Detroit Diesel 50 Series Manuals

Manuals and User Guides for Detroit Diesel 50 Series. We have 2 Detroit Diesel 50 Series manuals available for free PDF download: Service Manual, Operator's Manual

Detroit Diesel 50 Series Service Manual (1044 pages)

Brand: Detroit Diesel | Category: Engine | Size: 19 MB

Table of Contents
6
General Information
7
Scope and Use of this Manual
13
Service Parts Availability
13
Clearance of New Parts and Wear Limits
13
The Four-Cycle Principle
13
General Description
15
General Specifications
19
Engine Model, Serial Number and Option Label
20
Replacing and Repairing
22
Disassembly
22
Cleaning
23
Inspection
27
Safety Precautions
28
Fluoroelastomer (Viton) Caution
35
Engine Views
36
Decimal and Metric Equivalents
39
Cylinder Head
94
Valve and Injector Operating Mechanism
96
Rocker Cover
142
Crankshaft
152
Crankshaft Oil Seal
169
Crankshaft Main Bearing
181
Gear Case Cover
192
Gear Case
220
Crankshaft Vibration Damper
234
Crankshaft Pulley
244
Flywheel
251
Ring Gear
259
Flywheel Housing
261
Piston and Piston Ring
268
Piston and Connecting Rod Assembly
292
Connecting Rod
302
Cylinder Liner
309
Gear Train and Engine Timing
323
Camshaft and Camshaft Bearing
348
Shop Notes
487
Crankshaft Remanufacturing Procedures
489
Machining Operations
495
Glossary
501
Engine Plug and Dowel Charts
502
Specifications
508
Service Tools
520
Fuel Pump
582
Fuel Pump Drive
584
Fuel Filters (Spin-On)
585
Fuel Filter and Water Separator Assembly
589
Electronic Engine Control
595
DDEC Ill
596
Ddec II
596
Electronic Foot Pedal Assembly
610
Turbo Boost Pressure Sensor
612
Oil Pressure Sensor
613
Oil Temperature Sensor
616
Synchronous Reference Sensor
617
Timing Reference Sensor
620
Coolant Level Sensor
622
Fuel Pressure Sensor
624
Fuel Temperature Sensor
626
Oil Filters
635
Overview of Lubrication System
635
Oil Pump
640
Oil Pressure Regulator Valve
654
Oil Pressure Relief Valve
661
Oil Filter
666
Oil Filter Adaptor
668
Oil Cooler
674
Oil Level Dipstick Assembly
683
Oil Pan
687
Ventilating System
693
Cooling System
705
Aadditional Information
705
Cooling System Overview
707
Water Pump
745
Thermostat
745
Engine Cooling Fan
757
Coolant Filter and Conditioner
769
Radiator
771
Fuel, Lubricating Oil, and Coolant
777
Fuel
779
Lubricating Oil
786
Coolant
792
Air Intake System
811
Air Cleaner
811
Air Cleaner
815
Intake Manifold
817
Turbocharger
826
Intake Manifold
827
Turbocharger
837
Charge Air Cooler
839
Air Dryer
844
Aadditional Information
845
Overview of Electrical System
861
Battery Charging Alternator
862
Storage Battery
870
Cranking Motor
873
Aadditional Information
889
Preparation for a First Time Start
927
Starting
932
Running
933
Stopping
935
Operating Conditions
936
Engine Run-In Instructions
938
Exhaust System
970

Detroit Diesel 50 Series Operator's Manual (174 pages)

Brand: Detroit Diesel | Category: Engine | Size: 1 MB

Table of Contents
5
Introduction

15
- Non-Genuine and Rebuilt Component Quality Alert
  15
Caution Summary

17
- Engine Operation
  17
- Preventive Maintenance
  18
- Electrical System
  21
- Cooling System
  22
- Air Intake System
  22
- Fuel System
  23
- Starting Aids
  24
- Compressed Air
  25
- Lubricating Oil and Filters
  25
Engine Model and Serial Number Designation

26
- Option Labels
  27
- Certification Labels
  28
Operating Instructions for a First Time Start

29
- Preparations for Starting the Engine the First Time
  29
  - Cooling System Checks
    29
  - Lubrication System Checks
    30
    
    Extended Storage
    30
  - Fuel System Checks
    31
  - Other Checks
    32
- Starting the Engine
  32
  - Initial Engine Start
    33
    
    Electric Starter
    33
    
    Air Starter
    34
- Running the Engine
  34
  - Oil Pressure
    34
  - Warm-Up
    34
  - Inspection
    34
  - Avoid Unnecessary Idling
    35
Tableofcontents

35
- Stopping the Engine
  35
- Emergency Jump Starting
  36
Ddec IV System

37
- Ddec System
  37
  - Engine Protection
    38
  - Idle Shutdown Timer
    38
  - Cruise Control
    38
  - Engine Brakes
    40
  - Data Recording Capability
    41
- Ddec IV Operation
  41
  - Immediate Speed Reduction Option
    42
  - Stop Engine Light
    42
  - Diagnostic Data Reader
    42
  - Diagnostic Code List
    44
Ddec IV Engine Driving Tips

51
- Accelerating the Vehicle
  51
- Cruise Control
  51
- Engine Brakes and Cruise Control
  53
- Shifting
  53
- Idling
  54
  - Winter Fronts
    54
Engine Brake System

55
- Driver Control Switches
  55
  - Low/High Switch
    55
  - Low/Med/High Switch
    55
- Clutch Pedal and Throttle Position Controls
  55
- Engine Brake Operation
  56
- Anti-Lock Braking Systems
  57
- Driving on Flat, Dry Pavement
  57
- Descending a Long, Steep Grade
  57
- Driving on Wet or Slippery Pavement
  59
Engine Systems

60
- Fuel System
  60
- Lubrication System
  60
- Air System
  60
- Cooling System
  60
- Electrical System
  60
- Exhaust System
  60
- Exhaust Gas Recirculation System
  60
Maintenance

61
- Preventive Maintenance Intervals
  77
  - Item 1 - Lubricating Oil
    77
  - Item 2 - Fuel and Fuel Tank
    79
  - Item 3 - Fuel Lines, Flexible Hoses
    80
    
    Leaks
    80
    
    Hoses and Fittings
    81
    
    Hose Service Life
    81
  - Item 4 - Cooling System
    81
    
    Coolant Level
    81
    
    Coolant Inhibitors
    82
    
    Coolant Drain Interval
    82
  - Item 5 - Turbocharger, Air-To-Air Charge Cooler
    84
    
    Wastegated Turbochargers
    84
  - Item 6 - Battery
    85
  - Item 7 - Tachometer Drive
    86
  - Item 8 - Drive Belts
    86
    
    V-Belts
    87
    
    2-Groove Powerband
    87
    
    12-Rib Poly-V Belt
    88
    
    Belt Replacement
    88
  - Item 9 - Air Compressor
    88
  - Item 10 - Air Cleaner
    89
  - Item 11 - Lubricating Oil Filters
    89
  - Item 12 - Fuel Filters
    90
    
    Fuel Pro ® 382 Filters
    90
    
    Spin-On Filters
    90
  - Item 13 - Water Pump and Coolant Inhibitor Element
    91
    
    Water Pump Drain Hole
    91
    
    Coolant Inhibitor Element
    91
Tableofcontents

92
How-To Section

97
- How to Select Lubricating Oil
  97
  - Lubricant Requirements
    97
    
    Egr-Equipped Engines
    97
    
    Non-Egr Engines
    97
    
    Engines Built Prior to 1998
    97
  - Cold Weather Starting
    98
  - Synthetic Oils
    98
  - The Use of Supplemental Additives
    99
- When to Change Oil
  99
  - Disposing of Waste Oil
    100
- How to Replace the Lube Oil Filters
  100
  - Replace Spin-On Type Oil Filter
    100
- How to Select Fuel Oil
  102
  - Quality
    102
  - Fuel Contamination
    102
  - Prohibited Additives
    102
    
    Used Lubricating Oil
    103
    
    Gasoline
    103
- How to Replace the Fuel Filters
  103
- Engine out of Fuel - How to Restart
  108
  - Engines with Spin-On Filters
    109
  - Engines with Fuel Pro Filters
    109
- How to Select Coolant
  110
  - Definitions
    110
    
    Antifreeze
    110
    
    Coolant
    110
    
    Drop-Out
    110
    
    Fully Formulated Antifreeze
    110
    
    Initial-Fill Coolant
    110
    
    Oat
    110
    
    Sca
    110
  - Approved Coolants
    111
    
    Eg or Pg & Water + Sca Inhibitor
    112
    
    Mixing Eg or Pg Antifreeze and Water
    112
    
    Recycled Antifreeze
    114
    
    Eg or Pg & Water + Oat Inhibitor
    114
    
    Water Only + Sca or Water Only + Oat Inhibitor
    115
    
    Water Requirements
    116
  - Coolants Not Recommended
    116
    
    All Antifreezes and Coolants Containing
    116
    
    Phosphate
    116
    
    Automotive Type Coolants
    116
    
    Methyl Alcohol-Based Antifreeze
    117
    
    Methoxy Propanol-Based Antifreeze
    117
    
    Glycol-Based Coolants Formulated for Hvac
    117
  - Additives Not Recommended
    117
    
    Soluble Oil Additives
    117
    
    Chromate Additives
    117
  - Coolant Maintenance
    117
    
    Coolant Inhibitor Test Intervals
    117
    
    Supplemental Additives
    118
    
    Coolant Maintenance Intervals
    119
  - Sca Test Procedures
    121
  - Need-Release Filters (Non-Oat Systems)
    122
  - Dropout
    122
  - Extender Additive for Oat Coolant
    123
    
    Oat Coolant Drain Interval
    123
  - Chronic Coolant System Problems
    123
  - Maintenance Products
    123
    
    Power Cool Scas
    123
    
    Power Cool Coolant Filter Elements
    124
    
    Power Cool Cleaners
    124
  - Summary of Coolant Recommendations
    124
Tableofcontents

123
- How to Drain and Flush the Cooling System
  126
- When to Service the Dry Type Air Cleaner
  128
Basic Troubleshooting

129
Engine Storage

134
- Preparing the Engine for Storage
  134
Series 50 Service Publications

140
Customer Assistance

141
- In U.s. and Canada Call 1-800-445-1980
  144
- Working with DDC Service Outlets
  144
- Applications
  
  147
On-Highway Vehicle Engine Warranty

147
- Terms of Coverage: On-Highway Vehicle Engine Applications
  147
  - Uses
    147
  - Defects
    147
  - Repairs
    147
  - Warranty Period
    147
  - Like Replacement Engine
    148
  - Service Supplies
    148
  - Engine Removal and Reinstallation
    149
- This Warranty Does Not Cover
  149
  - Repairs Due to Accidents, Misuse, Storage Damage, Negligence or Certain Modifications
    149
  - Braking Devices
    149
  - Fuel Injectors after 100,000 Miles/160,000
    149
  - Kilometers
    149
  - Maintenance
    149
  - Incidental or Consequential Damage
    149
  - Other Limitations
    150
Warr Anty

151
Urban Bus, Motor Coach or Motor Home Engine Warranty

151
- Terms of Coverage: Urban Bus, Motor Coach or Motor Home Engine Applications
  151
  - Uses
    151
  - Defects
    151
  - Repairs
    151
  - Warranty Period
    151
  - Service Supplies
    152
  - Like Replacement Engine
    152
  - Engine Removal and Reinstallation
    153
- This Warranty Does Not Cover
  153
  - Repairs Due to Accidents, Misuse, Alteration, Storage Damage, Negligence or Certain Modifications
    153
  - Braking Devices
    153
  - Fuel Injectors after 200,000 Miles/320,000
    153
  - Kilometers
    153
  - Maintenance
    153
  - Incidental or Consequential Damage
    153
  - Other Limitations
    153
Construction/ Industrial Engine Warranty

155
- Terms of Coverage: Construction/Industrial Engine Applications
  155
  - Uses
    155
  - Defects
    155
  - Repairs
    155
  - Warranty Period
    155
  - Service Supplies
    155
  - Engine Removal and Reinstallation - Construction/Industrial Applications
    156
  - Mechanic's Travel Expenses
    156
  - Like Replacement Engine
    156
Tableofcontents

157
- This Warranty Does Not Cover
  157
- Applications
  
  159
Agricultural Machinery Engine Warranty

159
- Terms of Coverage: Agricultural Machinery Engine Applications
  159
  - Uses
    159
  - Defects
    159
  - Repairs
    159
  - Warranty Period
    160
- This Warranty Does Not Cover
  160
- Engine Applications
  
  162
Prime Power Generator Set Engine Warranty

162
- Terms of Coverage: Prime Power Generator Set Engine Applications
  162
  - Uses
    162
  - Defects
    162
  - Repairs
    162
  - Warranty Period
    162
  - Like Replacement Engine
    162
  - Service Supplies
    163
  - Mechanic's Travel Expenses
    163
- This Warranty Does Not Cover
  163
  - Repairs Due to Accidents, Misuse, Storage Damage
    163
  - Negligence or Certain Modifications
    163
  - Engine Removal and Reinstallation
    163
  - Non-DDC Supplied/Manufactured Components
    164
  - Maintenance
    164
  - Incidental or Consequential Damage
    164
  - Other Limitations
    164
Stand-By Generator Set Engine Warranty

165
- Terms of Coverage: Stand-By Generator Set Engine Applications
  165
  - Uses
    165
  - Defects
    165
  - Repairs
    165
  - Warranty Period
    166
  - Like Replacement Engine
    166
  - Service Supplies
    166
  - Mechanic's Travel Expenses
    166
- This Warranty Does Not Cover
  166
  - Repairs Due to Accidents, Misuse, Storage Damage
    166
  - Negligence or Certain Modifications
    166
  - Engine Removal and Reinstallation
    166
  - Non-DDC Supplied/Manufactured Components
    166
  - Maintenance
    167
  - Incidental or Consequential Damage
    167
  - Other Limitations
    167
Specifications

168
- Fuel and Lubricating Oil Filter Requirements
  168
  - Oil Pan
    168
    
    Oil Pan Capacity
    168
    
    Total Oil Capacity of the Engine
    168
- Power Cool Engine Products
  169
  - Fully Formulated Ieg Coolant
    169
  - Latin American Coolant
    169
  - 2000 Supplemental Coolant Additive
    170
  - 3000 Supplemental Additive Coolant Filters
    171
  - Supplemental Additive Need Release Filters
    171
  - Plus Extended Life Oat Coolant
    172
  - Coolant
    172
  - Plus 6000 Oat Inhibitor for Water-Only Systems
    173
  - Cooling System Cleaners
    173
  - Coolant Testing and Analysis Products
    174

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More Detroit Diesel Manuals

Detroit Diesel 50 Series Manuals

Detroit Diesel 50 Series Service Manual (1044 pages)

Table of Contents

Detroit Diesel 50 Series Operator's Manual (174 pages)

Table of Contents

Introduction

Caution Summary

Engine Model and Serial Number Designation

Operating Instructions for a First Time Start

Tableofcontents

Ddec IV System

Ddec IV Engine Driving Tips

Engine Brake System

Engine Systems

Maintenance

Tableofcontents

How-To Section

Tableofcontents

Basic Troubleshooting

Engine Storage

Series 50 Service Publications

Customer Assistance

Applications

On-Highway Vehicle Engine Warranty

Warr Anty

Urban Bus, Motor Coach or Motor Home Engine Warranty

Construction/ Industrial Engine Warranty

Tableofcontents

Applications

Agricultural Machinery Engine Warranty

Engine Applications

Prime Power Generator Set Engine Warranty

Stand-By Generator Set Engine Warranty

Specifications

Related Products

Detroit Diesel Categories