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Detroit Diesel 50 Series, Operator'S Manual

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Detroit Diesel 50 Series Operator'S Manual Download Page 54

DDEC IV ENGINE DRIVING TIPS

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

Idling

The common belief that idling a diesel
engine causes no engine damage is
wrong. Idling produces sulfuric acid,
which breaks down the oil and eats
into bearings, rings, valve stems and
engine surfaces. If you must idle the
engine for cab heat or cooling, the

high idle

function of the cruise control

switches should be used. An idle
speed of 1100 rpm should be enough
to provide cab heat in above 32 F (0

C) ambients.

Winter Fronts

A winter front may be used to improve
cab heating while idling, but it should
never cover more than 3/4 of the
grille while driving. Winter fronts
should only be used when the ambient
temperature remains below 10 F
(-12.2 C).

40

All information subject to change without notice.

(Rev. 01/ 04)

6SE550 0401

Copyright © 2004 DETROIT DIESEL CORPORATION

Summary of Contents for 50 Series

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Page 3: ...ation 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 s...

Page 4: ...t 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 Se...

Page 5: ...N 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 INSPECT...

Page 6: ...7 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 ...

Page 7: ...EGATED 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...

Page 8: ...NGINES 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 ...

Page 9: ...NING 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 RE...

Page 10: ...ADA 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 C...

Page 11: ...ENANCE 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 WARRA...

Page 12: ...NANCE 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 NE...

Page 13: ...IONS 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 FI...

Page 14: ...TABLE OF CONTENTS xii All information subject to change without notice Rev 01 04 6SE550 0401 Copyright 2004 DETROIT DIESEL CORPORATION ...

Page 15: ...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 ...

Page 16: ... 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 ...

Page 17: ...rom 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 ...

Page 18: ...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 th...

Page 19: ...sed 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...

Page 20: ...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 ai...

Page 21: ... 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...

Page 22: ...lipping 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 cool before removing any component Wear protective gloves To avoid injury from contact with rotating parts when an engine is operating with the air inlet piping removed install an air inlet screen shiel...

Page 23: ...d 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 ventila...

Page 24: ...tents 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 we...

Page 25: ... 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 potent...

Page 26: ...ser 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 ...

Page 27: ...ith 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 Fi...

Page 28: ...s 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 ...

Page 29: ...jury 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 ofte...

Page 30: ...ow 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 ...

Page 31: ...ly required if the filter elements are filled with clean fuel when installed and the manifolds are not drained of fuel NOTICE Prolonged use of the starting motor and engine fuel pump to prime the fuel system can result in damage to the starter fuel pump and injectors and may cause erratic engine operation due to the amount of air in the lines and filters from the fuel supply tank to the cylinder h...

Page 32: ...torn worn or glazed and are properly adjusted If lead acid or low maintenance batteries are used make sure battery electrolyte level is normal Check the turbocharger for signs of oil or exhaust leaks Leaks should be corrected before starting the engine Check engine mounting bolts for tightness Bolts should be retightened if necessary Starting the Engine Before starting the engine the first time re...

Page 33: ...e warning lights If everything is OK both lights will go out in approximately five seconds Start the engine after the lights go out If starting a vehicle start the engine with foot off the foot pedal NOTICE If the operating lights stay on consult with DDC Technical Service Operating the engine under these circumstances may result in engine damage Electric Starter Start an engine equipped with an e...

Page 34: ...sters pressure 5 psi or 35 kPa at idle speed If no pressure is indicated within 10 to 15 seconds stop the engine and check the lubrication system The pressure should not drop below 28 psi or 193 kPa at 1800 rpm and normal operating pressure should be higher If oil pressure does not fall within these guidelines it should be checked with a manual gage To avoid injury from hot oil do not operate the ...

Page 35: ...ission in neutral the engine coolant temperature may fall below the normal operating range The incomplete combustion of fuel in a cold engine will cause crankcase oil dilution formation of lacquer or gummy deposits on the valves pistons and rings and rapid accumulation of sludge in the engine When prolonged idling is necessary maintain at least 850 rpm spring summer and 1200 rpm fall winter Stoppi...

Page 36: ...tor and or equipment damage Before attempting to jump start the engine make sure the jumper cables are connected properly positive to positive negative to negative ground and in the proper sequence negative to negative ground last 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 A...

Page 37: ...rnal electronics Therefore there are no mechanical governor spring adjustments for idle and high speed control There is no need for a throttle delay Emission control is performed through the electronic control module ECM The Electronic Foot Pedal Assembly EFPA eliminates the need for any throttle linkage DDEC Features DDEC offers a variety of options designed to warn the operator of an engine malf...

Page 38: ...ption have a system override button or switch to allow engine operation for a short period of time Using the override button so the engine does not shutdown in 30 seconds but operates for an extended period may result in engine damage Idle Shutdown Timer The DDEC engine may also have an optional 1 to 100 minute idle shutdown system The purpose of this system is to conserve fuel by eliminating exce...

Page 39: ...l 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 NOTICE When descending a hill with cruise control OFF do not allow the engine to exceed 2 500 rpm under any conditions Failure to observe thi...

Page 40: ... engine brakes from operating Engine brakes will supply braking power even when in cruise control The electronic control module ECM will control the amount of engine braking with respect to the cruise control set speed The maximum amount of braking low medium high is selected with the dash switches To avoid injury from loss of vehicle control do not activate the Engine Brake system under the follo...

Page 41: ...uced rpm until the battery voltage reaches a point where the ECM will no longer function and the engine shuts down Should the CEL come on for any reason the vehicle can still be operated and the driver can proceed to the required destination This condition should be reported to an authorized Detroit Diesel distributor or dealer NOTICE When the SEL comes on the computer has detected a major malfunc...

Page 42: ... bring engine rpm back to a predetermined speed but will not shut down the engine The engine should not be restarted after it has been shut down by the engine protection system unless the problem has been located and corrected Stop Engine Light The conditions that will cause theSEL to come on are High coolant temperature Loss of coolant High oil temperature Low oil pressure Auxiliary shutdown It i...

Page 43: ...code can also be obtained by the operator A Diagnostic Request switch is provided which when pressed will cause the Check Engine light CEL to flash a code number It will for example flash twice pause flash once pause In other words a code 21 Code 21 indicates the throttle position sensor input voltage is high See Figure 8 NOTE A code 25 two flashes followed by 5 flashes indicates all systems are w...

Page 44: ...e conditions for code flashing are no longer satisfied To Read Codes Use the diagnostic data reader DDR or depress and hold the diagnostic request switch with the ignition ON and the engine AT IDLE or NOT RUNNING Press and hold the switch Active codes will be flashed on the SEL first followed by inactive codes flashed on the CEL The codes will continue to flash and repeat as long as the diagnostic...

Page 45: ...olant Level Sensor Input Voltage High 17 Throttle Plate Position Sensor Input Voltage High 17 Blower Bypass Position Input Voltage High 17 Relative Humidity Sensor Circuit Failed High 18 Throttle Plate Position Sensor Input Voltage Low 18 Blower Bypass Position Input Voltage Low 18 Relative Humidity Sensor Circuit Failed Low 21 Throttle Position Sensor Input Voltage High 22 Throttle Position Senso...

Page 46: ... Pressure Sensor Input Voltage High 34 Turbo Boost Pressure Sensor Input Voltage Low 35 High Range Oil Pressure Sensor Input Voltage High 35 Oil Pressure Sensor Input Voltage Low 36 High Range Oil Pressure Sensor Input Voltage High 36 Oil Pressure Sensor Input Voltage Low 37 High Range Fuel Pressure Sensor Input Voltage High 37 Fuel Restriction or Fuel Pressure Sensor Input Voltage High 38 High Ra...

Page 47: ...uel Pressure Fuel Pressure Turbo Boost Pressure Air Inlet Pressure or Injection Control Pressure High 48 High Range Fuel Pressure Fuel Pressure Air Inlet Pressure or Injection Control Pressure Low 48 TCI Temperature Below Range 48 Turbo Compressor Temperature Out High 48 EGR Differential Pressure or EGR Temperature Low 49 TCI Temperature Above Range 49 Turbo Compressor Out Temperature High 49 Engi...

Page 48: ... Abnormal Period 65 Throttle Plate Position Above Normal Range Below Normal Range Erratic or Not Responding 65 Air Filter Restriction Sensor Voltage High or Low 66 Oil Filter Restriction Sensor Voltage High or Low 66 Engine Knock Level Above Normal Range 66 Engine Knock Level Sensor Input Voltage High Low or Not Responding 67 High Range Coolant Pressure Sensor Input Voltage High 67 High Range Cool...

Page 49: ...oltage High 75 RTC Backup Battery Voltage High 75 Sensor Supply Voltage High 76 Engine Overspeed With Engine Brake 77 Miscellaneous Faults Refer to BASIC TROUBLESHOOT ING 78 Cruise Control Adaptive Cruise Control Fault 81 Oil Level Sensor Input or Crankcase Pressure Sensor Input Voltage High 81 Extended Crankcase Pressure Input Voltage High 81 Injection Control Pressure or Exhaust Temperature Sens...

Page 50: ... Crankcase Pressure High 83 Extended Crankcase Pressure High 83 Exhaust Temperature High 83 EGR Differential Pressure or EGR Temperature High 83 Exhaust Port Temperature 1 16 Sensor Voltage High 84 Oil Level or Crankcase Pressure Low 84 Extended Crankcase Pressure Low 85 Engine Overspeed 85 Engine Overspeed Signal 86 Pump Pressure Sensor or Barometric Pressure Sensor Input Voltage High 87 Pump Pre...

Page 51: ... at half throttle an advantage when driving under slippery conditions If you require wide open throttle engine response either accelerating or just plain pulling hard the throttle EFPA will have to be held to the floor To obtain 100 fueling at any speed the foot pedal will have to be maintained at the fully depressed position Cruise Control For added driver convenience and comfort DDEC IV also fea...

Page 52: ...ith the foot pedal because of the instantaneous and wide open throttle response That s why cruise control use is not suggested during slippery driving conditions Use cruise control after down shifting on a hill to pull the hill Hitting the Resume switch not the Set switch will keep the truck accelerating in the lower gears up to the rated engine speed Cruise control will disengage below 1100 rpm o...

Page 53: ...e brake assistance For an explanation of the engine brake retarder system and recommendations for proper operation refer to section ENGINE BRAKE SYSTEM Shifting Depending on your transmission model the gear split may vary from 500 to 300 rpm The electronic governor provides almost no overrun capability and if the transmission is downshifted too early you will experience a temporary loss of pulling...

Page 54: ...ly deliver more fuel at lower engine speeds than at rated speed Idling The common belief that idling a diesel engine causes no engine damage is wrong Idling produces sulfuric acid which breaks down the oil and eats into bearings rings valve stems and engine surfaces If you must idle the engine for cab heat or cooling the high idle function of the cruise control switches should be used An idle spee...

Page 55: ...activates three 3 brake cylinders supplying approximately 50 of normal engine braking horsepower The High setting activates all six 6 cylinders providing full engine braking horsepower Low Med High Switch The Low setting on this switch activates two 2 brake cylinders yielding about one third engine braking horsepower The Medium activates four 4 cylinders supplying about two thirds engine braking h...

Page 56: ...y from the clutch pedal and throttle The engine brake automatically deactivates itself when you depress the clutch pedal while shifting gears To avoid injury from loss of vehicle control do not activate the Engine Brake system under the following conditions On wet or slippery pavement unless the vehicle is equipped with ABS anti lock braking system and you have had prior experience driving under t...

Page 57: ...and greater slowing power is not required place the progressive braking switch in the LOW position 2 If you find you are still using the service brakes move the switch to a higher position until you do not need to use the service brakes to slow the vehicle down 3 If you are carrying a heavier load and road traction is good move the progressive braking switch to the High position 4 Check your progr...

Page 58: ... a long steep descent first determine if your engine brake system is operating properly by lifting your foot briefly off the throttle You should feel the system activate 2 When descending the grade make sure the progressive braking switch is in the appropriate power position Failure to keep the vehicle within safe control speed limits while descending a grade may result in loss of vehicle control ...

Page 59: ...brakes may be desirable to help keep the trailer stretched out Follow the manufacturer s recommended operating procedure when using your trailer brakes On wet or slippery pavement start with the master switch in the OFF position and use the gear you would normally use under these conditions If the vehicle is maintaining traction place the selective braking switch in the LOW position and turn ON th...

Page 60: ...ptimum protection of the engine from dust and other airborne contaminants service the dry type air cleaners when the maximum allowable air restriction has been reached or annually whichever occurs first Cooling System A radiator thermo modulated fan cooling system is used on Series 50 engines This system has a centrifugal type fresh water pump to circulate coolant within the engine Two full blocki...

Page 61: ...coach engines are listed in Table 4 Table 5 and Table 6 Recommended maintenance intervals for Series 50 construction industrial and stationary engines are listed in Table 7 Table 8 and Table 9 Recommended maintenance intervals for Series 50 fire fighting crash rescue and emergency vehicle engines are listed in Table 10 Table 11 and Table 12 Recommended maintenance intervals for Series 50 generator...

Page 62: ...10 Air Cleaner I 11 Lube Oil Filters R 12 Fuel Filters R 13 Coolant Inhibitor Level I All items are described in PREVENTIVE MAINTENANCE INTERVALS I Inspect service correct or replace as necessary R Replace Table 1 On Highway Truck Motor Coach Urban Bus and Motor Home Daily 7 500 Mile and 15 000 Mile Checks 48 All information subject to change without notice Rev 01 04 6SE550 0401 Copyright 2004 DET...

Page 63: ...lters Replace when lubricating oil is changed 12 Fuel Filters R R R R R R R R R R 13 Coolant Pump Inhibitor Level I I I I I I I I I I 14 Cranking Motor Follow manufacturer s recommendations 15 Air System I I I I I I I I I I 16 Exhaust System I I I I I I I I I I All items are described in PREVENTIVE MAINTENANCE INTERVALS I Inspect service correct or replace as necessary R Replace Table 2 On Highway...

Page 64: ...case Pressure I I 23 Fan Hub I 24 Thermostats Seals I 25 Crankcase Breather I 26 Engine Tune Up I 27 Vibration Damper Replace at major engine overhaul or earlier if dented or leaking All items are described in PREVENTIVE MAINTENANCE INTERVALS I Inspect service correct or replace as necessary R Replace Table 3 On Highway Truck Motor Coach Urban Bus and Motor Home Regular Maintenance Intervals conti...

Page 65: ...mpressor I 10 Air Cleaner I 11 Lube Oil Filters R 12 Fuel Filters R 13 Coolant Inhibitor Level I All items are described in PREVENTIVE MAINTENANCE INTERVALS I Inspect service correct or replace as necessary R Replace Table 4 Transit Coach Pick Up and Delivery Stop and Go and Short Trip Daily 6 000 Mile 7 500 Mile and 15 000 Mile Checks All information subject to change without notice Rev 01 04 51 ...

Page 66: ... 8 Drive Belts I I I I I I I R I I 9 Air Compressor I I I I I I I I I I 11 Lube Oil Filters Replace when lubricating oil is changed 12 Fuel Filters R R R R R R R R R R 13 Coolant Pump Inhibitor Level I I I I I I I I I I 14 Cranking Motor Follow manufacturer s recommendations 15 Air System I I I I I I I I I I All items are described in PREVENTIVE MAINTENANCE INTERVALS I Inspect service correct or r...

Page 67: ...ion Mounts I I 22 Crankcase Pressure I I 23 Fan Hub I 24 Thermostats Seals I 25 Crankcase Breather I 26 Engine Tune Up I 27 Vibration Damper Replace at major engine overhaul or earlier if dented or leaking All items are described in PREVENTIVE MAINTENANCE INTERVALS I Inspect service correct or replace as necessary R Replace Table 6 Transit Coach Pick Up and Delivery Stop and Go and Short Trip Main...

Page 68: ... I 10 Air Cleaner I 11 Lube Oil Filters R 12 Fuel Filters R 13 Coolant Inhibitor Level I 18 Radiator I 20 Battery Charging Alternator I All items are described in PREVENTIVE MAINTENANCE INTERVALS I Inspect service correct or replace as necessary R Replace Table 7 Stationary or Construction Industrial Engine Daily 100 Hour 150 Hour 200 Hour and 300 Hour Checks 54 All information subject to change w...

Page 69: ... Belts I I I I I I I R I I 9 Air Compressor I I I I I I I I I I 11 Lube Oil Filters Replace when lubricating oil is changed 12 Fuel Filters R R R R R R R R R R 13 Coolant Pump Inhibitor Level I I I I I I I I I I 14 Cranking Motor Follow manufacturer s recommendations 15 Air System I I I I I I I I I I All items are described in PREVENTIVE MAINTENANCE INTERVALS I Inspect service correct or replace a...

Page 70: ...ne Transmission Mounts I I 22 Crankcase Pressure I I 23 Fan Hub I 24 Thermostats Seals 25 Crankcase Breather I 26 Engine Tune Up I 27 Vibration Damper Replace at major engine overhaul or earlier if dented or leaking All items are described in PREVENTIVE MAINTENANCE INTERVALS I Inspect service correct or replace as necessary R Replace Table 9 Stationary or Construction Industrial Regular Maintenanc...

Page 71: ...ressor I 10 Air Cleaner I 11 Lube Oil Filter R 12 Fuel Filters R 13 Coolant Inhibitor Level I 18 Radiator I 20 Battery Charging Alternator I All items are described in PREVENTIVE MAINTENANCE INTERVALS I Inspect service correct or replace as necessary R Replace Table 10 Fire Fighting Crash Rescue and Emergency Vehicle Engine Daily 100 Hour and 300 Hour Checks All information subject to change witho...

Page 72: ... Replace when lubricating oil is changed 12 Fuel Filters R R R R R 13 Coolant Pump Inhibitor Level I I I I I 14 Cranking Motor Follow manufacturer s recommendations 15 Air System I I I I I 16 Exhaust System I I I I I All items are described in PREVENTIVE MAINTENANCE INTERVALS I Inspect service correct or replace as necessary R Replace Table 11 Fire Fighting Crash Rescue and Emergency Vehicle Engin...

Page 73: ...Fan Hub I 24 Thermostats Seals 25 Crankcase Breather I 26 Engine Tune Up I 27 Vibration Damper Replace at major engine overhaul or earlier if dented or leaking All items are described in PREVENTIVE MAINTENANCE INTERVALS I Inspect service correct or replace as necessary R Replace Table 12 Fire Fighting Crash Rescue and Emergency Vehicle Engine Regular Maintenance Intervals continued All information...

Page 74: ...oad Test P All items are described in PREVENTIVE MAINTENANCE INTERVALS I Inspect service correct or replace as necessary P Perform Perform these items at time of load test Load test should be at least 35 of the unit s full rated output Refer to generator set manufacturer s instructions Table 13 Generator Set Engine Prime Daily and Standby Monthly Maintenance Intervals 60 All information subject to...

Page 75: ...ters Replace when lubricating oil is changed 12 Fuel Filters Standby Replace every 150 hours or 1 year whichever comes first Prime Replace every 150 hours or 3 months whichever comes first 13 Coolant Pump Inhibitor Level I 14 Cranking Motor Follow manufacturer s recommendations All items are described in PREVENTIVE MAINTENANCE INTERVALS I Inspect service correct or replace as necessary R Replace T...

Page 76: ...ostats Seals R 25 Crankcase Breather I R 26 Engine Tune Up I 27 Vibration Damper Replace at major engine overhaul or earlier if dented or leaking All items are described in PREVENTIVE MAINTENANCE INTERVALS I Inspect service correct or replace as necessary R Replace Table 15 Generator Set Engine Regular Maintenance Intervals continued 62 All information subject to change without notice Rev 01 04 6S...

Page 77: ...tion 13 1 Preparations for Starting the Engine the First Time in the Series 50 Service Manual 6SE50 Preventive maintenance other than the Daily checks should be performed by authorized Detroit Diesel service outlets These outlets have the trained personnel and special tools to properly perform all services Item 1 Lubricating Oil Check the oil level daily with the engine stopped If the engine has j...

Page 78: ...oit Diesel service outlet Fuel or coolant dilution of lubricating oil can result in serious engine damage Before adding lubricating oil refer to How to Select Lubricating Oil in this guide Change lubricating oil and filters at the intervals listed in Table 16 when using fuel with a sulfur content of less than 0 05 mass percent When using fuel with a higher sulfur content refer to When to Change Oi...

Page 79: ...or 1 Year whichever comes first Change both full flow filters when lube oil is changed Table 16 Recommended Engine Oil Drain and Filter Change Intervals Diesel Fuel Sulfur Content Less Than 0 05 Mass Item 2 Fuel and Fuel Tank Keep the fuel tank filled to reduce condensation See Figure 12 Figure 12 Filled Fuel Tank Before adding fuel refer to section How to Select Fuel Oil in the How To section of ...

Page 80: ...tion of the flexible fuel lines Repair or replace the parts as necessary NOTICE Galvanized steel fuel tanks fittings pipes or supply lines should never be used because the fuel reacts chemically with the zinc coating to form powdery flakes that can quickly clog the fuel filters and damage the fuel pump and injectors Item 3 Fuel Lines Flexible Hoses A pre start inspection for leaks and of hosese an...

Page 81: ...ge and or indications of twisted worn crimped brittle cracked or leaking lines Hoses with their outer cover worn through or with damaged metal reinforcements should be considered unfit for further service All hoses in and out of machinery should be replaced during major overhaul and or after a maximum of five 5 years of service NOTE Fire resistant fuel and lube oil hose assemblies do not require a...

Page 82: ...itive 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 SCA s listed in this guide In addition the engine can be equipped with a coolant filter inhibitor system as an installed option or as an after sale item Coolant Drain Interval Detroit Diesel recommends replacing coolant at...

Page 83: ... of OAT organic acid technology coolant and water With proper maintenance coolant can be operated 4 years 600 000 miles 960 000 km or 10 000 operating hours whichever comes first 3 At this time the cooling system must be completely drained and cleaned before refill 1 Proper maintenance involves periodic evaluation using PowerTrac 3 Way Coolant Test Strips and the addition of required SCA as indica...

Page 84: ... insulating exhaust system blankets if used for damage on a daily basis Torn matted crushed oil soaked or otherwise damaged insulation blankets must be replaced immediately Wastegated Turbochargers The turbocharger wastegate actuator is factory calibrated and is not adjustable Check actuator operation at the intervals shown in the maintenance schedule To avoid injury from flying debris when using ...

Page 85: ... early failure Keep the terminal side of the battery clean When necessary wash with a solution of baking soda and water Rinse with fresh water Do not allow the soda solution to enter the cells Inspect the cables clamps and hold down brackets regularly Clean and reapply a light coating of petroleum jelly when needed Have corroded or damaged parts replaced If the engine is to be out of service for m...

Page 86: ...esult in crankshaft breakage A loose belt will slip and may cause damage to accessory components To avoid injury from rotating belts and fans do not remove and discard safety guards Use a belt tension gage such as Kent Moore tool J 23586 B V belt J 23600 B poly V belt J 41251 PowerBand and 12 rib poly V belt or equivalent when tensioning drive belts Tension belts to the values listed in Table 18 F...

Page 87: ...the 50 DN alternator To provide proper running tension for the belt current Series 50 engines use an auto belt tensioner which requires no adjustment See Figure 14 Earlier built Series 50 engines have a manual belt tensioner assembly See Figure 15 Tighten a new PowerBand drive belt to 200 lbs 890 N then run the engine for 10 minutes at 1200 rpm Stop the engine and allow a 10 15 minute cool down pe...

Page 88: ...bolt at the accessory adjusting pivot point is properly tightened as well as the bolt in the adjusting slot In addition check the torque on the alternator and bracket mounting bolts Retighten as required Item 9 Air Compressor All air compressor intake parts should be removed and cleaned at the following intervals On Highway Vehicle Engines 7 500 miles 12 000 km Industrial Engines 150 Hours or 4 50...

Page 89: ...ake restriction and a reduced air supply to the engine This in turn can result in increased fuel consumption inefficient engine operation and reduced engine life Inspect the entire air system for leaks daily Look especially for torn air inlet piping or boots and loose or damaged clamps Have worn or damaged parts repaired or replaced as required Retighten loose connections Item 11 Lubricating Oil F...

Page 90: ...uel pressure is 55 70 psi 375 483 kPa Change the fuel filters whenever the inlet restriction at the pump reaches 12 inches of mercury 41 kPa at normal operating speeds and whenever the fuel pressure at the inlet fitting falls to the minimum fuel pressure of 6 inches of mercury 20 3 kPa NOTE Filter change intervals may be shortened to conform with established preventive maintenance schedules but sh...

Page 91: ...ication of a defective water pump or seal Remove the build up with a mild detergent cleaner and a brush If coolant does not leak from the drain hole under normal conditions do not replace the water pump Coolant Inhibitor Element If the cooling system is protected by a supplemental coolant additive SCA element the coolant must be tested at required intervals and the element replaced if required See...

Page 92: ...ent every 60 000 miles 96 000 km or 2 000 hours whichever comes first NOTICE Do not apply steam or solvent directly to the battery charging alternator starting motor DDEC components sensors or other electrical components as damage to electrical equipment may result Item 18 Radiator The exterior of the radiator core should be inspected every 30 000 miles 48 000 km 12 months or 300 hours industrial ...

Page 93: ...unding an alternator s output wire or terminal which is always hot regardless of whether or not the engine is running and accidentally reversing the battery polarity will result in equipment damage 2 Do not reverse battery connections This can also cause damage 3 Never disconnect the battery while the alternator is operating Disconnecting the battery can result in damage to the battery diodes In a...

Page 94: ...acer ring Authorized Bosch distributors have the parts tools and trained personnel to perform these services General Service Requirements Bosch and Delco Remy Alternators Terminals should be checked for corrosion and loose connections and wiring inspected for damage and frayed insulation Have wiring repaired or replaced as required Check torque on alternator mounting bolts and bracketing every 15 ...

Page 95: ...nally mounted in the engine rocker cover crankcase breather assembly should be removed and the steel mesh pad washed in clean fuel oil every 100 000 to 120 000 miles 160 000 to 192 000 km on vehicle engines or every 1 000 hours of operation on non vehicle engines This cleaning period may be reduced or lengthened according to the severity of service See Figure 19 Figure 19 Internal in Rocker Cover ...

Page 96: ... normal engine operation may over a period of time cause the fluid within the damper to break down and lose its dampening properties For this reason the viscous vibration damper must be replaced at time of normal major engine overhaul regardless of apparent condition Figure 21 Viscous Vibration Damper Engine Application Initial Valve Lash and Injector Height Measurement Adjustment Period Vehicle E...

Page 97: ...e service which Detroit Diesel engines are designed to provide The proper lubricating oil for all Detroit Diesel engines is selected based on SAE viscosity grade and API American Petroleum Institute service designation Only oils licensed to display the API symbol should be used See Figure 22 Figure 22 API Symbol Lubricant Requirements Lubricant requirements are different for the EGR equipped and n...

Page 98: ...re engine damage NOTE Do not use fuel with sulfur content above 0 05 mass percent for Detroit Diesel EGR equipped engines When the use of high sulfur fuel greater than 0 05 mass sulfur in non EGR engines is unavoidable high alkalinity TBN lubricants are recommended High sulfur fuels require modification to oil drain intervals For further information refer to publication Engine Requirements Lubrica...

Page 99: ...te before an oil change depends upon the lubricant and fuel used engine oil consumption and the operating cycle The maximum interval at which the engine may operate before the oil and filters must be changed is listed in Table 20 Engine Application Drain Interval Highway Truck Motor Coach 15 000 Miles 24 000 km City Transit Coach 6 000 Miles 9 600 km 300 Hours or 3 Months whichever comes first Cit...

Page 100: ...pt responsibility for proper disposal of this material as part of the business of providing lubricant How to Replace the Lube Oil Filters Filters are an integral part of the lubricating oil system Proper filter selection and maintenance are important to satisfactory engine performance and service life Filters should be used to maintain a clean system not to clean up a contaminated system Filter pa...

Page 101: ...dd oil as required to bring the level to the Full mark on the dipstick 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...

Page 102: ...ion occurs as the result of improper fuel handling The most common types of contamination are water dirt and microbial growth black slime The formation of varnishes and gums resulting from poor stability or extended storage stale fuel also affects fuel quality The best treatment for contamination is prevention by maintaining a clean storage system and choosing a reputable fuel supplier Supplementa...

Page 103: ...he diesel fuel How to Replace the Fuel Filters Filters are an integral part of the fuel system Proper filter selection and maintenance are important to satisfactory engine operation and service life Filters should be used to maintain a clean system not to clean up a contaminated system Refer to the Specifications section of this guide for proper filter selection Spin on type primary and secondary ...

Page 104: ...ng to federal EPA and or state recommendations 5 If not previously filled fill new replacement filters with clean diesel fuel and coat the gaskets lightly with the fuel oil 6 Thread the new filters onto the adaptor inserts until the gaskets make full contact with the adaptor head and no side movement is evident Tighten filters an additional one half turn by hand or as indicated on the filter Figur...

Page 105: ... to prime the fuel filters Prolonged used of the starting motor and fuel pump to prime the fuel system can result in damage to the starter fuel pump and injectors and cause erratic running of the engine due to the amount of air in the fuel lines and filters Replace Fuel Water Separator Element If an optional primary filter water separator is installed replace the element as follows 1 Shut down the...

Page 106: ...lter head if equipped until the fuel purges at the filter assembly 10 Start the engine and check for leaks Shut down the engine Correct leaks with the engine off Replace Fuel Pro 382 382E Fuel Filter Element The Fuel Pro 382 383E diesel fuel filter system consists of a permanently mounted fuel processor a replaceable filter element and sealing grommet assembly a filter spring as see thru cover and...

Page 107: ...the separate sealing grommet is removed from the center stud before installing the new element 7 Dispose of the used element and grommet in an environmentally responsible manner according to federal EPA and or state recommendations 8 Check to make sure the sealing grommet is included in the base of the replacement filter element then install the element onto the center stud by pushing down and twi...

Page 108: ...engine and tighten the collar again by hand 16 Restart the engine and check for leaks NOTE The filter cover will not fill completely during engine operation It will gradually fill over time and the fuel level will rise as the filter medium becomes clogged The filter element does nor require changing until the fuel level has risen to the top of the element or after one year of service whichever com...

Page 109: ... tool J 5956 or equivalent Authorized Detroit Diesel distributors are properly equipped to perform this service Engines with Fuel Pro Filters Use the following procedure for an engine with Fuel Pro filters 1 Remove the vent cap from the top of the filter by turning counter clockwise Fill the cover full of clean fuel After making sure the O ring seal is installed on the vent plug reinstall the plug...

Page 110: ... or TMC RP 330 for propylene glycol Coolant The fluid mixture circulating in the engine cooling system typically a mixture of 50 water and 50 antifreeze Drop Out Precipitated sludge or deposit formation on cooling system components Fully Formulated Antifreeze Contains all the necessary inhibitors to protect a diesel engine and does not therefore require a pre charge of SCA before its first use Ini...

Page 111: ...t is replaced Coolant Fill Option Product Ethylene Glycol Water Corrosion Inhibitors 1 DDC Power Cool Commercial Equivalent of DDC Power Cool Fully Formulated TMC RP 329 Type A Antifreeze Water Propylene Glycol Water Corrosion Inhibitors 1 DDC Power Cool Plus Ethylene Glycol Water OAT Inhibitors DDC Power Cool Plus Water Only Corrosion Inhibitors 2 Water DDC Power Cool 3000 Water Only OAT Inhibito...

Page 112: ...olant must meet TMC RP 329 Type A requirements Fully formulated propylene glycol based antifreeze or coolant must meet TMC RP 330 Type A requirements Fully formulated antifreeze does not require a dosage of SCA supplemental coolant additive prior to initial use Mixing EG or PG Antifreeze and Water If a concentrated ethylene glycol EG or propylene glycol PG antifreeze is purchased mix the antifreez...

Page 113: ...reezing and boiling temperatures Figure 27 Coolant Temperatures vs IPG Concentration Sea Level Always verify that the freeze point and nitrite concentration of the antifreeze water mixture are correct by using a Power Trac 3 Way Coolant Test Strip If chemical analysis is used elements in the coolant must fall within the limits listed in Table 22 All information subject to change without notice Rev...

Page 114: ...vailable with an OAT Organic Acid Technology corrosion package These coolants require less maintenance over the useful life of the engine OAT coolants maintained as detailed in the Maintenance section of this guide may be operated up to 4 years 600 000 miles 960 000 km or 10 000 operating hours whichever comes first Refer to section Coolant Maintenance The cooling system should either be equipped ...

Page 115: ...volume with water For a list of Power Cool products refer to section SPECIFICATIONS in this guide Traditional SCA Power Cool 3000 can also be used to protect the engine Power Cool 3000 concentration limits are listed in Table 23 NOTE Do not use Power Trac 3 Way Test Strips to test OAT coolant Power Cool 3000 SCA inhibitors should be mixed at 5 by volume with water This is 1 quart per 5 gallons of ...

Page 116: ...sits Coolants Not Recommended The coolants in the following sections are not recommended for use in Detroit Diesel engines All Antifreezes and Coolants Containing Phosphate These coolants should be avoided Drop out overheating and water pump seal failures can result from the use of coolant or inhibitor packages based on phosphate Automotive Type Coolants These coolants generally contain high level...

Page 117: ...oluble oil increases fire deck temperature 6 A 2 50 concentration increases fire deck temperature 15 The use of soluble oil additives may result in engine overheating and or failure Chromate Additives These additives are not approved for use because chromate additives can form chromium hydroxide commonly called green slime This in turn can result in engine damage due to poor heat transfer Cooling ...

Page 118: ...gine operation SCAs replenish the protection for cooling system components The coolant must be maintained with the proper concentration of SCA Detroit Diesel Power Cool maintenance SCAs are recommended The proper application of SCA will provide pH control Restored inhibitor levels to prevent corrosion Water softening to deter formation of mineral deposits Cavitation protection to protect wet sleev...

Page 119: ... partially drained and filled with a 50 50 mix of water and EG or PG In this case the EG or PG should contain no inhibitors and should conform to ASTM D4985 This will dilute the over concentrated inhibitors NOTE In non OAT systems nitrite concentration of 5000 PPM or higher on a Series 50 engine suggests problematic additive over concentration This condition must be corrected by immediate draining...

Page 120: ...OAT Inhibitor A 600 000 Miles 960 000 km B 4 Years or 10 000 Hours Drain and clean system Replace with new coolant A 20 000 Miles 32 000 km or 3 Months B 500 Hours or 3 Months Test nitrite concentration with test strip Add SCA or dilute coolant as needed Water Only SCA Inhibitor A 300 000 Miles 480 000 km B 2 Years or 4 000 Hours Drain and clean system Replace with new coolant A 300 000 Miles 480 ...

Page 121: ...e the test strips as follows 1 Dip the strip into coolant for one second Remove and shake briskly to eliminate excess fluid 2 Immediately compare the pad end glycol to the color chart on the container 3 Sixty seconds one minute after dipping compare the nitrite pad to the color chart 4 Color change of the additive indicator middle pad indicates the presence of inhibitor that is not approved by Det...

Page 122: ... flow The deposit called dropout takes the color of the coolant when wet but appears as a white or gray powder when dry It can pick up solid particles in the coolant and become gritty causing excessive wear of water pump seals and other cooling system components To avoid injury when using caustic cleaning agents follow the chemical manufacturers usage disposal and safety instructions The wet gel c...

Page 123: ...o not use traditional SCAs in OAT coolant and do not use OAT extender in traditional coolant OAT Coolant Drain Interval A properly maintained OAT inhibited coolant will last 600 000 miles 960 000 km four 4 years or 10 000 operating hours whichever comes first At this time the coolant should be drained and the cooling system should be thoroughly cleaned flushed and filled with new properly inhibite...

Page 124: ...e Cleaner is used for light deposits Power Cool Dry Chemical Cleaner Conditioner is used for heavy deposits or scale Summary of Coolant Recommendations 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 ru...

Page 125: ...phosphate free coolant consisting of a 50 50 mix of antifreeze and water per TMC RP 329 Type A EG or TMC RP 330 Type A PG specifications can be operated for the life of the engine until overhaul The proper maintenance involves periodic evaluation using Power Trac 3 Way Coolant Test Strips and the addition of SCA as needed indicated by the strip test To verify coolant acceptability submit a sample ...

Page 126: ...le 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 1 With the engine cool drain the previous solution from the engine and radiator Dispose of the coolant in an environmentally friendly manner according to state and or federal EPA recommendations 2 Refill the cooling system...

Page 127: ...ine overheats and the coolant level is satisfactory the cooling system may require cleaning with a descaling solvent and backflushing Authorized Detroit Diesel service outlets are properly equipped to perform these services In addition to the cleaning procedure other components of the cooling system should be checked periodically to keep the engine operating at peak efficiency Hoses Cooling system...

Page 128: ...restriction indicator which aids in determining the servicing interval Cleaning and or reusing dry paper type air cleaner elements is not recommended unless the cleaning method used removes clogging without damaging the element Inspection and cleaning of elements must be done in accordance with the air cleaner manufacturer s recommendations if any 114 All information subject to change without noti...

Page 129: ...Smoke Blue Smoke White Smoke Damaged or dirty air cleaner X Improper grade of fuel X Excessive exhaust back pressure X Misfiring cylinders X Lubricating oil not burned in cylinder being burned in exhaust manifold or turbocharger X Faulty injector timing X Faulty oil control rings X Excessive installation angle X Excessive oil in crankcase X High ambient temperature X Thin air high altitude X Cetan...

Page 130: ...or missing X Insufficient Fuel Supply Air in fuel X Out of fuel X Loose fuel connections X Cracked fuel lines X Obstructed fuel filters lines X Faulty fuel pump X Faulty injector operation X Restricted fuel fitting missing X DDEC Malfunction X Installation operation of fuel check valve or shutoff valve X Low Compression Worn intake and exhaust valves X Worn piston rings liners X Leaking cylinder h...

Page 131: ...pression X X DDEC malfunction X X High air inlet restriction exhaust back pressure X Engine application X High air inlet temperature X High altitude operation X Incorrect engine gear train timing X Low coolant temperature X Oil picked up by inlet airstream X Faulty injector operation X Incorrect injector height setting X X All information subject to change without notice Rev 01 04 117 6SE550 0401 ...

Page 132: ...gle X Crankcase overfilled X Oil in air tanks air compressor malfunction X Plugged crankcase breather X Oil level low X Improper engine oil viscosity fuel in the oil X Faulty oil pressure regulator or relief valve X Worn crankshaft camshaft or connecting rod bearings X Missing cup plugs in rocker arm shafts X Air leaks in oil pump suction side X Worn or damaged oil pump X Faulty oil pressure gage ...

Page 133: ...ive belts X Faulty temperature controlled fan X Obstruction in front of radiator or intercooler X Low coolant level X Damaged hoses X Faulty thermostats X Faulty water pump X Faulty radiator pressure cap X Air in coolant X Thermostats not fully closed X Leakage around thermostat seals X Faulty temperature controlled fan X All information subject to change without notice Rev 01 04 119 6SE550 0401 C...

Page 134: ...orage area Temporary Storage 30 Days or Less To protect the engine for a temporary period of time 30 days or less follow this procedure 1 With the engine at ambient temperature and cool to the touch drain engine crankcase oil into a suitable container Dispose of the oil in an environmentally friendly manner according to state and or federal EPA recommendations 2 Fill the crankcase to the proper le...

Page 135: ... oil lubricating oil and transmission oil levels Extended Storage More than 30 Days To prepare an engine for extended storage more than 30 days follow this procedure 1 Drain the cooling system and flush with clean soft water Refill with clean soft water and add a rust inhibitor to the cooling system 2 Circulate the coolant by operating the engine until normal operating temperature is reached 3 Sto...

Page 136: ...all on the engine 8 Operate the engine for five 5 minutes to circulate the clean fuel throughout the engine Be sure the engine fuel system is full 9 Stop the engine and allow to cool Then disconnect the fuel return line and the inlet line at the primary filter and securely plug both to retain the fuel in the engine 10 Transmission Follow the manufacturer s recommendations for prolonged storage 11 ...

Page 137: ...if necessary and fully charge the battery Store the battery in a cool never below 0 C or 32 F dry place Keep the battery fully charged and check the level and specific gravity of the electrolyte regularly 17 Insert heavy paper strips between the pulleys and drive belts to prevent sticking 18 Seal all engine openings including the exhaust outlet with moisture resistant tape Use cardboard plywood or...

Page 138: ...plugs from the inlet and outlet fuel lines and reconnect the lines to their proper positions 3 Wash the exterior of the engine with fuel oil to remove the rust preventive Do not wash electrical components 4 Remove the rust preventive from the flywheel Flush any soluble oil rust inhibitor if used in the cooling system 5 Remove the paper strips from between the pulleys and drive belts 6 Fill the cra...

Page 139: ...Preparations for Starting the Engine the First Time 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 contro...

Page 140: ...ou Description Form No Series 50 Engine Service Manual 6SE50 DDEC III IV Single ECM Troubleshooting Guide 6SE497 U S and Canada Distributor Dealer Directory 6SE280 International Distributor Dealer Directory 6SE281 Series 50 60 Service Outlet Directory 6SA336 Engine Requirements Lubricating Oil Fuel and Filters 7SE270 Coolant Requirements for Engine Cooling Systems 7SE298 Technician s Guide Used Lu...

Page 141: ... and goodwill of the owners of Detroit Diesel engines are of primary concern to Detroit Diesel Corporation and its distributor dealer organizations All information subject to change without notice Rev 01 04 127 6SE550 0401 Copyright 2004 DETROIT DIESEL CORPORATION ...

Page 142: ...tomer Assurance Center Offices Construction Industrial and Mining Sales BX7 13400 Outer Drive West Detroit MI 48239 4001 Phone 313 592 5608 Fax 313 592 5625 Marine Sales BX6 13400 Outer Drive West Detroit MI 48239 4001 Phone 313 592 5124 Fax 313 592 5137 Powergen and Oil Field Sales BX11 13400 Outer Drive West Detroit MI 48239 4001 Phone 313 592 5708 Fax 313 592 5158 Government Sales BX11 13400 Ou...

Page 143: ...SIA PACIFIC REGION Off Highway Singapore No 1 Benoi Place Singapore 629923 Phone 65 686 15922 Fax 65 686 11550 PACIFIC REGION Off Highway Australia 11 13 Garling Road Kings Park NSW 2148 Beaumaris Victoria 3193 Australia Phone 612 8822 7000 Fax 612 8822 7083 AUSTRALIAN REGION On Highway P O Box 1472 Canterbury Victoria 3124 Australia Phone 61 39 836 0775 Fax 61 39 836 0770 MEXICO On Off Highway De...

Page 144: ...Check diagnostic codes refer to the Diagnostic Code List section in this guide If you call have the following information available Engine serial number Truck bus or equipment make and model Odometer mileage kilometers or hourmeter hours Truck bus or equipment owner company name Working with DDC Service Outlets As the owner of a Detroit Diesel product you have a complete network of over 2 000 Detr...

Page 145: ... with a dealer explain the matter to a management member of the distributorship with whom the dealer has a service agreement Step Two When it appears that your problem cannot be readily resolved at the distributor level without additional assistance contact the Detroit Diesel Regional Product Support Manager or Operations Manager responsible for your local distributor You will be assisted by a mem...

Page 146: ...7 FAX 313 592 7888 When contacting the regional or home office please keep in mind that ultimately your problem will likely be resolved at the distributorship or dealership utilizing their facilities equipment and personnel Therefore it is suggested that you follow the above steps in sequence when experiencing a problem 132 All information subject to change without notice Rev 01 04 6SE550 0401 Cop...

Page 147: ...Repairs To obtain warranty repairs you must request the needed repairs within the WARRANTY PERIOD from an authorized DDC service outlet Only new genuine parts or remanufactured parts or components supplied or approved by DDC will be used DDC may at its discretion replace rather than repair components A reasonable time must be allowed to perform the warranty repair after taking the engine to the au...

Page 148: ...bs Vehicle Systems braking devices and 50DN or T1 alternators if installed Cylinder Block Head Crankshaft Camshaft Main Bearing Bolts Flywheel Housing Connecting Rod Assemblies Oil Cooler Housing Water Pump Housing and Air Inlet Housing Table 28 Warranty Period Chart On Highway Vehicle Applications Like Replacement Engine Engine s supplied by DDC as a replacement for an engine still under warranty...

Page 149: ...ion is not covered by this warranty Maintenance DDC is not responsible for the cost of maintenance or repairs due to the lack of performance of required maintenance services as recommended by DDC or the failure to use fuel oil lubricants and coolant meeting DDC recommended specifications Performance of the required maintenance and use of proper fuel oil lubricants and coolant are the responsibilit...

Page 150: ...OIT DIESEL CORPORATION MAKES NO OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE DETROIT DIESEL CORPORATION SHALL NOT BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES AS DESCRIBED ABOVE Some states do not allow the limitation of how long this warranty may last or the limitation or exclusion of incidental or consequential...

Page 151: ... from defects in material and workmanship Repairs To obtain warranty repairs you must request the needed repairs within the WARRANTY PERIOD from an authorized DDC service outlet Only new genuine parts or remanufactured parts or components supplied or approved by DDC will be used DDC may at its discretion replace rather than repair components A reasonable time must be allowed to perform the warrant...

Page 152: ...e Systems braking devices 50DN or T1 alternators if so equipped Cylinder Block Head Crankshaft Camshaft Main Bearing Bolts Flywheel Housing Connecting Rod Assemblies Oil Cooler Housing Water Pump Housing and Air Inlet Housing Table 29 Warranty Period Chart Urban Bus Motor Coach and Motor Home Applications Service Supplies The cost of service supplies such as coolant oil and filters which are not r...

Page 153: ...maintenance or repairs due to the lack of performance of required maintenance services or the failure to use fuel oil lubricants and coolant meeting DDC recommended specifications Performance of the required maintenance and use of proper fuel oil lubricants and coolant are the responsibility of the owner Refer to the MAINTENANCE section in this guide for details Incidental or Consequential Damage ...

Page 154: ...NTABILITY OR FITNESS FOR A PARTICULAR PURPOSE DETROIT DIESEL CORPORATION SHALL NOT BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES AS DESCRIBED ABOVE Some states do not allow the limitation of how long this warranty may last or the limitation or exclusion of incidental or consequential damages so the above may not apply to you This warranty gives you specific legal rights and you may also ha...

Page 155: ...ed repairs within the WARRANTY PERIOD from an authorized DDC service outlet Only new genuine parts or remanufactured parts or components supplied or approved by DDC will be used DDC may at its discretion replace rather than repair components A reasonable time must be allowed to perform the warranty repair after taking the engine to the authorized service outlet Repairs will be performed during nor...

Page 156: ...Chart Construction Industrial Applications Engine Removal and Reinstallation Construction Industrial Applications Reasonable labor costs for Engine removal and reinstallation when necessary to make a warranty repair are covered by this warranty during the first twelve 12 months of service Mechanic s Travel Expenses DDC will pay reasonable travel expenses for the repairing mechanic to travel to and...

Page 157: ...tems Such items are covered by the equipment manufacturer Maintenance DDC is not responsible for the cost of maintenance or repairs due to lack of performance of required maintenance services as recommended by DDC or the failure to use fuel oil lubricants and coolant meeting DDC recommended specifications Performance of the required maintenance and use of proper fuel oil lubricants and coolant are...

Page 158: ...ERY AND STAND BY PUMP APPLICATIONS DETROIT DIESEL CORPORATION MAKES NO OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE DETROIT DIESEL CORPORATION SHALL NOT BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES AS DESCRIBED ABOVE Some states do not allow the limitation of how long this warranty may last or the limitation or e...

Page 159: ...n material and workmanship Warranty Period Warranty Limitations Whichever Occurs First Repair Charges to Be Paid by Owner Item Months Engine Hours Parts Labor Engine Up to 36 Up to 2 500 No Charge No Charge Accessories Up to 12 Up to 2 000 No Charge No Charge Table 31 Warranty Period Chart Agricultural Machinery Repairs To obtain warranty repairs you must request the needed repairs within the WARR...

Page 160: ...Engine removal and reinstallation when necessary to make a warranty repair are not covered by this warranty Non DDC Supplied Manufactured Components DDC is not responsible for repair of components and or assemblies which are manufactured or supplied by another manufacturer such as intake and exhaust systems Such items are covered by warranties issued by the manufacturer or supplier Maintenance DDC...

Page 161: ...HIS LIMITED WARRANTY IS THE ONLY WARRANTY APPLICABLE TO THE ENGINE AND ACCESSORIES AS USED IN AGRICULTURAL MACHINERY APPLICATIONS DETROIT DIESEL CORPORATION MAKES NO OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE DETROIT DIESEL CORPORATION SHALL NOT BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES AS DESCRIBED ABOVE So...

Page 162: ...epairs you must request the needed repairs within the WARRANTY PERIOD from an authorized DDC service outlet Only new genuine parts or remanufactured parts or components supplied or approved by DDC will be used DDC may at its discretion replace rather than repair components A reasonable time must be allowed to perform the warranty repair after taking the engine to the authorized service outlet Repa...

Page 163: ... filters which are not reusable due to warranted repairs is covered by this warranty Mechanic s Travel Expenses DDC will pay reasonable travel expenses for the repairing mechanic to travel to and from the repair site This Warranty Does Not Cover Repairs Due to Accidents Misuse Storage Damage Negligence or Certain Modifications Repairs due to an accident misuse misapplication storage damage neglige...

Page 164: ... loss including without limitation communication expenses meals lodging loss of use of the Engine loss of time inconvenience overtime transportation of the Engine or any other cost or expense resulting from a defect covered by this warranty Other Limitations THIS LIMITED WARRANTY IS THE ONLY WARRANTY APPLICABLE TO THE ENGINE AND ACCESSORIES AS USED IN PRIME POWER GENERATORS DETROIT DIESEL CORPORAT...

Page 165: ... the WARRANTY PERIOD resulting from defects in material or workmanship Repairs To obtain warranty repairs you must request the needed repairs within the WARRANTY PERIOD from an authorized DDC service outlet Only new genuine parts or remanufactured parts or components supplied or approved by DDC will be used DDC may at its discretion replace rather than repair components A reasonable time must be a...

Page 166: ...travel expenses for the repairing mechanic to travel to and from the repair site This Warranty Does Not Cover Repairs Due to Accidents Misuse Storage Damage Negligence or Certain Modifications Repairs due to an accident misuse misapplication storage damage negligence or modification exceeding DDC specifications are not covered by this warranty Engine Removal and Reinstallation Reasonable labor cos...

Page 167: ...nsportation of the Engine or any other cost or expense resulting from a defect covered by this warranty Other Limitations THIS LIMITED WARRANTY IS THE ONLY WARRANTY APPLICABLE TO THE ENGINE AS USED IN STAND BY GENERATORS DETROIT DIESEL CORPORATION MAKES NO OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE DETROIT DIESEL CORPOR...

Page 168: ...emax extended service element optional Optional May be used in place of but not together with the primary filter Table 34 Fuel Filters Series 50 Regualr Service Filter Type Detroit Diesel Part No Full Flow 23530573 Full Flow High Capacity DELF3998 Table 35 Lubricating Oil Filters Oil Pan All Series 50 truck oil pans front sump and rear sump require the same amount of engine oil Oil Pan Capacity 19...

Page 169: ...23529295 330 Gallon Tote Concentrated 23512140 Bulk Delivery 1 000 Gallon Min 23528203 1 Gallon Jug 6 Per Case 23518918 55 Gallon Drum 23528544 330 Gallon Tote Pre Blended 50 50 23513503 Bulk Delivery 1 000 Gallon Min Table 36 Power Cool Fully Formulated IEG Coolant Power Cool Latin American Coolant Coolant Type Part Number Description 23524923 55 Gallon Drum Pre Blended 67 33 23524924 Bulk Delive...

Page 170: ... 38 Power Cool 2000 Supplemental Coolant Additive Power Cool 3000 Supplemental Coolant Additive Coolant Type Part Number Description 23507854 Pint Bottle 12 Per Case 23507855 One Half Gallon Jug 6 Per Case 23507856 5 Gallon Pail For Power Cool IEG Coolant 23507857 55 Gallon Drum Table 39 Power Cool 3000 Supplemental Coolant Additive 156 All information subject to change without notice Rev 01 04 6S...

Page 171: ...For Power Cool IEG Coolant 23508428 53 Ounce 13 Pint Equivalent Table 40 Power Cool 3000 Supplemental Additive Coolant Filters Power Cool Supplemental Additive Need Release Filters Coolant Type Part Number Description 23516488 For 0 8 Gallon Systems For Power Cool IEG Coolant 23516489 For 8 20 Gallon Systems Table 41 Power Cool SUPPLEMENTAL ADDITIVE NEED RELEASE COOLANT FILTERS All information sub...

Page 172: ...um Pre Blended 50 50 23519399 Bulk Delivery 1 000 Gallon Min Table 42 Power Cool Plus Extended Life OAT Coolant Power Cool Plus Extender For Use With Power Cool Plus OAT Coolant Coolant Type Part Number Description For Power Cool Plus 23519400 Quart Bottle 6 Per Case Table 43 Power Cool Plus Extender for Use with Power Cool Plus OAT Coolant 158 All information subject to change without notice Rev ...

Page 173: ...lus 6000 OAT Inhibitor for Water Only Systems Power Cool Cooling System Cleaners Coolant Type Part Number Description 200164 On Half Gallon Jug 6 Per Case 200105 5 Gallon Pail On Line Cleaner 200155 55 Gallon Drum Twin Pack 201549 Twin Pack 2 Per Case Table 45 Power Cool Cooling System Cleaners All information subject to change without notice Rev 01 04 159 6SE550 0401 Copyright 2004 DETROIT DIESEL...

Page 174: ...olant Test Strips Bottle of 50 Indicates Nitrite Molybdate Glycol Levels 23522774 3 Way Coolant Test Strips Bottle of 10 Complete IEG IPG Coolant Analysis 23516921 Coolant Analysis Bottle Carton of 6 Organic Coolant Analysis 23523398 Laboratory Coolant Analysis Bottle Carton of 6 Table 46 Power Trac Coolant Testing and Analysis Products 160 All information subject to change without notice Rev 01 0...

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