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4 KNOCK

1. NOTE The best method to apply a load through Stall speed to 2100 RPM is to drive the vehicle up a hill locked into a lower gear to prevent transmission shifting If a hill is not available lock the vehicle in low gear and accelerate from a stop to 2100 RPM full load a Slowly operate the engine from Stall speed to 2100 RPM with an applied load b Repeat step 3 a until the engine runs smooth through this speed range 4 Road test the vehicle as follows a Operate the engine through a variety of speed and loads while looking for any misfires b Ifa particular RPM Manifold pressure range still experiences misfire then operate the engine around that point by running through that range slowly c Repeat step 4 a and step 4 b until the engine runs smooth without any lean misfires A smooth running engine means the Fuel System Learn Procedure is complete Rev 10 03 All information subject to change without notice 4 28 From Bulletin 4 50G 60GTS 03 6SE482 0109 Copyright 2003 DETROIT DIESEL CORPORATION SERIES 50G 60G TROUBLESHOOTING MANUAL 4 10 ACCESSORIES AND BRACKETS Check all accessories and brackets located on or near the engine as follows 1 Open engine compartment doors 2 Start the engine using the controls located at the engine bay 3 Turn the vehicle air conditioning on 4 Slowly take the engine from idle to 2100 RPM and back down to idle over a one minute time period 5 Observe and inspect the air co
2. 1 Tighten the two bolts from the throttle bracket to the gear case Rev 10 03 All information subject to change without notice 4 14 From Bulletin 4 50G 60GTS 03 6SE482 0109 Copyright 2003 DETROIT DIESEL CORPORATION SERIES 50G 60G TROUBLESHOOTING MANUAL Tighten the one bolt from the throttle bracket to the cylinder head Tighten the four bolts from the Mixer PSV assembly to the throttle Tighten the four bolts from the throttle to the inlet elbow Tighten the two bolts from the low pressure regulator Tighten the two bolts from the throttle bracket to the inlet elbow Sd Sch Re e Ze Tighten the four bolts from the bottom of the throttle bracket to the throttle 4 6 3 2 Throttle Assembly Procedure Replace the throttle assembly as follows All information subject to change without notice Rev 10 03 6SE482 0109 Copyright 2003 DETROIT DIESEL CORPORATION From Bulletin 4 50G 60GTS 03 4 15 4 6 PSV ASSEMBLY 1 Install the inlet elbow to the throttle body flange with the flow arrow on the throttle body pointing towards the inlet elbow Attach with four bolts but do not tighten See Figure 4 3 1 Fuel Pressure Sensor 9 Washer 2 Low Pressure Regulator 10 PSV O ring 3 Elbow 11 Bolt 4 Balance Line 12 Mixer Assembly 5 Fuel Transfer Tube 13 Gasket 6 O rings 14 Throttle Body 7 PSV 15 Elbow 8 Bolt 16 Air Temperature Sensor Figure 4 3 Assembling the Throttle Series 50G 2 Install mixer as
3. 4 Confirm the ground surfaces are properly connected to the vehicle ground Repair any bad ground connection and continue If the Fake Knock Code problem continues contact DDC technical service If there are no longer Knock Codes troubleshooting is done Rev 10 03 All information subject to change without notice From Bulletin 4 50G 60GTS 03 6SE482 0109 Copyright 2003 DETROIT DIESEL CORPORATION
4. 4 50G 60GTS 03 4 9 4 5 AIR INTAKE COMPONENTS b Clean or replace the Air Cleaner as required Refer to the vehicle OEM service manual c Road test the vehicle d If the engine still knocks check the PSV operation Refer to section 4 6 e Ifthe engine no longer knocks troubleshooting is done Rev 10 03 All information subject to change without notice 4 10 From Bulletin 4 50G 60GTS 03 6SE482 0109 Copyright 2003 DETROIT DIESEL CORPORATION SERIES 50G 60G TROUBLESHOOTING MANUAL 4 6 PSV ASSEMBLY The Pulse Width Modulated Stepper Motor Valve PSV biases gas flow to the venturi mixer to control the air fuel ratio See Figure 4 1 The following PSV component procedures are used to diagnose a natural gas Series 50G or Series 60G DDEC Engine which knocks during operation 1 PSV 5 Fuel Mixer 2 Bolt 6 Connector O rings 3 Washer 7 Fuel Transfer Tube 4 PSV O ring Figure 4 1 Pulse Width Modulated Stepper Motor Valve and Fuel Mixer 4 6 1 PSV Operation Check Check for proper PSV operation during cranking as follows 1 Connect the DDR or DDDL J 47500 and display PWM No 3 position and Gas Valve position All information subject to change without notice Rev 10 03 6SE482 0109 Copyright 2003 DETROIT DIESEL CORPORATION From Bulletin 4 50G 60GTS 03 4 11 4 6 PSV ASSEMBLY A caution To avoid injury from an explosion of natural gas the following precautions must be taken O Do not smoke when in
5. 50 41655 Figure 4 2 PSV Connector b If there is no voltage check the Engine Sensor Harness ESH and PSV connector Refer to DDEC III IV Single ECM Troubleshooting Guide 6SE497 Repair or replace the ESH as necessary Rev 10 03 All information subject to change without notice 4 12 From Bulletin 4 50G 60GTS 03 6SE482 0109 Copyright 2003 DETROIT DIESEL CORPORATION 4 6 2 SERIES 50G 60G TROUBLESHOOTING MANUAL c If there is a voltage check the PWM No 3 output Connect the voltmeter positive lead to wire 910 orange pin H and negative lead to wire 150A black pin B in PSV connector see Figure 4 2 With the DDR slew the PWM No 3 output from 10 to 50 and then to 90 d If there is a change in voltage then troubleshoot the PSV assembly refer to section 4 6 2 e If there is no change in voltage then troubleshoot the ESH and PSV connector Refer to DDEC HIV Single ECM Troubleshooting Guide 6SE497 Repair or replace the ESH as necessary If the gas valve does not move from 0 check the voltage using a voltmeter Connect positive lead to wire 446 red pin A and negative lead to wire 150A black pin B of the PSV connector see Figure 4 2 a If there is a voltage at the PSV connector then troubleshoot the PSV assembly refer to section 4 6 2 b If there is no voltage then troubleshoot the ESH PSV connector and the OEM power harness Refer to DDEC III IV Single ECM Troubleshooting Guide 6SE497 Rep
6. Check electrical connections and electronic controls a Confirm wiring harnesses at DDEC are connected b Confirm ground straps from engine to starter are connected Rev 10 03 All information subject to change without notice 4 4 From Bulletin 4 50G 60GTS 03 6SE482 0109 Copyright 2003 DETROIT DIESEL CORPORATION SERIES 50G 60G TROUBLESHOOTING MANUAL c Confirm the PLC Multiplex Electrical System is getting power d Confirm proper operation of the fire suppression system and the methane detection system Refer to OEM Vehicle Manual e Confirm proper operation of the fuel door magnetic switch Refer to OEM Vehicle Manual f Confirm proper operation of all tank valves and high pressure solenoid valve during cranking Refer to OEM Vehicle Manual g Confirm proper operation of the Stop Engine Light SEL h Confirm proper operation of the Check Engine Light CEL A cauTion To avoid injury from an explosion of natural gas the following precautions must be taken O Do not smoke when installing or servicing the engine or fuel system Q Installation or servicing of natural gas equipment must only be conducted in well ventilated natural gas compatible areas Do not install or service equipment in an enclosed area where ignition sources are present without first ensuring that an undetected gas leak may be safely vented without being ignited Bleed natural gas lines before installing or servicing any compon
7. Service Manual 6SES0 3 Check the valve lash Ensure the Intake valve lash is set at 0 28 mm 0 011 in and the exhaust valve lash is set at 0 91 mm 0 036 in Refer to Series 60 Service Manual 6SE483 or Series 50 Service Manual 6SESO NOTE Valve Lash must be measured with engine at room temperature a If the valves are not set at proper lash values reset the Intake valves at 0 28 mm 0 011 in and the exhaust valves at 0 91 mm 0 036 in b If the valves are set at the proper lash values check the Fuel Composition Refer to section 4 12 4 If the no longer knocks troubleshooting is done Rev 10 03 All information subject to change without notice 4 30 From Bulletin 4 50G 60GTS 03 6SE482 0109 Copyright 2003 DETROIT DIESEL CORPORATION SERIES 50G 60G TROUBLESHOOTING MANUAL 4 12 FUEL COMPOSITION The quality of fuel used is a very important factor in obtaining satisfactory engine performance long engine life and acceptable exhaust emission levels Listed in Table 4 2 are the DDC fuel specifications for both CNG and LNG Regardless of the type of fuel fuel entering the engine must meet or exceed DDC s published CNG specifications BA ASTM Test Property Limit Method Hydrocarbon Mole Percent Methane 88 min D 1945 Ethane 6 max Propane 1 7 max Other C4 and Higher 0 3 max Other Gaseous Species Mole Percent Hydrogen 0 1 max D 2650 Carbon dioxide Nit
8. Spark Plug 3 Gap spark plugs to 0 38 mm 0 015 in Tighten the spark plugs to 38 N m 28 ft lb Check the Accessories and Brackets refer to section 4 10 All information subject to change without notice Rev 10 03 6SE482 0109 Copyright 2003 DETROIT DIESEL CORPORATION From Bulletin 4 50G 60GTS 03 4 27 4 9 FUEL SYSTEM LEARN PROCEDURE 49 FUEL SYSTEM LEARN PROCEDURE Fill in the AFR table for the Fuel System as follows NOTE Use a chassis dynamometer to apply loads to the engine whenever appropriate as an alternative to on highway vehicle operation 1 Fill in the AFR table values from idle to No Load speed for the unloaded portion as follows a Reset the AFR table with the DDR b Slowly increase the engine speed from idle to No Load 0 100 throttle and then slowly decrease the speed back to idle 100 0 throttle over one minute c Repeat step I b two times 2 Fill in the AFR table values from idle to Stall speed for the loaded portion as follows a With an applied load slowly increase the engine speed from idle to Stall speed 0 100 throttle and then slowly decrease the speed back to idle 100 0 throttle over one minute b Repeat step 2 a two times 3 Fill in the AFR table above the Stall speed for the unloaded portion as follows NOTE The engine must operate in this speed boost range for a moderate length of time The AFR table will not completely fill in just passing through this range
9. 0 H to connect the DDR Use PC card J 38500 2300 installed in the computer to connect the DDDL J 47500 10 4 8 8 Read active and inactive codes by selecting the DIAGNOSTIC CODE MENU ACTIVE CODES on the DDR or DDDL J 47500 If the vehicle registers no knock codes then the original knock codes are real Check the Air Intake Components refer to section 4 5 If the vehicle still has knock codes then the original knock codes are fake and are being caused by wiring or bad grounds Check the starter and block ground connections refer to section 4 14 Rev 10 03 All information subject to change without notice From Bulletin 4 50G 60GTS 03 6SE482 0109 Copyright 2003 DETROIT DIESEL CORPORATION SERIES 50G 60G TROUBLESHOOTING MANUAL 4 5 AIR INTAKE COMPONENTS Check the intake manifold temperature and operation of the Charge Air Cooler Engine Cooling Fan and Air Cleaner as follows 1 Road test the vehicle 2 Turn on the ignition Plug the Diagnostic Data Reader DDR or the Diesel Diagnostic Data Link DDDL J 47500 into the Diagnostic Connector NOTE Use the Pro Link kit J 38500 H to connect the DDR Use PC card J 38500 2300 installed in the computer to connect the DDDL J 47500 3 Read active and inactive codes by selecting the DIAGNOSTIC CODE MENU ACTIVE CODES on the DDR or DDDL J 47500 4 With the vehicle is running use the DDR or DDDL to read the Intake Manifold Temperature a b If the Inta
10. 10 03 6SE482 0109 Copyright 2003 DETROIT DIESEL CORPORATION From Bulletin 4 50G 60GTS 03 4 21 4 8 IGNITION SYSTEM 4 8 IGNITION SYSTEM The Ignition System s main components are the ignition coil harness the igniter module the ignition coils the ignition boot assemblies the spark plugs and the ground strap see Figure 4 6 In addition the Ignition System requires a different rocker cover with extension tubes for the spark plugs attached to the rocker cover cap see Figure 4 7 Also the cylinder head is machined to accept the spark plug extension tubes 1 Boot and Spring Assembly 6 Ignition Coil Harness 2 Ignition Coil Assembly 7 Spark Plug 3 Igniter Module Bracket 8 O ring 4 Bolt 9 Ignition Coil and Boot Assembly 5 Igniter Module 10 Ground Strap Figure 4 6 Ignition System Series 50G Rev 10 03 All information subject to change without notice 4 22 From Bulletin 4 50G 60GTS 03 6SE482 0109 Copyright 2003 DETROIT DIESEL CORPORATION 1 Gasket O ring Extension Tube O ring Screw Cover Bolt N DO Oo A WD DY Figure 4 7 SERIES 50G 60G TROUBLESHOOTING MANUAL 8 Rocker Cover Cap 9 Bolt 10 Isolator 11 Spacer 12 Rocker Cover Base 13 Seal Ring Two Piece Rocker Cover Series 50G The following procedures are used to diagnose a natural gas Series 50G or Series 60G DDEC Engine which knocks during operation 4 8 1 Spark Plug Well Inspection Check the Spa
11. 4 KNOCK Section Page Aci INTRODUCTION co eebe eene leed 4 3 4 2 VEHICLE CONDITION EE 4 4 43 KNOCK INTERNA 4 7 4 4 VERIFICATION OF ENGINE KNOCK aaissssnnnnssssneernnnsssnerrnnsssnrennneeneene 4 8 4 5 AIR INTAKE COMPONENTS ccccccccssseeceeeeeeesenaeeeeeeeesesseeeeeeeeeesseas 4 9 4 6 PSVASSEMBLY EE 4 11 Ad OXYGEN SENSOR EE 4 20 4 8 IGNITION RE E NEEN 4 22 4 9 FUEL SYSTEM LEARN PROCEDURE ccccecssssssceseseseeessseees 4 28 4 10 ACCESSORIES AND BRACKETS cccccccccccccccsseteeeeeeeseeseneeeeeeeeesseeas 4 29 4 11 VALVE AND INJECTOR OPERATING MECHANISMS on nnnnnnnonnnnnnnneannnn 4 30 4 12 FUEL COMPOSITION 0 ccccssssssceeessssscceescecesssssseteeeeeeessscessseeseessssaees 4 31 4 13 INTERNAL ENGINE COMPONENTS nniiioonnnnnnneennnnnnnnsssnerrnnnnssserrnnneeenne 4 33 4 14 FAKE KNOCK CODES ere EE 4 34 Rev 10 03 All information subject to change without notice 4 2 From Bulletin 4 50G 60GTS 03 6SE482 0109 Copyright 2003 DETROIT DIESEL CORPORATION SERIES 50G 60G TROUBLESHOOTING MANUAL 4 1 INTRODUCTION The following section gives procedures to diagnose a natural gas Series 50G or Series 60G DDEC Engine which knocks during operation All information subject to change without notice Rev 10 03 6SE482 0109 Copyright 2003 DETROIT DIESEL CORPORATION From Bulletin 4 50G 60GTS 03 4 3 4 2 VEHICLE CONDITION 4 2 VEHICLE CONDITION Obvious part and component problems may caus
12. air or replace the ESH and the OEM power harness as necessary If the Gas Valve position moves but appears to have sluggish or erratic movement check voltage at the PSV connector with a voltmeter Connect positive lead to wire 446 red pin A and negative lead to wire 150A black pin B see Figure 4 2 a If there is less than 10 volts charge the batteries b If 10 12 volts are present during cranking then troubleshoot the PSV assembly refer to section 4 6 2 PSV Assembly Troubleshooting Troubleshoot the PSV assembly as follows 1 2 Remove PSV from engine Do not unplug electronic connector Remove 13 mm plug and install digital dial indicator Mitutoyo Digimatic Indicator part No 575 123 or equivalent Mitutoyo is a registered trademark of Mitutoyo Manufacturing Co LTD Plug in DDR reader and go to activate outputs Input 0 PWM to PWM No 3 Set digital indicator to 0 mm 0 in All information subject to change without notice Rev 10 03 6SE482 0109 Copyright 2003 DETROIT DIESEL CORPORATION From Bulletin 4 50G 60GTS 03 4 13 4 6 PSV ASSEMBLY 5 Input values listed in Table 4 1 from column 1 to PWM No 3 with the DDR PWM No 3 Reading Programmed Travel Travel Limits 0 mm 0m fee es 1 mm 0 04 in 0 9 1 1 mm 0 035 0 043 in 5 mm 0 20 in 4 9 5 1 mm 0 193 0 201 in 100 10 mm 0 39 in 9 9 10 1 mm 0 390 0 398 in Column 2 shows the programmed travel and column 3 shows the lim
13. e a Knock condition The first step in diagnosing the engine is to check related vehicle conditions 4 2 1 Troubleshooting the Vehicle To ensure obvious part and component problems are not causing a Knock condition troubleshoot as follows 1 Check the vehicle controls a Confirm the vehicle has natural gas in its tanks b Confirm the ignition system is on c Confirm the batteries are charged d Confirm the manual gas valve is open during cranking e Confirm the fuel door is closed A caAuTioN To avoid injury from an explosion of natural gas the following precautions must be taken O Do not smoke when installing or servicing the engine or fuel system Q Installation or servicing of natural gas equipment must only be conducted in well ventilated natural gas compatible areas Do not install or service equipment in an enclosed area where ignition sources are present without first ensuring that an undetected gas leak may be safely vented without being ignited Bleed natural gas lines before installing or servicing any component connected to the fuel lines Q Natural gas fuel systems are pressurized Relieve pressure from any fuel system component prior to installation or service of that component Natural gas is highly flammable and explosive and may be extremely cold 260 F 162 C f If the engine still knocks go to step 2 g If the engine no longer knocks troubleshooting is done 2
14. e pressurized Relieve pressure from any fuel system component prior to installation or service of that component Natural gas is highly flammable and explosive and may be extremely cold 260 F 162 C b If the engine still knocks check the knock intensity refer to section 4 3 c If the engine no longer knocks troubleshooting is done Rev 10 03 All information subject to change without notice From Bulletin 4 50G 60GTS 03 6SE482 0109 Copyright 2003 DETROIT DIESEL CORPORATION SERIES 50G 60G TROUBLESHOOTING MANUAL 4 3 KNOCK INTENSITY Determine the intensity and frequency of the knock condition as follows 1 Turn on the ignition Plug the Diagnostic Data Reader DDR or the Diesel Diagnostic Data Link DDDL J 47500 into the Diagnostic Connector NOTE Use the Pro Link kit J 38500 H to connect the DDR Use PC card J 38500 2300 installed in the computer to connect the DDDL J 47500 2 Read active and inactive codes by selecting the DIAGNOSTIC CODE MENU ACTIVE CODES on the DDR or DDDL J 47500 3 Determine if the vehicle has Engine Knock Level Above Normal Range SID 76 FMI 0 or Engine Knock Level Torque Reduction SID 76 FMI 7 a If the number of Engine Knock Level Above Normal Range SID 76 FMI 0 and Engine Knock Level Torque Reduction SID 76 FMI 7 codes is greater than or equal to four codes per engine operating hour from the first knock code occurrence to the last knock code occu
15. ent connected to the fuel lines Q Natural gas fuel systems are pressurized Relieve pressure from any fuel system component prior to installation or service of that component Natural gas is highly flammable and explosive and may be extremely cold 260 F 162 C i Ifthe engine still knocks go to step 3 j Ifthe engine no longer knocks troubleshooting is done 3 Check the installation requirements for the electronic system a Verify the installation requirements for the electronic system have been met Refer to section 8 If the engine installation requirements for the electronic system did not comply repair as required All information subject to change without notice Rev 10 03 6SE482 0109 Copyright 2003 DETROIT DIESEL CORPORATION From Bulletin 4 50G 60GTS 03 4 5 4 2 4 6 VEHICLE CONDITION A caution To avoid injury from an explosion of natural gas the following precautions must be taken O Do not smoke when installing or servicing the engine or fuel system Q Installation or servicing of natural gas equipment must only be conducted in well ventilated natural gas compatible areas Do not install or service equipment in an enclosed area where ignition sources are present without first ensuring that an undetected gas leak may be safely vented without being ignited Bleed natural gas lines before installing or servicing any component connected to the fuel lines Q Natural gas fuel systems ar
16. fications All information subject to change without notice Rev 10 03 6SE482 0109 Copyright 2003 DETROIT DIESEL CORPORATION From Bulletin 4 50G 60GTS 03 4 31 4 12 FUEL COMPOSITION Check the Fuel Composition for problems that could cause Knock as follows 1 Ask for a gas analysis from your local gas supplier and confirm that the gas that you are using is within DDC s specifications listed in Table 4 2 a If the fuel is within DDC s specification then check the Internal Engine Components Refer to section 4 13 b If the fuel is not within DDC s Specifications contact Technical Service 2 If the no longer knocks troubleshooting is done Rev 10 03 All information subject to change without notice 4 32 From Bulletin 4 50G 60GTS 03 6SE482 0109 Copyright 2003 DETROIT DIESEL CORPORATION SERIES 50G 60G TROUBLESHOOTING MANUAL 4 13 INTERNAL ENGINE COMPONENTS Check the internal engine components for problems that could cause Knock as follows 1 Check to see if the engine has been rebuilt a If the engine has been rebuilt make sure that it has the correct Connecting Rods NOTE The proper connecting rods for a Series 50G and 60G are shorter in length and are identified by the words Natural Gas on their side b If the proper connecting rods are installed proceed to Fake Knock Codes Refer to section 4 14 2 Check the valves intake and exhaust for built up combustion deposits a If there are no dep
17. il Fouled Electrode Rev 10 03 All information subject to change without notice 4 24 From Bulletin 4 50G 60GTS 03 6SE482 0109 Copyright 2003 DETROIT DIESEL CORPORATION SERIES 50G 60G TROUBLESHOOTING MANUAL b If any spark plug is shorted by carbon deposits see Figure 4 9 replace the spark plug and go to step 3 Soft sooty dry and black deposits around bottom of spark plug Figure 4 9 Carbon Fouled Spark Plug All information subject to change without notice Rev 10 03 6SE482 0109 Copyright 2003 DETROIT DIESEL CORPORATION From Bulletin 4 50G 60GTS 03 4 25 4 8 IGNITION SYSTEM c If any spark plug is shorted across the gap see Figure 4 10 by reforming of melted material from the electrodes go to step 3 There is melting of electrode material in the gap Figure 4 10 Spark Plug with Gap Bridging Rev 10 03 All information subject to change without notice 4 26 From Bulletin 4 50G 60GTS 03 6SE482 0109 Copyright 2003 DETROIT DIESEL CORPORATION SERIES 50G 60G TROUBLESHOOTING MANUAL d Ifthe spark plug shows normal operating conditions see Figure 4 11 with no deposits or only light tan or gray deposits reuse the spark plug Clean the spark plug and spark plug well Gap spark plug to 0 38 mm 0 015 in Install and tighten the spark plug to 38 N m 28 ft lb CG lt L a E en Lee LLU Light brown gray or tan deposits are acceptable Figure 4 11 Normal Operating
18. its of acceptable travel Table 4 1 PWM No 3 Input and Acceptable Travel 6 If the PSV assembly shows any of the following failure modes then replace the PSV assembly refer to section 4 6 3 and perform the Fuel System Learn Procedure refer to section 4 9 a PSV remains at or below approximately 50 of travel b PSV piston does not move indicator reads zero throughout c PSV moves slowly or does not move to the value listed in Table 4 1 Column 3 d PSV exhibits erratic operation 7 If engine no longer knocks troubleshooting is complete 8 If engine knocks check the Ignition System Refer to section 4 8 4 6 3 Replacing the Throttle Use the bolt loosening and tightening sequences and the throttle assembly procedure in the following sections when replacing the throttle Refer to section 4 6 3 1 for the bolt loosening and tightening sequences and refer to section 4 6 3 2 for the throttle assembly procedure 4 6 3 1 Bolt Tightening Sequence Loosen the bolts using the following sequence 1 Loosen the four bolts that attach the intake elbow to the rear of the throttle 2 Loosen the four bolts that attach the Mixer PSV assembly to the front of the throttle 3 Loosen the two bolts that attach the low pressure regulator to the intake elbow 4 Loosen the four bolts that attach the throttle to the throttle bracket Tighten all the bolts using the following sequence NOTE Torque for all bolts is 34 N m 25 ft lb
19. ke Manifold Temperature is below 150 F 66 C check the Fuel System Operation Refer to section 4 6 1 If the Intake Manifold Temperature is 150 F 66 C or higher check the Charge Air Cooler Refer to step 5 5 Check the operation of the Charge Air Cooler as follows a b c d e Inspect and pressure check the Charge Air Cooler system Refer to Series 60 Service Manual 6SE483 or Series 50 Service Manual 6SE50 If the Charge Air Cooler and plumbing are damaged or clogged replace them Refer to the vehicle OEM service manual Road test the vehicle If the engine still knocks go to step 6 If the engine no longer knocks troubleshooting is done 6 Check the operation of the Engine Cooling Fan as follows a b c d e Inspect Engine Cooling Fan Refer to Series 60 Service Manual 6SE483 or Series 50 Service Manual 6SE50 If the Engine Cooling Fan is damage repair or replace it as required Refer to Series 60 Service Manual 6SE483 or Series 50 Service Manual 6SE50 Road test the vehicle If the engine still knocks go to step 7 If the engine no longer knocks troubleshooting is done 7 Check the operation of the Air Cleaner as follows a Inspect engine Air Cleaner Refer to Series 60 Service Manual 6SE483 or Series 50 Service Manual 6SE50 All information subject to change without notice Rev 10 03 6SE482 0109 Copyright 2003 DETROIT DIESEL CORPORATION From Bulletin
20. mperature Sensor 2 Throttle Bracket 8 Elbow 3 Gear Case Cover to Bracket Bolts 9 Clamp 4 Throttle Actuator 10 Hose 5 Bushing 11 Inlet Manifold 6 Gasket Figure 4 4 Throttle Bracket and Inlet Elbow Assembly Series 50G 9 Install four bolts through the throttle bracket into the bottom of the throttle and two bolts through the side of the throttle bracket into the inlet elbow but do not tighten 10 Tighten the four mixer to throttle bolts at 34 N m 25 ft lb torque Rev 10 03 All information subject to change without notice 4 18 From Bulletin 4 50G 60GTS 03 6SE482 0109 Copyright 2003 DETROIT DIESEL CORPORATION SERIES 50G 60G TROUBLESHOOTING MANUAL 11 Tighten the four throttle to inlet elbow bolts at 34 N m 25 ft lb torque 12 Tighten the two bolts that hold the regulator to the inlet elbow and tighten the four screws that hold the PSV to the mixer 13 Adjust the two bolts through the throttle bracket to the inlet elbow and the four bolts through the bottom of the throttle bracket to the throttle alternatively to ensure that there is no bind in the throttle Torque the two brackets to the inlet elbow bolts at 34 N m 25 ft lb and the four throttle mounting bolts at 34 N m 25 ft lb All information subject to change without notice Rev 10 03 6SE482 0109 Copyright 2003 DETROIT DIESEL CORPORATION From Bulletin 4 50G 60GTS 03 4 19 4 7 OXYGEN SENSOR 4 7 OXYGEN SENSOR The oxygen sensor measures exhau
21. nditioner air compressor generator hydraulic pumps fan clutches etc and their associated brackets for excessive vibration or uncommon operation a If there is no vibration or uncommon operation check the Valve and Injector Operating Mechanisms Refer to section 4 11 b If there is excessive vibration or the accessories are not firmly attached repair and install the respective accessory properly Repeat step 4 b and confirm proper operation 6 Connect the DDR or DDDL J 47500 NOTE Use the Pro Link kit J 38500 H to connect the DDR Use PC card J 38500 2300 installed in the computer to connect the DDDL J 47500 7 Check for Knock Codes If the no Knock Codes are present troubleshooting is done All information subject to change without notice Rev 10 03 6SE482 0109 Copyright 2003 DETROIT DIESEL CORPORATION From Bulletin 4 50G 60GTS 03 4 29 4 11 VALVE AND INJECTOR OPERATING MECHANISMS 4 11 VALVE AND INJECTOR OPERATING MECHANISMS Check the Valve and Injector Operating Mechanisms for problems that could cause Knock as follows 1 Remove upper portion of the rocker cover assembly Refer to Series 60 Service Manual 6SE483 or Series 50 Service Manual 6SES50 NOTE For best results check the Valve and Injector Operating Mechanisms for problems with engine at room temperature 2 Ensure the Valve and Injector Operating Mechanisms are in good operating condition Refer to Series 60 Service Manual 6SE483 or Series 50
22. osits confirm proper operation of the Valve and Injector Operating Mechanisms b If there are deposits determine the cause of the excessive deposits Check valves valve guides seals and the cylinder kits Refer to the Series 60 Service Manual 6SE483 or refer to the Series 50 Service Manual 6SESO 3 If the no longer knocks troubleshooting is done All information subject to change without notice Rev 10 03 6SE482 0109 Copyright 2003 DETROIT DIESEL CORPORATION From Bulletin 4 50G 60GTS 03 4 33 4 14 FAKE KNOCK CODES 4 14 FAKE KNOCK CODES Check for poor grounds causing Fake Knock Codes as follows l 4 34 Confirm the Starter to Block ground is a No 00 cable a If cable wire gage is too small replace with a larger gage cable b If cable wire gage is suitable go to step 2 Confirm the Starter to Frame ground is a No 00 cable a If cable wire gage is too small replace with a larger gage cable b If cable wire gage is suitable go to step 3 Check the Starter to Block Starter to Frame and SNEF module ground wire No 954 black to block ground wires as follows a Using a digital volt ohmmeter measure resistance in each cable If the resistance is greater than 50 ml replace the ground wire b Examine the points for each cable If the points have rust paint and corrosion clean the points and reconnect c If all the resistances are less than 50 ml and the connections are clean go to step
23. rk Plug Wells as follows All information subject to change without notice Rev 10 03 6SE482 0109 Copyright 2003 DETROIT DIESEL CORPORATION From Bulletin 4 50G 60GTS 03 4 23 4 8 IGNITION SYSTEM Remove the coil cover Disconnect each coil Examine each ignition boot spark plug and spark plug well ee E A If oil is present on any ignition boot or in the spark plug well replace the O rings on the extension tube replace the ignition boot and clean and reinstall the ignition coils Perform the Fuel System Learn Procedure refer to section 4 9 5 If water is present in any spark plug well clean out the well and discard the defective spark plug and replace the mating boot and spring assembly Gap spark plug to 0 38 mm 0 015 in Install the spark plug Tighten the spark plug to 38 N m 28 ft lb Perform the Fuel System Learn Procedure refer to section 4 9 6 If ignition coils boots and spark plug wells are free of oil or other contamination check the Spark Plug Electrode refer to section 4 8 2 4 8 2 Spark Plug Electrode Inspection Check the Spark Plug Electrodes as follows 1 Remove each spark plug 2 Examine the spark plug electrodes for the following conditions a If any spark plug is shorted by excessive oil deposits around center and ground electrodes see Figure 4 8 replace the spark plug and go to step 3 Thick wet and black deposits around bottom of spark plug Figure 4 8 Spark Plug with O
24. rogen Oxygen 4 5 max D 1945 Carbon Monoxide 0 1 max D 2650 Other Species Methanol 0 mass No Test Method Sulfur Total 22 ppm v D4468 Performance Related Properties Motor Octane Number 115 min D 2623 Wobbe Number 1290 1380 BTU ft D 3588 Contaminants t Pressure Water Dew Point Temperature Max D 1142 Pressure Hydrocarbon Dew Point Temperature Max Below which will form 1 condensate Odorant I Test method D 2623 was obsoleted by ASTM in 1991 Wobbe Index WI also known as Wobbe Number is a measure of fuel energy flow rate through a fixed orifice under given inlet conditions Numerically WI dry higher heating value specific gravity t The compressed natural gas shall not contain dust sand dirt gums oils or other substances in an amount sufficient to be injurious to the fuel station equipment or the vehicle being fueled The dew point at vehicle fuel storage container pressure shall be at least 5 6 C 10 F below the 99 0 winter design temperature for Climatic Conditions for the United States in the American Society of Heating Refrigerating and Air conditioning Engineer s ASHRAE Handbook Testing for water vapor shall be in accordance with ASTM D 1142 utilizing the Bureau of Mines apparatus The natural gas at ambient conditions must have a distinctive odor potent enough for its presence to be detected down to a concentration in air of 1 by volume Table 4 2 Compressed Natural Gas Fuel Speci
25. rrence verify the knock condition is real Refer to section 4 4 b Ifthe number of Engine Knock Level Above Normal Range SID 76 FMI 0 and Engine Knock Level Torque Reduction SID 76 FMI 7 codes is less than four codes per engine operating hour from the first knock code occurrence to the last knock code occurrence then clear the codes put the vehicle back in service check vehicle again in 24 hours refer to step 1 and step 2 4 If the engine no longer knocks troubleshooting is done All information subject to change without notice Rev 10 03 6SE482 0109 Copyright 2003 DETROIT DIESEL CORPORATION From Bulletin 4 50G 60GTS 03 4 7 44 VERIFICATION OF ENGINE KNOCK 4 4 VERIFICATION OF ENGINE KNOCK Verify the engine knock codes are actual real or externally induced fake as follows 1 Turn the ignition off 2 Unscrew the Knock Sensor from the block 3 Hang the Knock Sensor in the engine compartment 4 Cuta 16 or 18 gage insulated copper wire 30 mm 12 in long Cut the rubber sheath off both ends to expose 5 mm 2 in of the copper leads 5 Wrap one end of the wire around the threads of the Knock Sensor secure with electrical tape and bolt the other end of the wire to a clean ground on the block 6 Road test the vehicle 7 Turn on the ignition Plug the Diagnostic Data Reader DDR or the Diesel Diagnostic Data Link DDDL J 47500 into the Diagnostic Connector NOTE Use the Pro Link kit J 38850
26. sembly and gasket to opposite flange with four bolts but do not tighten Rev 10 03 All information subject to change without notice 4 16 From Bulletin 4 50G 60GTS 03 6SE482 0109 Copyright 2003 DETROIT DIESEL CORPORATION SERIES 50G 60G TROUBLESHOOTING MANUAL 3 Attach the PSV and O ring to the mixer with four Allen head screws but do not tighten 4 Lubricate O rings used with fuel transfer tube with Lubriplate prior to assembly Lubriplate is a registered trademark of Fiske Brothers Refining Company 5 Install O rings to fuel transfer tube Apply Teflon liquid pipe sealant to threads Teflon is a registered trademark of E I DuPont de Nemours and Company Inc 6 Thread fuel transfer tube into regulator and tighten NOTE The fuel transfer tube must thread into the regulator just far enough so the O ring seal does not bottom out in the PSV valve and cut the seal when the regulator is bolted to the inlet elbow 7 Install the low pressure regulator and fuel transfer tube into the PSV Bolt regulator to inlet elbow with two bolts but do not tighten All information subject to change without notice Rev 10 03 6SE482 0109 Copyright 2003 DETROIT DIESEL CORPORATION From Bulletin 4 50G 60GTS 03 4 17 4 6 PSV ASSEMBLY 8 Install throttle PSV mixer and inlet elbow to engine positioning inlet hose over inlet elbow and inlet manifold Rest the throttle on the throttle bracket See Figure 4 4 1 Bolt 7 Air Te
27. st oxygen which is an indication of the air fuel ratio see Figure 4 5 The air fuel ratio is a fundamental parameter for a natural gas engine Precise control of the air fuel ratio allows the engine to operate closer to the lean limit As a result exhaust emissions fuel consumption and exhaust temperatures are reduced Figure 4 5 Oxygen Sensor If fuel system hardware fuel quality or engine operating conditions change DDEC will sense this and make corrections to keep the air fuel ratio on target This is called closed loop control The oxygen sensor must be installed in the exhaust pipe within 305 mm 12 in of the turbine outlet The sensor has pre applied anti seize on the threads The oxygen sensor harness must be used to connect the sensor to the oxygen sensor interface module located at the rear of the engine The wires must be routed away from the exhaust system and kept out of contact with moving parts Check the Oxygen Sensor for proper operation as follows 1 Place the diagnostic oxygen sensor Engine Control amp Monitoring Inc diagnostic oxygen sensor Lambda PRO kit or equivalent in the secondary port in the exhaust tube Lambda Pro trademark is owned by ECM Engine Control and Monitoring 2 Connect the DDR or DDDL J 47500 and display air fuel ratio Lambda value NOTE Use the Pro Link kit J 388500 H to connect the DDR Use PC card J 38500 2300 installed in the computer to connect the DDDL J 47500 Re
28. stalling or servicing the engine or fuel system Q Installation or servicing of natural gas equipment must only be conducted in well ventilated natural gas compatible areas Do not install or service equipment in an enclosed area where ignition sources are present without first ensuring that an undetected gas leak may be safely vented without being ignited Bleed natural gas lines before installing or servicing any component connected to the fuel lines Q Natural gas fuel systems are pressurized Relieve pressure from any fuel system component prior to installation or service of that component Natural gas is highly flammable and explosive and may be extremely cold 260 F 162 C 2 Crank the engine and read PWM No 3 position and Gas Valve position 3 If PWM No 3 position indicates 26 50 and Gas Valve position indicates 50 80 but the engine still knocks then check the operation of the Oxygen Sensor Refer to section 4 7 4 If PWM No 3 position indicates 26 50 and Gas Valve position is not moving then check the PSV power and PWM No 3 output as follows a Measure the voltage at the PSV connector see Figure 4 2 with a voltmeter Connect positive lead to wire 446 red pin A and negative lead to wire 150A black pin B 446 RED H A 150A BLK oO oO Lam 583 LT BLU BLK S B ORG BLK S 150B BLK 150C BLK gt 910 ORN
29. v 10 03 All information subject to change without notice 4 20 From Bulletin 4 50G 60GTS 03 6SE482 0109 Copyright 2003 DETROIT DIESEL CORPORATION SERIES 50G 60G TROUBLESHOOTING MANUAL NOTICE Use care not to overheat the transmission during the stall torque test Overheating the transmission will cause damage 3 Perform a transmission stall torque test a Run the stall for approximately 10 seconds NOTE Engine and transmission should be at normal operating temperatures b Record the air fuel ratio Lambda value displayed by DDEC and the diagnostic oxygen sensor 4 Waiting one minute between tests repeat step 3 twice a If the readings between the diagnostic oxygen sensor and DDEC oxygen sensor are constantly more than 0 02 Lambda different replace the Oxygen Sensor see Figure 4 5 and then perform the Learn Procedure Refer to section 4 9 b If the readings between the diagnostic oxygen sensor and DDEC oxygen sensor are generally less than or equal to 0 02 Lambda or less but fluctuate to 0 04 Lambda or higher replace the Low Pressure Regulator refer to section 4 6 3 c Ifthe readings between the diagnostic oxygen sensor and the DDEC oxygen sensor are always 0 02 Lambda or less and the engine still knocks then check the condition of the spark plug refer to section 4 8 5 If the engine operates normally troubleshooting is done All information subject to change without notice Rev

4 KNOCK

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