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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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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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.

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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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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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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.

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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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