Detroit Diesel Engine 50 Service Manual

Name: Detroit Diesel Engine 50
Brand: Detroit Diesel Engine
SKU: 4537391
Rating: 4.3 (3 reviews)

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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® engine used in vehicle, stationary, construction/industrial, agricultural, generator set or fire fighting apparatus applications. Maintenance instructions cover 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 contents 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.

Throughout this guide CAUTIONS 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.

Whenever possible, it will benefit you to rely on an authorized 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 for information on the latest revision. The right is reserved to make changes at any time without obligation.

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

NOTICE:

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 SCAs listed in this engine operator'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 from authorized Detroit Diesel service outlets.

Keep this Operator's Guide with the engine installation at all times. It contains important

operating, maintenance, and safety instructions.

Trademark Information

Detroit Diesel®, DDC®, DDEC®, Series 50®, Optimized Idle®, ProManager®, reliabilt®, Power Trac®, Power Cool®, and Power Guard® are registered trademarks of Detroit Diesel Corporation. Delco Remy® is a registered trademark of Delco Remy America, Inc. Bosch® is a registered trademark of Robert Bosch Company N.A. Fuel Pro®, Sea Pro® and Mega Filter® are registered trademarks of Davco Manufacturing, L.L.C. The PowerBand® is a registered trademark of Gates Rubber Company. Tectyl® is a registered 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 trademarks used are the property of their respective owners.

ii	All information subject to change without notice. (Rev. 01/ 04)
6SE550	0401 Copyright © 2004 DETROIT DIESEL 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 ..............................................................................	10
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 STARTING 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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TABLE OF CONTENTS
STOPPING THE ENGINE ................................................................		21
EMERGENCY JUMP STARTING ....................................................		22
DDEC IV SYSTEM ...............................................................................		23
DDEC SYSTEM ..............................................................................		23
ENGINE PROTECTION ...............................................................		24
IDLE SHUTDOWN TIMER ...........................................................		24
CRUISE CONTROL .....................................................................		24
ENGINE BRAKES .......................................................................		26
DATA RECORDING CAPABILITY ................................................		27
DDEC IV OPERATION .....................................................................		27
IMMEDIATE SPEED REDUCTION 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 FRONTS .......................................................................		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 MAINTENANCE INTERVALS ...................................	63
ITEM 1 – LUBRICATING OIL .......................................................	63
ITEM 2 – FUEL AND FUEL TANK ...............................................	65
ITEM 3 – FUEL LINES, FLEXIBLE HOSES ................................	66
LEAKS .....................................................................................	66
HOSES AND FITTINGS ..........................................................	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
WASTEGATED TURBOCHARGERS ......................................	70
ITEM 6 – BATTERY .....................................................................	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 ..........................................	77
ITEM 14 – CRANKING MOTOR ..................................................	78
ITEM 15 – AIR SYSTEM .............................................................	78
ITEM 16 – EXHAUST SYSTEM ...................................................	78
ITEM 17 – ENGINE (STEAM CLEAN) .........................................	78
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TABLE OF CONTENTS
ITEM 18 – RADIATOR .................................................................		78
ITEM 19 – OIL PRESSURE .........................................................		79
ITEM 20 – BATTERY-CHARGING ALTERNATOR ......................		79
BOSCH® T1 ALTERNATOR SERVICE REQUIREMENTS ......		80
GENERAL SERVICE REQUIREMENTS – BOSCH® AND
DELCO REMY® ALTERNATORS ............................................		80
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 BUILT PRIOR ..........................................TO 1998		83
COLD WEATHER STARTING ......................................................		84
SYNTHETIC OILS .......................................................................		84
THE USE OF SUPPLEMENTAL ..............................ADDITIVES		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 LUBRICATING .......................................................OIL		89
GASOLINE .............................................................................		89
HOW TO REPLACE THE .......................................FUEL FILTERS		89
REPLACE SPIN-ON ...................................FILTER ELEMENTS		89
REPLACE FUEL/WATER ....................SEPARATOR ELEMENT		91
REPLACE FUEL PRO ..................................FILTER ELEMENT		92
ENGINE OUT OF FUEL .............................— HOW TO RESTART		94
ENGINES WITH SPIN ...........................................-ON FILTERS		95
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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 ANTIFREEZE .....................................	96
INITIAL–FILL COOLANT .........................................................	96
OAT ..........................................................................................	96
SCA .........................................................................................	96
APPROVED COOLANTS ............................................................	97
EG OR PG & WATER + SCA INHIBITOR ...............................	98
MIXING EG OR PG ANTIFREEZE 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 ANTIFREEZE ......................	103
GLYCOL-BASED COOLANTS FORMULATED FOR HVAC ....	103
ADDITIVES NOT RECOMMENDED ...........................................	103
SOLUBLE OIL ADDITIVES .....................................................	103
CHROMATE ADDITIVES ........................................................	103
COOLANT MAINTENANCE ........................................................	103
COOLANT INHIBITOR TEST INTERVALS ............................	103
SUPPLEMENTAL ADDITIVES ................................................	104
COOLANT MAINTENANCE INTERVALS ...............................	105
SCA TEST PROCEDURES .........................................................	107
NEED-RELEASE FILTERS (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
All information subject to change without notice. (Rev. 01/ 04)	vii
6SE550 0401 Copyright © 2004 DETROIT DIESEL CORPORATION

TABLE OF CONTENTS
POWER COOL SCAS .............................................................		109
POWER COOL COOLANT FILTER ELEMENTS ....................		110
POWER COOL CLEANERS ...................................................		110
SUMMARY OF COOLANT RECOMMENDATIONS ....................		110
HOW TO DRAIN AND FLUSH THE COOLING SYSTEM ...............		112
WHEN TO SERVICE THE 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 REMOVAL 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 .........................		135
OTHER LIMITATIONS ..................................................................		136
viii	All information subject to change without notice. (Rev. 01/ 04)
6SE550	0401 Copyright © 2004 DETROIT DIESEL CORPORATION

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 REMOVAL 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 .........................	139
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 – AGRICULTURAL
MACHINERY AND STAND-BY PUMP APPLICATIONS ..............	143
All information subject to change without notice. (Rev. 01/ 04)	ix
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TABLE OF CONTENTS
NON-DDC SUPPLIED/MANUFACTURED COMPONENTS .......		143
MAINTENANCE ...........................................................................		143
INCIDENTAL OR CONSEQUENTIAL DAMAGE .........................		143
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 REMOVAL AND REINSTALLATION ..............................		146
NON-DDC SUPPLIED/MANUFACTURED COMPONENTS .......		146
MAINTENANCE ...........................................................................		146
INCIDENTAL OR CONSEQUENTIAL DAMAGE .........................		147
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 REMOVAL AND REINSTALLATION ..............................		149
NON-DDC SUPPLIED/MANUFACTURED COMPONENTS .......		150
MAINTENANCE ...........................................................................		150
INCIDENTAL OR CONSEQUENTIAL DAMAGE .........................		150
OTHER LIMITATIONS ..................................................................		150
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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 REMOVAL AND REINSTALLATION ..............................	152
NON-DDC SUPPLIED/MANUFACTURED COMPONENTS .......	152
MAINTENANCE ...........................................................................	153
INCIDENTAL OR CONSEQUENTIAL DAMAGE .........................	153
OTHER LIMITATIONS ..................................................................	153
SPECIFICATIONS ................................................................................	154
FUEL AND LUBRICATING OIL FILTER REQUIREMENTS .............	154
OIL PAN .......................................................................................	154
OIL PAN CAPACITY ................................................................	154
TOTAL OIL CAPACITY OF THE ENGINE ...............................	154
POWER COOL ENGINE PRODUCTS .............................................	155
FULLY FORMULATED IEG COOLANT .......................................	155
LATIN AMERICAN COOLANT .....................................................	155
2000 SUPPLEMENTAL COOLANT ADDITIVE ...........................	156
3000 SUPPLEMENTAL 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-ONLY SYSTEMS .....	159
COOLING SYSTEM CLEANERS ................................................	159
COOLANT TESTING AND ANALYSIS PRODUCTS ...................	160

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

TABLE OF CONTENTS

xii	All information subject to change without notice. (Rev. 01/ 04)
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SERIES 50 OPERATOR'S GUIDE

INTRODUCTION

This guide is intended for use by the operator of a Detroit Diesel Series 50® engine used in the following 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 aiding engine manufacturers in meeting the stringent emission requirements of the U.S. Environmental Protection Agency (U.S. EPA) 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 the manufacturer's warranty. Many of these maintenance procedures also ensure that the engine continues to comply with applicable emissions standards. The U.S. EPA 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 outlet or the operator or owner. The owner is responsible for determining the suitability of components to maintain 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 electronic controls is the electronic unit injector (EUI). The proper 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.

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

INTRODUCTION

Detroit Diesel cautions 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 Diesel 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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SERIES 50 OPERATOR'S GUIDE

CAUTION SUMMARY

The following cautions must be observed by the operator of the vehicle or equipment in which this engine is installed and/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 following cautions when operating the engine.

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.

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.

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.

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

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 Brake 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 constant 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.

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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 of flammable fluids as they occur. Failure to eliminate leaks could result in fire.

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

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 while the engine is at operating temperature. Remove the cap slowly to relieve pressure. Wear adequate protective clothing (face shield or safety goggles, rubber gloves, apron, and boots).

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

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

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 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, keep the engine area well ventilated during operation.

Lubricating oil is relatively harmless at ambient temperatures.

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.

6	All information subject to change without notice. (Rev. 01/ 04)
6SE550	0401 Copyright © 2004 DETROIT DIESEL CORPORATION

SERIES 50 OPERATOR'S GUIDE

Electrical System

Observe the following 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.

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.

Apply baking soda or lime to help neutralize the acid.

Flush your eyes with water.

Get medical attention immediately.

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

CAUTION SUMMARY

Cooling System

Observe the following cautions when servicing the cooling system.

Air Intake System

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

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

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

8	All information subject to change without notice. (Rev. 01/ 04)
6SE550	0401 Copyright © 2004 DETROIT DIESEL CORPORATION

SERIES 50 OPERATOR'S GUIDE

Fuel System

Observe the following 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 of flammable fluids as they occur. Failure to eliminate leaks could result in fire.

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 if a fuel leak is detected.

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, keep the engine area well ventilated during operation.

Diesel fuel is relatively harmless at ambient temperatures.

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

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

CAUTION SUMMARY

Starting Aids

Observe the following 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 cool dry area. Do not incinerate, puncture or attempt to remove cores from cylinders.

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

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.

10	All information subject to change without notice. (Rev. 01/ 04)
6SE550	0401 Copyright © 2004 DETROIT DIESEL CORPORATION

SERIES 50 OPERATOR'S GUIDE

Compressed Air

Observe the following 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 kPa) air pressure.

Lubricating Oil and Filters

Observe the following cautions when replacing the engine lubricating oil and filters.

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

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 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, keep the engine area well ventilated during operation.

Lubricating oil is relatively harmless at ambient temperatures.

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

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 below the intake manifold and above

the cast-in Detroit Diesel logo (as viewed from the flywheel end). See Figure 1

Figure 1 Location of Engine Serial and Model Numbers

12	All information subject to change without notice. (Rev. 01/ 04)
6SE550	0401 Copyright © 2004 DETROIT DIESEL CORPORATION

SERIES 50 OPERATOR'S GUIDE

Option Labels

Computerized engine 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 timing, valve lash, maximum no-load rpm, etc.).

With any order for parts, the engine model and serial number must 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-offs generally carry their own name plates. The model and serial number information on these plates is useful when ordering parts for these assemblies.

Figure 2 Typical Option Labels

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

ENGINE MODEL AND SERIAL NUMBER DESIGNATION

Certification Labels

If required, a certification label is attached to the valve rocker cover. This label certifies 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

14	All information subject to change without notice. (Rev. 01/ 04)
6SE550	0401 Copyright © 2004 DETROIT DIESEL CORPORATION

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 all 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.

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.

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

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 bottom of the filler neck to allow for

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

OPERATING INSTRUCTIONS FOR A FIRST TIME START

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

3.Entrapped air must be purged after filling the cooling 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 Checks

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 recommendation,

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)
6SE550	0401 Copyright © 2004 DETROIT DIESEL CORPORATION

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