NUMBER: S.M. REF.: Listed in Table ENGINE: DD Platform DATE: July 2009

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1 NUMBER: S.M. REF.: Listed in Table ENGINE: DD Platform DATE: July 2009 SUBJECT: Listed in Table ADDITIONS, REVISIONS, OR UPDATES Publication Number Platform Section Title Change Page Number(s) DDC-SVC-MAN-0002 DD15 Workshop Manual 1.9 Rocker All sections are 1 70 additions to the Cover 4 7 publications. 4.2 Charge 4 8 Air Cooler 2 48 Outlet Air Temperature Sensor Intake Manifold Air Temperature Sensor 2.12 Doser Block Assembly 3.6 Priming the Oil System DDC-SVC-MAN-0050 DD13 Workshop Manual 1.9 Rocker All sections are additions to the Cover publications. 4.2 Charge Air Cooler Outlet Air Temperature Sensor 4.3 Intake Manifold Air Temperature Sensor 2.12 Doser Block Assembly 3.6 Priming the Oil System NOTE: Page numbers are based on the most recent version of the individual publication and may be adjusted throughout the annual print cycle.

2 DESCRIPTION AND OPERATION OF ROCKER COVER AND RELATED PARTS The rocker cover is made of an aluminum or plastic material and uses an elastomer seal which completely encloses the valve operating mechanism including the overhead camshafts, brake assemblies and the injector harness. 1. Gasket 4. Air Cleaner Bracket 2. Rocker Cover 5. Stud (Bolt) 3. Bolt

3 REMOVAL OF THE ROCKER COVER Remove as follows: 1. Steam clean the engine. 2. Remove bolts or nuts (if equipped) from the two air filter housing brackets and remove housings from the rocker cover. 3. Loosen the bolts or stud bolts (if equipped); remove rocker cover. NOTE: Mark the location of the stud bolts; the stud bolts must be replaced in their original location during installation. 4. Remove rocker cover gasket, bolts and isolators from the rocker cover.

4 CLEANING AND INSPECTION OF THE ROCKER COVER Clean as follows: 1. Clean cover in clean solvent or fuel. 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. 2. Blow dry with compressed air. 3. Check the rocker cover, breather passage and seal for damage. Replace as necessary. 4. Inspect the bolts and isolators; replace if damaged. 5. Inspect the bolt holes for damage. Replace as necessary.

5 INSTALLATION OF THE ROCKER COVER Install as follows: 1. Install rocker cover gasket into groove in rocker cover. 2. Install bolts or stud bolts (if equipped) and isolators into rocker cover. 3. Install rocker cover onto camshaft frame. 4. Finger tighten all bolts and stud bolts; then torque to 20 N m (14 lb ft). 5. Install the two air filter brackets onto the rocker cover and torque the eight nuts to 20 N m (14 lb ft). ENGINE EXHAUST To avoid injury from inhaling engine exhaust, always operate the engine in a well-ventilated area. Engine exhaust is toxic. 6. Start the engine and check for leaks.

6 REMOVAL OF CHARGE AIR COOLER OUTLET AIR TEMPERATURE SENSOR Remove as follows: 1. Remove electrical harness connector from the sensor. 2. Remove the charge air cooler outlet air temperature sensor from the throttle valve adapter. INSTALLATION OF CHARGE AIR COOLER OUTLET AIR TEMPERATURE SENSOR Install as follows: 1. Install the charge air cooler outlet air temperature sensor. Torque to 35 N m (26 lb ft). 2. Install the electrical harness connection.

7 REMOVAL OF INTAKE MANIFOLD AIR TEMPERATURE SENSOR Remove as follows: 1. Remove electrical harness connector from the sensor. 2. Remove the intake manifold air temperature sensor from the intake manifold. INSTALLATION OF INTAKE MANIFOLD AIR TEMPERATURE SENSOR Install as follows: 1. Install the intake manifold air temperature sensor. Torque to 35 N m (26 lb ft). 2. Install the electrical harness connection.

8 REMOVAL OF THE DOSER BLOCK ASSEMBLY Remove as follows: 1. Steam clean the engine. 2. Place a drip pan under engine to collect fuel. 3. Disconnect air compressor inlet hose from doser bracket. 4. Disconnect and remove the fuel feed line from the high pressure flange to the doser block assembly. 5. Disconnect the fuel dosing line banjo bolt (6) from the doser block assembly (4). NOTE: Before unplugging the sensors note their positions. 6. Unplug connectors from Fuel Cutoff Valve (FCV), Fuel Line Pressure Sensor (FLP), Fuel Compensation Pressure Sensor (FCP), and Electronic Dosing Valve (EDV). 7. Loosen three bolts and remove the Doser Block Assembly (4). 8. If required, remove the doser block bracket (7) from the engine by removing the three bolts (3), bushings (2) and isolators (1).

9 INSTALLATION OF THE DOSER BLOCK ASSEMBLY Install as follows: 1. If removed, install the doser block bracket onto the engine. 2. Install the six isolators, three bushings, and three bolts. Torque to 25 N m (18 lb ft). 3. Install the Doser Block Assembly using three bolts; torque bolts to 34 N m (25 lb ft). 4. Plug in connectors to the FCV, FLP Sensor, FCP Sensor and EDV. 5. Attach the dosing fuel line to the doser block assembly. Torque to 25 N m (18 lb ft). 6. Connect fuel feed line from the high pressure flange to the doser block assembly. Torque banjo bolt to 25 N m (18 lb ft). Torque the swivel fitting to 23 N m (17 lb ft). 7. Start the engine. ENGINE EXHAUST To avoid injury from inhaling engine exhaust, always operate the engine in a well-ventilated area. Engine exhaust is toxic. 8. Use the HC Doser command to run the purge function in DDDL 7.0 to purge all the air from the doser valve and line.

10 REPLACING OIL PLUG WITH OIL SAMPLE VALVE Replace oil plug with oil sample valve as follows: 1. Using a 17 mm Allen tool, remove the Allen head plug from the oil priming port on the oil coolant module. 2. Install the oil sample valve with a new seal ring onto the oil coolant module. Torque to 80 N m (59 lb ft).

11 REMOVALOFOILSAMPLEVALVE Remove as follows: Remove the Oil sample valve and washer from the oil coolant module. INSTALLATION OF OIL SAMPLE VALVE Install as follows: Install the oil sample valve with a new seal ring onto the oil coolant module and torque to 80 N m (59 lb ft).

12 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.