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 FROMEGR COOLER AFTER INJECTOR FAILURE

ADDITIONS, REVISIONS, OR UPDATESPublication Number Platform Section Title Change Page Number(s)

DDC-SVC-MAN-0050 DD13 1.18 Engine Brake Procedures have been added toclean the EGR Cooler due to fuel,oil, or coolant contamination froma failed engine brake solenoid.

1–125

DDC-SVC-MAN-0002 DD15 1.18 Engine Brake Procedures have been added toclean the EGR Cooler due to fuel,oil, or coolant contamination froma failed engine brake solenoid.

1–118

DDC-SVC-MAN-0050 DD13 4.2 Turbocharger Procedures have been added toclean the EGR Cooler due to fuel,oil, or coolant contamination froma failed DD13 turbocharger.

4–11

DDC-SVC-MAN-0002 DD15 4.2 Turbocharger Procedures have been added toclean the EGR Cooler due to fuel,oil, or coolant contamination froma failed DD15 turbocharger.

4–18

DDC-SVC-MAN-0037 DD15 35.4 Fuel Injectors Procedures have been added toclean the EGR Cooler due to fuel,oil, or coolant contamination froma 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 COOLERAFTER ENGINE BRAKE SOLENOID FAILURE

Observe the following:

NOTICE:This cleaning procedure must be followed after replacing anengine brake solenoid so that any failure will not cause excessivefuel, oil, or coolant to enter the exhaust system. Failure to performthis procedure could cause severe engine damage.

1. Clamp 10. Banjo Union 19. Exhaust Gas Crossover Tube/LiftingEye

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 RecirculationCooler/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 otherapplicable 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 theexhaust 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 EGRcooler to clear any excess fuel, soot, and carbon.

7. After performing the cleaning procedure, refer to section 5.1.2 "Installation of the Exhaust GasRecirculation 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 COOLERAFTER ENGINE BRAKE SOLENOID FAILURE

Observe the following:

NOTICE:This cleaning procedure must be followed after replacing anengine brake solenoid so that any failure will not cause excessivefuel, oil, or coolant to enter the exhaust system. Failure to performthis 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 otherapplicable 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 theexhaust 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 EGRcooler to clear any excess fuel, soot, and carbon.

7. After performing the cleaning procedure, refer to section 1.6.2 "Installation of Front EngineLifter 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 COOLERAFTER TURBOCHARGER FAILURE

Observe the following:

NOTICE:This cleaning procedure must be followed after replacing a DD13turbocharger so that any failure will not cause excessive fuel, oil,or coolant to enter the exhaust system. Failure to perform thisprocedure could cause severe engine damage.

1. Clamp 10. Banjo Union 19. Exhaust Gas Crossover Tube/LiftingEye

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 RecirculationCooler/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 otherapplicable safety steps.

2. Remove the exhaust pipe (3) and inspect for any signs of liquid or moisture. The exhaust pipeand 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 exhaustpipe. 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 EGRcooler to clear any excess fuel, soot, and carbon.

7. After performing the cleaning procedure, refer to section 5.1.2 "Installation of the Exhaust GasRecirculation 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 COOLERAFTER TURBOCHARGER FAILURE

Observe the following:

NOTICE:This cleaning procedure must be followed after replacing a DD15turbocharger so that any failure will not cause excessive fuel, oil,or coolant to enter the exhaust system. Failure to perform thisprocedure 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 otherapplicable 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 exhaustpipe. 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 EGRcooler to clear any excess fuel, soot, and carbon.

7. After performing the cleaning procedure, refer to section 1.6.2 "Installation of Front EngineLifter 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 EGRCOOLER AFTER FUEL INJECTOR FAILURE

Observe the following:

NOTICE:This cleaning procedure must be followed after replacing a DD15fuel injector so that any failure will not cause excessive fuel, oil,or coolant to enter the exhaust system. Failure to perform thisprocedure 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 otherapplicable 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 exhaustpipe. 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 EGRcooler to clear any excess fuel, soot, and carbon.

7. After performing the cleaning procedure, refer to section 1.6.2 "Installation of Front EngineLifter 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.

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