©2006 Detroit Diesel Corporation and Technical Support. All Rights Reserved.

Filename/11/14/2016

1
DD15

January 2008
 Design And Manufacturing Of The DD15

Common Base Engine

Design
•Developed as an EGR engine
©2006 Detroit Diesel Corporation and Technical Support. All Rights Reserved. Filename/11/14/2016

- baseline NOx reduction

strategy
•Ability to apply new technologies
to a common platform
•Capture best practices of all
current engines and manufacturing
processes
•First launch in NAFTA with Europe
and Asia following in 2010

January 2008
2
 Engine Configurations
All displacements similar design and construction
•In line 6-cylinder with wet liners, cast block, one piece (slab) cylinder head and Engine Family
dual overhead camshafts (intake and exhaust)
14.8 L/15.6 L
Robust webbed cylinder block for noise and vibration reduction
•Capable of increased cylinder pressures up to 18.4:1
©2006 Detroit Diesel Corporation and Technical Support. All Rights Reserved. Filename/11/14/2016

Rear gear train configuration

Bosch flexible common rail fuel system
•NOx reduction potential w/o fuel economy penalty
12.8 L
Integral Jake Brake
•Built into the rocker arm assembly

Cooled EGR system

New MCM specifically for DD15
CPC electronic controls common platform
•DD15/S60/900/4000

January 2008
3
 Engine Horse Power Ratings

455/475 HP, 1550 LB-FT 455/515 HP, 1750 LB-FT

Standard Fleet Rating Standard Performance Rating
©2006 Detroit Diesel Corporation and Technical Support. All Rights Reserved. Filename/11/14/2016

455/505 HP, 1650 LB-FT 475/HP, 1650/1850 LB-FT

Premium Fleet Rating Premium Fuel Economy Rating

475/505 HP, 1650 LB-FT 485/530 HP, 1850 LB-FT

Premium Fleet Rating Premium Performance Rating

455 HP, 1550 / 1750 LB-FT 500/560 HP, 1850 LB-FT

Fuel Economy Rating Premium Performance Rating

January 2008
4
 ©2006 Detroit Diesel Corporation and Technical Support. All Rights Reserved. Filename/11/14/2016

5
Engine Serial Number Location

January 2008
 Engine Components Right Side
EGR Cooler 1
11 A/C Compressor
Location
EGR Valve and Actuator 2

Axial Power Turbine 3

©2006 Detroit Diesel Corporation and Technical Support. All Rights Reserved. Filename/11/14/2016

Fuel Doser
Valve 4

10 Alternator

APT Gear Box 5

Starter Location 6

Air Seal Pressure Regulator 7

Valve
Crankcase Breather 8
9 Turbocharger
January 2008
6
 Engine Components Left Side

High Pressure Fuel 1

Rail
12 Intake Manifold
Oil/ Coolant Module 2

11 Doser Block Assembly

©2006 Detroit Diesel Corporation and Technical Support. All Rights Reserved. Filename/11/14/2016

Coolant Pump 3

10 High
Thermostat 4
Pressure
Fuel Pump

Low Pressure
9
Fuel Pump
8 Air Compressor
MCM 5 7 Power Steering Pump (NAFTA)

6 Fuel Filter Module

January 2008
7
 ©2006 Detroit Diesel Corporation and Technical Support. All Rights Reserved. Filename/11/14/2016

8
Axial Power Turbine

Oil In
Oil to APT

January 2008
 ©2006 Detroit Diesel Corporation and Technical Support. All Rights Reserved. Filename/11/14/2016

9
Elbow
EGR Delivery
EGR Valve/ Actuator

Thermal Washer
Coolant In

Actuator
Coolant Out

January 2008
 Throttle Valve

EGR Temperature Sensor

Grid Heater
©2006 Detroit Diesel Corporation and Technical Support. All Rights Reserved. Filename/11/14/2016

Air Intake Elbow

Delivery Pipe

Air Intake Manifold Pressure

Air Intake Temperature Sensor

Intake Throttle January 2008
10
 Delta P Sensor

• Delta P sensor values

•0.50 V = -17.2 mbar or -6.9 “h2o
•0.69 V = 0 mbar or 0 “h2o
©2006 Detroit Diesel Corporation and Technical Support. All Rights Reserved. Filename/11/14/2016

•4.50 V = 344.7 mbar or 138.4 “h2o

January 2008
11
 Oil/Coolant Module
9 EGR Coolant Supply
(Water Pump Pressure Supply)
Coolant Filter 1
Block Heater Port 6

8
Cabin Heater
2
Return
©2006 Detroit Diesel Corporation and Technical Support. All Rights Reserved. Filename/11/14/2016

Fuel Cooler/ Air (Suction Side)

Compressor
Coolant Return
(Water Pump
Suction Side)

Coolant Bypass (Return

Flow Of The Crankcase
To The Thermostat 7
Suction Side) Fill Line From Expansion
4 Tank (Suction Side)
Drain Plug for Bypass Circuit
5 Coolant Inlet Of Bypass Circuit
Or Radiator Circuit
January 2008
12
 ©2006 Detroit Diesel Corporation and Technical Support. All Rights Reserved. Filename/11/14/2016

13
Fuel System

January 2008
 ©2006 Detroit Diesel Corporation and Technical Support. All Rights Reserved. Filename/11/14/2016

14
(APCRS)
Fuel System

Amplified Pressure
Common Rail System

January 2008
 Fuel System
• High Pressure Fuel Rail 14 13 High Pressure Feed
•

Lines with Damper

10 Low Pressure Feed

•

to High pressure
Pump
©2006 Detroit Diesel Corporation and Technical Support. All Rights Reserved. Filename/11/14/2016

11 Quantity Control Valve

•

• Final Filter 9
12 Low Pressure return
Water Separator 8 from High Pressure
pump

Fuel In 1

Heat Exchanger to Fuel Filter 3

5 Suction- Low Pressure Feed
Module
•

7 Low Pressure Supply to Filter

Fuel to Heat Exchanger (MCM) 2 Module
4 6 • Low Pressure Pump
• 4. Pre- Filter

January 2008
15
 Fuel System
Transfer Tube 15 Pressure Limiting
19
Valve (PLV)
Rail 22 20 (PLV) Return
Pressure
Sensor
17 Amplification
Return Line
©2006 Detroit Diesel Corporation and Technical Support. All Rights Reserved. Filename/11/14/2016

18 Needle Return
Line
Injector 16
21 Emergency
• Pump Lubrication
Return to Tank 26 Line
•

Water In Fuel Sensor 23

24
Doser Block Assembly Fuel
Supply

25 Amplification Return Into Prefilter

January 2008
16
 Fuel Filter Module (Functions)

• Removing water from fuel

•Reducing the temperature of returned amplification fuel
•Providing connections for several fuel returns at the fuel gallery
©2006 Detroit Diesel Corporation and Technical Support. All Rights Reserved. Filename/11/14/2016

•Notifying if the water level becomes critical with a water in fuel

(WIF) sensor
•Monitor fuel supply temperature with a temperature sensor
•providing a hand pump for fuel system priming
•Providing a COMPU check valve for external fuel priming
•Providing one-way assembly valves on the inlet and
outlet connections
•Monitor filter life with the element service indicator

January 2008
17
 Fuel Filter (Pre Screen)

• 1. Bypass Valve
• 2. Check Ball
• 3. Filter Element
©2006 Detroit Diesel Corporation and Technical Support. All Rights Reserved. Filename/11/14/2016

• 4. Fuel Inlet
• 5. Fuel Outlet
• D. Unfiltered Fuel
• E. Pre- Filtered Fuel

January 2008
18
 Water Separator

1
•1. Ventilation Bore
•2. Water Separator Element
•3. Water Collector
2
©2006 Detroit Diesel Corporation and Technical Support. All Rights Reserved. Filename/11/14/2016

8
•4. Drain Valve
5. Fuel Temperature Sensor A
•
A B
•6. Stand Pipe A
7
A
•7. Final Filter Element 6
•8. Ventilation Bore 3

•A. Pre- Cleaned Fuel

•B. Cleaned Fuel A

5
4

January 2008
19
 Fuel System Priming

After Filter Change

1. Ensure priming canister is ¾ full of fuel.
2. Install fuel priming canister to the priming port on the fuel filter
module.
3. Ensure priming canister shutoff valve is closed.
©2006 Detroit Diesel Corporation and Technical Support. All Rights Reserved. Filename/11/14/2016

4. Pressurize priming canister.

5. Open shutoff valve and allow system to fill for 60 seconds.
6. Close shutoff valve.
7. Crank engine for 15 seconds.
8. If engine does not start, allow for a 60 second cool down and
repeat step 4-8. The starting cycle can be repeated up to three
times.
9. If engine still fails to start:
- Use DDDL to check for fault codes, repair as necessary.
- Complete steps 5-9.
10. If engine starts, remove priming canister from filter module.
11. Allow engine to reach operating temperature 60C (140 F).
12. Increase engine RPM to 1,800 for 2 minutes.
13. Reduce RPM and check for fuel leaks, repair if necessary.

January 2008
20
 Fuel System Priming

• High Pressure Pump Change or Completely Dry

System
• 1. Ensure priming canister is ¾ full (approximately 9 liters) of fuel.
• 2. Install fuel priming tool to the priming port on the fuel filter module.
©2006 Detroit Diesel Corporation and Technical Support. All Rights Reserved. Filename/11/14/2016

• 3. Ensure priming canister shutoff valve is closed.

• 4. Pressurize priming canister to maximum pressure.
• 5. Open shutoff valve and allow system to fill for 2 1/2 minutes.
• 6. Close shutoff valve.
• 7. Check for fuel system leaks.
• 8. Re-pressurize priming canister to maximum pressure.
• 9. Open shutoff valve.
• - Pressure in the priming canister will drop
• As the system is filling, continue to pump the priming canister for one
minute minimum.
• This process may take an additional 5-15 pumps of the priming canister.
• Note: If using an electric priming pump, ensure the pump is capable of
producing 70 PSI.

January 2008
21
 Fuel System Priming

• High Pressure Pump Change or Completely Dry

System
• 10. Close shutoff valve.
11. Crank engine for 20 seconds.
©2006 Detroit Diesel Corporation and Technical Support. All Rights Reserved. Filename/11/14/2016

• 12. If engine does not start, allow for a 60 second cool down and
repeat step 11.
• The starting cycle can be repeated up to 3 times.
• 13. If the engine still fails to start; 1-use DDDL check for fault codes,
repair if necessary. 2-Complete steps 7-11.
• 14. Remove the electric priming pump from the module.

• CAUTION: NEVER INTENTIONALLY TRY TO RUN THE ENGINE OUT

OF FUEL. THIS COULD CAUSE POTENTIAL PERFORMANCE ISSUES

January 2008
22
 ©2006 Detroit Diesel Corporation and Technical Support. All Rights Reserved. Filename/11/14/2016

23
Water In Fuel Sensor

January 2008
 ©2006 Detroit Diesel Corporation and Technical Support. All Rights Reserved. Filename/11/14/2016

24
4

5
2

6
1

7
High Pressure Pump

11

8
9
10
1

January 2008
10
 High Pressure Pump
High Pressure Valve 7

6 High Pressure Valve

Intake Valves 8
5 High Pressure Pump
Housing
©2006 Detroit Diesel Corporation and Technical Support. All Rights Reserved. Filename/11/14/2016

4 High Pressure Piston

3 Compression Spring
2 Roller Tappet

1 Camshaft

January 2008
25
 ©2006 Detroit Diesel Corporation and Technical Support. All Rights Reserved. Filename/11/14/2016

26
Safety Relief
1
Oil Pump

3
Regulator

Block

January 2008
Oil Feed from
 ©2006 Detroit Diesel Corporation and Technical Support. All Rights Reserved. Filename/11/14/2016

27
Internal Components

January 2008
 ©2006 Detroit Diesel Corporation and Technical Support. All Rights Reserved. Filename/11/14/2016

28
Piston

Protrusion Bridge
W4705890031000 Piston
Oil Drain Hole

J-47386 Ring Compressor

January 2008
 ©2006 Detroit Diesel Corporation and Technical Support. All Rights Reserved. Filename/11/14/2016

29
Rear Geartrain

January 2008
 Rear Geartrain
Camshaft Gear (Intake) 1

12 Camshaft Gear (Exhaust)

Fuel Pump Gear 2
11 Idler Gear 5
10 Idler Gear 3
©2006 Detroit Diesel Corporation and Technical Support. All Rights Reserved. Filename/11/14/2016

Idler Gear 1 3

9 Idler Gear 2

Air Compressor 4

Gear
8 APT Gear
Oil Pump Gear 5
7 Idler Gear 4
6 Crankshaft Gear

January 2008
30
 ©2006 Detroit Diesel Corporation and Technical Support. All Rights Reserved. Filename/11/14/2016

31
Overhead/ Jake Brake

January 2008
 Exhaust Rocker Arm and Jake Brake

Exhaust Arm Engine Brake

Assembly
©2006 Detroit Diesel Corporation and Technical Support. All Rights Reserved. Filename/11/14/2016

Engine Brake Mode Exhaust Rocker

Engine Power Mode Exhaust Rocker

January 2008
32
 ©2006 Detroit Diesel Corporation and Technical Support. All Rights Reserved. Filename/11/14/2016

33
Fuel System Diagnostics

January 2008
 ©2006 Detroit Diesel Corporation and Technical Support. All Rights Reserved. Filename/11/14/2016

34
DDEC VI

January 2008
 Left Side Sensor Locations
EGR Temp 1
(on intake Manifold) 14 Fuel Rail
EGR Delta P 2 Pressure

Intake Air Temp 3 13 Cam Position

©2006 Detroit Diesel Corporation and Technical Support. All Rights Reserved. Filename/11/14/2016

Intake 12 Grid Heater

Manifold
Pressure 4
11 Quantity
Coolant Inlet 5
Control
Temp Valve

Oil Temp 6 10 Crank Position

Oil Pressure 7
9 Fuel Temp
8 Water In Fuel

January 2008
35
 Right Side Sensor Locations

Turbocharger Speed 1
©2006 Detroit Diesel Corporation and Technical Support. All Rights Reserved. Filename/11/14/2016

3 Coolant Outlet
Temperature

2 Turbocharger Inlet
Temperature

January 2008
36