MAN Series 50 Operator's Guide

SERIES 50 OPERATOR'S GUIDE To the Operator Whenever possible, it will benefit you to rely on an authorized Detroit Diesel service outlet for all your service needs from maintenance to major parts replacement. Authorized service outlets worldwide stock factory-original parts and have the specialized equipment and experienced, trained personnel to provide prompt preventive maintenance and skilled engine repairs. This guide contains instructions on the safe operation and preventive maintenance of your Detroit Diesel Series 50® engine used in vehicle, stationary, construction/industrial, agricultural, generator set or fire fighting apparatus applications.

Maintenance instructions cover routine engine services such as lube oil and filter changes in enough detail to permit self-servicing, if desired. The operator should become familiar with the contents of this guide before operating the engine or carrying out maintenance procedures. The information and specifications in this publication are based on the information in effect at the time of approval for printing. Contact an authorized Detroit Diesel service outlet for information on the latest revision. The right is reserved to make changes at any time without obligation. Power-driven equipment is only as safe as the person operating the controls.

You are urged, as the operator of this diesel engine, to keep fingers and clothing away from the revolving belts, drive shafts, pulleys, etc. on the engine installation. Throughout this guide CAUTIONS regarding personal safety and NOTICES regarding engine performance or service life will appear. To avoid personal injury and ensure long engine service life, always heed these instructions. All information subject to change without notice. (Rev. 01/04) i DDC-SVC-MAN-0058 Copyright © 2004 DETROIT DIESEL CORPORATION

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NOTICE: Trademark Information Failure to check and maintain SCA (supplemental coolant additive) levels at required concentrations will result in severe damage (corrosion) to the engine cooling system and related components. Coolant must be inhibited with the recommended SCAs listed in this engine operator's guide.Refer to section How to Select Coolant. In addition, the engine can be equipped with a coolant filter/inhibitor system as an installed option or as an after-sale item. Detroit Diesel®, DDC®, DDEC®, Series 50®, Optimized Idle®, ProManager®, reliabilt®, POWER Trac ®, POWER COOL ®, and POWER GUARD ® are registered trademarks of Detroit Diesel Corporation.

Delco Remy® is a registered trademark of Delco Remy America, Inc. Bosch® is a registered trademark of Robert Bosch Company N.A. Fuel Pro®, Sea Pro® and Mega Filter® are registered trademarks of Davco Manufacturing, L.L.C. The PowerBand® is a registered trademark of Gates Rubber Company. Tectyl® is a registered trademark of Daubert Chemical Company, Inc. Biobor® is a registered trademark of United States Borax and Chemical Corporation. DuPont® is a registered trademark of E.I. DuPont de Nemours and Company, Inc. All other trademarks used are the property of their respective owners.

WARRANTY The limited warranties for each engine application are covered in the Limited Warranty pages of this guide and in the booklet, “Warranty Information for Series 50 Engines,” available from authorized Detroit Diesel service outlets. Keep this Operator's Guide with the engine installation at all times. It contains important operating, maintenance, and safety instructions. ii All information subject to change without notice. (Rev. 01/04) DDC-SVC-MAN-0058 Copyright © 2004 DETROIT DIESEL CORPORATION

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SERIES 50 OPERATOR'S GUIDE TABLE OF CONTENTS INTRODUCTION .................................................................................. 1 NON-GENUINE AND REBUILT COMPONENT QUALITY ALERT .. 1 CAUTION SUMMARY .......................................................................... 3 ENGINE OPERATION ..................................................................... 3 PREVENTIVE MAINTENANCE ....................................................... 4 ELECTRICAL SYSTEM ................................................................... 7 COOLING SYSTEM .........................................................................

8 AIR INTAKE SYSTEM ...................................................................... 8 FUEL SYSTEM ................................................................................ 9 STARTING AIDS .............................................................................. 9 COMPRESSED AIR ......................................................................... 11 LUBRICATING OIL AND FILTERS .................................................. 11 ENGINE MODEL AND SERIAL NUMBER DESIGNATION ................ 12 OPTION LABELS ............................................................................. 13 CERTIFICATION LABELS ...............................................................

14 OPERATING INSTRUCTIONS FOR A FIRST TIME START .............. 15 PREPARATIONS FOR STARTING THE ENGINE THE FIRST TIME ................................................................................................. 15 COOLING SYSTEM CHECKS .................................................... 15 LUBRICATION SYSTEM CHECKS ............................................. 16 EXTENDED STORAGE .......................................................... 16 FUEL SYSTEM CHECKS ............................................................ 17 OTHER CHECKS ........................................................................

18 STARTING THE ENGINE ................................................................ 18 INITIAL ENGINE START ............................................................. 19 ELECTRIC STARTER ............................................................. 19 AIR STARTER ......................................................................... 20 RUNNING THE ENGINE ................................................................. 20 OIL PRESSURE .......................................................................... 20 WARM-UP ...................................................................................

20 INSPECTION ............................................................................... 20 AVOID UNNECESSARY IDLING ................................................. 21 All information subject to change without notice. (Rev. 01/04) iii DDC-SVC-MAN-0058 Copyright © 2004 DETROIT DIESEL CORPORATION

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TABLE OF CONTENTS STOPPING THE ENGINE ................................................................ 21 EMERGENCY JUMP STARTING .................................................... 22 DDEC IV SYSTEM ............................................................................... 23 DDEC SYSTEM .............................................................................. 23 ENGINE PROTECTION .............................................................. 24 IDLE SHUTDOWN TIMER .......................................................... 24 CRUISE CONTROL .....................................................................

24 ENGINE BRAKES ....................................................................... 26 DATA RECORDING CAPABILITY ............................................... 27 DDEC IV OPERATION ..................................................................... 27 IMMEDIATE SPEED REDUCTION OPTION ............................... 28 STOP ENGINE LIGHT ................................................................. 28 DIAGNOSTIC DATA READER .................................................... 28 DIAGNOSTIC CODE LIST .......................................................... 30 DDEC IV ENGINE DRIVING TIPS .......................................................

37 ACCELERATING THE VEHICLE ..................................................... 37 CRUISE CONTROL ......................................................................... 37 ENGINE BRAKES AND CRUISE CONTROL .................................. 39 SHIFTING ........................................................................................ 39 IDLING ............................................................................................. 40 WINTER FRONTS ....................................................................... 40 ENGINE BRAKE SYSTEM ..................................................................

41 DRIVER CONTROL SWITCHES ..................................................... 41 LOW/HIGH SWITCH ................................................................... 41 LOW/MED/HIGH SWITCH .......................................................... 41 CLUTCH PEDAL AND THROTTLE POSITION CONTROLS .......... 41 ENGINE BRAKE OPERATION ........................................................ 41 ANTI-LOCK BRAKING SYSTEMS ................................................... 42 DRIVING ON FLAT, DRY PAVEMENT ............................................. 43 DESCENDING A LONG, STEEP GRADE ....................................... 43 DRIVING ON WET OR SLIPPERY PAVEMENT ..............................

44 ENGINE SYSTEMS ............................................................................. 46 FUEL SYSTEM ................................................................................ 46 LUBRICATION SYSTEM ................................................................. 46 AIR SYSTEM ................................................................................... 46 COOLING SYSTEM ......................................................................... 46 iv All information subject to change without notice. (Rev. 01/04) DDC-SVC-MAN-0058 Copyright © 2004 DETROIT DIESEL CORPORATION

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