Engines Detroit Diesel Series 50, repair e-manual

Content

General information

• Scope and use of this manual
• Service parts availability
• Clearance of new parts and wear limits
• The four-cycle principle
• General description
• General specifications
• General specifications for the series 50G engine
• Engine model, serial number and option label
• Engine model, serial number and option label (series 50G)
• Replacing and repairing
• Disassembly
• Cleaning
• Inspection
• Safety precautions
• Fluoroelastomer (viton) caution
• Engine views and electronic control module mounting
• English to metric conversion
• Decimal and metric equivalents
• Specifications

Engine

• Cylinder block and cylinder liner
• Cylinder head
• Valve and injector operating mechanism
• Valves, springs, guides, inserts, seals and rotators
• Engine lifter brackets
• Rocker cover
• Crankshaft
• Crankshaft oil seals
• Crankshaft main bearings
• Gear case cover
• Gear case
• Crankshaft vibration damper
• Crankshaft pulley
• Flywheel
• Ring gear
• Flywheel housing
• Piston and piston ring
• Piston and connecting rod
• Cylinder liner
• Gear train and engine timing
• Camshaft and camshaft bearing
• Thrust plate perimeter seal
• Camshaft drive gear
• Adjustable idler gear assembly
• Bull gear and camshaft idler gear assembly
• Crankshaft timing gear and timing wheel
• Balance shaft and oil pump mechanism
• Accessory drive
• Jake brake
• Additional information

Fuel system

• Fuel system overview
• Vehicle safety for the natural gas engine
• Electronic unit injector
• Fuel injector tube and o-ring
• Fuel pump
• Fuel pump drive
• Fuel filters (spin-on)
• Fuel filter and water separator assembly
• Fuel pro 380/380e fuel filter system
• Electronic engine control
• DDEC III
• DDEC II ECM
• Electronic foot pedal assembly
• Turbo boost pressure sensor
• Turbo boost pressure sensor for the series 50G engines
• Manifold absolute pressure sensor
• Air intake pressure sensor
• Oil pressure sensor
• Oil temperature sensor
• Synchronous reference sensor
• Timing reference sensor
• Coolant level sensor
• Fuel pressure sensor
• Fuel temperature sensor
• Exhaust gas oxygen sensor for series 50G engines
• Exhaust temperature sensor for the series 50G engines
• Knock sensor and signal to noise enhancement filter (s.N.E.F.) module for the series 50G automotive engines
• Overview of the high pressure fuel system for the series 50G automotive engine (pre 1998)
• Overview of high pressure fuel system for 1998 and later series 50G automotive engines
• Barometric pressure sensor for the series 50G engine with high pressure fuel system 1998 and later
• High pressure fuel regulator for the series 50G engine
• High pressure fuel regulator for the series 50G engine prior to 1998
• Fuel mixer for the series 50g high pressure system 1998 and later
• Fuel shutoff valve for 1998 and later series 50G engine with high pressure fuel system
• Fuel pressure gages for the series 50g engine with a high pressure fuel system
• Venting and leak checking procedures for a natural gas engine (high pressure system)
• fuel mixer for the series 50G engine with high pressure fuel system (prior to 1998)
• Pulse width modulated stepper motor valve (PSV) for 1998 and later series 50G automotive engines
• Overview of the low pressure fuel system for the series 50G generator set engine (1998 and later)
• IMPCO low pressure fuel regulator for the series 50G engine
• Low pressure fuel regulator for the series 50G engine
• Fuel mixer for the series 50G low pressure system
• Venting and leak checking procedures for a natural gas engine (low pressure system)
• Compuvalve for the series 50G engine
• Fuel shutoff valves for the series 50G engine prior to 1998
• Hose, fitting, and filter for the series 50G engine
• Fuel filter type for the series 50G engine
• Additional information

Lubrication system

• Overview of lubricating system
• Oil pump
• Oil pressure regulator valve
• Oil pressure relief valve
• Oil filter
• Oil filter adaptor
• Oil cooler
• Oil level dipstick assembly
• Oil pan
• Ventilating system

Cooling system

• Cooling system overview
• Water pump
• Thermostat
• Coolant pressure control cap
• Engine cooling fan
• Coolant filter and conditioner
• Radiator
• Additional information

Fuel, lubricating oil, and coolant

• Fuel
• Lubricating oil
• Lubricating oil for the series 50G engine
• Coolant

Air intake system

• Air intake system overview
• Air cleaner
• Intake manifold
• Closed crankcase breather for s50G automotive engines (1998 and later)
• Turbocharger series 50 diesel
• Turbocharger series 50 gas
• Charge air cooler
• throttle actuator for the series 50G engine
• Air dryer
• Additional information

Exhaust system

• Overview of exhaust system
• Exhaust manifold

Electrical equipment

• Overview of electrical system
• Overview of electrical system for series 50G engine
• Battery charging alternator
• Storage battery
• Cranking motor
• DDEC III wiring harness
• Metri-pack 150 series connectors
• Micro-pack series connectors
• Weather pack and metri-pack 280 series connectors
• Connector tools
• Splicing guidelines
• Additional information

Powertake-off

• Rear engine power take-off (repto) assembly
• Front mounted power take-off

Special equipment

• Air compressor
• Air compressor drive hub
• Air compressor drive assembly
• Additional information

Operation and verification

• Preparation for a first time start
• Starting
• Running
• Stopping
• Operating conditions
• Series 50G operating conditions
• Manifold absolute pressure sensor (map sensor) for the series 50G engine
• Engine run-in instructions

Engine tune-up

• Engine tune-up procedures
• Valve lash, injector height (timing) and jake brake lash adjustments
• Engine tune-up procedures for the series 50G engine
• Valve lash for the series 50G engine

Preventive maintenance

• Maintenance overview
• Daily maintenance - all applications
• Maintenance of vehicle engines
• Maintenance of engines used in stationary and industrial applications
• Description of maintenance items
• Preventive maintenance for the series 50G engine (city transit coach)
• Maintenance of series 50G engines
• Maintenance of series 50G engines for generator set
• Lubricating oil and filter change intervals for genset
• Lubricating oil and filter change intervals for genset (with high sulfur fuels)
• Detecting internal fuel leaks
• Cleaning contaminated lubrication oil system

Engine storage

• Preparing engine for storage
• Restoring an extended storage engine

Ignition system

• Overview of ignition system
• Remote mount ignition coils
• Ignition wire harness
• Waste wire harness
• Ignition boot
• Ignition wire and waste wire routing
• Ignition wire brackets
• Ignition boot retainers
• Ignition coil harness
• Spark plugs
• Coil over plug ignition system
• Ignition boot assembly
• Igniter module
• Igniter module bracket
• Ignition coil harness
• Spark plugs

Misfiring cylinder

• Poor vehicle ground
• Aerated fuel
• Improper injector calibration setting (DDEC III engines only)
• Improper valve clearance or injector height, worn or damaged camshaft lobes and rollers
• Faulty fuel injector
• Faulty electronic control module
• Worn or damaged valve or cylinder kit

Starting difficulty (engine rotates)

• Empty fuel tank
• Electronic control module wiring harness
• Low battery voltage
• Corroded or damaged battery terminals
• Defective magnetic switch
• Defective starter
• Low cranking speed
• Fuel supply valve
• Plugged fuel filter(s)
• Fuel pump
• Aerated fuel
• Restrictive air filter
• Low compression

No start (engine will not rotate)

• Discharged battery
• Defective magnetic switch
• Defective starter
• Internal engine damage

Excessive oil consumption

• Miscalibrated dipstick
• External oil leaks
• Leaking oil cooler core
• Defective air compressor
• Defective turbocharger
• Worn or damaged valve or cylinder kit

Excessive crankcase pressure

• Obstruction or damage to rocker cover breather
• Defective air compressor
• Defective turbocharger
• Worn or damaged valve or cylinder kit

Excessive exhaust smoke (black or gray)

• Improper grade of fuel oil
• Restricted air cleaner element
• Restricted or cracked charge air cooler
• Faulty exhaust system
• Faulty fuel injector
• Defective turbocharger

Excessive blue smoke

• Defective turbocharger
• Worn or damaged valve or cylinder kit
• Excessive white smoke

Improper grade of fuel

• Defective fuel pump
• Aerated fuel
• Improper injector calibration setting (DDEC III engines only)
• Improper valve clearance or injector height, worn or damaged camshaft lobes and rollers
• Faulty fuel injector
• Faulty electronic control module

Rough running or stalling

• Low battery voltage
• Aerated fuel oil
• Insufficient fuel oil flow
• High fuel oil temperature return
• Improper injector calibration setting (DDEC III engines only)
• Low compression pressure

Lack of power

• Aerated fuel
• High fuel pressure
• High fuel oil temperature return
• Restricted air cleaner element
• Restricted or cracked charge air cooler or leaking intake manifold
• Faulty exhaust system
• High inlet air temperature
• High altitude operation
• Incorrect camshaft timing

Low oil pressure

• Improper engine oil level
• Improper lubricating oil viscosity
• Lubricating oil diluted with fuel oil or engine coolant
• Faulty oil pressure gage sensor
• Oil pressure gage line obstructed
• Rocker arm shaft plugs missing (new or rebuilt engines only)
• Restricted oil cooler
• Nonfunctional or sticking oil pressure regulator valve
• Defective bypass valve
• Defective pressure relief valve
• Defective pickup screen tube and screen assembly
• Defective crankshaft main bearing shells
• Defective oil pump assembly

High engine coolant temperature

• Improper engine coolant level
• Insufficient radiator air circulation
• Faulty pressure control cap
• Defective coolant hoses
• Fan belts are incorrectly adjusted
• Inoperative thermo-modulated fan
• Faulty thermostats
• Faulty water pump
• Combustion gases in coolant
• Abnormal radiator coolant flow

Low coolant temperature

• Faulty thermostats
• Insufficient radiator air circulation

Common tests

• Proper use of manometer
• Cylinder compression test
• Crankcase pressure test (governed speed no load)
• Crankcase pressure test (dynamic)
• Lube oil consumption report
• Diesel fuel quality and selection
• Fuel oil flow test
• Lubricating oil criteria

Common repairs

• Lead repair

Index

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