. Single belts of similar size should not be used as a substitute for a matched belt set. Premature b elt wear can result because of belt length variation. All belts within a matched set are within .032 in. (0.8 mm) of their specified center distances.

When installing or adjusting an accessory drive belt, be sure the bolt at the accessory adjusting pivot point is properly tightened, as well as the bolt in the adjusting slot. In addition, check the torque on the alternator an d bracket mounting bolts. Retighten as required.

Item 9 – Air Compressor

All air compressor intake parts should be removed and cleaned at the following intervals:

On Highway Vehicle Engines – 7,500 miles (12,000 km)

Industrial Engines – 150 Hours or 4,500 miles (7,200 km)

To clean either the hair type or the polyurethane type compressor air strainer element, saturate it and squeeze it in fuel oil or any other cleaning agent that is not detrimental to the element until it is dirt-free. Then saturate the elem e nt in lubricating oil and squeeze it dry before placing it back into the air strainer.

For air strainer replacement, contact the nearest servicing dealer. Replace hair type elements with the polyurethane type, if available.

The air compressor mounting bolts should be tightened every 12 months or 30,000 miles (48,000 km) for on-highway engines or every 300 hours for industrial applications.

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Item 10 – Air Cleaner

The air cleaner element should be inspected every 15,000 miles (24,000 km) for vehicle engines, 150 hou rs for non-vehicle engines, or more often if the engine is operated under severe dust conditions. Replace the element, if necessary. Check the gaskets for deterioration and replace, if necessary. If the dry type air cleaner is equipped with an aspirator, check for aspirator damage or clogging. Clean, repair or replace, as necessary.

Dry type air cleaner elements should be replaced after one year of service or when the maximum allowable air in take restriction has been reached, whichever comes first. Refer to section When to Service the Dry Type Air Cleaner in this guide for additional information.

NOTICE:

piping or boots an d loose or damaged clamps. Have worn or damaged parts repaired or replaced, as required. Retighten loose connections.

Item 11 – Lubricating Oil Filters

For on-highway vehicle engines, install new spin-on oil filters at a maximum of 15,000 miles (24,000 km). For city transit coach engines, install filters at a maximum of 6,000 miles (9,600 km). For industrial engines, install filters every 150 hours of operation or each time the engine oil is changed, whichever comes first.

To avoid injury from slipping and falling, immediately clean up any spilled liquids.

Do not allow the air inlet restriction to exceed 20 inches of water (5.0 kPa) under any engine operating conditions. 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 e ngine life.

Install the new f ilters, turning them until they contact the gasket fully w ith no side movement. Turn full-flow filters an additio nal 2/3 turn by hand, or as indicated on the filter. See Figure 16.

Inspect the entire air system for leaks daily. Look especially for torn air inlet

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Figure 16 Lubricating Oil Filters

Make a visual check of all lubricating oil lines for wear and/or chafing. If any indication of wear is evident, replace the oil lines and correct the cause.

Check for oil leaks after starting the engine.

At normal operating speed and with the standard .080 inch restriction fittings, the fuel pressu re is 55 – 70 psi (375 – 483 kPa). Change the fuel filters whenever the inlet restrictio n at the pump reaches 12 inches of mercury (41 kPa) at normal operating speeds and whenever the fuel pressure at the inlet fitting falls to the minimum fuel pressure of 6 inches of mercury (20.3 kPa).

NOTE:

Filter change intervals may be shortened to conform with established preventive maintenance schedules, but should never be extended.

Fuel Pro®382 Filters — Install new Fuel Pro

382 primary fuel filter elements when the fuel level in the see-thru cover reaches the top of the element or after one year of service, whichever comes first.

Item 12 – Fuel Filters

One method o f determining when filters are plugged to the extent that they need replacing is based on the fuel pressure at the cylinder head fuel inlet fitting and the inlet restriction

Spin-On Filters — Install new spin-on primary and secondary fuel filter elements on vehicle engines every 15,000 miles (24,000 km) or every six months, whichever comes first. See Figure 17.

at the fuel pump. In a clean system the maximum pump inlet restriction should not exceed 6 inches of mercury (20.3 kPa). In a dirty system it must not exceed 12 inches of mercury (41 kPa).

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Figure 17 Spin-On Fuel Filter

Location

Install new spin-on filter elements on non-vehicle engines every 150 hours. Replace spin-on filter elements immediately if plugging is indicated, regardless of mileage or hour intervals.

Item 13 – Water Pump and Coolant Inhibitor Element

SERIES 50 OPERATOR'S GUIDE

Coolant Inhibitor Element — If the cooling system is protected by a supplemental coolant additive (SCA) element, the coolant must be tested at required intervals and the element replaced, if required. See Figure 18.

Check the water pump and the coolant inhibitor element.

Water Pump Drain Hole — The

Figure 18 Coolant Inhibitor

Element

water pump drain hole should be inspected every 6 months to make sure it is open. A small chemical build-up or streaking at the drain hole may occur. This is not an indication

of a defective water pump or seal.

Remove the build-up with a mild detergent cleaner and a brush. If

Required test intervals are listed in Table 25. For SCA test procedures refer to How to Select Coolant and then SCA Test Procedures in this guide. Use the coolant filter element required.

coolant does not leak from the drain hole under normal conditions, d o not replace the water pump.

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Refer to SPECIFICATIONS for element part number listing. The valves mounted on the filter adaptor head must be opened after the element is replaced.

Item 14 – Cranking Motor

For cranking motor (starter) information, contact an authorized Delco Remy

or Bosch®service

center, depending on m anufacturer.

Item 15 – Air System

All the connections in the air system should be checked to make sure they are tight and leak free. Check all hoses and ducting for punctures, deterioration or other d a mag e and replace, if necessary.

Item 16 – Exhaust System

Have the exhaust manifold retaining bolts and other connections checked for tightness. Have the exhaust pipe rain cap checked for proper operation, if so equipped.

NOTICE:

Do not apply steam or solvent directly to the battery-charging alternator, starting motor, DD E C components, sensors or other electrical components, as damage to electrical equipment may result.

Item 18 – Radiator

The exterior of the radiator core should be inspected every 30,000 miles (48,000 km), 12 months, or 300 hours ( industrial ap plications) and cleaned, if n ecessary.

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.

Item 17 – Engine (Steam Clean)

Steam clean the engine and engine compartment every 60,000 miles (96,000 km ) or 2,000 hours, whichever comes first.

as mineral spirits, and dry with compressed air. Fuel oil, kerosene or

gasoline should not be used.

It may be necessary to clean the radiator more frequently if the engine is being operated in extremely dusty or dirty areas.

Use a quality grease solvent, such

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SERIES 50 OPERATOR'S GUIDE

If the low coolant level sensor is installedinthetoptankoftheradiator, it should be tested for proper operation every 100 ,000 miles (160,000 km) or 12 months, whichever comes first. Authorized Detroit Diesel distributors are properly equipped to perform this service.

Item 19 – Oil Pressure

Under normal o peration , oil pressure is noted each time the engine is started. In the event the equipment has warn ing lights rather than pressure indicators, the pressure should be checked and recorded every 60,000 miles (96,000 km) for vehicle engines or 600 hours for stationary and industrial engines.

Item 20 – B attery-Charging Alternator

Precautions must be taken when working on or aroun d the alternator. The diodes and transistors in the alternator circuit are very sensitive and can be easily destroyed.

2. Do not reverse battery connections. This can also cause damage.

3. Never disconnect the battery while the alternator is operating. Disconnecting the batter y can result in damage to the battery diodes. In applications which have two (2) sets of batteries, switching from one set to the other while the engine is running will momentarily disconnect the batteries. This can result in equipment damage.

4. If a booster battery is to be used, batteries must be connected correctly (negative to negative, positive to positive) to avoid equipment damage.

5. Never use a fast charger with the batteries connected or as a booster for battery output.

For information on the alternator assembly, contact an authorized Delco Remy

or Bosch®distributor,

depending on manu facturer.

1. Avoid grounding the output terminal. Grounding an alternator's output wire or terminal (which is always “hot,” regardless of whether or not the engine is running) and accidentally reversing the battery polarity will result in equipment damage.

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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.

Applybakingsodaorlimeto

help neutralize the acid.

Flush your eyes with water.

Get m edical attention

immediately.

Bosch®T1 Alternator Service Requirements — The transistor

regulator must b e replaced every 100,000 m iles (160,000 km) using kit part number 235246 13 (includes regulator assembly and brushes). Front and rear bearings must be replaced every 200,000 miles (320,000 km) using k it 23524614 (includes bearings, seals and spacer ring). Authorized Bosch distributors have the parts, tools and trained personnel to perform these services.

General Service Requirements –Bosch

and Delco Remy

Alternators — Terminals should

be checked for corrosion and loose connections and wiring inspected for damage and frayed insulation. Have wiring repaired or replaced, as required.

Check torque on alternator mounting bolts and brack eting every 15,000 miles (24,000 km) on truck and coach engines or every 300 hours on all other engines. Retighten, if necessary.

Item 21 – Engine and Transmission Mounts

The engine and transmission mounting bolts and the condition of the m o unting pads should be checked every 60,000 miles (96,000 km) or 600 hours. Tighten and/or rep a ir as necessary.

Item 22 – Crankcase Pressure

The crankcase pressure should be checked and recorded every 60,000 miles (96,000 k m ) or 600 ho urs.

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Item 23 – 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 quality lithium-base, multi-purpose grease every 1 00,00 0 miles (160,000 km) for vehicle engines or 1,000 hours for non-vehicle engines. Care should be taken not to overfill the beari ng housing.

Item 24 – Thermostats and Seals

Replace the therm ostats and seals every 240 ,000 miles (384,000 km) on vehicle engines. On non-vehicle engines, replace the thermostats and seals every 4,000 hours or 24 months, whichever comes first.

Item 25 – Crankcase Breather

SERIES 50 OPERATOR'S GUIDE

Figure 19 Internal (in Rocker

Cover) Breath er Location

The rocker cover-mounted breather assembly (part number 23512984) used in the closed crankcase breather system should be replaced every 4000 operating hours. It is not reusable and no attempt should be made to clean or reuse it. See Figure 20.

The internally mounted (in the engine rocker cover) crankcase breather assembly should be removed and

the steel mesh pa d washed in clean fuel oil every 100,000 to 120,000

miles (160,000 to 192,000 km) on vehicle engines or every 1,000 hours of operation on non-vehicle engines. This cleaning period m ay be reduced or lengthened according to the severity ofservice. SeeFigure19).

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Figure 20 Rocker Cover-Mounted

Breather

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Item 26 – Engine Tune-Up

There is no scheduled interval for performing an engine tune-up. However, the valve lash and injector heights must be measured and, if necessary, adjusted at the initial interval listed in Table 19. Once the initial measurements/adjustments have been made, any adjustments beyond th is point should be made only as required to maintain satisfactory engine performance.

Item 27 – Vibration Damper

The viscous vibration damper should be inspected periodically and replaced if dented or leaking. See Figure 21.

Heat from normal engine operation may, over a period of time, cause the fluid within the damper to break down and lose its dampening properties. For this reason the viscous vibration damper must be replaced at time

of normal major engine overhaul, regardless of apparent condition.

Figure 21 Viscous Vibration

Damper

Engine Application

Vehicle Engines

Stationary, Construction/Industrial,

Agricultural, or Generator Set Engines

* Whichever comes first.

Initial Valve Lash and Injector Height

Measurement/Adjustment Period

60,000 Miles (96,000 km) or

24 Months*

1,500 Hours or 45,000 Miles

(72,000 km)*

Table 19 Valve Lash and Injector Height Adjustment

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HOW-TO SECTION

This section covers Detroit Diesel's recommendations o n how to select lubricating oil, fuel oil, and coolant and includes basic engine maintenance procedures which can be performed by the operator.

NOTICE:

The manufacturer's warranty applicable to Series 50 engines provides in part that the provisions of such warranty shall not apply to any engine unit that has been subject to misuse, negligence or accident. Accordingly, malfunctions attributable to neglect or failure to follow the manufacturer's fuel or lubricating recommendations may not be within the coverage of the warranty.

How to Select Lubricating Oil

The selection of the proper lubricating oil is important to achieve the long and trouble-free service which Detroit Diesel engines are designed to provide. The proper lubricating oil for all Detroit Diesel engines is selected basedonSAEviscositygradeand API (American Petroleum Institute) service designation. Only oils licensed to display the API symbol should be used. See Figure 22.

SERIES 50 OPERATOR'S GUIDE

Figure 22 API Symbol

Lubricant Requirements

Lubricant requirements are different for the EGR-equipped and non-EGR engines.

EGR-Equipped Engines — API CI-4 oils must be used in October 2002 and later–build Series 50 engines with cooled EGR (exhaust gas recirculation) devices. API

Service Category CI-4 is intended for use with cooled EGR engines m eeting 2002 and later exhaust emission regulations.

Non-EGR Engines — API CI-4 or CH-4 oils are recommended for use i n all non-EGR engines.

Engines Built Prior to 1998 —

Lubricants meeting API Service

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CategoryCG-4maybeusedin engines built prior to 1998 when API CI-4 or CH-4 oils are not available.

NOTE:

The use of CG-4 oils in these engines may require a reduction in oil drain interval, depending upon the application and the fuel sulfur level.

Cold Weather Starting

At ambient temperatures below –20 C(–4 F) when sufficient starter speed cannot be achieved with SAE 15W-40 oils, the use of 5W-XX oils and 10W-XX oils, where XX is 30 or 40, is allowed to improve startability, provided they are API CI-4 (for EGR-equipped engines) or API CI-4 or CH-4 (for non-EGR-equipped engines) and have demonstrated field performance in DDC engines. These oils m ust possess a HT/HS of 3.7 minimum.

NOTICE:

Monograde oils should not be used in Series 50 engines, regardless o f API service classification. Monograde oils

gel at lower ambient temperatures, reducing lubricant flow, and they do not provide adequate lubricity at higher engine operating temperatures. These factors can result in severe engine damage.

NOTE: Do not use fuel with sulfur content above0.05masspercentforDetroit Diesel EGR-equipped engines.

When the use of high sulfur fuel (greater than 0.05% mass sulfur) in non-EGR engines is unavoidable, high alkalinity (TBN) lubricants are recommended. High sulfur fuels require modification to oil drain intervals. For further information, refe r to publication

Engine Requirements – Lubricating Oil, Fuel and Filters, 7SE270,

available f ro m authorized Detroit Diesel distributors.

Synthetic Oils

Synthetic oils may be used in Detroit Diesel engines, provided they are API licensed and meet the performance and chemical requirements of non-synthetic oils outlined in this publication. Synthetic oils offer improved low-temperature flow properties and high-temperature oxidation resistance. However, they are generally more costly than non-synthetic oils.

Product information about synthetic oils shou ld be reviewed carefully. Performance additive systems often respond differently in synthetic oils. Their use does not permit extension of recommended oil drain intervals.

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The Use of Supplemental

When to Change Oil

Additives

Lubricants meeting the Detroit Diesel specifications outlined in this publication already contain a balanced additive treatment. Supplemental additives are generally not necessary and can even be harmful. These additives may be marketed as either

To avoid injury from contact with the contaminants in used engine oil, wear protective gloves and apron.

oil treatments or engine treatments and are discouraged from use in Detroit Diesel engines. Engine

damage resulting from the use of such materials is not covered by your Detroit Diesel Corporation warranty. Detroit Diesel will not

provide statements beyond this publication relative to their use.

The length of time an engine may operate before an oil change depends upon the lubricant and fuel used, engine oil consumption, and the operating cycle. The maximum interval at which the engine may operate before the oil and filters must be changed is listed in Table 20.

Engine Application Drain Interval

Highway Truck & Motor Coach 15,000 Miles (24,000 km)

City Transit Coa ch#

City Transit Coach Model 6047MK1E 3,000 Miles (4,800 km)

Construction, Industrial or Agriculture

Stationary Generator, Prime Power or Continuous

Stationary Generator, Standby

# All Series 50 transit coach engines, e xcept model 6047MK1E.

6,000 Miles (9,600 km), 300 Hours or 3 Months, whichever comes first

250 Hours or 1 Year, whichever comes first

300 Hours or 3 Months, whichever comes first

150 Hours or 1 Year, whichever comes first

Table 20 Maximum Oil Drain and Filter C hange Interval (Fuel Sulfur

0.05 Weight Percent or Less)

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Oil analysis may be used to determine whether this interval should be shortened, but it should not be used to lengthen the interval.

The use of fuels with sulfur content above 0.05 ma ss percent will require a shortening of drain intervals and/or the use of a higher TBN o il. See the information listed in Table 20. For detailed information refer to publication Engine Requirements –

Lubricating Oil, Fuel and Filters

(7SE270), availab le from authorized Detroit Diesel distributors.

Disposing of Waste Oil

Disposeofusedlubricatingoil and filters in an environmentally responsible manner, according to federal (EPA) and/or state recommendations. The disposal of wasteoilmaybebestaddressedbythe engine oil supplier, who may accept responsibility for proper disposal of this material as p art of the business o f providing lubricant.

system. Fil ter part numbers are listed in the Specifications section of this guide.

Replace Spin-On Type Oil Filter

Replace spin-on type filters as follows:

1. Place a suitable container under the engine oil pan, remove drain plug and drain the lubricating oil. Replace the dr ain plug and tighten securely.

2. Remove spin-on filters using tool J 29 917, or equivalent, and a 1/2-inch drive socket wrench and extension.

How to Replace the Lube Oil Filters

Filters are an integral part of the lubricating oil system. Proper filter selection and main tenan ce are important to satisfactory engine performance and service life. Filters should be used to m aintain a clean system, not to clean up a contaminated

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Figure 23 Spin-On Oil Filters

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Detroit Diesel Engine 50 Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual