Transcript
NUMBER: 6 06–09
S.M. REF.: Listed in Table 1
ENGINE: DD15
DATE: June 2009
SUBJECT: EXHAUST GAS RECIRCULATION COOLER ADDITIONS, REVISIONS, OR UPDATES Publication Number
Platform
Section Title
Change
Page Number(s)
DDC-SVC-MAN-0002
DD15
5.1 Exhaust Gas Recirculation Cooler
The EGR cooler removal and installation procedures have been revised to include more detail of inspection and reuse of connecting tubes.
5–3
NOTE: Page numbers are based on the most recent version of the individual publication and may be adjusted throughout the annual print cycle.
Table 1
EXHAUST GAS RECIRCULATION COOLER
The primary purpose of the EGR cooler is to cool the engine exhaust gases prior to entering the intake manifold. Exhaust gas cooling is accomplished by the flow of exhaust gases through the EGR cooler tubes. The EGR cooler core then transfers the heat removed from the exhaust gases to the engine coolant. The cooled exhaust gases are then mixed with incoming air from the Charge Air Cooler (CAC) before being sent to the intake manifold.
1. Venturi
9. Banjo Union
17. Water Manifold
2. Screw
10. Banjo Bolt
18. Support
3. Gasket
11. Exhaust Gas Cooler
19. Clamp
4. Bolt
12. Strap
20. Hose
5. Exhaust Gas Crossover Tube/Lifting Eye
13. Shim
21. Mixer Pipe
6. Connecting Tube
14. Clamp
22. Coolant Delivery Pipe
7. Connecting Tube
15. Seal Washer
23. Seal Ring
8. Seal Ring
16. Exhaust Pipe
REMOVAL OF THE EGR COOLER
Remove the EGR cooler as follows:
PERSONAL INJURY To avoid injury from hot surfaces, wear protective gloves, or allow engine to cool before removing any component.
1. Steam clean the engine. 2. Drain the engine coolant. NOTE: Note the orientation of clamps before removal.
3. Remove the two clamps from the exhaust pipe. 4. Remove the exhaust pipe from the EGR cooler and the EGR valve. 5. Remove four bolts from the EGR cooler straps and remove straps. 6. Remove the retaining plate bolts at the front of the cooler. 7. Remove the EGR cooler from the water manifold. INSPECTION OF THE EGR COOLER
Inspection is as follows: 1. Inspect the EGR cooler for damage; replace if necessary. 2. Inspect the EGR cooler connecting tubes; replace if necessary. 3. Perform an EGR Cooler Leak Test. Refer to the EPA07 DD13/DD15 Troubleshooting Manual, section 8.6.1 “EGR Cooler Leak Test.” INSTALLATION OF THE EGR COOLER
Install the EGR cooler as follows: 1. Inspect the coolant connecting tubes and EGR connecting tube for cuts, tears, cracks, or signs of leakage. If damage is found, replace the connecting tube. NOTICE: Ensure items 6 and 7 connecting tubes (refer to Figure "EGR Cooler and Related Parts") are lubricated with clean oil. If the tubes are not lubricated, the tubes cannot not be fully installed, or the rubber can be cut.
2. Install connecting tubes into the water manifold, the exhaust gas crossover tube / lifting eye and the coolant delivery pipe. 3. Install the EGR cooler to the water manifold. 4. Install four EGR cooler straps with strap bolts and tighten bolts to 20 N·m (14 lb·ft).
5. Install exhaust pipe on EGR cooler and EGR valve with two clamps and tighten clamp bolts to 12 N·m (9 lb·ft). 6. Fill engine with coolant.
ADDITIONAL SERVICE INFORMATION
Additional service information is available in Power Service Literature.
Detroit Diesel®, DDC®, Series 60® and the spinning arrows design are registered trademarks of Detroit Diesel Corporation. © Copyright 2009 Detroit Diesel Corporation. All rights reserved. Printed in U.S.A.
