Detroit Diesel Engine Series 50 - Operators and Maintenance Manual

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DETROIT DIESEL ENGINE SERIES 50 - OPERATORS AND MAINTENANCE MANUAL

- English Operators and Maintenance Manual, to engines Detroit Diesel Engine Series 50.

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
- 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
- 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
- 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
- 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
- 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
- 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
- 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
- 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