Detroit Diesel 50 Series Manual

SERIES 50 OPERATOR'S GUIDE
To the Operator
This guide contains instructions on
the safe operation and preventive
maintenance of your Detroit Diesel
Series 50®engine used in vehicle,
stationary, construction/industrial,
agricultural, generator set or fire
fighting apparatus applications.
Maintenance instructions cover
routine engine services such as lube
oil and filter changes in enough detail
to permit self-servicing, if desired.
The operator should become familiar
with the contents of this guide before
operating the engine or carrying out
maintenance procedures.
Power-driven equipment is only
as safe as the person operating the
controls. You are urged, as the
operator of this diesel engine, to keep
fingers and clothing away from the
revolving belts, drive shafts, pulleys,
etc. on the engine installation.
Throughout this guide CAUTIONS
regarding personal safety and
NOTICES regarding engine
performance or service life will
appear. To avoid personal injury and
ensure long engine service life, always
heed these instructions.
Whenever possible, it will benefit
youtorelyonanauthorized Detroit
Diesel service outlet for all your
service needs from maintenance to
major parts replacement. Authorized
service outlets worldwide stock
factory-original parts and have
the specialized equipment and
experienced, trained personnel
to provide prompt preventive
maintenance and skilled engine
repairs.
The information and specifications
in this publication are based on the
information in effect at the time of
approval for printing. Contact an
authorized Detroit Diesel service
outlet for information on the latest
revision. The right is reserved to
make changes at any time without
obligation.
All information subject to change without notice. (Rev. 01/ 04) i
6SE550 0401 Copyright © 2004 DETROIT DIESEL CORPORATION

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
SCAslistedinthisengineoperator's
guide.Refer to section How to Select
Coolant. In addition, the engine
can be equipped with a coolant
filter/inhibitor system as an installed
option or as an after-sale item.
WARRANTY
The limited warranties for each
engine application are covered in
the Limited Warranty pages of this
guide and in the booklet, “Warranty
Information for Series 50 Engines,”
available from authorized Detroit
Diesel service outlets.
Keep this Operator's Guide
with the engine installation at
all times. It contains important
operating, maintenance, and safety
instructions.
Trademark Information
Detroit Diesel®,DDC
®,DDEC ®,
Series 50®, Optimized Idle®,
ProManager®, reliabilt®,Power
Trac®,Power Cool®,andPower
Guard®are registered trademarks of
DetroitDieselCorporation. Delco
Remy®is a registered trademark of
Delco Remy America, Inc. Bosch®
is a registered trademark of Robert
Bosch Company N.A. Fuel Pro®,Sea
Pro®and Mega Filter®are registered
trademarks of Davco Manufacturing,
L.L.C. The PowerBand®is a
registered trademark of Gates Rubber
Company. Tectyl®is a registered
trademark of Daubert Chemical
Company, Inc. Biobor®is a registered
trademark of United States Borax and
Chemical Corporation. DuPont®is a
registered trademark of E.I. DuPont
de Nemours and Company, Inc. All
other trademarks used are the property
of their respective owners.
ii All information subject to change without notice. (Rev. 01/ 04)
6SE550 0401 Copyright © 2004 DETROIT DIESEL CORPORATION

SERIES 50 OPERATOR'S GUIDE
TABLE OF CONTENTS
INTRODUCTION .................................................................................. 1
NON-GENUINE AND REBUILT COMPONENT QUALITY ALERT .. 1
CAUTION SUMMARY .......................................................................... 3
ENGINE OPERATION ...................................................................... 3
PREVENTIVE MAINTENANCE ....................................................... 4
ELECTRICAL SYSTEM ................................................................... 7
COOLING SYSTEM ......................................................................... 8
AIR INTAKE SYSTEM ...................................................................... 8
FUEL SYSTEM ................................................................................ 9
STARTING AIDS .............................................................................. 10
COMPRESSED AIR ......................................................................... 11
LUBRICATING OIL AND FILTERS ................................................... 11
ENGINE MODEL AND SERIAL NUMBER DESIGNATION ................ 12
OPTION LABELS ............................................................................. 13
CERTIFICATION LABELS ............................................................... 14
OPERATING INSTRUCTIONS FOR A FIRST TIME START .............. 15
PREPARATIONS FOR STARTING THE ENGINE THE FIRST
TIME ................................................................................................. 15
COOLING SYSTEM CHECKS .................................................... 15
LUBRICATION SYSTEM CHECKS ............................................. 16
EXTENDED STORAGE ........................................................... 16
FUEL SYSTEM CHECKS ............................................................ 17
OTHER CHECKS ........................................................................ 18
STARTING THE ENGINE ................................................................ 18
INITIAL ENGINE START .............................................................. 19
ELECTRIC STARTER ............................................................. 19
AIR STARTER ......................................................................... 20
RUNNING THE ENGINE ................................................................. 20
OIL PRESSURE .......................................................................... 20
WARM-UP ................................................................................... 20
INSPECTION ............................................................................... 20
AVOID UNNECESSARY IDLING ................................................. 21
All information subject to change without notice. (Rev. 01/ 04) iii
6SE550 0401 Copyright © 2004 DETROIT DIESEL CORPORATION

TABLEOFCONTENTS
STOPPING THE ENGINE ................................................................ 21
EMERGENCY JUMP STARTING .................................................... 22
DDEC IV SYSTEM ............................................................................... 23
DDEC SYSTEM .............................................................................. 23
ENGINE PROTECTION ............................................................... 24
IDLE SHUTDOWN TIMER ........................................................... 24
CRUISE CONTROL ..................................................................... 24
ENGINE BRAKES ....................................................................... 26
DATA RECORDING CAPABILITY ................................................ 27
DDEC IV OPERATION ..................................................................... 27
IMMEDIATE SPEED REDUCTION OPTION ............................... 28
STOP ENGINE LIGHT ................................................................. 28
DIAGNOSTIC DATA READER ..................................................... 28
DIAGNOSTIC CODE LIST ........................................................... 30
DDEC IV ENGINE DRIVING TIPS ....................................................... 37
ACCELERATING THE VEHICLE ..................................................... 37
CRUISE CONTROL ......................................................................... 37
ENGINE BRAKES AND CRUISE CONTROL .................................. 39
SHIFTING ........................................................................................ 39
IDLING ............................................................................................. 40
WINTER FRONTS ....................................................................... 40
ENGINE BRAKE SYSTEM .................................................................. 41
DRIVER CONTROL SWITCHES ..................................................... 41
LOW/HIGH SWITCH .................................................................... 41
LOW/MED/HIGH SWITCH ........................................................... 41
CLUTCH PEDAL AND THROTTLE POSITION CONTROLS .......... 41
ENGINE BRAKE OPERATION ........................................................ 42
ANTI-LOCK BRAKING SYSTEMS ................................................... 43
DRIVING ON FLAT, DRY PAVEMENT ............................................. 43
DESCENDING A LONG, STEEP GRADE ....................................... 43
DRIVING ON WET OR SLIPPERY PAVEMENT .............................. 45
ENGINE SYSTEMS ............................................................................. 46
FUEL SYSTEM ................................................................................ 46
LUBRICATION SYSTEM .................................................................. 46
AIR SYSTEM ................................................................................... 46
COOLING SYSTEM ......................................................................... 46
iv All information subject to change without notice. (Rev. 01/ 04)
6SE550 0401 Copyright © 2004 DETROIT DIESEL CORPORATION

SERIES 50 OPERATOR'S GUIDE
ELECTRICAL SYSTEM ................................................................... 46
EXHAUST SYSTEM ......................................................................... 46
EXHAUST GAS RECIRCULATION SYSTEM .................................. 46
MAINTENANCE ................................................................................... 47
PREVENTIVE MAINTENANCE INTERVALS ................................... 63
ITEM 1 – LUBRICATING OIL ....................................................... 63
ITEM 2 – FUEL AND FUEL TANK ............................................... 65
ITEM 3 – FUEL LINES, FLEXIBLE HOSES ................................ 66
LEAKS ..................................................................................... 66
HOSES AND FITTINGS .......................................................... 67
HOSE SERVICE LIFE ............................................................. 67
ITEM 4 – COOLING SYSTEM ..................................................... 67
COOLANT LEVEL ................................................................... 67
COOLANT INHIBITORS .......................................................... 68
COOLANT DRAIN INTERVAL ................................................. 68
ITEM 5 – TURBOCHARGER, AIR-TO-AIR CHARGE COOLER . 70
WASTEGATED TURBOCHARGERS ...................................... 70
ITEM 6 – BATTERY ..................................................................... 71
ITEM 7 – TACHOMETER DRIVE ................................................. 72
ITEM 8 – DRIVE BELTS .............................................................. 72
V-BELTS .................................................................................. 73
2-GROOVE POWERBAND ..................................................... 73
12–RIB POLY-V BELT ............................................................. 74
BELT REPLACEMENT ............................................................ 74
ITEM 9 – AIR COMPRESSOR .................................................... 74
ITEM 10 – AIR CLEANER ........................................................... 75
ITEM 11 – LUBRICATING OIL FILTERS ..................................... 75
ITEM 12 – FUEL FILTERS ........................................................... 76
FUEL PRO®382 FILTERS ...................................................... 76
SPIN-ON FILTERS .................................................................. 76
ITEM 13 – WATER PUMP AND COOLANT INHIBITOR
ELEMENT .................................................................................... 77
WATER PUMP DRAIN HOLE .................................................. 77
COOLANT INHIBITOR ELEMENT .......................................... 77
ITEM 14 – CRANKING MOTOR .................................................. 78
ITEM 15 – AIR SYSTEM ............................................................. 78
ITEM 16 – EXHAUST SYSTEM ................................................... 78
ITEM 17 – ENGINE (STEAM CLEAN) ......................................... 78
All information subject to change without notice. (Rev. 01/ 04) v
6SE550 0401 Copyright © 2004 DETROIT DIESEL CORPORATION

TABLEOFCONTENTS
ITEM 18 – RADIATOR ................................................................. 78
ITEM 19 – OIL PRESSURE ......................................................... 79
ITEM 20 – BATTERY-CHARGING ALTERNATOR ...................... 79
BOSCH®T1 ALTERNATOR SERVICE REQUIREMENTS ...... 80
GENERAL SERVICE REQUIREMENTS – BOSCH®AND
DELCO REMY®ALTERNATORS ............................................ 80
ITEM 21 – ENGINE AND TRANSMISSION MOUNTS ................ 80
ITEM 22 – CRANKCASE PRESSURE ........................................ 80
ITEM 23 – FAN HUB .................................................................... 81
ITEM 24 – THERMOSTATS AND SEALS .................................... 81
ITEM 25 – CRANKCASE BREATHER ......................................... 81
ITEM 26 – ENGINE TUNE-UP .................................................... 82
ITEM 27 – VIBRATION DAMPER ................................................ 82
HOW-TO SECTION .............................................................................. 83
HOW TO SELECT LUBRICATING OIL ............................................ 83
LUBRICANT REQUIREMENTS .................................................. 83
EGR-EQUIPPED ENGINES .................................................... 83
NON-EGR ENGINES .............................................................. 83
ENGINES BUILT PRIOR TO 1998 .......................................... 83
COLD WEATHER STARTING ...................................................... 84
SYNTHETIC OILS ....................................................................... 84
THE USE OF SUPPLEMENTAL ADDITIVES .............................. 85
WHEN TO CHANGE OIL ................................................................. 85
DISPOSING OF WASTE OIL ...................................................... 86
HOW TO REPLACE THE LUBE OIL FILTERS ................................ 86
REPLACE SPIN-ON TYPE OIL FILTER ...................................... 86
HOW TO SELECT FUEL OIL ........................................................... 88
QUALITY ...................................................................................... 88
FUEL CONTAMINATION ............................................................. 88
PROHIBITED ADDITIVES ........................................................... 88
USED LUBRICATING OIL ....................................................... 89
GASOLINE ............................................................................. 89
HOW TO REPLACE THE FUEL FILTERS ....................................... 89
REPLACE SPIN-ON FILTER ELEMENTS ................................... 89
REPLACE FUEL/WATER SEPARATOR ELEMENT .................... 91
REPLACE FUEL PRO FILTER ELEMENT .................................. 92
ENGINE OUT OF FUEL — HOW TO RESTART ............................. 94
ENGINES WITH SPIN-ON FILTERS ........................................... 95
vi All information subject to change without notice. (Rev. 01/ 04)
6SE550 0401 Copyright © 2004 DETROIT DIESEL CORPORATION

SERIES 50 OPERATOR'S GUIDE
ENGINES WITH FUEL PRO FILTERS ........................................ 95
HOW TO SELECT COOLANT ......................................................... 96
DEFINITIONS .............................................................................. 96
ANTIFREEZE .......................................................................... 96
COOLANT ............................................................................... 96
DROP-OUT ............................................................................. 96
FULLY FORMULATED ANTIFREEZE ..................................... 96
INITIAL–FILL COOLANT ......................................................... 96
OAT .......................................................................................... 96
SCA ......................................................................................... 96
APPROVED COOLANTS ............................................................ 97
EG OR PG & WATER + SCA INHIBITOR ............................... 98
MIXING EG OR PG ANTIFREEZE AND WATER .................... 98
RECYCLED ANTIFREEZE .................................................... 100
EG OR PG & WATER + OAT INHIBITOR ................................ 100
WATER ONLY + SCA OR WATER ONLY + OAT INHIBITOR . 101
WATER REQUIREMENTS ..................................................... 102
COOLANTS NOT RECOMMENDED ........................................... 102
ALL ANTIFREEZES AND COOLANTS CONTAINING
PHOSPHATE ........................................................................... 102
AUTOMOTIVE TYPE COOLANTS .......................................... 102
METHYL ALCOHOL-BASED ANTIFREEZE ........................... 103
METHOXY PROPANOL-BASED ANTIFREEZE ...................... 103
GLYCOL-BASED COOLANTS FORMULATED FOR HVAC .... 103
ADDITIVES NOT RECOMMENDED ........................................... 103
SOLUBLE OIL ADDITIVES ..................................................... 103
CHROMATE ADDITIVES ........................................................ 103
COOLANT MAINTENANCE ........................................................ 103
COOLANT INHIBITOR TEST INTERVALS ............................ 103
SUPPLEMENTAL ADDITIVES ................................................ 104
COOLANT MAINTENANCE INTERVALS ............................... 105
SCA TEST PROCEDURES ......................................................... 107
NEED-RELEASE FILTERS (NON-OAT SYSTEMS) .................... 108
DROPOUT ................................................................................... 108
EXTENDER ADDITIVE FOR OAT COOLANT ............................. 109
OAT COOLANT DRAIN INTERVAL ......................................... 109
CHRONIC COOLANT SYSTEM PROBLEMS ............................. 109
MAINTENANCE PRODUCTS ..................................................... 109
All information subject to change without notice. (Rev. 01/ 04) vii
6SE550 0401 Copyright © 2004 DETROIT DIESEL CORPORATION

TABLEOFCONTENTS
POWER COOL SCAS ............................................................. 109
POWER COOL COOLANT FILTER ELEMENTS .................... 110
POWER COOL CLEANERS ................................................... 110
SUMMARY OF COOLANT RECOMMENDATIONS .................... 110
HOW TO DRAIN AND FLUSH THE COOLING SYSTEM ............... 112
WHEN TO SERVICE THE DRY TYPE AIR CLEANER .................... 114
BASIC TROUBLESHOOTING ............................................................. 115
ENGINE STORAGE ............................................................................. 120
PREPARING THE ENGINE FOR STORAGE .................................. 120
TEMPORARY STORAGE (30 DAYS OR LESS) .......................... 120
EXTENDED STORAGE (MORE THAN 30 DAYS) ....................... 121
RESTORING ENGINE TO SERVICE .......................................... 124
SERIES 50 SERVICE PUBLICATIONS ............................................... 126
CUSTOMER ASSISTANCE ................................................................. 127
IN U.S. AND CANADA CALL 1–800–445–1980 .............................. 130
WORKING WITH DDC SERVICE OUTLETS .................................. 130
ON-HIGHWAY VEHICLE ENGINE WARRANTY ................................. 133
TERMS OF COVERAGE: ON-HIGHWAY VEHICLE ENGINE
APPLICATIONS .............................................................................. 133
USES ........................................................................................... 133
DEFECTS .................................................................................... 133
REPAIRS ..................................................................................... 133
WARRANTY PERIOD .................................................................. 133
LIKE REPLACEMENT ENGINE .................................................. 134
SERVICE SUPPLIES ................................................................... 134
ENGINE REMOVAL AND REINSTALLATION .............................. 135
THIS WARRANTY DOES NOT COVER: ......................................... 135
REPAIRS DUE TO ACCIDENTS, MISUSE, STORAGE DAMAGE,
NEGLIGENCE OR CERTAIN MODIFICATIONS ......................... 135
BRAKING DEVICES .................................................................... 135
FUEL INJECTORS AFTER 100,000 MILES/160,000
KILOMETERS .............................................................................. 135
MAINTENANCE ........................................................................... 135
INCIDENTAL OR CONSEQUENTIAL DAMAGE ......................... 135
OTHER LIMITATIONS .................................................................. 136
viii All information subject to change without notice. (Rev. 01/ 04)
6SE550 0401 Copyright © 2004 DETROIT DIESEL CORPORATION

SERIES 50 OPERATOR'S GUIDE
URBAN BUS, MOTOR COACH OR MOTOR HOME ENGINE
WARRANTY ......................................................................................... 137
TERMS OF COVERAGE: URBAN BUS, MOTOR COACH OR
MOTOR HOME ENGINE APPLICATIONS ...................................... 137
USES ........................................................................................... 137
DEFECTS .................................................................................... 137
REPAIRS ..................................................................................... 137
WARRANTY PERIOD .................................................................. 137
SERVICE SUPPLIES ................................................................... 138
LIKE REPLACEMENT ENGINE .................................................. 138
ENGINE REMOVAL AND REINSTALLATION .............................. 139
THIS WARRANTY DOES NOT COVER: ......................................... 139
REPAIRS DUE TO ACCIDENTS, MISUSE, ALTERATION,
STORAGE DAMAGE, NEGLIGENCE OR CERTAIN
MODIFICATIONS ......................................................................... 139
BRAKING DEVICES .................................................................... 139
FUEL INJECTORS AFTER 200,000 MILES/320,000
KILOMETERS .............................................................................. 139
MAINTENANCE ........................................................................... 139
INCIDENTAL OR CONSEQUENTIAL DAMAGE ......................... 139
OTHER LIMITATIONS .................................................................. 139
CONSTRUCTION/ INDUSTRIAL ENGINE WARRANTY .................... 141
TERMS OF COVERAGE: CONSTRUCTION/INDUSTRIAL ENGINE
APPLICATIONS ............................................................................... 141
USES ........................................................................................... 141
DEFECTS .................................................................................... 141
REPAIRS ..................................................................................... 141
WARRANTY PERIOD .................................................................. 141
SERVICE SUPPLIES ................................................................... 141
ENGINE REMOVAL AND REINSTALLATION –
CONSTRUCTION/INDUSTRIAL APPLICATIONS ....................... 142
MECHANIC'S TRAVEL EXPENSES ........................................... 142
LIKE REPLACEMENT ENGINE .................................................. 142
THIS WARRANTY DOES NOT COVER: ......................................... 143
REPAIRS DUE TO ACCIDENTS, MISUSE, STORAGE DAMAGE,
NEGLIGENCE OR CERTAIN MODIFICATIONS ......................... 143
ENGINE REMOVAL AND REINSTALLATION – AGRICULTURAL
MACHINERY AND STAND-BY PUMP APPLICATIONS .............. 143
All information subject to change without notice. (Rev. 01/ 04) ix
6SE550 0401 Copyright © 2004 DETROIT DIESEL CORPORATION

TABLEOFCONTENTS
NON-DDC SUPPLIED/MANUFACTURED COMPONENTS ....... 143
MAINTENANCE ........................................................................... 143
INCIDENTAL OR CONSEQUENTIAL DAMAGE ......................... 143
OTHER LIMITATIONS .................................................................. 144
AGRICULTURAL MACHINERY ENGINE WARRANTY ...................... 145
TERMS OF COVERAGE: AGRICULTURAL MACHINERY ENGINE
APPLICATIONS ............................................................................... 145
USES ........................................................................................... 145
DEFECTS .................................................................................... 145
REPAIRS ..................................................................................... 145
WARRANTY PERIOD .................................................................. 146
THIS WARRANTY DOES NOT COVER: ......................................... 146
REPAIRS DUE TO ACCIDENTS, MISUSE, STORAGE DAMAGE,
NEGLIGENCE OR CERTAIN MODIFICATIONS ......................... 146
ENGINE REMOVAL AND REINSTALLATION .............................. 146
NON-DDC SUPPLIED/MANUFACTURED COMPONENTS ....... 146
MAINTENANCE ........................................................................... 146
INCIDENTAL OR CONSEQUENTIAL DAMAGE ......................... 147
OTHER LIMITATIONS .................................................................. 147
PRIME POWER GENERATOR SET ENGINE WARRANTY ............... 148
TERMS OF COVERAGE: PRIME POWER GENERATOR SET
ENGINE APPLICATIONS ................................................................. 148
USES ........................................................................................... 148
DEFECTS .................................................................................... 148
REPAIRS ..................................................................................... 148
WARRANTY PERIOD .................................................................. 148
LIKE REPLACEMENT ENGINE .................................................. 148
SERVICE SUPPLIES ................................................................... 149
MECHANIC'S TRAVEL EXPENSES ........................................... 149
THIS WARRANTY DOES NOT COVER: ......................................... 149
REPAIRS DUE TO ACCIDENTS, MISUSE, STORAGE DAMAGE,
NEGLIGENCE OR CERTAIN MODIFICATIONS ......................... 149
ENGINE REMOVAL AND REINSTALLATION .............................. 149
NON-DDC SUPPLIED/MANUFACTURED COMPONENTS ....... 150
MAINTENANCE ........................................................................... 150
INCIDENTAL OR CONSEQUENTIAL DAMAGE ......................... 150
OTHER LIMITATIONS .................................................................. 150
xAll information subject to change without notice. (Rev. 01/ 04)
6SE550 0401 Copyright © 2004 DETROIT DIESEL CORPORATION

SERIES 50 OPERATOR'S GUIDE
STAND-BY GENERATOR SET ENGINE WARRANTY ....................... 151
TERMS OF COVERAGE: STAND-BY GENERATOR SET ENGINE
APPLICATIONS ............................................................................... 151
USES ........................................................................................... 151
DEFECTS .................................................................................... 151
REPAIRS ..................................................................................... 151
WARRANTY PERIOD .................................................................. 152
LIKE REPLACEMENT ENGINE .................................................. 152
SERVICE SUPPLIES ................................................................... 152
MECHANIC'S TRAVEL EXPENSES ........................................... 152
THIS WARRANTY DOES NOT COVER: ......................................... 152
REPAIRS DUE TO ACCIDENTS, MISUSE, STORAGE DAMAGE,
NEGLIGENCE OR CERTAIN MODIFICATIONS ......................... 152
ENGINE REMOVAL AND REINSTALLATION .............................. 152
NON-DDC SUPPLIED/MANUFACTURED COMPONENTS ....... 152
MAINTENANCE ........................................................................... 153
INCIDENTAL OR CONSEQUENTIAL DAMAGE ......................... 153
OTHER LIMITATIONS .................................................................. 153
SPECIFICATIONS ................................................................................ 154
FUEL AND LUBRICATING OIL FILTER REQUIREMENTS ............. 154
OIL PAN ....................................................................................... 154
OIL PAN CAPACITY ................................................................ 154
TOTAL OIL CAPACITY OF THE ENGINE ............................... 154
POWER COOL ENGINE PRODUCTS ............................................. 155
FULLY FORMULATED IEG COOLANT ....................................... 155
LATIN AMERICAN COOLANT ..................................................... 155
2000 SUPPLEMENTAL COOLANT ADDITIVE ........................... 156
3000 SUPPLEMENTAL COOLANT ADDITIVE ........................... 156
3000 SUPPLEMENTAL ADDITIVE COOLANT FILTERS ............ 157
SUPPLEMENTAL ADDITIVE NEED RELEASE FILTERS ........... 157
PLUS EXTENDED LIFE OAT COOLANT .................................... 158
PLUS EXTENDER FOR USE WITH POWER COOL PLUS OAT
COOLANT ................................................................................... 158
PLUS 6000 OAT INHIBITOR FOR WATER-ONLY SYSTEMS ..... 159
COOLING SYSTEM CLEANERS ................................................ 159
COOLANT TESTING AND ANALYSIS PRODUCTS ................... 160
All information subject to change without notice. (Rev. 01/ 04) xi
6SE550 0401 Copyright © 2004 DETROIT DIESEL CORPORATION

TABLEOFCONTENTS
xii All information subject to change without notice. (Rev. 01/ 04)
6SE550 0401 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
durability and to ensure coverage of
the engine under the manufacturer's
warranty. Many of these maintenance
procedures also ensure that the engine
continues to comply with applicable
emissions standards. The U.S. EPA
specifically defines an engine's
“useful emission life” — currently
established as 290,000 miles (464,000
kilometers) for on-highway engines.
Proper maintenance procedures, using
specific components engineered to
comply with emissions regulations,
may be performed by an authorized
Detroit Diesel distributor or dealer,
an independent outlet or the operator
or owner. The owner is responsible
for determining the suitability of
components to maintain emissions
compliance during the engine's useful
emission life.
Electronic controls and components
have significantly increased in
sophistication, but the fundamental
objective remains the same — precise
timing and delivery of fuel. The very
heart of the Detroit Diesel electronic
controls is the electronic unit injector
(EUI). The proper functioning of the
EUI is absolutely paramount if the
benefits of electronic controls are to be
realized. Detroit Diesel Corporation
has built over 650,000 engines with
electronic unit injectors — more than
anyone else in the business.
All information subject to change without notice. (Rev. 01/ 04) 1
6SE550 0401 Copyright © 2004 DETROIT DIESEL CORPORATION

INTRODUCTION
Detroit Diesel cautions that the
indiscriminate rebuilding of precision
components, without the benefit of
specifications, specialized equipment,
and knowledge of the electronic
operating system, will jeopardize
performance or lead to more serious
problems, and can take the engine
outside of compliance with U.S. EPA
or CARB emissions standards.
There are other components in
an engine, such as turbocharger,
camshaft, piston, etc., which
are specifically designed and
manufactured to exacting standards
for emissions compliance. It is
important that these components, if
replaced, modified or substituted, can
be verified to ensure that the engine
remains in compliance with emissions
standards. The use of inadequately
engineered, manufactured or tested
components in repair or rebuild of
the engine may be in violation of the
federal Clean Air Act and applicable
U.S. EPA or CARB regulations.
Furthermore, modern engines exhibit
operating parameters which require
the use of proper fluids, such as
fuel, coolant and lubricating oil, to
maintain long engine life. The use of
fluids that do not meet Detroit Diesel
Corporation specifications may result
in early wear out or engine failure.
2All information subject to change without notice. (Rev. 01/ 04)
6SE550 0401 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.
To avoid injury from loss of
vehicle/vessel control, the
operator of a DDEC equipped
engine must not attempt to use
or read the Diagnostic Data
Reader when the vehicle/vessel
is moving.
Diesel engine exhaust and some
of its constituents are known to
the State of California to cause
cancer, birth defects, and other
reproductive harm.
Always start and operate an
engine in a well ventilated
area.
If operating an engine in
an enclosed area, vent the
exhaust to the outside.
Do not modify or tamper
with the exhaust system or
emission control system.
To avoid injury from engine
shutdown in an unsafe situation,
ensure the operator knows how
to override the stop engine
condition on a DDEC-equipped
unit.
All information subject to change without notice. (Rev. 01/ 04) 3
6SE550 0401 Copyright © 2004 DETROIT DIESEL CORPORATION

CAUTION SUMMARY
To avoid injury from loss of
vehicle control, do not activate
the Engine Brake system under
the following conditions:
On wet or slippery pavement,
unless the vehicle is equipped
with ABS (anti-lock braking
system) and you have had
prior experience driving
under these conditions.
When driving without a trailer
(bobtailing) or pulling and
empty trailer.
If the tractor drive wheels
begin to lock or there is
fishtail motion after the
Engine Brake is activated.
Deactivate the brake system
immediately, if this occurs.
Failure to observe these
precautions may result in
loss of vehicle control and/or
personal injury.
To avoid injury from the loss of
vehicle control, do not use cruise
control under these conditions:
When it is not possible to
keep the vehicle at a constant
speed (on winding roads, in
heavy traffic, in traffic that
varies in speed, etc.).
On slippery roads
(wet pavement, ice-or
snow-covered roads, loose
gravel, etc.).
Preventive Maintenance
Observe the following cautions when
performing preventative maintenance.
To avoid injury when working
near or on an operating engine,
remove loose items of clothing,
jewelry, tie back or contain long
hair that could be caught in any
moving part causing injury.
4All information subject to change without notice. (Rev. 01/ 04)
6SE550 0401 Copyright © 2004 DETROIT DIESEL CORPORATION

SERIES 50 OPERATOR'S GUIDE
To avoid injury when working
on or near an operating engine,
wear protective clothing,
eye protection, and hearing
protection.
To avoid injury from hot oil, do
not operate the engine with the
rocker cover(s) removed.
To avoid injury from fire, contain
and eliminate leaks of flammable
fluids as they occur. Failure to
eliminate leaks could result in
fire.
To avoid injury from contact with
the contaminants in used engine
oil, wear protective gloves and
apron.
To avoid injury from slipping and
falling, immediately clean up any
spilled liquids.
To avoid injury from the expulsion
of hot coolant, never remove the
cooling system pressure cap
whiletheengineisatoperating
temperature. Remove the cap
slowly to relieve pressure. Wear
adequate protective clothing
(face shield or safety goggles,
rubber gloves, apron, and boots).
To avoid injury from hot surfaces,
allow engine to cool before
removing any component. Wear
protective gloves.
All information subject to change without notice. (Rev. 01/ 04) 5
6SE550 0401 Copyright © 2004 DETROIT DIESEL CORPORATION

CAUTION SUMMARY
To avoid injury, use care when
working around moving belts and
rotating parts on the engine.
To avoid injury from fire caused
by heated lubricating-oil vapors:
Keep those people who
are not directly involved
in servicing away from the
engine.
Stop the engine immediately
if an oil leak is detected.
Do not allow open flames or
smoke when working on an
operating engine.
Wear adequate protective
clothing (face shield,
insulated gloves, apron, etc.)
to avoid burns.
To prevent a buildup of
potentially volatile vapors,
keep the engine area well
ventilated during operation.
Lubricating oil is relatively
harmless at ambient
temperatures.
To avoid injury from rotating belts
and fans, do not remove and
discard safety guards.
To avoid injury from contact
with rotating parts when an
engine is operating with the air
inlet piping removed, install an
air inlet screen shield over the
turbocharger air inlet. The shield
prevents contact with rotating
parts.
To avoid injury when using
caustic cleaning agents, follow
the chemical manufacturers
usage, disposal, and safety
instructions.
6All information subject to change without notice. (Rev. 01/ 04)
6SE550 0401 Copyright © 2004 DETROIT DIESEL CORPORATION