Detroit Series 50 Engine Service Repair Manual

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Covers: Detroit Series 50 Engine (Diesel and Natural Gas)
Pages: 1,683
Format: PDF
Compatibility: Windows/Mac/Tablet
File size: 14mb
Note: DDEC troubleshooting sold separately

This repair manual contains complete instructions on operation, adjustment (tune-up), preventive maintenance, and mechanical repair (including complete overhaul) for the basic Series 50 Inline Diesel Engines. This repair manual was written primarily for persons servicing and overhauling the engine. Basic maintenance and overhaul procedures are common to all Series 50 Engines, and apply to all engine models. Please note this manual does not include DDEC electronic troubleshooting.

Topics in the Detroit Series 50 Service Repair Manual:

  •  General Information 
  •  1 Engine
  •  1.1 Cylinder Block and Cylinder Liner
  •  1.2 Cylinder Head
  •  1.3 Valve and Injector Operating Mechanism
  •  1.4 Valves, Springs, Guides, Inserts, Seals and Rotators
  •  1.5 Engine Lifter Brackets
  •  1.6 Rocker Cover
  •  1.7 Crankshaft
  •  1.8 Crankshaft Oil Seals
  •  1.9 Crankshaft Main Bearings
  •  1.10 Gear Case Cover
  •  1.11 Gear Case
  •  1.12 Crankshaft Vibration Damper
  •  1.13 Crankshaft Pulley
  •  1.14 Flywheel
  •  1.15 Ring Gear
  •  1.16 Flywheel Housing
  •  1.17 Piston and Piston Ring
  •  1.18 Piston and Connecting Rod Assembly
  •  1.19 Connecting Rod
  •  1.20 Cylinder Liner
  •  1.21 Gear Train and Engine Timing
  •  1.22 Camshaft and Camshaft Bearing
  •  1.23 Thrust Plate Perimeter Seal
  •  1.24 Camshaft Drive Gear
  •  1.25 Adjustable Idler Gear Assembly
  •  1.26 Bull Gear and Camshaft Idler Gear Assembly
  •  1.27 Crankshaft Timing Gear and Timing Wheel
  •  1.28 Balance Shaft and Oil Pump Mechanism
  •  1.29 Accessory Drive
  •  1.30 Jake Brake
  •  2 Fuel System
  •  2.1 Fuel System Overview
  •  2.2 Vehicle Safety for the Natural Gas Engine
  •  2.3 Electronic Unit Injector
  •  2.4 Fuel Injector Tube and O-Ring
  •  2.5 Fuel Pump
  •  2.6 Fuel Pump Drive
  •  2.7 Fuel Filters (Spin-On)
  •  2.8 Fuel Filter and Water Separator Assembly
  •  2.9 Fuel Pro ® 380/380E Fuel Filter System
  •  2.10 Electronic Engine Control
  •  2.11 DDEC III
  •  2.12 DDEC II ECM
  •  2.13 Electronic Foot Pedal Assembly
  •  2.14 Turbo Boost Pressure Sensor
  •  2.15 Turbo Boost Pressure Sensor for the Series 50G Engines
  •  2.16 Manifold Absolute Pressure Sensor
  •  2.17 Air Intake Pressure Sensor
  •  2.18 Oil Pressure Sensor
  •  2.19 Oil Temperature Sensor
  •  2.20 Synchronous Reference Sensor
  •  2.21 Timing Reference Sensor
  •  2.22 Coolant Level Sensor
  •  2.23 Fuel Pressure Sensor
  •  2.24 Fuel Temperature Sensor
  •  2.25 Exhaust Gas Oxygen Sensor for Series 50G Engines
  •  2.26 Exhaust Temperature Sensor for the Series 50G Engines
  •  2.27 Knock Sensor and Signal to Noise Enhancement Filter (S.n.e.f.) Module for the Series 50G Automotive Engines
  •  2.28 Overview of the High Pressure Fuel System for the Series 50G Automotive Engine (Pre 1998)
  •  2.29 Overview of High Pressure Fuel System for 1998 and Later Series 50G Automotive Engines
  •  2.30 Barometric Pressure Sensor for the Series 50G Engine With High Pressure Fuel System 1998 and Later
  •  2.31 High Pressure Fuel Regulator for the Series 50G Engine
  •  2.32 High Pressure Fuel Regulator for the Series 50G Engine Prior to 1998
  •  2.33 Fuel Mixer for the Series 50G High Pressure System 1998 and Later
  •  2.34 Fuel Shutoff Valve for 1998 and Later Series 50G Engine With High Pressure Fuel System
  •  2.35 Fuel Pressure Gages for the Series 50G Engine With a High Pressure Fuel System
  •  2.36 Venting and Leak Checking Procedures for a Natural Gas Engine (High Pressure System)
  •  2.37 Fuel Mixer for the Series 50G Engine With High Pressure Fuel System (Prior to 1998)
  •  2.38 Pulse Width Modulated Stepper Motor Valve (Psv) for 1998 and Later Series 50G Automotive Engines
  •  2.39 Overview of the Low Pressure Fuel System for the Series 50G Generator Set Engine (1998 and Later)
  •  2.40 Impco Low Pressure Fuel Regulator for the Series 50G Engine
  •  2.41 Low Pressure Fuel Regulator for the Series 50G Engine
  •  2.42 Fuel Mixer for the Series 50G Low Pressure System
  •  2.43 Venting and Leak Checking Procedures for a Natural Gas Engine (Low Pressure System)
  •  2.44 Compuvalve for the Series 50G Engine
  •  2.45 Fuel Shutoff Valves for the Series 50G Engine Prior to 1998
  •  2.46 Hose, Fitting, and Filter for the Series 50G Engine
  •  2.47 Fuel Filter Type for the Series 50G Engine
  •  3 Lubrication System
  •  3.1 Overview of Lubricating System
  •  3.2 Oil Pump
  •  3.3 Oil Pressure Regulator Valve
  •  3.4 Oil Pressure Relief Valve
  •  3.5 Oil Filter
  •  3.6 Oil Filter Adaptor
  •  3.7 Oil Cooler
  •  3.8 Oil Level Dipstick Assembly
  •  3.9 Oil Pan
  •  3.10 Ventilating System
  •  4 Cooling System
  •  4.1 Cooling System Overview
  •  4.2 Water Pump
  •  4.3 Thermostat
  •  4.4 Coolant Pressure Control Cap
  •  4.5 Engine Cooling Fan
  •  4.6 Coolant Filter and Conditioner
  •  4.7 Radiator
  •  5 Fuel, Lubricating Oil, and Coolant
  •  5.1 Fuel
  •  5.2 Lubricating Oil
  •  5.3 Lubricating Oil for the Series 50G Engine
  •  5.4 Coolant
  •  6 Air Intake System
  •  6.1 Air Intake System Overview
  •  6.2 Air Cleaner
  •  6.3 Intake Manifold
  •  6.4 Closed Crankcase Breather for S50g Automotive Engines (1998 and Later)
  •  6.5 Turbocharger Series 50 Diesel
  •  6.6 Turbocharger Series 50 Gas
  •  6.7 Charge Air Cooler
  •  6.8 Throttle Actuator for the Series 50G Engine
  •  6.9 Air Dryer
  •  7 Exhaust System
  •  7.1 Overview of Exhaust System
  •  7.2 Exhaust Manifold
  •  8 Electrical Equipment
  •  8.1 Overview of Electrical System
  •  8.2 Overview of Electrical System for Series 50G Engine
  •  8.3 Battery Charging Alternator
  •  8.4 Storage Battery
  •  8.5 Cranking Motor
  •  8.6 DDEC III Wiring Harness
  •  8.7 Metri-Pack™ 150 Series Connectors
  •  8.8 Micro-Pack™ Series Connectors
  •  8.9 Weather Pack™ and Metri-Pack 280 Series Connectors
  •  8.10 Connector Tools
  •  8.11 Splicing Guidelines
  •  9 Power Take-Off
  •  9.1 Rear Engine Power Take-Off (REPTO) Assembly
  •  9.2 Front Mounted Power Take-Off
  •  10 Special Equipment
  •  10.1 Air Compressor
  •  10.2 Air Compressor Drive Hub
  •  10.3 Air Compressor Drive Assembly
  •  11 Operation and Verification
  •  11.1 Preparation for a First Time Start
  •  11.2 Starting
  •  11.3 Running
  •  11.4 Stopping
  •  11.5 Operating Conditions
  •  11.6 Series 50G Operating Conditions
  •  11.7 Manifold Absolute Pressure Sensor (Map Sensor) for the Series 50G Engine
  •  11.8 Engine Run-in Instructions
  •  12 Engine Tune-Up
  •  12.1 Engine Tune-Up Procedures
  •  12.2 Valve Lash, Injector Height (Timing) and Jake Brake ® Lash Adjustments
  •  12.3 Engine Tune-Up Procedures for the Series 50G Engine
  •  12.4 Valve Lash for the Series 50G Engine
  •  13 Preventive Maintenance
  •  13.1 Maintenance Overview
  •  13.2 Daily Maintenance – All Applications
  •  13.3 Maintenance of Vehicle Engines
  •  13.4 Maintenance of Engines Used in Stationary and Industrial Applications
  •  13.5 Description of Maintenance Items
  •  13.6 Preventive Maintenance for the Series 50G Engine (City Transit Coach)
  •  13.7 Maintenance of Series 50G Engines
  •  13.8 Maintenance of Series 50G Engines for Generator Set
  •  13.9 Lubricating Oil and Filter Change Intervals for Genset
  •  13.10 Lubricating Oil and Filter Change Intervals for Genset (With High Sulfur Fuels)
  •  13.11 Detecting Internal Fuel Leaks
  •  13.12 Cleaning Contaminated Lubrication Oil System
  •  14 Engine Storage
  •  14.1 Preparing Engine for Storage
  •  14.2 Restoring An Extended Storage Engine
  •  15 Ignition System
  •  15.1 Overview of Ignition System
  •  15.2 Remote Mount Ignition Coils
  •  15.3 Ignition Wire Harness
  •  15.4 Waste Wire Harness
  •  15.5 Ignition Boot
  •  15.6 Ignition Wire and Waste Wire Routing
  •  15.7 Ignition Wire Brackets
  •  15.8 Ignition Boot Retainers
  •  15.9 Ignition Coil Harness
  •  15.10 Spark Plugs
  •  15.11 Coil Over Plug Ignition System
  •  15.12 Ignition Boot Assembly
  •  15.13 Igniter Module
  •  15.14 Igniter Module Bracket
  •  15.15 Ignition Coil Harness
  •  15.16 Spark Plugs
  •  16 Misfiring Cylinder
  •  16.1 Poor Vehicle Ground
  •  16.2 Aerated Fuel
  •  16.3 Improper Injector Calibration Setting (DDEC III Engines Only)
  •  16.4 Improper Valve Clearance or Injector Height, Worn or Damaged Camshaft Lobes and Rollers
  •  16.5 Faulty Fuel Injector
  •  16.6 Faulty Electronic Control Module
  •  16.7 Worn or Damaged Valve or Cylinder Kit
  •  17 Starting Difficulty (Engine Rotates)
  •  17.1 Empty Fuel Tank
  •  17.2 Electronic Control Module Wiring Harness
  •  17.3 Low Battery Voltage
  •  17.4 Corroded or Damaged Battery Terminals
  •  17.5 Defective Magnetic Switch
  •  17.6 Defective Starter
  •  17.7 Low Cranking Speed
  •  17.8 Fuel Supply Valve
  •  17.9 Plugged Fuel Filter(S)
  •  17.10 Fuel Pump
  •  17.11 Aerated Fuel
  •  17.12 Restrictive Air Filter
  •  17.13 Low Compression
  •  18 No Start (Engine Will Not Rotate)
  •  18.1 Discharged Battery
  •  18.2 Defective Magnetic Switch
  •  18.3 Defective Starter
  •  18.4 Internal Engine Damage
  •  19 Excessive Oil Consumption
  •  19.1 Miscalibrated Dipstick
  •  19.2 External Oil Leaks
  •  19.3 Leaking Oil Cooler Core
  •  19.4 Defective Air Compressor
  •  19.5 Defective Turbocharger
  •  19.6 Worn or Damaged Valve or Cylinder Kit
  •  20 Excessive Crankcase Pressure
  •  20.1 Obstruction or Damage to Rocker Cover Breather
  •  20.2 Defective Air Compressor
  •  20.3 Defective Turbocharger
  •  20.4 Worn or Damaged Valve or Cylinder Kit
  •  21 Excessive Exhaust Smoke (Black or Gray)
  •  21.1 Improper Grade of Fuel Oil
  •  21.2 Restricted Air Cleaner Element
  •  21.3 Restricted or Cracked Charge Air Cooler
  •  21.4 Faulty Exhaust System
  •  21.5 Faulty Fuel Injector
  •  21.6 Defective Turbocharger
  •  22 Excessive Blue Smoke
  •  22.1 Defective Turbocharger
  •  22.2 Worn or Damaged Valve or Cylinder Kit
  •  23 Excessive White Smoke
  •  23.1 Improper Grade of Fuel
  •  23.2 Defective Fuel Pump
  •  23.3 Aerated Fuel
  •  23.4 Improper Injector Calibration Setting (DDEC III Engines Only)
  •  23.5 Improper Valve Clearance or Injector Height, Worn or Damaged Camshaft Lobes and Rollers
  •  23.6 Faulty Fuel Injector
  •  23.7 Faulty Electronic Control Module
  •  24 Rough Running or Stalling
  •  24.1 Low Battery Voltage
  •  24.2 Aerated Fuel Oil
  •  24.3 Insufficient Fuel Oil Flow
  •  24.4 High Fuel Oil Temperature Return
  •  24.5 Improper Injector Calibration Setting (DDEC III Engines Only)
  •  24.6 Low Compression Pressure
  •  25 Lack of Power
  •  25.1 Aerated Fuel
  •  25.2 High Fuel Pressure
  •  25.3 High Fuel Oil Temperature Return
  •  25.4 Restricted Air Cleaner Element
  •  25.5 Restricted or Cracked Charge Air Cooler or Leaking Intake Manifold
  •  25.6 Faulty Exhaust System
  •  25.7 High Inlet Air Temperature
  •  25.8 High Altitude Operation
  •  25.9 Incorrect Camshaft Timing
  •  26 Low Oil Pressure
  •  26.1 Improper Engine Oil Level
  •  26.2 Improper Lubricating Oil Viscosity
  •  26.3 Lubricating Oil Diluted With Fuel Oil or Engine Coolant
  •  26.4 Faulty Oil Pressure Gage Sensor
  •  26.5 Oil Pressure Gage Line Obstructed
  •  26.6 Rocker Arm Shaft Plugs Missing (New or Rebuilt Engines Only)
  •  26.7 Restricted Oil Cooler
  •  26.8 Nonfunctional or Sticking Oil Pressure Regulator Valve
  •  26.9 Defective Bypass Valve
  •  26.10 Defective Pressure Relief Valve
  •  26.11 Defective Pickup Screen Tube and Screen Assembly
  •  26.12 Defective Crankshaft Main Bearing Shells
  •  26.13 Defective Oil Pump Assembly
  •  27 High Engine Coolant Temperature
  •  27.1 Improper Engine Coolant Level
  •  27.2 Insufficient Radiator Air Circulation
  •  27.3 Faulty Pressure Control Cap
  •  27.4 Defective Coolant Hoses
  •  27.5 Fan Belts Are Incorrectly Adjusted
  •  27.6 Inoperative Thermo-Modulated Fan
  •  27.7 Faulty Thermostats
  •  27.8 Faulty Water Pump
  •  27.9 Combustion Gases in Coolant
  •  27.10 Abnormal Radiator Coolant Flow
  •  28 Low Coolant Temperature
  •  28.1 Faulty Thermostats
  •  29 Common Tests
  •  29.1 Proper Use of Manometer
  •  29.2 Cylinder Compression Test
  •  29.3 Crankcase Pressure Test (Governed Speed No Load)
  •  29.4 Crankcase Pressure Test (Dynamic)
  •  29.5 Lube Oil Consumption Report
  •  29.6 Diesel Fuel Quality and Selection
  •  29.7 Fuel Oil Flow Test
  •  29.8 Lubricating Oil Criteria
  •  30 Common Repairs

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