Transcript
NUMBER: 7 15–09
S.M. REF.: Listed in Table 1
ENGINE: DD Platform
DATE: July 2009
SUBJECT: EGR COOLER CLEANING PROCEDURE TO REMOVE EXCESS FUEL FROM EGR COOLER AFTER INJECTOR FAILURE ADDITIONS, REVISIONS, OR UPDATES Publication Number
Platform
Section Title
Change
Page Number(s)
DDC-SVC-MAN-0050 DD13
1.18 Engine Brake
Procedures have been added to clean the EGR Cooler due to fuel, oil, or coolant contamination from a failed engine brake solenoid.
1–125
DDC-SVC-MAN-0002 DD15
1.18 Engine Brake
Procedures have been added to clean the EGR Cooler due to fuel, oil, or coolant contamination from a failed engine brake solenoid.
1–118
DDC-SVC-MAN-0050 DD13
4.2 Turbocharger
Procedures have been added to clean the EGR Cooler due to fuel, oil, or coolant contamination from a failed DD13 turbocharger.
4–11
DDC-SVC-MAN-0002 DD15
4.2 Turbocharger
Procedures have been added to clean the EGR Cooler due to fuel, oil, or coolant contamination from a failed DD15 turbocharger.
4–18
DDC-SVC-MAN-0037 DD15
35.4 Fuel Injectors
Procedures have been added to clean the EGR Cooler due to fuel, oil, or coolant contamination from a failed fuel injector.
35–12
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
DD13 WORKSHOP MANUAL NOTE: The following information supports DDC-SVC-MAN-0050.
EGR COOLER CLEANING PROCEDURE TO REMOVE EXCESS FUEL FROM EGR COOLER AFTER ENGINE BRAKE SOLENOID FAILURE
Observe the following: NOTICE: This cleaning procedure must be followed after replacing an engine brake solenoid so that any failure will not cause excessive fuel, oil, or coolant to enter the exhaust system. Failure to perform this procedure could cause severe engine damage.
1. Clamp
10. Banjo Union
19. Exhaust Gas Crossover Tube/Lifting Eye
2. Hose
11. Banjo Bolt
20. Gasket
3. Coolant Crossover Pipe
12. Bolt
21. Bolt
4. Bolt
13. Bolt
22. Venturi
5. Support
14. Outlet Nipple
23. Mixer Pipe
6. Coolant Connecting Tube
15. Seal
24. Seal Ring
7. Exhaust Gas Connecting Tube
16. Exhaust Gas Recirculation Cooler/Water Manifold Assembly
25. Bolt
8. Gasket
17. Clamps
26. Bolt
9. Seal Ring
18. Exhaust Pipe
Figure 1
DD13 EGR Cooler/Water Manifold and Related Parts
Check as follows: 1. Shut off the engine, apply the parking brake, chock the wheels, and perform any other applicable safety steps. 2. Remove the exhaust pipe (3) and inspect for any signs of liquid or moisture. The exhaust pipe (3) and EGR cooler inlet (1) should have a black dry soot residue inside. [a]
If liquid or moisture is present in the exhaust pipe, go to the next step.
[b]
If there is no sign of liquid or moisture in the exhaust pipe or EGR cooler, install the exhaust pipe. No further action is required.
3. Remove the mixer pipe (1) from the cold boost pipe (2).
4. Remove the exhaust gas crossover tube/lifting eye (2) and venturi (6).
5. Place a towel over the outlet of the EGR cooler and retain it with a zip tie. 6. Using a rubber tipped blow gun, blow compressed shop air into the individual tubes in the EGR cooler to clear any excess fuel, soot, and carbon. 7. After performing the cleaning procedure, refer to section 5.1.2 "Installation of the Exhaust Gas Recirculation Cooler Water Manifold Assembly." to install the: [a]
mixer pipe.
[b]
exhaust gas crossover tube/lifting eye.
[c]
venturi.
DD15 WORKSHOP MANUAL NOTE: The following information supports DDC-SVC-MAN-0002.
EGR COOLER CLEANING PROCEDURE TO REMOVE EXCESS FUEL FROM EGR COOLER AFTER ENGINE BRAKE SOLENOID FAILURE
Observe the following: NOTICE: This cleaning procedure must be followed after replacing an engine brake solenoid so that any failure will not cause excessive fuel, oil, or coolant to enter the exhaust system. Failure to perform this procedure could cause severe engine damage.
1. Venturi
9. Banjo Union
17. Water Manifold
2. Bolt
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. Exhaust Gas Connecting Tube
14. Clamp
22. Coolant Crossover Pipe
7. Coolant Connecting Tube
15. Seal Washer
23. Seal Ring
8. Seal Ring
16. Exhaust Pipe
Figure 2
DD15 EGR Cooler and Related Parts
Check as follows: 1. Shut off the engine, apply the parking brake, chock the wheels, and perform any other applicable safety steps. 2. Remove the exhaust pipe (4) and gaskets (3) and inspect for any signs of liquid or moisture. The exhaust pipe and EGR cooler inlet should have a black dry soot residue inside. [a]
If liquid or moisture is present in the exhaust pipe, go to the next step.
[b]
If there is no sign of liquid or moisture in the exhaust pipe or EGR cooler, install the exhaust pipe. No further action is required.
3. Remove the mixer pipe (4) from the cold boost pipe (1).
4. Remove the exhaust gas crossover tube/lifting eye (2) and venturi (3).
5. Place a towel over the outlet of the EGR cooler and retain it with a zip tie. 6. Using a rubber tipped blow gun, blow compressed shop air into the individual tubes in the EGR cooler to clear any excess fuel, soot, and carbon. 7. After performing the cleaning procedure, refer to section 1.6.2 "Installation of Front Engine Lifter Bracket" to install the: [a]
mixer pipe.
[b]
exhaust gas crossover tube/lifting eye.
[c]
venturi.
DD13 WORKSHOP MANUAL NOTE: The following information supports DDC-SVC-MAN-0050.
EGR COOLER CLEANING PROCEDURE TO REMOVE EXCESS OIL FROM EGR COOLER AFTER TURBOCHARGER FAILURE
Observe the following: NOTICE: This cleaning procedure must be followed after replacing a DD13 turbocharger so that any failure will not cause excessive fuel, oil, or coolant to enter the exhaust system. Failure to perform this procedure could cause severe engine damage.
1. Clamp
10. Banjo Union
19. Exhaust Gas Crossover Tube/Lifting Eye
2. Hose
11. Banjo Bolt
20. Gasket
3. Coolant Crossover Pipe
12. Bolt
21. Bolt
4. Bolt
13. Bolt
22. Venturi
5. Support
14. Outlet Nipple
23. Mixer Pipe
6. Coolant Connecting Tube
15. Seal
24. Seal Ring
7. Exhaust Gas Connecting Tube
16. Exhaust Gas Recirculation Cooler/Water Manifold Assembly
25. Bolt
8. Gasket
17. Clamps
26. Bolt
9. Seal Ring
18. Exhaust Pipe
Figure 3
DD13 EGR Cooler/Water Manifold and Related Parts
Check as follows: 1. Shut off the engine, apply the parking brake, chock the wheels, and perform any other applicable safety steps. 2. Remove the exhaust pipe (3) and inspect for any signs of liquid or moisture. The exhaust pipe and EGR cooler inlet should have a black dry soot residue inside. [a]
If liquid or moisture is present in the exhaust pipe, go to the next step.
[b]
If there is no sign of liquid or moisture in the pipe or EGR cooler, install the exhaust pipe. No further action is required.
3. Remove the mixer pipe (1) from the cold boost pipe (2).
4. Remove the exhaust gas crossover tube/lifting eye (2) and venturi (6).
5. Place a towel over the outlet of the EGR cooler and retain it with a zip tie. 6. Using a rubber tipped blow gun, blow compressed shop air into the individual tubes in the EGR cooler to clear any excess fuel, soot, and carbon. 7. After performing the cleaning procedure, refer to section 5.1.2 "Installation of the Exhaust Gas Recirculation Cooler Water Manifold Assembly." to install the: [a]
mixer pipe.
[b]
exhaust gas crossover tube/lifting eye.
[c]
venturi.
DD15 WORKSHOP MANUAL NOTE: The following information supports DDC-SVC-MAN-0002.
EGR COOLER CLEANING PROCEDURE TO REMOVE EXCESS OIL FROM EGR COOLER AFTER TURBOCHARGER FAILURE
Observe the following:
NOTICE: This cleaning procedure must be followed after replacing a DD15 turbocharger so that any failure will not cause excessive fuel, oil, or coolant to enter the exhaust system. Failure to perform this procedure could cause severe engine damage.
1. Venturi
9. Banjo Union
17. Water Manifold
2. Bolt
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. Exhaust Gas Connecting Tube
14. Clamp
22. Coolant Crossover Pipe
7. Coolant Connecting Tube
15. Seal Washer
23. Seal Ring
8. Seal Ring
16. Exhaust Pipe
Figure 4
DD15 EGR Cooler and Related Parts
Check as follows: 1. Shut off the engine, apply the parking brake, chock the wheels, and perform any other applicable safety steps. 2. Remove the exhaust pipe (4) and gaskets (3) and inspect for any signs of liquid or moisture. The exhaust pipe and EGR cooler inlet should have a black dry soot residue inside. [a]
If liquid or moisture is present in the pipe, go to the next step.
[b]
If there is no sign of liquid or moisture in the pipe or EGR cooler, install the exhaust pipe. No further action is required.
3. Remove the mixer pipe (4) from the cold boost pipe (1).
4. Remove the exhaust gas crossover tube/lifting eye (2) and venturi (3).
5. Place a towel over the outlet of the EGR cooler and retain it with a zip tie. 6. Using a rubber tipped blow gun, blow compressed shop air into the individual tubes in the EGR cooler to clear any excess fuel, soot, and carbon. 7. After performing the cleaning procedure, refer to section 1.6.2 "Installation of Front Engine Lifter Bracket" to install the: [a]
mixer pipe.
[b]
exhaust gas crossover tube/lifting eye.
[c]
venturi.
DD15 FUEL SYSTEM TECHNICIANS GUIDE NOTE: The following information supports DDC-SVC-MAN-0037.
35.4.1 EGR COOLER CLEANING PROCEDURE TO REMOVE EXCESS FUEL FROM EGR COOLER AFTER FUEL INJECTOR FAILURE
Observe the following: NOTICE: This cleaning procedure must be followed after replacing a DD15 fuel injector so that any failure will not cause excessive fuel, oil, or coolant to enter the exhaust system. Failure to perform this procedure could cause severe engine damage.
1. Venturi
9. Banjo Union
17. Water Manifold
2. Bolt
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. Exhaust Gas Connecting Tube
14. Clamp
22. Coolant Crossover Pipe
7. Coolant Connecting Tube
15. Seal Washer
23. Seal Ring
8. Seal Ring
16. Exhaust Pipe
Figure 5
DD15 EGR Cooler and Related Parts
Check as follows: 1. Shut off the engine, apply the parking brake, chock the wheels, and perform any other applicable safety steps. 2. Remove the exhaust pipe (4) and gaskets (3) and inspect for any signs of liquid or moisture. The exhaust pipe and EGR cooler inlet should have a black dry soot residue inside. [a]
If liquid or moisture is present in the pipe, go to the next step.
[b]
If there is no sign of liquid or moisture in the pipe or EGR cooler, install the exhaust pipe. No further action is required.
3. Remove the mixer pipe (4) from the cold boost pipe (1).
4. Remove the exhaust gas crossover tube/lifting eye (2) and venturi (3).
5. Place a towel over the outlet of the EGR cooler and retain it with a zip tie. 6. Using a rubber tipped blow gun, blow compressed shop air into the individual tubes in the EGR cooler to clear any excess fuel, soot, and carbon. 7. After performing the cleaning procedure, refer to section 1.6.2 "Installation of Front Engine Lifter Bracket" to install the: [a]
mixer pipe.
[b]
exhaust gas crossover tube/lifting eye.
[c]
venturi.
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.
