Detroit Diesel 50-Series Diesel & Natural Gas Engines (6SE50, 50G incl. DDEC II/III, 1998+) Workshop Repair Service Manual PDF - MDD50OPEK.zip
The complete factory service guide for Detroit Diesel 50-Series engines running on both diesel and natural gas, packed with everything you need to service, troubleshoot, fix, and overhaul these units at a professional level.
Inside this workshop and repair manual for the Detroit Diesel 50-Series Diesel & Natural Gas-Fueled Engines, you'll find:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
Detroit Diesel Diesel and Natural Gas-Fueled Engines Service Manual (6SE50, Mar-2004).pdf
PRODUCT DETAILS:
Total Pages: 1,683 pages
File Format: PDF (bookmarked, Searchable, Printable, high quality)
Language: English
TABLE OF CONTENTS
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 31
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 ASSEMBLY 1-3
1.A 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
2.15 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
2.A 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
3.10 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
4.A COOLING SYSTEM
COOLING SYSTEM OVERVIEW
WATER PUMP
THERMOSTAT
COOLANT PRESSURE CONTROL CAP
ENGINE COOLING FAN
COOLANT FILTER AND CONDITIONER
RADIATOR
ADDITIONAL INFORMATION 4-3
5.4 FUEL, LUBRICATING OIL, AND COOLANT
FUEL
LUBRICATING OIL
LUBRICATING OIL FOR THE SERIES 50G ENGINE
COOLANT 5-3
6.A 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 6-20
7.2 EXHAUST SYSTEM
OVERVIEW OF EXHAUST SYSTEM
EXHAUST MANIFOLD 7-3
8.A 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-PACKTM 150 SERIES CONNECTORS
MICRO-PACKTM SERIES CONNECTORS
WEATHER PACKTM AND METRI-PACK 280 SERIES CONNECTORS
CONNECTOR TOOLS
SPLICING GUIDELINES
ADDITIONAL INFORMATION 8-3
9.1 POWER TAKE-OFF
REAR ENGINE POWER TAKE-OFF (REPTO) ASSEMBLY 9-3
9.2 FRONT MOUNTED POWER TAKE-OFF
10.A SPECIAL EQUIPMENT
AIR COMPRESSOR 10-3
AIR COMPRESSOR DRIVE HUB 10-9
AIR COMPRESSOR DRIVE ASSEMBLY 10-14
ADDITIONAL INFORMATION 10-31
11.7 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
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
14.2 ENGINE STORAGE
PREPARING ENGINE FOR STORAGE
RESTORING AN EXTENDED STORAGE ENGINE 14-3
15.2 IGNITION SYSTEM
OVERVIEW OF IGNITION SYSTEM
REMOTE MOUNT IGNITION COILS 15-3
15.16 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
16.7 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
17.13 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
18.4 NO START (ENGINE WILL NOT ROTATE)
DISCHARGED BATTERY 18-3
DEFECTIVE MAGNETIC SWITCH 18-5
DEFECTIVE STARTER 18-8
INTERNAL ENGINE DAMAGE 18-10
19.1 EXCESSIVE OIL CONSUMPTION
MISCALIBRATED DIPSTICK
19.6 EXTERNAL OIL LEAKS 19-4
LEAKING OIL COOLER CORE 19-6
DEFECTIVE AIR COMPRESSOR 19-8
DEFECTIVE TURBOCHARGER 19-10
WORN OR DAMAGED VALVE OR CYLINDER KIT 19-11
20.4 EXCESSIVE CRANKCASE PRESSURE
OBSTRUCTION OR DAMAGE TO ROCKER COVER BREATHER
DEFECTIVE AIR COMPRESSOR
DEFECTIVE TURBOCHARGER
WORN OR DAMAGED VALVE OR CYLINDER KIT
21.6 EXCESSIVE EXHAUST SMOKE (BLACK OR GRAY)
IMPROPER GRADE OF FUEL OIL 21-3
RESTRICTED AIR CLEANER ELEMENT 21-5
RESTRICTED OR CRACKED CHARGE AIR COOLER 21-7
FAULTY EXHAUST SYSTEM 21-10
FAULTY FUEL INJECTOR 21-12
DEFECTIVE TURBOCHARGER 21-14
22.2 EXCESSIVE BLUE SMOKE
DEFECTIVE TURBOCHARGER
WORN OR DAMAGED VALVE OR CYLINDER KIT
23.4 EXCESSIVE WHITE SMOKE
IMPROPER GRADE OF FUEL
DEFECTIVE FUEL PUMP
AERATED FUEL
IMPROPER INJECTOR CALIBRATION SETTING (DDEC III ENGINES ONLY)