NUMBER: 7 9 09 S.M. REF.: Listed in Table 1 ENGINE: DD15 DATE: July 2009 SUBJECT: CAMSHAFT AND ROCKER SHAFT ASSEMBLIES ADDITIONS, REVISIONS, OR UPDATES Publication Number Platform Section Title Change Page Number(s) DDC-SVC-MAN-0002 DD15 1.4 Camshaft and Rocker Shaft Assemblies The Camshaft and Rocker Shaft Assemblies Section ofthedd15workshop Manual is revised. 1 39 DDC-SVC-MAN-0002 DD15 1.19 Engine Brake The Engine Brake Section of the DD15 Series Workshop Manual is revised. 1 128 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
CAMSHAFT AND ROCKER SHAFT ASSEMBLIES The engine uses a dual overhead camshaft and rocker shaft design. The intake and exhaust camshafts must be timed to each other and also timed to the crankshaft. The timing is accomplished through the geartrain. The engine uses an integral engine brake. Engine braking is controlled electronically by the engine control system with an electric solenoid. When activated, the solenoid allows oil pressure to activate a piston on the exhaust rocker arm. Engine braking is accomplished with a single exhaust valve in each cylinder. The exhaust camshaft uses a separate engine brake-only lobe that allows for double valve activation for high efficiency braking. The exhaust valve is firstoperatedtowardthecompletionof the intake stroke, closed during the compression stroke and opened a second time when the compression stroke is completed. CAMSHAFT AND ROCKER SHAFT ASSEMBLY REMOVAL Remove as follows: 1. Turn engine OFF, (key OFF, engine OFF). 2. Steam clean the engine. 3. Disconnect the battery power to the engine. 4. Remove the air cleaner and the turbocharger inlet pipe and hose. 5. Remove air cleaner housing. 6. Remove eight bolts from air cleaner bracket and remove bracket. 7. Remove nineteen bolts from rocker cover and remove rocker cover. 8. Remove the injector harness. NOTE: TDC can be confirmed by installing front camshaft timing tool (W470589054000). 9. Rotate the engine to top dead center (TDC) on cylinder No. 1 using engine barring tool (J-46392). 10. Remove the crankshaft position sensor (CKP) from the rear of the flywheel housing.
11. Install flywheel housing crankshaft locking tool (W470589001500) into the CKP sensor hole located in the rear of the flywheel housing. The plastic tip protrudes into the cutout in the tone wheel to accurately locate TDC. NOTICE: Ensure when loosening the rocker shaft bolts that the bolts are loosened from the inside bolts outward in 1/2 turn increments. The increment procedure needs to be followed to prevent the rocker shaft from breaking. 12. Completely loosen all of the adjusting screws on all of the rocker arms. 13. Loosen the seven bolts securing the intake rocker shaft to the camshaft caps. 14. Using rocker arm lifter and spacer tool (W470589004000), remove the intake rocker shaft assembly. 15. Loosen the seven bolts securing the exhaust rocker shaft to the camshaft cap.
16. Using rocker arm lifter and spacer tool (W470589004000), remove the exhaust rocker shaft assembly. NOTE: The engine brake solenoids do not have to be removed unless damaged. 17. Remove the remaining bolts from the camshaft caps and remove with cam bearing cap puller (J 48883). 18. Remove the intake and exhaust camshaft assemblies from the camshaft housing. INSPECTION OF THE CAMSHAFT AND ROCKER SHAFT ASSEMBLIES Inspect the camshaft and rocker shaft assemblies as follows: 1. Inspect the camshafts for lobe damage; replace if necessary. 2. Inspect the camshaft gears for damage; replace if necessary. 3. Inspect the rocker shaft for scoring or scuffing; replace if necessary. 4. Inspect rocker arms for roller and bushing damage; replace if necessary. 5. Inspect adjusting screws and buttons; replace if necessary. 6. Inspect cam caps and cam journals in cam frame for damage; replace if necessary. 7. Inspect the tone wheel on the intake camshaft for cracks, bending or any damage. If damage is found, replace the intake camshaft.
INSTALLATION OF THE CAMSHAFT AND ROCKER SHAFT ASSEMBLIES Install as follows: 1. Verify that the crankshaft is at top dead center (TDC) on cylinder number one using crankshaft locking tool (W470589001500) installed in Crankshaft Position Sensor (CKP) hole located in the flywheel housing. 2. Install camshaft timing tool (W470589054000) (1) to the rear of the camshaft housing. Tighten the two bolts.
3. Locate the etched triangle on the camshaft gear teeth and mark the teeth with a paint pen. 4. Lubricate the lower camshaft bearing surfaces and camshaft journals before installing the camshafts. Install the exhaust and intake camshaft gear assemblies into the cam frame. 5. Align the marked gear teeth with the marks on the timing tool. 6. Install timing tool (W470589054000) (1) to the front of the camshaft frame and into the grooves cut into the camshafts. Secure timing tool to the camshaft with a bolt. [a] At this point the front timing tool should slide into the camshaft grooves easily with no drag. [b] If there is excessive drag when installing the tool, the camshafts are out of time.
7. Verify that the marks on the gear teeth match the marks on the timing tool. NOTICE The camshaft caps are numbered and need to be installed correctly. 8. Install the seven camshaft caps onto intake and exhaust camshafts. 9. The first and seventh camshaft caps hold the engine brake solenoid to camshaft cap. Replace the O-rings on the solenoid prior to reinstallation. Install the engine brake solenoid. NOTE: There are 28 bolts retaining the camshaft assemblies; 14 120 mm (M10) bolts, seven 108 mm (M10) bolts and seven 63 mm (M8) bolts. 10. Install the 28 bolts to camshaft caps; finger tighten the bolts. Refer to figure for proper bolt placement.
11. Torque M10 camshaft cap bolts to 20 N m (15 lb ft) and then torque to 50-55 N m (37-40 lb ft) using torque sequence shown in figure. 12. Torque the seven 63 mm M8 bolts to 30 N m (22 lb ft) using the torque sequence. 13. Remove crankshaft locking tool (W470589001500) from CKP sensor hole in the flywheel housing. 14. Install CKP sensor. 15. Install a dial indicator onto gear case and zero out the dial indicator. 16. Position the stem of dial indicator to rest between the teeth on the camshaft gear. 17. Hold the number five idler gear with a screwdriver. Check the lash between the camshaft gear and idler gear number five.
18. The dial indicator should read 0.051-0.257 mm (0.002002-0.01010 in.). If the gear lash is excessive between either camshaft gear and the number five idler gear, inspect the number five idler gear spindle, camshaft gear and camshaft housing. Repair as necessary. NOTICE: The camshaft journal area (1) is lubricated by oil that has to travel through the rocker shaft. If the rocker shaft is installed incorrectly, oil passages do not line up. This results in insufficient lubrication and damage to the camshaft journals. Incorrect shaft installation may also result in the engine brakes not functioning and cause damage to the rocker arm bushings.
NOTICE: Ensure when tightening the rocker shaft bolts that the bolts are drawn down from the inside bolts outward in 1/2 turn increments, before final torque. If the rocker shaft bolt is fully torqued without using the increment procedure the rocker shaft can break. 19. Using rocker arm lifter and spacer tool (1) (W470589004000), install the assembled intake rocker arm assembly to the camshaft cap and secure with seven clamping blocks and bolts. 20. Torque the bolts to 50-55 N m (36-41 lb ft) +90 degrees following torque sequence in figure below.
21. Using rocker arm lifter and spacer tool (W470589004000), install the assembled exhaust rocker arm assembly to the camshaft cap. 22. Torque the bolts to 50-55 N m (36-41 lb ft) +90 degrees following torque sequence in figure below. 23. Remove timing tools. 24. Install the injectors and harness. Refer to section 2.14.5. 25. Lash the valves and engine brakes. Refer to section 1.19.3. 26. Install the rocker cover. Refer to section 1.10.2. 27. Reconnect the battery power to the engine. 28. Install air cleaner bracket with eight bolts. 29. Install air cleaner housing.
30. Install the turbocharger inlet pipe and hose, and air cleaner. ENGINE BRAKE The engine uses a dual overhead camshaft and rocker shaft design. The intake and exhaust camshafts must be timed to each other and also timed to the crankshaft. The timing is accomplished through the geartrain. The engine uses an integral engine brake. Engine braking is controlled electronically by the engine control system with an electric solenoid. When activated, the solenoid allows oil pressure to activate a piston on the exhaust rocker arm. Engine braking is accomplished with a single exhaust valve in each cylinder. The exhaust camshaft uses a separate engine brake-only lobe that allows for double valve activation for high efficiency braking. The exhaust valve is firstoperatedtowardthecompletionof the intake stroke, closed during the compression stroke and opened a second time when the compression stroke is completed. The engine brake system is enabled using the following components: Engine brake solenoid valve low (Y132). Engine brake solenoid valve medium (Y133). Six exhaust rocker arms with actuator pistons (2). Six brake rocker arms (3) which are actuated by the brake cam lobes (10). Exhaust rocker arm shaft (6) with an oil passage for lubricating the rocker arm and two additional oil passages (oil passage for cylinders 1 and 2 (4) and oil passage for cylinders 3 to 6 (5)) for supplying pressurized oil to the exhaust rocker arm with actuator piston (2). Exhaust camshaft (7) with one brake cam lobe (10) per cylinder. 1. Exhaust Rocker Arm 7. Exhaust Camshaft 2. Exhaust Rocker Arm with Actuator Piston 8. Actuator Piston 3. Brake Rocker Arm 9. Outlet Valve 4. Oil Passage for Cylinders 1 and 2 10. Brake Cam Lobe 5. Oil Passage for Cylinders 3 6 Y132 Engine Brake Solenoid Valve Low 6. Exhaust Rocker Arm Shaft Y133 Engine Brake Solenoid Valve Medium
REMOVAL OF THE ENGINE BRAKE Remove as follows: 1. Turn engine OFF, (key OFF, engine OFF). 2. Steam clean the engine. NOTE: Ensure the engine is at ambient temperature. 3. Disconnect the starting system. 4. Remove the air cleaner and the turbocharger inlet pipe and hose. 5. Disconnect the battery power to the engine. 6. Remove air cleaner housing. 7. Remove eight bolts from air cleaner bracket and remove bracket. 8. Remove nineteen bolts from rocker cover and remove rocker cover. 9. Disconnect the harness from engine brake solenoids (Y132 and Y133) and the injectors. Remove the engine brake solenoid (Y132 and Y133) and injector connections. 10. Remove the engine brake solenoid (Y132 and Y133). NOTICE: Ensure when loosening the rocker shaft bolts that the bolts are loosened from the inside bolts outward in 1/2 turn increments. The rocker shaft can break without using the increment procedure. NOTE: After the rocker shaft bolts are loosened completely, remove the brake rocker arm springs before removing the shaft assembly; there is a risk that the springs can fall into the gear case.
11. Completely loosen all of the adjusting screws on all of the exhaust rocker arms. 12. Loosen the seven bolts securing the exhaust rocker arm to the bridge. 13. Using rocker arm lifter and spacer tool (W470589004000), remove exhaust rocker assembly. INSPECTION OF THE ENGINE BRAKE Inspect as follows: 1. Inspect the exhaust rocker arm with actuator piston for damage or wear; replace if necessary. 2. Inspect the two engine brake solenoids for wear or damage; replace if necessary. 3. Inspect the brake rocker arm for wear or damage; replace if necessary.
INSTALLATION OF THE ENGINE BRAKE Install as follows: 1. Install the exhaust rocker arm with actuator piston and brake rocker arm onto exhaust rocker shaft. NOTICE: The camshaft journal area (1) is lubricated by oil that has to travel through the rocker shaft. If the rocker shaft is installed incorrectly, oil passages do not line up. This results in insufficient lubrication and damage to the camshaft journals. Incorrect shaft installation may also result in the engine brakes not functioning and cause damage to the rocker arm bushings. 2. Using rocker arm lifter and spacer tool (W470589004000), install the assembly into the camshaft housing.
NOTICE: Ensure when tightening the rocker shaft bolts that the bolts are drawn down from the inside bolts outward in 1/2 turn increments, before final torque. If the rocker shaft bolt is fully torqued without using the increment procedure the rocker shaft (1) can break. NOTE: Assemble the brake rocker arm springs before tightening shaft bolts. 3. Install seven bolts into the rocker shaft and bracket. 4. Tighten the seven bolts 50 55 N m (36 40 lb ft) plus 90 degree torque turn. NOTE: Ensure solenoid is completely seated in bore prior to torquing screw. NOTE: The hold-down screws are located in the injector harness.
5. Install the two brake solenoids (3) with new seal O-rings (4). Torque the solenoid hold-down screws to 10 N m (7.4 lb ft). NOTICE: Ensure when tightening the terminal connector (2) that the connector (1) does not contact the solenoid housing. A short to all the injectors will occur if contact is made. 6. Install injector harness contacts to solenoids.
7. Place a 0.65 mm feeler gauge (1), (or equivalent) as a spacer between the connector (3) and the solenoid housing (2) to keep sufficient clearance to avoid a short between the connector and solenoid housing. Torque the connector nut to 1.5 N m (13 lb in.). 8. Install rocker cover. NOTE: Anytime the engine brake lash is set the valve lash will need to be adjusted. NOTE: Set the valve lash before setting the engine brake lash. VALVE LASH ADJUSTMENT Adjust the valves as follows: 1. Turn engine OFF, (key OFF, engine OFF). 2. Steam clean the engine. 3. Disconnect battery power to the engine. 4. Remove the air cleaner and the turbocharger inlet pipe and hose. 5. Remove air cleaner housing. 6. Remove eight bolts from air cleaner bracket and remove bracket. 7. Remove nineteen bolts from rocker cover. 8. Remove rocker cover.
9. Bar the engine over until cylinder number one is at top dead center (TDC). 1. Feeler Gauge Location between the Rocker Armand Valve 2. Feeler Gauge 10. Lash intake valves one, two and four to 0.4 mm (0.016 in.). 11. Lash exhaust valves one, three and five to 0.6 mm (0.024 in.). 12. Rotate the engine 360 from the flywheel housing, until cylinder number six is at TDC, for a setting of 180 from the camshafts. 13. Lash intake valves three, five, and six to 0.4 mm (0.016 in.). 14. Lash exhaust valves two, four and six to 0.6 mm (0.024 in.). 15. Torque the locknut valve adjusting screw to 50 N m (37 lb ft). 16. Remove any tools used for this procedure. 17. Install the rocker cover. 18. Reconnect the battery power to the engine. 19. Install air cleaner bracket with eight bolts. 20. Install air cleaner housing. 21. Install the turbocharger inlet pipe and hose, and air cleaner.
SETTING THE ENGINE BRAKE LASH Set the lash as follows: 1. Set the lash on all the exhaust adjusting screws first (all the adjusting screws in direct contact with the exhaust valves). 2. Rotate the engine until a given cylinder is at maximum intake lift. When this is reached, the brake lash can be set on this cylinder. 3. When the brake rocker arm is in contact with the exhaust valve, set the lash between the brake rocker arm adjusting screw and the actuator piston stem. Set the lash to 4.1 mm (0.1614 in.). 4. Lash the engine brakes in the following firing order; 1, 5, 3, 6, 2, and 4. 5. Torque the locknut valve adjusting screw to 50 N m (37 lb ft).
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.