Detroit Diesel DD15 Engine Service & Repair Manual

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Generated on 10-13-2008 General Information SCOPE AND USE OF THIS MANUAL This manual contains complete instructions on operation, adjustment (tune-up), preventive maintenance, and repair (including complete overhaul) for the DD15 Engine. This manual was written primarily for persons servicing and overhauling the engine. In addition, this manual contains all of the instructions essential to the operators and users. Basic maintenance and overhaul procedures are common to all DD15 Engines, and apply to all engine models. This manual is divided into numbered sections. Section one covers the engine (less major assemblies). The following sections cover a complete system such as the fuel system, lubrication system, or air system. Each section is divided into subsections which contain complete maintenance and operating instructions for a specific engine subassembly. Each section begins with a table of contents. Pages and illustrations are numbered consecutively within each section. Information can be located by using the table of contents at the front of the manual or the table of contents at the beginning of each section. Information on specific subassemblies or accessories within the major section is listed immediately following the section title. CLEARANCE OF NEW PARTS AND WEAR LIMITS New parts clearances apply only when all new parts are used at the point where the various specifications apply. This also applies to references within the text of the manual. The column entitled "Limits" must be qualified by the judgement of personnel responsible for installing new parts. For additional information, refer to the section entitled "Inspection" within this section. THE FOUR CYCLE PRINCIPLE FOR DIESEL ENGINES The diesel engine is an internal combustion engine, in which the energy of burning fuel is converted into energy to work the cylinder of the engine. In the diesel engine, air alone is compressed in the cylinder, raising its temperature significantly. After the air has been compressed, a charge of fuel is sprayed into the cylinder and ignition is accomplished by the heat of compression. The four piston strokes of the cycle occur in the following order: intake, compression, power and exhaust. Intake Stroke During the intake stroke, the piston travels downward, the intake valves are open, and the exhaust valves are closed. The down stroke of the piston facilitates air from the intake manifold to enter the cylinder through the open intake valve. The turbocharger, by increasing the air pressure in the engine intake manifold, assures a full charge of air is available for the cylinder. The intake charge consists of air only with no fuel mixture. Compression Stroke Page 1 of 24 Power Service Literature

At the end of the intake stroke, the intake valves close and the piston starts upward on the compression stroke. The exhaust valves remain closed. At the end of the compression stroke, the air in the combustion chamber has been compressed by the piston to occupy a space about one-seventeenth as great in volume as it occupied at the beginning of the stroke. Thus, the compression ratio is 18.1 Compressing the air into a small space causes the temperature of that air to rise. During the last part of the compression stroke and the early part of the power stroke, a small metered charge of fuel is injected into the combustion chamber. Almost immediately after the fuel charge is injected into the combustion chamber, the fuel is ignited by the hot air and starts to burn, beginning the power stroke. Power Stroke During the power stroke, the piston travels downward and all intake and exhaust valves are closed. As the fuel is added and burns, the gases get hotter, the pressure increases, pushing the piston downward and adding to crankshaft rotation. Exhaust Stroke During the exhaust stroke, the intake valves are closed; the exhaust valves are open, and the piston is on its up stroke. The burned gases are forced out of the combustion chamber through the open exhaust valve port by the upward travel of the piston. From the preceding description, it is apparent that the proper operation of the engine depends upon the two separate functions: first, compression for ignition, and second, that fuel be measured and injected into the compressed air in the cylinder in the proper quantity and at the proper time. GENERAL DESCRIPTION The DD15 Engine described in this manual is a four-stroke cycle, high speed, diesel engine. It uses an inline cast iron block and has a cast iron cylinder head that contains a duel overhead camshaft. The camshafts actuates all the valves (two intake, two exhaust per cylinder). The vertically aligned gear train, located at the rear end of the engine in a gear case, contains drive gears for the lubricating oil pump, crankshaft, camshafts, air compressor drive, fuel pump drive. Full pressure lubrication is supplied to all main, connecting, camshaft and rocker assembly bearings and to other moving parts. The oil spray nozzles spray engine oil continuously below the piston crowns to ensure that they are cooled. A gear-type pump draws oil from the oil pan through a screen and delivers it to the oil coolant module. The engine oil is first fed through the oil/water heat exchanger located on the oil coolant module. During the cold start phase of the Page 2 of 24 Power Service Literature

engine the oil/water heat exchanger will rapidly warm the oil. After the warm-up phase of the engine the oil/water heat exchanger will cool the engine oil. Once the engine oil has passed through the oil/water heat exchanger it then goes to the oil filter. In the oil filter part of the engine oil (about 90%) flows through the filter element and is cleaned. The rest of the oil (about 10%) goes into the oil centrifuge. The engine oil cleaned in the centrifuge and flows unpressurized back into the oil pan. Part of the oil goes to the camshaft frame where it feeds the camshaft bearings and rocker assemblies. The remainder of the oil goes to the main bearings and connecting rod bearings via the drilled oil passages in the crankshaft. The turbocharger is supplied with engine oil by an external oil line. Return flow of the engine oil by return ducts and return holes in the cylinder head and cylinder block and back to the oil pan. Coolant is circulated through the engine by a centrifugal-type water pump. The cooling system, including the radiator, is a closed system. Heat is removed from the coolant by the radiator. Control of the engine temperature is accomplished by thermostats that regulate the flow of the coolant within the cooling system. The fuel supply ensures that the fuel required for combustion is available under all operating conditions in the sufficient quantity, at the correct time and at the required pressure. Fuel to the individual cylinders is supplied via the Amplified Pressure Common Rail System (APCRS) which is supplied by the fuel low pressure circuit with fuel. The fuel low pressure circuit ensures that the fuel is cleaned and is provided in the sufficient quantities and at the required pressure to the APCRS Air is supplied by the turbocharger to the intake manifold and into the engine cylinders after passing through an air-to-air charge air cooler mounted ahead of the cooling system radiator. The charge air cooler cools the pressurized intake air charge coming from the turbocharger before it enters the intake manifold. Engine starting is provided by an electric motor energized by a storage battery. A battery charging alternator, with a suitable voltage regulator, serves to keep the battery charged. The DD15 Engine was designed to be electronically controlled. The Detroit Diesel Electronic Control (DDEC) system has evolved with the product. DDEC VI The DDEC VI Motor Control Unit (MCM) receives electronic inputs from sensors on the engine and vehicle, and uses the information to control engine operation. It computes fuel timing and fuel quantity based upon predetermined calibration tables in its memory. DDEC VI provides an indication of engine and vehicle malfunctions. The Motor Control Unit (MCM) continually monitors the DDEC VI system. Any faults that occur are stored as codes in the MCM's memory. A DDDL® can be used to read the codes. GENERAL SPECIFICATIONS The general specifications for the DD15 Engine are listed in Table "Specifications for the DD15 Engine" . Page 3 of 24 Power Service Literature

Filling Capacities are listed in Table "Filling Capacity" . Piston specifications are listed in Table "Piston Specifications" . Piston pin specifications are listed in Table "Piston Pin Specifications" . Fuel system specifications are listed in Table "Fuel System Specifications" . Crankshaft bearing specifications are listed in Table "Crankshaft Bearing Specifications" . Connecting rod specifications are listed in Table "Connecting Rod Specifications" . Connecting rod bearing specifications are listed in Table "Connecting Rod Bearing Specifications" . Cylinder block specifications are listed in Table "Cylinder Block Specifications" . See see Figure "Cylinder Designation and Firing Order" for the cylinder designation and firing order. Table 1. Specifications for the DD15 Engine Table 2. Filling Capacity Table 3. Piston Specifications General Specifications 14L Family Total Displacement (L) 14.8 Number of Cylinders 6 Valve Control DOHC Number of Valves per Cylinder (Intake/Exhaust) 2/2 Idle Speed 600 (rpm) Output 382 - 478 (kW) Combustion Pressure max. 250 (bar) Compression Ratio 18:0 Stroke 163 (mm) Hub Bore Ratio 1.17 Initial Filling Capacity of Oil Pan 44.5 l (47.02 qt) Oil Pan Capacity 40 l (42.27 qt) Oil Capacity of Oil Coolant Module 4.5 l (4.755 qt) Diameter 139 mm (5.472 in.) Total Height 124.5 mm (4.902 in.) Compression Height 83.5 mm (3.287 in.) Shank Length 54.5 mm (2.146 in.) Inside Diameter 23 mm (0.9055 in.) Outside Diameter 62 mm (2.441 in.) Page 4 of 24 Power Service Literature

Table 4. Piston Pin Specifications Table 5. Fuel System Specifications Table 6. Crankshaft Bearing Specifications Table 7. Connecting Rod Specifications Table 8. Connecting Rod Bearing Specifications Table 9. Cylinder Block Specifications Figure 1. Cylinder Designation and Firing Order ENGINE MODEL, SERIAL NUMBER The engine serial and model numbers are stamped on the left side cylinder block. Serial number will be laser engraved at the front left side of the engine block. Length 92 mm (3.622 in) Rail Pressure max. 900 bar Injection Pressure max. 2200 bar Diameter 120 mm (4.724 in.) Width 39.5 mm (1.555 in) Length 276 mm (10.87 in.) Diameter 100 mm (3.937 in.) Width 39.5 mm (1.555 in.) Cylinder Diameter (mm) 139 mm (5.472 in.) Cylinder Clearance (mm) 173 mm (6.811 in.) Page 5 of 24 Power Service Literature

Figure 2. Serial Number Location REPLACING AND REPAIRING In many cases, a technician is justified in replacing parts with new material rather than attempting repair. However, there are times when a slight amount of reworking or reconditioning may save a customer considerable added expense. Exchange assemblies such as injectors, fuel pumps, water pumps and turbochargers are desirable service items. Various factors such as the type of operation of the engine, hours in service and the next overhaul period must be considered when determining whether new parts are installed or used parts are reconditioned to provide trouble-free operation. For convenience and logical order in disassembly and assembly, the various subassemblies and other related parts mounted on the cylinder block will be treated as separate items in the various sections of the manual. DISASSEMBLY A technician can be severely injured if caught in pulleys, belts or the fan of an engine that is accidentally started. To avoid such a misfortune, take the following precautions before starting to work on an engine. PERSONAL INJURY Page 6 of 24 Power Service Literature

Before any major disassembly, the engine must be drained of lubricating oil, coolant and fuel. To perform a major overhaul or other extensive repairs, the complete engine assembly, after removal from the engine base and drive mechanism, should be mounted on an engine overhaul stand; then the various subassemblies should be removed from the engine. When only a few items need replacement, it is not always necessary to mount the engine on an overhaul stand. Parts removed from an individual engine should be kept together so they will be available for inspection and assembly. Those items having machined faces, which might be easily damaged by steel or concrete, should be stored on suitable wooden racks or blocks, or a parts dolly. CLEANING Before removing any of the subassemblies from the engine (but after removal of the electrical equipment), the exterior of the engine should be thoroughly cleaned. Then, after each subassembly is removed and disassembled, the individual parts should be cleaned. Thorough cleaning of each part is absolutely necessary before it can be satisfactorily inspected. Various items of equipment needed for general cleaning are listed below. The cleaning procedure used for all ordinary cast iron parts is the same as the following cylinder block cleaning procedure. Any special cleaning procedures will be mentioned when required. Remove cylinder liners before putting the block in cleaning or descaling baths, to avoid trapping cleaning agents in block liner seating bores. To avoid injury from accidental engine startup while servicing the engine, disconnect/disable the starting system. PERSONAL INJURY To avoid injury from the sudden release of a high-pressure hose connection, wear a face shield or goggles. Bleed the air from the air starter system before disconnecting the air supply hose. NOTICE: The DD15 Engine is equipped with various sensors and other electronic components which may be damaged if subjected to the high temperatures in a solvent tank. Do not immerse any electrical components in a solvent tank. Care should be taken to ensure that all electronic components are removed from the various engine assemblies before they are immersed in a solvent tank. Refer to "2 Fuel System" for a description of these components. Page 7 of 24 Power Service Literature

After stripping and before removing the cylinder block from the overhaul stand for cleaning and inspection, install the two metric eye bolts into head bolt holes at each end of the cylinder block. Remove all oil and water gallery and weep hole plugs to allow the cleaning solution to enter the inside of the oil and water passages. 1. Using two metric eye bolts installed in the head bolt holes at opposite ends of the block, and with a suitable lifting device and spreader bar, immerse and agitate the block in a hot bath of a commercial, heavy-duty alkaline solution. 2. Wash the block in hot water or steam clean it to remove the alkaline solution. 3. If the water jackets are heavily scaled, proceed as follows: a. Agitate the block in a bath of inhibited phosphoric acid. b. Allow the block to remain in the acid bath until the bubbling action stops (approximately 30 minutes). c. Lift the block, drain it and immerse it again in the same acid solution for 10 more minutes. Repeat until all scale is removed from the water jacket area. d. Rinse the block in clear, hot water to remove the acid solution. e. Neutralize the acid that may cling to the casting by immersing the block in an alkaline bath. f. Wash the block in clean water or steam clean it. 4. Dry the cylinder block with compressed air. 5. Blow out all of the bolt holes and passages with compressed air. Note: The above cleaning procedure may be used on all ordinary cast iron and steel parts for the engine. Aluminum parts, such as flywheel housing, air intake manifold, oil filter adaptor and the camshaft gear access cover should NOT be cleaned in this manner. Mention will be made of special procedures when necessary. 6. Be certain that all water passages and oil galleries have been thoroughly cleaned. After the cylinder block has been thoroughly cleaned and dried, install weep hole plugs and precoated pipe plugs. Install new cup plugs using a coating of good grade non-hardening EYE INJURY To avoid injury from flying debris when using compressed air, wear adequate eye protection (face shield or safety goggles) and do not exceed 276 kPa (40 psi) air pressure. EYE INJURY To avoid injury from flying debris when using compressed air, wear adequate eye protection (face shield or safety goggles) and do not exceed 276 kPa (40 psi) air pressure. Page 8 of 24 Power Service Literature

sealant such as Loctite® 620 or equivalent. Loctite® is a registered trademark of The Loctite Corporation. Steam Cleaning A steam cleaner is a necessary item in a large shop and is useful for removing heavy accumulations of grease and dirt from the exterior of the engine and its subassemblies. Solvent Tank Cleaning A tank of sufficient size to accommodate the largest part that will require cleaning (usually the cylinder block) should be provided and provisions made for heating the cleaning solution. Fill the tank with a commercial heavy-duty solvent, that is heated to 52°C (125°F). Lower large parts directly into the tank with a hoist. Place small parts in a wire mesh basket and lower them into the tank. Immerse the parts long enough to loosen all of the grease and dirt. Aluminum or plastic parts such as the flywheel housing, fuel pump drive, air intake manifold, oil filter adaptor, camshaft gear access cover, oil pan or rocker covers, should not be cleaned in this manner. Rinsing Bath Provide another tank of similar size containing hot water for rinsing the parts. Drying Parts may be dried with compressed air. The heat from the hot tanks will quite frequently complete drying of the parts without the use of compressed air. PERSONAL INJURY To avoid injury while performing the test or procedure, wear adequate eye, face protection, and heat-resistant gloves. EYE INJURY To avoid injury from flying debris when using compressed air, wear adequate eye protection (face shield or safety goggles) and do not exceed 276 kPa (40 psi) air pressure. Page 9 of 24 Power Service Literature

Detroit Diesel DD15 Engine Service & Repair Manual

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