DDC-SVC-MAN-0058
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.
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.
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.
All information subject to change without notice. (Rev. 01/04)
DDC-SVC-MAN-0058
Copyright © 2004 DETROIT DIESEL CORPORATION
i
Trademark Information
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.
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.
Keep this Operator's Guide
with the engine installation at
all times. It contains important
operating, maintenance, and safety
instructions.
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DDC-SVC-MAN-0058
All information subject to change without notice. (Rev. 01/04)
Copyright © 2004 DETROIT DIESEL CORPORATION
SERIES 50 OPERATOR'S GUIDE
TABLE OF CONTENTS
INTRODUCTION ..................................................................................
NON-GENUINE AND REBUILT COMPONENT QUALITY ALERT ..
1
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 .............................................................................. 9
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 ..............
PREPARATIONS FOR STARTING THE ENGINE THE FIRST
TIME .................................................................................................
COOLING SYSTEM CHECKS ....................................................
LUBRICATION SYSTEM CHECKS .............................................
EXTENDED STORAGE ..........................................................
FUEL SYSTEM CHECKS ............................................................
OTHER CHECKS ........................................................................
STARTING THE ENGINE ................................................................
INITIAL ENGINE START .............................................................
ELECTRIC STARTER .............................................................
AIR STARTER .........................................................................
RUNNING THE ENGINE .................................................................
OIL PRESSURE ..........................................................................
WARM-UP ...................................................................................
INSPECTION ...............................................................................
AVOID UNNECESSARY IDLING .................................................
All information subject to change without notice. (Rev. 01/04)
DDC-SVC-MAN-0058
Copyright © 2004 DETROIT DIESEL CORPORATION
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STOPPING THE ENGINE ................................................................ 21
EMERGENCY JUMP STARTING .................................................... 22
DDEC IV SYSTEM ...............................................................................
DDEC SYSTEM ..............................................................................
ENGINE PROTECTION ..............................................................
IDLE SHUTDOWN TIMER ..........................................................
CRUISE CONTROL .....................................................................
ENGINE BRAKES .......................................................................
DATA RECORDING CAPABILITY ...............................................
DDEC IV OPERATION .....................................................................
IMMEDIATE SPEED REDUCTION OPTION ...............................
STOP ENGINE LIGHT .................................................................
DIAGNOSTIC DATA READER ....................................................
DIAGNOSTIC CODE LIST ..........................................................
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DDEC IV ENGINE DRIVING TIPS .......................................................
ACCELERATING THE VEHICLE .....................................................
CRUISE CONTROL .........................................................................
ENGINE BRAKES AND CRUISE CONTROL ..................................
SHIFTING ........................................................................................
IDLING .............................................................................................
WINTER FRONTS .......................................................................
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ENGINE BRAKE SYSTEM ..................................................................
DRIVER CONTROL SWITCHES .....................................................
LOW/HIGH SWITCH ...................................................................
LOW/MED/HIGH SWITCH ..........................................................
CLUTCH PEDAL AND THROTTLE POSITION CONTROLS ..........
ENGINE BRAKE OPERATION ........................................................
ANTI-LOCK BRAKING SYSTEMS ...................................................
DRIVING ON FLAT, DRY PAVEMENT .............................................
DESCENDING A LONG, STEEP GRADE .......................................
DRIVING ON WET OR SLIPPERY PAVEMENT ..............................
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ENGINE SYSTEMS .............................................................................
FUEL SYSTEM ................................................................................
LUBRICATION SYSTEM .................................................................
AIR SYSTEM ...................................................................................
COOLING SYSTEM .........................................................................
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All information subject to change without notice. (Rev. 01/04)
Copyright © 2004 DETROIT DIESEL CORPORATION
SERIES 50 OPERATOR'S GUIDE
ELECTRICAL SYSTEM ................................................................... 46
EXHAUST SYSTEM ........................................................................ 46
EXHAUST GAS RECIRCULATION SYSTEM .................................. 46
MAINTENANCE ...................................................................................
PREVENTIVE MAINTENANCE INTERVALS ..................................
ITEM 1 – LUBRICATING OIL ......................................................
ITEM 2 – FUEL AND FUEL TANK ...............................................
ITEM 3 – FUEL LINES, FLEXIBLE HOSES ................................
LEAKS .....................................................................................
HOSES AND FITTINGS ..........................................................
HOSE SERVICE LIFE .............................................................
ITEM 4 – COOLING SYSTEM .....................................................
COOLANT LEVEL ...................................................................
COOLANT INHIBITORS ..........................................................
COOLANT DRAIN INTERVAL .................................................
ITEM 5 – TURBOCHARGER, AIR-TO-AIR CHARGE COOLER .
WASTEGATED TURBOCHARGERS ......................................
ITEM 6 – BATTERY .....................................................................
ITEM 7 – TACHOMETER DRIVE ................................................
ITEM 8 – DRIVE BELTS ..............................................................
V-BELTS ..................................................................................
2-GROOVE POWERBAND .....................................................
12–RIB POLY-V BELT .............................................................
BELT REPLACEMENT ............................................................
ITEM 9 – AIR COMPRESSOR ....................................................
ITEM 10 – AIR CLEANER ...........................................................
ITEM 11 – LUBRICATING OIL FILTERS .....................................
ITEM 12 – FUEL FILTERS ..........................................................
FUEL PRO® 382 FILTERS .....................................................
SPIN-ON FILTERS ..................................................................
ITEM 13 – WATER PUMP AND COOLANT INHIBITOR
ELEMENT ....................................................................................
WATER PUMP DRAIN HOLE .................................................
COOLANT INHIBITOR ELEMENT ..........................................
ITEM 14 – CRANKING MOTOR ..................................................
ITEM 15 – AIR SYSTEM .............................................................
ITEM 16 – EXHAUST SYSTEM ..................................................
ITEM 17 – ENGINE (STEAM CLEAN) .........................................
All information subject to change without notice. (Rev. 01/04)
DDC-SVC-MAN-0058
Copyright © 2004 DETROIT DIESEL CORPORATION
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TABLE OF CONTENTS
ITEM 18 – RADIATOR .................................................................
ITEM 19 – OIL PRESSURE .........................................................
ITEM 20 – BATTERY-CHARGING ALTERNATOR ......................
BOSCH® T1 ALTERNATOR SERVICE REQUIREMENTS .....
GENERAL SERVICE REQUIREMENTS – BOSCH® AND
DELCO REMY® ALTERNATORS ...........................................
ITEM 21 – ENGINE AND TRANSMISSION MOUNTS ................
ITEM 22 – CRANKCASE PRESSURE ........................................
ITEM 23 – FAN HUB ....................................................................
ITEM 24 – THERMOSTATS AND SEALS ...................................
ITEM 25 – CRANKCASE BREATHER ........................................
ITEM 26 – ENGINE TUNE-UP ....................................................
ITEM 27 – VIBRATION DAMPER ................................................
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HOW-TO SECTION ..............................................................................
HOW TO SELECT LUBRICATING OIL ............................................
LUBRICANT REQUIREMENTS ..................................................
EGR-EQUIPPED ENGINES ....................................................
NON-EGR ENGINES ..............................................................
ENGINES BUILT PRIOR TO 1998 ..........................................
COLD WEATHER STARTING .....................................................
SYNTHETIC OILS .......................................................................
THE USE OF SUPPLEMENTAL ADDITIVES ..............................
WHEN TO CHANGE OIL .................................................................
DISPOSING OF WASTE OIL ......................................................
HOW TO REPLACE THE LUBE OIL FILTERS ................................
REPLACE SPIN-ON TYPE OIL FILTER ......................................
HOW TO SELECT FUEL OIL ..........................................................
QUALITY .....................................................................................
FUEL CONTAMINATION .............................................................
PROHIBITED ADDITIVES ...........................................................
USED LUBRICATING OIL .......................................................
GASOLINE .............................................................................
HOW TO REPLACE THE FUEL FILTERS .......................................
REPLACE SPIN-ON FILTER ELEMENTS ..................................
REPLACE FUEL/WATER SEPARATOR ELEMENT ....................
REPLACE FUEL PRO FILTER ELEMENT ..................................
ENGINE OUT OF FUEL — HOW TO RESTART .............................
ENGINES WITH SPIN-ON FILTERS ...........................................
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All information subject to change without notice. (Rev. 01/04)
Copyright © 2004 DETROIT DIESEL CORPORATION
SERIES 50 OPERATOR'S GUIDE
ENGINES WITH FUEL PRO FILTERS ........................................
HOW TO SELECT COOLANT .........................................................
DEFINITIONS ..............................................................................
ANTIFREEZE ..........................................................................
COOLANT ...............................................................................
DROP-OUT .............................................................................
FULLY FORMULATED ANTIFREEZE .....................................
INITIAL–FILL COOLANT .........................................................
OAT .........................................................................................
SCA .........................................................................................
APPROVED COOLANTS ............................................................
EG OR PG & WATER + SCA INHIBITOR ...............................
MIXING EG OR PG ANTIFREEZE AND WATER ...................
RECYCLED ANTIFREEZE ....................................................
EG OR PG & WATER + OAT INHIBITOR ...............................
WATER ONLY + SCA OR WATER ONLY + OAT INHIBITOR
WATER REQUIREMENTS .....................................................
COOLANTS NOT RECOMMENDED ..........................................
ALL ANTIFREEZES AND COOLANTS CONTAINING
PHOSPHATE ...........................................................................
AUTOMOTIVE TYPE COOLANTS ..........................................
METHYL ALCOHOL-BASED ANTIFREEZE ...........................
METHOXY PROPANOL-BASED ANTIFREEZE .....................
GLYCOL-BASED COOLANTS FORMULATED FOR HVAC ...
ADDITIVES NOT RECOMMENDED ...........................................
SOLUBLE OIL ADDITIVES .....................................................
CHROMATE ADDITIVES ........................................................
COOLANT MAINTENANCE ........................................................
COOLANT INHIBITOR TEST INTERVALS ............................
SUPPLEMENTAL ADDITIVES ................................................
COOLANT MAINTENANCE INTERVALS ...............................
SCA TEST PROCEDURES .........................................................
NEED-RELEASE FILTERS (NON-OAT SYSTEMS) ....................
DROPOUT ...................................................................................
EXTENDER ADDITIVE FOR OAT COOLANT ............................
OAT COOLANT DRAIN INTERVAL ........................................
CHRONIC COOLANT SYSTEM PROBLEMS .............................
MAINTENANCE PRODUCTS .....................................................
All information subject to change without notice. (Rev. 01/04)
DDC-SVC-MAN-0058
Copyright © 2004 DETROIT DIESEL CORPORATION
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TABLE OF CONTENTS
POWER COOL SCAS .............................................................
POWER COOL COOLANT FILTER ELEMENTS ....................
POWER COOL CLEANERS ...................................................
SUMMARY OF COOLANT RECOMMENDATIONS ....................
COOLANT LIFE OF GLYCOL COOLANT: ..............................
COOLANT LIFE OF OAT COOLANT ......................................
COOLANT LIFE OF OTHER COOLANTS ..............................
HOW TO DRAIN AND FLUSH THE COOLING SYSTEM ...............
WHEN TO SERVICE THE DRY TYPE AIR CLEANER ...................
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BASIC TROUBLESHOOTING ............................................................. 116
ENGINE STORAGE .............................................................................
PREPARING THE ENGINE FOR STORAGE ..................................
TEMPORARY STORAGE (30 DAYS OR LESS) .........................
EXTENDED STORAGE (MORE THAN 30 DAYS) ......................
RESTORING ENGINE TO SERVICE ..........................................
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SERIES 50 SERVICE PUBLICATIONS ............................................... 127
CUSTOMER ASSISTANCE ................................................................. 128
IN U.S. AND CANADA CALL 1–800–445–1980 .............................. 131
WORKING WITH DDC SERVICE OUTLETS .................................. 131
ON-HIGHWAY VEHICLE ENGINE WARRANTY ................................. 134
TERMS OF COVERAGE: ON-HIGHWAY VEHICLE ENGINE
APPLICATIONS .............................................................................. 134
USES ........................................................................................... 134
DEFECTS .................................................................................... 134
REPAIRS ..................................................................................... 134
WARRANTY PERIOD .................................................................. 134
LIKE REPLACEMENT ENGINE .................................................. 135
SERVICE SUPPLIES .................................................................. 135
ENGINE REMOVAL AND REINSTALLATION ............................. 135
THIS WARRANTY DOES NOT COVER: ......................................... 136
REPAIRS DUE TO ACCIDENTS, MISUSE, STORAGE DAMAGE,
NEGLIGENCE OR CERTAIN MODIFICATIONS ......................... 136
BRAKING DEVICES .................................................................... 136
FUEL INJECTORS AFTER 100,000 MILES/160,000
KILOMETERS .............................................................................. 136
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DDC-SVC-MAN-0058
All information subject to change without notice. (Rev. 01/04)
Copyright © 2004 DETROIT DIESEL CORPORATION
SERIES 50 OPERATOR'S GUIDE
MAINTENANCE ........................................................................... 136
INCIDENTAL OR CONSEQUENTIAL DAMAGE ......................... 136
OTHER LIMITATIONS ................................................................. 136
URBAN BUS, MOTOR COACH OR MOTOR HOME ENGINE
WARRANTY .........................................................................................
TERMS OF COVERAGE: URBAN BUS, MOTOR COACH OR
MOTOR HOME ENGINE APPLICATIONS .....................................
USES ...........................................................................................
DEFECTS ....................................................................................
REPAIRS .....................................................................................
WARRANTY PERIOD ..................................................................
SERVICE SUPPLIES ..................................................................
LIKE REPLACEMENT ENGINE ..................................................
ENGINE REMOVAL AND REINSTALLATION .............................
THIS WARRANTY DOES NOT COVER: .........................................
REPAIRS DUE TO ACCIDENTS, MISUSE, ALTERATION,
STORAGE DAMAGE, NEGLIGENCE OR CERTAIN
MODIFICATIONS ........................................................................
BRAKING DEVICES ....................................................................
FUEL INJECTORS AFTER 200,000 MILES/320,000
KILOMETERS ..............................................................................
MAINTENANCE ...........................................................................
INCIDENTAL OR CONSEQUENTIAL DAMAGE .........................
OTHER LIMITATIONS .................................................................
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CONSTRUCTION/ INDUSTRIAL ENGINE WARRANTY .................... 142
TERMS OF COVERAGE: CONSTRUCTION/INDUSTRIAL ENGINE
APPLICATIONS ............................................................................... 142
USES ........................................................................................... 142
DEFECTS .................................................................................... 142
REPAIRS ..................................................................................... 142
WARRANTY PERIOD .................................................................. 142
SERVICE SUPPLIES .................................................................. 142
ENGINE REMOVAL AND REINSTALLATION – CONSTRUCTION/INDUSTRIAL APPLICATIONS ........................................... 143
MECHANIC'S TRAVEL EXPENSES ........................................... 143
LIKE REPLACEMENT ENGINE .................................................. 143
THIS WARRANTY DOES NOT COVER: ......................................... 144
All information subject to change without notice. (Rev. 01/04)
DDC-SVC-MAN-0058
Copyright © 2004 DETROIT DIESEL CORPORATION
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TABLE OF CONTENTS
REPAIRS DUE TO ACCIDENTS, MISUSE, STORAGE DAMAGE,
NEGLIGENCE OR CERTAIN MODIFICATIONS ......................... 144
ENGINE REMOVAL AND REINSTALLATION – AGRICULTURAL
MACHINERY AND STAND-BY PUMP APPLICATIONS ............. 144
NON-DDC SUPPLIED/MANUFACTURED COMPONENTS ....... 144
MAINTENANCE ........................................................................... 144
INCIDENTAL OR CONSEQUENTIAL DAMAGE ......................... 144
OTHER LIMITATIONS ................................................................. 145
AGRICULTURAL MACHINERY ENGINE WARRANTY ...................... 146
TERMS OF COVERAGE: AGRICULTURAL MACHINERY ENGINE
APPLICATIONS ............................................................................... 146
USES ........................................................................................... 146
DEFECTS .................................................................................... 146
REPAIRS ..................................................................................... 146
WARRANTY PERIOD .................................................................. 147
THIS WARRANTY DOES NOT COVER: ......................................... 147
REPAIRS DUE TO ACCIDENTS, MISUSE, STORAGE DAMAGE,
NEGLIGENCE OR CERTAIN MODIFICATIONS ......................... 147
ENGINE REMOVAL AND REINSTALLATION ............................. 147
NON-DDC SUPPLIED/MANUFACTURED COMPONENTS ....... 147
MAINTENANCE ........................................................................... 147
INCIDENTAL OR CONSEQUENTIAL DAMAGE ......................... 148
OTHER LIMITATIONS ................................................................. 148
PRIME POWER GENERATOR SET ENGINE WARRANTY ............... 149
TERMS OF COVERAGE: PRIME POWER GENERATOR SET
ENGINE APPLICATIONS ................................................................ 149
USES ........................................................................................... 149
DEFECTS .................................................................................... 149
REPAIRS ..................................................................................... 149
WARRANTY PERIOD .................................................................. 149
LIKE REPLACEMENT ENGINE .................................................. 149
SERVICE SUPPLIES .................................................................. 150
MECHANIC'S TRAVEL EXPENSES ........................................... 150
THIS WARRANTY DOES NOT COVER: ......................................... 150
REPAIRS DUE TO ACCIDENTS, MISUSE, STORAGE DAMAGE,
NEGLIGENCE OR CERTAIN MODIFICATIONS ......................... 150
ENGINE REMOVAL AND REINSTALLATION ............................. 150
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DDC-SVC-MAN-0058
All information subject to change without notice. (Rev. 01/04)
Copyright © 2004 DETROIT DIESEL CORPORATION
SERIES 50 OPERATOR'S GUIDE
NON-DDC SUPPLIED/MANUFACTURED COMPONENTS .......
MAINTENANCE ...........................................................................
INCIDENTAL OR CONSEQUENTIAL DAMAGE .........................
OTHER LIMITATIONS .................................................................
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STAND-BY GENERATOR SET ENGINE WARRANTY ....................... 152
TERMS OF COVERAGE: STAND-BY GENERATOR SET ENGINE
APPLICATIONS ............................................................................... 152
USES ........................................................................................... 152
DEFECTS .................................................................................... 152
REPAIRS ..................................................................................... 152
WARRANTY PERIOD .................................................................. 153
LIKE REPLACEMENT ENGINE .................................................. 153
SERVICE SUPPLIES .................................................................. 153
MECHANIC'S TRAVEL EXPENSES ........................................... 153
THIS WARRANTY DOES NOT COVER: ......................................... 153
REPAIRS DUE TO ACCIDENTS, MISUSE, STORAGE DAMAGE,
NEGLIGENCE OR CERTAIN MODIFICATIONS ......................... 153
ENGINE REMOVAL AND REINSTALLATION ............................. 153
NON-DDC SUPPLIED/MANUFACTURED COMPONENTS ....... 153
MAINTENANCE ........................................................................... 154
INCIDENTAL OR CONSEQUENTIAL DAMAGE ......................... 154
OTHER LIMITATIONS ................................................................. 154
SPECIFICATIONS ................................................................................
FUEL AND LUBRICATING OIL FILTER REQUIREMENTS ............
OIL PAN .......................................................................................
OIL PAN CAPACITY ................................................................
TOTAL OIL CAPACITY OF THE ENGINE ...............................
POWER COOL ENGINE PRODUCTS ............................................
FULLY FORMULATED IEG COOLANT .......................................
LATIN AMERICAN COOLANT ....................................................
2000 SUPPLEMENTAL COOLANT ADDITIVE ...........................
3000 SUPPLEMENTAL COOLANT ADDITIVE ...........................
3000 SUPPLEMENTAL ADDITIVE COOLANT FILTERS ............
SUPPLEMENTAL ADDITIVE NEED RELEASE FILTERS ...........
PLUS EXTENDED LIFE OAT COOLANT ....................................
PLUS EXTENDER FOR USE WITH POWER COOL PLUS OAT
COOLANT ...................................................................................
All information subject to change without notice. (Rev. 01/04)
DDC-SVC-MAN-0058
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TABLE OF CONTENTS
PLUS 6000 OAT INHIBITOR FOR WATER-ONLY SYSTEMS .... 160
COOLING SYSTEM CLEANERS ................................................ 160
COOLANT TESTING AND ANALYSIS PRODUCTS ................... 161
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DDC-SVC-MAN-0058
All information subject to change without notice. (Rev. 01/04)
Copyright © 2004 DETROIT DIESEL CORPORATION
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
All information subject to change without notice. (Rev. 01/04)
DDC-SVC-MAN-0058
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.
Copyright © 2004 DETROIT DIESEL CORPORATION
1
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.
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.
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.
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DDC-SVC-MAN-0058
All information subject to change without notice. (Rev. 01/04)
Copyright © 2004 DETROIT DIESEL CORPORATION
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.
PERSONAL INJURY
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.
PERSONAL INJURY
To avoid injury from loss of
vehicle/vessel control, the
operator of a DDEC equipped
engine must not use or read
any diagnostic tool while the
vehicle/vessel is moving.
All information subject to change without notice. (Rev. 01/04)
DDC-SVC-MAN-0058
PERSONAL INJURY
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.
Copyright © 2004 DETROIT DIESEL CORPORATION
3
CAUTION SUMMARY
LOSS OF VEHICLE CONTROL
LOSS OF VEHICLE CONTROL
To avoid injury from loss of
vehicle control, do not activate
the Engine Brake system under
the following conditions:
To avoid injury from the loss of
vehicle control, do not use cruise
control under these 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 an
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.
□ 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.
PERSONAL INJURY
To avoid injury when working
near or on an operating engine,
remove loose items of clothing
and jewelry. Tie back or contain
long hair that could be caught in
any moving part causing injury.
4
DDC-SVC-MAN-0058
All information subject to change without notice. (Rev. 01/04)
Copyright © 2004 DETROIT DIESEL CORPORATION
SERIES 50 OPERATOR'S GUIDE
PERSONAL INJURY
To avoid injury when working
on or near an operating engine,
wear protective clothing,
eye protection, and hearing
protection.
USED ENGINE OIL
To avoid injury to skin from
contact with the contaminants in
used engine oil, wear protective
gloves and apron.
PERSONAL INJURY
HOT OIL
To avoid injury from hot oil, do
not operate the engine with the
rocker cover(s) removed.
To avoid injury from slipping and
falling, immediately clean up any
spilled liquids.
PERSONAL INJURY
FIRE
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 hot surfaces,
wear protective gloves, or allow
engine to cool before removing
any component.
PERSONAL INJURY
To avoid injury, use care when
working around moving belts and
rotating parts on the engine.
All information subject to change without notice. (Rev. 01/04)
DDC-SVC-MAN-0058
Copyright © 2004 DETROIT DIESEL CORPORATION
5
CAUTION SUMMARY
FIRE
FIRE
To avoid injury from combustion
of heated lubricating-oil vapors,
stop the engine immediately if an
oil leak is detected.
To avoid injury from fire, do not
smoke or allow open flames when
working on an operating engine.
FIRE
PERSONAL INJURY
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 from fire from a
buildup of volatile vapors, keep
the engine area well ventilated
during operation.
PERSONAL INJURY
To avoid injury from rotating belts
and fans, do not remove and
discard safety guards.
HOT COOLANT
To avoid scalding from the
expulsion of hot coolant, never
remove the cooling system
pressure cap while the engine is
at operating temperature. Wear
adequate protective clothing
(face shield, rubber gloves,
apron, and boots). Remove the
cap slowly to relieve pressure.
6
DDC-SVC-MAN-0058
All information subject to change without notice. (Rev. 01/04)
Copyright © 2004 DETROIT DIESEL CORPORATION
SERIES 50 OPERATOR'S GUIDE
PERSONAL INJURY
To avoid injury when using
caustic cleaning agents, follow
the chemical manufacturers
usage, disposal, and safety
instructions.
Electrical System
Observe the following cautions when
jump starting an engine, charging
a battery, or working with the
vehicle/application electrical system.
Battery Explosion and Acid Burn
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. 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.
PERSONAL INJURY
To avoid injury from accidental
engine startup while servicing
the engine, disconnect/disable
the starting system.
ELECTRICAL SHOCK
To avoid injury from electrical
shock, do not touch battery
terminals, alternator terminals, or
wiring cables while the engine is
operating.
All information subject to change without notice. (Rev. 01/04)
DDC-SVC-MAN-0058
Copyright © 2004 DETROIT DIESEL CORPORATION
7
CAUTION SUMMARY
Cooling System
Air Intake System
Observe the following cautions when
servicing the cooling system.
Observe the following cautions when
working on the air intake system.
HOT COOLANT
PERSONAL INJURY
To avoid scalding from the
expulsion of hot coolant, never
remove the cooling system
pressure cap while the engine is
at operating temperature. Wear
adequate protective clothing
(face shield, rubber gloves,
apron, and boots). Remove the
cap slowly to relieve pressure.
To avoid injury from hot surfaces,
wear protective gloves, or allow
engine to cool before removing
any component.
PERSONAL INJURY
PERSONAL INJURY
To avoid injury from slipping and
falling, immediately clean up any
spilled liquids.
8
DDC-SVC-MAN-0058
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.
All information subject to change without notice. (Rev. 01/04)
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.
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.
FIRE
To avoid injury from fire, keep all
potential ignition sources away
from diesel fuel, including open
flames, sparks, and electrical
resistance heating elements. Do
not smoke when refueling.
□ Stop the engine immediately if
a fuel leak is detected.
□ Do not smoke or allow open
flames when working on an
operating engine.
□ Wear adequate protective
clothing (face shield,
insulated gloves and apron,
etc.).
FIRE
To avoid injury from fire, contain
and eliminate leaks of flammable
fluids as they occur. Failure to
eliminate leaks could result in
fire.
□ To prevent a buildup of
potentially volatile vapors,
keep the engine area well
ventilated during operation.
FIRE
To avoid increased risk of a fuel
fire, do not mix gasoline and
diesel fuel.
Starting Aids
Observe the following cautions when
using starting aids.
All information subject to change without notice. (Rev. 01/04)
DDC-SVC-MAN-0058
Copyright © 2004 DETROIT DIESEL CORPORATION
9
CAUTION SUMMARY
FLAMES, EXPLOSION AND
TOXICITY
FLAMES, EXPLOSION AND
TOXICITY
To avoid injury from flames,
explosion, and toxicants when
using ether, the following
precautions must be taken:
To avoid injury from flames,
explosion, and toxicants when
using ether, the following
precautions must be taken:
□ Always wear goggles when
testing.
□ Do not smoke when servicing
ether system.
□ 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.
□ Work in well ventilated area.
□ Contents of cylinder are under
pressure. Store cylinders
in a cool dry area. Do not
incinerate, puncture or
attempt to remove cores from
cylinders.
10
DDC-SVC-MAN-0058
□ 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.
All information subject to change without notice. (Rev. 01/04)
Copyright © 2004 DETROIT DIESEL CORPORATION
SERIES 50 OPERATOR'S GUIDE
Compressed Air
Observe the following cautions when
using compressed air.
FIRE
To avoid injury from fire, do not
smoke or allow open flames when
working on an operating engine.
EYE INJURY
To avoid injury from flying debris
when using compressed air, wear
adequate eye protection (face
shield or safety goggles) and do
not exceed 276 kPa (40 psi) air
pressure.
Lubricating Oil and Filters
Observe the following cautions when
replacing the engine lubricating oil
and filters.
FIRE
To avoid injury from fire from a
buildup of volatile vapors, keep
the engine area well ventilated
during operation.
PERSONAL INJURY
To avoid injury from slipping and
falling, immediately clean up any
spilled liquids.
FIRE
To avoid injury from combustion
of heated lubricating-oil vapors,
stop the engine immediately if an
oil leak is detected.
All information subject to change without notice. (Rev. 01/04)
DDC-SVC-MAN-0058
Copyright © 2004 DETROIT DIESEL CORPORATION
11
ENGINE MODEL AND SERIAL NUMBER DESIGNATION
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
Figure 1
12
the cast-in Detroit Diesel logo (as
viewed from the flywheel end).
See Figure 1
Location of Engine Serial and Model Numbers
DDC-SVC-MAN-0058
All information subject to change without notice. (Rev. 01/04)
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
Figure 2
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.
Typical Option Labels
All information subject to change without notice. (Rev. 01/04)
DDC-SVC-MAN-0058
Copyright © 2004 DETROIT DIESEL CORPORATION
13
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
Figure 3
14
emissions regulations for its particular
application. It also gives the operating
conditions under which certification
was made. See Figure 3.
Typical Engine Certification Labels
DDC-SVC-MAN-0058
All information subject to change without notice. (Rev. 01/04)
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.
PERSONAL INJURY
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.
All information subject to change without notice. (Rev. 01/04)
DDC-SVC-MAN-0058
PERSONAL INJURY
To avoid injury when working
near or on an operating engine,
remove loose items of clothing
and 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 expansion
Copyright © 2004 DETROIT DIESEL CORPORATION
15
OPERATING INSTRUCTIONS FOR A FIRST TIME START
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.
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.
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
Figure 4
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
16
DDC-SVC-MAN-0058
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
All information subject to change without notice. (Rev. 01/04)
Copyright © 2004 DETROIT DIESEL CORPORATION
SERIES 50 OPERATOR'S GUIDE
replacing the engine lubricating oil
and filters after extended storage.
NOTICE:
Failure to eliminate water-diluted
lubricating oil may lead to serious
engine damage at startup.
Fuel System Checks
Fill the tanks with the recommended
fuel. Keeping tanks full reduces water
condensation and helps keep fuel
cool, which is important to engine
performance. Full tanks also reduce
the chance for microbe (black slime)
growth. For fuel recommendations,
refer to the How to Select Fuel Oil
section in this guide. Make sure the
fuel shutoff valve (if used) is open.
To insure prompt starting and even
running, the fuel system must
be primed if air has entered the fuel
system. Priming is done by connecting
a manual or electric priming pump
to the secondary fuel filter adaptor.
Authorized Detroit Diesel service
outlets are properly equipped and have
the trained technicians to perform this
service.
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 head.
Engines equipped with starting
devices dependent on compressed
air or gas reservoirs should always
be primed before initial startup.
Otherwise, reserve pressure can
be exhausted and injectors may be
damaged from lack of lubrication
and cooling.
Under no circumstances should
a starting aid such as ether be
used to run the engine until the
fuel system is primed. Injector
damage will result if this method
is used. The heat generated by the
external fuel source will cause the
injector tips to be damaged when
the fuel cools them. The injector
plunger and bushing can be scored
from running without lubrication.
Priming is not normally required if
the filter elements are filled with clean
fuel when installed and the manifolds
are not drained of fuel.
All information subject to change without notice. (Rev. 01/04)
DDC-SVC-MAN-0058
Copyright © 2004 DETROIT DIESEL CORPORATION
17
OPERATING INSTRUCTIONS FOR A FIRST TIME START
If the engine is equipped with a
fuel/water separator, drain off any
water that has accumulated. Water
in fuel can seriously affect engine
performance and may cause engine
damage. Detroit Diesel recommends
installation of a fuel/water separator
wherever water contamination is a
concern.
Other Checks
Check drive belts to make sure they
are in good condition (not cracked,
torn, worn or glazed) and are properly
adjusted.
If lead-acid or low-maintenance
batteries are used, make sure battery
electrolyte level is normal.
Check the turbocharger for signs of
oil or exhaust leaks. Leaks should be
corrected before starting the engine.
Check engine mounting bolts for
tightness. Bolts should be retightened,
if necessary.
Make sure the transmission is
filled to the proper level with the
fluid recommended by the gear
manufacturer. Do not overfill.
Make sure cable connections to
the storage batteries are clean and
tight. Check the hydrometer “eye” of
maintenance-free batteries for charge.
See Figure 5.
Starting the Engine
Before starting the engine the first
time, refer to the System Checks
section and perform the operations
listed.
NOTICE:
The turbocharger may be seriously
damaged if the engine is cranked
with the air shutdown in the closed
position.
If the engine has an emergency manual
or automatic shutdown system, make
sure the control is set in the open
position before starting.
Figure 5
18
Maintenance-Free
Battery “Eye”
DDC-SVC-MAN-0058
The engine may require the use of a
cold weather starting aid if the ambient
temperature is below 40° F (4° C).
All information subject to change without notice. (Rev. 01/04)
Copyright © 2004 DETROIT DIESEL CORPORATION
SERIES 50 OPERATOR'S GUIDE
OK, both lights will go out in
approximately five seconds.
FLAMES, EXPLOSION AND
TOXICITY
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.
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.
□ Do not work near open flames,
pilot flames (gas or oil
heaters), or sparks.
□ Do not weld or carry an open
flame near the ether system if
you smell ether or otherwise
suspect a leak.
Initial Engine Start
To start a Series 50 engine, make sure
the transmission is in neutral and turn
the ignition key on.
You will notice that both the yellow
Check Engin Light (CEL) and the red
Stop Engine Light (SEL) will come
on.
This is the result of theDetroit
Diesel Electronic Control (DDEC®)
computer diagnosing the system
to ensure everything is functional,
including the light bulbs for the
warning lights. If everything is
All information subject to change without notice. (Rev. 01/04)
DDC-SVC-MAN-0058
Electric Starter — Start an engine
equipped with an electric starting
motor as follows:
1. With foot OFF the foot pedal,
press the starter switch firmly.
NOTICE:
To prevent serious starting motor
damage, do not press the starter
switch again after the engine has
started.
2. If the engine fails to start within
15 seconds, release the starter
switch and allow the starter to
cool for 15 seconds before trying
again. If the engine fails to start
after four attempts, an inspection
should be made to determine the
cause.
Copyright © 2004 DETROIT DIESEL CORPORATION
19
OPERATING INSTRUCTIONS FOR A FIRST TIME START
Air Starter — Because of the limited
volume of most compressed air
storage tanks and the relatively short
duration of the cranking cycle, it is
important to make sure the engine is
ready to start before activating the air
starter. Start an engine equipped with
an air starter as follows:
1. Check the pressure in the air
storage tank. If necessary, add air
to bring the pressure up to at least
the recommended minimum for
starting.
2. With foot OFF the foot pedal,
press the starter button firmly and
hold until the engine starts.
Running the Engine
While the engine is operating, monitor
the battery charge indicator light,
the oil pressure and avoid excessive
idling.
Oil Pressure
Observe the oil pressure gage
immediately after starting the engine.
A good indicator that all moving parts
are getting lubrication is when the
oil pressure gage registers pressure
(5 psi or 35 kPa at idle speed). If
no pressure is indicated within 10
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
20
DDC-SVC-MAN-0058
operating pressure should be higher. If
oil pressure does not fall within these
guidelines, it should be checked with
a manual gage.
HOT OIL
To avoid injury from hot oil, do
not operate the engine with the
rocker cover(s) removed.
Warm-up
Run the engine at part throttle for
about five minutes to allow it to warm
up before applying a load.
Inspection
While the engine is idling, inspect the
transmission, check for fluid leaks,
check the crankcase and turbocharger.
Transmission – While the engine
is idling, check the automatic
transmission (if equipped) for proper
oil level and add oil as required.
Fluid Leaks – Look for coolant,
fuel or lubricating oil leaks. If any
are found, shut down the engine
immediately and have the leaks
repaired after the engine has cooled.
All information subject to change without notice. (Rev. 01/04)
Copyright © 2004 DETROIT DIESEL CORPORATION
SERIES 50 OPERATOR'S GUIDE
Crankcase – If the engine oil was
replaced, stop the engine after normal
operating temperature has been
reached. Allow the oil to drain
back into the crankcase for about
twenty minutes, then check the oil
level. If necessary, add oil to bring
the level to the proper mark on the
dipstick. Use only the heavy-duty oils
recommended. Refer to the How to
Select Lubricating Oil section in this
guide.
Turbocharger – Make a visual
inspection of the turbocharger for
oil leaks, exhaust leaks, excessive
noise or vibration. Stop the engine
immediately if a leak or unusual noise
or vibration is noted. Do not restart
the engine until the cause of the
concern has been investigated and
corrected. Authorized Detroit Diesel
service outlets are properly equipped
to perform this service.
Avoid Unnecessary Idling
Whenever possible, avoid unnecessary
idling.
During long engine idling periods
with the transmission 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
All information subject to change without notice. (Rev. 01/04)
DDC-SVC-MAN-0058
sludge in the engine. When prolonged
idling is necessary, maintain at least
850 rpm spring/summer and 1200 rpm
fall/winter.
Stopping the Engine
Stop an engine under normal operating
conditions as follows:
1. Reduce engine speed to idle and
put all shift levers in the neutral
position.
NOTICE:
Stopping a turbocharged engine
immediately after high-speed
operation without allowing a
sufficient cool-down period may
cause damage to the turbocharger,
as it will continue to turn without an
oil supply to the bearings.
2. Allow the engine to run between
idle and 1000 rpm with no load
for four or five minutes. This
allows the engine to cool and
permits the turbocharger to slow
down. After four or five minutes,
shut down the engine.
Copyright © 2004 DETROIT DIESEL CORPORATION
21
OPERATING INSTRUCTIONS FOR A FIRST TIME START
Emergency Jump Starting
The DDEC IV system operates on
12 or 24 volts DC. If an engine with
an electric starting motor requires
emergency jump starting, do not
exceed 32 volts DC.
are connected properly (positive to
positive, negative to negative ground)
and in the proper sequence (negative
to negative ground last).
Battery Explosion and Acid Burn
NOTICE:
Jump starting with voltages greater
than those indicated or reversing
battery polarity may damage the
Electronic Control Module.
To avoid injury from battery
explosion or contact with battery
acid, work in a well ventilated
area, wear protective clothing,
and avoid sparks or flames near
the battery. If you come in contact
with battery acid:
□ Flush your skin with water.
□ Apply baking soda or lime to
help neutralize the acid.
BATTERY EXPLOSION
To avoid injury from battery
explosion when jump starting the
engine, do not attach the cable
end to the negative terminal of
the disabled battery.
□ Flush your eyes with water.
□ Get medical attention
immediately.
NOTICE:
Failure to connect jumper cables
in the proper sequence can result
in alternator and/or equipment
damage.
Before attempting to jump start the
engine, make sure the jumper cables
22
DDC-SVC-MAN-0058
All information subject to change without notice. (Rev. 01/04)
Copyright © 2004 DETROIT DIESEL CORPORATION
SERIES 50 OPERATOR'S GUIDE
DDEC IV SYSTEM
The DDEC sytem's engine-mounted
Electronic Control Module (ECM)
includes control logic to provide
overall engine management. The
ECM continuously performs
self-diagnostic checks and monitors
other system components. System
diagnostic checks are made at
ignition-on and continue throughout
all engine-operating modes.
Detroit Diesel Series 50 engines
equipped with DDEC IV are identified
by the letter “K” in the sixth position
of the model number. Example:
6047GK27.
The DDEC engine is equipped
with an electronically controlled
fuel injection system. There are no
control racks or mechanical linkages
to adjust. This system not only helps
to improve fuel economy and vehicle
performance, it also helps to reduce
cold starting time and increase initial
idle speed for fast engine warm-up
and virtual elimination of cold smoke.
The DDEC engine has no
mechanical governor. Engine
horsepower, torque, idle, and engine
speed are contained in the internal
electronics. Therefore, there are
no mechanical governor spring
adjustments for idle and high-speed
control.
All information subject to change without notice. (Rev. 01/04)
DDC-SVC-MAN-0058
There is no need for a throttle delay.
Emission control is performed through
the electronic control module (ECM).
The Electronic Foot Pedal Assembly
(EFPA) eliminates the need for any
throttle linkage.
DDEC Features
DDEC offers a variety of options
designed to warn the operator of an
engine malfunction. Options can
range from the CEL and SEL panel
lights to automatic reduction in engine
power followed by automatic engine
shutdown.
The power-down/shutdown option
may be activated by a low coolant
level, low oil pressure or high engine
oil or coolant temperature.
The DDEC engine has the ability to
perform diagnostics for self-checks
and continuous monitoring of other
system components. Depending
on the application, DDEC can also
monitor oil temperature, coolant
temperature, oil pressure, fuel
pressure, coolant level and remote
sensors (if used). This diagnostic
system is connected to the CEL and
the SEL to provide a visual warning
of a system malfunction.
Copyright © 2004 DETROIT DIESEL CORPORATION
23
DDEC IV SYSTEM
Engine Protection
NOTICE:
The DDEC engine protection
system monitors all engine sensors
and electronic components, and
recognizes system malfunctions. If
a critical fault is detected, the CEL
and SEL illuminate. The malfunction
codes are logged into the ECM's
memory.
The standard parameters which are
monitored for engine protection
are: low coolant level, high coolant
temperature, low oil pressure, and
high oil temperature
This system features a 30-second,
stepped-power shutdown sequence
or an immediate speed reduction
without shutdown in the event a major
engine malfunction occurs, such as
low oil pressure, high oil or coolant
temperature, or low coolant level.
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.
DDC-SVC-MAN-0058
Idle Shutdown Timer
The DDEC engine may also have
an optional 1 to 100 minute idle
shutdown system. The purpose of
this system is to conserve fuel by
eliminating excessive idling and to
allow for a turbocharger cool-down
period. To activate the shutdown, the
transmission must be in neutral with
the vehicle parking brakes set and the
engine in idle or fast-idle mode.
Cruise Control
PERSONAL INJURY
24
Engines equipped with the
power-down/shutdown option have
a system override button or switch
to allow engine operation for a
short period of time. Using the
override button so the engine does
not shutdown in 30 seconds but
operates for an extended period
may result in engine damage
Cruise Control is available with
any DDEC engine. Cruise Control
maintains a set vehicle or engine
speed setting. The driver/operator
has switches to set, activate and
deactivate the system. See Figure
6. A slight pressure on the brake or
clutch deactivates the system, as well.
The minimum speed at which cruise
control can be used is programmable.
All information subject to change without notice. (Rev. 01/04)
Copyright © 2004 DETROIT DIESEL CORPORATION
SERIES 50 OPERATOR'S GUIDE
LOSS OF VEHICLE CONTROL
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.).
Figure 6
Typical Cruise Control
Switches
Cruise Control may also be
programmed to permit fast idle
using the cruise control switches.
With the engine at normal idle,
transmission in neutral and service
brakes on, turn on the cruise control
“ON/OFF” switch, and use the
“Resume” switch. The engine rpm
should increase to a pre-defined
speed. The engine rpm can be raised
or lowered from this point using the
“Set” and “Resume” switches.
Cruise Control will maintain the set
speed under normal road and load
conditions.
All information subject to change without notice. (Rev. 01/04)
DDC-SVC-MAN-0058
□ 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 this precaution can result
in overspeeding and serious engine
damage.
Cruise Control cannot limit vehicle
speeds on down grades if available
engine braking effort is exceeded, nor
can it maintain speed on upgrades if
power requirements exceed engine
power capability.
Copyright © 2004 DETROIT DIESEL CORPORATION
25
DDEC IV SYSTEM
When the Cruise Control switch
is in the ON position, cruise
control is engaged by momentarily
contacting the “Set/Coast” switch
to the ON position. Holding the
switch in the ON position allows the
vehicle to slow to a lower speed.
Toggling the switch will result in a
one mile-per-hour (1.6 kph) decrease
in vehicle speed. If cruise control
has been disabled, toggling the
“Resume/Accel” switch restores the
vehicle to the previously set cruise
speed.
Using either the brake or the clutch
will disable cruise control.
Engine Brakes
Engine brakes are enabled by an
ON/OFF switch mounted on the dash.
A separate intensity switch is used to
select low, medium or high braking
power. The engine brakes will only
operate when the electronic foot pedal
assembly (EFPA) is fully released.
Disengaging the clutch will prevent
the engine brakes from operating.
LOSS OF VEHICLE CONTROL
To avoid injury from loss of
vehicle control, do not activate
the Engine Brake system under
the following conditions:
□ On wet or slippery pavement,
unless the vehicle is equipped
with ABS (anti-lock braking
system) and you have had
prior experience driving
under these conditions.
□ When driving without a trailer
(bobtailing) or pulling an
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.
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.
26
DDC-SVC-MAN-0058
All information subject to change without notice. (Rev. 01/04)
Copyright © 2004 DETROIT DIESEL CORPORATION
SERIES 50 OPERATOR'S GUIDE
Data Recording Capability
DDEC Reports is a data recording
capability that is standard on all DDEC
IV engines. DDEC Reports contains
information on driver activities,
engine performance and critical
incidence reporting. The information
can be extracted with Detroit Diesel
Diagnostic Link® 2.1 (DDDL 2.1)
or later software. To perform the
extraction, at least a 486 computer
with a 16-MB RAM is required.
DDEC IV Operation
NOTE:
This engine is equipped with DDEC
software. This software generally
assures optimal engine performance.
The installation of software upgrades
may cause minor changes in features
and engine performance.
Since the DDEC system is electronic,
a battery is required to operate the
computer. The system operates at 12
or 24 volts. However, in the event of a
power supply malfunction, the system
will continue to operate at reduced
voltage. When this occurs, the CEL
will come on.
The engine will only operate at
reduced rpm until the battery voltage
reaches a point where the ECM will
no longer function and the engine
shuts down.
All information subject to change without notice. (Rev. 01/04)
DDC-SVC-MAN-0058
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
malfunction in the engine that
requires immediate attention. It is
the operator's responsibility to
shut down the engine to avoid
serious damage.
The engine can be configured to
give a warning only, to ramp down
(reduce power) or to shut down.
Ramp down will reduce engine rpm
to a pre-determined speed, but will
not shut down the engine. With
the 30-second shutdown option, the
engine will begin a 30-second, stepped
power-down sequence until it shuts
down completely.
Stop Engine Override can be supplied
in case the vehicle is to operate in a
critical location.
NOTE:
The Stop Engine Override (SEO)
switch and the Diagnostic Request
switch are the same.
Copyright © 2004 DETROIT DIESEL CORPORATION
27
DDEC IV SYSTEM
In this situation the operator may
elect to override the automatic stop
engine sequence by pressing the Stop
Engine Override switch every 15 to 20
seconds to prevent engine shutdown
from occurring.
Stop Engine Light
NOTE:
For some applications, holding down
the Stop Engine Override switch will
not prevent the engine shutdown
sequence. You must continue to reset
the automatic shutdown system by
pressing the Stop Engine Override
switch at intervals of approximately 15
to 20 seconds.
□ High oil temperature
It takes 30 seconds from the time the
automatic shutdown sequence begins
until engine shutdown. Therefore,
the operator must press the override
switch just prior to engine shutdown
and continue to do so until the vehicle
can be brought to a stop in a safe
location.
Immediate Speed Reduction
Option
The immediate speed reduction option
will bring engine rpm back to a
predetermined speed, but will not shut
down the engine.
The conditions that will cause the SEL
to come on are:
□ High coolant temperature
□ Loss of coolant
□ Low oil pressure
□ Auxiliary shutdown
It is important to point out that
whenever the CEL or the SEL
comes on, the DDEC computer will
determine where the problem is and
will then store this information in its
memory.
If the malfunction is intermittent, the
lights will come on and go off as the
computer senses the changing engine
condition.
Diagnostic Data Reader
The Diagnostic Data Reader (DDR)
is a special diagnostic tool that can
be plugged into the engine computer
memory to extract information
related to the cause of the problem.
See Figure 7.
The engine should not be restarted
after it has been shut down by the
engine protection system, unless
the problem has been located and
corrected.
28
DDC-SVC-MAN-0058
All information subject to change without notice. (Rev. 01/04)
Copyright © 2004 DETROIT DIESEL CORPORATION
SERIES 50 OPERATOR'S GUIDE
The malfunction code recorded in the
computer memory will remain until it
is erased by a technician.
Figure 7
Diagnostic Data Reader
J 38500
Once the malfunction has been
corrected, the DDEC system will
return the engine to normal operation.
The DDR can distinguish between
codes now active and those stored in
the ECM memory (inactive).
Figure 8
The malfunction code can also be
obtained by the operator. A Diagnostic
Request switch is provided which,
when pressed, will cause the 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
working satisfactorily.
SEL/CEL Flashing Code Examples
All information subject to change without notice. (Rev. 01/04)
DDC-SVC-MAN-0058
Copyright © 2004 DETROIT DIESEL CORPORATION
29
DDEC IV SYSTEM
Active Codes – The active codes will
be flashed on the SEL in the order of
most recent to least recent occurrence
based on engine hours. If there are no
active codes, a code 25 will be flashed.
Inactive Codes – The inactive codes
will be flashed on the CEL in the
order of most recent to least recent
occurrence based on engine hours. If
there are no inactive codes, a code 25
will be flashed.
Only One Light Flashes at a Time –
Only one light will be flashing codes
at any time. When code flashing is
initiated, the active codes (or code
25) will be flashed on the SEL. Then
the inactive codes (or code 25) will
be flashed on the CEL. When all the
inactive codes (or code 25) have been
flashed, the process of flashing all
the active codes followed by all the
inactive codes will repeat until the
conditions for code flashing are no
longer satisfied.
To Read Codes: Use the diagnostic
data reader (DDR) or depress and hold
the 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.
Diagnostic Code List
Diagnostic codes are listed in the next
several pages.
PERSONAL INJURY
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.
PERSONAL INJURY
To avoid injury from loss of
vehicle/vessel control, the
operator of a DDEC equipped
engine must not use or read
any diagnostic tool while the
vehicle/vessel is moving.
The codes will continue to flash and
repeat as long as the diagnostic request
switch is held in the ON position with
the ignition on.
30
DDC-SVC-MAN-0058
All information subject to change without notice. (Rev. 01/04)
Copyright © 2004 DETROIT DIESEL CORPORATION
SERIES 50 OPERATOR'S GUIDE
Flash
Code
Description
11
Variable Speed Governor Sensor Voltage Low
11
Variable Speed Governor Switch System Not Responding
12
Variable Speed Governor Sensor Voltage High
13
Coolant Level Sensor Input Voltage Low
13
Add Coolant Level Sensor Input Voltage Low
14
Intercooler Coolant Temperature Sensor Input Voltage High
14
Coolant Temperature Sensor Input Voltage High
14
Oil Temperature Sensor Input Voltage High
15
Intercooler Coolant Temperature Sensor Input Voltage Low
15
Coolant Temperature Sensor Input Voltage Low
15
Oil Temperature Sensor Input Voltage Low
16
Coolant Level Sensor Input Voltage High
16
Add Coolant 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 Sensor Input Voltage Low
23
Fuel Temperature Sensor Input Voltage High
23
Oxygen Content Circuit Input Voltage High
24
Fuel Temperature Sensor Input Voltage Low
24
Oxygen Content Circuit Input Voltage Low
25
Reserved for “No Codes"
26
Aux. Shutdown #1 Active
26
Aux. Shutdown #2 Active
27
Intake Manifold Temperature Sensor Input Voltage High
All information subject to change without notice. (Rev. 01/04)
DDC-SVC-MAN-0058
Copyright © 2004 DETROIT DIESEL CORPORATION
31
DDEC IV SYSTEM
Flash
Code
32
Description
27
Ambient Air Temperature Sensor Input Voltage High
27
Air Temperature Sensor Input Voltage High
28
Intake Manifold Temperature Sensor Input Voltage Low
28
Ambient Air Temperature Sensor Input Voltage Low
28
Air Temperature Sensor Input Voltage Low
29
TCI Temperature Circuit Failed Low
29
Turbo Compressor Temperature Out Sensor Input Voltage
Low
31
Aux. Output #3 or #4 Open Circuit (High Side)
31
Aux. Output #3 or #4 Short To Ground (High Side)
31
Aux. Output #3 or #4 Mechanical System Failure
32
SEL or CEL Short to Battery (+)
32
SEL or CEL Open Circuit
33
Turbo Boost 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 Range Fuel Pressure Sensor Input Voltage Low
38
Fuel Restriction or Fuel Pressure Sensor Input Voltage Low
39
EGR Leak — Boost Power
39
EGR Leak — Boost Jake
39
EGR Valve Not Responding
39
VNT Vanes Not Responding — Boost Power
39
VNT Vanes at Max — Jake
39
VNT Vanes Not Responding — Boost Jake
DDC-SVC-MAN-0058
All information subject to change without notice. (Rev. 01/04)
Copyright © 2004 DETROIT DIESEL CORPORATION
SERIES 50 OPERATOR'S GUIDE
Flash
Code
Description
39
EGR Flow too Low
39
VNT Vanes Not Responding — EGR
41
Too Many SRS (missing TRS)
42
Too few SRS (missing SRS)
43
Coolant Level Low
44
Intercooler Coolant Temperature High
44
Engine Derate Due to Intake Manifold Temp or Coolant Temp
44
Intake Manifold Temp, Coolant Temp, Air Inlet Temp, or Oil
Temp High
45
High Range Oil Pressure Low
45
Oil Pressure Low
46
ECM Battery Voltage Low
46
RTC Backup Battery Voltage Low
46
Sensor Supply Voltage Low
47
48
High Range Fuel Pressure, Fuel Pressure, Turbo Boost
Pressure, Air Inlet Pressure, or Injection Control Pressure
High
High Range Fuel Pressure, Fuel Pressure, Air Inlet Pressure,
or Injection Control Pressure Low
48
TCI Temperature Below Range
48
Turbo Compressor Temperature Out High
48
EGR Differential Pressure or EGR Temperature Low
49
TCI Temperature Above Range
49
Turbo Compressor Out Temperature High
49
Engine Derate Due to TCO Temperature
51
TCI Temperature Circuit Failed High
51
Turbo Compressor Out Temperature Sensor Input Voltage
High
52
A/D Conversion Fail
53
Nonvolatile Checksum Incorrect
53
EEPROM Write Error
All information subject to change without notice. (Rev. 01/04)
DDC-SVC-MAN-0058
Copyright © 2004 DETROIT DIESEL CORPORATION
33
DDEC IV SYSTEM
Flash
Code
53
Out of Calibration
54
Vehicle Speed Sensor Fault
55
Missing information from another ECU
55
J1939 Data Link, Proprietary Data Link (Master), or
Proprietary Data Link (Receiver) Fault
56
J1587 Data Link or J1922 Data Link Fault
58
Torque Overload
61
Injector xxx Response Time Long
62
63
34
Description
Aux. Output #1, #2, #5, #6, #7, or #8 Short to Battery
(+), Open Circuit, or Mechanical System Not Responding
Properly
PWM #1, #2, #3, or #4 Above Normal Range, Below Normal
Range, Short to Battery (+), or Open Circuit
64
Turbo Overspeed
64
Turbo Speed Sensor Input Failure — Abnormal Period
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 Coolant Pressure Sensor Input Voltage Low
67
Air Inlet Pressure Sensor Input Voltage High or Low
67
Coolant Pressure Sensor Input Voltage High or Low
68
TPS Idle Validation Circuit Fault (open circuit or short to
ground)
71
Injector xxx Response Time Short
72
Vehicle Overspeed
72
Vehicle Overspeed (Absolute)
DDC-SVC-MAN-0058
All information subject to change without notice. (Rev. 01/04)
Copyright © 2004 DETROIT DIESEL CORPORATION
SERIES 50 OPERATOR'S GUIDE
Flash
Code
Description
72
Oxygen Content Too High or Too Low
73
Air Filter Restriction High
73
Gas Valve Position Above or Below Normal Range
73
Gas Valve Position Input Voltage High or Low
73
Gas Metering Valve Not Responding
73
ESS Transmission Stuck in Gear
73
Transmission Neutral Switch Failure (ESS Transmission)
73
Aux Analog Input Data Erratic, Intermittent, or Incorrect
(ESS Transmission)
73
Aux Analog Input #1 Voltage High or Low (ESS Transmission)
74
Optimized Idle Safety Loop Short to Ground
74
Oil Filter Restriction High
75
ECM Battery Voltage High
75
RTC Backup Battery Voltage High
75
Sensor Supply Voltage High
76
Engine Overspeed With Engine Brake
77
Miscellaneous Faults – Refer to BASIC TROUBLESHOOTING
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
81
Injection Control Pressure or Exhaust Temperature Sensor
Input Voltage High
EGR Differential Pressure Sensor Circuit or EGR
Temperature Circuit Failed High
81
Timing Actuator Failed High or Low
81
Exhaust Port Temperature #1, #2, #3, #4, #5, #6, #7, #8, #9,
#10, #11, #12, #13, #14, #15 or #16 Sensor Voltage High
81
EGR Mass Flow Smart Sensor not Responding or Failed
82
Oil Level Sensor or Crankcase Pressure Sensor Input
Voltage Low
All information subject to change without notice. (Rev. 01/04)
DDC-SVC-MAN-0058
Copyright © 2004 DETROIT DIESEL CORPORATION
35
DDEC IV SYSTEM
Flash
Code
82
82
82
82
Extended Crankcase Pressure Input Voltage Low
Injection Control Pressure Sensor or Exhaust Temperature
Sensor Input Voltage Low
EGR Temperature Circuit or EGR Diffferential Pressure
Sensor Circuit Failed Low
Exhaust Port Temperature #1, #2, #3, #4, #5, #6, #7, #8, #9,
#10, #11, #12, #13, #14, #15 or #16 Sensor Voltage Low
82
EGR Temperature Smart Sensor not Responding or Failed
83
Oil Level, Pump Pressure, or Crankcase Pressure High
83
Extended Crankcase Pressure High
83
Exhaust Temperature High
83
EGR Differential Pressure or EGR Temperature High
83
Exhaust Port Temperature #1 — #16 Sensor Voltage High
84
Oil Level or Crankcase Pressure Low
84
Extended Crankcase Pressure Low
85
Engine Overspeed
85
Engine Overspeed Signal
86
87
36
Description
Pump Pressure Sensor or Barometric Pressure Sensor Input
Voltage High
Pump Pressure Sensorr or Barometric Pressure Sensor
Input Voltage Low
88
High Range Coolant Pressure or Coolant Pressure Low
89
Fuel Restriction High
89
Maintenance Alert Coolant Level Fault
DDC-SVC-MAN-0058
All information subject to change without notice. (Rev. 01/04)
Copyright © 2004 DETROIT DIESEL CORPORATION
SERIES 50 OPERATOR'S GUIDE
DDEC IV ENGINE DRIVING TIPS
Driving with an electronically
controlled engine feels different from
driving with a mechancially governed
engine.
Accelerating the Vehicle
Engine response versus pedal
movement may feel different from the
mechanical-governed engine you were
driving. The electronic foot pedal
assembly (EFPA) was designed to
communicate “percentage” foot pedal
travel to the engine's electronic control
module (ECM). The engine will
respond accordingly to the driver's
demand.
Cruise Control
For added driver convenience and
comfort, DDEC IV also features a
cruise control option that works just
like the system in your car. It can
be operated in any gear above 1000
rpm or road speed faster than 20
mph (32 kph), up to the rated engine
speed. And it can be programmed to
hold your road speed at or below the
maximum vehicle speed. The switch
to energize cruise control is usually
mounted on the instrument panel.
See Figure 9.
Another throttle or governor
characteristic you may need time to
get used to is the DDEC limiting
speed governor. This allows the driver
to command total engine response
between idle and rated speed, such
as accelerating 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.
All information subject to change without notice. (Rev. 01/04)
DDC-SVC-MAN-0058
Figure 9
Typical Cruise Control
Switches
Copyright © 2004 DETROIT DIESEL CORPORATION
37
DDEC IV ENGINE DRIVING TIPS
Turn the switch ON to energize the
system. When you reach your road
speed, press the “Set” switch to
activate cruise control. The cruise
light will come on. To increase
road speed in one mile-per-hour
(1.6 kilometer-per-hour) increments,
press the “Resume/Accel” switch. To
reduce road speed, press and hold the
“Set/Coast” switch until the lower
speed is reached.
Cruise control is deactivated by
slightly depressing the service brakes,
clutch pedal, or trailer brake. The
“On/Off” switch will also deactivate
cruise control.
Cruise control will maintain vehicle
speed even on up grades, unless power
requirements demand a downshift.
And, of course, cruise control does
not limit your speed on down grades.
Most likely, cruise control will feel
stronger than driving with the foot
pedal because of the instantaneous and
wide-open throttle response. That's
why cruise control use is not suggested
during slippery driving conditions.
38
DDC-SVC-MAN-0058
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 or 20 mph (32 kph) road
speed. When using cruise control,
if you want to pull the engine below
1100 rpm, remember to hold the
throttle pedal to the floor to keep the
engine pulling at wide-open throttle.
Realistically, the engine will pull to
about 1050 rpm.
Remember: The electronic data
programmed into the ECM will
not allow you to hurt or overfuel
the engine at low or “lug” engine
speeds. There is enough oil pressure
to withstand hard pulls at low engine
speeds.
All information subject to change without notice. (Rev. 01/04)
Copyright © 2004 DETROIT DIESEL CORPORATION
SERIES 50 OPERATOR'S GUIDE
Engine Brakes and Cruise
Control
If your engine is equipped with
both cruise control and engine brake
retarders, the engine retarders can
operate automatically while you
are in cruise control. If the cruise
control/engine brake function is turned
ON in the ECM (electronic control
module) programming, the engine
retarders will come on “low” when
your set road speed increases a few
miles-per-hour (kilometers per hour)
above your cruise set speed. If your
speed continues to increase, the ECM
will increase the engine retarders'
braking power progressively. When
the vehicle returns to the set cruise
speed, the engine retarders will “turn
off” until you need them.
For safety reasons, don't use cruise
control when it is not possible to keep
the vehicle at constant speed due to:
□ Winding roads
Shifting
Depending on your transmission
model, the gear split may vary from
500 to 300 rpm. The electronic
governor provides almost no overrun
capability; and, if the transmission
is downshifted too early, you will
experience a temporary loss of pulling
power until the engine speed falls
below rated speed.
In general, when using a 7- or 9-speed
transmission, you should always
downshift between 1250 and 1300
rpm. This is true even on steep grades
with heavy loads. When using an
18-, 15- or 13-speed transmission,
you will need to downshift at an
rpm that allows “less than rated”
rpm before throttle application in the
next gear down. You may want to
limit engine speed to 1900 rpm in all
gears. The Series 50 provides constant
horsepower from 1800 rpm through
2100 rpm, but fuel economy is not as
efficient above 1800 rpm.
□ Heavy traffic
□ Slippery pavement
□ Descending grades that call for
engine brake assistance.
For an explanation of the engine brake
retarder system and recommendations
for proper operation, refer to section
ENGINE BRAKE SYSTEM.
All information subject to change without notice. (Rev. 01/04)
DDC-SVC-MAN-0058
Copyright © 2004 DETROIT DIESEL CORPORATION
39
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.
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).
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.
40
DDC-SVC-MAN-0058
All information subject to change without notice. (Rev. 01/04)
Copyright © 2004 DETROIT DIESEL CORPORATION
SERIES 50 OPERATOR'S GUIDE
ENGINE BRAKE SYSTEM
Certain Series 50 vehicle engines
are equipped with engine brakes,
commonly referred to as retarders.
Before operating the vehicle, you
must familiarize yourself with the
retarder system to obtain optimum
benefit from it. Engine brake control
systems may vary slightly, depending
on the engine brake configuration and
cab design. However, basic operator
controls are similar for all models.
Driver Control Switches
Vehicles with manual transmissions
allow the driver to turn the engine
brake on and off and select a low,
medium or high level of braking. Two
types of switches are available.
Low/High Switch
The Low setting on this switch
activates three (3) brake cylinders,
supplying approximately 50% of
normal engine braking horsepower.
The High setting activates all six
(6) cylinders, providing full engine
braking horsepower.
Low/Med/High Switch
The Low setting on this switch
activates two (2) brake cylinders,
yielding about one-third engine
braking horsepower. The Medium
activates four (4) cylinders, supplying
All information subject to change without notice. (Rev. 01/04)
DDC-SVC-MAN-0058
about two-thirds engine braking
horsepower. The High setting
activates all six (6) cylinders,
providing full braking horsepower.
Clutch Pedal and Throttle
Position Controls
Engine brakes have two additional
controls, one activated by the position
of the clutch pedal and the other
activated by the position of the
throttle. These controls permit fully
automatic operation of the engine
braking system.
Engine Brake Operation
NOTE:
The engine brake retarder system
depends on a full-pressure flow
of warm engine lubricating oil for
proper lubrication of moving parts
and optimum performance. It is
important to allow the engine to reach
full operating temperature before
switching on the engine brake system.
Under normal driving conditions the
engine brake system is left in the ON
position. However, this should change
if roads become wet or slippery.
Copyright © 2004 DETROIT DIESEL CORPORATION
41
ENGINE BRAKE SYSTEM
After it is switched on, the engine
brake system is automatically
activated each time you remove your
feet completely from the clutch pedal
and throttle.
The engine brake automatically
deactivates itself when you press the
clutch pedal while shifting gears.
To avoid injury from loss of
vehicle control, do not activate
the Engine Brake system under
the following conditions:
□ On wet or slippery pavement,
unless the vehicle is equipped
with ABS (anti-lock braking
system) and you have had
prior experience driving
under these conditions.
□ When driving without a trailer
(bobtailing) or pulling an
empty trailer.
42
DDC-SVC-MAN-0058
NOTICE:
Do not attempt to “double clutch”
the transmission while the engine
brake system is turned on. Shifting
gears without depressing the clutch
or using the engine brake to reduce
engine rpm may result in serious
powertrain damage.
LOSS OF VEHICLE CONTROL
□ 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.
NOTE:
Some systems may be programmed
to activate themselves only when the
brake pedal is pressed, so read your
vehicle owner's manual thoroughly to
find out if you have this option.
Anti-Lock Braking
Systems
Vehicles equipped with ABS
(anti-lock braking systems) have
the ability to turn the engine brake
retarder OFF if a wheel-slip condition
is detected. The engine brake will
automatically turn itself ON once
the wheel slip is no longer detected.
The DDEC system will deactivate
the engine brake system when the
engine speed falls below 1000 rpm
or when the vehicle slows down to a
pre-set speed, depending on DDEC
programming. This prevents stalling
the engine. Engine brakes can also
be used with vehicle cruise control
TURNED ON.
All information subject to change without notice. (Rev. 01/04)
Copyright © 2004 DETROIT DIESEL CORPORATION
SERIES 50 OPERATOR'S GUIDE
Driving on Flat, Dry
Pavement
Use the following guidelines when
driving on flat, dry pavement:
1. If driving on flat, dry, open
stretches with a light load 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 progressive braking
switch often for proper position,
since road conditions can change
quickly. Never skip a step when
operating the progressive braking
switch. Always go from OFF
to LOW, and then to a higher
position.
Descending a Long, Steep
Grade
An explanation of “control speed”
may be helpful in understanding how
to use the engine brake system while
descending a grade. Control Speed
is the constant speed at which the
All information subject to change without notice. (Rev. 01/04)
DDC-SVC-MAN-0058
forces pushing the vehicle forward on
a grade are equal to the forces holding
it back, without using the vehicle
service brakes. In other words, this
is the speed the vehicle will maintain
without using the service brakes or
fueling.
BRAKE FADE
To avoid injury, do not over
apply the vehicle service brakes
when descending a long, steep
grade. Excessive use of the
vehicle brakes will cause them
to heat up, reducing their
stopping ability. This condition,
referred to as “brake fade”, may
result in loss of braking, which
could lead to personal injury or
vehicle/property damage or both.
Use the following guidelines when
descending a long, steep grade:
1. Before beginning 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.
Copyright © 2004 DETROIT DIESEL CORPORATION
43
ENGINE BRAKE SYSTEM
PERSONAL INJURY
Failure to keep the vehicle within
safe control speed limits while
descending a grade may result
in loss of vehicle control, which
could cause personal injury.
4. Check your progressive braking
switch often for proper position,
since road conditions can change
quickly. Never skip a step when
operating the progressive braking
switch. Always go from OFF
to LOW and then to a higher
position when on slippery roads.
Driving on Wet or Slippery
Pavement
NOTICE:
Failure to keep the vehicle within
safe control speed limits while
descending a grade may result in
vehicle or property damage or both.
3. When descending a grade, do
not exceed the safe control speed
of your vehicle. Example: You
could descend a 6% grade under
control only at 10 mph (16 kph)
without an engine brake, but at
25 mph (40 kph) with an engine
brake. You could not descend
that same hill at 50 mph (80
kph) and still expect to remain
under control. Know how much
slowing power your engine brake
can provide. Know your engine
brake system before climbing
hills and do not exceed a safe
control speed.
44
DDC-SVC-MAN-0058
Do not attempt to use the engine brake
system on wet or slippery roads until
you have some experience with it on
dry pavement.
NOTE:
On single trailers or combinations,
a light air application of the trailer
brakes may be desirable to help
keep the trailer stretched out. Follow
the manufacturer's recommended
operating procedure when using your
trailer brakes.
On wet or slippery pavement, start
with the master switch in the OFF
position and use the gear you would
normally use under these conditions.
All information subject to change without notice. (Rev. 01/04)
Copyright © 2004 DETROIT DIESEL CORPORATION
SERIES 50 OPERATOR'S GUIDE
OFF immediately and do not activate
it until road conditions improve.
LOSS OF VEHICLE CONTROL
To avoid injury from loss of
vehicle control, do not activate
the Engine Brake system under
the following conditions:
□ On wet or slippery pavement,
unless the vehicle is equipped
with ABS (anti-lock braking
system) and you have had
prior experience driving
under these conditions.
Check your progressive braking
switch often for proper position, since
road conditions can change quickly.
Never skip a step when operating the
progressive braking system. Always
go from OFF to LOWand then to a
higher position
□ When driving without a trailer
(bobtailing) or pulling an
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.
If the vehicle is maintaining traction,
place the selective braking switch in
the LOW position and turn ON the
engine brake system. If the drive
wheels are maintaining traction and
you desire greater slowing power,
move the braking switch to the next
highest position.
However, if the tractor drive wheels
begin to lock or there is a fishtail
motion, turn the engine brake system
All information subject to change without notice. (Rev. 01/04)
DDC-SVC-MAN-0058
Copyright © 2004 DETROIT DIESEL CORPORATION
45
ENGINE SYSTEMS
ENGINE SYSTEMS
The engine system are the following:
Fuel System
The fuel system consists of the
DDEC, fuel injectors, fuel manifolds
(integral with the cylinder head), fuel
pump, a cooling plate for the ECM
on non-automotive engines, primary
and secondary fuel filters, and the
necessary connecting fuel lines.
Lubrication System
The lubricating oil system consists of
an oil pump, oil cooler, two full-flow
oil filters, bypass valves at the oil
pump and oil filter adaptor, and
oil pressure regulator valve in the
cylinder block vertical oil gallery.
Air System
The outside air drawn into the
engine passes through the air filter
and is pulled into the turbocharger
and compressed. It then moves to
the air-to-air charge cooler (heat
exchanger) and is cooled. Next it
flows to the intake manifold and into
the cylinders, where it mixes with
atomized fuel from the injectors.
For optimum protection of the
engine from dust and other airborne
contaminants, service the dry type air
cleaners when the maximum allowable
46
DDC-SVC-MAN-0058
air restriction has been reached, or
annually, whichever occurs first.
Cooling System
A radiator/thermo-modulated fan
cooling system is used on Series 50
engines. This system has a centrifugal
type fresh water pump to circulate
coolant within the engine. Two
full-blocking type thermostats located
in a housing attached to the right side
of the cylinder head control the flow
of coolant.
Electrical System
The electrical system consists of
a starting motor, starting switch,
battery-charging alternator, storage
batteries, and the necessary wiring.
Exhaust System
Hot exhaust gas flowing from the
exhaust manifold into the exhaust riser
is used to drive the turbocharger.
Exhaust Gas Recirculation
System
The purpose of the Exhaust Gas
Recirculation System (EGR) is to
reduce engine exhaust gas emissions
in accordance with EPA regulations.
All information subject to change without notice. (Rev. 01/04)
Copyright © 2004 DETROIT DIESEL CORPORATION
SERIES 50 OPERATOR'S GUIDE
MAINTENANCE
The following is intended as a
guide for establishing preventive
maintenance intervals. The
recommendations given should
be followed as closely as possible
to obtain long life and optimum
performance from your engine.
Maintenance intervals indicated are
time (hours) of actual operation. The
intervals shown apply only to the
maintenance functions described.
These functions should be coordinated
with other regularly scheduled
maintenance.
A description of the maintenance to
be performed for each item in the
following tables can be found in the
Preventive Maintenance Intervals
section
Recommended maintenance intervals
for Series 50 on-highway truck
and parlor coach engines are
listed in Table 1, Table 2 and
Table3. Recommended maintenance
intervals for Series 50 transit coach
engines are listed in Table 4, Table
5, 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
All information subject to change without notice. (Rev. 01/04)
DDC-SVC-MAN-0058
12. Recommended maintenance
intervals for Series 50 generator drive
engines are listed in Table 13, Table
14, and Table 15.
NOTICE:
Failure to check and maintain
SCA (supplemental coolant
additive) levels at required
concentrations will result in
severe damage (corrosion)
to the engine cooling system
and related components.
Coolant must be inhibited with the
recommended SCAs listed in this
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.
Copyright © 2004 DETROIT DIESEL CORPORATION
47
MAINTENANCE
Item
Daily
Checks
7,500 Miles
(12,000 Km)
1.
Lubricating Oil
I
2.
Fuel Tank
I
3.
Fuel Lines & Flex Hoses
I
4.
Cooling System
I
5.
Turbocharger
I
6.
Battery
I
8.
Drive Belts
I
9.
Air Compressor
I
15,000 Miles
(24,000 Km)
R
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 1
48
On-Highway Truck, Motor Coach, Urban Bus and Motor
Home Daily, 7,500 Mile, and 15,000 Mile Checks
DDC-SVC-MAN-0058
All information subject to change without notice. (Rev. 01/04)
Copyright © 2004 DETROIT DIESEL CORPORATION
SERIES 50 OPERATOR'S GUIDE
Item
Months
6
Miles/Km
( X 1000)
15/
24
12
18
24
30
30/ 45/ 60/ 75/
48 72 96 120
36
42
48
54
60
90/ 105/ 120/ 135/ 150/
144 168 192 216 240
1.
Lubricating Oil
2.
Fuel Tank
Replace lubricating oil every 15,000 miles (24,000 km).
4.
Cooling System
5.
Turbocharger
8.
Drive Belts
I
I
I
I
I
9.
Air Compressor
I
I
I
I
I
11.
Lube Oil Filters
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
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
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
R
I
I
I
I
I
I
I
Replace when lubricating oil is changed.
Follow manufacturer's recommendations.
All items are described in Preventive Maintenance Intervals.
I – Inspect, service, correct or replace as necessary.
R – Replace.
Table 2
On-Highway Truck, Motor Coach, Urban Bus and Motor
Home Regular Maintenance Intervals
All information subject to change without notice. (Rev. 01/04)
DDC-SVC-MAN-0058
Copyright © 2004 DETROIT DIESEL CORPORATION
49
MAINTENANCE
Months
Item
Miles/Km
( X 1000)
6
12
18
Engine
(Steam Clean)
18. Radiator & A/A Charge
Cooler
17.
42
I
I
48
54
60
I
I
19. Oil Pressure
20. Battery Charging
Alternator
21. Engine & Transmission
Mounts
24 30 36
15/ 30/ 45/ 60/ 75/ 90/ 105/ 120/ 135/ 150/
24 48 72 96 120 144 168 192 216 240
I
I
I
I
22. Crankcase Pressure
I
I
I
I
I
I
I
I
I
I
I
I
I
24. Thermostats & Seals
I
25. Crankcase Breather
I
27. Vibration Damper
I
I
23. Fan Hub
26. Engine Tune-Up
I
I
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
50
On-Highway Truck, Motor Coach, Urban Bus and Motor
Home Regular Maintenance Intervals (continued)
DDC-SVC-MAN-0058
All information subject to change without notice. (Rev. 01/04)
Copyright © 2004 DETROIT DIESEL CORPORATION
SERIES 50 OPERATOR'S GUIDE
Daily
6,000 Miles
Checks (9,600 Km)
Item
7,500 Miles
(12,000 Km)
1.
Lubricating Oil
I
2.
Fuel Tank
I
3.
Fuel Lines &
Flexible Hoses
I
4.
Cooling System
I
5.
Turbocharger
I
6.
Battery
I
8.
Drive Belts
I
9.
Air Compressor
I
15,000 Miles
(24,000 Km)
R
I
10. Air Cleaner
I
11. Lube Oil Filters
R
12. Fuel Filters
13.
R
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)
DDC-SVC-MAN-0058
Copyright © 2004 DETROIT DIESEL CORPORATION
51
MAINTENANCE
Months
Item
Miles/Km
( X 1000)
6
12
18
24
30
36
42
48
54
60
15/ 30/ 45/ 60/ 75/ 90/ 105/ 120/ 135/ 150/
24 48 72 96 120 144 168 192 216 240
Replace lubricating oil every 6,000 miles (9,600
km) or every three months, whichever comes first.
On transit coach model 6047MK1E only, replace
oil every 3,000 miles (4,800 km).
1.
Lubricating Oil
2.
Fuel Tank
4.
Cooling System
5.
Turbocharger
I
I
I
I
I
I
I
I
I
I
7.
Tachometer
Drive
I
I
I
I
I
I
I
I
I
I
8.
Drive Belts
I
I
I
I
I
I
I
R
I
I
9.
Air Compressor
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
11. Lube Oil Filters
I
I
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
I
I
14. Cranking Motor
15. Air System
Follow manufacturer's recommendations.
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 5
52
Transit Coach, Pick-Up and Delivery, Stop-and-Go and
Short Trip Regular Maintenance Intervals
DDC-SVC-MAN-0058
All information subject to change without notice. (Rev. 01/04)
Copyright © 2004 DETROIT DIESEL CORPORATION
SERIES 50 OPERATOR'S GUIDE
Item
Months
6
Miles/Km
( X 1000)
15/
24
16. Exhaust System
I
17. Engine
(Steam Clean)
18. Radiator & A/A
Cooler
19. Oil Pressure
12
18
24
30/ 45/ 60/
48 72 96
I
I
I
30
36
42
I
I
I
I
I
I
I
I
I
22. Crankcase Pressure
I
I
I
I
I
60
I
I
I
I
I
I
I
I
I
I
I
23. Fan Hub
I
24. Thermostats & Seals
I
25. Crankcase Breather
I
I
I
26. Engine Tune-Up
27. Vibration Damper
54
I
I
20. Battery Charging
Alternator
21. Engine &
Transmission
Mounts
48
75/ 90/ 105/ 120/ 135/ 150/
120 144 168 192 216 240
I
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 Maintenance Intervals (continued)
All information subject to change without notice. (Rev. 01/04)
DDC-SVC-MAN-0058
Copyright © 2004 DETROIT DIESEL CORPORATION
53
MAINTENANCE
Daily
Checks
Item
1. Lubricating Oil
I
2. Fuel Tank
I
Fuel Lines &
3.
Flexible Hoses
I
4. Cooling System
I
5. Turbocharger
I
100 Hr
or
3,000 Mi
6. Battery*
150 Hr
or
4,500 Mi
200 Hr
or
6,000 Mi
300 Hr
or
9,000 Mi
R
I
I
7. Tachometer
Drive
8. Drive Belts
I
I
9. Air Compressor
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
54
Stationary or Construction/Industrial Engine Daily, 100
Hour, 150 Hour, 200 Hour, and 300 Hour Checks
DDC-SVC-MAN-0058
All information subject to change without notice. (Rev. 01/04)
Copyright © 2004 DETROIT DIESEL CORPORATION
SERIES 50 OPERATOR'S GUIDE
Hours
Item
150 300 450 600 750 900 1050 1200 1350 1500
Miles/Km
( X 1000)
4.5/ 9.0/ 13.5/ 18/ 22.5/ 27/ 31.5/ 36/ 40.5/ 45/
7.2 14.4 21.6 28.8 36 43.2 50.4 57.6 64.6 72
Replace lubricating oil every 150 hours or 4,500
miles (7,200 km), whichever comes first.
1.
Lubricating Oil
2.
Fuel Tank
4.
Cooling
System
5.
Turbocharger
I
I
I
I
I
I
I
I
I
I
7.
Tachometer
Drive
I
I
I
I
I
I
I
I
I
I
8.
Drive Belts
I
I
I
I
I
I
I
R
I
I
9.
Air
Compressor
I
I
I
I
I
I
I
I
I
I
I
Lube Oil Filters
12.
Fuel Filters
13.
Coolant Pump/
Inhibitor Level
Cranking
Motor
15.
Air System
I
I
I
11.
14.
I
I
I
Replace when lubricating oil is changed.
R
R
R
R
R
R
R
R
R
R
I
I
I
I
I
I
I
I
I
I
Follow manufacturer's recommendations.
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 8
Stationary or Construction/Industrial Regular Maintenance
Intervals
All information subject to change without notice. (Rev. 01/04)
DDC-SVC-MAN-0058
Copyright © 2004 DETROIT DIESEL CORPORATION
55
MAINTENANCE
Hours
Item
Miles/Km
( X 1000)
16. Exhaust
System
17. Engine
(Steam Clean)
18. Radiator & A/A
Charge Cooler
19. Oil Pressure
20. Battery
Charging
Alternator
21. Engine &
Transmission
Mounts
22. Crankcase
Pressure
150
300 450 600 750 900 1050 1200 1350 1500
4.5/
7.2
9.0/ 13.5/ 18/ 22.5/ 27/ 31.5/ 36/ 40.5/ 45/
14.4 21.6 28.8 36 43.2 50.4 57.6 64.6 72
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
23. Fan Hub
I
I
24. Thermostats &
Seals
25. Crankcase
Breather
26. Engine
Tune-Up
27. Vibration
Damper
I
I
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
56
Stationary or Construction/Industrial Regular Maintenance
Intervals (continued)
DDC-SVC-MAN-0058
All information subject to change without notice. (Rev. 01/04)
Copyright © 2004 DETROIT DIESEL CORPORATION
SERIES 50 OPERATOR'S GUIDE
Daily
Checks
Item
1.
Lubricating Oil
I
2.
Fuel Tank
I
3.
Fuel Lines & Flexible Hoses
I
4.
Cooling System
I
5.
Turbocharger
I
6.
Battery
7.
Tachometer Drive
8.
Drive Belts
9.
Air Compressor
100 Hours or
3,000 Miles
( 4,800 Km)
300 Hours or
6,000 Miles
( 9,600 Km)
R
I
I
I
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 without notice. (Rev. 01/04)
DDC-SVC-MAN-0058
Copyright © 2004 DETROIT DIESEL CORPORATION
57
MAINTENANCE
Item
Hours
300
600
Miles/Km
(X 1000)
6/1.6
12/9.6
900
1,200
18/28.8 24/38.4
1,500
30/48
Replace lubricating oil every 300 hours or
6,000 miles (1,600 km), whichever comes first.
1.
Lubricating Oil
2.
Fuel Tank
4.
Cooling System
5.
Turbocharger
I
I
I
I
I
7.
Tachometer Drive
I
I
I
I
I
9.
Air Compressor
I
I
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
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
58
Fire Fighting, Crash/Rescue and Emergency Vehicle
Engine Regular Maintenance Intervals
DDC-SVC-MAN-0058
All information subject to change without notice. (Rev. 01/04)
Copyright © 2004 DETROIT DIESEL CORPORATION
SERIES 50 OPERATOR'S GUIDE
Item
Hours
300
600
Miles/Km
(X 1000)
6/1.6
12/9.6
I
I
900
1,200
18/28.8 24/38.4
1,500
30/48
17. Engine (Steam Clean)
18. Radiator & A/A Charge
Cooler
19. Oil Pressure
I
I
20. Battery Charging
Alternator*
21. Engine & Transmission
Mounts
I
I
I
I
I
I
22. Crankcase Pressure
I
I
23. Fan Hub
I
I
I
I
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 subject to change without notice. (Rev. 01/04)
DDC-SVC-MAN-0058
Copyright © 2004 DETROIT DIESEL CORPORATION
59
MAINTENANCE
Item
Prime
Daily
Standby
Monthly
1.
Lubricating Oil
I
I*
2.
]Fuel Tank
I
I
3.
Fuel Lines & Flexible Hoses
I
4.
Cooling System
I
5.
Turbocharger
I
6.
Battery
8.
Drive Belts
I*
I
I
I
10. Air System, Cleaner
I
I
12. Fuel Filters, Water Separator
I
I*
16. Exhaust System
I
19. Oil Pressure
I
Load Test
I*
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
60
Generator Set Engine Prime Daily and Standby Monthly
Maintenance Intervals
DDC-SVC-MAN-0058
All information subject to change without notice. (Rev. 01/04)
Copyright © 2004 DETROIT DIESEL CORPORATION
SERIES 50 OPERATOR'S GUIDE
Item
Hours
150
300
600
1.
Lubricating Oil
2.
Fuel Tank
I
3.
Fuel Lines &
Flexible Hoses
I
4.
Cooling System
6.
Battery
I
7.
Tachometer
Drive
I
8.
Drive Belts
I
10. Air Cleaner
I
11. Lube Oil Filters
12. Fuel Filters
13. Coolant Pump/
Inhibitor Level
14. Cranking Motor
1,000 1,500 2,000 3,000
4,000
Standby: Replace every 150 hours or 1 year,
whichever comes first.
Prime: Replace every 250 hours or 3 months,
whichever comes first.
R
R
Replace when lubricating oil is changed.
Standby: Replace every 150 hours or 1 year,
whichever comes first.
Prime: Replace every 150 hours or 3 months,
whichever comes first.
I
Follow manufacturer's recommendations.
All items are described in Preventive Maintenance Intervals.
I – Inspect, service, correct or replace as necessary.
R – Replace
Table 14
Generator Set Engine Regular Maintenance Intervals
All information subject to change without notice. (Rev. 01/04)
DDC-SVC-MAN-0058
Copyright © 2004 DETROIT DIESEL CORPORATION
61
MAINTENANCE
Hours
Item
150
300
16. Exhaust System
600
1,000 1,500 2,000 3,000 4,000
I
17. Engine
(Steam Clean)
18. Radiator
I
I
19. Oil Pressure
I
20. Battery
Charging
Alternator
21. Engine &
Generator
Mounts
22. Crankcase
Pressure
I
I
I
23. Fan Hub
I
24. Thermostats &
Seals
25. Crankcase
Breather
R
I
26. Engine Tune-Up
27. Vibration
Damper
I
R
I
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
62
Generator Set Engine Regular Maintenance Intervals
(continued)
DDC-SVC-MAN-0058
All information subject to change without notice. (Rev. 01/04)
Copyright © 2004 DETROIT DIESEL CORPORATION
SERIES 50 OPERATOR'S GUIDE
Preventive Maintenance
Intervals
The following is intended as a
guide for establishing preventive
maintenance intervals. The
recommendations given should
be followed as closely as possible
to obtain long life and optimum
performance from your engine.
Maintenance intervals indicated are
time (hours) of actual operation.
Item 1 – Lubricating Oil
Check the oil level daily with the
engine stopped. If the engine has
just been stopped and is warm, wait
approximately 20 minutes to allow the
oil to drain back into the oil pan before
checking. Add the proper grade of oil
to maintain the correct level on the
dipstick. See Figure 10.
The intervals shown apply only to
the maintenance functions described
and should be coordinated with other
regularly scheduled maintenance.
The “Daily” instructions apply to
routine or daily starting of the engine.
They do not apply to a new engine
or one that has been operated for a
considerable period of time.
For new or stored engines, refer
to Section 13.1, “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.
All information subject to change without notice. (Rev. 01/04)
DDC-SVC-MAN-0058
Figure 10
Check Oil Level Daily
NOTICE:
When adding lubricating oil, do
not overfill. Oil may be blown out
through the crankcase breather if
the crankcase is overfilled.
All diesel engines are designed to
use some oil, so the periodic addition
of oil is normal. See Figure 11 to
determine the degree of oil usage.
Copyright © 2004 DETROIT DIESEL CORPORATION
63
MAINTENANCE
Figure 11
Engine Oil Consumption Guidelines
NOTICE:
If the oil level is constantly above
normal and excess oil has not been
added to the crankcase, consult with
an authorized Detroit Diesel service
outlet. Fuel or coolant dilution of
lubricating oil can result in serious
engine damage.
Service Application
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 Oil in this
guide.
Lube Oil and Filter Change Interval*
Highway Truck & Motor Coach
15,000 Miles (24,000 Kilometers)
City Transit Coach except model
6047MK1E
6,000 Miles (9,600 Kilometers), 300
Hours or 3 Months†
City Transit Coach Model 6047MK1E
3,000 Miles (4,800 Kilometers)
Fire Fighting, Crash/Rescue, &
Emergency Vehicles
6,000 Miles (9,600 Kilometers), 300
Hours or 1 Year†
Construction, Industrial & Agricultural
250 Hours or 1 Year†
Stationary Generator – Prime Power
or Continuous
300 Hours or 3 Months†
Stationary Generator – Standby
150 Hours or 1 Year†
* Change both full-flow filters when lube oil is changed.
† Whichever comes first
Table 16
64
Engine Oil Drain and Filter Change Intervals (Diesel Fuel
Sulfur Content Less Than 0.05 Mass %)
DDC-SVC-MAN-0058
All information subject to change without notice. (Rev. 01/04)
Copyright © 2004 DETROIT DIESEL CORPORATION
SERIES 50 OPERATOR'S GUIDE
Item 2 – Fuel and Fuel Tank
Keep the fuel tank filled to reduce
condensation. See Figure 12.
(48,000 kilometers) or 300 hours for
construction/industrial applications to
drain off any water and/or sediment.
PERSONAL INJURY
Figure 12
Filled Fuel Tank
Before adding fuel, refer to section
How to Select Fuel Oil in the How To
section of this guide.
Refill the tank at the end of each day's
operation to prevent condensation
from contaminating the fuel.
Condensation formed in a partially
filled tank promotes the growth of
microorganisms that can clog fuel
filters and restrict fuel flow.
To avoid injury from improper use
of chemicals, follow the chemical
manufacturer’s usage, handling,
and disposal instructions.
Observe all manufacturer’s
cautions.
Every 120,000 miles (192,000
kilometers), 12 months, or 600
hours for construction/industrial
applications tighten all fuel tank
mountings and brackets. At the same
time, check the seal in the fuel tank
cap, the breather hole in the cap and
the condition of the flexible fuel
lines. Repair or replace the parts, as
necessary.
To prevent microbe growth, add a
biocide to the fuel tank or primary
fuel supply.
Water accumulation can be controlled
by using additives containing methyl
carbitol or butyl cellusolve. Follow
manufacturer's usage, handling and
safety precautions.
Open the drain at the bottom of
the fuel tank every 30,000 miles
All information subject to change without notice. (Rev. 01/04)
DDC-SVC-MAN-0058
Copyright © 2004 DETROIT DIESEL CORPORATION
65
MAINTENANCE
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 and fittings must be made.
Leaks — Make a visual check for
fuel leaks at all engine-mounted fuel
lines and connections, and at the
fuel tank suction and return lines.
Since fuel tanks are susceptible to
road hazards, leaks in this area may
best be detected by checking for an
accumulation of fuel under the tank.
FIRE
To avoid injury from fire, contain
and eliminate leaks of flammable
fluids as they occur. Failure to
eliminate leaks could result in
fire.
result in added expense caused by the
need to replace lost fluids.
Hoses and Fittings — Check
hoses daily as part of the pre-start
inspection. Examine hoses for leaks,
and check all fittings, clamps and
ties carefully. Make sure hoses are
not resting on or touching shafts,
couplings, heated surfaces including
exhaust manifolds, any sharp edges,
or other obviously hazardous areas.
Since all machinery vibrates and
moves to a certain extent, clamps and
ties can fatigue with age. To ensure
continued proper support, inspect
fasteners frequently and tighten or
replace them as necessary. If fittings
have loosened or cracked or if hoses
have ruptured or worn through, take
corrective action immediately.
Hose Service Life — A hose has
a finite service life. All hoses should
be thoroughly inspected at least every
500 operating hours (1,000 hours
for fire-resistant fuel and lubricating
oil hoses) and/or annually. Look
for cover damage and/or indications
of twisted, worn, crimped, brittle,
cracked or leaking lines. Hoses with
their outer cover worn through or with
damaged metal reinforcements should
be considered unfit for further service.
Leaks are not only detrimental to
machine operation, but they can also
66
DDC-SVC-MAN-0058
All information subject to change without notice. (Rev. 01/04)
Copyright © 2004 DETROIT DIESEL CORPORATION
SERIES 50 OPERATOR'S GUIDE
All hoses in and out of machinery
should be replaced during major
overhaul and/or after a maximum of
five (5) years of service.
NOTE:
Fire-resistant fuel and lube oil hose
assemblies do not require automatic
replacement after five years of service
or at major overhaul, but should be
inspected carefully before being put
back into service.
Item 4 – Cooling System
HOT COOLANT
To avoid scalding from the
expulsion of hot coolant, never
remove the cooling system
pressure cap while the engine is
at operating temperature. Wear
adequate protective clothing
(face shield, rubber gloves,
apron, and boots). Remove the
cap slowly to relieve pressure.
required, but do not overfill. Before
adding coolant, refer to section How
to Select Coolant in this guide.
Make a daily visual check for
cooling system leaks. Look for an
accumulation of coolant when the
engine is running and when it is
stopped. Coolant leaks may be more
apparent on a engine when it is cold.
Coolant Inhibitors — The
inhibitors in antifreeze solutions must
be replenished with a non-chromate
corrosion inhibitor supplement when
indicated by testing the coolant. In
addition, the engine can be equipped
with a coolant filter/inhibitor system as
an installed option or as an after-sale
item.
The cooling system must be full for
proper operation of the engine.
Coolant Level — Check the coolant
level daily and maintain it near the
bottom of the filler neck on the
radiator. On some installations this
is done by checking an overflow
bottle or sight glass. Add coolant as
All information subject to change without notice. (Rev. 01/04)
DDC-SVC-MAN-0058
Copyright © 2004 DETROIT DIESEL CORPORATION
67
MAINTENANCE
Refer to section How to Select Coolant
for required test intervals and inhibitor
levels.
NOTICE:
Failure to check and maintain
SCA 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.
68
DDC-SVC-MAN-0058
All information subject to change without notice. (Rev. 01/04)
Copyright © 2004 DETROIT DIESEL CORPORATION
SERIES 50 OPERATOR'S GUIDE
Coolant Drain Interval —
Detroit Diesel recommends
replacing coolant at the intervals
listed in Table 17.
up to the intervals listed. At
these intervals the coolant must
be drained and disposed of in an
environmentally responsible manner
according to state and/or federal
(EPA) recommendations.
A coolant system properly maintained
and protected with supplemental
coolant inhibitors can be operated
Coolant Type
Coolant Replacement Interval
A 50/50 mix of PowerCool® fully
formulated, inhibited ethylene
glycol antifreeze and water or
a 50/50 mix of fully formulated,
inhibited propylene glycol
antifreeze and water
With proper maintenance1 coolant can be
operated 2 years, 300,000 miles (480,000
km), or 4,000 hours, whichever comes first.
At this time the cooling system must be
completely drained and cleaned before refill.
With proper maintenance1 coolant can be
operated for the life of the engine until
A 50/50 mix of phosphate-free
overhaul.2 For life to overhaul, pre-charged
TMC RP-329 “Type A“
coolant in combination with a need-release
(propylene glycol) antifreeze
filter must be used. At this time the cooling
and water.
system must be completely drained and
cleaned before refill.
With proper maintenance coolant can be
operated 4 years, 600,000 miles (960,000
A 50/50 mix of OAT (organic
km), or 10,000 operating hours, whichever
acid technology) coolant and
comes first. 3 At this time the cooling system
water.
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
indicated by the test strip.
2
To verify coolant acceptability, submit a sample to DDC for coolant
analysis every 3 years, 300,000 miles (480,000 km) or 6,000
operating hours, whichever comes first. Submit sample using
PowerTrac coolant analysis kit, part number 23516921 (IEG/IPG
coolant) or 23523398 (organic coolant).
3
OAT coolants require the addition of an extender every 2 years,
300,000 miles (480,000 km), or 5,000 hours, whichever comes first.
Use 1 pint to 20 gallons of OAT coolant.
Table 17
Coolant Drain Intervals
All information subject to change without notice. (Rev. 01/04)
DDC-SVC-MAN-0058
Copyright © 2004 DETROIT DIESEL CORPORATION
69
MAINTENANCE
Item 5 – Turbocharger, Air-to-Air
Charge Cooler
Visually inspect the turbocharger
mountings, intake and exhaust ducting
and connections for leaks daily. Check
the lube oil inlet and outlet lines for
leaks or restrictions to oil flow. Check
for unusual noise or vibration and, if
excessive, stop the engine and do not
operate until the cause is determined.
PERSONAL INJURY
To avoid injury from hot surfaces,
wear protective gloves, or allow
engine to cool before removing
any component.
Periodically inspect the air-to-air
charge cooler (if used) for buildup of
dirt, mud, etc. and wash off. Check
the charge cooler, ductwork, and
flexible connections for leaks and
have repaired or replaced, as required.
Check turbocharger heat-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.
70
DDC-SVC-MAN-0058
Wastegated Turbochargers —
The turbocharger wastegate actuator
is factory-calibrated and is not
adjustable. Check actuator operation
at the intervals shown in the
maintenance schedule.
EYE INJURY
To avoid injury from flying debris
when using compressed air, wear
adequate eye protection (face
shield or safety goggles) and do
not exceed 276 kPa (40 psi) air
pressure.
NOTICE:
Do not exceed 30 psi (207 kPa) air
pressure when checking wastegate
actuator operation. Excessive air
pressure can damage the actuator.
To verify correct wastegate actuator
operation, apply 30 psi (207 kPa)
of regulated shop air and watch for
actuator rod movement.
All information subject to change without notice. (Rev. 01/04)
Copyright © 2004 DETROIT DIESEL CORPORATION
SERIES 50 OPERATOR'S GUIDE
Item 6 – Battery
Check the hydrometer “eye” of
maintenance-free batteries for charge.
See Figure 13.
Maintain the electrolyte level
according to the battery manufacturer's
recommendations, but do not overfill.
Overfilling can cause poor battery
performance or early failure.
Keep the terminal side of the 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.
Figure 13
Maintenance-Free
Battery “Eye”
PERSONAL INJURY
To avoid injury from accidental
engine startup while servicing
the engine, disconnect/disable
the starting system.
If the engine is to be out of service
for more than 30 days, remove the
batteries and store in a cool, dry
place. Keep batteries fully charged,
if possible. Replace any battery that
fails to hold a charge.
Periodically check battery connections
for corrosion and tightness. If
necessary, remove connections
and wire brush any corrosion from
terminals and cable ends. Replace
damaged wiring.
If lead-acid or low-maintenance
batteries are used, check the specific
gravity of each cell every 150
operating hours. Check more
frequently in warm weather due to
the more rapid loss of water through
evaporation.
All information subject to change without notice. (Rev. 01/04)
DDC-SVC-MAN-0058
Copyright © 2004 DETROIT DIESEL CORPORATION
71
MAINTENANCE
Item 7 – Tachometer Drive
A typical tachometer drive take-off
location is the camshaft drive gear
access cover on the front of the gear
case cover. Lubricate the tachometer
drive (if so equipped) every 150 hours
or 15,000 miles (24,000 km) with an
all-purpose grease. At temperatures
above –1° C (+30° F) use a No. 2
grade grease. Use a No. 1 grade
grease below this temperature.
Item 8 – Drive Belts
Belts should be neither too tight nor
too loose. Belts that are too tight
impose extra loads on the crankshaft,
fan and/or alternator bearings,
shortening both belt and bearing life.
Excessively overtightened belts can
result in crankshaft breakage. A loose
belt will slip and may cause damage
to accessory components.
PERSONAL INJURY
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.
Fan Drive
Single Belt
2 or 3 Belts
80 – 100 lbs (356 – 445 N)
60 – 80 lbs (267 – 356 N)
Alternator Drive
Belt
New
Used
Two 1/2–in. V-Groove
125 lbs (556 N)
100 lbs (445 N)
2–Groove PowerBand®
200 lbs (890 N)
150 lbs (667 N)
12–Rib Poly-V (50 DN Alternator)
350 lbs (1,557 N)
250 lbs (1,112 N)
Table 18
72
Drive Belt Tensioning
DDC-SVC-MAN-0058
All information subject to change without notice. (Rev. 01/04)
Copyright © 2004 DETROIT DIESEL CORPORATION
SERIES 50 OPERATOR'S GUIDE
V-Belts — New standard V-belts
will stretch after the first few hours
of operation. Tighten V-belts as
listed in Table 18. Run the engine
for 10 to 15 minutes to seat the belts,
then readjust tension. Check and
retension belts after 1/2 hour and
again after 8 hours or 250 miles (400
km) of operation. Thereafter, check
the tension of the drive belts every
100 hours or 6,000 miles (10,000 km)
and adjust, if necessary.
If a belt tension gage is not available,
adjust the belt tension so that a firm
push with the thumb, at a point
midway between the two pulleys, will
depress the belt .50 in. – .75 in. (13
– 19 mm).
tensioning, measure belt tension
every month or every 7,500 miles
(12,000 km), whichever comes first.
Retension belt to 150 lbs (667 N) at
these intervals.
Figure 14
Auto Belt Tensioner
Assembly with 50 DN
Alternator
Figure 15
Manual Tensioner
Assembly with 50 DN
Alternator
2-Groove PowerBand — The
2-groove PowerBand® is used with
the 50 DN alternator. To provide
proper running tension for the belt,
current Series 50 engines use an auto
belt tensioner, which requires no
adjustment. See Figure 14.
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 period. Check tension. If
less than 150 lbs (667 N), retension
to 150 lbs (667 N). Following initial
All information subject to change without notice. (Rev. 01/04)
DDC-SVC-MAN-0058
Copyright © 2004 DETROIT DIESEL CORPORATION
73
MAINTENANCE
12–Rib Poly-V Belt — Tighten a
12–rib poly-V belt to 350 lbs (1,557
N), then run the engine at high idle for
30 minutes. Stop the engine and allow
a 10 – 15 minute cool down period.
Check tension with tool J 41251–B
or equivalent. If tension is 250 lbs
(1,112 N) or more, no retensioning is
required. If tension is less than 250 lbs
(1,112 N), retension to 250 lbs (1,112
N). Measure belt tension every month
or every 7,500 miles (12,000 km),
whichever comes first. Retension to
250 lbs (1,112 N) as required.
Belt Replacement — Drive belts
(V and poly-V) should be replaced
every 2,000 hours or 100,000 miles
(160,000 km).
Replace all belts in a set when one
is worn. Single belts of similar size
should not be used as a substitute for
a matched belt set. Premature belt
wear can result because of belt length
variation. All belts within a matched
set are within .032 in. (0.8 mm) of
their specified center distances.
When installing or adjusting an
accessory drive belt, be sure the bolt
at the accessory adjusting pivot point
is properly tightened, as well as the
bolt in the adjusting slot. In addition,
check the torque on the alternator and
bracket mounting bolts. Retighten as
required.
74
DDC-SVC-MAN-0058
Item 9 – Air Compressor
All air compressor intake parts
should be removed and cleaned at the
following intervals:
□ On Highway Vehicle Engines –
7,500 miles (12,000 km)
□ Industrial Engines – 150 Hours or
4,500 miles (7,200 km)
To clean either the hair type or the
polyurethane type compressor air
strainer element, saturate it and
squeeze it in fuel oil or any other
cleaning agent that is not detrimental
to the element until it is dirt-free. Then
saturate the element in lubricating oil
and squeeze it dry before placing it
back into the air strainer.
For air strainer replacement,
contact the nearest servicing dealer.
Replace hair type elements with the
polyurethane type, if available.
The air compressor mounting bolts
should be tightened every 12 months
or 30,000 miles (48,000 km) for
on-highway engines or every 300
hours for industrial applications.
All information subject to change without notice. (Rev. 01/04)
Copyright © 2004 DETROIT DIESEL CORPORATION
SERIES 50 OPERATOR'S GUIDE
Item 10 – Air Cleaner
The air cleaner element should be
inspected every 15,000 miles (24,000
km) for vehicle engines, 150 hours for
non-vehicle engines, or more often if
the engine is operated under severe
dust conditions. Replace the element,
if necessary. Check the gaskets for
deterioration and replace, if necessary.
If the dry type air cleaner is equipped
with an aspirator, check for aspirator
damage or clogging. Clean, repair or
replace, as necessary.
Dry type air cleaner elements
should be replaced after one year
of service or when the maximum
allowable air intake restriction has
been reached, whichever comes first.
Refer to section When to Service the
Dry Type Air Cleaner in this guide for
additional information.
NOTICE:
Do not allow the air inlet restriction
to exceed 20 inches of water (5.0
kPa) under any engine operating
conditions. A clogged air cleaner
element will cause excessive
intake restriction and a reduced
air supply to the engine. This, in
turn, can result in increased fuel
consumption, inefficient engine
operation and reduced engine life.
All information subject to change without notice. (Rev. 01/04)
DDC-SVC-MAN-0058
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 Filters
For on-highway vehicle engines,
install new spin-on oil filters at a
maximum of 15,000 miles (24,000
km).
For city transit coach engines, install
filters at a maximum of 6,000 miles
(9,600 km).
For industrial engines, install filters
every 150 hours of operation or
each time the engine oil is changed,
whichever comes first.
PERSONAL INJURY
To avoid injury from slipping and
falling, immediately clean up any
spilled liquids.
Copyright © 2004 DETROIT DIESEL CORPORATION
75
MAINTENANCE
Install the new filters, turning them
until they contact the gasket fully with
no side movement. Turn full-flow
filters an additional 2/3 turn by
hand, or as indicated on the filter.
See Figure 16.
fuel pressure at the cylinder head fuel
inlet fitting and the inlet restriction
at the fuel pump. In a clean system
the maximum pump inlet restriction
should not exceed 6 inches of mercury
(20.3 kPa). In a dirty system it must
not exceed 12 inches of mercury
(41 kPa).
At normal operating speed and with
the standard .080 inch restriction
fittings, the fuel 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).
Figure 16
Lubricating Oil Filters
Make a visual check of all lubricating
oil lines for wear and/or chafing. If
any indication of wear is evident,
replace the oil lines and correct the
cause.
Check for oil leaks after starting the
engine.
NOTE:
Filter change intervals may be
shortened to conform with established
preventive maintenance schedules,
but should never be extended.
Fuel Pro® 382 Filters — Install
new Fuel Pro® 382 primary fuel filter
elements when the fuel level in the
see-thru cover reaches the top of the
element or after one year of service,
whichever comes first.
Item 12 – Fuel Filters
One method of determining when
filters are plugged to the extent that
they need replacing is based on the
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DDC-SVC-MAN-0058
Spin-On Filters — Install new
spin-on primary and secondary fuel
filter elements on vehicle engines
every 15,000 miles (24,000 km) or
All information subject to change without notice. (Rev. 01/04)
Copyright © 2004 DETROIT DIESEL CORPORATION
SERIES 50 OPERATOR'S GUIDE
every six months, whichever comes
first. See Figure 17.
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 Figure 18.
Figure 17
Spin-On Fuel Filter
Location
Install new spin-on filter elements
on non-vehicle engines every 150
hours. Replace spin-on filter elements
immediately if plugging is indicated,
regardless of mileage or hour intervals.
Item 13 – Water Pump and
Coolant Inhibitor Element
Check the water pump and the coolant
inhibitor element.
Water Pump Drain Hole — The
water pump drain hole should be
inspected every 6 months to make
sure it is open. A small chemical
build-up or streaking at the drain hole
may occur. This is not an indication
of a defective water pump or seal.
Remove the build-up with a mild
detergent cleaner and a brush. If
All information subject to change without notice. (Rev. 01/04)
DDC-SVC-MAN-0058
Figure 18
Coolant Inhibitor
Element
Required test intervals are
listed in Table 25. For SCA test
procedures refer to How to Select
Coolant and then SCA Test Procedures
in this guide. Use the coolant filter
element required.
Copyright © 2004 DETROIT DIESEL CORPORATION
77
MAINTENANCE
Refer to SPECIFICATIONS for
element part number listing. The
valves mounted on the filter adaptor
head must be opened after the element
is replaced.
Item 14 – Cranking Motor
For cranking motor (starter)
information, contact an authorized
Delco Remy® or Bosch® service
center, depending on manufacturer.
All the connections in the air system
should be checked to make sure
they are tight and leak free. Check
all hoses and ducting for punctures,
deterioration or other damage and
replace, if necessary.
Item 16 – Exhaust System
Have the exhaust manifold retaining
bolts and other connections checked
for tightness. Have the exhaust pipe
rain cap checked for proper operation,
if so equipped.
Item 17 – Engine (Steam Clean)
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DDC-SVC-MAN-0058
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
Item 15 – Air System
Steam clean the engine and engine
compartment every 60,000 miles
(96,000 km) or 2,000 hours,
whichever comes first.
NOTICE:
The exterior of the radiator core
should be inspected every 30,000
miles (48,000 km), 12 months, or 300
hours (industrial applications) and
cleaned, if necessary.
EYE INJURY
To avoid injury from flying debris
when using compressed air, wear
adequate eye protection (face
shield or safety goggles) and do
not exceed 276 kPa (40 psi) air
pressure.
Use a quality grease solvent, such
as mineral spirits, and dry with
compressed air. Fuel oil, kerosene or
gasoline should not be used.
It may be necessary to clean the
radiator more frequently if the engine
is being operated in extremely dusty
or dirty areas.
All information subject to change without notice. (Rev. 01/04)
Copyright © 2004 DETROIT DIESEL CORPORATION
SERIES 50 OPERATOR'S GUIDE
If the low coolant level sensor is
installed in the top tank of the radiator,
it should be tested for proper operation
every 100,000 miles (160,000 km)
or 12 months, whichever comes first.
Authorized Detroit Diesel distributors
are properly equipped to perform this
service.
Item 19 – Oil Pressure
Under normal operation, oil pressure
is noted each time the engine is
started. In the event the equipment
has warning lights rather than pressure
indicators, the pressure should be
checked and recorded every 60,000
miles (96,000 km) for vehicle engines
or 600 hours for stationary and
industrial engines.
Item 20 – Battery-Charging
Alternator
Precautions must be taken when
working on or around the alternator.
The diodes and transistors in the
alternator circuit are very sensitive
and can be easily destroyed.
2. Do not reverse battery
connections. This can also
cause damage.
3. Never disconnect the battery
while the alternator is operating.
Disconnecting the battery can
result in damage to the battery
diodes. In applications which
have two (2) sets of batteries,
switching from one set to the
other while the engine is running
will momentarily disconnect
the batteries. This can result in
equipment damage.
4. If a booster battery is to be used,
batteries must be connected
correctly (negative to negative,
positive to positive) to avoid
equipment damage.
5. Never use a fast charger with the
batteries connected or as a booster
for battery output.
For information on the alternator
assembly, contact an authorized
Delco Remy® or Bosch® distributor,
depending on manufacturer.
1. Avoid grounding the output
terminal. Grounding an
alternator's output wire or
terminal (which is always “hot,”
regardless of whether or not
the engine is running) and
accidentally reversing the battery
polarity will result in equipment
damage.
All information subject to change without notice. (Rev. 01/04)
DDC-SVC-MAN-0058
Copyright © 2004 DETROIT DIESEL CORPORATION
79
MAINTENANCE
Battery Explosion and Acid Burn
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. If you come in contact
with battery acid:
□ Flush your skin with water.
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 15,000
miles (24,000 km) on truck and coach
engines or every 300 hours on all
other engines. Retighten, if necessary.
□ Apply baking soda or lime to
help neutralize the acid.
Item 21 – Engine and
Transmission Mounts
□ Flush your eyes with water.
The engine and transmission mounting
bolts and the condition of the mounting
pads should be checked every 60,000
miles (96,000 km) or 600 hours.
Tighten and/or repair as necessary.
□ Get medical attention
immediately.
Bosch® T1 Alternator Service
Requirements — The transistor
regulator must be replaced every
100,000 miles (160,000 km) using
kit part number 23524613 (includes
regulator assembly and brushes).
Front and rear bearings must be
replaced every 200,000 miles
(320,000 km) using kit 23524614
(includes bearings, seals and spacer
ring). Authorized Bosch distributors
have the parts, tools and trained
personnel to perform these services.
General Service Requirements
– Bosch® and Delco Remy®
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DDC-SVC-MAN-0058
Item 22 – Crankcase Pressure
The crankcase pressure should be
checked and recorded every 60,000
miles (96,000 km) or 600 hours.
Item 23 – Fan Hub
If the fan bearing hub assembly has a
grease fitting, use a hand grease gun
to lubricate the bearings with one shot
of quality lithium-base, multi-purpose
grease every 100,000 miles (160,000
km) for vehicle engines or 1,000 hours
for non-vehicle engines. Care should
be taken not to overfill the bearing
housing.
All information subject to change without notice. (Rev. 01/04)
Copyright © 2004 DETROIT DIESEL CORPORATION
SERIES 50 OPERATOR'S GUIDE
Item 24 – Thermostats and Seals
Replace the thermostats and seals
every 240,000 miles (384,000 km)
on vehicle engines. On non-vehicle
engines, replace the thermostats and
seals every 4,000 hours or 24 months,
whichever comes first.
used in the closed crankcase breather
system should be replaced every 4000
operating hours. It is not reusable and
no attempt should be made to clean or
reuse it. See Figure 20.
Item 25 – Crankcase Breather
The internally 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) Breather
Location
The rocker cover-mounted breather
assembly (part number 23512984)
All information subject to change without notice. (Rev. 01/04)
DDC-SVC-MAN-0058
Figure 20
Rocker Cover-Mounted
Breather
Item 26 – Engine Tune-Up
There is no scheduled interval for
performing an engine tune-up.
However, the valve lash and injector
heights must be measured and, if
necessary, adjusted at the initial
interval listed in Table 19. Once the
initial measurements/adjustments
have been made, any adjustments
beyond this point should be made only
as required to maintain satisfactory
engine performance.
Item 27 – Vibration Damper
The viscous vibration damper should
be inspected periodically and replaced
if dented or leaking. See Figure 21.
Copyright © 2004 DETROIT DIESEL CORPORATION
81
MAINTENANCE
Heat from normal engine operation
may, over a period of time, cause the
fluid within the damper to break down
and lose its dampening properties.
For this reason the viscous vibration
damper must be replaced at time
of normal major engine overhaul,
regardless of apparent condition.
Figure 21
Engine Application
Vehicle Engines
Stationary, Construction/Industrial,
Agricultural, or Generator Set Engines
Viscous Vibration
Damper
Initial Valve Lash and Injector Height
Measurement/Adjustment Period
60,000 Miles (96,000 km) or
24 Months*
1,500 Hours or 45,000 Miles
(72,000 km)*
* Whichever comes first.
Table 19
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Valve Lash and Injector Height Adjustment
DDC-SVC-MAN-0058
All information subject to change without notice. (Rev. 01/04)
Copyright © 2004 DETROIT DIESEL CORPORATION
SERIES 50 OPERATOR'S GUIDE
HOW-TO SECTION
This section covers Detroit Diesel's
recommendations on how to select
lubricating oil, fuel oil, and coolant
and includes basic engine maintenance
procedures which can be performed
by the operator.
NOTICE:
The manufacturer's warranty
applicable to Series 50 engines
provides in part that the provisions
of such warranty shall not apply
to any engine unit that has been
subject to misuse, negligence or
accident. Accordingly, malfunctions
attributable to neglect or failure to
follow the manufacturer's fuel or
lubricating recommendations may
not be within the coverage of the
warranty.
How to Select Lubricating
Oil
The selection of the proper lubricating
oil is important to achieve the long
and trouble-free service which Detroit
Diesel engines are designed to
provide. The proper lubricating oil for
all Detroit Diesel engines is selected
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.
All information subject to change without notice. (Rev. 01/04)
DDC-SVC-MAN-0058
Figure 22
API Symbol
Lubricant Requirements
Lubricant requirements are different
for the EGR-equipped and non-EGR
engines.
EGR-Equipped Engines — API
CI-4 oils must be used in October
2002 and later–build Series 50
engines with cooled EGR (exhaust
gas recirculation) devices. API
Service Category CI-4 is intended for
use with cooled EGR engines meeting
2002 and later exhaust emission
regulations.
Non-EGR Engines — API CI-4 or
CH-4 oils are recommended for use in
all non-EGR engines.
Engines Built Prior to 1998 —
Lubricants meeting API Service
Copyright © 2004 DETROIT DIESEL CORPORATION
83
HOW-TO SECTION
Category CG-4 may be used in
engines built prior to 1998 when API
CI-4 or CH-4 oils are not available.
NOTE:
The use of CG-4 oils in these
engines may require a reduction in
oil drain interval, depending upon the
application and the fuel sulfur level.
Cold Weather Starting
At ambient temperatures below –20°
C (–4 °F) when sufficient starter
speed cannot be achieved with SAE
15W-40 oils, the use of 5W-XX oils
and 10W-XX oils, where XX is 30 or
40, is allowed to improve startability,
provided they are API CI-4 (for
EGR-equipped engines) or API CI-4
or CH-4 (for non-EGR-equipped
engines) and have demonstrated field
performance in DDC engines. These
oils must possess a HT/HS of 3.7
minimum.
NOTICE:
Monograde oils should not
be used in Series 50 engines,
regardless of API service
classification. Monograde oils
gel at lower ambient temperatures,
reducing lubricant flow, and
they do not provide adequate
lubricity at higher engine operating
temperatures. These factors can
result in severe engine damage.
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DDC-SVC-MAN-0058
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 – Lubricating
Oil, Fuel and Filters, 7SE270,
available from authorized Detroit
Diesel distributors.
Synthetic Oils
Synthetic oils may be used in Detroit
Diesel engines, provided they are API
licensed and meet the performance
and chemical requirements of
non-synthetic oils outlined in this
publication. Synthetic oils offer
improved low-temperature flow
properties and high-temperature
oxidation resistance. However,
they are generally more costly than
non-synthetic oils.
Product information about synthetic
oils should be reviewed carefully.
Performance additive systems often
respond differently in synthetic oils.
Their use does not permit extension of
recommended oil drain intervals.
All information subject to change without notice. (Rev. 01/04)
Copyright © 2004 DETROIT DIESEL CORPORATION
SERIES 50 OPERATOR'S GUIDE
The Use of Supplemental
Additives
Lubricants meeting the Detroit
Diesel specifications outlined in this
publication already contain a balanced
additive treatment. Supplemental
additives are generally not necessary
and can even be harmful. These
additives may be marketed as either
oil treatments or engine treatments
and are discouraged from use in
Detroit Diesel engines. Engine
damage resulting from the use of
such materials is not covered by
your Detroit Diesel Corporation
warranty. Detroit Diesel will not
provide statements beyond this
publication relative to their use.
Engine Application
When to Change Oil
USED ENGINE OIL
To avoid injury to skin from
contact with the contaminants in
used engine oil, wear protective
gloves and apron.
The length of time an engine may
operate before an oil change depends
upon the lubricant and fuel used,
engine oil consumption, and the
operating cycle. The maximum
interval at which the engine may
operate before the oil and filters must
be changed is listed in Table 20.
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
City Transit Coach Model 6047MK1E
3,000 Miles (4,800 km)
Construction, Industrial or Agriculture
250 Hours or 1 Year, whichever comes
first
Stationary Generator, Prime Power or
Continuous
300 Hours or 3 Months, whichever
comes first
Stationary Generator, Standby
150 Hours or 1 Year, whichever comes
first
# All Series 50 transit coach engines, except model 6047MK1E.
Table 20
Maximum Oil Drain and Filter Change Interval (Fuel Sulfur
0.05 Weight Percent or Less)
All information subject to change without notice. (Rev. 01/04)
DDC-SVC-MAN-0058
Copyright © 2004 DETROIT DIESEL CORPORATION
85
HOW-TO SECTION
Oil analysis may be used to determine
whether this interval should be
shortened, but it should not be used to
lengthen the interval.
system. Filter part numbers are listed
in the Specifications section of this
guide.
The use of fuels with sulfur content
above 0.05 mass percent will require
a shortening of drain intervals and/or
the use of a higher TBN oil. See
the information listed in Table 20.
For detailed information refer to
publication Engine Requirements –
Lubricating Oil, Fuel and Filters
(7SE270), available from authorized
Detroit Diesel distributors.
Replace Spin-On Type Oil Filter
Disposing of Waste Oil
Replace spin-on type filters as follows:
1. Place a suitable container under
the engine oil pan, remove drain
plug and drain the lubricating
oil. Replace the drain plug and
tighten securely.
2. Remove spin-on filters using tool
J 29917, or equivalent, and a
1/2-inch drive socket wrench and
extension.
Dispose of used lubricating oil
and filters in an environmentally
responsible manner, according
to federal (EPA) and/or state
recommendations. The disposal of
waste oil may be best addressed by the
engine oil supplier, who may accept
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
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DDC-SVC-MAN-0058
Figure 23
Spin-On Oil Filters
All information subject to change without notice. (Rev. 01/04)
Copyright © 2004 DETROIT DIESEL CORPORATION
SERIES 50 OPERATOR'S GUIDE
3. Dispose of used oil and
filters in an environmentally
responsible manner, according
to federal (EPA) and/or state
recommendations.
PERSONAL INJURY
4. Clean the filter gasket-contact
surface of the adaptor head with a
clean, lint-free cloth.
Diesel engine exhaust and some
of its constituents are known to
the State of California to cause
cancer, birth defects, and other
reproductive harm.
5. Fill the new filters with clean
lubricating oil and lightly coat the
filter gaskets with the same oil.
□ Always start and operate an
engine in a well ventilated
area.
6. Start the new filters on the adaptor
head and tighten by hand until
the gaskets touch the mounting
adaptor head. Tighten filters an
additional two-thirds turn by
hand, or as indicated on the
filter.
□ If operating an engine in
an enclosed area, vent the
exhaust to the outside.
NOTICE:
Do not overtighten filters.
Overtightening may crack or
distort the filter adaptor.
7. Add oil as required to bring the
level to the “Full” mark on the
dipstick.
All information subject to change without notice. (Rev. 01/04)
DDC-SVC-MAN-0058
□ Do not modify or tamper
with the exhaust system or
emission control system.
8. Start and run the engine for
a short period and check for
leaks. After any leaks have been
corrected, stop the engine long
enough for oil from various parts
of the engine to drain back to
the crankcase (approximately 20
minutes). Add oil as required to
bring the level to the “Full” mark
on the dipstick.
Copyright © 2004 DETROIT DIESEL CORPORATION
87
HOW-TO SECTION
Fuel Contamination
NOTICE:
If the engine oil level is constantly
above normal and excess lube
oil has not been added to the
crankcase, consult with an
authorized Detroit Diesel service
outlet for the cause. Fuel or coolant
dilution of lube oil can result in
serious engine damage.
How to Select Fuel Oil
Detroit Diesel engines are designed to
operate on most diesel fuels marketed
today.
Quality
Fuel quality is an important factor
in obtaining satisfactory engine
performance, long engine life, and
acceptable exhaust emission levels.
In general, fuels meeting the
properties of ASTM designation
D 975 (grades 1-D and 2-D) have
provided satisfactory performance.
The fuels used must be clean,
completely distilled, stable, and
non-corrosive. For more information
regarding the significance of these
properties and selection of the proper
fuel, refer to publication, Engine
Requirements – Lubricating Oil, Fuel
and Filters (7SE270), available from
authorized Detroit Diesel distributors.
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DDC-SVC-MAN-0058
Generally, fuel contamination
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.
Supplemental additives are not
recommended due to potential
injector system or engine damage.
Our experience has been that such
additives increase operating costs
without providing benefit.
The use of supplemental fuel additives
does not necessarily void the engine
warranty. However, repair expenses
which result from fuel system or
engine component malfunctions
or damage attributed to their
use will not be covered. These
products should be accompanied by
performance data supporting their
merit. It is not the policy of Detroit
Diesel Corporation to test, evaluate,
approve or endorse such products.
All information subject to change without notice. (Rev. 01/04)
Copyright © 2004 DETROIT DIESEL CORPORATION
SERIES 50 OPERATOR'S GUIDE
Prohibited Additives
The following fuel additives are not
allowed and MUST NOT be mixed
with diesel fuel.
Used Lubricating Oil — Detroit
Diesel specifically prohibits the
use of used lubricating oil in diesel
fuel. Used lubricating oil contains
combustion acids and particulate
materials which can severely erode
fuel injector components, resulting in
loss of power and increased exhaust
emissions. In addition, the use of
drained lubricating oil will increase
maintenance requirements due to filter
plugging and combustion deposits.
Gasoline — The addition of
gasoline to diesel fuel will create a
serious fire hazard. The presence
of gasoline in diesel fuel will reduce
fuel cetane number and increase
combustion temperatures.
Detroit Diesel Corporation will not be
responsible for any detrimental effects
it determines resulted from adding
drained lubricating oil or gasoline to
the 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
fuel filters are used on Series 50
engines. The spin-on type filter
consists of a shell, element and gasket
unitized into a single cartridge and a
filter adaptor which includes threaded
inserts to accept the spin-on cartridges.
An optional fuel/water separator may
be installed in place of the standard
primary filter.
FIRE
To avoid increased risk of a fuel
fire, do not mix gasoline and
diesel fuel.
Tanks which contain such mixtures
should be drained and cleaned as soon
as possible.
All information subject to change without notice. (Rev. 01/04)
DDC-SVC-MAN-0058
Copyright © 2004 DETROIT DIESEL CORPORATION
89
HOW-TO SECTION
Replace Spin-On Type Primary
or Secondary Fuel Filter
Elements
Replace spin-on fuel filter elements as
follows:
1. Shut down the engine and allow
it to cool.
2. With the engine at ambient
temperature and cool to the touch,
place a suitable container under
the filter.
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.
3. A fuel shutoff valve may be
installed on the discharge side
of the secondary fuel filter. If
installed, turn the handle on
the shutoff valve to the closed
position (perpendicular to the
valve).
NOTICE:
To improve engine starting, have
replacement filters filled with fuel
and ready to install immediately
after used filters are removed. This
will prevent possible siphoning and
fuel system aeration.
4. Using a suitable band type filter
wrench, remove the primary
and secondary fuel filters.
See Figure 24. Dispose of the
filters in an environmentally
responsible manner, according
to federal (EPA) and/or state
recommendations.
90
DDC-SVC-MAN-0058
Figure 24
Typical Spin-On Type
Fuel Filter
All information subject to change without notice. (Rev. 01/04)
Copyright © 2004 DETROIT DIESEL CORPORATION
SERIES 50 OPERATOR'S GUIDE
NOTICE:
Do not overtighten the filter.
Overtightening may crack or distort
the adaptors.
7. Turn the handle on the shutoff
valve to the Open position (in
line with the valve).
PERSONAL INJURY
equivalent. Authorized Detroit Diesel
distributors are properly equipped to
perform this service.
NOTICE:
Under no circumstances should
the starting motor and fuel pump
be used 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.
Diesel engine exhaust and some
of its constituents are known to
the State of California to cause
cancer, birth defects, and other
reproductive harm.
Replace Fuel/Water Separator
Element
□ Always start and operate an
engine in a well ventilated
area.
If an optional primary filter/water
separator is installed, replace the
element as follows:
□ 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.
8. Start the engine and check for
leaks. Shut down the engine.
Correct any leaks with the engine
off.
If the engine fails to start after filter
replacement, the fuel system will
require priming with tool J 5956, or
All information subject to change without notice. (Rev. 01/04)
DDC-SVC-MAN-0058
1. Shut down the engine and allow
it to cool.
2. With the engine at ambient
temperature and cool to the touch,
place a suitable container under
the filter.
3. A fuel shutoff valve may be
installed on the discharge side
of the fuel/water separator. If
installed, turn the shutoff valve
handle to the closed position
(perpendicular to the valve).
4. Drain off some fuel by opening
the drain
Copyright © 2004 DETROIT DIESEL CORPORATION
91
HOW-TO SECTION
5. Using a strap wrench, remove
the element and bowl together,
then remove the bowl from the
element. The filter and bowl
have right-hand threads, so turn
counter-clockwise to remove.
6. Clean the bowl and O-ring seal.
7. Apply a light coating or clean
fuel or grease to the O-ring seal,
thread the bowl onto the new filter
and tighten by hand.
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 seal, a cover collar, and a
vent cap and seal. See Figure 25.
NOTICE:
To avoid damaging the bowl or
the filter, do not use tools when
tightening.
8. Apply a light coating of clean fuel
oil or grease to the new O-ring
seal on the top of the filter. Thread
the filter and bowl assembly onto
the filter head and tighten by
hand until snug.
9. To eliminate air from the filter,
operate the primer pump on the
filter 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.
92
DDC-SVC-MAN-0058
Figure 25
Fuel Pro 382E Fuel
Processor Assembly
All information subject to change without notice. (Rev. 01/04)
Copyright © 2004 DETROIT DIESEL CORPORATION
SERIES 50 OPERATOR'S GUIDE
The Fuel Pro 382E system also
includes a fuel heater element,
thermostatic switch and wiring
harness.
Replace the element as follows:
1. Shut down the engine and allow
it to cool.
2. With the engine at ambient
temperature and cool to the touch,
place a suitable container under
the filter.
3. A fuel shutoff valve may be
installed on the discharge side of
the fuel filter. If installed, turn the
handle on the shutoff valve to the
closed position (perpendicular to
the valve).
4. Open the drain valve at the base
of the fuel processor and drain the
fuel until it is below the bottom
of the filter in the see-thru cover.
Close the drain valve. The fuel
may be returned to the tank.
5. Using filter collar/vent cap
wrench part number 232002 or
equivalent, remove the collar
by turning counter-clockwise.
Remove the cover, filter spring
and cover seal ring by lifting
straight up and over the filter
element.
6. Remove the element from the
center stud (fuel outlet pipe)
by pulling upward and twisting
slightly.
All information subject to change without notice. (Rev. 01/04)
DDC-SVC-MAN-0058
NOTE:
Current filter elements include an
integral sealing grommet. If a former
element is replaced, make sure 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
twisting slightly.
9. Check to make sure the spring is
installed at the top of the cover.
If missing, this spring must be
replaced to insure proper filter
operation. Wipe the cover lip and
cover seal clean.
NOTICE:
To avoid cover or collar damage,
do not use a wrench to tighten the
collar.
10. After making sure the seal is
properly positioned at the base of
the cover, install the cover and
collar onto the fuel processor.
Copyright © 2004 DETROIT DIESEL CORPORATION
93
HOW-TO SECTION
Tighten the collar by hand until
secure.
11. Using filter collar/vent cap
wrench 232002 or equivalent,
remove the vent cap from the top
of the cover by turning the cap
counter-clockwise. Fill the cover
full of clean fuel.
NOTICE:
To avoid cover or vent cap damage,
do not use tools to tighten the vent
cap.
12. After making sure the O-ring
seal is installed on the vent cap,
reinstall the cap and tighten by
hand.
13. Open the fuel shutoff valve (if
installed) and start the engine.
When the lubrication system
reaches its normal operating
pressure, increase engine speed to
high idle for 2 to 3 minutes.
the vent cap. The fuel level in
the cover will start falling. When
the fuel level falls to the top of
the collar, tighten the vent cap
quickly by hand.
15. Shut down the 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 comes first.
NOTICE:
Do not allow the fuel level in the
see-thru cover to fall below the top
of the collar, since this may lead
to interruption of the fuel flow and
engine stalling.
14. After the air is purged and with
the engine still running, loosen
94
DDC-SVC-MAN-0058
All information subject to change without notice. (Rev. 01/04)
Copyright © 2004 DETROIT DIESEL CORPORATION
SERIES 50 OPERATOR'S GUIDE
Engine Out of Fuel — How
to Restart
When an engine has run out of fuel,
there is a definite procedure to follow
when restarting it.
NOTICE:
Under no circumstances should
the starting motor and fuel pump
be used 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.
Engines with Spin-On Filters
Use the following procedure for an
engine with spin-on filters.
1. Fill the fuel tank with the
recommended grade of fuel. If
only partial filling is possible,
add a minimum of 10 gallons (38
liters) of fuel to the tank.
2. Close the fuel shutoff valve (if
installed) on the secondary filter
head and remove the spin-on
fuel filters. Fill with clean fuel
through the fuel inlet holes (the
outer ring of small holes on the
element) to insure the fuel is
filtered. Thread the elements
onto the adaptor inserts until the
All information subject to change without notice. (Rev. 01/04)
DDC-SVC-MAN-0058
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.
3. Open the fuel shutoff valve (if
installed), start the engine and
check for leaks. Shut down the
engine before correcting leaks.
NOTE:
If the engine fails to start after
replacement of fuel filters, the fuel
system will require priming with 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:
NOTICE:
To avoid cover or vent cap damage,
do not use tools to tighten the vent
cap.
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
and tighten by hand only.
Copyright © 2004 DETROIT DIESEL CORPORATION
95
HOW-TO SECTION
Definitions
NOTICE:
Do not allow the fuel level in the
see-thru cover to fall below the top
of the collar, since this may lead
to interruption of the fuel flow and
engine stalling.
This section covers selection of
the required coolant for Series 50
engines. To help ensure complete
understanding of the information, the
definitions of the following terms are
provided:
2. Start the engine and allow the
lubrication system to reach its
normal operating pressure, then
increase engine speed to high idle
for 2 to 3 minutes. After the air is
purged and with the engine still
running, loosen the vent cap on
the filter cover. the fuel level in
the cover will start falling. When
the fuel level falls to the top of
the collar on the Fuel Pro cover,
tighten the vent cap quickly by
hand.
Antifreeze — Ethylene glycol
or propylene glycol containing a
corrosion inhibitor package and which
meets an appropriate heavy-duty
specification (i.e., TMC RP-329 for
ethylene glycol or TMC RP-330 for
propylene glycol).
NOTE:
If the engine fails to start after
replacement of fuel filters, the fuel
system will require priming with tool
J 5956, or equivalent. Authorized
Detroit Diesel distributors are properly
equipped to perform this service.
How to Select Coolant
The section coves selection of the
required coolant for Series 50 engines.
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DDC-SVC-MAN-0058
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.
Initial–Fill Coolant — The coolant
that is used in a new or rebuilt engine,
or any time the cooling system is
emptied and then refilled with coolant.
All information subject to change without notice. (Rev. 01/04)
Copyright © 2004 DETROIT DIESEL CORPORATION
SERIES 50 OPERATOR'S GUIDE
OAT — Organic Acid Technology.
An inhibitor system based on
organic acid inhibitors, instead of
traditional North American inhibitor
formulations.
these coolants should be maintained
according to the procedures discussed
under Maintenance in this section.
NOTICE:
Required specifications for water,
ethylene glycol, propylene glycol,
inhibitor packages and inhibitor
concentration are included in
this section. To avoid possible
engine damage from inadequate
or overconcentrated coolant,
this information should be read
thoroughly before the coolant is
replaced.
SCA — Supplemental Coolant
Additive. SCAs are used in a
preventive maintenance program to
prevent corrosion, cavitation, and the
formation of deposits.
Approved Coolants
The approved and preferred
coolants for Series 50 engines
are listed in Table 21. Once installed,
Product
Coolant Fill Option
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 Inhibitors
1
2
2
Water + DDC Power Cool Plus 6000
Preferred Coolant
Water-only coolant systems offer no freeze protection and should not
be used where ambient temperatures can fall to 32 °F (0 °C).
Table 21
Initial Fill Coolant Options
All information subject to change without notice. (Rev. 01/04)
DDC-SVC-MAN-0058
Copyright © 2004 DETROIT DIESEL CORPORATION
97
HOW-TO SECTION
Ethylene Glycol & Water Plus
SCA Inhibitor or Propylene
Glycol & Water Plus SCA
Inhibitor — These products are
available as fully formulated,
phosphate-free, extended service
interval (ESI) coolants. They are
commercially available from Detroit
Diesel (recommended) and other
manufacturers as either a concentrated
antifreeze or as a pre-mixed antifreeze.
The pre-mixed antifreeze is ready for
use, while the concentrated coolant
must be mixed with water prior to use.
Detroit Diesel Power Cool engine
coolant (part number 23512138)
is the preferred ethylene glycol
coolant. If other commercial brands
of ethylene glycol are used, they
must be equivalent to the Power Cool
(see following paragraph). Detroit
Diesel does not market a propylene
glycol coolant. If a propylene glycol
coolant is used, it must also meet the
requirements listed in the following
paragraph.
Mixing EG or PG Antifreeze
and Water — If a concentrated
ethylene glycol (EG) or propylene
glycol (PG) antifreeze is purchased,
mix the antifreeze with water meeting
the required quality standards
listed in Table 24 and fill the cooling
system.
If a pre-diluted, fully formulated
coolant is purchased, simply fill
the cooling system. For best
overall performance, a coolant
consisting of 50% concentration
of antifreeze (50% antifreeze,
50% water) is recommended. An
antifreeze concentration over 67%
(67% antifreeze, 33% water) is
not recommended due to poor heat
transfer, reduced freeze protection
(IEG only), and possible silicate
dropout. An antifreeze concentration
below 33% (33% antifreeze, 67%
water) offers too little freeze and/or
corrosion protection and is not
recommended.
Fully formulated ethylene
glycol-based, low silicate antifreeze
or coolant 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.
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DDC-SVC-MAN-0058
All information subject to change without notice. (Rev. 01/04)
Copyright © 2004 DETROIT DIESEL CORPORATION
SERIES 50 OPERATOR'S GUIDE
See Figure 26 for ethylene glycol-base
coolant concentration versus freezing
and boiling temperatures.
Figure 26
Coolant Temperatures vs. IEG Concentration (Sea Level)
All information subject to change without notice. (Rev. 01/04)
DDC-SVC-MAN-0058
Copyright © 2004 DETROIT DIESEL CORPORATION
99
HOW-TO SECTION
See Figure 27 for propylene
glycol-base coolant concentration
versus freezing and boiling
temperatures.
Always verify that the freeze point
and nitrite concentration of the
Figure 27
100
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.
Coolant Temperatures vs. IPG Concentration (Sea Level)
DDC-SVC-MAN-0058
All information subject to change without notice. (Rev. 01/04)
Copyright © 2004 DETROIT DIESEL CORPORATION
SERIES 50 OPERATOR'S GUIDE
Fully Formulated Glycol Coolant Concentration Limits
Table 22
Boron
125 – 500 PPM
Nitrite
900 – 3200 PPM
Nitrate
200 – 3200 PPM
Silicon
50 – 250 PPM
Phosphorous
0 PPM
pH
8.0 – 11.0
Fully Formulated Glycol Coolant Limits with TMC RP-329,
TMC RP-330 Chemistry Type A (50/50 Coolant/Water
Mixture)
Recycled Antifreeze — Antifreeze
or coolant recycled by reverse
osmosis, distillation, and ion
exchange, properly re-inhibited
to meet TMC RP-329 Type A or
TMC RP-330 Type A requirements,
has been demonstrated to provide
service equivalent to virgin antifreeze.
Recycled antifreeze or coolants of
these types are preferred. Other
recycled coolants, especially coolants
recycled through filtration processes,
are not recommended.
Ethylene Glycol/Water +
OAT Inhibitor or Propylene
Glycol/Water + OAT Inhibitor —
Ethylene glycol and propylene glycol
are also available 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
All information subject to change without notice. (Rev. 01/04)
DDC-SVC-MAN-0058
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 with a
“blank” coolant filter, or the coolant
filter and piping may be omitted from
the system.
OAT fully formulated antifreezes
are available as concentrated and
pre-mixed. Concentrated antifreezes
should be mixed 50% (50% antifreeze,
50% water).
OAT coolants should not be mixed
with conventional coolants. If they
are mixed, no damage will result, but
the long-life advantages of the OAT
coolant will be lost. In this event,
the coolant should be maintained as a
fully formulated IEG coolant, not as
an OAT (Organic Acid Technology)
coolant.
Copyright © 2004 DETROIT DIESEL CORPORATION
101
HOW-TO SECTION
Detroit Diesel markets a OATinhibited ethylene glycol coolant,
DDC Power Cool Plus, which
contains all the required additives.
If a non-DDC OAT antifreeze is
used, it must conform to TMC 338
specification. Do not add extender to
new OAT antifreeze or coolant.
should be mixed at 7.5% – 10% by
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.
Water Only + SCA or Water
Only + OAT Inhibitor — In
warm climates a coolant based
on water with corrosion inhibitors
is approved for use. Water-only
systems need to be treated with the
proper dosage of corrosion inhibitors.
Detroit Diesel-approved SCAs or
OAT corrosion inhibitors must be
added to the water to provide required
corrosion and cavitation erosion
protection. OAT inhibitors such as
Power Cool Plus 6000 are available
for water-only systems. Inhibitor
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 water. These additions
can be made by adding liquid SCAs
available in a variety of sizes. Coolant
filters are also available for different
cooling system capacities. These
filters release the proper amount of
SCA at initial fill.
Power Cool 3000 Coolant Concentration Limits
Table 23
Boron
125 – 500 PPM
Nitrite
900 – 3200 PPM
Nitrate
0 – 1000 PPM
Silicon
50 – 250 PPM
Phosphorous
0 PPM
pH
8.0 – 11.0
Power Cool 3000 Concentration Limits (5% Power Cool
3000/ 95% Water)
Water Requirements —
Distilled, reverse osmosis-purified,
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DDC-SVC-MAN-0058
or de-ionized water which eliminates
the adverse effects of minerals in
All information subject to change without notice. (Rev. 01/04)
Copyright © 2004 DETROIT DIESEL CORPORATION
SERIES 50 OPERATOR'S GUIDE
Coolants Not Recommended
tap water is preferred. High levels
of dissolved chlorides, sulfates,
magnesium, and calcium in some tap
water causes scale deposits and/or
corrosion. These deposits have been
shown to result in water pump failures
and poor heat transfer, resulting in
overheating. If tap water is used, the
mineral content in the water must be
below the maximum allowable limits
listed in Table 24.
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.
NOTICE:
Automotive Type Coolants —
These coolants generally contain high
levels of phosphate and silicate, offer
no liner pitting protection, and are
not suitable for use in Detroit Diesel
engines.
Do not add additional SCA to
new, fully formulated antifreeze or
coolant. This can result in dropout
and/or the formation of deposits.
Maximum Allowable
Tap Water Components
Parts per Million
Grains per Gallon
Chlorides
40
2.5
Sulfates
100
5.8
Total Dissolved Solids
340
20
Total Hardness –
Magnesium and Calcium
170
10
Table 24
Satisfactory Water Limits
All information subject to change without notice. (Rev. 01/04)
DDC-SVC-MAN-0058
Copyright © 2004 DETROIT DIESEL CORPORATION
103
HOW-TO SECTION
Methyl Alcohol-Based
Antifreeze — This coolant
must not be used because of its effect
on the non-metallic components of
the cooling system and its low boiling
point.
Methoxy Propanol-Based
Antifreeze — This coolant must not
be used because it is not compatible
with the fluoroelastomer seals found
in the cooling system.
Glycol-based Coolants
Formulated For HVAC —
These coolants formulated for
heating/ventilation/air conditioning
(HVAC) should not be used. These
coolants generally contain high levels
of phosphates, which can deposit
on hot internal engine surfaces and
reduce heat transfer.
Additives Not Recommended
The additives in the following sections
are not recommended for use in Series
50 engines cooling systems.
Soluble Oil Additives —
These additives are not approved
for use because a small amount
of oil adversely affects heat
transfer. For example, a 1.25%
concentration of soluble oil increases
fire deck temperature 6%. A 2.50%
concentration increases fire deck
104
DDC-SVC-MAN-0058
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 systems
operated with chromium-inhibited
coolant must be chemically cleaned
with Power Cool dry chemical
cooling system cleaner/conditioner
(or equivalent sulfamic acid/sodium
carbonate cleaner) and flushed.
Coolant Maintenance
Coolant maintenance involves
checking the coolant inhibitor levels
at regular intervals and checking to
ensure that the coolant has the proper
concentration of SCA.
Coolant Inhibitor Test Intervals
— The coolant inhibitor level
should be checked at the intervals
listed in Table 25. If topping off is
needed, add coolant which is identical
to the initial fill coolant.
All information subject to change without notice. (Rev. 01/04)
Copyright © 2004 DETROIT DIESEL CORPORATION
SERIES 50 OPERATOR'S GUIDE
Service Application
Inhibitor Test Interval
On-Highway Trucks and Motor
Coaches
20,000 Miles (32,000 Kilometers)
City Transit Coaches, Pick-Up and
Delivery, Short Trip, and Emergency
Vehicles
6,000 Miles (9,600 Kilometers) or
3 Months, whichever comes first
Industrial, Continuous– Duty
Generator Set and All Other
Applications, except Standby
Generator Set
500 Hours or 3 Months, whichever
comes first
Stand-By Generator Set
200 Hours or Yearly, whichever comes
first
Table 25
Required Coolant Inhibitor Test Intervals
Supplemental Coolant Additives
for Fully Formulated Coolant
— The concentrations of some
inhibitors will gradually deplete
during normal engine 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:
NOTICE:
Failure to properly maintain
coolant with SCA can result in
damage to the cooling system
and its related components.
Conversely, over-concentration
of SCA inhibitor can result in
poor heat transfer, leading to
engine damage. Always maintain
concentrations at recommended
levels. Do not use traditional SCAs
with OAT coolant.
□ pH control.
□ Restored inhibitor levels to prevent
corrosion.
□ Water softening to deter formation
of mineral deposits.
□ Cavitation protection to protect
wet sleeve cylinder liners.
All information subject to change without notice. (Rev. 01/04)
DDC-SVC-MAN-0058
Copyright © 2004 DETROIT DIESEL CORPORATION
105
HOW-TO SECTION
Coolant Maintenance
Intervals — Check the nitrite
concentration at the regular intervals
listed in Table 26 with a Power Trac
3–Way Test Strip. Nitrite levels must
be within the ranges listed in Table
22. Additional SCA must be added to
the coolant when it becomes depleted,
as indicated by a nitrite concentration
of 900 PPM or less. If the nitrite
concentration is greater than 900
PPM, do not add additional SCA. If
the nitrite concentration is above 3200
PPM, the system is over-inhibited and
should be partially drained and filled
with a 50/50 mix of water and EG or
PG.
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 and flushing of the cooling
system. Refill the system with new fully
formulated or pre-charged coolant.
Check the nitrite concentration level at
the next maintenance interval with a
Power Trac 3–Way Test Strip.
In this case the EG or PG should
contain no inhibitors and should
conform to ASTM D4985. This
will dilute the over-concentrated
inhibitors.
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DDC-SVC-MAN-0058
All information subject to change without notice. (Rev. 01/04)
Copyright © 2004 DETROIT DIESEL CORPORATION
SERIES 50 OPERATOR'S GUIDE
Coolant
Antifreeze / Water +
SCA Inhibitor
(DDC Power Cool)
Action
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.
Drain and clean system.
Replace with new
coolant.
Test nitrite concentration
with test strip. Add
SCA or dilute coolant as
needed.
Drain and clean system.
Replace with new
coolant.
A. 300,000 Miles
(480,000 km)
B. 2 Years or 4,000 Hours*
A. 20,000 Miles (32,000 km)
or 3 Months*
B. 500 Hours or 3 Months*
Ethylene Glycol
/ Water + SCA
Inhibitor
or
Propylene Glycol
/ Water + SCA
Inhibitor
Ethylene Glycol /
Water + OAT Inhibitor
or
Propylene Glycol /
Water + OAT Inhibitor
Water Only + SCA
Inhibitor
Interval 1
A. 300,000 Miles
(480,000 km)
B. 2 Years or 4,000 Hours*
A. 300,000 Miles
(480,000 km) or 2 Years*
B. 5,000 Hours
A. 600,000 Miles
(960,000 km)
B.4 Years or 10,000 Hours*
A. 20,000 Miles (32,000 km)
or 3 Months*
B. 500 Hours or 3 Months*
Add Power Cool Plus
Extender
Drain and clean system.
Replace with new
coolant.
Test nitrite concentration
with test strip. Add
SCA or dilute coolant as
needed.
Drain and clean system.
Replace with new
coolant.
A. 300,000 Miles
(480,000 km)
B. 2 Years or 4,000 Hours
A. 300,000 Miles
Add Power Cool Plus
(480,000 km) or 2 Years*
Extender
Water Only + OAT
B. 5,000 Hours
A. 600,000 Miles
Clean and drain.
Coolant
(960,000 km)
Replace with new
B. 4 Years or 10,000 Hours
coolant.
1
Maintenance interval based on application. Drain interval dependent
on proper maintenance.
A. On-Highway Trucks and Motor Coaches, City Transit Coaches,
Pick-Up and Delivery, Short Trip and Emergency Vehicles
B. Industrial, Generator Set and Other Applications
Table 26
Coolant Maintenance Intervals
All information subject to change without notice. (Rev. 01/04)
DDC-SVC-MAN-0058
Copyright © 2004 DETROIT DIESEL CORPORATION
107
HOW-TO SECTION
SCA Test Procedures
1. Dip the strip into coolant for
one second. Remove and shake
briskly to eliminate excess fluid.
Detroit Diesel Power Trac 3–Way
Coolant Test Strips should be
used to measure nitrite and
glycol concentrations. Part
numbers are Listed in Table 46.
Cavitation/corrosion is indicated
on the strip by the level of nitrite
concentration. Freeze/boil over
protection is determined by glycol
concentration.
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 Detroit Diesel.
HOT COOLANT
To avoid scalding from the
expulsion of hot coolant, never
remove the cooling system
pressure cap while the engine is
at operating temperature. Wear
adequate protective clothing
(face shield, rubber gloves,
apron, and boots). Remove the
cap slowly to relieve pressure.
For best results make the test while
the coolant is between 50 – 140 °F
(10.0 – 60 °C). Wait at least 60, but
not longer than 75, seconds before
reading the nitrite level. Use the test
strips as follows:
108
DDC-SVC-MAN-0058
Promptly replace and tighten the test
strip container cap after each use.
Discard unused strips if they have
turned light pink or tan.
A factory coolant analysis program
is available through authorized
Detroit Diesel service outlets. Part
numbers are listed in Table 46 in the
Specifications section. To verify
coolant acceptability, submit a sample
for coolant analysis every three (3)
years, 300,000 miles (480,000 km),
or 6,000 operating hours, whichever
comes first.
All information subject to change without notice. (Rev. 01/04)
Copyright © 2004 DETROIT DIESEL CORPORATION
SERIES 50 OPERATOR'S GUIDE
Need-Release Coolant Filters
(Non-OAT Systems)
Spin-on coolant filters are available for
Detroit Diesel engines. Membranes
in the filters release SCAs before
the coolant approaches a corrosive
condition, protecting the engine from
corrosion. The elements release the
SCA charge as needed, as opposed to
the maintenance SCA elements, which
instantaneously release the SCA
charge. Coolant filter elements should
be replaced after one (1) year, 120,000
miles (192,000 km) or 2,000 operating
hours, whichever comes first.
PERSONAL INJURY
To avoid injury when using
caustic cleaning agents, follow
the chemical manufacturers
usage, disposal, and safety
instructions.
The wet gel can be removed by using
a non-acid (alkali) type heavy-duty
cleaner, such as Detroit Diesel Power
Cool On-Line Cleaner (sodium
nitrite/sodium tetraborate). Part
numbers are listed in Table 45.
Dropout
Excessive amounts of some inhibitors
in the coolant can cause a gel or
crystalline deposit that reduces heat
transfer and coolant 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.
All information subject to change without notice. (Rev. 01/04)
DDC-SVC-MAN-0058
NOTE:
If the gel is allowed to dry, it is
necessary to disassemble the
engine and clean it with a caustic
solution or physically clean individual
components.
Copyright © 2004 DETROIT DIESEL CORPORATION
109
HOW-TO SECTION
Coolant Extender Inhibitor
Additive for “OAT” Coolant
The inhibitors in OAT coolant must
also be maintained, but less often
than traditional SCA-type coolants.
A portable test is available to test the
levels of OAT inhibitors in coolant.
Where this is not used, fleet testing
has determined that a OAT coolant
extender package should be added to
the coolant at 300,000 miles (480,000
km), two (2) years, or 5,000 hours,
whichever comes first. The proper
maintenance dosages for all OAT
coolants are listed in Table 26 ,
reflecting 0.6% by volume extender.
This dosage should be added to the
water-only and the glycol systems at
the same interval.
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
inhibited OAT coolant.
Chronic Coolant System
Problems
The most commonly seen coolant
system problems result from
maintenance and formulation factors
such as:
□ Hard water
The proper application of extender to
OAT coolant will provide:
□ Dilution of the coolant by the
addition of untreated water
□ pH Control
□ Over dosage or under dosage of
corrosion inhibitors
□ Restored inhibitor levels to prevent
corrosion
□ Cavitation protection to protect
wet sleeve cylinder liners
□ Mixing SCAs
NOTE:
Do not use traditional SCAs in
OAT coolant, and do not use
OAT extender in traditional coolant.
110
DDC-SVC-MAN-0058
□ Improper corrosion inhibitor (most
often phosphated)
□ Improper testing
All information subject to change without notice. (Rev. 01/04)
Copyright © 2004 DETROIT DIESEL CORPORATION
SERIES 50 OPERATOR'S GUIDE
Detroit Diesel Cooling System
Maintenance Products
The following products are available
to use for cooling system maintenance.
Power Cool SCAs — Power Cool
SCAs are water-soluble chemical
compounds. These products are
available in coolant filter elements,
liquid packages, and in fully
formulated Power Cool antifreeze.
NOTE:
Power Cool 3000 liquid SCA is more
compatible with hard water than
Power Cool 2000 SCA.
Power Cool Coolant Filter
Elements — Power Cool coolant
filter elements (spin-on canisters) are
available in various sizes suitable for
cooling systems of varying capacities.
Selection of the proper element size
is vital when pre-charging non-fully
formulated coolant (i.e., water) at
initial fill and at maintenance intervals.
A fully formulated antifreeze must
not have SCA added at initial fill.
Do not use SCA-containing filters
with OAT antifreeze or coolant.
The need for maintenance elements
is determined by the results of the
nitrite concentration test performed
at each cooling system interval. Do
not automatically install maintenance
elements at maintenance intervals,
All information subject to change without notice. (Rev. 01/04)
DDC-SVC-MAN-0058
unless the nitrite concentration falls
below 900 parts per million.
Power Cool Cleaners — Power
Cool Liquid On-Line Cleaner is used
for light deposits. Power Cool Dry
Chemical Cleaner/Conditioner is used
for heavy deposits or scale.
Summary of Coolant
Recommendations
HOT COOLANT
To avoid scalding from the
expulsion of hot coolant, never
remove the cooling system
pressure cap while the engine is
at operating temperature. Wear
adequate protective clothing
(face shield, rubber gloves,
apron, and boots). Remove the
cap slowly to relieve pressure.
1. Always maintain the engine
coolant to meet Detroit Diesel
specifications.
2. Only use water that meets the
specifications listed in Table 24.
Distilled, de-mineralized (reverse
osmosis) or de-ionized water is
preferred.
3. The proper dosage of inhibitors
must be included in the coolant
at initial fill for all Detroit Diesel
Copyright © 2004 DETROIT DIESEL CORPORATION
111
HOW-TO SECTION
engines. This dosage is usually
included in the fully formulated
antifreeze used, or it may need to
be added if water alone or if less
than 50% antifreeze is used. The
user is urged to refer to the full
text of this section to determine
the proper dosage. Mixing
of different manufacturers'
technologies (brands) could cause
cooling system problems.
4. Maintain the inhibitor at the
prescribed concentration. Test
the nitrite concentration by using
a titration kit or Detroit Diesel
Power Trac 3-Way Coolant Test
Strips. Add SCA only if the nitrite
concentration is below 900 PPM.
Do not use SCA in OAT coolant,
and do not use Power Trac 3-Way
Coolant Test Strips to test OAT
coolant.
5. Do not use another manufacturer's
test kit to measure the SCA
concentration of Detroit Diesel
maintenance products.
6. Pre-mix coolant makeup solutions
to the proper concentration before
adding to the cooling system.
7. Do not mix OAT and other
coolants in the same engine.
8. Do not use automotive coolants
or coolants with phosphates.
antifreeze that meets TMC
RP-329 “Type A” (EG) or
TMC RP-330 “Type A” (PG)
specifications. Always maintain
coolant at the proper level.
10. Do not use the following in
Detroit Diesel engine cooling
systems:
□ Soluble oil
□ High silicate, automotive-type
antifreeze
□ Chromate SCAs
□ Methoxy propanol-base
coolant
□ Methyl alcohol-base coolant
□ Sealer additives or coolant
containing sealer additives.
□ HVAC coolant
□ Phosphated coolants
Coolant Life of Glycol
Coolant: — A properly
maintained cooling system, filled with
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.
9. Where antifreeze/boil over
protection is required, use only
112
DDC-SVC-MAN-0058
All information subject to change without notice. (Rev. 01/04)
Copyright © 2004 DETROIT DIESEL CORPORATION
SERIES 50 OPERATOR'S GUIDE
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.
How to Drain and Flush the
Cooling System
To verify coolant acceptability, submit
a sample for coolant analysis every
300,000 miles (480,000 km), three
(3) years, or 5,000 operating hours,
whichever comes first. Submit the
sample in a DDC Power Trac Coolant
Test Bottle. Required part numbers
are listed in Table 46.
HOT COOLANT
Coolant Life of OAT Coolant — A
properly maintained OAT coolant may
be operated 600,000 miles (960,000
km), four (4) years, or until overhaul,
whichever comes first. At this time the
system must be completely drained,
thoroughly cleaned, and refilled.
OAT Coolants require the addition of
an extender at 300,000 miles (480,000
km), two (2) years, or 5,000 hours,
whichever comes first. Use 1 pint
of extender for every 20 gallons of
coolant.
Coolant Life of Other Coolants —
Other properly maintained coolants
may be operated up to 250,000 miles
(480,000 km), two (2) years, or 4,000
operating hours, whichever comes
first. At this time the system must
be completely drained, thoroughly
cleaned, and refilled.
All information subject to change without notice. (Rev. 01/04)
DDC-SVC-MAN-0058
To avoid scalding from the
expulsion of hot coolant, never
remove the cooling system
pressure cap while the engine is
at operating temperature. Wear
adequate protective clothing
(face shield, rubber gloves,
apron, and boots). Remove the
cap slowly to relieve pressure.
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
with clean, soft water and a
good cooling system cleaning
compound, such as those
listed in Table 45 in the
Specifications section. If
the engine is warm, fill slowly
to prevent the rapid cooling and
distortion of the metal castings.
3. Start the engine and operate it for
fifteen minutes to circulate the
solution thoroughly.
Copyright © 2004 DETROIT DIESEL CORPORATION
113
HOW-TO SECTION
4. Stop the engine and allow it to
cool.
NOTICE:
5. With the engine cool, drain the
cooling system completely.
6. Refill the cooling system with
clean, soft water and operate it for
fifteen minutes.
7. Stop the engine and allow it to
cool.
8. With the engine cool, drain the
cleaner residue from the cooling
system.
9. Refill the system with the required
coolant. Refer to section How to
Select Coolant.
10. Entrapped air must be purged
after filling the cooling system.
To do this, allow the engine to
warm up without the pressure cap
installed. With the transmission
in neutral, increase engine speed
above 1000 RPM and add coolant
as required. Install the pressure
cap after the coolant level has
stabilized at the bottom of the
radiator filler neck.
114
DDC-SVC-MAN-0058
If the engine 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 hoses should
be inspected and any hose that shows
obvious signs of damage or feels
abnormally soft or hard should be
replaced. Damaged clamps should
also be replaced. All external leaks
should be corrected as soon as
detected.
NOTE:
If Detroit Diesel Power Cool
antifreeze/coolant (or equivalent fully
formulated, precharged antifreeze)
is used, a precharge element is not
required. Coolant inhibitor levels
must be checked at the intervals
listed in Table 25.
All information subject to change without notice. (Rev. 01/04)
Copyright © 2004 DETROIT DIESEL CORPORATION
SERIES 50 OPERATOR'S GUIDE
When to Service the Dry
Type Air Cleaner
Replace dry type air cleaner elements
when the maximum allowable air
cleaner restriction (20 inches of
water or 5.0 kPa) has been reached
or annually, whichever comes first.
Some air cleaners are equipped with
a 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.
All information subject to change without notice. (Rev. 01/04)
DDC-SVC-MAN-0058
Copyright © 2004 DETROIT DIESEL CORPORATION
115
BASIC TROUBLESHOOTING
BASIC TROUBLESHOOTING
operating the engine carefully and
maintaining it properly, make sure to
correct any malfunction promptly.
This section covers basic
troubleshooting of engine operation
or performance malfunctions and
their probable causes. In addition to
Objectionable Exhaust Symptoms and Probable Causes
Probable Causes
Black or
Gray Smoke
Damaged or dirty air
cleaner
X
Improper grade of fuel
X
Excessive exhaust back
pressure
X
Blue Smoke
X
Misfiring cylinders
Lubricating oil not burned
in cylinder (being burned
in exhaust manifold or
turbocharger)
Faulty injector timing
White
Smoke
X
X
Faulty oil control rings
X
Excessive installation angle
X
Excessive oil in crankcase
X
High ambient temperature
X
Thin air (high altitude)
X
Cetane rating of fuel too
low
X
Air in the fuel system
X
116
DDC-SVC-MAN-0058
All information subject to change without notice. (Rev. 01/04)
Copyright © 2004 DETROIT DIESEL CORPORATION
SERIES 50 OPERATOR'S GUIDE
Hard Starting Symptoms and Probable Causes
Low
Engine
Engine Will
Cranking
Probable Causes
Cranks But
Not Rotate
Speed
Will Not Start
Low Battery Voltage
X
X
Loose cranking motor
connections
Faulty cranking motor
X
X
X
Faulty cranking motor switch
X
X
Internal seizure
X
Improper lube oil
X
X
Circuit breaker/electronic
control malfunction
Fuse blown or missing
X
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
Low Compression
X
Worn intake and exhaust
valves
Worn piston rings/liners
X
Leaking cylinder head gasket
X
Improper intake and exhaust
valve adjustments
X
All information subject to change without notice. (Rev. 01/04)
DDC-SVC-MAN-0058
Copyright © 2004 DETROIT DIESEL CORPORATION
X
117
BASIC TROUBLESHOOTING
Abnormal Engine Operation Symptoms and Probable Causes
Rough
Running or
Low Power
Detonation
Probable Causes
Frequent
Stalling
Misfiring cylinder
X
X
Insufficient fuel
High return fuel
temperature
Low compression
X
X
X
X
X
X
DDEC malfunction
High air inlet
restriction/exhaust back
pressure
Engine application
X
X
X
X
High air inlet temperature
X
High altitude operation
Incorrect engine gear train
timing
Low coolant temperature
Oil picked up by inlet
airstream
Faulty injector operation
Incorrect injector height
setting
X
118
DDC-SVC-MAN-0058
X
X
X
X
X
X
All information subject to change without notice. (Rev. 01/04)
Copyright © 2004 DETROIT DIESEL CORPORATION
SERIES 50 OPERATOR'S GUIDE
Abnormal Operating Condition Symptoms and Probable Causes
High
Lubricating Oil
Probable Causes
Low Oil
Consumption
Pressure
Loose connections
X
Cracked lines
X
Damaged gaskets or seal rings
X
* Lube oil loss at breather tube
X
* Lube oil loss at dipstick tube
X
Leaking oil cooler
X
Leaking valve stem seals
X
Worn/broken oil control rings
X
Scored liner and/or piston
X
Excessive engine installation angle
X
Crankcase overfilled
Oil in air tanks (air compressor
malfunction)
Plugged crankcase breather
X
X
X
Oil level low
Improper engine oil viscosity (fuel
in the oil)
Faulty oil pressure regulator or
relief valve
Worn crankshaft, camshaft or
connecting rod bearings
Missing cup plugs in rocker arm
shafts
Air leaks in oil pump (suction side)
X
Worn or damaged oil pump
X
Faulty oil pressure gage
Faulty electrical components (for
gage)
Plugged oil line or orifice
X
X
X
X
X
X
X
X
* Indicates high crankcase pressure
All information subject to change without notice. (Rev. 01/04)
DDC-SVC-MAN-0058
Copyright © 2004 DETROIT DIESEL CORPORATION
119
BASIC TROUBLESHOOTING
Abnormal Coolant Temperature Symptoms and Probable Causes
Probable Causes
Above Normal
Temperature
Restricted cooling system
passages
X
Restricted radiator core passages
X
Slipping fan drive 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
Below Normal
Temperature
Thermostats not fully closed
X
Leakage around thermostat seals
X
Faulty temperature-controlled fan
X
120
DDC-SVC-MAN-0058
All information subject to change without notice. (Rev. 01/04)
Copyright © 2004 DETROIT DIESEL CORPORATION
SERIES 50 OPERATOR'S GUIDE
ENGINE STORAGE
When an engine is to be stored or
removed from operation for a period
of time, special precautions should
be taken to protect the interior and
exterior of the engine, transmission
and other parts from rust accumulation
and corrosion. The parts requiring
attention and the recommended
preparations are given below.
Preparing the Engine for
Storage
It will be necessary to remove all
rust or corrosion completely from
any exposed part before applying rust
preventive compound. Therefore,
it is recommended that the engine
be processed for storage as soon as
possible after removal from operation.
The engine should be stored in
a building that is dry and can be
heated during the winter months.
Moisture-absorbing chemicals are
available commercially for use when
excessive dampness prevails in the
storage area.
All information subject to change without notice. (Rev. 01/04)
DDC-SVC-MAN-0058
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
level with the recommended
viscosity and grade of oil.
3. Fill the fuel tank with the
recommended grade of fuel oil.
Operate the engine for two (2)
minutes at 1200 rpm and no load.
Do not drain the fuel system or
the crankcase after this run.
4. Check the air cleaner and service
it, if necessary.
5. If freezing weather is expected
during the storage period, check
the antifreeze/coolant for required
freeze and inhibitor protection.
Add antifreeze solution to the
cooling system in accordance
with DDC's recommendations.
Copyright © 2004 DETROIT DIESEL CORPORATION
121
ENGINE STORAGE
Extended Storage (More than 30
Days)
Refer to the How to Select
Coolant section.
NOTE:
If an antifreeze solution is not required
during storage, flush the cooling
system with a good soluble oil (3% –
5% by volume) rust inhibitor to prevent
rusting of the outside diameter of the
cylinder liners.
To avoid injury from flying debris
when using compressed air, wear
adequate eye protection (face
shield or safety goggles) and do
not exceed 276 kPa (40 psi) air
pressure.
6. Clean the exterior of the engine
(except electrical parts) with fuel
oil and dry with compressed air.
7. Seal all engine openings. The
material used must be waterproof,
vaporproof and possess sufficient
physical strength to resist
puncture and damage from the
expansion of entrapped air.
An engine prepared in this manner can
be returned to service in a short time
by removing the seals at the engine
openings and by checking the engine
coolant, fuel oil, lubricating oil and
transmission oil levels.
DDC-SVC-MAN-0058
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.
EYE INJURY
122
To prepare an engine for extended
storage (more than 30 days), follow
this procedure:
3. Stop the engine.
4. With the engine at ambient
temperature and cool to the touch,
drain the engine crankcase oil
into a suitable container. Remove
the oil filters. Dispose of the oil
and filters in an environmentally
friendly manner, according
to state and/or federal (EPA)
recommendations. Replace the
drain plug and tighten to 45 – 50
N·m (33 – 37 lb-ft) torque.
5. Install new lubricating oil
filters. Fill the crankcase to
the proper level with Tectyl®
930A preservative lubricating
oil or an equivalent 30–weight
preservative lubricating oil
meeting Mil-L-21260C, Grade 2
Specification.
All information subject to change without notice. (Rev. 01/04)
Copyright © 2004 DETROIT DIESEL CORPORATION
SERIES 50 OPERATOR'S GUIDE
6. Drain the fuel tank. Refill with
enough clean No. 1 diesel fuel
or pure kerosene to permit the
engine to operate for about ten
(10) minutes. If draining the
fuel tank is not convenient, use
a separate, portable supply of
recommended fuel.
NOTE:
If engines are stored where
condensation of water in the fuel
tank may be a problem, additives
containing methyl carbitol or butyl
cellusolve may be added to the fuel.
Follow manufacturer's instructions
for treatment. Where biological
contamination of fuel may be a
problem, add a biocide such as
Biobor® JF (or equivalent) to the
fuel. When using a biocide, follow
the manufacturer's concentration
recommendations and observe all
cautions and warnings.
7. Drain the fuel system and remove
the fuel filters. Dispose of used
filters in an environmentally
responsible manner, according
to state and/or federal (EPA)
recommendations. Fill the new
filters with No. 1 diesel fuel or
pure kerosene and install 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.
All information subject to change without notice. (Rev. 01/04)
DDC-SVC-MAN-0058
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. Power Take-Off: If equipped,
follow manufacturer's
recommendations for prolonged
storage.
NOTICE:
Failure to properly seal off the
turbocharger air inlet and exhaust
outlet openings before engine
storage may permit air drafts to
circulate through the turbocharger
and rotate the turbine/compressor
shaft without an adequate flow of
lubricating oil to the center housing
bearings. This can result in severe
bearing damage.
12. Turbocharger: Since
turbocharger bearings are
pressure lubricated through the
external oil line leading from
the oil filter adaptor while the
engine is operating, no further
attention is required. However,
the turbocharger air inlet and
turbine exhaust outlet connection
Copyright © 2004 DETROIT DIESEL CORPORATION
123
ENGINE STORAGE
should be sealed off with
moisture-resistant tape.
13. Apply a non-friction rust
preventive compound to all
exposed engine parts. If
convenient, apply the rust
preventive compound to the
engine flywheel. If not, disengage
the clutch mechanism to prevent
the clutch disc from sticking to
the flywheel.
NOTE:
Do not apply oil, grease or any
wax-base compound to the flywheel.
The cast iron will absorb these
substances, which can “sweat” out
during operation and cause the clutch
to slip.
14. Drain the engine cooling system.
15. Drain the preservative oil from
the engine crankcase. Reinstall
and torque the 3/4” – 14 square,
magnetic drain plug to 45 – 50
N·m (33 – 37 lb-ft).
16. Remove and clean the battery
and battery cables with a baking
soda-water solution and rinse
with fresh water. Do not allow
the soda solution to enter the
battery. Add distilled water to
the electrolyte (if necessary) and
fully charge the battery. Store the
battery in a cool (never below 0°
C or 32° F) dry place. Keep the
124
DDC-SVC-MAN-0058
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 metal
covers where practical.
19. Clean and dry the exterior painted
surfaces of the engine and spray
with a suitable liquid automobile
body wax, a synthetic resin
varnish, or a rust preventive
compound.
20. Protect the engine with a good
weather-resistant tarpaulin and
store it under cover, preferably
in a dry building which can be
heated during the winter months.
Outdoor storage of the engine is not
recommended. If units must be kept
out of doors, follow the preparation
and storage instructions already
given. Protect units with quality,
weather-resistant tarpaulins (or other
suitable covers) arranged to provide
for air circulation.
All information subject to change without notice. (Rev. 01/04)
Copyright © 2004 DETROIT DIESEL CORPORATION
SERIES 50 OPERATOR'S GUIDE
NOTICE:
Do not use plastic sheeting for
outdoor storage. Plastic is fine
for indoor storage. When used
outdoors, however, enough moisture
can condense on the inside of the
plastic to rust ferrous metal surfaces
and pit aluminum surfaces. If a unit
is stored outside for any extended
period of time, severe corrosion
damage can result.
The stored engine should be inspected
periodically. If there are any
indications of rust or corrosion,
corrective steps must be taken to
prevent damage to the engine parts.
Perform a complete inspection at the
end of one year and apply additional
treatment as required.
Procedure for Restoring to
Service an Engine that Has Been
in Extended Storage
If an engine has been in extended
storage, prepare it for service as
follows:
1. Remove the covers and tape from
all the openings of the engine, fuel
tank and electrical equipment. Do
not overlook the exhaust outlet.
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 crankcase to the proper
level with the required grade of
lubricating oil. Use a pressure
lubricator to insure all bearings
and rocker shafts are lubricated.
7. Fill the fuel tank with the required
fuel.
8. Close all drain cocks and fill the
engine cooling system with clean,
soft water and required inhibitors.
If the engine is to be exposed
to freezing temperatures, install
genuine Detroit Diesel Power
Cool antifreeze or an equivalent
ethylene glycol-base or propylene
glycol-base antifreeze solution
which provides required freeze,
boilover, and inhibitor protection.
Refer to section How to Select
Coolant.
2. Remove the plugs from the inlet
and outlet fuel lines and reconnect
the lines to their proper positions.
All information subject to change without notice. (Rev. 01/04)
DDC-SVC-MAN-0058
Copyright © 2004 DETROIT DIESEL CORPORATION
125
ENGINE STORAGE
9. Install and connect the battery.
Make sure the average specific
gravity of the battery is 1.260
or higher. Charge the battery, if
necessary.
10. Service the air cleaner, if required.
11. Transmission: Follow the
manufacturer's recommendations
covering the return of the
transmission to service.
12. Power Take-Off: If equipped,
follow the manufacturer's
recommendations covering the
return of the power take-off to
service.
PERSONAL INJURY
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.
13. Turbocharger: Remove the
covers from the turbocharger
air inlet and turbine outlet
connections. Reconnect
piping as required. Prelube
the turbocharger center bearing
housing. Refer to section
Lubrication System Checks in
section Preparations for Starting
the Engine the First Time.
□ Do not modify or tamper
with the exhaust system or
emission control system.
14. After all preparations are
completed, start the engine.
NOTE:
The small amount of rust preventive
which remains in the fuel system
will cause smoky exhaust for a few
minutes.
NOTE:
Before subjecting the engine to a
load or high speed, allow it to reach
normal operating temperature. Then
monitor the DDEC Diagnostic Data
Link (DDL) for trouble codes.
126
DDC-SVC-MAN-0058
All information subject to change without notice. (Rev. 01/04)
Copyright © 2004 DETROIT DIESEL CORPORATION
SERIES 50 OPERATOR'S GUIDE
SERIES 50 SERVICE PUBLICATIONS
The service manual covering Detroit
Diesel Series 50 engines and various
reference works which may be of
interest to the owner/operator are
listed in Table 27.
To purchase a copy of any of these
publications, contact an authorize
Detroit Diesel distributor in the U.S.
or Canada. Check the Yellow Pages
under “Engine, Diesel” or refer to the
Distributor and Dealer Directory listed
below for the distributor or service
outlet nearest you.
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 Lubricating Oil Analysis
7SE398
Technician's Guide – Turbocharger
7SE374
Technician's Guide – Cooling System
7SE390
Series 50 Bus Engine Poster
31SA412
Table 27
Service Publications
All information subject to change without notice. (Rev. 01/04)
DDC-SVC-MAN-0058
Copyright © 2004 DETROIT DIESEL CORPORATION
127
CUSTOMER ASSISTANCE
CUSTOMER ASSISTANCE
The satisfaction and goodwill of the
owners of Detroit Diesel engines are
of primary concern to Detroit Diesel
128
DDC-SVC-MAN-0058
Corporation and its distributor/dealer
organizations.
All information subject to change without notice. (Rev. 01/04)
Copyright © 2004 DETROIT DIESEL CORPORATION
SERIES 50 OPERATOR'S GUIDE
Detroit Diesel North American NAFTA On-Highway Offices
Western Region
Irvine, California
7700 Irvine Center, Suite 275
Irvine, CA 92618
Telephone: 949-753-7710
Fax: 949-753-7711
Eastern Region
Piscataway, New Jersey
169 Old New Brunswich Road
Piscataway, NJ 08854
Telephone: 732-926-9622
Fax: 732-926-8522
Canadian Region
London, Ontario
Detroit Diesel of Canada, Ltd.
150 Dufferin Ave., Suite 701
London, ON N5A 5N6
Phone: 519-661-0149
Fax: 519-661-0171
DDC/MTU Off-Highway Sales and Customer 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
Powergen and Oil Field Sales
(BX11)
13400 Outer Drive, West
Detroit, MI 48239-4001
Phone: 313-592-5708
Fax: 313-592-5158
Customer Assurance (M24)
13400 Outer Drive, West
Detroit, MI 48239-4001
Phone: 313-592-5550
Fax: 313-592-5717
Marine Sales (BX6)
13400 Outer Drive, West
Detroit, MI 48239-4001
Phone: 313-592-5124
Fax: 313-592-5137
Government Sales (BX11)
13400 Outer Drive, West
Detroit, MI 48239-4001
Phone: 313-592-5875
Fax: 313-592-5158
All information subject to change without notice. (Rev. 01/04)
DDC-SVC-MAN-0058
Copyright © 2004 DETROIT DIESEL CORPORATION
129
CUSTOMER ASSISTANCE
DDC INTERNATIONAL REGIONAL OFFICE LOCATIONS
EUROPE, MIDDLE EAST, AFRICA
(EMA) REGION (On/Off-Highway)
The Netherlands
Ridderpoort 9
2984 Ridderkerk
The Netherlands
Phone: (31) 180-442-900
Fax: (31) 180-419-544
LATIN AMERICAN REGION
(Off-Highway)
Miami, Florida
2277 N.W. 14th Street
Latin America Building
Miami, FL 33125-0068
Phone: 305-637-1555
Fax: 305-637-1580
ASIAN REGION (On-Highway)
13400 Outer Drive, West
Detroit, Michigan 48239
Phone: 313-592-5990
Fax: 313-592-5887
ASIA/PACIFIC REGION
(Off-Highway)
Singapore
No. 1 Benoi Place
Singapore 629923
Phone: (65) 686-15922
Fax: (65) 686-11550
PACIFIC REGION (Off-Highway)
Australia
488 Blackshaws Road
Altona North, Victoria 3025
Australia
Phone: (61) 3 9243-9292
Fax: (61) 3 9243-9262
AUSTRALIAN REGION
(On-Highway)
488 Blackshaws Road
Altona North, Victoria 3025
Australia
Phone: (61) 3 9243-9292
Fax: (61) 3 9243-9262
MEXICO (On/Off-Highway)
Detroit Diesel Allison de Mexico, S.A.
Av. Santa Rosa 58
Col. Ampliacion Norte
San Juan Ixtacala, Tlanepantla
C.P. 54160, Edo de Mexico
Phone: 52-555-333-1802
52-5555-333-1870
130
DDC-SVC-MAN-0058
All information subject to change without notice. (Rev. 01/04)
Copyright © 2004 DETROIT DIESEL CORPORATION
SERIES 50 OPERATOR'S GUIDE
Road Service In U.S. and
Canada
If you call, have the following
information available:
If you require road service for any
reason in the U.S. or Canada, you may
call the 1–800–445–1980 customer
assistance phone number. An operator
will assist you in determining what
type of service is required. Not all
problems are engine related and not
all problems are covered by engine
or vehicle warranties. YOU MAY
BE RESPONSIBLE FOR REPAIR
EXPENSES.
□ Engine serial number
Before calling Customer Assistance,
please do the following:
□ Check coolant level
□ Check fuel level
□ Check DDEC fuses
□ Check for fuel leaks
□ Make sure manual shutoff valve (if
installed) on the fuel filter adaptor,
fuel processor body or fuel supply
line is open.
□ 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 Detroit Diesel service
outlets in the U.S. and Canada, plus
many outlets worldwide that are
prepared to meet your parts and
service needs.
□ Service by trained personnel.
□ Sales team to help determine your
specific power requirements.
□ Check the oil level on the dipstick.
□ In many areas, emergency service
24 hours a day.
□ Check diagnostic codes,
refer to the Diagnostic Code
List section in this guide.
□ Complete parts support, including
reliabilt® remanufactured
components.
□ Product information and literature.
All information subject to change without notice. (Rev. 01/04)
DDC-SVC-MAN-0058
Copyright © 2004 DETROIT DIESEL CORPORATION
131
CUSTOMER ASSISTANCE
We recognize, however, that despite
the best intentions of everyone
concerned, misunderstandings may
occur. Normally, any situation that
arises in connection with the sale,
operation or service of your product
will be handled by the authorized
service outlet in your area. In the U.S.
and Canada, check the Yellow Pages
for the Detroit Diesel service outlet
nearest you.
To further assure your complete
satisfaction, we have developed the
following procedure to be followed in
the event you have a problem that has
not been handled satisfactorily.
Step One
Discuss your problem with a member
of management from the authorized
service outlet. Frequently, complaints
are the result of a breakdown in
communication and can quickly be
resolved by a member of management.
If you have already discussed the
problem with the Sales or Service
Manager, contact the General
Manager. If your complaint originates
with a dealer, explain the matter
to a management member of the
distributorship with whom the dealer
has a service agreement.
132
DDC-SVC-MAN-0058
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 member of the manager's
staff, depending upon the nature of
your problem.
Prior to this contact, have the
following information available:
□ Engine model* 604 _ _ _ _ _ .
□ Engine serial number* 04R0_ _ _
___.
□ Type and make of equipment.
□ Engine delivery date and
accumulated miles or hours
of operation.
□ Nature of problem.
□ Chronological summary of
engine's history.
□ Name and location of authorized
service outlet.
*Important: Your engine model
number and serial number should be
written on the lines provided. They
will identify your engine and all
service parts, plus provide warranty
and extended coverage information.
All information subject to change without notice. (Rev. 01/04)
Copyright © 2004 DETROIT DIESEL CORPORATION
SERIES 50 OPERATOR'S GUIDE
Step Three
If you are still not satisfied, present the
entire matter in writing or by phone to:
Vice President, Customer Assurance
Detroit Diesel Corporation
13400 Outer Drive, West
Detroit, MI 48239–4001
Phone: 313–592–7357
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.
All information subject to change without notice. (Rev. 01/04)
DDC-SVC-MAN-0058
Copyright © 2004 DETROIT DIESEL CORPORATION
133
LIMITED WARRANTY ON ENGINES USED IN ON-HIGHWAY VEHICLE
APPLICATIONS
LIMITED WARRANTY ON ENGINES USED IN
ON-HIGHWAY VEHICLE APPLICATIONS
Terms Of Coverage:
On-Highway Vehicle
Engine Applications
Uses
This warranty applies to the first retail
purchaser and subsequent owners
during the WARRANTY PERIOD
of new Detroit Diesel Series 50®
Engines (referred to as Engine)
manufactured by Detroit Diesel
Corporation and/or supplied by
Detroit Diesel Corporation, Detroit
Diesel of Canada Limited, or
Detroit Diesel Overseas Distribution
Corporation (all which are collectively
referred to as DDC) which are used in
on-highway vehicle applications.
Defects
This warranty covers Engine
REPAIRS to correct any malfunction
occurring during the WARRANTY
PERIOD resulting from defects in
material and workmanship.
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.
The owner is responsible for the
percentage of repair costs shown in
the warranty period chart. Repairs will
be performed during normal business
hours.
Warranty Period
The WARRANTY PERIOD begins
on the date the engine is delivered
to the first retail purchaser or put in
use prior to sale at retail, whichever
date comes first, and ends at the time
or mileage/kilometer limits in the
WARRANTY PERIOD chart (Table
28).
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
134
DDC-SVC-MAN-0058
All information subject to change without notice. (Rev. 01/04)
Copyright © 2004 DETROIT DIESEL CORPORATION
SERIES 50 OPERATOR'S GUIDE
WARRANTY PERIOD
Warranty Limitations
(Whichever Occurs First)
Item
Repair Charges to Be
Paid by Owner
Months
Miles/
Kilometers
Parts
Labor
Engine #
0–24
Unlimited
No Charge
No Charge
Accessories
0–24
0–100,000 Miles
0–160,000 Km
No Charge
No Charge
No Charge
No Charge
Upon expiration of the 24-month warranty coverage, but within 500,000 miles/
800,000 km of use, the warranty continues to apply as follows:
Major
Components †
25 – 60
0 – 500,000 Miles
0–800,000 Km
No Charge
100% of
Service
Outlet's
Normal
Charge
# Includes Jacobs 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 will assume the identity of
the Engine being replaced and be
entitled to the remaining warranty
coverage.
Service Supplies
not reusable due to needed warranty
repairs is covered by this warranty.
Engine Removal and
Reinstallation
Labor costs for Engine removal and
reinstallation, when necessary to make
a warranty repair, are covered by this
warranty.
The cost of service supplies such
as coolant, oil and filters which are
All information subject to change without notice. (Rev. 01/04)
DDC-SVC-MAN-0058
Copyright © 2004 DETROIT DIESEL CORPORATION
135
LIMITED WARRANTY ON ENGINES USED IN ON-HIGHWAY VEHICLE
APPLICATIONS
This Warranty Does Not
Cover:
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.
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.
Braking Devices
DDC is not responsible for the
repair of non-factory-installed or
DDC distributor-installed mechanical
braking devices installed on the
engine. Such devices are warranted
by the brake manufacturer.
Fuel Injectors after 100,000
Miles/160,000 Kilometers
Incidental or Consequential
Damage
Detroit Diesel Corporation is
not responsible for incidental or
consequential costs or expenses which
the owner may incur as a result of
a malfunction or failure covered by
this warranty, such as communication
expenses, meals, lodging, overtime,
towing, loss of use of the engine or
vehicle (“downtime”), loss of time,
inconveniences, cargo loss or damage,
and other similar costs and expenses.
Other Limitations
The repair or replacement of fuel
injectors after 100,000 miles/160,000
kilometers of operation is not covered
by this warranty.
Maintenance
The performance of REPAIRS is the
exclusive Owner's remedy under this
warranty. DDC does not authorize
any person to assume or create for
it any other obligation or liability
in connection with the engine or
accessories.
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
136
DDC-SVC-MAN-0058
All information subject to change without notice. (Rev. 01/04)
Copyright © 2004 DETROIT DIESEL CORPORATION
SERIES 50 OPERATOR'S GUIDE
THIS LIMITED WARRANTY
AND THE EMISSIONS CONTROL
WARRANTY ARE THE ONLY
WARRANTIES APPLICABLE
TO THE ENGINE AND
ACCESSORIES AS USED
IN ON-HIGHWAY VEHICLE
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 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 have other
rights which may vary from state to
state.
All information subject to change without notice. (Rev. 01/04)
DDC-SVC-MAN-0058
Copyright © 2004 DETROIT DIESEL CORPORATION
137
LIMITED WARRANTY ON ENGINES POWERING URBAN BUS, MOTOR
COACH OR MOTOR HOME APPLICATIONS
LIMITED WARRANTY ON ENGINES POWERING URBAN
BUS, MOTOR COACH OR MOTOR HOME APPLICATIONS
Terms Of Coverage: Urban
Bus, Motor Coach Or Motor
Home Engine Applications
Uses
This warranty applies to the first retail
purchaser and subsequent owners
during the WARRANTY PERIOD of
new Detroit Diesel Series 50® Engines
(referred to as Engine) manufactured
by Detroit Diesel Corporation
and/or supplied by Detroit Diesel
Corporation, Detroit Diesel of Canada
Limited, or Detroit Diesel Overseas
Distribution Corporation (all which
are collectively referred to as DDC)
powering urban bus, motor coach or
motor home applications sold at retail
on or after January 1, 2004.
Defects
This warranty covers Engine
REPAIRS to correct any malfunction
occurring during the WARRANTY
PERIOD resulting from defects in
material and workmanship.
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.
The owner is responsible for the
percentage of repair costs shown in the
Warranty Period Chart. Repairs will
be performed during normal business
hours.
Warranty Period
The WARRANTY PERIOD begins
on the date the engine is delivered
to the first retail purchaser or put in
use prior to sale at retail, whichever
date comes first, and ends at the time
or mileage/kilometer limits in the
WARRANTY PERIOD chart (Table
29).
Repairs
To obtain warranty repairs, you must
request the needed repairs within
the WARRANTY PERIOD from an
authorized DDC service outlet. Only
138
DDC-SVC-MAN-0058
All information subject to change without notice. (Rev. 01/04)
Copyright © 2004 DETROIT DIESEL CORPORATION
SERIES 50 OPERATOR'S GUIDE
Warranty Period
Warranty Limitations
(Whichever Occurs
First)
Item
Repair Charge to Be
Paid By Owner
Months
Miles/
Kilometers
Parts
Labor
Engine *
0 – 24
Unlimited
No Charge
No Charge
Accessories
0 – 24
0–100,000 Miles
0–160,000 Km
No Charge
No Charge
Upon expiration of the 24-month warranty coverage, but
within 500,000 miles/800,000 km of use, the warranty
continues to apply as follows:
Major
Components †
25 – 60
0 – 500,000 Miles
0 – 800,000 Km
No Charge
100% of
service
outlet's
normal
charge
* Includes Jacobs Vehicle 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 reusable due to needed warranty
repairs is covered by this warranty.
warranty will assume the identity of
the Engine being replaced and be
entitled to the remaining warranty
coverage.
Like Replacement Engine
Engine(s) supplied by DDC as a
replacement for an engine still under
All information subject to change without notice. (Rev. 01/04)
DDC-SVC-MAN-0058
Copyright © 2004 DETROIT DIESEL CORPORATION
139
LIMITED WARRANTY ON ENGINES POWERING URBAN BUS, MOTOR
COACH OR MOTOR HOME APPLICATIONS
Maintenance
Engine Removal and
Reinstallation
Reasonable labor costs for Engine
removal and reinstallation, when
necessary to make a warranty repair,
are covered by this warranty.
This Warranty Does Not
Cover:
Repairs Due to Accidents,
Misuse, Alteration, Storage
Damage, Negligence or Certain
Modifications
Repairs due to an accident, misuse,
alteration, misapplication, storage
damage, negligence or modification
exceeding DDC specifications are not
covered by this warranty.
Braking Devices
DDC is not responsible for the
repair of non-Jacobs Vehicle Systems
mechanical braking devices installed
on the Engine. Such devices are
warranted by the brake manufacturer.
The repair or replacement of fuel
injectors after 200,000 miles/320,000
kilometers of operation is not covered
by this warranty.
DDC-SVC-MAN-0058
Incidental or Consequential
Damage
Detroit Diesel Corporation is
not responsible for incidental or
consequential costs or expenses which
the owner may incur as a result of
a malfunction or failure covered by
this warranty, such as communication
expenses, meals, lodging, loss of use
of the engine or vehicle (“downtime”),
loss of time, inconvenience, cargo loss
or damage, and other similar costs and
expenses.
Other Limitations
Fuel Injectors after 200,000
Miles/320,000 Kilometers
140
DDC is not responsible for the cost
of 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.
The performance of REPAIRS is the
exclusive Owner's remedy under this
warranty. DDC does not authorize
any person to assume or create for
it any other obligation or liability in
connection with the Engine.
All information subject to change without notice. (Rev. 01/04)
Copyright © 2004 DETROIT DIESEL CORPORATION
SERIES 50 OPERATOR'S GUIDE
THIS LIMITED WARRANTY
AND THE EMISSIONS CONTROL
WARRANTY ARE THE ONLY
WARRANTIES APPLICABLE TO
THESE ENGINES POWERING
URBAN BUS, MOTOR
COACH OR MOTOR HOME
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 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 have other
rights which may vary from state to
state.
All information subject to change without notice. (Rev. 01/04)
DDC-SVC-MAN-0058
Copyright © 2004 DETROIT DIESEL CORPORATION
141
LIMITED WARRANTY ON ENGINES AND ENGINE ACCESSORIES USED IN
CONSTRUCTION/INDUSTRIAL APPLICATIONS
LIMITED WARRANTY ON ENGINES AND ENGINE
ACCESSORIES USED IN CONSTRUCTION/INDUSTRIAL
APPLICATIONS
Terms Of Coverage:
Construction/Industrial
Engine Applications
Uses
This warranty applies to the first retail
purchaser and subsequent owners
during the WARRANTY PERIOD
of new Detroit Diesel Series 50®
Engines (referred to as Engine)
manufactured by Detroit Diesel
Corporation and/or supplied by
Detroit Diesel Corporation, Detroit
Diesel of Canada Limited, or
Detroit Diesel Overseas Distribution
Corporation (all which are collectively
referred to as DDC) which are used in
construction/industrial applications.
Defects
This warranty covers Engine
REPAIRS to correct any malfunction
occurring during the WARRANTY
PERIOD resulting 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
142
DDC-SVC-MAN-0058
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
normal business hours.
The owner is responsible for the
percentage of repair costs shown in
the WARRANTY PERIOD chart
(Table 30).
Warranty Period
The WARRANTY PERIOD begins on
the date the engine is delivered to the
first retail purchaser or put in use prior
to sale at retail, whichever date occurs
first, and ends at the time or hour
limits shown in the WARRANTY
PERIOD chart (Table 30).
Service Supplies
The cost of service supplies such as
coolant, oil and filters which are not
reusable due to warranted repairs is
covered by this warranty.
All information subject to change without notice. (Rev. 01/04)
Copyright © 2004 DETROIT DIESEL CORPORATION
SERIES 50 OPERATOR'S GUIDE
Warranty Period
Warranty Limitations
(Whichever Occurs First)
Item
Adjustments to Be Paid
by the Owner
Months
Engine
Hours
Parts
Labor
Engine
0 – 12
No Limit
No Charge
No Charge
Accessories
0 – 12
0 – 2,000
No Charge
No Charge
Upon expiration of the twelve (12) month warranty
coverage, but within 12,000 hours of use, the warranty
continues to apply as follows:
Block,
Crankshaft
and
Connecting
Rods
Table 30
13 – 36
0 – 12,000
No Charge
No Charge
Warranty Period 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.
Like Replacement Engine
Engine(s) supplied by DDC as a
replacement for an Engine still under
warranty will assume the identity of
the Engine being replaced and be
entitled to the remaining warranty
coverage.
Mechanic's Travel Expenses
DDC will pay reasonable travel
expenses for the repairing mechanic
to travel to and from the repair site.
All information subject to change without notice. (Rev. 01/04)
DDC-SVC-MAN-0058
Copyright © 2004 DETROIT DIESEL CORPORATION
143
LIMITED WARRANTY ON ENGINES AND ENGINE ACCESSORIES USED IN
CONSTRUCTION/INDUSTRIAL APPLICATIONS
This Warranty Does Not
Cover:
Maintenance
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 – Agricultural
Machinery and Stand-by Pump
Applications
Labor and material costs for engine
removal and reinstallation, when
necessary to make a warranty
repair, are not covered by this
warranty when the engine is in an
agricultural machinery or stand-by
pump application.
Non-DDC
Supplied/Manufactured
Components
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 the responsibility of the owner.
Refer to the MAINTENANCE section
in this guide for details.
Incidental or Consequential
Damage
DDC is not responsible for incidental
or consequential costs or expenses
which the owner may incur as a
result of a malfunction or failure
covered by this warranty, such as
communication expenses, meals,
lodging, overtime, towing, and any
associated loss of use of the Engine or
equipment (“downtime”), loss of time,
inconvenience, cargo loss or damage,
and other similar costs and expenses.
DDC is not responsible for repair
of components and/or assemblies
which are manufactured or supplied
by another manufacturer, such as
non-DDC power take-offs and
intake and exhaust systems. Such
items are covered by the equipment
manufacturer.
144
DDC-SVC-MAN-0058
All information subject to change without notice. (Rev. 01/04)
Copyright © 2004 DETROIT DIESEL CORPORATION
SERIES 50 OPERATOR'S GUIDE
Other Limitations
The performance of REPAIRS is the
exclusive Owner's remedy under this
warranty. DDC does not authorize
any person to assume or create for
it any other obligation or liability in
connection with the Engine or the
Accessories.
rights which may vary from state to
state.
THIS LIMITED WARRANTY
AND THE EMISSIONS CONTROL
WARRANTY ARE THE ONLY
WARRANTIES APPLICABLE
TO THE ENGINE AND
ACCESSORIES AS USED IN
CONSTRUCTION/INDUSTRIAL,
AGRICULTURAL MACHINERY
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 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 have other
All information subject to change without notice. (Rev. 01/04)
DDC-SVC-MAN-0058
Copyright © 2004 DETROIT DIESEL CORPORATION
145
LIMITED WARRANTY ON ENGINES USED IN AGRICULTURAL MACHINERY
LIMITED WARRANTY ON ENGINES USED IN
AGRICULTURAL MACHINERY
Terms Of Coverage:
Agricultural Machinery
Engine Applications
Diesel of Canada Limited, or
Detroit Diesel Overseas Distribution
Corporation (all which are collectively
referred to as DDC) which are used in
agricultural machinery.
Uses
This warranty applies to the first retail
purchaser and subsequent owners
during the WARRANTY PERIOD
of new Detroit Diesel Series 50®
Engines (referred to as Engine)
manufactured by Detroit Diesel
Corporation and/or supplied by
Detroit Diesel Corporation, Detroit
Defects
This warranty covers Engine
REPAIRS to correct any malfunction
occurring during the WARRANTY
PERIOD resulting from defects in
material and workmanship.
Warranty Period
Warranty Limitations
(Whichever Occurs First)
Item
Repair Charges to Be
Paid by Owner
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 WARRANTY PERIOD from an
authorized DDC service outlet. Only
new genuine parts or remanufactured
parts or components supplied or
146
DDC-SVC-MAN-0058
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
normal business hours.
All information subject to change without notice. (Rev. 01/04)
Copyright © 2004 DETROIT DIESEL CORPORATION
SERIES 50 OPERATOR'S GUIDE
The owner is responsible for the
percentage of repair costs shown in
the WARRANTY PERIOD chart
(Table 31).
Warranty Period
The WARRANTY PERIOD begins on
the date the engine is delivered to the
first retail purchaser or put in use prior
to sale at retail, whichever date occurs
first, and ends at the time or hour
limits shown in the WARRANTY
PERIOD chart (Table 31).
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.
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 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 the responsibility of the owner.
Refer to the MAINTENANCE section
in this guide for details.
Engine Removal and
Reinstallation
Labor costs for Engine removal and
reinstallation, when necessary to make
a warranty repair, are not covered by
this warranty.
All information subject to change without notice. (Rev. 01/04)
DDC-SVC-MAN-0058
Copyright © 2004 DETROIT DIESEL CORPORATION
147
LIMITED WARRANTY ON ENGINES USED IN AGRICULTURAL MACHINERY
Incidental or Consequential
Damage
OR CONSEQUENTIAL DAMAGES
AS DESCRIBED ABOVE.
This warranty does not cover any
economic loss, including without
limitation, communication expenses,
meals, lodging, loss of use of the
Engine or equipment (“downtime”),
loss of time, inconvenience, cargo loss
or damage, overtime, towing or any
other cost or expense resulting from a
defect covered by this warranty.
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 have other
rights which may vary from state to
state.
Other Limitations
The performance of REPAIRS is the
exclusive Owner's remedy under this
warranty. DDC does not authorize
any person to assume or create for
it any other obligation or liability in
connection with the Engine or the
Accessories.
THIS 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
148
DDC-SVC-MAN-0058
All information subject to change without notice. (Rev. 01/04)
Copyright © 2004 DETROIT DIESEL CORPORATION
SERIES 50 OPERATOR'S GUIDE
LIMITED WARRANTY ON ENGINES USED IN PRIME
POWER GENERATOR SETS
Terms Of Coverage: Prime
Power Generator Set
Engine Applications
Uses
This warranty applies to the first retail
purchaser and subsequent owners
during the WARRANTY PERIOD
of new Detroit Diesel Series 50®
Engines (referred to as Engine)
manufactured by Detroit Diesel
Corporation and/or supplied by
Detroit Diesel Corporation, Detroit
Diesel of Canada Limited, or
Detroit Diesel Overseas Distribution
Corporation (all which are collectively
referred to as DDC) which are used in
prime power generators delivered in
the U.S. or Canada.
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
normal business hours.
Warranty Period
The WARRANTY PERIOD begins on
the date the engine is delivered to the
first retail purchaser or put in use prior
to sale at retail, whichever date occurs
first, and ends at the time or hour
limits shown in the WARRANTY
PERIOD chart listed in Table 32.
Defects
Like Replacement Engine
This warranty covers Engine
REPAIRS to correct any malfunction
occurring during the WARRANTY
PERIOD resulting from defects in
material or workmanship.
Engine(s) supplied by DDC as a
replacement for an Engine still under
warranty will assume the identity of
the Engine being replaced and be
entitled to the remaining warranty
coverage.
Repairs
To obtain warranty repairs, you must
request the needed repairs within
the WARRANTY PERIOD from an
authorized DDC service outlet. Only
All information subject to change without notice. (Rev. 01/04)
DDC-SVC-MAN-0058
Copyright © 2004 DETROIT DIESEL CORPORATION
149
LIMITED WARRANTY ON ENGINES USED IN PRIME POWER GENERATOR
SETS
Warranty Period
Warranty Limitations
(Whichever Occurs First)
Item
Engine
Repair Charges to Be
Paid by Owner
Month
Engine
Hours
Parts
Labor
0 – 12
Unlimited
No Charge
No Charge
Upon expiration of the 12 month warranty coverage, but within 12,000
hours of use, the warranty continues to apply as follows:
Block,
Crankshaft,
and
Connecting
Rods
(assemblies)
Table 32
13 – 36
0 – 12,000
No Charge
100% of
Service
Outlet's
Normal
Charge
Warranty Period Chart – Prime Power Generator Set
Service Supplies
The cost of service supplies such as
coolant, oil and filters which are not
reusable due to warranted repairs is
covered by this warranty.
Mechanic's Travel Expenses
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.
DDC will pay reasonable travel
expenses for the repairing mechanic
to travel to and from the repair site.
Engine Removal and
Reinstallation
This Warranty Does Not
Cover:
Reasonable labor costs for Engine
removal and reinstallation, when
necessary to make a warranty repair,
are covered by this warranty.
Repairs Due to Accidents,
Misuse, Storage Damage,
150
DDC-SVC-MAN-0058
All information subject to change without notice. (Rev. 01/04)
Copyright © 2004 DETROIT DIESEL CORPORATION
SERIES 50 OPERATOR'S GUIDE
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
may be 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,
coolant, cooling air and ventilation
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
Other Limitations
THIS LIMITED WARRANTY
IS THE ONLY WARRANTY
APPLICABLE TO THE ENGINE
AND ACCESSORIES AS
USED IN PRIME POWER
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
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 have other
rights which may vary from state to
state.
This warranty does not cover any
economic 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.
All information subject to change without notice. (Rev. 01/04)
DDC-SVC-MAN-0058
Copyright © 2004 DETROIT DIESEL CORPORATION
151
LIMITED WARRANTY ON ENGINES USED IN STAND-BY GENERATOR SETS
LIMITED WARRANTY ON ENGINES USED IN STAND-BY
GENERATOR SETS
Terms Of Coverage:
Stand-By Generator Set
Engine Applications
Defects
Uses
This warranty applies to the first retail
purchaser and subsequent owners
during the WARRANTY PERIOD of
new Detroit Diesel Series 50® Engines
(referred to as Engine) manufactured
by Detroit Diesel Corporation
and/or supplied by Detroit Diesel
Corporation, Detroit Diesel of Canada
Limited, or Detroit Diesel Overseas
Distribution Corporation (all which
are collectively referred to as DDC)
which are used in stand-by generators
delivered in the U.S. or Canada.
This warranty covers Engine
REPAIRS to correct any malfunction
occurring during 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 allowed to perform
the warranty repair after taking the
engine to the authorized service outlet.
Repairs will be performed during
normal business hours.
Warranty Period
Item
Engine
Table 33
152
Warranty Limitations
(Whichever Occurs First)
Repair Charges to Be
Paid by Owner
Months
Engine
Hours
Parts
Labor
Up to 24
0 – 800
No Charge
No Charge
Warranty Period Chart – Stand-By Generator Set
DDC-SVC-MAN-0058
All information subject to change without notice. (Rev. 01/04)
Copyright © 2004 DETROIT DIESEL CORPORATION
SERIES 50 OPERATOR'S GUIDE
Warranty Period
The WARRANTY PERIOD begins
on the date the engine is delivered to
the first retail purchaser or put in use
prior to sale at retail, whichever date
occurs first, and ends at the time limits
shown in the WARRANTY PERIOD
chart listed in Table 33.
Like Replacement Engine
Engine(s) supplied by DDC as a
replacement for an Engine still under
warranty will assume the identity of
the Engine being replaced and be
entitled to the remaining warranty
coverage.
Service Supplies
The cost of service supplies such as
coolant, oil and 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.
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 costs for Engine
removal and reinstallation, when
necessary to make a warranty repair,
are 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 and fuel storage
tanks. Such items may be covered by
warranties issued by the manufacturer
or supplier.
This Warranty Does Not
Cover:
Repairs Due to Accidents,
Misuse, Storage Damage,
All information subject to change without notice. (Rev. 01/04)
DDC-SVC-MAN-0058
Copyright © 2004 DETROIT DIESEL CORPORATION
153
LIMITED WARRANTY ON ENGINES USED IN STAND-BY GENERATOR SETS
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,
coolant, cooling air and ventilation
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
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 damages,
so the above may not apply to you.
This warranty gives you specific legal
rights, and you may also have other
rights which may vary from state to
state.
This warranty does not cover any
economic 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
AS USED IN STAND-BY
GENERATORS. DETROIT DIESEL
CORPORATION MAKES NO
OTHER WARRANTIES EXPRESS
OR IMPLIED, INCLUDING
ANY IMPLIED WARRANTY
154
DDC-SVC-MAN-0058
All information subject to change without notice. (Rev. 01/04)
Copyright © 2004 DETROIT DIESEL CORPORATION
SERIES 50 OPERATOR'S GUIDE
SPECIFICATIONS
This section lists the fuel and
lubrication oil filters needed for the
Series 50 engine. Also listed as
the various POWER COOL®engine
products
Fuel and Lubricating Oil
Filters
The fuel filters and their part numbers
are listed in Table 34. The lubricating
oil filters and their part numbers are
listed in Table 35.
Filter Type
Detroit Diesel Part No.
Primary — Spin-On
23530706
Primary Fuel/Water Separator
— Spin-On†
23512317†
Secondary — Spin-On
22530707
Primary — Fuel Pro 380/382 Element
23521528 or 23529168#
# Elemax™ 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 quarts to
the LOW mark without oil filters. 22
All information subject to change without notice. (Rev. 01/04)
DDC-SVC-MAN-0058
quarts to the FULL mark without oil
filters.
Total Oil Capacity Of The
Engine — 29 quarts to the FULL
mark with oil filters installed and
filters and oil galleries charged.
Copyright © 2004 DETROIT DIESEL CORPORATION
155
SPECIFICATIONS
POWER COOL® ENGINE
PRODUCTS
Power Cool Fully Formulated
IEG Coolant
Maintenance of the cooling system
requires the chemical make-up of the
system to be balanced
The part numbers and sizes of
concentrated Power Cool and
pre-blended 50:50 Power Cool are
listed in Table 36.
Coolant Type
Part Number
Description
23512138
1 Gallon Jug – 6
Per Case
23512139
55 Gallon Drum
23529295
330 Gallon Tote
23512140
Bulk Delivery – 1,000
Gallon Min.
23528203
1 Gallon Jug – 6
Per Case
23518918
55 Gallon Drum
23528544
330 Gallon Tote
23513503
Bulk Delivery – 1,000
Gallon Min.
Concentrated
Pre-Blended 50:50
Table 36
Power Cool Fully Formulated IEG Coolant
Power Cool Latin American
Coolant
Coolant Type
Part Number
Description
23524923
55 Gallon Drum
23524924
Bulk Delivery – 1,000
Gallon Minimum
Pre-Blended 67:33
Table 37
156
Power Cool Latin American Coolant Products
DDC-SVC-MAN-0058
All information subject to change without notice. (Rev. 01/04)
Copyright © 2004 DETROIT DIESEL CORPORATION
SERIES 50 OPERATOR'S GUIDE
Power Cool 2000 Supplemental
Coolant Additive
Coolant Type
For Power Cool IEG
Coolant
Table 38
Part Number
Description
23507858
Pint Bottle – 12 Per case
23507859
One-Half Gallon Jug
– 6 Per Case
23507860
5 Gallon Pail
23507861
55 Gallon Drum
Power Cool 2000 Supplemental Coolant Additive
Power Cool 3000 Supplemental
Coolant Additive
Coolant Type
For Power Cool IEG
Coolant
Table 39
Part Number
Description
23507854
Pint Bottle – 12 Per Case
23507855
One-Half Gallon Jug
– 6 Per Case
23507856
5 Gallon Pail
23507857
55 Gallon Drum
Power Cool 3000 Supplemental Coolant Additive
All information subject to change without notice. (Rev. 01/04)
DDC-SVC-MAN-0058
Copyright © 2004 DETROIT DIESEL CORPORATION
157
SPECIFICATIONS
Power Cool 3000 Supplemental
Additive Coolant Filters
Coolant Type
Part Number
Description
23507545
4 Ounce (1 Pint
Equivalent)
23508425
8 Ounce (2 Pint
Equivalent)
23508426
12 Ounce (3 Pint
Equivalent)
23507189
16 Ounce (4 Pint
Equivalent)
23508427
32 Ounce (8 Pint
Equivalent)
23508428
53 Ounce (13 Pint
Equivalent)
For Power Cool IEG
Coolant
Table 40
Power Cool 3000 Supplemental Additive Coolant Filters
Power Cool Supplemental
Additive Need-Release Filters
Coolant Type
For Power Cool IEG
Coolant
Table 41
158
Part Number
Description
23516488
For 0 – 8 Gallon Systems
23516489
For 8 – 20 Gallon
Systems
Power Cool SUPPLEMENTAL ADDITIVE NEED-RELEASE
COOLANT FILTERS
DDC-SVC-MAN-0058
All information subject to change without notice. (Rev. 01/04)
Copyright © 2004 DETROIT DIESEL CORPORATION
SERIES 50 OPERATOR'S GUIDE
Power Cool Plus Extended Life
Oat Coolant
Coolant Type
Concentrated
Pre-Blended 50:50
Table 42
Part Number
Description
23519397
1 Gallon Jug – 6
Per Case
23519394
55 Gallon Drum
23519395
Bulk Delivery – 1,000
Gallon Min.
23519396
1 Gallon Jug – 6
Per Case
23519398
55 Gallon Drum
23519399
Bulk Delivery – 1,000
Gallon Min.
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
All information subject to change without notice. (Rev. 01/04)
DDC-SVC-MAN-0058
Copyright © 2004 DETROIT DIESEL CORPORATION
159
SPECIFICATIONS
Power Cool Plus 6000 OAT
Inhibitor For Water-Only
Systems
Coolant Type
Part Number
Description
23522127
1 Gallon Jug – 6
Per Case
23522128
5 Gallon Pail
Water Only
Table 44
Power Cool Plus 6000 OAT Inhibitor for Water-Only
Systems
Power Cool Cooling System
Cleaners
Coolant Type
On-Line Cleaner
Twin Pack
Table 45
160
Part Number
Description
200164
On-Half Gallon Jug –
6 Per Case
200105
5 Gallon Pail
200155
55 Gallon Drum
201549
Twin Pack – 2 Per Case
Power Cool Cooling System Cleaners
DDC-SVC-MAN-0058
All information subject to change without notice. (Rev. 01/04)
Copyright © 2004 DETROIT DIESEL CORPORATION
SERIES 50 OPERATOR'S GUIDE
POWER Trac® Coolant Testing
And Analysis Products
Application
Part Number
Indicates Nitrite,
Molybdate & Glycol
Levels
Indicates Nitrite,
Molybdate & Glycol
Levels
Indicates Nitrite,
Molybdate & Glycol
Levels
Complete IEG/IPG
Coolant Analysis
Organic Coolant
Analysis
Table 46
23519401
23519402
23522774
23516921
23523398
Description
3-Way Coolant Test
Strips
(Single Foil Packs)
3-Way Coolant Test
Strips
(Bottle of 50)
3-Way Coolant Test
Strips
(Bottle of 10)
Coolant Analysis Bottle
(Carton of 6)
Laboratory Coolant
Analysis Bottle
(Carton of 6)
Power Trac Coolant Testing and Analysis Products
All information subject to change without notice. (Rev. 01/04)
DDC-SVC-MAN-0058
Copyright © 2004 DETROIT DIESEL CORPORATION
161
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