DDC-SVC-MAN-0058

SERIES 50 OPERATOR'S GUIDE

To the Operator

This guide contains instructions onthe safe operation and preventivemaintenance of your Detroit DieselSeries 50® engine used in vehicle,stationary, construction/industrial,agricultural, generator set or firefighting apparatus applications.Maintenance instructions coverroutine engine services such as lubeoil and filter changes in enough detailto permit self-servicing, if desired.

The operator should become familiarwith the contents of this guide beforeoperating the engine or carrying outmaintenance procedures.

Power-driven equipment is onlyas safe as the person operating thecontrols. You are urged, as theoperator of this diesel engine, to keepfingers and clothing away from therevolving belts, drive shafts, pulleys,etc. on the engine installation.

Throughout this guide CAUTIONSregarding personal safety andNOTICES regarding engineperformance or service life willappear. To avoid personal injury andensure long engine service life, alwaysheed these instructions.

Whenever possible, it will benefityou to rely on an authorized DetroitDiesel service outlet for all yourservice needs from maintenance tomajor parts replacement. Authorizedservice outlets worldwide stockfactory-original parts and havethe specialized equipment andexperienced, trained personnelto provide prompt preventivemaintenance and skilled enginerepairs.

The information and specificationsin this publication are based on theinformation in effect at the time ofapproval for printing. Contact anauthorized Detroit Diesel serviceoutlet for information on the latestrevision. The right is reserved tomake changes at any time withoutobligation.

All information subject to change without notice. (Rev. 01/04) iDDC-SVC-MAN-0058 Copyright © 2004 DETROIT DIESEL CORPORATION

NOTICE:Failure to check and maintainSCA (supplemental coolantadditive) levels at requiredconcentrations will result insevere damage (corrosion) tothe engine cooling system andrelated components.Coolant mustbe inhibited with the recommendedSCAs listed in this engine operator'sguide.Refer to section How to SelectCoolant. In addition, the enginecan be equipped with a coolantfilter/inhibitor system as an installedoption or as an after-sale item.

WARRANTYThe limited warranties for eachengine application are covered inthe Limited Warranty pages of thisguide and in the booklet, “WarrantyInformation for Series 50 Engines,”available from authorized DetroitDiesel service outlets.

Keep this Operator's Guidewith the engine installation atall times. It contains importantoperating, maintenance, and safetyinstructions.

Trademark Information

Detroit Diesel®, DDC®, DDEC®,Series 50®, Optimized Idle®,ProManager®, reliabilt®, POWERTrac®, POWER COOL®, andPOWER GUARD® are registeredtrademarks of Detroit DieselCorporation. Delco Remy® is aregistered trademark of Delco RemyAmerica, Inc. Bosch® is a registeredtrademark of Robert Bosch CompanyN.A. Fuel Pro®, Sea Pro® and MegaFilter® are registered trademarksof Davco Manufacturing, L.L.C.The PowerBand® is a registeredtrademark of Gates Rubber Company.Tectyl® is a registered trademark ofDaubert Chemical Company, Inc.Biobor® is a registered trademark ofUnited States Borax and ChemicalCorporation. DuPont® is a registeredtrademark of E.I. DuPont de Nemoursand Company, Inc. All othertrademarks used are the property oftheir respective owners.

ii All information subject to change without notice. (Rev. 01/04)DDC-SVC-MAN-0058 Copyright © 2004 DETROIT DIESEL CORPORATION


TABLE OF CONTENTS

INTRODUCTION .................................................................................. 1NON-GENUINE AND REBUILT COMPONENT QUALITY ALERT .. 1

CAUTION SUMMARY .......................................................................... 3ENGINE OPERATION ..................................................................... 3PREVENTIVE MAINTENANCE ....................................................... 4ELECTRICAL SYSTEM ................................................................... 7COOLING SYSTEM ......................................................................... 8AIR INTAKE SYSTEM ...................................................................... 8FUEL SYSTEM ................................................................................ 9STARTING AIDS .............................................................................. 9COMPRESSED AIR ......................................................................... 11LUBRICATING OIL AND FILTERS .................................................. 11

ENGINE MODEL AND SERIAL NUMBER DESIGNATION ................ 12OPTION LABELS ............................................................................. 13CERTIFICATION LABELS ............................................................... 14

OPERATING INSTRUCTIONS FOR A FIRST TIME START .............. 15PREPARATIONS FOR STARTING THE ENGINE THE FIRSTTIME ................................................................................................. 15

COOLING SYSTEM CHECKS .................................................... 15LUBRICATION SYSTEM CHECKS ............................................. 16

EXTENDED STORAGE .......................................................... 16FUEL SYSTEM CHECKS ............................................................ 17OTHER CHECKS ........................................................................ 18

STARTING THE ENGINE ................................................................ 18INITIAL ENGINE START ............................................................. 19

ELECTRIC STARTER ............................................................. 19AIR STARTER ......................................................................... 20

RUNNING THE ENGINE ................................................................. 20OIL PRESSURE .......................................................................... 20WARM-UP ................................................................................... 20INSPECTION ............................................................................... 20AVOID UNNECESSARY IDLING ................................................. 21

All information subject to change without notice. (Rev. 01/04) iiiDDC-SVC-MAN-0058 Copyright © 2004 DETROIT DIESEL CORPORATION

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STOPPING THE ENGINE ................................................................ 21EMERGENCY JUMP STARTING .................................................... 22

DDEC IV SYSTEM ............................................................................... 23DDEC SYSTEM .............................................................................. 23

ENGINE PROTECTION .............................................................. 24IDLE SHUTDOWN TIMER .......................................................... 24CRUISE CONTROL ..................................................................... 24ENGINE BRAKES ....................................................................... 26DATA RECORDING CAPABILITY ............................................... 27

DDEC IV OPERATION ..................................................................... 27IMMEDIATE SPEED REDUCTION OPTION ............................... 28STOP ENGINE LIGHT ................................................................. 28DIAGNOSTIC DATA READER .................................................... 28DIAGNOSTIC CODE LIST .......................................................... 30

DDEC IV ENGINE DRIVING TIPS ....................................................... 37ACCELERATING THE VEHICLE ..................................................... 37CRUISE CONTROL ......................................................................... 37ENGINE BRAKES AND CRUISE CONTROL .................................. 39SHIFTING ........................................................................................ 39IDLING ............................................................................................. 40

WINTER FRONTS ....................................................................... 40

ENGINE BRAKE SYSTEM .................................................................. 41DRIVER CONTROL SWITCHES ..................................................... 41

LOW/HIGH SWITCH ................................................................... 41LOW/MED/HIGH SWITCH .......................................................... 41

CLUTCH PEDAL AND THROTTLE POSITION CONTROLS .......... 41ENGINE BRAKE OPERATION ........................................................ 41ANTI-LOCK BRAKING SYSTEMS ................................................... 42DRIVING ON FLAT, DRY PAVEMENT ............................................. 43DESCENDING A LONG, STEEP GRADE ....................................... 43DRIVING ON WET OR SLIPPERY PAVEMENT .............................. 44

ENGINE SYSTEMS ............................................................................. 46FUEL SYSTEM ................................................................................ 46LUBRICATION SYSTEM ................................................................. 46AIR SYSTEM ................................................................................... 46COOLING SYSTEM ......................................................................... 46

iv All information subject to change without notice. (Rev. 01/04)DDC-SVC-MAN-0058 Copyright © 2004 DETROIT DIESEL CORPORATION


ELECTRICAL SYSTEM ................................................................... 46EXHAUST SYSTEM ........................................................................ 46EXHAUST GAS RECIRCULATION SYSTEM .................................. 46

MAINTENANCE ................................................................................... 47PREVENTIVE MAINTENANCE INTERVALS .................................. 63

ITEM 1 – LUBRICATING OIL ...................................................... 63ITEM 2 – FUEL AND FUEL TANK ............................................... 65ITEM 3 – FUEL LINES, FLEXIBLE HOSES ................................ 66

LEAKS ..................................................................................... 66HOSES AND FITTINGS .......................................................... 66HOSE SERVICE LIFE ............................................................. 66

ITEM 4 – COOLING SYSTEM ..................................................... 67COOLANT LEVEL ................................................................... 67COOLANT INHIBITORS .......................................................... 67COOLANT DRAIN INTERVAL ................................................. 69

ITEM 5 – TURBOCHARGER, AIR-TO-AIR CHARGE COOLER . 70WASTEGATED TURBOCHARGERS ...................................... 70

ITEM 6 – BATTERY ..................................................................... 71ITEM 7 – TACHOMETER DRIVE ................................................ 72ITEM 8 – DRIVE BELTS .............................................................. 72

V-BELTS .................................................................................. 732-GROOVE POWERBAND ..................................................... 7312–RIB POLY-V BELT ............................................................. 74BELT REPLACEMENT ............................................................ 74

ITEM 9 – AIR COMPRESSOR .................................................... 74ITEM 10 – AIR CLEANER ........................................................... 75ITEM 11 – LUBRICATING OIL FILTERS ..................................... 75ITEM 12 – FUEL FILTERS .......................................................... 76

FUEL PRO® 382 FILTERS ..................................................... 76SPIN-ON FILTERS .................................................................. 76

ITEM 13 – WATER PUMP AND COOLANT INHIBITORELEMENT .................................................................................... 77

WATER PUMP DRAIN HOLE ................................................. 77COOLANT INHIBITOR ELEMENT .......................................... 77

ITEM 14 – CRANKING MOTOR .................................................. 78ITEM 15 – AIR SYSTEM ............................................................. 78ITEM 16 – EXHAUST SYSTEM .................................................. 78ITEM 17 – ENGINE (STEAM CLEAN) ......................................... 78

All information subject to change without notice. (Rev. 01/04) vDDC-SVC-MAN-0058 Copyright © 2004 DETROIT DIESEL CORPORATION

TABLE OF CONTENTS

ITEM 18 – RADIATOR ................................................................. 78ITEM 19 – OIL PRESSURE ......................................................... 79ITEM 20 – BATTERY-CHARGING ALTERNATOR ...................... 79

BOSCH® T1 ALTERNATOR SERVICE REQUIREMENTS ..... 80GENERAL SERVICE REQUIREMENTS – BOSCH® ANDDELCO REMY® ALTERNATORS ........................................... 80

ITEM 21 – ENGINE AND TRANSMISSION MOUNTS ................ 80ITEM 22 – CRANKCASE PRESSURE ........................................ 80ITEM 23 – FAN HUB .................................................................... 80ITEM 24 – THERMOSTATS AND SEALS ................................... 81ITEM 25 – CRANKCASE BREATHER ........................................ 81ITEM 26 – ENGINE TUNE-UP .................................................... 81ITEM 27 – VIBRATION DAMPER ................................................ 81

HOW-TO SECTION .............................................................................. 83HOW TO SELECT LUBRICATING OIL ............................................ 83

LUBRICANT REQUIREMENTS .................................................. 83EGR-EQUIPPED ENGINES .................................................... 83NON-EGR ENGINES .............................................................. 83ENGINES BUILT PRIOR TO 1998 .......................................... 83

COLD WEATHER STARTING ..................................................... 84SYNTHETIC OILS ....................................................................... 84THE USE OF SUPPLEMENTAL ADDITIVES .............................. 85

WHEN TO CHANGE OIL ................................................................. 85DISPOSING OF WASTE OIL ...................................................... 86

HOW TO REPLACE THE LUBE OIL FILTERS ................................ 86REPLACE SPIN-ON TYPE OIL FILTER ...................................... 86

HOW TO SELECT FUEL OIL .......................................................... 88QUALITY ..................................................................................... 88FUEL CONTAMINATION ............................................................. 88PROHIBITED ADDITIVES ........................................................... 89

USED LUBRICATING OIL ....................................................... 89GASOLINE ............................................................................. 89

HOW TO REPLACE THE FUEL FILTERS ....................................... 89REPLACE SPIN-ON FILTER ELEMENTS .................................. 90REPLACE FUEL/WATER SEPARATOR ELEMENT .................... 91REPLACE FUEL PRO FILTER ELEMENT .................................. 92

ENGINE OUT OF FUEL — HOW TO RESTART ............................. 95ENGINES WITH SPIN-ON FILTERS ........................................... 95

vi All information subject to change without notice. (Rev. 01/04)DDC-SVC-MAN-0058 Copyright © 2004 DETROIT DIESEL CORPORATION


ENGINES WITH FUEL PRO FILTERS ........................................ 95HOW TO SELECT COOLANT ......................................................... 96

DEFINITIONS .............................................................................. 96ANTIFREEZE .......................................................................... 96COOLANT ............................................................................... 96DROP-OUT ............................................................................. 96FULLY FORMULATED ANTIFREEZE ..................................... 96INITIAL–FILL COOLANT ......................................................... 96OAT ......................................................................................... 97SCA ......................................................................................... 97

APPROVED COOLANTS ............................................................ 97EG OR PG & WATER + SCA INHIBITOR ............................... 98MIXING EG OR PG ANTIFREEZE AND WATER ................... 98RECYCLED ANTIFREEZE .................................................... 101EG OR PG & WATER + OAT INHIBITOR ............................... 101WATER ONLY + SCA OR WATER ONLY + OAT INHIBITOR 102WATER REQUIREMENTS ..................................................... 102

COOLANTS NOT RECOMMENDED .......................................... 103ALL ANTIFREEZES AND COOLANTS CONTAININGPHOSPHATE ........................................................................... 103AUTOMOTIVE TYPE COOLANTS .......................................... 103METHYL ALCOHOL-BASED ANTIFREEZE ........................... 104METHOXY PROPANOL-BASED ANTIFREEZE ..................... 104GLYCOL-BASED COOLANTS FORMULATED FOR HVAC ... 104

ADDITIVES NOT RECOMMENDED ........................................... 104SOLUBLE OIL ADDITIVES ..................................................... 104CHROMATE ADDITIVES ........................................................ 104

COOLANT MAINTENANCE ........................................................ 104COOLANT INHIBITOR TEST INTERVALS ............................ 104SUPPLEMENTAL ADDITIVES ................................................ 105COOLANT MAINTENANCE INTERVALS ............................... 106

SCA TEST PROCEDURES ......................................................... 108NEED-RELEASE FILTERS (NON-OAT SYSTEMS) .................... 109DROPOUT ................................................................................... 109EXTENDER ADDITIVE FOR OAT COOLANT ............................ 110

OAT COOLANT DRAIN INTERVAL ........................................ 110CHRONIC COOLANT SYSTEM PROBLEMS ............................. 110MAINTENANCE PRODUCTS ..................................................... 111

All information subject to change without notice. (Rev. 01/04) viiDDC-SVC-MAN-0058 Copyright © 2004 DETROIT DIESEL CORPORATION

TABLE OF CONTENTS

POWER COOL SCAS ............................................................. 111POWER COOL COOLANT FILTER ELEMENTS .................... 111POWER COOL CLEANERS ................................................... 111

SUMMARY OF COOLANT RECOMMENDATIONS .................... 111COOLANT LIFE OF GLYCOL COOLANT: .............................. 112COOLANT LIFE OF OAT COOLANT ...................................... 113COOLANT LIFE OF OTHER COOLANTS .............................. 113

HOW TO DRAIN AND FLUSH THE COOLING SYSTEM ............... 113WHEN TO SERVICE THE DRY TYPE AIR CLEANER ................... 115

BASIC TROUBLESHOOTING ............................................................. 116

ENGINE STORAGE ............................................................................. 121PREPARING THE ENGINE FOR STORAGE .................................. 121

TEMPORARY STORAGE (30 DAYS OR LESS) ......................... 121EXTENDED STORAGE (MORE THAN 30 DAYS) ...................... 122RESTORING ENGINE TO SERVICE .......................................... 125

SERIES 50 SERVICE PUBLICATIONS ............................................... 127

CUSTOMER ASSISTANCE ................................................................. 128IN U.S. AND CANADA CALL 1–800–445–1980 .............................. 131WORKING WITH DDC SERVICE OUTLETS .................................. 131

ON-HIGHWAY VEHICLE ENGINE WARRANTY ................................. 134TERMS OF COVERAGE: ON-HIGHWAY VEHICLE ENGINEAPPLICATIONS .............................................................................. 134

USES ........................................................................................... 134DEFECTS .................................................................................... 134REPAIRS ..................................................................................... 134WARRANTY PERIOD .................................................................. 134LIKE REPLACEMENT ENGINE .................................................. 135SERVICE SUPPLIES .................................................................. 135ENGINE REMOVAL AND REINSTALLATION ............................. 135

THIS WARRANTY DOES NOT COVER: ......................................... 136REPAIRS DUE TO ACCIDENTS, MISUSE, STORAGE DAMAGE,NEGLIGENCE OR CERTAIN MODIFICATIONS ......................... 136BRAKING DEVICES .................................................................... 136FUEL INJECTORS AFTER 100,000 MILES/160,000KILOMETERS .............................................................................. 136

viii All information subject to change without notice. (Rev. 01/04)DDC-SVC-MAN-0058 Copyright © 2004 DETROIT DIESEL CORPORATION


MAINTENANCE ........................................................................... 136INCIDENTAL OR CONSEQUENTIAL DAMAGE ......................... 136OTHER LIMITATIONS ................................................................. 136

URBAN BUS, MOTOR COACH OR MOTOR HOME ENGINEWARRANTY ......................................................................................... 138

TERMS OF COVERAGE: URBAN BUS, MOTOR COACH ORMOTOR HOME ENGINE APPLICATIONS ..................................... 138

USES ........................................................................................... 138DEFECTS .................................................................................... 138REPAIRS ..................................................................................... 138WARRANTY PERIOD .................................................................. 138SERVICE SUPPLIES .................................................................. 139LIKE REPLACEMENT ENGINE .................................................. 139ENGINE REMOVAL AND REINSTALLATION ............................. 140

THIS WARRANTY DOES NOT COVER: ......................................... 140REPAIRS DUE TO ACCIDENTS, MISUSE, ALTERATION,STORAGE DAMAGE, NEGLIGENCE OR CERTAINMODIFICATIONS ........................................................................ 140BRAKING DEVICES .................................................................... 140FUEL INJECTORS AFTER 200,000 MILES/320,000KILOMETERS .............................................................................. 140MAINTENANCE ........................................................................... 140INCIDENTAL OR CONSEQUENTIAL DAMAGE ......................... 140OTHER LIMITATIONS ................................................................. 140

CONSTRUCTION/ INDUSTRIAL ENGINE WARRANTY .................... 142TERMS OF COVERAGE: CONSTRUCTION/INDUSTRIAL ENGINEAPPLICATIONS ............................................................................... 142

USES ........................................................................................... 142DEFECTS .................................................................................... 142REPAIRS ..................................................................................... 142WARRANTY PERIOD .................................................................. 142SERVICE SUPPLIES .................................................................. 142ENGINE REMOVAL AND REINSTALLATION – CONSTRUC-TION/INDUSTRIAL APPLICATIONS ........................................... 143MECHANIC'S TRAVEL EXPENSES ........................................... 143LIKE REPLACEMENT ENGINE .................................................. 143

THIS WARRANTY DOES NOT COVER: ......................................... 144

All information subject to change without notice. (Rev. 01/04) ixDDC-SVC-MAN-0058 Copyright © 2004 DETROIT DIESEL CORPORATION

TABLE OF CONTENTS

REPAIRS DUE TO ACCIDENTS, MISUSE, STORAGE DAMAGE,NEGLIGENCE OR CERTAIN MODIFICATIONS ......................... 144ENGINE REMOVAL AND REINSTALLATION – AGRICULTURALMACHINERY AND STAND-BY PUMP APPLICATIONS ............. 144NON-DDC SUPPLIED/MANUFACTURED COMPONENTS ....... 144MAINTENANCE ........................................................................... 144INCIDENTAL OR CONSEQUENTIAL DAMAGE ......................... 144OTHER LIMITATIONS ................................................................. 145

AGRICULTURAL MACHINERY ENGINE WARRANTY ...................... 146TERMS OF COVERAGE: AGRICULTURAL MACHINERY ENGINEAPPLICATIONS ............................................................................... 146

USES ........................................................................................... 146DEFECTS .................................................................................... 146REPAIRS ..................................................................................... 146WARRANTY PERIOD .................................................................. 147

THIS WARRANTY DOES NOT COVER: ......................................... 147REPAIRS DUE TO ACCIDENTS, MISUSE, STORAGE DAMAGE,NEGLIGENCE OR CERTAIN MODIFICATIONS ......................... 147ENGINE REMOVAL AND REINSTALLATION ............................. 147NON-DDC SUPPLIED/MANUFACTURED COMPONENTS ....... 147MAINTENANCE ........................................................................... 147INCIDENTAL OR CONSEQUENTIAL DAMAGE ......................... 148OTHER LIMITATIONS ................................................................. 148

PRIME POWER GENERATOR SET ENGINE WARRANTY ............... 149TERMS OF COVERAGE: PRIME POWER GENERATOR SETENGINE APPLICATIONS ................................................................ 149

USES ........................................................................................... 149DEFECTS .................................................................................... 149REPAIRS ..................................................................................... 149WARRANTY PERIOD .................................................................. 149LIKE REPLACEMENT ENGINE .................................................. 149SERVICE SUPPLIES .................................................................. 150MECHANIC'S TRAVEL EXPENSES ........................................... 150

THIS WARRANTY DOES NOT COVER: ......................................... 150REPAIRS DUE TO ACCIDENTS, MISUSE, STORAGE DAMAGE,NEGLIGENCE OR CERTAIN MODIFICATIONS ......................... 150ENGINE REMOVAL AND REINSTALLATION ............................. 150

x All information subject to change without notice. (Rev. 01/04)DDC-SVC-MAN-0058 Copyright © 2004 DETROIT DIESEL CORPORATION


NON-DDC SUPPLIED/MANUFACTURED COMPONENTS ....... 151MAINTENANCE ........................................................................... 151INCIDENTAL OR CONSEQUENTIAL DAMAGE ......................... 151OTHER LIMITATIONS ................................................................. 151

STAND-BY GENERATOR SET ENGINE WARRANTY ....................... 152TERMS OF COVERAGE: STAND-BY GENERATOR SET ENGINEAPPLICATIONS ............................................................................... 152

USES ........................................................................................... 152DEFECTS .................................................................................... 152REPAIRS ..................................................................................... 152WARRANTY PERIOD .................................................................. 153LIKE REPLACEMENT ENGINE .................................................. 153SERVICE SUPPLIES .................................................................. 153MECHANIC'S TRAVEL EXPENSES ........................................... 153

THIS WARRANTY DOES NOT COVER: ......................................... 153REPAIRS DUE TO ACCIDENTS, MISUSE, STORAGE DAMAGE,NEGLIGENCE OR CERTAIN MODIFICATIONS ......................... 153ENGINE REMOVAL AND REINSTALLATION ............................. 153NON-DDC SUPPLIED/MANUFACTURED COMPONENTS ....... 153MAINTENANCE ........................................................................... 154INCIDENTAL OR CONSEQUENTIAL DAMAGE ......................... 154OTHER LIMITATIONS ................................................................. 154

SPECIFICATIONS ................................................................................ 155FUEL AND LUBRICATING OIL FILTER REQUIREMENTS ............ 155

OIL PAN ....................................................................................... 155OIL PAN CAPACITY ................................................................ 155TOTAL OIL CAPACITY OF THE ENGINE ............................... 155

POWER COOL ENGINE PRODUCTS ............................................ 156FULLY FORMULATED IEG COOLANT ....................................... 156LATIN AMERICAN COOLANT .................................................... 1562000 SUPPLEMENTAL COOLANT ADDITIVE ........................... 1573000 SUPPLEMENTAL COOLANT ADDITIVE ........................... 1573000 SUPPLEMENTAL ADDITIVE COOLANT FILTERS ............ 158SUPPLEMENTAL ADDITIVE NEED RELEASE FILTERS ........... 158PLUS EXTENDED LIFE OAT COOLANT .................................... 159PLUS EXTENDER FOR USE WITH POWER COOL PLUS OATCOOLANT ................................................................................... 159

All information subject to change without notice. (Rev. 01/04) xiDDC-SVC-MAN-0058 Copyright © 2004 DETROIT DIESEL CORPORATION

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PLUS 6000 OAT INHIBITOR FOR WATER-ONLY SYSTEMS .... 160COOLING SYSTEM CLEANERS ................................................ 160COOLANT TESTING AND ANALYSIS PRODUCTS ................... 161

xii All information subject to change without notice. (Rev. 01/04)DDC-SVC-MAN-0058 Copyright © 2004 DETROIT DIESEL CORPORATION


INTRODUCTION

This guide is intended for use by theoperator of a Detroit Diesel Series50® engine used in the followingapplications:

□ On-Highway Vehicles

□ Construction/Industrial

□ Agricultural Machinery

□ Generator Drive Engines

Operators of Series 50 engines usedin prime power or stand-by generatorset applications should also referto the Detroit Diesel Generator SetOperator's Guide, 6SE513. Guidesare available from authorized DetroitDiesel distributors.

NON-GENUINE ANDREBUILT COMPONENTQUALITY ALERTIn recent years, electronic enginecontrols have been instrumentalin aiding engine manufacturers inmeeting the stringent emissionrequirements of the U.S.Environmental Protection Agency(U.S. EPA) and the California AirResources Board (CARB) andalso in meeting the ever-increasingperformance demands of the customer.

Maintenance procedures are tobe followed in order to continuesatisfactory performance and

durability and to ensure coverage ofthe engine under the manufacturer'swarranty. Many of these maintenanceprocedures also ensure that the enginecontinues to comply with applicableemissions standards. The U.S.EPA specifically defines an engine's“useful emission life” — currentlyestablished as 290,000 miles (464,000kilometers) for on-highway engines.Proper maintenance procedures, usingspecific components engineered tocomply with emissions regulations,may be performed by an authorizedDetroit Diesel distributor or dealer,an independent outlet or the operatoror owner. The owner is responsiblefor determining the suitability ofcomponents to maintain emissionscompliance during the engine's usefulemission life.

Electronic controls and componentshave significantly increased insophistication, but the fundamentalobjective remains the same — precisetiming and delivery of fuel. The veryheart of the Detroit Diesel electroniccontrols is the electronic unit injector(EUI). The proper functioning of theEUI is absolutely paramount if thebenefits of electronic controls are to berealized. Detroit Diesel Corporationhas built over 650,000 engines withelectronic unit injectors — more thananyone else in the business.

All information subject to change without notice. (Rev. 01/04) 1DDC-SVC-MAN-0058 Copyright © 2004 DETROIT DIESEL CORPORATION

INTRODUCTION

Detroit Diesel cautions that theindiscriminate rebuilding of precisioncomponents, without the benefit ofspecifications, specialized equipment,and knowledge of the electronicoperating system, will jeopardizeperformance or lead to more seriousproblems, and can take the engineoutside of compliance with U.S. EPAor CARB emissions standards.

There are other components inan engine, such as turbocharger,camshaft, piston, etc., whichare specifically designed andmanufactured to exacting standardsfor emissions compliance. It isimportant that these components, ifreplaced, modified or substituted, canbe verified to ensure that the engineremains in compliance with emissionsstandards. The use of inadequatelyengineered, manufactured or testedcomponents in repair or rebuild ofthe engine may be in violation of thefederal Clean Air Act and applicableU.S. EPA or CARB regulations.

Furthermore, modern engines exhibitoperating parameters which requirethe use of proper fluids, such asfuel, coolant and lubricating oil, tomaintain long engine life. The use offluids that do not meet Detroit DieselCorporation specifications may resultin early wear out or engine failure.

2 All information subject to change without notice. (Rev. 01/04)DDC-SVC-MAN-0058 Copyright © 2004 DETROIT DIESEL CORPORATION


CAUTION SUMMARY

The following cautions must beobserved by the operator of thevehicle or equipment in which thisengine is installed and/or by thoseperforming basic engine preventivemaintenance. Failure to read andheed these cautions and exercisereasonable care for personal safetyand the safety of others whenoperating the vehicle/equipmentor performing basic enginepreventive maintenance may resultin personal injury and engineand/or vehicle/equipment damage.

Engine OperationObserve the following cautions whenoperating the engine.

PERSONAL INJURY

To avoid injury from loss ofvehicle/vessel control, theoperator of a DDEC equippedengine must not use or readany diagnostic tool while thevehicle/vessel is moving.

PERSONAL INJURY

Diesel engine exhaust and someof its constituents are known tothe State of California to causecancer, birth defects, and otherreproductive harm.

□ Always start and operate anengine in a well ventilatedarea.

□ If operating an engine inan enclosed area, vent theexhaust to the outside.

□ Do not modify or tamperwith the exhaust system oremission control system.

PERSONAL INJURY

To avoid injury from engineshutdown in an unsafe situation,ensure the operator knows howto override the stop enginecondition on a DDEC-equippedunit.


CAUTION SUMMARY

LOSS OF VEHICLE CONTROL

To avoid injury from loss ofvehicle control, do not activatethe Engine Brake system underthe following conditions:

□ On wet or slippery pavement,unless the vehicle is equippedwith ABS (anti-lock brakingsystem) and you have hadprior experience drivingunder these conditions.

□ When driving without a trailer(bobtailing) or pulling anempty trailer.

□ If the tractor drive wheelsbegin to lock or there isfishtail motion after theEngine Brake is activated,deactivate the brake systemimmediately if this occurs.


To avoid injury from the loss ofvehicle control, do not use cruisecontrol under these conditions:

□ When it is not possible tokeep the vehicle at a constantspeed (on winding roads, inheavy traffic, in traffic thatvaries in speed, etc.).

□ On slippery roads(wet pavement, ice-orsnow-covered roads, loosegravel, etc.).

Preventive MaintenanceObserve the following cautions whenperforming preventative maintenance.

PERSONAL INJURY

To avoid injury when workingnear or on an operating engine,remove loose items of clothingand jewelry. Tie back or containlong hair that could be caught inany moving part causing injury.



PERSONAL INJURY

To avoid injury when workingon or near an operating engine,wear protective clothing,eye protection, and hearingprotection.

HOT OIL

To avoid injury from hot oil, donot operate the engine with therocker cover(s) removed.

FIRE

To avoid injury from fire, containand eliminate leaks of flammablefluids as they occur. Failure toeliminate leaks could result infire.

USED ENGINE OIL

To avoid injury to skin fromcontact with the contaminants inused engine oil, wear protectivegloves and apron.

PERSONAL INJURY

To avoid injury from slipping andfalling, immediately clean up anyspilled liquids.

PERSONAL INJURY

To avoid injury from hot surfaces,wear protective gloves, or allowengine to cool before removingany component.

PERSONAL INJURY

To avoid injury, use care whenworking around moving belts androtating parts on the engine.


CAUTION SUMMARY

FIRE

To avoid injury from combustionof heated lubricating-oil vapors,stop the engine immediately if anoil leak is detected.

PERSONAL INJURY

To avoid injury from contactwith rotating parts when anengine is operating with the airinlet piping removed, install anair inlet screen shield over theturbocharger air inlet. The shieldprevents contact with rotatingparts.

HOT COOLANT

To avoid scalding from theexpulsion of hot coolant, neverremove the cooling systempressure cap while the engine isat operating temperature. Wearadequate protective clothing(face shield, rubber gloves,apron, and boots). Remove thecap slowly to relieve pressure.

FIRE

To avoid injury from fire, do notsmoke or allow open flames whenworking on an operating engine.

FIRE

To avoid injury from fire from abuildup of volatile vapors, keepthe engine area well ventilatedduring operation.

PERSONAL INJURY

To avoid injury from rotating beltsand fans, do not remove anddiscard safety guards.



PERSONAL INJURY

To avoid injury when usingcaustic cleaning agents, followthe chemical manufacturersusage, disposal, and safetyinstructions.

Electrical SystemObserve the following cautions whenjump starting an engine, charginga battery, or working with thevehicle/application electrical system.

PERSONAL INJURY

To avoid injury from accidentalengine startup while servicingthe engine, disconnect/disablethe starting system.

ELECTRICAL SHOCK

To avoid injury from electricalshock, do not touch batteryterminals, alternator terminals, orwiring cables while the engine isoperating.

Battery Explosion and Acid Burn

To avoid injury from batteryexplosion or contact with batteryacid, work in a well ventilatedarea, wear protective clothing,and avoid sparks or flames nearthe battery. If you come in contactwith battery acid:

□ Flush your skin with water.

□ Apply baking soda or lime tohelp neutralize the acid.

□ Flush your eyes with water.

□ Get medical attentionimmediately.


CAUTION SUMMARY

Cooling SystemObserve the following cautions whenservicing the cooling system.

HOT COOLANT


PERSONAL INJURY


Air Intake SystemObserve the following cautions whenworking on the air intake system.

PERSONAL INJURY


PERSONAL INJURY

To avoid injury from contactwith rotating parts when anengine is operating with the airinlet piping removed, install anair inlet screen shield over theturbocharger air inlet. The shieldprevents contact with rotatingparts.



Fuel SystemObserve the following cautions whenfueling the vehicle or working withthe fuel system.

FIRE

To avoid injury from fire, keep allpotential ignition sources awayfrom diesel fuel, including openflames, sparks, and electricalresistance heating elements. Donot smoke when refueling.

FIRE


FIRE

To avoid injury from fire causedby heated diesel-fuel vapors:

□ Keep those people who are notdirectly involved in servicingaway from the engine.

□ Stop the engine immediately ifa fuel leak is detected.

□ Do not smoke or allow openflames when working on anoperating engine.

□ Wear adequate protectiveclothing (face shield,insulated gloves and apron,etc.).

□ To prevent a buildup ofpotentially volatile vapors,keep the engine area wellventilated during operation.

FIRE

To avoid increased risk of a fuelfire, do not mix gasoline anddiesel fuel.

Starting AidsObserve the following cautions whenusing starting aids.


CAUTION SUMMARY

FLAMES, EXPLOSION ANDTOXICITY

To avoid injury from flames,explosion, and toxicants whenusing ether, the followingprecautions must be taken:

□ Always wear goggles whentesting.

□ If fluid enters the eyes or iffumes irritate the eyes, washeyes with large quantities ofclean water for 15 minutes.A physician, preferably aneye specialist, should becontacted.

□ Contents of cylinder are underpressure. Store cylindersin a cool dry area. Do notincinerate, puncture orattempt to remove cores fromcylinders.



□ Do not smoke when servicingether system.

□ Work in well ventilated area.

□ Do not work near open flames,pilot flames (gas or oilheaters), or sparks.

□ Do not weld or carry an openflame near the ether system ifyou smell ether or otherwisesuspect a leak.



Compressed AirObserve the following cautions whenusing compressed air.

EYE INJURY

To avoid injury from flying debriswhen using compressed air, wearadequate eye protection (faceshield or safety goggles) and donot exceed 276 kPa (40 psi) airpressure.

Lubricating Oil and FiltersObserve the following cautions whenreplacing the engine lubricating oiland filters.

PERSONAL INJURY


FIRE

To avoid injury from combustionof heated lubricating-oil vapors,stop the engine immediately if anoil leak is detected.

FIRE

To avoid injury from fire, do notsmoke or allow open flames whenworking on an operating engine.

FIRE

To avoid injury from fire from abuildup of volatile vapors, keepthe engine area well ventilatedduring operation.


ENGINE MODEL AND SERIAL NUMBER DESIGNATION


The engine serial number and modelnumber are laser etched on thecylinder block on the left side justbelow the intake manifold and above

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

Figure 1 Location of Engine Serial and Model Numbers



Option LabelsComputerized engine option labelsare attached to the valve rockercover. These labels contain the engineserial number and model numberand, in addition, list any optionalequipment used on the engine.Labels also include required tune-upinformation (injection timing, valvelash, maximum no-load rpm, etc.).

With any order for parts, the enginemodel and serial number must be

given. If a type number is shownon the option label covering theequipment required, this numbershould also be included on the partsorder. See Figure 2.

Transmissions and power take-offsgenerally carry their own nameplates. The model and serial numberinformation on these plates isuseful when ordering parts for theseassemblies.

Figure 2 Typical Option Labels



Certification LabelsIf required, a certification label isattached to the valve rocker cover.This label certifies that the engineconforms to federal and certain state

emissions regulations for its particularapplication. It also gives the operatingconditions under which certificationwas made. See Figure 3.

Figure 3 Typical Engine Certification Labels



OPERATING INSTRUCTIONS FOR A FIRST TIME START

When preparing to start a new or newlyoverhauled engine which has been instorage, perform all of the operationslisted below. Failure to follow theseinstructions may result in seriousengine damage. Before a routine start,see the “Daily” checks for your enginein the MAINTENANCE section.

PERSONAL INJURY





PERSONAL INJURY

To avoid injury when workingnear or on an operating engine,remove loose items of clothingand jewelry. Tie back or containlong hair that could be caught inany moving part causing injury.

System ChecksPerform the following system checksbefore starting for the first time.

Cooling System Checks

Check the cooling system as follows:

1. Make sure all drain cocks inthe cooling system are installed(drain cocks are often removedfor shipping) and are closedtightly.

2. Remove the radiator pressurecontrol cap and fill with genuineDetroit Diesel Power Coolantifreeze or an equivalent qualityethylene glycol or propyleneglycol-base antifreeze solutionin the required concentration.In extremely hot environments,properly inhibited water maybe used in the summer. Keep thecoolant level at the bottom of thefiller neck to allow for expansion



of the coolant. For more detailedrecommendations, refer to theHow to Select Coolant section inthis guide.

3. Entrapped air must be purgedafter filling the cooling system.To do this, allow the engine towarm up with the pressure capremoved. With the transmissionin neutral, increase engine speedabove 1,000 rpm and add coolantto the radiator as required.

4. Check to make sure the frontof the radiator and air-to-aircharge cooler (if equipped) areunblocked and free of debris.

Lubrication System Checks

The lubricating oil film on the rotatingparts and bearings of a new or newlyoverhauled engine, or one which hasbeen in storage for six months ormore, may be insufficient when theengine is started for the first time.

NOTICE:Insufficient lubrication at startup cancause serious damage to enginecomponents.

To insure an immediate flow ofoil to all bearing surfaces at initialengine startup, the engine lubricationsystem should be charged with acommercially available pressure

pre-lubricator. If this is impractical,rocker covers should be removed andclean lubricating oil should be pouredover the rocker arms. The oil shouldbe the same weight and viscosityas that used in the crankcase. Afterpre-lubricating, add additional oil tobring the level to the proper mark onthe dipstick. See Figure 4.

Figure 4 Check Lube Oil LevelBefore Starting

For lubricant recommendation,refer to the How to Select LubricatingOil section in this guide.

Extended Storage — An enginein storage for an extended periodof time (over winter, for example)may accumulate water in the oilpan through normal condensation ofmoisture (always present in the air)on the cold, internal surfaces of theengine. Lube oil diluted by watercannot provide adequate bearingprotection at engine startup. For thisreason, Detroit Diesel recommends



replacing the engine lubricating oiland filters after extended storage.

NOTICE:Failure to eliminate water-dilutedlubricating oil may lead to seriousengine damage at startup.

Fuel System Checks

Fill the tanks with the recommendedfuel. Keeping tanks full reduces watercondensation and helps keep fuelcool, which is important to engineperformance. Full tanks also reducethe chance for microbe (black slime)growth. For fuel recommendations,refer to the How to Select Fuel Oilsection in this guide. Make sure thefuel shutoff valve (if used) is open.

To insure prompt starting and evenrunning, the fuel system mustbe primed if air has entered the fuelsystem. Priming is done by connectinga manual or electric priming pumpto the secondary fuel filter adaptor.Authorized Detroit Diesel serviceoutlets are properly equipped and havethe trained technicians to perform thisservice.

Priming is not normally required ifthe filter elements are filled with cleanfuel when installed and the manifoldsare not drained of fuel.

NOTICE:Prolonged use of the starting motorand engine fuel pump to prime thefuel system can result in damage tothe starter, fuel pump and injectorsand may cause erratic engineoperation due to the amount of airin the lines and filters from the fuelsupply tank to the cylinder head.Engines equipped with startingdevices dependent on compressedair or gas reservoirs should alwaysbe primed before initial startup.Otherwise, reserve pressure canbe exhausted and injectors may bedamaged from lack of lubricationand cooling.Under no circumstances shoulda starting aid such as ether beused to run the engine until thefuel system is primed. Injectordamage will result if this methodis used. The heat generated by theexternal fuel source will cause theinjector tips to be damaged whenthe fuel cools them. The injectorplunger and bushing can be scoredfrom running without lubrication.



If the engine is equipped with afuel/water separator, drain off anywater that has accumulated. Waterin fuel can seriously affect engineperformance and may cause enginedamage. Detroit Diesel recommendsinstallation of a fuel/water separatorwherever water contamination is aconcern.

Other Checks

Make sure the transmission isfilled to the proper level with thefluid recommended by the gearmanufacturer. Do not overfill.

Make sure cable connections tothe storage batteries are clean andtight. Check the hydrometer “eye” ofmaintenance-free batteries for charge.See Figure 5.

Figure 5 Maintenance-FreeBattery “Eye”

Check drive belts to make sure theyare in good condition (not cracked,torn, worn or glazed) and are properlyadjusted.

If lead-acid or low-maintenancebatteries are used, make sure batteryelectrolyte level is normal.

Check the turbocharger for signs ofoil or exhaust leaks. Leaks should becorrected before starting the engine.

Check engine mounting bolts fortightness. Bolts should be retightened,if necessary.

Starting the EngineBefore starting the engine the firsttime, refer to the System Checkssection and perform the operationslisted.

NOTICE:The turbocharger may be seriouslydamaged if the engine is crankedwith the air shutdown in the closedposition.

If the engine has an emergency manualor automatic shutdown system, makesure the control is set in the openposition before starting.

The engine may require the use of acold weather starting aid if the ambienttemperature is below 40° F (4° C).





□ Do not smoke when servicingether system.

□ Work in well ventilated area.

□ Do not work near open flames,pilot flames (gas or oilheaters), or sparks.

□ Do not weld or carry an openflame near the ether system ifyou smell ether or otherwisesuspect a leak.

Initial Engine Start

To start a Series 50 engine, make surethe transmission is in neutral and turnthe ignition key on.

You will notice that both the yellowCheck Engin Light (CEL) and the redStop Engine Light (SEL) will comeon.

This is the result of theDetroitDiesel Electronic Control (DDEC®)computer diagnosing the systemto ensure everything is functional,including the light bulbs for thewarning lights. If everything is

OK, both lights will go out inapproximately five seconds.

Start the engine after the lights goout. If starting a vehicle, start theengine with foot off the foot pedal.

NOTICE:If the operating lights stay on,consult with DDC Technical Service.Operating the engine under thesecircumstances may result in enginedamage.

Electric Starter — Start an engineequipped with an electric startingmotor as follows:

1. With foot OFF the foot pedal,press the starter switch firmly.

NOTICE:To prevent serious starting motordamage, do not press the starterswitch again after the engine hasstarted.

2. If the engine fails to start within15 seconds, release the starterswitch and allow the starter tocool for 15 seconds before tryingagain. If the engine fails to startafter four attempts, an inspectionshould be made to determine thecause.



Air Starter — Because of the limitedvolume of most compressed airstorage tanks and the relatively shortduration of the cranking cycle, it isimportant to make sure the engine isready to start before activating the airstarter. Start an engine equipped withan air starter as follows:

1. Check the pressure in the airstorage tank. If necessary, add airto bring the pressure up to at leastthe recommended minimum forstarting.

2. With foot OFF the foot pedal,press the starter button firmly andhold until the engine starts.

Running the EngineWhile the engine is operating, monitorthe battery charge indicator light,the oil pressure and avoid excessiveidling.

Oil Pressure

Observe the oil pressure gageimmediately after starting the engine.A good indicator that all moving partsare getting lubrication is when theoil pressure gage registers pressure(5 psi or 35 kPa at idle speed). Ifno pressure is indicated within 10to 15 seconds, stop the engine andcheck the lubrication system. Thepressure should not drop below 28 psior 193 kPa at 1800 rpm, and normal

operating pressure should be higher. Ifoil pressure does not fall within theseguidelines, it should be checked witha manual gage.

HOT OIL

To avoid injury from hot oil, donot operate the engine with therocker cover(s) removed.

Warm-up

Run the engine at part throttle forabout five minutes to allow it to warmup before applying a load.

Inspection

While the engine is idling, inspect thetransmission, check for fluid leaks,check the crankcase and turbocharger.

Transmission – While the engineis idling, check the automatictransmission (if equipped) for properoil level and add oil as required.

Fluid Leaks – Look for coolant,fuel or lubricating oil leaks. If anyare found, shut down the engineimmediately and have the leaksrepaired after the engine has cooled.



Crankcase – If the engine oil wasreplaced, stop the engine after normaloperating temperature has beenreached. Allow the oil to drainback into the crankcase for abouttwenty minutes, then check the oillevel. If necessary, add oil to bringthe level to the proper mark on thedipstick. Use only the heavy-duty oilsrecommended. Refer to the How toSelect Lubricating Oil section in thisguide.

Turbocharger – Make a visualinspection of the turbocharger foroil leaks, exhaust leaks, excessivenoise or vibration. Stop the engineimmediately if a leak or unusual noiseor vibration is noted. Do not restartthe engine until the cause of theconcern has been investigated andcorrected. Authorized Detroit Dieselservice outlets are properly equippedto perform this service.

Avoid Unnecessary Idling

Whenever possible, avoid unnecessaryidling.

During long engine idling periodswith the transmission in neutral, theengine coolant temperature may fallbelow the normal operating range.The incomplete combustion of fuelin a cold engine will cause crankcaseoil dilution, formation of lacquer orgummy deposits on the valves, pistons,and rings, and rapid accumulation of

sludge in the engine. When prolongedidling is necessary, maintain at least850 rpm spring/summer and 1200 rpmfall/winter.

Stopping the EngineStop an engine under normal operatingconditions as follows:

1. Reduce engine speed to idle andput all shift levers in the neutralposition.

NOTICE:Stopping a turbocharged engineimmediately after high-speedoperation without allowing asufficient cool-down period maycause damage to the turbocharger,as it will continue to turn without anoil supply to the bearings.

2. Allow the engine to run betweenidle and 1000 rpm with no loadfor four or five minutes. Thisallows the engine to cool andpermits the turbocharger to slowdown. After four or five minutes,shut down the engine.



Emergency Jump StartingThe DDEC IV system operates on12 or 24 volts DC. If an engine withan electric starting motor requiresemergency jump starting, do notexceed 32 volts DC.

NOTICE:Jump starting with voltages greaterthan those indicated or reversingbattery polarity may damage theElectronic Control Module.

BATTERY EXPLOSION

To avoid injury from batteryexplosion when jump starting theengine, do not attach the cableend to the negative terminal ofthe disabled battery.

NOTICE:Failure to connect jumper cablesin the proper sequence can resultin alternator and/or equipmentdamage.

Before attempting to jump start theengine, make sure the jumper cables

are connected properly (positive topositive, negative to negative ground)and in the proper sequence (negativeto negative ground last).









DDEC IV SYSTEM

The DDEC sytem's engine-mountedElectronic Control Module (ECM)includes control logic to provideoverall engine management. TheECM continuously performsself-diagnostic checks and monitorsother system components. Systemdiagnostic checks are made atignition-on and continue throughoutall engine-operating modes.

Detroit Diesel Series 50 enginesequipped with DDEC IV are identifiedby the letter “K” in the sixth positionof the model number. Example:6047GK27.

The DDEC engine is equippedwith an electronically controlledfuel injection system. There are nocontrol racks or mechanical linkagesto adjust. This system not only helpsto improve fuel economy and vehicleperformance, it also helps to reducecold starting time and increase initialidle speed for fast engine warm-upand virtual elimination of cold smoke.

The DDEC engine has nomechanical governor. Enginehorsepower, torque, idle, and enginespeed are contained in the internalelectronics. Therefore, there areno mechanical governor springadjustments for idle and high-speedcontrol.

There is no need for a throttle delay.Emission control is performed throughthe electronic control module (ECM).

The Electronic Foot Pedal Assembly(EFPA) eliminates the need for anythrottle linkage.

DDEC FeaturesDDEC offers a variety of optionsdesigned to warn the operator of anengine malfunction. Options canrange from the CEL and SEL panellights to automatic reduction in enginepower followed by automatic engineshutdown.

The power-down/shutdown optionmay be activated by a low coolantlevel, low oil pressure or high engineoil or coolant temperature.

The DDEC engine has the ability toperform diagnostics for self-checksand continuous monitoring of othersystem components. Dependingon the application, DDEC can alsomonitor oil temperature, coolanttemperature, oil pressure, fuelpressure, coolant level and remotesensors (if used). This diagnosticsystem is connected to the CEL andthe SEL to provide a visual warningof a system malfunction.


DDEC IV SYSTEM

Engine Protection

The DDEC engine protectionsystem monitors all engine sensorsand electronic components, andrecognizes system malfunctions. Ifa critical fault is detected, the CELand SEL illuminate. The malfunctioncodes are logged into the ECM'smemory.

The standard parameters which aremonitored for engine protectionare: low coolant level, high coolanttemperature, low oil pressure, andhigh oil temperature

This system features a 30-second,stepped-power shutdown sequenceor an immediate speed reductionwithout shutdown in the event a majorengine malfunction occurs, such aslow oil pressure, high oil or coolanttemperature, or low coolant level.

PERSONAL INJURY


NOTICE:Engines equipped with thepower-down/shutdown option havea system override button or switchto allow engine operation for ashort period of time. Using theoverride button so the engine doesnot shutdown in 30 seconds butoperates for an extended periodmay result in engine damage

Idle Shutdown Timer

The DDEC engine may also havean optional 1 to 100 minute idleshutdown system. The purpose ofthis system is to conserve fuel byeliminating excessive idling and toallow for a turbocharger cool-downperiod. To activate the shutdown, thetransmission must be in neutral withthe vehicle parking brakes set and theengine in idle or fast-idle mode.

Cruise Control

Cruise Control is available withany DDEC engine. Cruise Controlmaintains a set vehicle or enginespeed setting. The driver/operatorhas switches to set, activate anddeactivate the system. See Figure6. A slight pressure on the brake orclutch deactivates the system, as well.The minimum speed at which cruisecontrol can be used is programmable.



Figure 6 Typical Cruise ControlSwitches

Cruise Control may also beprogrammed to permit fast idleusing the cruise control switches.With the engine at normal idle,transmission in neutral and servicebrakes on, turn on the cruise control“ON/OFF” switch, and use the“Resume” switch. The engine rpmshould increase to a pre-definedspeed. The engine rpm can be raisedor lowered from this point using the“Set” and “Resume” switches.

Cruise Control will maintain the setspeed under normal road and loadconditions.


To avoid injury from the loss ofvehicle control, do not use cruisecontrol under these conditions:

□ When it is not possible tokeep the vehicle at a constantspeed (on winding roads, inheavy traffic, in traffic thatvaries in speed, etc.).

□ On slippery roads(wet pavement, ice-orsnow-covered roads, loosegravel, etc.).

NOTICE:When descending a hill withcruise control OFF, do not allowthe engine to exceed 2,500 rpmunder any conditions. Failure toobserve this precaution can resultin overspeeding and serious enginedamage.

Cruise Control cannot limit vehiclespeeds on down grades if availableengine braking effort is exceeded, norcan it maintain speed on upgrades ifpower requirements exceed enginepower capability.


DDEC IV SYSTEM

When the Cruise Control switchis in the ON position, cruisecontrol is engaged by momentarilycontacting the “Set/Coast” switchto the ON position. Holding theswitch in the ON position allows thevehicle to slow to a lower speed.Toggling the switch will result in aone mile-per-hour (1.6 kph) decreasein vehicle speed. If cruise controlhas been disabled, toggling the“Resume/Accel” switch restores thevehicle to the previously set cruisespeed.

Using either the brake or the clutchwill disable cruise control.

Engine Brakes

Engine brakes are enabled by anON/OFF switch mounted on the dash.A separate intensity switch is used toselect low, medium or high brakingpower. The engine brakes will onlyoperate when the electronic foot pedalassembly (EFPA) is fully released.Disengaging the clutch will preventthe engine brakes from operating.

Engine brakes will supply brakingpower even when in cruise control.The electronic control module (ECM)will control the amount of enginebraking with respect to the cruisecontrol set speed. The maximumamount of braking (low, medium, high)is selected with the dash switches.








Data Recording Capability

DDEC Reports is a data recordingcapability that is standard on all DDECIV engines. DDEC Reports containsinformation on driver activities,engine performance and criticalincidence reporting. The informationcan be extracted with Detroit DieselDiagnostic Link® 2.1 (DDDL 2.1)or later software. To perform theextraction, at least a 486 computerwith a 16-MB RAM is required.

DDEC IV Operation

NOTE:This engine is equipped with DDECsoftware. This software generallyassures optimal engine performance.The installation of software upgradesmay cause minor changes in featuresand engine performance.

Since the DDEC system is electronic,a battery is required to operate thecomputer. The system operates at 12or 24 volts. However, in the event of apower supply malfunction, the systemwill continue to operate at reducedvoltage. When this occurs, the CELwill come on.

The engine will only operate atreduced rpm until the battery voltagereaches a point where the ECM willno longer function and the engineshuts down.

Should the CEL come on for anyreason, the vehicle can still beoperated and the driver can proceedto the required destination. Thiscondition should be reported to anauthorized Detroit Diesel distributoror dealer.

NOTICE:When the SEL comes on, thecomputer has detected a majormalfunction in the engine thatrequires immediate attention. It isthe operator's responsibility toshut down the engine to avoidserious damage.

The engine can be configured togive a warning only, to ramp down(reduce power) or to shut down.Ramp down will reduce engine rpmto a pre-determined speed, but willnot shut down the engine. Withthe 30-second shutdown option, theengine will begin a 30-second, steppedpower-down sequence until it shutsdown completely.

Stop Engine Override can be suppliedin case the vehicle is to operate in acritical location.

NOTE:The Stop Engine Override (SEO)switch and the Diagnostic Requestswitch are the same.


DDEC IV SYSTEM

In this situation the operator mayelect to override the automatic stopengine sequence by pressing the StopEngine Override switch every 15 to 20seconds to prevent engine shutdownfrom occurring.

NOTE:For some applications, holding downthe Stop Engine Override switch willnot prevent the engine shutdownsequence. You must continue to resetthe automatic shutdown system bypressing the Stop Engine Overrideswitch at intervals of approximately 15to 20 seconds.

It takes 30 seconds from the time theautomatic shutdown sequence beginsuntil engine shutdown. Therefore,the operator must press the overrideswitch just prior to engine shutdownand continue to do so until the vehiclecan be brought to a stop in a safelocation.

Immediate Speed ReductionOption

The immediate speed reduction optionwill bring engine rpm back to apredetermined speed, but will not shutdown the engine.

The engine should not be restartedafter it has been shut down by theengine protection system, unlessthe problem has been located andcorrected.

Stop Engine Light

The conditions that will cause the SELto come on are:

□ High coolant temperature

□ Loss of coolant

□ High oil temperature

□ Low oil pressure

□ Auxiliary shutdown

It is important to point out thatwhenever the CEL or the SELcomes on, the DDEC computer willdetermine where the problem is andwill then store this information in itsmemory.

If the malfunction is intermittent, thelights will come on and go off as thecomputer senses the changing enginecondition.

Diagnostic Data Reader

The Diagnostic Data Reader (DDR)is a special diagnostic tool that canbe plugged into the engine computermemory to extract informationrelated to the cause of the problem.See Figure 7.



Figure 7 Diagnostic Data ReaderJ 38500

Once the malfunction has beencorrected, the DDEC system willreturn the engine to normal operation.

The DDR can distinguish betweencodes now active and those stored inthe ECM memory (inactive).

The malfunction code recorded in thecomputer memory will remain until itis erased by a technician.

The malfunction code can also beobtained by the operator. A DiagnosticRequest switch is provided which,when pressed, will cause the CELto flash a code number. It will, forexample, flash twice. . . pause . . .flash once. . . pause. In other words, acode 21. Code 21 indicates the throttleposition sensor input voltage is high.See Figure 8.

NOTE:A code 25 (two flashes followed by5 flashes) indicates all systems areworking satisfactorily.

Figure 8 SEL/CEL Flashing Code Examples


DDEC IV SYSTEM

Active Codes – The active codes willbe flashed on the SEL in the order ofmost recent to least recent occurrencebased on engine hours. If there are noactive codes, a code 25 will be flashed.

Inactive Codes – The inactive codeswill be flashed on the CEL in theorder of most recent to least recentoccurrence based on engine hours. Ifthere are no inactive codes, a code 25will be flashed.

Only One Light Flashes at a Time –Only one light will be flashing codesat any time. When code flashing isinitiated, the active codes (or code25) will be flashed on the SEL. Thenthe inactive codes (or code 25) willbe flashed on the CEL. When all theinactive codes (or code 25) have beenflashed, the process of flashing allthe active codes followed by all theinactive codes will repeat until theconditions for code flashing are nolonger satisfied.

To Read Codes: Use the diagnosticdata reader (DDR) or depress and holdthe diagnostic request switch withthe ignition ON and the engine ATIDLE or NOT RUNNING. Press andhold the switch. Active codes will beflashed on the SEL first, followed byinactive codes flashed on the CEL.

The codes will continue to flash andrepeat as long as the diagnostic requestswitch is held in the ON position withthe ignition on.

Diagnostic Code List

Diagnostic codes are listed in the nextseveral pages.

PERSONAL INJURY


PERSONAL INJURY

To avoid injury from loss ofvehicle/vessel control, theoperator of a DDEC equippedengine must not use or readany diagnostic tool while thevehicle/vessel is moving.



FlashCode 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


DDEC IV SYSTEM


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 VoltageLow

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




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 OilTemp 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

47High Range Fuel Pressure, Fuel Pressure, Turbo BoostPressure, Air Inlet Pressure, or Injection Control PressureHigh

48 High Range Fuel Pressure, Fuel Pressure, Air Inlet Pressure,or Injection Control Pressure Low

48 TCI Temperature Below Range

48 Turbo Compressor Temperature Out High

48 EGR Differential Pressure or EGR Temperature Low

49 TCI Temperature Above Range

49 Turbo Compressor Out Temperature High

49 Engine Derate Due to TCO Temperature

51 TCI Temperature Circuit Failed High

51 Turbo Compressor Out Temperature Sensor Input VoltageHigh

52 A/D Conversion Fail

53 Nonvolatile Checksum Incorrect

53 EEPROM Write Error


DDEC IV SYSTEM


53 Out of Calibration

54 Vehicle Speed Sensor Fault

55 Missing information from another ECU

55 J1939 Data Link, Proprietary Data Link (Master), orProprietary Data Link (Receiver) Fault

56 J1587 Data Link or J1922 Data Link Fault

58 Torque Overload

61 Injector xxx Response Time Long

62Aux. Output #1, #2, #5, #6, #7, or #8 Short to Battery(+), Open Circuit, or Mechanical System Not RespondingProperly

63 PWM #1, #2, #3, or #4 Above Normal Range, Below NormalRange, 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 NormalRange, 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 NotResponding

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 toground)

71 Injector xxx Response Time Short

72 Vehicle Overspeed

72 Vehicle Overspeed (Absolute)




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 TROUBLESHOOT-ING

78 Cruise Control/Adaptive Cruise Control Fault

81 Oil Level Sensor Input or Crankcase Pressure Sensor InputVoltage High

81 Extended Crankcase Pressure Input Voltage High

81 Injection Control Pressure or Exhaust Temperature SensorInput Voltage High

81 EGR Differential Pressure Sensor Circuit or EGRTemperature 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 InputVoltage Low


DDEC IV SYSTEM


82 Extended Crankcase Pressure Input Voltage Low

82 Injection Control Pressure Sensor or Exhaust TemperatureSensor Input Voltage Low

82 EGR Temperature Circuit or EGR Diffferential PressureSensor Circuit Failed Low

82 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 Pump Pressure Sensor or Barometric Pressure Sensor InputVoltage High

87 Pump Pressure Sensorr or Barometric Pressure SensorInput Voltage Low

88 High Range Coolant Pressure or Coolant Pressure Low

89 Fuel Restriction High

89 Maintenance Alert Coolant Level Fault



DDEC IV ENGINE DRIVING TIPS

Driving with an electronicallycontrolled engine feels different fromdriving with a mechancially governedengine.

Accelerating the VehicleEngine response versus pedalmovement may feel different from themechanical-governed engine you weredriving. The electronic foot pedalassembly (EFPA) was designed tocommunicate “percentage” foot pedaltravel to the engine's electronic controlmodule (ECM). The engine willrespond accordingly to the driver'sdemand.

Another throttle or governorcharacteristic you may need time toget used to is the DDEC limitingspeed governor. This allows the driverto command total engine responsebetween idle and rated speed, suchas accelerating at half throttle —an advantage when driving underslippery conditions.

If you require wide-open throttleengine response, either acceleratingor just plain pulling hard, the throttle(EFPA) will have to be held to thefloor. To obtain 100% fueling at anyspeed, the foot pedal will have tobe maintained at the fully depressedposition.

Cruise ControlFor added driver convenience andcomfort, DDEC IV also features acruise control option that works justlike the system in your car. It canbe operated in any gear above 1000rpm or road speed faster than 20mph (32 kph), up to the rated enginespeed. And it can be programmed tohold your road speed at or below themaximum vehicle speed. The switchto energize cruise control is usuallymounted on the instrument panel.See Figure 9.

Figure 9 Typical Cruise ControlSwitches



Turn the switch ON to energize thesystem. When you reach your roadspeed, press the “Set” switch toactivate cruise control. The cruiselight will come on. To increaseroad speed in one mile-per-hour(1.6 kilometer-per-hour) increments,press the “Resume/Accel” switch. Toreduce road speed, press and hold the“Set/Coast” switch until the lowerspeed is reached.

Cruise control is deactivated byslightly depressing the service brakes,clutch pedal, or trailer brake. The“On/Off” switch will also deactivatecruise control.

Cruise control will maintain vehiclespeed even on up grades, unless powerrequirements demand a downshift.And, of course, cruise control doesnot limit your speed on down grades.Most likely, cruise control will feelstronger than driving with the footpedal because of the instantaneous andwide-open throttle response. That'swhy cruise control use is not suggestedduring slippery driving conditions.

Use cruise control after downshifting on a hill to pull the hill.Hitting the “Resume” switch (notthe “Set” switch) will keep the truckaccelerating in the lower gears up tothe rated engine speed.

Cruise control will disengage below1100 rpm or 20 mph (32 kph) roadspeed. When using cruise control,if you want to pull the engine below1100 rpm, remember to hold thethrottle pedal to the floor to keep theengine pulling at wide-open throttle.Realistically, the engine will pull toabout 1050 rpm.

Remember: The electronic dataprogrammed into the ECM willnot allow you to hurt or overfuelthe engine at low or “lug” enginespeeds. There is enough oil pressureto withstand hard pulls at low enginespeeds.



Engine Brakes and CruiseControlIf your engine is equipped withboth cruise control and engine brakeretarders, the engine retarders canoperate automatically while youare in cruise control. If the cruisecontrol/engine brake function is turnedON in the ECM (electronic controlmodule) programming, the engineretarders will come on “low” whenyour set road speed increases a fewmiles-per-hour (kilometers per hour)above your cruise set speed. If yourspeed continues to increase, the ECMwill increase the engine retarders'braking power progressively. Whenthe vehicle returns to the set cruisespeed, the engine retarders will “turnoff” until you need them.

For safety reasons, don't use cruisecontrol when it is not possible to keepthe vehicle at constant speed due to:

□ Winding roads

□ Heavy traffic

□ Slippery pavement

□ Descending grades that call forengine brake assistance.

For an explanation of the engine brakeretarder system and recommendationsfor proper operation, refer to sectionENGINE BRAKE SYSTEM.

ShiftingDepending on your transmissionmodel, the gear split may vary from500 to 300 rpm. The electronicgovernor provides almost no overruncapability; and, if the transmissionis downshifted too early, you willexperience a temporary loss of pullingpower until the engine speed fallsbelow rated speed.

In general, when using a 7- or 9-speedtransmission, you should alwaysdownshift between 1250 and 1300rpm. This is true even on steep gradeswith heavy loads. When using an18-, 15- or 13-speed transmission,you will need to downshift at anrpm that allows “less than rated”rpm before throttle application in thenext gear down. You may want tolimit engine speed to 1900 rpm in allgears. The Series 50 provides constanthorsepower from 1800 rpm through2100 rpm, but fuel economy is not asefficient above 1800 rpm.



If you decide to drive at lower rpm'sfor improved fuel economy, don't letdifferent engine noises throw youoff guard. The Series 50 soundsquiet at 1400 rpm, almost as if ithad quit pulling. Don't believe it!If you had a boost gage to look atwhile driving, you would noticethe turbocharger maintaining steadyintake manifold pressure, even asrpm's fall. Depending on the airintake arrangement, you may alsoexperience a “chuffing” sound as theengine starts to pull hard at lowerrpm's. This is caused by the velocitychanges of the air flow within the airintake plumbing. Electronic enginescan actually deliver more fuel at lowerengine speeds than at rated speed.

IdlingThe common belief that idling a dieselengine causes no engine damage iswrong. Idling produces sulfuric acid,which breaks down the oil and eatsinto bearings, rings, valve stems andengine surfaces. If you must idle theengine for cab heat or cooling, thehigh idle function of the cruise controlswitches should be used. An idlespeed of 1100 rpm should be enoughto provide cab heat in above 32° F (0°C) ambients.

Winter Fronts

A winter front may be used to improvecab heating while idling, but it shouldnever cover more than 3/4 of thegrille while driving. Winter frontsshould only be used when the ambienttemperature remains below 10° F(-12.2 °C).



ENGINE BRAKE SYSTEM

Certain Series 50 vehicle enginesare equipped with engine brakes,commonly referred to as retarders.Before operating the vehicle, youmust familiarize yourself with theretarder system to obtain optimumbenefit from it. Engine brake controlsystems may vary slightly, dependingon the engine brake configuration andcab design. However, basic operatorcontrols are similar for all models.

Driver Control SwitchesVehicles with manual transmissionsallow the driver to turn the enginebrake on and off and select a low,medium or high level of braking. Twotypes of switches are available.

Low/High Switch

The Low setting on this switchactivates three (3) brake cylinders,supplying approximately 50% ofnormal engine braking horsepower.The High setting activates all six(6) cylinders, providing full enginebraking horsepower.

Low/Med/High Switch

The Low setting on this switchactivates two (2) brake cylinders,yielding about one-third enginebraking horsepower. The Mediumactivates four (4) cylinders, supplying

about two-thirds engine brakinghorsepower. The High settingactivates all six (6) cylinders,providing full braking horsepower.

Clutch Pedal and ThrottlePosition ControlsEngine brakes have two additionalcontrols, one activated by the positionof the clutch pedal and the otheractivated by the position of thethrottle. These controls permit fullyautomatic operation of the enginebraking system.

Engine Brake Operation

NOTE:The engine brake retarder systemdepends on a full-pressure flowof warm engine lubricating oil forproper lubrication of moving partsand optimum performance. It isimportant to allow the engine to reachfull operating temperature beforeswitching on the engine brake system.

Under normal driving conditions theengine brake system is left in the ONposition. However, this should changeif roads become wet or slippery.


ENGINE BRAKE SYSTEM

After it is switched on, the enginebrake system is automaticallyactivated each time you remove yourfeet completely from the clutch pedaland throttle.

The engine brake automaticallydeactivates itself when you press theclutch pedal while shifting gears.






NOTE:Some systems may be programmedto activate themselves only when thebrake pedal is pressed, so read yourvehicle owner's manual thoroughly tofind out if you have this option.

NOTICE:Do not attempt to “double clutch”the transmission while the enginebrake system is turned on. Shiftinggears without depressing the clutchor using the engine brake to reduceengine rpm may result in seriouspowertrain damage.

Anti-Lock BrakingSystemsVehicles equipped with ABS(anti-lock braking systems) havethe ability to turn the engine brakeretarder OFF if a wheel-slip conditionis detected. The engine brake willautomatically turn itself ON oncethe wheel slip is no longer detected.The DDEC system will deactivatethe engine brake system when theengine speed falls below 1000 rpmor when the vehicle slows down to apre-set speed, depending on DDECprogramming. This prevents stallingthe engine. Engine brakes can alsobe used with vehicle cruise controlTURNED ON.



Driving on Flat, DryPavementUse the following guidelines whendriving on flat, dry pavement:

1. If driving on flat, dry, openstretches with a light load andgreater slowing power is notrequired, place the progressivebraking switch in the LOWposition.

2. If you find you are still using theservice brakes, move the switchto a higher position until you donot need to use the service brakesto slow the vehicle down.

3. If you are carrying a heavier loadand road traction is good, movethe progressive braking switch tothe “High” position.

4. Check your progressive brakingswitch often for proper position,since road conditions can changequickly. Never skip a step whenoperating the progressive brakingswitch. Always go from OFFto LOW, and then to a higherposition.

Descending a Long, SteepGradeAn explanation of “control speed”may be helpful in understanding howto use the engine brake system whiledescending a grade. Control Speedis the constant speed at which the

forces pushing the vehicle forward ona grade are equal to the forces holdingit back, without using the vehicleservice brakes. In other words, thisis the speed the vehicle will maintainwithout using the service brakes orfueling.

BRAKE FADE

To avoid injury, do not overapply the vehicle service brakeswhen descending a long, steepgrade. Excessive use of thevehicle brakes will cause themto heat up, reducing theirstopping ability. This condition,referred to as “brake fade”, mayresult in loss of braking, whichcould lead to personal injury orvehicle/property damage or both.

Use the following guidelines whendescending a long, steep grade:

1. Before beginning a long, steepdescent, first determine if yourengine brake system is operatingproperly by lifting your footbriefly off the throttle. Youshould feel the system activate.

2. When descending the grade,make sure the progressive brakingswitch is in the appropriate powerposition.


ENGINE BRAKE SYSTEM

PERSONAL INJURY

Failure to keep the vehicle withinsafe control speed limits whiledescending a grade may resultin loss of vehicle control, whichcould cause personal injury.

NOTICE:Failure to keep the vehicle withinsafe control speed limits whiledescending a grade may result invehicle or property damage or both.

3. When descending a grade, donot exceed the safe control speedof your vehicle. Example: Youcould descend a 6% grade undercontrol only at 10 mph (16 kph)without an engine brake, but at25 mph (40 kph) with an enginebrake. You could not descendthat same hill at 50 mph (80kph) and still expect to remainunder control. Know how muchslowing power your engine brakecan provide. Know your enginebrake system before climbinghills and do not exceed a safecontrol speed.

4. Check your progressive brakingswitch often for proper position,since road conditions can changequickly. Never skip a step whenoperating the progressive brakingswitch. Always go from OFFto LOW and then to a higherposition when on slippery roads.

Driving on Wet or SlipperyPavementDo not attempt to use the engine brakesystem on wet or slippery roads untilyou have some experience with it ondry pavement.

NOTE:On single trailers or combinations,a light air application of the trailerbrakes may be desirable to helpkeep the trailer stretched out. Followthe manufacturer's recommendedoperating procedure when using yourtrailer brakes.

On wet or slippery pavement, startwith the master switch in the OFFposition and use the gear you wouldnormally use under these conditions.








If the vehicle is maintaining traction,place the selective braking switch inthe LOW position and turn ON theengine brake system. If the drivewheels are maintaining traction andyou desire greater slowing power,move the braking switch to the nexthighest position.

However, if the tractor drive wheelsbegin to lock or there is a fishtailmotion, turn the engine brake system

OFF immediately and do not activateit until road conditions improve.

Check your progressive brakingswitch often for proper position, sinceroad conditions can change quickly.Never skip a step when operating theprogressive braking system. Alwaysgo from OFF to LOWand then to ahigher position


ENGINE SYSTEMS

ENGINE SYSTEMS

The engine system are the following:

Fuel SystemThe fuel system consists of theDDEC, fuel injectors, fuel manifolds(integral with the cylinder head), fuelpump, a cooling plate for the ECMon non-automotive engines, primaryand secondary fuel filters, and thenecessary connecting fuel lines.

Lubrication SystemThe lubricating oil system consists ofan oil pump, oil cooler, two full-flowoil filters, bypass valves at the oilpump and oil filter adaptor, andoil pressure regulator valve in thecylinder block vertical oil gallery.

Air SystemThe outside air drawn into theengine passes through the air filterand is pulled into the turbochargerand compressed. It then moves tothe air-to-air charge cooler (heatexchanger) and is cooled. Next itflows to the intake manifold and intothe cylinders, where it mixes withatomized fuel from the injectors.

For optimum protection of theengine from dust and other airbornecontaminants, service the dry type aircleaners when the maximum allowable

air restriction has been reached, orannually, whichever occurs first.

Cooling SystemA radiator/thermo-modulated fancooling system is used on Series 50engines. This system has a centrifugaltype fresh water pump to circulatecoolant within the engine. Twofull-blocking type thermostats locatedin a housing attached to the right sideof the cylinder head control the flowof coolant.

Electrical SystemThe electrical system consists ofa starting motor, starting switch,battery-charging alternator, storagebatteries, and the necessary wiring.

Exhaust SystemHot exhaust gas flowing from theexhaust manifold into the exhaust riseris used to drive the turbocharger.

Exhaust Gas RecirculationSystemThe purpose of the Exhaust GasRecirculation System (EGR) is toreduce engine exhaust gas emissionsin accordance with EPA regulations.



MAINTENANCE

The following is intended as aguide for establishing preventivemaintenance intervals. Therecommendations given shouldbe followed as closely as possibleto obtain long life and optimumperformance from your engine.Maintenance intervals indicated aretime (hours) of actual operation. Theintervals shown apply only to themaintenance functions described.These functions should be coordinatedwith other regularly scheduledmaintenance.

A description of the maintenance tobe performed for each item in thefollowing tables can be found in thePreventive Maintenance Intervalssection

Recommended maintenance intervalsfor Series 50 on-highway truckand parlor coach engines arelisted in Table 1, Table 2 andTable3. Recommended maintenanceintervals for Series 50 transit coachengines are listed in Table 4, Table5, and Table 6. Recommendedmaintenance intervals for Series 50construction/industrial and stationaryengines are listed in Table 7, Table8, and Table 9. Recommendedmaintenance intervals for Series50 fire fighting, crash/rescue, andemergency vehicle engines arelisted in Table 10, Table 11, and Table

12. Recommended maintenanceintervals for Series 50 generator driveengines are listed in Table 13, Table14, and Table 15.

NOTICE:Failure to check and maintainSCA (supplemental coolantadditive) levels at requiredconcentrations will result insevere damage (corrosion)to the engine cooling systemand related components.Coolant must be inhibited with therecommended SCAs listed in thisguide. Refer to section How toSelect Coolant. In addition, theengine can be equipped with acoolant filter/inhibitor system as aninstalled option or as an after-saleitem.


MAINTENANCE

Item DailyChecks

7,500 Miles(12,000 Km)

15,000 Miles(24,000 Km)

1. Lubricating Oil I R

2. Fuel Tank I

3. Fuel Lines & Flex Hoses I

4. Cooling System I

5. Turbocharger I I

6. Battery I

8. Drive Belts I

9. Air Compressor 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 On-Highway Truck, Motor Coach, Urban Bus and MotorHome Daily, 7,500 Mile, and 15,000 Mile Checks



Months 6 12 18 24 30 36 42 48 54 60Item Miles/Km

( X 1000)15/24

30/48

45/72

60/96

75/120

90/144

105/168

120/192

135/216

150/240

1. Lubricating Oil Replace lubricating oil every 15,000 miles (24,000 km).

2. Fuel Tank I I I I I

4. Cooling System I I

5. Turbocharger 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

11. Lube Oil Filters Replace when lubricating oil is changed.

12. Fuel Filters R R R R R R R R R R

13. Coolant Pump/Inhibitor Level I I I I I I I I I I

14. Cranking Motor Follow manufacturer's recommendations.

15. Air System I I I I I I I I I I

16. Exhaust System I I I I I I I I I I


Table 2 On-Highway Truck, Motor Coach, Urban Bus and MotorHome Regular Maintenance Intervals


MAINTENANCE


( X 1000)15/24

30/48

45/72

60/96

75/120

90/144

105/168

120/192

135/216

150/240

17. Engine(Steam Clean) I I

18. Radiator & A/A ChargeCooler I I I I I

19. Oil Pressure I I20. Battery Charging

Alternator I I I I I I I I I I

21. Engine & TransmissionMounts I I

22. Crankcase Pressure I I

23. Fan Hub I

24. Thermostats & Seals I

25. Crankcase Breather I

26. Engine Tune-Up I

27. Vibration Damper Replace at major engine overhaul or earlierif dented or leaking.


Table 3 On-Highway Truck, Motor Coach, Urban Bus and MotorHome Regular Maintenance Intervals (continued)



Item DailyChecks

6,000 Miles(9,600 Km)

7,500 Miles(12,000 Km)

15,000 Miles(24,000 Km)


2. Fuel Tank I

3. Fuel Lines &Flexible Hoses I

4. Cooling System I

5. Turbocharger I I

6. Battery I

8. Drive Belts I

9. Air Compressor I

10. Air Cleaner I


12. Fuel Filters R

13. Coolant/ InhibitorLevel I


Table 4 Transit Coach, Pick-Up and Delivery, Stop-and-Go andShort Trip Daily, 6,000 Mile, 7,500 Mile, and 15,000 MileChecks


MAINTENANCE


( X 1000)15/24

30/48

45/72

60/96

75/120

90/144

105/168

120/192

135/216

150/240

1. Lubricating Oil

Replace lubricating oil every 6,000 miles (9,600km) or every three months, whichever comes first.On transit coach model 6047MK1E only, replace

oil every 3,000 miles (4,800 km).2. Fuel Tank I I I I I


5. Turbocharger I I I I I I I I I I

7. TachometerDrive 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


12. Fuel Filters R R R R R R R R R R13. Coolant Pump/

Inhibitor Level I I I I I I I I I I




Table 5 Transit Coach, Pick-Up and Delivery, Stop-and-Go andShort Trip Regular Maintenance Intervals




( X 1000)15/24

30/48

45/72

60/96

75/120

90/144

105/168

120/192

135/216

150/240

16. Exhaust System I I I I I I I I I I17. Engine

(Steam Clean) I I

18. Radiator & A/ACooler I I I I I


Alternator I I I I I I I I I I

21. Engine &TransmissionMounts

I I


23. Fan Hub I

24. Thermostats & Seals I



27. Vibration Damper Replace at major engine overhaul or earlierif dented or leaking.


Table 6 Transit Coach, Pick-Up and Delivery, Stop-and-Go andShort Trip Maintenance Intervals (continued)


MAINTENANCE

Item DailyChecks

100 Hror

3,000 Mi

150 Hror

4,500 Mi

200 Hror

6,000 Mi

300 Hror

9,000 Mi1. Lubricating Oil I R

2. Fuel Tank I I

3. Fuel Lines &Flexible Hoses I

4. Cooling System I

5. Turbocharger I

6. Battery* I7. Tachometer

Drive I

8. Drive Belts I

9. Air Compressor I

10. Air Cleaner I


12. Fuel Filters R13. Coolant/

Inhibitor Level I

18. Radiator I20. Battery

ChargingAlternator

I


Table 7 Stationary or Construction/Industrial Engine Daily, 100Hour, 150 Hour, 200 Hour, and 300 Hour Checks



Hours 150 300 450 600 750 900 1050 1200 1350 1500Item Miles/Km

( X 1000)4.5/7.2

9.0/14.4

13.5/21.6

18/28.8

22.5/36

27/43.2

31.5/50.4

36/57.6

40.5/64.6

45/72

1. Lubricating Oil Replace lubricating oil every 150 hours or 4,500miles (7,200 km), whichever comes first.

2. Fuel Tank I I I I I4. Cooling

System I I

5. Turbocharger I I I I I I I I I I7. Tachometer

Drive I I I I I I I I I I

8. Drive Belts I I I I I I I R I I9. Air

Compressor I I I I I I I I I I


12. Fuel Filters R R R R R R R R R R13. Coolant Pump/

Inhibitor Level I I I I I I I I I I

14. CrankingMotor Follow manufacturer's recommendations.



Table 8 Stationary or Construction/Industrial Regular MaintenanceIntervals


MAINTENANCE

Hours 150 300 450 600 750 900 1050 1200 1350 1500Item Miles/Km

( X 1000)4.5/7.2

9.0/14.4

13.5/21.6

18/28.8

22.5/36

27/43.2

31.5/50.4

36/57.6

40.5/64.6

45/72

16. ExhaustSystem I I I I I I I I I I

17. Engine(Steam Clean)

18. Radiator & A/ACharge Cooler I I I I I

19. Oil Pressure I I20. Battery

ChargingAlternator

I I I I I

21. Engine &TransmissionMounts

I I

22. CrankcasePressure I I

23. Fan Hub I24. Thermostats &

Seals25. Crankcase

Breather I

26. EngineTune-Up I

27. VibrationDamper

Replace at major engine overhaul or earlierif dented or leaking.


Table 9 Stationary or Construction/Industrial Regular MaintenanceIntervals (continued)



Item DailyChecks

100 Hours or3,000 Miles( 4,800 Km)

300 Hours or6,000 Miles( 9,600 Km)


2. Fuel Tank I

3. Fuel Lines & Flexible Hoses I

4. Cooling System I

5. Turbocharger I

6. Battery I

7. Tachometer Drive I

8. Drive Belts I

9. Air Compressor 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


Table 10 Fire Fighting, Crash/Rescue and Emergency VehicleEngine Daily, 100 Hour and 300 Hour Checks


MAINTENANCE

Hours 300 600 900 1,200 1,500Item Miles/Km

(X 1000) 6/1.6 12/9.6 18/28.8 24/38.4 30/48

1. Lubricating Oil Replace lubricating oil every 300 hours or6,000 miles (1,600 km), whichever comes first.

2. Fuel Tank I I I I I


5. Turbocharger I I I I I

7. Tachometer Drive I I I I I

9. Air Compressor I I I I I


12. Fuel Filters R R R R R13. 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


Table 11 Fire Fighting, Crash/Rescue and Emergency VehicleEngine Regular Maintenance Intervals



Hours 300 600 900 1,200 1,500Item Miles/Km

(X 1000) 6/1.6 12/9.6 18/28.8 24/38.4 30/48

17. Engine (Steam Clean)18. Radiator & A/A Charge

Cooler I I I I I


Alternator* I I I I I

21. Engine & TransmissionMounts I I


23. Fan Hub I

24. Thermostats & Seals



27. Vibration Damper Replace at major engine overhaul orearlier if dented or leaking.


Table 12 Fire Fighting, Crash/Rescue and Emergency VehicleEngine Regular Maintenance Intervals (continued)


MAINTENANCE

Item PrimeDaily

StandbyMonthly

1. Lubricating Oil I I*

2. ]Fuel Tank I I

3. Fuel Lines & Flexible Hoses I

4. Cooling System I I*

5. Turbocharger I

6. Battery I

8. Drive Belts I I

10. Air System, Cleaner I I

12. Fuel Filters, Water Separator I I*

16. Exhaust System I

19. Oil Pressure I I*

Load Test P

All items are described in Preventive Maintenance Intervals.I – Inspect, service, correct or replace as necessary.P – Perform* Perform these items at time of load test. Load test should be at

least 35% of the unit's full rated output. Refer to generator setmanufacturer's instructions.

Table 13 Generator Set Engine Prime Daily and Standby MonthlyMaintenance Intervals



HoursItem

150 300 600 1,000 1,500 2,000 3,000 4,000

1. Lubricating Oil

Standby: Replace every 150 hours or 1 year,whichever comes first.

Prime: Replace every 250 hours or 3 months,whichever comes first.

2. Fuel Tank I3. Fuel Lines &

Flexible Hoses I R

4. Cooling System R

6. Battery I7. Tachometer

Drive I

8. Drive Belts I

10. Air Cleaner I11. Lube Oil Filters Replace when lubricating oil is changed.

12. Fuel Filters

Standby: Replace every 150 hours or 1 year,whichever comes first.

Prime: Replace every 150 hours or 3 months,whichever comes first.

13. Coolant Pump/Inhibitor Level I


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


MAINTENANCE

HoursItem

150 300 600 1,000 1,500 2,000 3,000 4,000

16. Exhaust System I17. Engine

(Steam Clean) I I

18. Radiator I

19. Oil Pressure I20. Battery

ChargingAlternator

I

21. Engine &GeneratorMounts

I

22. CrankcasePressure I

23. Fan Hub I24. Thermostats &

Seals R

25. CrankcaseBreather I R

26. Engine Tune-Up I27. Vibration

DamperReplace at major engine overhaul or earlier

if dented or leaking.All items are described in Preventive Maintenance Intervals.I – Inspect, service, correct or replace as necessary.R – Replace

Table 15 Generator Set Engine Regular Maintenance Intervals(continued)



Preventive MaintenanceIntervalsThe following is intended as aguide for establishing preventivemaintenance intervals. Therecommendations given shouldbe followed as closely as possibleto obtain long life and optimumperformance from your engine.Maintenance intervals indicated aretime (hours) of actual operation.

The intervals shown apply only tothe maintenance functions describedand should be coordinated with otherregularly scheduled maintenance.

The “Daily” instructions apply toroutine or daily starting of the engine.They do not apply to a new engineor one that has been operated for aconsiderable period of time.

For new or stored engines, referto Section 13.1, “Preparations forStarting the Engine the First Time,” inthe Series 50 Service Manual (6SE50).

Preventive maintenance other than the“Daily” checks should be performedby authorized Detroit Diesel serviceoutlets. These outlets have the trainedpersonnel and special tools to properlyperform all services.

Item 1 – Lubricating Oil

Check the oil level daily with theengine stopped. If the engine hasjust been stopped and is warm, waitapproximately 20 minutes to allow theoil to drain back into the oil pan beforechecking. Add the proper grade of oilto maintain the correct level on thedipstick. See Figure 10.

Figure 10 Check Oil Level Daily

NOTICE:When adding lubricating oil, donot overfill. Oil may be blown outthrough the crankcase breather ifthe crankcase is overfilled.

All diesel engines are designed touse some oil, so the periodic additionof oil is normal. See Figure 11 todetermine the degree of oil usage.


MAINTENANCE

Figure 11 Engine Oil Consumption Guidelines

NOTICE:If the oil level is constantly abovenormal and excess oil has not beenadded to the crankcase, consult withan authorized Detroit Diesel serviceoutlet. Fuel or coolant dilution oflubricating oil can result in seriousengine damage.

Before adding lubricating oil, refer toHow to Select Lubricating Oil in thisguide. Change lubricating oil andfilters at the intervals listed in Table 16when using fuel with a sulfur contentof less than 0.05 mass percent. Whenusing fuel with a higher sulfur content,refer to When to Change Oil in thisguide.

Service Application Lube Oil and Filter Change Interval*Highway Truck & Motor Coach 15,000 Miles (24,000 Kilometers)City Transit Coach except model6047MK1E

6,000 Miles (9,600 Kilometers), 300Hours 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), 300Hours or 1 Year†

Construction, Industrial & Agricultural 250 Hours or 1 Year†Stationary Generator – Prime Poweror 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 Engine Oil Drain and Filter Change Intervals (Diesel FuelSulfur Content Less Than 0.05 Mass %)



Item 2 – Fuel and Fuel Tank

Keep the fuel tank filled to reducecondensation. See Figure 12.

Figure 12 Filled Fuel Tank

Before adding fuel, refer to sectionHow to Select Fuel Oil in the How Tosection of this guide.

Refill the tank at the end of each day'soperation to prevent condensationfrom contaminating the fuel.Condensation formed in a partiallyfilled tank promotes the growth ofmicroorganisms that can clog fuelfilters and restrict fuel flow.

To prevent microbe growth, add abiocide to the fuel tank or primaryfuel supply.

Water accumulation can be controlledby using additives containing methylcarbitol or butyl cellusolve. Followmanufacturer's usage, handling andsafety precautions.

Open the drain at the bottom ofthe fuel tank every 30,000 miles

(48,000 kilometers) or 300 hours forconstruction/industrial applications todrain off any water and/or sediment.

PERSONAL INJURY

To avoid injury from improper useof chemicals, follow the chemicalmanufacturer’s usage, handling,and disposal instructions.Observe all manufacturer’scautions.

Every 120,000 miles (192,000kilometers), 12 months, or 600hours for construction/industrialapplications tighten all fuel tankmountings and brackets. At the sametime, check the seal in the fuel tankcap, the breather hole in the cap andthe condition of the flexible fuellines. Repair or replace the parts, asnecessary.


MAINTENANCE

NOTICE:Galvanized steel fuel tanks, fittings,pipes or supply lines should neverbe used, because the fuel reactschemically with the zinc coating toform powdery flakes that can quicklyclog the fuel filters and damage thefuel pump and injectors.

Item 3 – Fuel Lines, FlexibleHoses

A pre-start inspection for leaks and ofhosese and fittings must be made.

Leaks — Make a visual check forfuel leaks at all engine-mounted fuellines and connections, and at thefuel tank suction and return lines.Since fuel tanks are susceptible toroad hazards, leaks in this area maybest be detected by checking for anaccumulation of fuel under the tank.

FIRE


Leaks are not only detrimental tomachine operation, but they can also

result in added expense caused by theneed to replace lost fluids.

Hoses and Fittings — Checkhoses daily as part of the pre-startinspection. Examine hoses for leaks,and check all fittings, clamps andties carefully. Make sure hoses arenot resting on or touching shafts,couplings, heated surfaces includingexhaust manifolds, any sharp edges,or other obviously hazardous areas.Since all machinery vibrates andmoves to a certain extent, clamps andties can fatigue with age. To ensurecontinued proper support, inspectfasteners frequently and tighten orreplace them as necessary. If fittingshave loosened or cracked or if hoseshave ruptured or worn through, takecorrective action immediately.

Hose Service Life — A hose hasa finite service life. All hoses shouldbe thoroughly inspected at least every500 operating hours (1,000 hoursfor fire-resistant fuel and lubricatingoil hoses) and/or annually. Lookfor cover damage and/or indicationsof twisted, worn, crimped, brittle,cracked or leaking lines. Hoses withtheir outer cover worn through or withdamaged metal reinforcements shouldbe considered unfit for further service.



All hoses in and out of machineryshould be replaced during majoroverhaul and/or after a maximum offive (5) years of service.

NOTE:Fire-resistant fuel and lube oil hoseassemblies do not require automaticreplacement after five years of serviceor at major overhaul, but should beinspected carefully before being putback into service.

Item 4 – Cooling System

HOT COOLANT


The cooling system must be full forproper operation of the engine.

Coolant Level — Check the coolantlevel daily and maintain it near thebottom of the filler neck on theradiator. On some installations thisis done by checking an overflowbottle or sight glass. Add coolant as

required, but do not overfill. Beforeadding coolant, refer to section Howto Select Coolant in this guide.

Make a daily visual check forcooling system leaks. Look for anaccumulation of coolant when theengine is running and when it isstopped. Coolant leaks may be moreapparent on a engine when it is cold.

Coolant Inhibitors — Theinhibitors in antifreeze solutions mustbe replenished with a non-chromatecorrosion inhibitor supplement whenindicated by testing the coolant. Inaddition, the engine can be equippedwith a coolant filter/inhibitor system asan installed option or as an after-saleitem.


MAINTENANCE

Refer to section How to Select Coolantfor required test intervals and inhibitorlevels.

NOTICE:Failure to check and maintainSCA levels at requiredconcentrations will result insevere damage (corrosion) tothe engine cooling system andrelated components.Coolant mustbe inhibited with the recommendedSCA's listed in this guide.



Coolant Drain Interval —Detroit Diesel recommendsreplacing coolant at the intervalslisted in Table 17.

A coolant system properly maintainedand protected with supplementalcoolant inhibitors can be operated

up to the intervals listed. Atthese intervals the coolant mustbe drained and disposed of in anenvironmentally responsible manneraccording to state and/or federal(EPA) recommendations.

Coolant Type Coolant Replacement IntervalA 50/50 mix of PowerCool® fullyformulated, inhibited ethyleneglycol antifreeze and water ora 50/50 mix of fully formulated,inhibited propylene glycolantifreeze and water

With proper maintenance1 coolant can beoperated 2 years, 300,000 miles (480,000km), or 4,000 hours, whichever comes first.At this time the cooling system must becompletely drained and cleaned before refill.

A 50/50 mix of phosphate-freeTMC RP-329 “Type A“(propylene glycol) antifreezeand water.

With proper maintenance1 coolant can beoperated for the life of the engine untiloverhaul.2 For life to overhaul, pre-chargedcoolant in combination with a need-releasefilter must be used. At this time the coolingsystem must be completely drained andcleaned before refill.

A 50/50 mix of OAT (organicacid technology) coolant andwater.

With proper maintenance coolant can beoperated 4 years, 600,000 miles (960,000km), or 10,000 operating hours, whichevercomes first. 3 At this time the cooling systemmust be completely drained and cleanedbefore refill.

1 Proper maintenance involves periodic evaluation using PowerTrac®3-Way Coolant Test Strips and the addition of required SCA, asindicated by the test strip.

2 To verify coolant acceptability, submit a sample to DDC for coolantanalysis every 3 years, 300,000 miles (480,000 km) or 6,000operating hours, whichever comes first. Submit sample usingPowerTrac coolant analysis kit, part number 23516921 (IEG/IPGcoolant) 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


MAINTENANCE

Item 5 – Turbocharger, Air-to-AirCharge Cooler

Visually inspect the turbochargermountings, intake and exhaust ductingand connections for leaks daily. Checkthe lube oil inlet and outlet lines forleaks or restrictions to oil flow. Checkfor unusual noise or vibration and, ifexcessive, stop the engine and do notoperate until the cause is determined.

PERSONAL INJURY


Periodically inspect the air-to-aircharge cooler (if used) for buildup ofdirt, mud, etc. and wash off. Checkthe charge cooler, ductwork, andflexible connections for leaks andhave repaired or replaced, as required.

Check turbocharger heat-insulatingexhaust system blankets (if used) fordamage on a daily basis. Torn, matted,crushed, oil-soaked or otherwisedamaged insulation blankets must bereplaced immediately.

Wastegated Turbochargers —The turbocharger wastegate actuatoris factory-calibrated and is notadjustable. Check actuator operationat the intervals shown in themaintenance schedule.

EYE INJURY


NOTICE:Do not exceed 30 psi (207 kPa) airpressure when checking wastegateactuator operation. Excessive airpressure can damage the actuator.

To verify correct wastegate actuatoroperation, apply 30 psi (207 kPa)of regulated shop air and watch foractuator rod movement.



Item 6 – Battery

Check the hydrometer “eye” ofmaintenance-free batteries for charge.See Figure 13.

Figure 13 Maintenance-FreeBattery “Eye”

PERSONAL INJURY

To avoid injury from accidentalengine startup while servicingthe engine, disconnect/disablethe starting system.

If lead-acid or low-maintenancebatteries are used, check the specificgravity of each cell every 150operating hours. Check morefrequently in warm weather due tothe more rapid loss of water throughevaporation.

Maintain the electrolyte levelaccording to the battery manufacturer'srecommendations, but do not overfill.Overfilling can cause poor batteryperformance or early failure.

Keep the terminal side of the batteryclean. When necessary, wash witha solution of baking soda and water.Rinse with fresh water. Do not allowthe soda solution to enter the cells.

Inspect the cables, clamps andhold-down brackets regularly. Cleanand reapply a light coating ofpetroleum jelly when needed. Havecorroded or damaged parts replaced.

If the engine is to be out of servicefor more than 30 days, remove thebatteries and store in a cool, dryplace. Keep batteries fully charged,if possible. Replace any battery thatfails to hold a charge.

Periodically check battery connectionsfor corrosion and tightness. Ifnecessary, remove connectionsand wire brush any corrosion fromterminals and cable ends. Replacedamaged wiring.


MAINTENANCE

Item 7 – Tachometer Drive

A typical tachometer drive take-offlocation is the camshaft drive gearaccess cover on the front of the gearcase cover. Lubricate the tachometerdrive (if so equipped) every 150 hoursor 15,000 miles (24,000 km) with anall-purpose grease. At temperaturesabove –1° C (+30° F) use a No. 2grade grease. Use a No. 1 gradegrease below this temperature.

Item 8 – Drive Belts

Belts should be neither too tight nortoo loose. Belts that are too tightimpose 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 loosebelt will slip and may cause damageto accessory components.

PERSONAL INJURY

To avoid injury from rotating beltsand fans, do not remove anddiscard safety guards.

Use a belt tension gage, such asKent-Moore® tool J 23586–B(V-belt), J 23600–B (poly-V belt),J 41251 (PowerBand® and 12–ribpoly-V belt), or equivalent, whentensioning drive belts. Tension beltsto the values listed in Table 18.

Fan DriveSingle Belt 2 or 3 Belts

80 – 100 lbs (356 – 445 N) 60 – 80 lbs (267 – 356 N)

Alternator DriveBelt 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 Drive Belt Tensioning



V-Belts — New standard V-beltswill stretch after the first few hoursof operation. Tighten V-belts aslisted in Table 18. Run the enginefor 10 to 15 minutes to seat the belts,then readjust tension. Check andretension belts after 1/2 hour andagain after 8 hours or 250 miles (400km) of operation. Thereafter, checkthe tension of the drive belts every100 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 firmpush with the thumb, at a pointmidway between the two pulleys, willdepress the belt .50 in. – .75 in. (13– 19 mm).

2-Groove PowerBand — The2-groove PowerBand® is used withthe 50 DN alternator. To provideproper running tension for the belt,current Series 50 engines use an autobelt tensioner, which requires noadjustment. See Figure 14.

Earlier-built Series 50 engines havea manual belt tensioner assembly.See Figure 15.

Tighten a new PowerBand® drive beltto 200 lbs (890 N), then run the enginefor 10 minutes at 1200 rpm. Stop theengine and allow a 10 – 15 minutecool down period. Check tension. Ifless than 150 lbs (667 N), retensionto 150 lbs (667 N). Following initial

tensioning, measure belt tensionevery month or every 7,500 miles(12,000 km), whichever comes first.Retension belt to 150 lbs (667 N) atthese intervals.

Figure 14 Auto Belt TensionerAssembly with 50 DNAlternator

Figure 15 Manual TensionerAssembly with 50 DNAlternator


MAINTENANCE

12–Rib Poly-V Belt — Tighten a12–rib poly-V belt to 350 lbs (1,557N), then run the engine at high idle for30 minutes. Stop the engine and allowa 10 – 15 minute cool down period.Check tension with tool J 41251–Bor equivalent. If tension is 250 lbs(1,112 N) or more, no retensioning isrequired. If tension is less than 250 lbs(1,112 N), retension to 250 lbs (1,112N). Measure belt tension every monthor every 7,500 miles (12,000 km),whichever comes first. Retension to250 lbs (1,112 N) as required.

Belt Replacement — Drive belts(V and poly-V) should be replacedevery 2,000 hours or 100,000 miles(160,000 km).

Replace all belts in a set when oneis worn. Single belts of similar sizeshould not be used as a substitute fora matched belt set. Premature beltwear can result because of belt lengthvariation. All belts within a matchedset are within .032 in. (0.8 mm) oftheir specified center distances.

When installing or adjusting anaccessory drive belt, be sure the boltat the accessory adjusting pivot pointis properly tightened, as well as thebolt in the adjusting slot. In addition,check the torque on the alternator andbracket mounting bolts. Retighten asrequired.

Item 9 – Air Compressor

All air compressor intake partsshould be removed and cleaned at thefollowing intervals:

□ On Highway Vehicle Engines –7,500 miles (12,000 km)

□ Industrial Engines – 150 Hours or4,500 miles (7,200 km)

To clean either the hair type or thepolyurethane type compressor airstrainer element, saturate it andsqueeze it in fuel oil or any othercleaning agent that is not detrimentalto the element until it is dirt-free. Thensaturate the element in lubricating oiland squeeze it dry before placing itback into the air strainer.

For air strainer replacement,contact the nearest servicing dealer.Replace hair type elements with thepolyurethane type, if available.

The air compressor mounting boltsshould be tightened every 12 monthsor 30,000 miles (48,000 km) foron-highway engines or every 300hours for industrial applications.



Item 10 – Air Cleaner

The air cleaner element should beinspected every 15,000 miles (24,000km) for vehicle engines, 150 hours fornon-vehicle engines, or more often ifthe engine is operated under severedust conditions. Replace the element,if necessary. Check the gaskets fordeterioration and replace, if necessary.If the dry type air cleaner is equippedwith an aspirator, check for aspiratordamage or clogging. Clean, repair orreplace, as necessary.

Dry type air cleaner elementsshould be replaced after one yearof service or when the maximumallowable air intake restriction hasbeen reached, whichever comes first.Refer to section When to Service theDry Type Air Cleaner in this guide foradditional information.

NOTICE:Do not allow the air inlet restrictionto exceed 20 inches of water (5.0kPa) under any engine operatingconditions. A clogged air cleanerelement will cause excessiveintake restriction and a reducedair supply to the engine. This, inturn, can result in increased fuelconsumption, inefficient engineoperation and reduced engine life.

Inspect the entire air system for leaksdaily. Look especially for torn air inletpiping or boots and loose or damagedclamps. Have worn or damaged partsrepaired or replaced, as required.Retighten loose connections.

Item 11 – Lubricating Oil Filters

For on-highway vehicle engines,install new spin-on oil filters at amaximum of 15,000 miles (24,000km).

For city transit coach engines, installfilters at a maximum of 6,000 miles(9,600 km).

For industrial engines, install filtersevery 150 hours of operation oreach time the engine oil is changed,whichever comes first.

PERSONAL INJURY



MAINTENANCE

Install the new filters, turning themuntil they contact the gasket fully withno side movement. Turn full-flowfilters an additional 2/3 turn byhand, or as indicated on the filter.See Figure 16.

Figure 16 Lubricating Oil Filters

Make a visual check of all lubricatingoil lines for wear and/or chafing. Ifany indication of wear is evident,replace the oil lines and correct thecause.

Check for oil leaks after starting theengine.

Item 12 – Fuel Filters

One method of determining whenfilters are plugged to the extent thatthey need replacing is based on the

fuel pressure at the cylinder head fuelinlet fitting and the inlet restrictionat the fuel pump. In a clean systemthe maximum pump inlet restrictionshould not exceed 6 inches of mercury(20.3 kPa). In a dirty system it mustnot exceed 12 inches of mercury(41 kPa).

At normal operating speed and withthe standard .080 inch restrictionfittings, the fuel pressure is 55 – 70psi (375 – 483 kPa). Change the fuelfilters whenever the inlet restrictionat the pump reaches 12 inches ofmercury (41 kPa) at normal operatingspeeds and whenever the fuel pressureat the inlet fitting falls to the minimumfuel pressure of 6 inches of mercury(20.3 kPa).

NOTE:Filter change intervals may beshortened to conform with establishedpreventive maintenance schedules,but should never be extended.

Fuel Pro® 382 Filters — Installnew Fuel Pro® 382 primary fuel filterelements when the fuel level in thesee-thru cover reaches the top of theelement or after one year of service,whichever comes first.

Spin-On Filters — Install newspin-on primary and secondary fuelfilter elements on vehicle enginesevery 15,000 miles (24,000 km) or



every six months, whichever comesfirst. See Figure 17.

Figure 17 Spin-On Fuel FilterLocation

Install new spin-on filter elementson non-vehicle engines every 150hours. Replace spin-on filter elementsimmediately if plugging is indicated,regardless of mileage or hour intervals.

Item 13 – Water Pump andCoolant Inhibitor Element

Check the water pump and the coolantinhibitor element.

Water Pump Drain Hole — Thewater pump drain hole should beinspected every 6 months to makesure it is open. A small chemicalbuild-up or streaking at the drain holemay occur. This is not an indicationof a defective water pump or seal.Remove the build-up with a milddetergent cleaner and a brush. If

coolant does not leak from the drainhole under normal conditions, do notreplace the water pump.

Coolant Inhibitor Element — Ifthe cooling system is protected by asupplemental coolant additive (SCA)element, the coolant must be testedat required intervals and the elementreplaced, if required. See Figure 18.

Figure 18 Coolant InhibitorElement

Required test intervals arelisted in Table 25. For SCA testprocedures refer to How to SelectCoolant and then SCA Test Proceduresin this guide. Use the coolant filterelement required.


MAINTENANCE

Refer to SPECIFICATIONS forelement part number listing. Thevalves mounted on the filter adaptorhead must be opened after the elementis replaced.

Item 14 – Cranking Motor

For cranking motor (starter)information, contact an authorizedDelco Remy® or Bosch® servicecenter, depending on manufacturer.

Item 15 – Air System

All the connections in the air systemshould be checked to make surethey are tight and leak free. Checkall hoses and ducting for punctures,deterioration or other damage andreplace, if necessary.

Item 16 – Exhaust System

Have the exhaust manifold retainingbolts and other connections checkedfor tightness. Have the exhaust piperain cap checked for proper operation,if so equipped.

Item 17 – Engine (Steam Clean)

Steam clean the engine and enginecompartment every 60,000 miles(96,000 km) or 2,000 hours,whichever comes first.

NOTICE:Do not apply steam or solventdirectly to the battery-chargingalternator, starting motor, DDECcomponents, sensors or otherelectrical components, as damageto electrical equipment may result.

Item 18 – Radiator

The exterior of the radiator coreshould be inspected every 30,000miles (48,000 km), 12 months, or 300hours (industrial applications) andcleaned, if necessary.

EYE INJURY


Use a quality grease solvent, suchas mineral spirits, and dry withcompressed air. Fuel oil, kerosene orgasoline should not be used.

It may be necessary to clean theradiator more frequently if the engineis being operated in extremely dustyor dirty areas.



If the low coolant level sensor isinstalled in the top tank of the radiator,it should be tested for proper operationevery 100,000 miles (160,000 km)or 12 months, whichever comes first.Authorized Detroit Diesel distributorsare properly equipped to perform thisservice.

Item 19 – Oil Pressure

Under normal operation, oil pressureis noted each time the engine isstarted. In the event the equipmenthas warning lights rather than pressureindicators, the pressure should bechecked and recorded every 60,000miles (96,000 km) for vehicle enginesor 600 hours for stationary andindustrial engines.

Item 20 – Battery-ChargingAlternator

Precautions must be taken whenworking on or around the alternator.The diodes and transistors in thealternator circuit are very sensitiveand can be easily destroyed.

1. Avoid grounding the outputterminal. Grounding analternator's output wire orterminal (which is always “hot,”regardless of whether or notthe engine is running) andaccidentally reversing the batterypolarity will result in equipmentdamage.

2. Do not reverse batteryconnections. This can alsocause damage.

3. Never disconnect the batterywhile the alternator is operating.Disconnecting the battery canresult in damage to the batterydiodes. In applications whichhave two (2) sets of batteries,switching from one set to theother while the engine is runningwill momentarily disconnectthe batteries. This can result inequipment damage.

4. If a booster battery is to be used,batteries must be connectedcorrectly (negative to negative,positive to positive) to avoidequipment damage.

5. Never use a fast charger with thebatteries connected or as a boosterfor battery output.

For information on the alternatorassembly, contact an authorizedDelco Remy® or Bosch® distributor,depending on manufacturer.


MAINTENANCE







Bosch® T1 Alternator ServiceRequirements — The transistorregulator must be replaced every100,000 miles (160,000 km) usingkit part number 23524613 (includesregulator assembly and brushes).Front and rear bearings must bereplaced every 200,000 miles(320,000 km) using kit 23524614(includes bearings, seals and spacerring). Authorized Bosch distributorshave the parts, tools and trainedpersonnel to perform these services.

General Service Requirements– Bosch® and Delco Remy®

Alternators — Terminals shouldbe checked for corrosion and looseconnections and wiring inspectedfor damage and frayed insulation.Have wiring repaired or replaced, asrequired.

Check torque on alternator mountingbolts and bracketing every 15,000miles (24,000 km) on truck and coachengines or every 300 hours on allother engines. Retighten, if necessary.

Item 21 – Engine andTransmission Mounts

The engine and transmission mountingbolts and the condition of the mountingpads should be checked every 60,000miles (96,000 km) or 600 hours.Tighten and/or repair as necessary.

Item 22 – Crankcase Pressure

The crankcase pressure should bechecked and recorded every 60,000miles (96,000 km) or 600 hours.

Item 23 – Fan Hub

If the fan bearing hub assembly has agrease fitting, use a hand grease gunto lubricate the bearings with one shotof quality lithium-base, multi-purposegrease every 100,000 miles (160,000km) for vehicle engines or 1,000 hoursfor non-vehicle engines. Care shouldbe taken not to overfill the bearinghousing.



Item 24 – Thermostats and Seals

Replace the thermostats and sealsevery 240,000 miles (384,000 km)on vehicle engines. On non-vehicleengines, replace the thermostats andseals every 4,000 hours or 24 months,whichever comes first.

Item 25 – Crankcase Breather

The internally mounted (in the enginerocker cover) crankcase breatherassembly should be removed andthe steel mesh pad washed in cleanfuel oil every 100,000 to 120,000miles (160,000 to 192,000 km) onvehicle engines or every 1,000 hoursof operation on non-vehicle engines.This cleaning period may be reducedor lengthened according to the severityof service. See Figure 19).

Figure 19 Internal (in RockerCover) BreatherLocation

The rocker cover-mounted breatherassembly (part number 23512984)

used in the closed crankcase breathersystem should be replaced every 4000operating hours. It is not reusable andno attempt should be made to clean orreuse it. See Figure 20.

Figure 20 Rocker Cover-MountedBreather

Item 26 – Engine Tune-Up

There is no scheduled interval forperforming an engine tune-up.However, the valve lash and injectorheights must be measured and, ifnecessary, adjusted at the initialinterval listed in Table 19. Once theinitial measurements/adjustmentshave been made, any adjustmentsbeyond this point should be made onlyas required to maintain satisfactoryengine performance.

Item 27 – Vibration Damper

The viscous vibration damper shouldbe inspected periodically and replacedif dented or leaking. See Figure 21.


MAINTENANCE

Heat from normal engine operationmay, over a period of time, cause thefluid within the damper to break downand lose its dampening properties.For this reason the viscous vibrationdamper must be replaced at timeof normal major engine overhaul,regardless of apparent condition.

Figure 21 Viscous VibrationDamper

Engine Application Initial Valve Lash and Injector HeightMeasurement/Adjustment Period

Vehicle Engines 60,000 Miles (96,000 km) or24 Months*

Stationary, Construction/Industrial,Agricultural, or Generator Set Engines

1,500 Hours or 45,000 Miles(72,000 km)*

* Whichever comes first.

Table 19 Valve Lash and Injector Height Adjustment



HOW-TO SECTION

This section covers Detroit Diesel'srecommendations on how to selectlubricating oil, fuel oil, and coolantand includes basic engine maintenanceprocedures which can be performedby the operator.

NOTICE:The manufacturer's warrantyapplicable to Series 50 enginesprovides in part that the provisionsof such warranty shall not applyto any engine unit that has beensubject to misuse, negligence oraccident. Accordingly, malfunctionsattributable to neglect or failure tofollow the manufacturer's fuel orlubricating recommendations maynot be within the coverage of thewarranty.

How to Select LubricatingOilThe selection of the proper lubricatingoil is important to achieve the longand trouble-free service which DetroitDiesel engines are designed toprovide. The proper lubricating oil forall Detroit Diesel engines is selectedbased on SAE viscosity grade andAPI (American Petroleum Institute)service designation. Only oils licensedto display the API symbol should beused. See Figure 22.

Figure 22 API Symbol

Lubricant Requirements

Lubricant requirements are differentfor the EGR-equipped and non-EGRengines.

EGR-Equipped Engines — APICI-4 oils must be used in October2002 and later–build Series 50engines with cooled EGR (exhaustgas recirculation) devices. APIService Category CI-4 is intended foruse with cooled EGR engines meeting2002 and later exhaust emissionregulations.

Non-EGR Engines — API CI-4 orCH-4 oils are recommended for use inall non-EGR engines.

Engines Built Prior to 1998 —Lubricants meeting API Service


HOW-TO SECTION

Category CG-4 may be used inengines built prior to 1998 when APICI-4 or CH-4 oils are not available.

NOTE:The use of CG-4 oils in theseengines may require a reduction inoil drain interval, depending upon theapplication and the fuel sulfur level.

Cold Weather Starting

At ambient temperatures below –20°C (–4 °F) when sufficient starterspeed cannot be achieved with SAE15W-40 oils, the use of 5W-XX oilsand 10W-XX oils, where XX is 30 or40, is allowed to improve startability,provided they are API CI-4 (forEGR-equipped engines) or API CI-4or CH-4 (for non-EGR-equippedengines) and have demonstrated fieldperformance in DDC engines. Theseoils must possess a HT/HS of 3.7minimum.

NOTICE:Monograde oils should notbe used in Series 50 engines,regardless of API serviceclassification. Monograde oilsgel at lower ambient temperatures,reducing lubricant flow, andthey do not provide adequatelubricity at higher engine operatingtemperatures. These factors canresult in severe engine damage.

NOTE:Do not use fuel with sulfur contentabove 0.05 mass percent for DetroitDiesel EGR-equipped engines.

When the use of high sulfur fuel(greater than 0.05% mass sulfur) innon-EGR engines is unavoidable,high alkalinity (TBN) lubricantsare recommended. High sulfurfuels require modification tooil drain intervals. For furtherinformation, refer to publicationEngine Requirements – LubricatingOil, Fuel and Filters, 7SE270,available from authorized DetroitDiesel distributors.

Synthetic Oils

Synthetic oils may be used in DetroitDiesel engines, provided they are APIlicensed and meet the performanceand chemical requirements ofnon-synthetic oils outlined in thispublication. Synthetic oils offerimproved low-temperature flowproperties and high-temperatureoxidation resistance. However,they are generally more costly thannon-synthetic oils.

Product information about syntheticoils should be reviewed carefully.Performance additive systems oftenrespond differently in synthetic oils.Their use does not permit extension ofrecommended oil drain intervals.



The Use of SupplementalAdditives

Lubricants meeting the DetroitDiesel specifications outlined in thispublication already contain a balancedadditive treatment. Supplementaladditives are generally not necessaryand can even be harmful. Theseadditives may be marketed as eitheroil treatments or engine treatmentsand are discouraged from use inDetroit Diesel engines. Enginedamage resulting from the use ofsuch materials is not covered byyour Detroit Diesel Corporationwarranty. Detroit Diesel will notprovide statements beyond thispublication relative to their use.

When to Change Oil

USED ENGINE OIL

To avoid injury to skin fromcontact with the contaminants inused engine oil, wear protectivegloves and apron.

The length of time an engine mayoperate before an oil change dependsupon the lubricant and fuel used,engine oil consumption, and theoperating cycle. The maximuminterval at which the engine mayoperate before the oil and filters mustbe changed is listed in Table 20.

Engine Application Drain Interval

Highway Truck & Motor Coach 15,000 Miles (24,000 km)

City Transit Coach# 6,000 Miles (9,600 km), 300 Hours or3 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 comesfirst

Stationary Generator, Prime Power orContinuous

300 Hours or 3 Months, whichevercomes first

Stationary Generator, Standby 150 Hours or 1 Year, whichever comesfirst

# All Series 50 transit coach engines, except model 6047MK1E.

Table 20 Maximum Oil Drain and Filter Change Interval (Fuel Sulfur0.05 Weight Percent or Less)


HOW-TO SECTION

Oil analysis may be used to determinewhether this interval should beshortened, but it should not be used tolengthen the interval.

The use of fuels with sulfur contentabove 0.05 mass percent will requirea shortening of drain intervals and/orthe use of a higher TBN oil. Seethe information listed in Table 20.For detailed information refer topublication Engine Requirements –Lubricating Oil, Fuel and Filters(7SE270), available from authorizedDetroit Diesel distributors.

Disposing of Waste Oil

Dispose of used lubricating oiland filters in an environmentallyresponsible manner, accordingto federal (EPA) and/or staterecommendations. The disposal ofwaste oil may be best addressed by theengine oil supplier, who may acceptresponsibility for proper disposal ofthis material as part of the business ofproviding lubricant.

How to Replace the LubeOil FiltersFilters are an integral part of thelubricating oil system. Properfilter selection and maintenanceare important to satisfactory engineperformance and service life. Filtersshould be used to maintain a cleansystem, not to clean up a contaminated

system. Filter part numbers are listedin the Specifications section of thisguide.

Replace Spin-On Type Oil Filter

Replace spin-on type filters as follows:

1. Place a suitable container underthe engine oil pan, remove drainplug and drain the lubricatingoil. Replace the drain plug andtighten securely.

2. Remove spin-on filters using toolJ 29917, or equivalent, and a1/2-inch drive socket wrench andextension.

Figure 23 Spin-On Oil Filters



3. Dispose of used oil andfilters in an environmentallyresponsible manner, accordingto federal (EPA) and/or staterecommendations.

4. Clean the filter gasket-contactsurface of the adaptor head with aclean, lint-free cloth.

5. Fill the new filters with cleanlubricating oil and lightly coat thefilter gaskets with the same oil.

6. Start the new filters on the adaptorhead and tighten by hand untilthe gaskets touch the mountingadaptor head. Tighten filters anadditional two-thirds turn byhand, or as indicated on thefilter.

NOTICE:Do not overtighten filters.Overtightening may crack ordistort the filter adaptor.

7. Add oil as required to bring thelevel to the “Full” mark on thedipstick.

PERSONAL INJURY





8. Start and run the engine fora short period and check forleaks. After any leaks have beencorrected, stop the engine longenough for oil from various partsof the engine to drain back tothe crankcase (approximately 20minutes). Add oil as required tobring the level to the “Full” markon the dipstick.


HOW-TO SECTION

NOTICE:If the engine oil level is constantlyabove normal and excess lubeoil has not been added to thecrankcase, consult with anauthorized Detroit Diesel serviceoutlet for the cause. Fuel or coolantdilution of lube oil can result inserious engine damage.

How to Select Fuel OilDetroit Diesel engines are designed tooperate on most diesel fuels marketedtoday.

Quality

Fuel quality is an important factorin obtaining satisfactory engineperformance, long engine life, andacceptable exhaust emission levels.

In general, fuels meeting theproperties of ASTM designationD 975 (grades 1-D and 2-D) haveprovided satisfactory performance.

The fuels used must be clean,completely distilled, stable, andnon-corrosive. For more informationregarding the significance of theseproperties and selection of the properfuel, refer to publication, EngineRequirements – Lubricating Oil, Fueland Filters (7SE270), available fromauthorized Detroit Diesel distributors.

Fuel Contamination

Generally, fuel contaminationoccurs as the result of improper fuelhandling. The most common typesof contamination are water, dirt, andmicrobial growth (“black slime”).The formation of varnishes andgums resulting from poor stability orextended storage (“stale fuel”) alsoaffects fuel quality. The best treatmentfor contamination is prevention bymaintaining a clean storage systemand choosing a reputable fuel supplier.

Supplemental additives are notrecommended due to potentialinjector system or engine damage.Our experience has been that suchadditives increase operating costswithout providing benefit.

The use of supplemental fuel additivesdoes not necessarily void the enginewarranty. However, repair expenseswhich result from fuel system orengine component malfunctionsor damage attributed to theiruse will not be covered. Theseproducts should be accompanied byperformance data supporting theirmerit. It is not the policy of DetroitDiesel Corporation to test, evaluate,approve or endorse such products.



Prohibited Additives

The following fuel additives are notallowed and MUST NOT be mixedwith diesel fuel.

Used Lubricating Oil — DetroitDiesel specifically prohibits theuse of used lubricating oil in dieselfuel. Used lubricating oil containscombustion acids and particulatematerials which can severely erodefuel injector components, resulting inloss of power and increased exhaustemissions. In addition, the use ofdrained lubricating oil will increasemaintenance requirements due to filterplugging and combustion deposits.

Gasoline — The addition ofgasoline to diesel fuel will create aserious fire hazard. The presenceof gasoline in diesel fuel will reducefuel cetane number and increasecombustion temperatures.

FIRE

To avoid increased risk of a fuelfire, do not mix gasoline anddiesel fuel.

Tanks which contain such mixturesshould be drained and cleaned as soonas possible.

Detroit Diesel Corporation will not beresponsible for any detrimental effectsit determines resulted from addingdrained lubricating oil or gasoline tothe diesel fuel.

How to Replace the FuelFiltersFilters are an integral part of thefuel system. Proper filter selectionand maintenance are important tosatisfactory engine operation andservice life. Filters should be used tomaintain a clean system, not to cleanup a contaminated system. Referto the Specifications section of thisguide for proper filter selection.

Spin-on type primary and secondaryfuel filters are used on Series 50engines. The spin-on type filterconsists of a shell, element and gasketunitized into a single cartridge and afilter adaptor which includes threadedinserts to accept the spin-on cartridges.An optional fuel/water separator maybe installed in place of the standardprimary filter.


HOW-TO SECTION

Replace Spin-On Type Primaryor Secondary Fuel FilterElements

Replace spin-on fuel filter elements asfollows:

1. Shut down the engine and allowit to cool.

2. With the engine at ambienttemperature and cool to the touch,place a suitable container underthe filter.

3. A fuel shutoff valve may beinstalled on the discharge sideof the secondary fuel filter. Ifinstalled, turn the handle onthe shutoff valve to the closedposition (perpendicular to thevalve).

NOTICE:To improve engine starting, havereplacement filters filled with fueland ready to install immediatelyafter used filters are removed. Thiswill prevent possible siphoning andfuel system aeration.

4. Using a suitable band type filterwrench, remove the primaryand secondary fuel filters.See Figure 24. Dispose of thefilters in an environmentallyresponsible manner, accordingto federal (EPA) and/or staterecommendations.

5. If not previously filled, fill newreplacement filters with cleandiesel fuel and coat the gasketslightly with the fuel oil.

6. Thread the new filters onto theadaptor inserts until the gasketsmake full contact with the adaptorhead and no side movementis evident. Tighten filters anadditional one-half turn by hand,or as indicated on the filter.

Figure 24 Typical Spin-On TypeFuel Filter



NOTICE:Do not overtighten the filter.Overtightening may crack or distortthe adaptors.

7. Turn the handle on the shutoffvalve to the Open position (inline with the valve).

PERSONAL INJURY





8. Start the engine and check forleaks. Shut down the engine.Correct any leaks with the engineoff.

If the engine fails to start after filterreplacement, the fuel system willrequire priming with tool J 5956, or

equivalent. Authorized Detroit Dieseldistributors are properly equipped toperform this service.

NOTICE:Under no circumstances shouldthe starting motor and fuel pumpbe used to prime the fuel filters.Prolonged used of the starting motorand fuel pump to prime the fuelsystem can result in damage to thestarter, fuel pump and injectors andcause erratic running of the enginedue to the amount of air in the fuellines and filters.

Replace Fuel/Water SeparatorElement

If an optional primary filter/waterseparator is installed, replace theelement as follows:



3. A fuel shutoff valve may beinstalled on the discharge sideof the fuel/water separator. Ifinstalled, turn the shutoff valvehandle to the closed position(perpendicular to the valve).

4. Drain off some fuel by openingthe drain


HOW-TO SECTION

5. Using a strap wrench, removethe element and bowl together,then remove the bowl from theelement. The filter and bowlhave right-hand threads, so turncounter-clockwise to remove.

6. Clean the bowl and O-ring seal.

7. Apply a light coating or cleanfuel or grease to the O-ring seal,thread the bowl onto the new filterand tighten by hand.

NOTICE:To avoid damaging the bowl orthe filter, do not use tools whentightening.

8. Apply a light coating of clean fueloil or grease to the new O-ringseal on the top of the filter. Threadthe filter and bowl assembly ontothe filter head and tighten byhand until snug.

9. To eliminate air from the filter,operate the primer pump on thefilter head (if equipped) until thefuel purges at the filter assembly.

10. Start the engine and check forleaks. Shut down the engine.Correct leaks with the engine off.

Replace “Fuel Pro® 382/382E”Fuel Filter Element

The Fuel Pro 382/383E diesel fuelfilter system consists of a permanentlymounted fuel processor, a replaceablefilter element and sealing grommetassembly, a filter spring, as see-thrucover and seal, a cover collar, and avent cap and seal. See Figure 25.

Figure 25 Fuel Pro 382E FuelProcessor Assembly



The Fuel Pro 382E system alsoincludes a fuel heater element,thermostatic switch and wiringharness.

Replace the element as follows:



3. A fuel shutoff valve may beinstalled on the discharge side ofthe fuel filter. If installed, turn thehandle on the shutoff valve to theclosed position (perpendicular tothe valve).

4. Open the drain valve at the baseof the fuel processor and drain thefuel until it is below the bottomof the filter in the see-thru cover.Close the drain valve. The fuelmay be returned to the tank.

5. Using filter collar/vent capwrench part number 232002 orequivalent, remove the collarby turning counter-clockwise.Remove the cover, filter springand cover seal ring by liftingstraight up and over the filterelement.

6. Remove the element from thecenter stud (fuel outlet pipe)by pulling upward and twistingslightly.

NOTE:Current filter elements include anintegral sealing grommet. If a formerelement is replaced, make sure theseparate sealing grommet is removedfrom the center stud before installingthe new element.

7. Dispose of the used element andgrommet in an environmentallyresponsible manner, accordingto federal (EPA) and/or staterecommendations.

8. Check to make sure the sealinggrommet is included in the baseof the replacement filter element,then install the element onto thecenter stud by pushing down andtwisting slightly.

9. Check to make sure the spring isinstalled at the top of the cover.If missing, this spring must bereplaced to insure proper filteroperation. Wipe the cover lip andcover seal clean.

NOTICE:To avoid cover or collar damage,do not use a wrench to tighten thecollar.

10. After making sure the seal isproperly positioned at the base ofthe cover, install the cover andcollar onto the fuel processor.


HOW-TO SECTION

Tighten the collar by hand untilsecure.

11. Using filter collar/vent capwrench 232002 or equivalent,remove the vent cap from the topof the cover by turning the capcounter-clockwise. Fill the coverfull of clean fuel.

NOTICE:To avoid cover or vent cap damage,do not use tools to tighten the ventcap.

12. After making sure the O-ringseal is installed on the vent cap,reinstall the cap and tighten byhand.

13. Open the fuel shutoff valve (ifinstalled) and start the engine.When the lubrication systemreaches its normal operatingpressure, increase engine speed tohigh idle for 2 to 3 minutes.

NOTICE:Do not allow the fuel level in thesee-thru cover to fall below the topof the collar, since this may leadto interruption of the fuel flow andengine stalling.

14. After the air is purged and withthe engine still running, loosen

the vent cap. The fuel level inthe cover will start falling. Whenthe fuel level falls to the top ofthe collar, tighten the vent capquickly by hand.

15. Shut down the engine and tightenthe collar again by hand .

16. Restart the engine and check forleaks.

NOTE:The filter cover will not fill completelyduring engine operation. It willgradually fill over time, and the fuellevel will rise as the filter mediumbecomes clogged. The filter elementdoes nor require changing untilthe fuel level has risen to the topof the element, or after one year ofservice, whichever comes first.



Engine Out of Fuel — Howto RestartWhen an engine has run out of fuel,there is a definite procedure to followwhen restarting it.

NOTICE:Under no circumstances shouldthe starting motor and fuel pumpbe used to prime the fuel filters.Prolonged used of the starting motorand fuel pump to prime the fuelsystem can result in damage to thestarter, fuel pump and injectors andcause erratic running of the enginedue to the amount of air in the fuellines and filters.

Engines with Spin-On Filters

Use the following procedure for anengine with spin-on filters.

1. Fill the fuel tank with therecommended grade of fuel. Ifonly partial filling is possible,add a minimum of 10 gallons (38liters) of fuel to the tank.

2. Close the fuel shutoff valve (ifinstalled) on the secondary filterhead and remove the spin-onfuel filters. Fill with clean fuelthrough the fuel inlet holes (theouter ring of small holes on theelement) to insure the fuel isfiltered. Thread the elementsonto the adaptor inserts until the

gaskets make full contact withthe adaptor head and no sidemovement is evident. Tightenfilters an additional one-half turnby hand, or as indicated on thefilter.

3. Open the fuel shutoff valve (ifinstalled), start the engine andcheck for leaks. Shut down theengine before correcting leaks.

NOTE:If the engine fails to start afterreplacement of fuel filters, the fuelsystem will require priming with toolJ 5956, or equivalent. AuthorizedDetroit Diesel distributors are properlyequipped to perform this service.

Engines with Fuel Pro Filters

Use the following procedure for anengine with Fuel Pro filters:

NOTICE:To avoid cover or vent cap damage,do not use tools to tighten the ventcap.

1. Remove the vent cap fromthe top of the filter by turningcounter-clockwise. Fill the coverfull of clean fuel. After makingsure the O-ring seal is installed onthe vent plug, reinstall the plugand tighten by hand only.


HOW-TO SECTION

NOTICE:Do not allow the fuel level in thesee-thru cover to fall below the topof the collar, since this may leadto interruption of the fuel flow andengine stalling.

2. Start the engine and allow thelubrication system to reach itsnormal operating pressure, thenincrease engine speed to high idlefor 2 to 3 minutes. After the air ispurged and with the engine stillrunning, loosen the vent cap onthe filter cover. the fuel level inthe cover will start falling. Whenthe fuel level falls to the top ofthe collar on the Fuel Pro cover,tighten the vent cap quickly byhand.

NOTE:If the engine fails to start afterreplacement of fuel filters, the fuelsystem will require priming with toolJ 5956, or equivalent. AuthorizedDetroit Diesel distributors are properlyequipped to perform this service.

How to Select CoolantThe section coves selection of therequired coolant for Series 50 engines.

Definitions

This section covers selection ofthe required coolant for Series 50engines. To help ensure completeunderstanding of the information, thedefinitions of the following terms areprovided:

Antifreeze — Ethylene glycolor propylene glycol containing acorrosion inhibitor package and whichmeets an appropriate heavy-dutyspecification (i.e., TMC RP-329 forethylene glycol or TMC RP-330 forpropylene glycol).

Coolant — The fluid mixturecirculating in the engine coolingsystem, typically a mixture of 50%water and 50% antifreeze.

Drop-Out — Precipitated sludge ordeposit formation on cooling systemcomponents.

Fully Formulated Antifreeze —Contains all the necessary inhibitorsto protect a diesel engine, and doesnot, therefore, require a pre-charge ofSCA before its first use.

Initial–Fill Coolant — The coolantthat is used in a new or rebuilt engine,or any time the cooling system isemptied and then refilled with coolant.



OAT — Organic Acid Technology.An inhibitor system based onorganic acid inhibitors, instead oftraditional North American inhibitorformulations.

SCA — Supplemental CoolantAdditive. SCAs are used in apreventive maintenance program toprevent corrosion, cavitation, and theformation of deposits.

Approved Coolants

The approved and preferredcoolants for Series 50 enginesare listed in Table 21. Once installed,

these coolants should be maintainedaccording to the procedures discussedunderMaintenance in this section.

NOTICE:Required specifications for water,ethylene glycol, propylene glycol,inhibitor packages and inhibitorconcentration are included inthis section. To avoid possibleengine damage from inadequateor overconcentrated coolant,this information should be readthoroughly before the coolant isreplaced.

Coolant Fill Option Product

Ethylene Glycol & Water + CorrosionInhibitors 1

DDC Power Cool

Commercial Equivalent of DDC PowerCool

Fully Formulated TMC RP-329 Type AAntifreeze & Water

Propylene Glycol & Water + CorrosionInhibitors 1

DDC Power Cool Plus

Ethylene Glycol & Water + OATInhibitors

DDC Power Cool Plus

Water Only + Corrosion Inhibitors 2 Water + DDC Power Cool 3000

Water Only + OAT Inhibitors 2 Water + DDC Power Cool Plus 60001 Preferred Coolant2 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


HOW-TO SECTION

Ethylene Glycol & Water PlusSCA Inhibitor or PropyleneGlycol & Water Plus SCAInhibitor — These products areavailable as fully formulated,phosphate-free, extended serviceinterval (ESI) coolants. They arecommercially available from DetroitDiesel (recommended) and othermanufacturers as either a concentratedantifreeze or as a pre-mixed antifreeze.The pre-mixed antifreeze is ready foruse, while the concentrated coolantmust be mixed with water prior to use.

Detroit Diesel Power Cool enginecoolant (part number 23512138)is the preferred ethylene glycolcoolant. If other commercial brandsof ethylene glycol are used, theymust be equivalent to the Power Cool(see following paragraph). DetroitDiesel does not market a propyleneglycol coolant. If a propylene glycolcoolant is used, it must also meet therequirements listed in the followingparagraph.

Fully formulated ethyleneglycol-based, low silicate antifreezeor coolant must meet TMC RP-329“Type A” requirements. Fullyformulated propylene glycol-basedantifreeze or coolant must meet TMCRP-330 “Type A” requirements. Fullyformulated antifreeze does not requirea dosage of SCA (supplementalcoolant additive) prior to initial use.

Mixing EG or PG Antifreezeand Water — If a concentratedethylene glycol (EG) or propyleneglycol (PG) antifreeze is purchased,mix the antifreeze with water meetingthe required quality standardslisted in Table 24 and fill the coolingsystem.

If a pre-diluted, fully formulatedcoolant is purchased, simply fillthe cooling system. For bestoverall performance, a coolantconsisting of 50% concentrationof antifreeze (50% antifreeze,50% water) is recommended. Anantifreeze concentration over 67%(67% antifreeze, 33% water) isnot recommended due to poor heattransfer, reduced freeze protection(IEG only), and possible silicatedropout. An antifreeze concentrationbelow 33% (33% antifreeze, 67%water) offers too little freeze and/orcorrosion protection and is notrecommended.



See Figure 26 for ethylene glycol-basecoolant concentration versus freezingand boiling temperatures.

Figure 26 Coolant Temperatures vs. IEG Concentration (Sea Level)


HOW-TO SECTION

See Figure 27 for propyleneglycol-base coolant concentrationversus freezing and boilingtemperatures.

Always verify that the freeze pointand nitrite concentration of the

antifreeze/water mixture are correctby using a POWER Trac® 3–WayCoolant Test Strip. If chemicalanalysis is used, elements in thecoolant must fall within the limitslisted in Table 22.

Figure 27 Coolant Temperatures vs. IPG Concentration (Sea Level)



Fully Formulated Glycol Coolant Concentration LimitsBoron 125 – 500 PPM

Nitrite 900 – 3200 PPM

Nitrate 200 – 3200 PPM

Silicon 50 – 250 PPM

Phosphorous 0 PPM

pH 8.0 – 11.0

Table 22 Fully Formulated Glycol Coolant Limits with TMC RP-329,TMC RP-330 Chemistry Type A (50/50 Coolant/WaterMixture)

Recycled Antifreeze — Antifreezeor coolant recycled by reverseosmosis, distillation, and ionexchange, properly re-inhibitedto meet TMC RP-329 Type A orTMC RP-330 Type A requirements,has been demonstrated to provideservice equivalent to virgin antifreeze.Recycled antifreeze or coolants ofthese types are preferred. Otherrecycled coolants, especially coolantsrecycled through filtration processes,are not recommended.

Ethylene Glycol/Water +OAT Inhibitor or PropyleneGlycol/Water + OAT Inhibitor —Ethylene glycol and propylene glycolare also available with an OAT (Organic Acid Technology) corrosionpackage. These coolants require lessmaintenance over the useful life of theengine. OAT coolants, maintained asdetailed in the Maintenance section

of this guide, may be operated up to4 years, 600,000 miles (960,000 km),or 10,000 operating hours, whichevercomes first. Refer to section CoolantMaintenance. The cooling systemshould either be equipped with a“blank” coolant filter, or the coolantfilter and piping may be omitted fromthe system.

OAT fully formulated antifreezesare available as concentrated andpre-mixed. Concentrated antifreezesshould be mixed 50% (50% antifreeze,50% water).

OAT coolants should not be mixedwith conventional coolants. If theyare mixed, no damage will result, butthe long-life advantages of the OATcoolant will be lost. In this event,the coolant should be maintained as afully formulated IEG coolant, not asan OAT (Organic Acid Technology)coolant.


HOW-TO SECTION

Detroit Diesel markets a OAT-inhibited ethylene glycol coolant,DDC Power Cool Plus, whichcontains all the required additives.If a non-DDC OAT antifreeze isused, it must conform to TMC 338specification. Do not add extender tonew OAT antifreeze or coolant.

Water Only + SCA or WaterOnly + OAT Inhibitor — Inwarm climates a coolant basedon water with corrosion inhibitorsis approved for use. Water-onlysystems need to be treated with theproper dosage of corrosion inhibitors.Detroit Diesel-approved SCAs orOAT corrosion inhibitors must beadded to the water to provide requiredcorrosion and cavitation erosionprotection. OAT inhibitors such asPower Cool Plus 6000 are availablefor water-only systems. Inhibitor

should be mixed at 7.5% – 10% byvolume with water. For a list ofPower Cool products, refer to sectionSPECIFICATIONS in this guide.Traditional SCA (Power Cool 3000)can also be used to protect the engine.Power Cool 3000 concentration limitsare listed in Table 23.

NOTE:Do not use Power Trac 3–Way TestStrips to test OAT coolant.

Power Cool 3000 SCA inhibitorsshould be mixed at 5% by volumewith water. This is 1 quart per 5gallons of water. These additionscan be made by adding liquid SCAsavailable in a variety of sizes. Coolantfilters are also available for differentcooling system capacities. Thesefilters release the proper amount ofSCA at initial fill.

Power Cool 3000 Coolant Concentration LimitsBoron 125 – 500 PPM

Nitrite 900 – 3200 PPM

Nitrate 0 – 1000 PPM

Silicon 50 – 250 PPM

Phosphorous 0 PPM

pH 8.0 – 11.0

Table 23 Power Cool 3000 Concentration Limits (5% Power Cool3000/ 95% Water)

Water Requirements —Distilled, reverse osmosis-purified,

or de-ionized water which eliminatesthe adverse effects of minerals in



tap water is preferred. High levelsof dissolved chlorides, sulfates,magnesium, and calcium in some tapwater causes scale deposits and/orcorrosion. These deposits have beenshown to result in water pump failuresand poor heat transfer, resulting inoverheating. If tap water is used, themineral content in the water must bebelow the maximum allowable limitslisted in Table 24.

NOTICE:Do not add additional SCA tonew, fully formulated antifreeze orcoolant. This can result in dropoutand/or the formation of deposits.

Coolants Not Recommended

The coolants in the following sectionsare not recommended for use inDetroit Diesel engines.

All Antifreezes and CoolantsContaining Phosphate — Thesecoolants should be avoided. Dropout, overheating and water pump sealfailures can result from the use ofcoolant or inhibitor packages based onphosphate.

Automotive Type Coolants —These coolants generally contain highlevels of phosphate and silicate, offerno liner pitting protection, and arenot suitable for use in Detroit Dieselengines.

Maximum AllowableTap 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


HOW-TO SECTION

Methyl Alcohol-BasedAntifreeze — This coolantmust not be used because of its effecton the non-metallic components ofthe cooling system and its low boilingpoint.

Methoxy Propanol-BasedAntifreeze — This coolant must notbe used because it is not compatiblewith the fluoroelastomer seals foundin the cooling system.

Glycol-based CoolantsFormulated For HVAC —These coolants formulated forheating/ventilation/air conditioning(HVAC) should not be used. Thesecoolants generally contain high levelsof phosphates, which can depositon hot internal engine surfaces andreduce heat transfer.

Additives Not Recommended

The additives in the following sectionsare not recommended for use in Series50 engines cooling systems.

Soluble Oil Additives —These additives are not approvedfor use because a small amountof oil adversely affects heattransfer. For example, a 1.25%concentration of soluble oil increasesfire deck temperature 6%. A 2.50%concentration increases fire deck

temperature 15%. The use of solubleoil additives may result in engineoverheating and/or failure.

Chromate Additives — Theseadditives are not approved for usebecause chromate additives can formchromium hydroxide, commonlycalled “green slime.” This, in turn,can result in engine damage due topoor heat transfer. Cooling systemsoperated with chromium-inhibitedcoolant must be chemically cleanedwith Power Cool dry chemicalcooling system cleaner/conditioner(or equivalent sulfamic acid/sodiumcarbonate cleaner) and flushed.

Coolant Maintenance

Coolant maintenance involveschecking the coolant inhibitor levelsat regular intervals and checking toensure that the coolant has the properconcentration of SCA.

Coolant Inhibitor Test Intervals— The coolant inhibitor levelshould be checked at the intervalslisted in Table 25. If topping off isneeded, add coolant which is identicalto the initial fill coolant.



Service Application Inhibitor Test IntervalOn-Highway Trucks and MotorCoaches 20,000 Miles (32,000 Kilometers)

City Transit Coaches, Pick-Up andDelivery, Short Trip, and EmergencyVehicles

6,000 Miles (9,600 Kilometers) or3 Months, whichever comes first

Industrial, Continuous– DutyGenerator Set and All OtherApplications, except StandbyGenerator Set

500 Hours or 3 Months, whichevercomes first

Stand-By Generator Set 200 Hours or Yearly, whichever comesfirst

Table 25 Required Coolant Inhibitor Test Intervals

Supplemental Coolant Additivesfor Fully Formulated Coolant— The concentrations of someinhibitors will gradually depleteduring normal engine operation.SCAs replenish the protection forcooling system components. Thecoolant must be maintained with theproper concentration of SCA. DetroitDiesel Power Cool maintenanceSCAs are recommended. The properapplication of SCA will provide:

□ pH control.

□ Restored inhibitor levels to preventcorrosion.

□ Water softening to deter formationof mineral deposits.

□ Cavitation protection to protectwet sleeve cylinder liners.

NOTICE:Failure to properly maintaincoolant with SCA can result indamage to the cooling systemand its related components.Conversely, over-concentrationof SCA inhibitor can result inpoor heat transfer, leading toengine damage. Always maintainconcentrations at recommendedlevels. Do not use traditional SCAswith OAT coolant.


HOW-TO SECTION

Coolant MaintenanceIntervals — Check the nitriteconcentration at the regular intervalslisted in Table 26 with a Power Trac3–Way Test Strip. Nitrite levels mustbe within the ranges listed in Table22. Additional SCA must be added tothe coolant when it becomes depleted,as indicated by a nitrite concentrationof 900 PPM or less. If the nitriteconcentration is greater than 900PPM, do not add additional SCA. Ifthe nitrite concentration is above 3200PPM, the system is over-inhibited andshould be partially drained and filledwith a 50/50 mix of water and EG orPG.

In this case the EG or PG shouldcontain no inhibitors and shouldconform to ASTM D4985. Thiswill dilute the over-concentratedinhibitors.

NOTE:In non-OAT systems, nitriteconcentration of 5000 PPM orhigher on a Series 50 enginesuggests problematic additiveover-concentration. This conditionmust be corrected by immediatedraining and flushing of the coolingsystem. Refill the system with new fullyformulated or pre-charged coolant.Check the nitrite concentration level atthe next maintenance interval with aPower Trac 3–Way Test Strip.



Coolant Interval 1 ActionA. 20,000 Miles (32,000 km)or 3 Months*B. 500 Hours or 3 Months*

Test nitrite concentrationwith test strip. AddSCA or dilute coolant asneeded.

Antifreeze / Water +SCA Inhibitor(DDC Power Cool) A. 300,000 Miles

(480,000 km)B. 2 Years or 4,000 Hours*

Drain and clean system.Replace with newcoolant.

A. 20,000 Miles (32,000 km)or 3 Months*B. 500 Hours or 3 Months*


Ethylene Glycol/ Water + SCAInhibitororPropylene Glycol/ Water + SCAInhibitor

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

Add Power Cool PlusExtender

Ethylene Glycol /Water + OAT InhibitororPropylene Glycol /Water + OAT Inhibitor

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*


Water Only + SCAInhibitor 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

Add Power Cool PlusExtenderWater Only + OAT

Coolant A. 600,000 Miles(960,000 km)B. 4 Years or 10,000 Hours

Clean and drain.Replace with newcoolant.

1 Maintenance interval based on application. Drain interval dependenton 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


HOW-TO SECTION

SCA Test Procedures

Detroit Diesel Power Trac 3–WayCoolant Test Strips should beused to measure nitrite andglycol concentrations. Partnumbers are Listed in Table 46.Cavitation/corrosion is indicatedon the strip by the level of nitriteconcentration. Freeze/boil overprotection is determined by glycolconcentration.

HOT COOLANT


For best results make the test whilethe coolant is between 50 – 140 °F(10.0 – 60 °C). Wait at least 60, butnot longer than 75, seconds beforereading the nitrite level. Use the teststrips as follows:

1. Dip the strip into coolant forone second. Remove and shakebriskly to eliminate excess fluid.

2. Immediately compare the pad end(% glycol) to the color chart onthe container.

3. Sixty seconds (one minute) afterdipping, compare the nitrite padto the color chart.

4. Color change of the additiveindicator (middle pad) indicatesthe presence of inhibitor that isnot approved by Detroit Diesel.

Promptly replace and tighten the teststrip container cap after each use.Discard unused strips if they haveturned light pink or tan.

A factory coolant analysis programis available through authorizedDetroit Diesel service outlets. Partnumbers are listed in Table 46 in theSpecifications section. To verifycoolant acceptability, submit a samplefor coolant analysis every three (3)years, 300,000 miles (480,000 km),or 6,000 operating hours, whichevercomes first.



Need-Release Coolant Filters(Non-OAT Systems)

Spin-on coolant filters are available forDetroit Diesel engines. Membranesin the filters release SCAs beforethe coolant approaches a corrosivecondition, protecting the engine fromcorrosion. The elements release theSCA charge as needed, as opposed tothe maintenance SCA elements, whichinstantaneously release the SCAcharge. Coolant filter elements shouldbe replaced after one (1) year, 120,000miles (192,000 km) or 2,000 operatinghours, whichever comes first.

Dropout

Excessive amounts of some inhibitorsin the coolant can cause a gel orcrystalline deposit that reduces heattransfer and coolant flow. The deposit,called “dropout,” takes the color ofthe coolant when wet, but appears as awhite or gray powder when dry. It canpick up solid particles in the coolantand become gritty, causing excessivewear of water pump seals and othercooling system components.

PERSONAL INJURY

To avoid injury when usingcaustic cleaning agents, followthe chemical manufacturersusage, disposal, and safetyinstructions.

The wet gel can be removed by usinga non-acid (alkali) type heavy-dutycleaner, such as Detroit Diesel PowerCool On-Line Cleaner (sodiumnitrite/sodium tetraborate). Partnumbers are listed in Table 45.

NOTE:If the gel is allowed to dry, it isnecessary to disassemble theengine and clean it with a causticsolution or physically clean individualcomponents.


HOW-TO SECTION

Coolant Extender InhibitorAdditive for “OAT” Coolant

The inhibitors in OAT coolant mustalso be maintained, but less oftenthan traditional SCA-type coolants.A portable test is available to test thelevels of OAT inhibitors in coolant.Where this is not used, fleet testinghas determined that a OAT coolantextender package should be added tothe coolant at 300,000 miles (480,000km), two (2) years, or 5,000 hours,whichever comes first. The propermaintenance dosages for all OATcoolants are listed in Table 26 ,reflecting 0.6% by volume extender.This dosage should be added to thewater-only and the glycol systems atthe same interval.

The proper application of extender toOAT coolant will provide:

□ pH Control

□ Restored inhibitor levels to preventcorrosion

□ Cavitation protection to protectwet sleeve cylinder liners

NOTE:Do not use traditional SCAs inOAT coolant, and do not useOAT extender in traditional coolant.

OAT Coolant Drain Interval —A properly maintained OAT-inhibitedcoolant will last 600,000 miles(960,000 km), four (4) years, or10,000 operating hours, whichevercomes first. At this time the coolantshould be drained, and the coolingsystem should be thoroughly cleaned,flushed, and filled with new, properlyinhibited OAT coolant.

Chronic Coolant SystemProblems

The most commonly seen coolantsystem problems result frommaintenance and formulation factorssuch as:

□ Hard water

□ Dilution of the coolant by theaddition of untreated water

□ Over dosage or under dosage ofcorrosion inhibitors

□ Improper corrosion inhibitor (mostoften phosphated)

□ Mixing SCAs

□ Improper testing



Detroit Diesel Cooling SystemMaintenance Products

The following products are availableto use for cooling system maintenance.

Power Cool SCAs — Power CoolSCAs are water-soluble chemicalcompounds. These products areavailable in coolant filter elements,liquid packages, and in fullyformulated Power Cool antifreeze.

NOTE:Power Cool 3000 liquid SCA is morecompatible with hard water thanPower Cool 2000 SCA.

Power Cool Coolant FilterElements — Power Cool coolantfilter elements (spin-on canisters) areavailable in various sizes suitable forcooling systems of varying capacities.Selection of the proper element sizeis vital when pre-charging non-fullyformulated coolant (i.e., water) atinitial fill and at maintenance intervals.A fully formulated antifreeze mustnot have SCA added at initial fill.Do not use SCA-containing filterswith OAT antifreeze or coolant.The need for maintenance elementsis determined by the results of thenitrite concentration test performedat each cooling system interval. Donot automatically install maintenanceelements at maintenance intervals,

unless the nitrite concentration fallsbelow 900 parts per million.

Power Cool Cleaners — PowerCool Liquid On-Line Cleaner is usedfor light deposits. Power Cool DryChemical Cleaner/Conditioner is usedfor heavy deposits or scale.

Summary of CoolantRecommendations

HOT COOLANT


1. Always maintain the enginecoolant to meet Detroit Dieselspecifications.

2. Only use water that meets thespecifications listed in Table 24.Distilled, de-mineralized (reverseosmosis) or de-ionized water ispreferred.

3. The proper dosage of inhibitorsmust be included in the coolantat initial fill for all Detroit Diesel


HOW-TO SECTION

engines. This dosage is usuallyincluded in the fully formulatedantifreeze used, or it may need tobe added if water alone or if lessthan 50% antifreeze is used. Theuser is urged to refer to the fulltext of this section to determinethe proper dosage. Mixingof different manufacturers'technologies (brands) could causecooling system problems.

4. Maintain the inhibitor at theprescribed concentration. Testthe nitrite concentration by usinga titration kit or Detroit DieselPower Trac 3-Way Coolant TestStrips. Add SCA only if the nitriteconcentration is below 900 PPM.Do not use SCA in OAT coolant,and do not use Power Trac 3-WayCoolant Test Strips to test OATcoolant.

5. Do not use another manufacturer'stest kit to measure the SCAconcentration of Detroit Dieselmaintenance products.

6. Pre-mix coolant makeup solutionsto the proper concentration beforeadding to the cooling system.

7. Do not mix OAT and othercoolants in the same engine.

8. Do not use automotive coolantsor coolants with phosphates.

9. Where antifreeze/boil overprotection is required, use only

antifreeze that meets TMCRP-329 “Type A” (EG) orTMC RP-330 “Type A” (PG)specifications. Always maintaincoolant at the proper level.

10. Do not use the following inDetroit Diesel engine coolingsystems:

□ Soluble oil

□ High silicate, automotive-typeantifreeze

□ Chromate SCAs

□ Methoxy propanol-basecoolant

□ Methyl alcohol-base coolant

□ Sealer additives or coolantcontaining sealer additives.

□ HVAC coolant

□ Phosphated coolants

Coolant Life of GlycolCoolant: — A properlymaintained cooling system, filled withphosphate-free coolant consisting of a50/50 mix of antifreeze and water perTMC RP-329 “Type A” (EG) or TMCRP-330 “Type A” (PG) specificationscan be operated for the life of theengine until overhaul.



The proper maintenance involvesperiodic evaluation using Power Trac3-Way Coolant Test Strips and theaddition of SCA as needed, indicatedby the strip test.

To verify coolant acceptability, submita sample for coolant analysis every300,000 miles (480,000 km), three(3) years, or 5,000 operating hours,whichever comes first. Submit thesample in a DDC Power Trac CoolantTest Bottle. Required part numbersare listed in Table 46.

Coolant Life of OAT Coolant — Aproperly maintained OAT coolant maybe operated 600,000 miles (960,000km), four (4) years, or until overhaul,whichever comes first. At this time thesystem must be completely drained,thoroughly cleaned, and refilled.

OAT Coolants require the addition ofan extender at 300,000 miles (480,000km), two (2) years, or 5,000 hours,whichever comes first. Use 1 pintof extender for every 20 gallons ofcoolant.

Coolant Life of Other Coolants—Other properly maintained coolantsmay be operated up to 250,000 miles(480,000 km), two (2) years, or 4,000operating hours, whichever comesfirst. At this time the system mustbe completely drained, thoroughlycleaned, and refilled.

How to Drain and Flush theCooling System

HOT COOLANT


1. With the engine cool, drain theprevious solution from the engineand radiator. Dispose of thecoolant in an environmentallyfriendly manner, accordingto state and/or federal (EPA)recommendations.

2. Refill the cooling systemwith clean, soft water and agood cooling system cleaningcompound, such as thoselisted in Table 45 in theSpecifications section. Ifthe engine is warm, fill slowlyto prevent the rapid cooling anddistortion of the metal castings.

3. Start the engine and operate it forfifteen minutes to circulate thesolution thoroughly.


HOW-TO SECTION

4. Stop the engine and allow it tocool.

5. With the engine cool, drain thecooling system completely.

6. Refill the cooling system withclean, soft water and operate it forfifteen minutes.

7. Stop the engine and allow it tocool.

8. With the engine cool, drain thecleaner residue from the coolingsystem.

9. Refill the system with the requiredcoolant. Refer to section How toSelect Coolant.

10. Entrapped air must be purgedafter filling the cooling system.To do this, allow the engine towarm up without the pressure capinstalled. With the transmissionin neutral, increase engine speedabove 1000 RPM and add coolantas required. Install the pressurecap after the coolant level hasstabilized at the bottom of theradiator filler neck.

NOTICE:If the engine overheats andthe coolant level is satisfactory,the cooling system may requirecleaning with a descaling solventand backflushing. AuthorizedDetroit Diesel service outlets areproperly equipped to perform theseservices.

In addition to the cleaning procedure,other components of the coolingsystem should be checked periodicallyto keep the engine operating at peakefficiency.

Hoses. Cooling system hoses shouldbe inspected and any hose that showsobvious signs of damage or feelsabnormally soft or hard should bereplaced. Damaged clamps shouldalso be replaced. All external leaksshould be corrected as soon asdetected.

NOTE:If Detroit Diesel Power Coolantifreeze/coolant (or equivalent fullyformulated, precharged antifreeze)is used, a precharge element is notrequired. Coolant inhibitor levelsmust be checked at the intervalslisted in Table 25.



When to Service the DryType Air CleanerReplace dry type air cleaner elementswhen the maximum allowable aircleaner restriction (20 inches ofwater or 5.0 kPa) has been reachedor annually, whichever comes first.Some air cleaners are equipped witha restriction indicator which aids indetermining the servicing interval.

Cleaning and/or reusing dry papertype air cleaner elements is notrecommended unless the cleaningmethod used removes cloggingwithout damaging the element.Inspection and cleaning of elementsmust be done in accordance withthe air cleaner manufacturer'srecommendations, if any.


BASIC TROUBLESHOOTING


This section covers basictroubleshooting of engine operationor performance malfunctions andtheir probable causes. In addition to

operating the engine carefully andmaintaining it properly, make sure tocorrect any malfunction promptly.

Objectionable Exhaust Symptoms and Probable Causes

Probable Causes Black orGray Smoke Blue Smoke White

SmokeDamaged or dirty aircleaner

X

Improper grade of fuel X

Excessive exhaust backpressure

X

Misfiring cylinders X

Lubricating oil not burnedin cylinder (being burnedin exhaust manifold orturbocharger)

X

Faulty injector timing X

Faulty oil control rings X

Excessive installation angle X

Excessive oil in crankcase X

High ambient temperature X

Thin air (high altitude) X

Cetane rating of fuel toolow

X

Air in the fuel system X



Hard Starting Symptoms and Probable Causes

Probable Causes Engine WillNot Rotate

LowCrankingSpeed

EngineCranks ButWill Not Start

Low Battery Voltage X X

Loose cranking motorconnections

X

Faulty cranking motor X X

Faulty cranking motor switch X X X

Internal seizure X

Improper lube oil X

Circuit breaker/electroniccontrol malfunction

X

Fuse blown or missing X

Insufficient Fuel SupplyAir 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 fuelcheck valve or shutoff valve

X

Low CompressionWorn intake and exhaustvalves

X

Worn piston rings/liners X

Leaking cylinder head gasket X

Improper intake and exhaustvalve adjustments

X



Abnormal Engine Operation Symptoms and Probable Causes

Probable Causes

RoughRunning orFrequentStalling

Low Power Detonation

Misfiring cylinder X X

Insufficient fuel X XHigh return fueltemperature X X

Low compression X X

DDEC malfunction X XHigh air inletrestriction/exhaust backpressure

X

Engine application XHigh air inlet temperature XHigh altitude operation XIncorrect engine gear traintiming X

Low coolant temperature XOil picked up by inletairstream X

Faulty injector operation XIncorrect injector heightsetting X X



Abnormal Operating Condition Symptoms and Probable Causes

Probable CausesHigh

Lubricating OilConsumption

Low OilPressure

Loose connections X

Cracked lines XDamaged gaskets or seal rings X

* Lube oil loss at breather tube X* Lube oil loss at dipstick tube XLeaking oil cooler XLeaking valve stem seals XWorn/broken oil control rings XScored liner and/or piston XExcessive engine installation angle X

Crankcase overfilled XOil in air tanks (air compressormalfunction) X

Plugged crankcase breather X

Oil level low XImproper engine oil viscosity (fuelin the oil) XFaulty oil pressure regulator orrelief valve XWorn crankshaft, camshaft orconnecting rod bearings XMissing cup plugs in rocker armshafts X

Air leaks in oil pump (suction side) XWorn or damaged oil pump XFaulty oil pressure gage XFaulty electrical components (forgage) X

Plugged oil line or orifice X

* Indicates high crankcase pressure



Abnormal Coolant Temperature Symptoms and Probable Causes

Probable Causes Above NormalTemperature

Below NormalTemperature

Restricted cooling systempassages X

Restricted radiator core passages X

Slipping fan drive belts X

Faulty temperature-controlled fan X

Obstruction in front of radiatoror intercooler X

Low coolant level X

Damaged hoses X

Faulty thermostats X

Faulty water pump X

Faulty radiator pressure cap X

Air in coolant X

Thermostats not fully closed X

Leakage around thermostat seals X

Faulty temperature-controlled fan X



ENGINE STORAGE

When an engine is to be stored orremoved from operation for a periodof time, special precautions shouldbe taken to protect the interior andexterior of the engine, transmissionand other parts from rust accumulationand corrosion. The parts requiringattention and the recommendedpreparations are given below.

Preparing the Engine forStorageIt will be necessary to remove allrust or corrosion completely fromany exposed part before applying rustpreventive compound. Therefore,it is recommended that the enginebe processed for storage as soon aspossible after removal from operation.

The engine should be stored ina building that is dry and can beheated during the winter months.Moisture-absorbing chemicals areavailable commercially for use whenexcessive dampness prevails in thestorage area.

Temporary Storage (30 Days orLess)

To protect the engine for a temporaryperiod of time (30 days or less), followthis procedure:

1. With the engine at ambienttemperature and cool to the touch,drain engine crankcase oil into asuitable container. Dispose of theoil in an environmentally friendlymanner, according to state and/orfederal (EPA) recommendations.

2. Fill the crankcase to the properlevel with the recommendedviscosity and grade of oil.

3. Fill the fuel tank with therecommended grade of fuel oil.Operate the engine for two (2)minutes at 1200 rpm and no load.Do not drain the fuel system orthe crankcase after this run.

4. Check the air cleaner and serviceit, if necessary.

5. If freezing weather is expectedduring the storage period, checkthe antifreeze/coolant for requiredfreeze and inhibitor protection.Add antifreeze solution to thecooling system in accordancewith DDC's recommendations.


ENGINE STORAGE

Refer to the How to SelectCoolant section.

NOTE:If an antifreeze solution is not requiredduring storage, flush the coolingsystem with a good soluble oil (3% –5% by volume) rust inhibitor to preventrusting of the outside diameter of thecylinder liners.

EYE INJURY


6. Clean the exterior of the engine(except electrical parts) with fueloil and dry with compressed air.

7. Seal all engine openings. Thematerial used must be waterproof,vaporproof and possess sufficientphysical strength to resistpuncture and damage from theexpansion of entrapped air.

An engine prepared in this manner canbe returned to service in a short timeby removing the seals at the engineopenings and by checking the enginecoolant, fuel oil, lubricating oil andtransmission oil levels.

Extended Storage (More than 30Days)

To prepare an engine for extendedstorage (more than 30 days), followthis procedure:

1. Drain the cooling system andflush with clean, soft water. Refillwith clean, soft water and adda rust inhibitor to the coolingsystem.

2. Circulate the coolant by operatingthe engine until normal operatingtemperature is reached.

3. Stop the engine.

4. With the engine at ambienttemperature and cool to the touch,drain the engine crankcase oilinto a suitable container. Removethe oil filters. Dispose of the oiland filters in an environmentallyfriendly manner, accordingto state and/or federal (EPA)recommendations. Replace thedrain plug and tighten to 45 – 50N·m (33 – 37 lb-ft) torque.

5. Install new lubricating oilfilters. Fill the crankcase tothe proper level with Tectyl®930A preservative lubricatingoil or an equivalent 30–weightpreservative lubricating oilmeeting Mil-L-21260C, Grade 2Specification.



6. Drain the fuel tank. Refill withenough clean No. 1 diesel fuelor pure kerosene to permit theengine to operate for about ten(10) minutes. If draining thefuel tank is not convenient, usea separate, portable supply ofrecommended fuel.

NOTE:If engines are stored wherecondensation of water in the fueltank may be a problem, additivescontaining methyl carbitol or butylcellusolve may be added to the fuel.Follow manufacturer's instructionsfor treatment. Where biologicalcontamination of fuel may be aproblem, add a biocide such asBiobor® JF (or equivalent) to thefuel. When using a biocide, followthe manufacturer's concentrationrecommendations and observe allcautions and warnings.

7. Drain the fuel system and removethe fuel filters. Dispose of usedfilters in an environmentallyresponsible manner, accordingto state and/or federal (EPA)recommendations. Fill the newfilters with No. 1 diesel fuel orpure kerosene and install on theengine.

8. Operate the engine for five (5)minutes to circulate the clean fuelthroughout the engine. Be surethe engine fuel system is full.

9. Stop the engine and allow tocool. Then disconnect the fuelreturn line and the inlet line atthe primary filter and securelyplug both to retain the fuel in theengine.

10. Transmission: Follow themanufacturer's recommendationsfor prolonged storage.

11. Power Take-Off: If equipped,follow manufacturer'srecommendations for prolongedstorage.

NOTICE:Failure to properly seal off theturbocharger air inlet and exhaustoutlet openings before enginestorage may permit air drafts tocirculate through the turbochargerand rotate the turbine/compressorshaft without an adequate flow oflubricating oil to the center housingbearings. This can result in severebearing damage.

12. Turbocharger: Sinceturbocharger bearings arepressure lubricated through theexternal oil line leading fromthe oil filter adaptor while theengine is operating, no furtherattention is required. However,the turbocharger air inlet andturbine exhaust outlet connection


ENGINE STORAGE

should be sealed off withmoisture-resistant tape.

13. Apply a non-friction rustpreventive compound to allexposed engine parts. Ifconvenient, apply the rustpreventive compound to theengine flywheel. If not, disengagethe clutch mechanism to preventthe clutch disc from sticking tothe flywheel.

NOTE:Do not apply oil, grease or anywax-base compound to the flywheel.The cast iron will absorb thesesubstances, which can “sweat” outduring operation and cause the clutchto slip.

14. Drain the engine cooling system.

15. Drain the preservative oil fromthe engine crankcase. Reinstalland torque the 3/4” – 14 square,magnetic drain plug to 45 – 50N·m (33 – 37 lb-ft).

16. Remove and clean the batteryand battery cables with a bakingsoda-water solution and rinsewith fresh water. Do not allowthe soda solution to enter thebattery. Add distilled water tothe electrolyte (if necessary) andfully charge the battery. Store thebattery in a cool (never below 0°C or 32° F) dry place. Keep the

battery fully charged and checkthe level and specific gravity ofthe electrolyte regularly.

17. Insert heavy paper strips betweenthe pulleys and drive belts toprevent sticking.

18. Seal all engine openings,including the exhaust outlet,with moisture-resistant tape. Usecardboard, plywood or metalcovers where practical.

19. Clean and dry the exterior paintedsurfaces of the engine and spraywith a suitable liquid automobilebody wax, a synthetic resinvarnish, or a rust preventivecompound.

20. Protect the engine with a goodweather-resistant tarpaulin andstore it under cover, preferablyin a dry building which can beheated during the winter months.

Outdoor storage of the engine is notrecommended. If units must be keptout of doors, follow the preparationand storage instructions alreadygiven. Protect units with quality,weather-resistant tarpaulins (or othersuitable covers) arranged to providefor air circulation.



NOTICE:Do not use plastic sheeting foroutdoor storage. Plastic is finefor indoor storage. When usedoutdoors, however, enough moisturecan condense on the inside of theplastic to rust ferrous metal surfacesand pit aluminum surfaces. If a unitis stored outside for any extendedperiod of time, severe corrosiondamage can result.

The stored engine should be inspectedperiodically. If there are anyindications of rust or corrosion,corrective steps must be taken toprevent damage to the engine parts.Perform a complete inspection at theend of one year and apply additionaltreatment as required.

Procedure for Restoring toService an Engine that Has Beenin Extended Storage

If an engine has been in extendedstorage, prepare it for service asfollows:

1. Remove the covers and tape fromall the openings of the engine, fueltank and electrical equipment. Donot overlook the exhaust outlet.

2. Remove the plugs from the inletand outlet fuel lines and reconnectthe lines to their proper positions.

3. Wash the exterior of the enginewith fuel oil to remove therust preventive. Do not washelectrical components.

4. Remove the rust preventive fromthe flywheel. Flush any solubleoil rust inhibitor (if used) in thecooling system.

5. Remove the paper strips frombetween the pulleys and drivebelts.

6. Fill the crankcase to the properlevel with the required grade oflubricating oil. Use a pressurelubricator to insure all bearingsand rocker shafts are lubricated.

7. Fill the fuel tank with the requiredfuel.

8. Close all drain cocks and fill theengine cooling system with clean,soft water and required inhibitors.If the engine is to be exposedto freezing temperatures, installgenuine Detroit Diesel PowerCool antifreeze or an equivalentethylene glycol-base or propyleneglycol-base antifreeze solutionwhich provides required freeze,boilover, and inhibitor protection.Refer to section How to SelectCoolant.


ENGINE STORAGE

9. Install and connect the battery.Make sure the average specificgravity of the battery is 1.260or higher. Charge the battery, ifnecessary.

10. Service the air cleaner, if required.

11. Transmission: Follow themanufacturer's recommendationscovering the return of thetransmission to service.

12. Power Take-Off: If equipped,follow the manufacturer'srecommendations covering thereturn of the power take-off toservice.

13. Turbocharger: Remove thecovers from the turbochargerair inlet and turbine outletconnections. Reconnectpiping as required. Prelubethe turbocharger center bearinghousing. Refer to sectionLubrication System Checks insection Preparations for Startingthe Engine the First Time.

PERSONAL INJURY





14. After all preparations arecompleted, start the engine.

NOTE:The small amount of rust preventivewhich remains in the fuel systemwill cause smoky exhaust for a fewminutes.

NOTE:Before subjecting the engine to aload or high speed, allow it to reachnormal operating temperature. Thenmonitor the DDEC Diagnostic DataLink (DDL) for trouble codes.



SERIES 50 SERVICE PUBLICATIONS

The service manual covering DetroitDiesel Series 50 engines and variousreference works which may be ofinterest to the owner/operator arelisted in Table 27.

To purchase a copy of any of thesepublications, contact an authorize

Detroit Diesel distributor in the U.S.or Canada. Check the Yellow Pagesunder “Engine, Diesel” or refer to theDistributor and Dealer Directory listedbelow for the distributor or serviceoutlet 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


CUSTOMER ASSISTANCE

CUSTOMER ASSISTANCE

The satisfaction and goodwill of theowners of Detroit Diesel engines areof primary concern to Detroit Diesel

Corporation and its distributor/dealerorganizations.



Detroit Diesel North American NAFTA On-Highway OfficesWestern RegionIrvine, California7700 Irvine Center, Suite 275Irvine, CA 92618Telephone: 949-753-7710Fax: 949-753-7711

Eastern RegionPiscataway, New Jersey169 Old New Brunswich RoadPiscataway, NJ 08854Telephone: 732-926-9622Fax: 732-926-8522

Canadian RegionLondon, OntarioDetroit Diesel of Canada, Ltd.150 Dufferin Ave., Suite 701London, ON N5A 5N6Phone: 519-661-0149Fax: 519-661-0171

DDC/MTU Off-Highway Sales and Customer AssuranceCenter Offices

Construction, Industrial andMining Sales (BX7)13400 Outer Drive, WestDetroit, MI 48239-4001Phone: 313-592-5608Fax: 313-592-5625

Marine Sales (BX6)13400 Outer Drive, WestDetroit, MI 48239-4001Phone: 313-592-5124Fax: 313-592-5137

Powergen and Oil Field Sales(BX11)13400 Outer Drive, WestDetroit, MI 48239-4001Phone: 313-592-5708Fax: 313-592-5158

Government Sales (BX11)13400 Outer Drive, WestDetroit, MI 48239-4001Phone: 313-592-5875Fax: 313-592-5158

Customer Assurance (M24)13400 Outer Drive, WestDetroit, MI 48239-4001Phone: 313-592-5550Fax: 313-592-5717


CUSTOMER ASSISTANCE

DDC INTERNATIONAL REGIONAL OFFICE LOCATIONSEUROPE, MIDDLE EAST, AFRICA(EMA) REGION (On/Off-Highway)The NetherlandsRidderpoort 92984 RidderkerkThe NetherlandsPhone: (31) 180-442-900Fax: (31) 180-419-544

LATIN AMERICAN REGION(Off-Highway)Miami, Florida2277 N.W. 14th StreetLatin America BuildingMiami, FL 33125-0068Phone: 305-637-1555Fax: 305-637-1580

ASIAN REGION (On-Highway)13400 Outer Drive, WestDetroit, Michigan 48239Phone: 313-592-5990Fax: 313-592-5887

ASIA/PACIFIC REGION(Off-Highway)SingaporeNo. 1 Benoi PlaceSingapore 629923Phone: (65) 686-15922Fax: (65) 686-11550

PACIFIC REGION (Off-Highway)Australia488 Blackshaws RoadAltona North, Victoria 3025AustraliaPhone: (61) 3 9243-9292Fax: (61) 3 9243-9262

AUSTRALIAN REGION(On-Highway)488 Blackshaws RoadAltona North, Victoria 3025AustraliaPhone: (61) 3 9243-9292Fax: (61) 3 9243-9262

MEXICO (On/Off-Highway)Detroit Diesel Allison de Mexico, S.A.Av. Santa Rosa 58Col. Ampliacion NorteSan Juan Ixtacala, TlanepantlaC.P. 54160, Edo de MexicoPhone: 52-555-333-180252-5555-333-1870



Road Service In U.S. andCanadaIf you require road service for anyreason in the U.S. or Canada, you maycall the 1–800–445–1980 customerassistance phone number. An operatorwill assist you in determining whattype of service is required. Not allproblems are engine related and notall problems are covered by engineor vehicle warranties. YOU MAYBE RESPONSIBLE FOR REPAIREXPENSES.

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 (ifinstalled) on the fuel filter adaptor,fuel processor body or fuel supplyline is open.

□ Check the oil level on the dipstick.

□ Check diagnostic codes,refer to the Diagnostic CodeList section in this guide.

If you call, have the followinginformation available:

□ Engine serial number

□ Truck, bus or equipment make andmodel

□ Odometer mileage (kilometers) orhourmeter hours

□ Truck, bus or equipmentowner/company name

Working with DDC ServiceOutletsAs the owner of a Detroit Dieselproduct you have a complete networkof over 2,000 Detroit Diesel serviceoutlets in the U.S. and Canada, plusmany outlets worldwide that areprepared to meet your parts andservice needs.

□ Service by trained personnel.

□ Sales team to help determine yourspecific power requirements.

□ In many areas, emergency service24 hours a day.

□ Complete parts support, includingreliabilt® remanufacturedcomponents.

□ Product information and literature.


CUSTOMER ASSISTANCE

We recognize, however, that despitethe best intentions of everyoneconcerned, misunderstandings mayoccur. Normally, any situation thatarises in connection with the sale,operation or service of your productwill be handled by the authorizedservice outlet in your area. In the U.S.and Canada, check the Yellow Pagesfor the Detroit Diesel service outletnearest you.

To further assure your completesatisfaction, we have developed thefollowing procedure to be followed inthe event you have a problem that hasnot been handled satisfactorily.

Step One

Discuss your problem with a memberof management from the authorizedservice outlet. Frequently, complaintsare the result of a breakdown incommunication and can quickly beresolved by a member of management.If you have already discussed theproblem with the Sales or ServiceManager, contact the GeneralManager. If your complaint originateswith a dealer, explain the matterto a management member of thedistributorship with whom the dealerhas a service agreement.

Step Two

When it appears that your problemcannot be readily resolved at thedistributor level without additionalassistance, contact the Detroit DieselRegional Product Support Manageror Operations Manager responsiblefor your local distributor. You will beassisted by a member of the manager'sstaff, depending upon the nature ofyour problem.

Prior to this contact, have thefollowing information available:

□ Engine model* 604 _ _ _ _ _ .

□ Engine serial number* 04R0_ _ __ _ _ .

□ Type and make of equipment.

□ Engine delivery date andaccumulated miles or hoursof operation.

□ Nature of problem.

□ Chronological summary ofengine's history.

□ Name and location of authorizedservice outlet.

*Important: Your engine modelnumber and serial number should bewritten on the lines provided. Theywill identify your engine and allservice parts, plus provide warrantyand extended coverage information.



Step Three

If you are still not satisfied, present theentire matter in writing or by phone to:

Vice President, Customer AssuranceDetroit Diesel Corporation13400 Outer Drive, WestDetroit, MI 48239–4001Phone: 313–592–7357FAX: 313–592–7888

When contacting the regional orhome office, please keep in mind thatultimately your problem will likelybe resolved at the distributorship ordealership, utilizing their facilities,equipment, and personnel. Therefore,it is suggested that you followthe above steps in sequence whenexperiencing a problem.


LIMITED WARRANTY ON ENGINES USED IN ON-HIGHWAY VEHICLEAPPLICATIONS

LIMITED WARRANTY ON ENGINES USED INON-HIGHWAY VEHICLE APPLICATIONS

Terms Of Coverage:On-Highway VehicleEngine Applications

Uses

This warranty applies to the first retailpurchaser and subsequent ownersduring the WARRANTY PERIODof new Detroit Diesel Series 50®Engines (referred to as Engine)manufactured by Detroit DieselCorporation and/or supplied byDetroit Diesel Corporation, DetroitDiesel of Canada Limited, orDetroit Diesel Overseas DistributionCorporation (all which are collectivelyreferred to as DDC) which are used inon-highway vehicle applications.

Defects

This warranty covers EngineREPAIRS to correct any malfunctionoccurring during the WARRANTYPERIOD resulting from defects inmaterial and workmanship.

Repairs

To obtain warranty repairs, you mustrequest the needed repairs withinthe WARRANTY PERIOD from anauthorized DDC service outlet. Onlynew genuine parts or remanufactured

parts or components supplied orapproved by DDC will be used. DDCmay, at its discretion, replace ratherthan repair components. A reasonabletime must be allowed to performthe warranty repair after taking theengine to the authorized service outlet.The owner is responsible for thepercentage of repair costs shown inthe warranty period chart. Repairs willbe performed during normal businesshours.

Warranty Period

The WARRANTY PERIOD beginson the date the engine is deliveredto the first retail purchaser or put inuse prior to sale at retail, whicheverdate comes first, and ends at the timeor mileage/kilometer limits in theWARRANTY PERIOD chart (Table28).



WARRANTY PERIOD

Warranty Limitations(Whichever Occurs First)

Repair Charges to BePaid by Owner

ItemMonths Miles/

Kilometers Parts Labor

Engine # 0–24 Unlimited No Charge No Charge

Accessories 0–24 0–100,000 Miles0–160,000 Km

No ChargeNo Charge

No ChargeNo 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:

MajorComponents † 25 – 60 0 – 500,000 Miles

0–800,000 Km No Charge

100% ofServiceOutlet'sNormalCharge

# Includes Jacobs Vehicle Systems braking devices and 50DN or T1alternators, 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 areplacement for an engine still underwarranty will assume the identity ofthe Engine being replaced and beentitled to the remaining warrantycoverage.

Service Supplies

The cost of service supplies suchas coolant, oil and filters which are

not reusable due to needed warrantyrepairs is covered by this warranty.

Engine Removal andReinstallation

Labor costs for Engine removal andreinstallation, when necessary to makea warranty repair, are covered by thiswarranty.


LIMITED WARRANTY ON ENGINES USED IN ON-HIGHWAY VEHICLEAPPLICATIONS

This Warranty Does NotCover:

Repairs Due to Accidents,Misuse, Storage Damage,Negligence or CertainModifications

Repairs due to an accident, misuse,misapplication, storage damage,negligence or modification exceedingDDC specifications are not covered bythis warranty.

Braking Devices

DDC is not responsible for therepair of non-factory-installed orDDC distributor-installed mechanicalbraking devices installed on theengine. Such devices are warrantedby the brake manufacturer.

Fuel Injectors after 100,000Miles/160,000 Kilometers

The repair or replacement of fuelinjectors after 100,000 miles/160,000kilometers of operation is not coveredby this warranty.

Maintenance

DDC is not responsible for thecost of maintenance or repairsdue to the lack of performanceof required maintenance servicesas recommended by DDC, or thefailure to use fuel, oil, lubricants and

coolant meeting DDC-recommendedspecifications. Performance of therequired maintenance and use ofproper fuel, oil, lubricants and coolantare the responsibility of the owner.Refer to the MAINTENANCE sectionin this guide for details.

Incidental or ConsequentialDamage

Detroit Diesel Corporation isnot responsible for incidental orconsequential costs or expenses whichthe owner may incur as a result ofa malfunction or failure covered bythis warranty, such as communicationexpenses, meals, lodging, overtime,towing, loss of use of the engine orvehicle (“downtime”), loss of time,inconveniences, cargo loss or damage,and other similar costs and expenses.

Other Limitations

The performance of REPAIRS is theexclusive Owner's remedy under thiswarranty. DDC does not authorizeany person to assume or create forit any other obligation or liabilityin connection with the engine oraccessories.



THIS LIMITED WARRANTYAND THE EMISSIONS CONTROLWARRANTY ARE THE ONLYWARRANTIES APPLICABLETO THE ENGINE ANDACCESSORIES AS USEDIN ON-HIGHWAY VEHICLEAPPLICATIONS. DETROIT DIESELCORPORATION MAKES NOOTHER WARRANTIES EXPRESSOR IMPLIED, INCLUDINGANY IMPLIED WARRANTYOF MERCHANTABILITY ORFITNESS FOR A PARTICULARPURPOSE. DETROIT DIESELCORPORATION SHALL NOT BELIABLE FOR ANY INCIDENTALOR CONSEQUENTIAL DAMAGESAS DESCRIBED ABOVE.

Some states do not allow the limitationof how long this warranty may lastor the limitation or exclusion ofincidental or consequential damages,so the above may not apply to you.This warranty gives you specific legalrights, and you may also have otherrights which may vary from state tostate.


LIMITED WARRANTY ON ENGINES POWERING URBAN BUS, MOTORCOACH OR MOTOR HOME APPLICATIONS

LIMITED WARRANTY ON ENGINES POWERING URBANBUS, MOTOR COACH OR MOTOR HOME APPLICATIONS

Terms Of Coverage: UrbanBus, Motor Coach Or MotorHome Engine Applications

Uses

This warranty applies to the first retailpurchaser and subsequent ownersduring the WARRANTY PERIOD ofnew Detroit Diesel Series 50® Engines(referred to as Engine) manufacturedby Detroit Diesel Corporationand/or supplied by Detroit DieselCorporation, Detroit Diesel of CanadaLimited, or Detroit Diesel OverseasDistribution Corporation (all whichare collectively referred to as DDC)powering urban bus, motor coach ormotor home applications sold at retailon or after January 1, 2004.

Defects


Repairs

To obtain warranty repairs, you mustrequest the needed repairs withinthe WARRANTY PERIOD from anauthorized DDC service outlet. Only

new genuine parts or remanufacturedparts or components supplied orapproved by DDC will be used. DDCmay, at its discretion, replace ratherthan repair components. A reasonabletime must be allowed to performthe warranty repair after taking theengine to the authorized service outlet.The owner is responsible for thepercentage of repair costs shown in theWarranty Period Chart. Repairs willbe performed during normal businesshours.

Warranty Period

The WARRANTY PERIOD beginson the date the engine is deliveredto the first retail purchaser or put inuse prior to sale at retail, whicheverdate comes first, and ends at the timeor mileage/kilometer limits in theWARRANTY PERIOD chart (Table29).



Warranty Period

Warranty Limitations(Whichever Occurs

First)

Repair Charge to BePaid By Owner

Item

Months Miles/Kilometers Parts Labor

Engine * 0 – 24 Unlimited No Charge No Charge

Accessories 0 – 24 0–100,000 Miles0–160,000 Km No Charge No Charge

Upon expiration of the 24-month warranty coverage, butwithin 500,000 miles/800,000 km of use, the warranty

continues to apply as follows:

MajorComponents † 25 – 60 0 – 500,000 Miles

0 – 800,000 Km No Charge

100% ofserviceoutlet'snormalcharge

* Includes Jacobs Vehicle Systems braking devices, 50DN or T1alternators, 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 andMotor Home Applications

Service Supplies

The cost of service supplies suchas coolant, oil and filters which arenot reusable due to needed warrantyrepairs is covered by this warranty.


Engine(s) supplied by DDC as areplacement for an engine still under

warranty will assume the identity ofthe Engine being replaced and beentitled to the remaining warrantycoverage.


LIMITED WARRANTY ON ENGINES POWERING URBAN BUS, MOTORCOACH OR MOTOR HOME APPLICATIONS


Reasonable labor costs for Engineremoval and reinstallation, whennecessary to make a warranty repair,are covered by this warranty.


Repairs Due to Accidents,Misuse, Alteration, StorageDamage, Negligence or CertainModifications

Repairs due to an accident, misuse,alteration, misapplication, storagedamage, negligence or modificationexceeding DDC specifications are notcovered by this warranty.

Braking Devices

DDC is not responsible for therepair of non-Jacobs Vehicle Systemsmechanical braking devices installedon the Engine. Such devices arewarranted by the brake manufacturer.

Fuel Injectors after 200,000Miles/320,000 Kilometers

The repair or replacement of fuelinjectors after 200,000 miles/320,000kilometers of operation is not coveredby this warranty.

Maintenance

DDC is not responsible for the costof maintenance or repairs due tothe lack of performance of requiredmaintenance services or the failureto use fuel, oil, lubricants andcoolant meeting DDC-recommendedspecifications. Performance of therequired maintenance and use ofproper fuel, oil, lubricants and coolantare the responsibility of the owner.Refer to the MAINTENANCE sectionin this guide for details.


Detroit Diesel Corporation isnot responsible for incidental orconsequential costs or expenses whichthe owner may incur as a result ofa malfunction or failure covered bythis warranty, such as communicationexpenses, meals, lodging, loss of useof the engine or vehicle (“downtime”),loss of time, inconvenience, cargo lossor damage, and other similar costs andexpenses.

Other Limitations

The performance of REPAIRS is theexclusive Owner's remedy under thiswarranty. DDC does not authorizeany person to assume or create forit any other obligation or liability inconnection with the Engine.



THIS LIMITED WARRANTYAND THE EMISSIONS CONTROLWARRANTY ARE THE ONLYWARRANTIES APPLICABLE TOTHESE ENGINES POWERINGURBAN BUS, MOTORCOACH OR MOTOR HOMEAPPLICATIONS. DETROIT DIESELCORPORATION MAKES NOOTHER WARRANTIES EXPRESSOR IMPLIED, INCLUDINGANY IMPLIED WARRANTYOF MERCHANTABILITY ORFITNESS FOR A PARTICULARPURPOSE. DETROIT DIESELCORPORATION SHALL NOT BELIABLE FOR ANY INCIDENTALOR CONSEQUENTIAL DAMAGESAS DESCRIBED ABOVE.



LIMITED WARRANTY ON ENGINES AND ENGINE ACCESSORIES USED INCONSTRUCTION/INDUSTRIAL APPLICATIONS

LIMITED WARRANTY ON ENGINES AND ENGINEACCESSORIES USED IN CONSTRUCTION/INDUSTRIALAPPLICATIONS

Terms Of Coverage:Construction/IndustrialEngine Applications

Uses

This warranty applies to the first retailpurchaser and subsequent ownersduring the WARRANTY PERIODof new Detroit Diesel Series 50®Engines (referred to as Engine)manufactured by Detroit DieselCorporation and/or supplied byDetroit Diesel Corporation, DetroitDiesel of Canada Limited, orDetroit Diesel Overseas DistributionCorporation (all which are collectivelyreferred to as DDC) which are used inconstruction/industrial applications.

Defects


Repairs


new genuine parts or remanufacturedparts or components supplied orapproved by DDC will be used. DDCmay, at its discretion, replace ratherthan repair components. A reasonabletime must be allowed to performthe warranty repair after taking theengine to the authorized service outlet.Repairs will be performed duringnormal business hours.

The owner is responsible for thepercentage of repair costs shown inthe WARRANTY PERIOD chart(Table 30).

Warranty Period

The WARRANTY PERIOD begins onthe date the engine is delivered to thefirst retail purchaser or put in use priorto sale at retail, whichever date occursfirst, and ends at the time or hourlimits shown in the WARRANTYPERIOD chart (Table 30).

Service Supplies

The cost of service supplies such ascoolant, oil and filters which are notreusable due to warranted repairs iscovered by this warranty.



Warranty Period


Adjustments to Be Paidby the Owner

ItemMonths 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 warrantycoverage, but within 12,000 hours of use, the warranty

continues to apply as follows:

Block,Crankshaft

andConnecting

Rods

13 – 36 0 – 12,000 No Charge No Charge

Table 30 Warranty Period Chart – Construction/IndustrialApplications

Engine Removaland Reinstallation –Construction/IndustrialApplications

Reasonable labor costs for Engineremoval and reinstallation, whennecessary to make a warranty repair,are covered by this warranty duringthe first twelve (12) months of service.

Mechanic's Travel Expenses

DDC will pay reasonable travelexpenses for the repairing mechanicto travel to and from the repair site.


Engine(s) supplied by DDC as areplacement for an Engine still underwarranty will assume the identity ofthe Engine being replaced and beentitled to the remaining warrantycoverage.


LIMITED WARRANTY ON ENGINES AND ENGINE ACCESSORIES USED INCONSTRUCTION/INDUSTRIAL APPLICATIONS




Engine Removal andReinstallation – AgriculturalMachinery and Stand-by PumpApplications

Labor and material costs for engineremoval and reinstallation, whennecessary to make a warrantyrepair, are not covered by thiswarranty when the engine is in anagricultural machinery or stand-bypump application.

Non-DDCSupplied/ManufacturedComponents

DDC is not responsible for repairof components and/or assemblieswhich are manufactured or suppliedby another manufacturer, such asnon-DDC power take-offs andintake and exhaust systems. Suchitems are covered by the equipmentmanufacturer.

Maintenance

DDC is not responsible for thecost of maintenance or repairsdue to lack of performance ofrequired maintenance services asrecommended by DDC, or thefailure to use fuel, oil, lubricants andcoolant meeting DDC-recommendedspecifications. Performance of therequired maintenance and use ofproper fuel, oil, lubricants and coolantare the responsibility of the owner.Refer to the MAINTENANCE sectionin this guide for details.


DDC is not responsible for incidentalor consequential costs or expenseswhich the owner may incur as aresult of a malfunction or failurecovered by this warranty, such ascommunication expenses, meals,lodging, overtime, towing, and anyassociated loss of use of the Engine orequipment (“downtime”), loss of time,inconvenience, cargo loss or damage,and other similar costs and expenses.



Other Limitations

The performance of REPAIRS is theexclusive Owner's remedy under thiswarranty. DDC does not authorizeany person to assume or create forit any other obligation or liability inconnection with the Engine or theAccessories.

THIS LIMITED WARRANTYAND THE EMISSIONS CONTROLWARRANTY ARE THE ONLYWARRANTIES APPLICABLETO THE ENGINE ANDACCESSORIES AS USED INCONSTRUCTION/INDUSTRIAL,AGRICULTURAL MACHINERYAND STAND-BY PUMPAPPLICATIONS. DETROIT DIESELCORPORATION MAKES NOOTHER WARRANTIES EXPRESSOR IMPLIED, INCLUDINGANY IMPLIED WARRANTYOF MERCHANTABILITY ORFITNESS FOR A PARTICULARPURPOSE. DETROIT DIESELCORPORATION SHALL NOT BELIABLE FOR ANY INCIDENTALOR CONSEQUENTIAL DAMAGESAS DESCRIBED ABOVE.

Some states do not allow the limitationof how long this warranty may lastor the limitation or exclusion ofincidental or consequential damages,so the above may not apply to you.This warranty gives you specific legalrights, and you may also have other

rights which may vary from state tostate.


LIMITED WARRANTY ON ENGINES USED IN AGRICULTURAL MACHINERY

LIMITED WARRANTY ON ENGINES USED INAGRICULTURAL MACHINERY

Terms Of Coverage:Agricultural MachineryEngine Applications

Uses

This warranty applies to the first retailpurchaser and subsequent ownersduring the WARRANTY PERIODof new Detroit Diesel Series 50®Engines (referred to as Engine)manufactured by Detroit DieselCorporation and/or supplied byDetroit Diesel Corporation, Detroit

Diesel of Canada Limited, orDetroit Diesel Overseas DistributionCorporation (all which are collectivelyreferred to as DDC) which are used inagricultural machinery.

Defects


Warranty Period



ItemMonths 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 mustrequest the needed repairs withinthe WARRANTY PERIOD from anauthorized DDC service outlet. Onlynew genuine parts or remanufacturedparts or components supplied or

approved by DDC will be used. DDCmay, at its discretion, replace ratherthan repair components. A reasonabletime must be allowed to performthe warranty repair after taking theengine to the authorized service outlet.Repairs will be performed duringnormal business hours.



The owner is responsible for thepercentage of repair costs shown inthe WARRANTY PERIOD chart(Table 31).

Warranty Period

The WARRANTY PERIOD begins onthe date the engine is delivered to thefirst retail purchaser or put in use priorto sale at retail, whichever date occursfirst, and ends at the time or hourlimits shown in the WARRANTYPERIOD chart (Table 31).





Labor costs for Engine removal andreinstallation, when necessary to makea warranty repair, are not covered bythis warranty.


DDC is not responsible for repair ofcomponents and/or assemblies whichare manufactured or supplied byanother manufacturer, such as intakeand exhaust systems. Such items arecovered by warranties issued by themanufacturer or supplier.

Maintenance

DDC is not responsible for thecost of maintenance or repairsdue to lack of performance ofrequired maintenance services asrecommended by DDC, or thefailure to use fuel, oil, lubricants andcoolant meeting DDC-recommendedspecifications. Performance of therequired maintenance and use ofproper fuel, oil, lubricants and coolantare the responsibility of the owner.Refer to the MAINTENANCE sectionin this guide for details.


LIMITED WARRANTY ON ENGINES USED IN AGRICULTURAL MACHINERY


This warranty does not cover anyeconomic loss, including withoutlimitation, communication expenses,meals, lodging, loss of use of theEngine or equipment (“downtime”),loss of time, inconvenience, cargo lossor damage, overtime, towing or anyother cost or expense resulting from adefect covered by this warranty.

Other Limitations

The performance of REPAIRS is theexclusive Owner's remedy under thiswarranty. DDC does not authorizeany person to assume or create forit any other obligation or liability inconnection with the Engine or theAccessories.

THIS LIMITED WARRANTYIS THE ONLY WARRANTYAPPLICABLE TO THE ENGINEAND ACCESSORIES AS USED INAGRICULTURAL MACHINERYAPPLICATIONS. DETROIT DIESELCORPORATION MAKES NOOTHER WARRANTIES EXPRESSOR IMPLIED, INCLUDINGANY IMPLIED WARRANTYOF MERCHANTABILITY ORFITNESS FOR A PARTICULARPURPOSE. DETROIT DIESELCORPORATION SHALL NOT BELIABLE FOR ANY INCIDENTAL

OR CONSEQUENTIAL DAMAGESAS DESCRIBED ABOVE.




LIMITED WARRANTY ON ENGINES USED IN PRIMEPOWER GENERATOR SETS

Terms Of Coverage: PrimePower Generator SetEngine Applications

Uses

This warranty applies to the first retailpurchaser and subsequent ownersduring the WARRANTY PERIODof new Detroit Diesel Series 50®Engines (referred to as Engine)manufactured by Detroit DieselCorporation and/or supplied byDetroit Diesel Corporation, DetroitDiesel of Canada Limited, orDetroit Diesel Overseas DistributionCorporation (all which are collectivelyreferred to as DDC) which are used inprime power generators delivered inthe U.S. or Canada.

Defects

This warranty covers EngineREPAIRS to correct any malfunctionoccurring during the WARRANTYPERIOD resulting from defects inmaterial or workmanship.

Repairs


new genuine parts or remanufacturedparts or components supplied orapproved by DDC will be used. DDCmay, at its discretion, replace ratherthan repair components. A reasonabletime must be allowed to performthe warranty repair after taking theengine to the authorized service outlet.Repairs will be performed duringnormal business hours.

Warranty Period

The WARRANTY PERIOD begins onthe date the engine is delivered to thefirst retail purchaser or put in use priorto sale at retail, whichever date occursfirst, and ends at the time or hourlimits shown in the WARRANTYPERIOD chart listed in Table 32.




LIMITED WARRANTY ON ENGINES USED IN PRIME POWER GENERATORSETS

Warranty Period



ItemMonth Engine

Hours Parts Labor

Engine 0 – 12 Unlimited No Charge No Charge

Upon expiration of the 12 month warranty coverage, but within 12,000hours of use, the warranty continues to apply as follows:

Block,Crankshaft,

andConnecting

Rods(assemblies)

13 – 36 0 – 12,000 No Charge

100% ofServiceOutlet'sNormalCharge

Table 32 Warranty Period Chart – Prime Power Generator Set

Service Supplies





Repairs Due to Accidents,Misuse, Storage Damage,

Negligence or CertainModifications







DDC is not responsible for repair ofcomponents and/or assemblies whichare manufactured or supplied byanother manufacturer, such as intakeand exhaust systems. Such itemsmay be covered by the equipmentmanufacturer.

Maintenance

DDC is not responsible for the cost ofmaintenance or repairs due to lack ofperformance of required maintenanceservices as recommended by DDC, orthe failure to use fuel, oil, lubricants,coolant, cooling air and ventilationmeeting DDC-recommendedspecifications. Performance of therequired maintenance and use ofproper fuel, oil, lubricants and coolantare the responsibility of the owner.Refer to the MAINTENANCE sectionin this guide for details.


This warranty does not cover anyeconomic loss, including withoutlimitation, communication expenses,meals, lodging, loss of use of theEngine, loss of time, inconvenience,overtime, transportation of the Engineor any other cost or expense resultingfrom a defect covered by this warranty.

Other Limitations

THIS LIMITED WARRANTYIS THE ONLY WARRANTYAPPLICABLE TO THE ENGINEAND ACCESSORIES ASUSED IN PRIME POWERGENERATORS. DETROIT DIESELCORPORATION MAKES NOOTHER WARRANTIES EXPRESSOR IMPLIED, INCLUDINGANY IMPLIED WARRANTYOF MERCHANTABILITY ORFITNESS FOR A PARTICULARPURPOSE. DETROIT DIESELCORPORATION SHALL NOT BELIABLE FOR ANY INCIDENTALOR CONSEQUENTIAL DAMAGESAS DESCRIBED ABOVE.



LIMITED WARRANTY ON ENGINES USED IN STAND-BY GENERATOR SETS

LIMITED WARRANTY ON ENGINES USED IN STAND-BYGENERATOR SETS

Terms Of Coverage:Stand-By Generator SetEngine Applications

Uses

This warranty applies to the first retailpurchaser and subsequent ownersduring the WARRANTY PERIOD ofnewDetroit Diesel Series 50® Engines(referred to as Engine) manufacturedby Detroit Diesel Corporationand/or supplied by Detroit DieselCorporation, Detroit Diesel of CanadaLimited, or Detroit Diesel OverseasDistribution Corporation (all whichare collectively referred to as DDC)which are used in stand-by generatorsdelivered in the U.S. or Canada.

Defects

This warranty covers EngineREPAIRS to correct any malfunctionoccurring during the WARRANTYPERIOD resulting from defects inmaterial or workmanship.

Repairs

To obtain warranty repairs, you mustrequest the needed repairs withinthe WARRANTY PERIOD from anauthorized DDC service outlet. Onlynew genuine parts or remanufacturedparts or components supplied orapproved by DDC will be used. DDCmay, at its discretion, replace ratherthan repair components. A reasonabletime must be allowed to performthe warranty repair after taking theengine to the authorized service outlet.Repairs will be performed duringnormal business hours.

Warranty Period



ItemMonths Engine

Hours Parts Labor

Engine Up to 24 0 – 800 No Charge No Charge

Table 33 Warranty Period Chart – Stand-By Generator Set



Warranty Period

The WARRANTY PERIOD beginson the date the engine is delivered tothe first retail purchaser or put in useprior to sale at retail, whichever dateoccurs first, and ends at the time limitsshown in the WARRANTY PERIODchart listed in Table 33.



Service Supplies





Repairs Due to Accidents,Misuse, Storage Damage,

Negligence or CertainModifications





DDC is not responsible for repair ofcomponents and/or assemblies whichare manufactured or supplied byanother manufacturer, such as intakeand exhaust systems and fuel storagetanks. Such items may be covered bywarranties issued by the manufactureror supplier.


LIMITED WARRANTY ON ENGINES USED IN STAND-BY GENERATOR SETS

Maintenance

DDC is not responsible for the cost ofmaintenance or repairs due to lack ofperformance of required maintenanceservices as recommended by DDC, orthe failure to use fuel, oil, lubricants,coolant, cooling air and ventilationmeeting DDC-recommendedspecifications. Performance of therequired maintenance and use ofproper fuel, oil, lubricants and coolantare the responsibility of the owner.Refer to the MAINTENANCE sectionin this guide for details.


This warranty does not cover anyeconomic loss, including withoutlimitation, communication expenses,meals, lodging, loss of use of theEngine, loss of time, inconvenience,overtime, transportation of the Engineor any other cost or expense resultingfrom a defect covered by this warranty.

Other Limitations

THIS LIMITED WARRANTYIS THE ONLY WARRANTYAPPLICABLE TO THE ENGINEAS USED IN STAND-BYGENERATORS. DETROIT DIESELCORPORATION MAKES NOOTHER WARRANTIES EXPRESSOR IMPLIED, INCLUDINGANY IMPLIED WARRANTY

OF MERCHANTABILITY ORFITNESS FOR A PARTICULARPURPOSE. DETROIT DIESELCORPORATION SHALL NOT BELIABLE FOR ANY INCIDENTALOR CONSEQUENTIAL DAMAGESAS DESCRIBED ABOVE.




SPECIFICATIONS

This section lists the fuel andlubrication oil filters needed for theSeries 50 engine. Also listed asthe various POWER COOL®engineproducts

Fuel and Lubricating OilFiltersThe fuel filters and their part numbersare listed in Table 34. The lubricatingoil filters and their part numbers arelisted 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 (frontsump and rear sump) require the sameamount of engine oil.

Oil Pan Capacity — 19 quarts tothe LOW mark without oil filters. 22

quarts to the FULL mark without oilfilters.

Total Oil Capacity Of TheEngine — 29 quarts to the FULLmark with oil filters installed andfilters and oil galleries charged.


SPECIFICATIONS

POWER COOL® ENGINEPRODUCTSMaintenance of the cooling systemrequires the chemical make-up of thesystem to be balanced

Power Cool Fully FormulatedIEG Coolant

The part numbers and sizes ofconcentrated Power Cool andpre-blended 50:50 Power Cool arelisted in Table 36.

Coolant Type Part Number Description

23512138 1 Gallon Jug – 6Per Case

23512139 55 Gallon Drum

23529295 330 Gallon ToteConcentrated

23512140 Bulk Delivery – 1,000Gallon Min.



23528544 330 Gallon TotePre-Blended 50:50


Table 36 Power Cool Fully Formulated IEG Coolant

Power Cool Latin AmericanCoolant


23524923 55 Gallon DrumPre-Blended 67:33

23524924 Bulk Delivery – 1,000Gallon Minimum

Table 37 Power Cool Latin American Coolant Products



Power Cool 2000 SupplementalCoolant Additive


23507858 Pint Bottle – 12 Per case

23507859 One-Half Gallon Jug– 6 Per Case

23507860 5 Gallon Pail

For Power Cool IEGCoolant


Table 38 Power Cool 2000 Supplemental Coolant Additive

Power Cool 3000 SupplementalCoolant Additive


23507854 Pint Bottle – 12 Per Case

23507855 One-Half Gallon Jug– 6 Per Case




Table 39 Power Cool 3000 Supplemental Coolant Additive


SPECIFICATIONS

Power Cool 3000 SupplementalAdditive Coolant Filters


23507545 4 Ounce (1 PintEquivalent)







Table 40 Power Cool 3000 Supplemental Additive Coolant Filters

Power Cool SupplementalAdditive Need-Release Filters


23516488 For 0 – 8 Gallon SystemsFor Power Cool IEG

Coolant 23516489 For 8 – 20 GallonSystems

Table 41 Power Cool SUPPLEMENTAL ADDITIVE NEED-RELEASECOOLANT FILTERS



Power Cool Plus Extended LifeOat Coolant



23519394 55 Gallon DrumConcentrated



23519398 55 Gallon DrumPre-Blended 50:50


Table 42 Power Cool Plus Extended Life OAT Coolant

Power Cool Plus Extender ForUse With Power Cool Plus OATCoolant


For Power Cool Plus 23519400 Quart Bottle – 6 PerCase

Table 43 Power Cool Plus Extender for Use with Power Cool PlusOAT Coolant


SPECIFICATIONS

Power Cool Plus 6000 OATInhibitor For Water-OnlySystems


23522127 1 Gallon Jug – 6Per CaseWater Only


Table 44 Power Cool Plus 6000 OAT Inhibitor for Water-OnlySystems

Power Cool Cooling SystemCleaners


200164 On-Half Gallon Jug –6 Per Case

200105 5 Gallon PailOn-Line Cleaner


Twin Pack 201549 Twin Pack – 2 Per Case

Table 45 Power Cool Cooling System Cleaners



POWER Trac® Coolant TestingAnd Analysis Products

Application Part Number DescriptionIndicates Nitrite,

Molybdate & GlycolLevels

235194013-Way Coolant Test

Strips(Single Foil Packs)

Indicates Nitrite,Molybdate & Glycol

Levels23519402

3-Way Coolant TestStrips

(Bottle of 50)Indicates Nitrite,

Molybdate & GlycolLevels

235227743-Way Coolant Test

Strips(Bottle of 10)

Complete IEG/IPGCoolant Analysis 23516921 Coolant Analysis Bottle

(Carton of 6)

Organic CoolantAnalysis 23523398

Laboratory CoolantAnalysis Bottle(Carton of 6)

Table 46 Power Trac Coolant Testing and Analysis Products


DDC-SVC-MAN-0058

Documents

DDC-SVC-MAN-0058