NUMBER: S.M. REF.: Listed in Table ENGINE: DD15 DATE: February 2009

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1 NUMBER: S.M. REF.: Listed in Table ENGINE: DD15 DATE: February 2009 SUBJECT: CAMSHAFT TIMING ADDITIONS, REVISIONS, OR UPDATES Publication Number Platform Section Title Change Page Number(s) DDC-SVC-MAN-0002 EPA07 DD gear train and engine timing The timing tool number for the front and rear camshafts has been changed. A new camshaft timing section has been added. NOTE: Page numbers are based on the most recent version of the individual publication and may be adjusted throughout the annual print cycle

2 GEAR TRAIN AND ENGINE TIMING The gear train is located at the rear of the engine. The gear train consists of intake and exhaust camshaft gears,idlergearsno.1,2,3,4,and5,crankshaftgear, oil pump gear, fuel pump gear, air compressor gear, and axial power turbine gear.

3 1. Idler Gear No Crankshaft Gear 2. Idler Gear No Oil Pump Gear 3. Idler Gear No Camshaft Gear Exhaust 4. Idler Gear No Camshaft Gear Intake 5. Idler Gear No. 5 A. Level A 6. Air Compressor Gear B. Level B 7. Fuel Pump Gear C. Level C 8. Axial Power Turbine Gear x. ToFrontofEngine

4 The gear train on the DD Series engines is located at the rear of the engine and has three levels. Level A consists of the outer most gears (closest to the flywheel), level B consists of the middle gears, and level C consists of the forward most gears (closest to the block). The gears in the gear train are both directly and indirectly driven by the crankshaft gear. Level A: The outer gears include the crankshaft gear which drives the No. 1 outer idler gear and the oil pump. The No. 4 idler gear is on the crankshaft gear and the axial power turbine drives the No. 4 idler gear when the Axial Power Turbine (APT) is creating power. The APT can add additional torque to the crankshaft through No. 4 idler gear up to 260 N m (192 lb ft). These gears are all helical cut. Level B: The middle gears include No. 1 inner idler gear which drives the air compressor gear and the No. 2 idler gear. The No. 2 idler gear drives the high pressure fuel pump and the No. 3 outer idler gear. These gears are all straight cut. Level C: The inner gears include the No. 3 inner idler gear which drives the No. 5 idler gear. The No. 5 idler gear drives both intake and exhaust camshafts. These gears are all straight cut. Gear train noise is an indication of excessive gear lash, chipped or burred gear teeth. Therefore, when noise develops in a gear train, the gear train needs to be inspected. A rattling noise usually indicates excessive gear lash. A whining noise indicates too little gear lash. The power steering pump can be mounted in two places. If the engine is equipped with a single-cylinder air compressor, it will be mounted to the front of the air compressor. If the engine is equipped with a two cylinder air compressor, then it will be mounted on the back of the gear case to the fuel pump.

5 GEAR TRAIN AND ENGINE TIMING WITH GEAR TRAIN REMOVED Time the gear train as follows: NOTE: Do not remove timing tools until all the gears have been installed. NOTE: Coat the inside of the gears, bushings and gear train with clean oil before installation. 1. Install timing tool (1) (W ) into the holes at the rear of the camshaft frame and secure to the camshaft frame with two bolts.

6 2. Install timing tool (1) (W ) into the holes at the front of the camshaft frame and secure to the camshaft frame with one bolt. NOTE: Timing marks are etched on the exhaust and intake gears. 3. Ensure timing marks on camshaft gear are at TDC for intake and exhaust gear.

7 4. Rotate the crankshaft to top dead center (TDC) on cylinder No. 1. Lock tool J into place with bolt. 5. If removed, install idler gear No. 5 with tool J Install two bolts into idler gear No. 5. Remove shoulder bolt J and final torque to N m (44 48 lb ft).

8 7. Install timing tool J on idler gear No. 3. NOTE: Ensure timing mark on spindle and gear for idler gear No. 3 align. 8. Install idler gear No. 3 with spindle and tool J onto cylinder block. 9. Install two bolts into the spindle and idler gear No. 3; snug the bolts. NOTE: When idler gear No. 3 and timing tool J are installed to the gear case, timing tool J should come off of the gear with ease. If the timing tool is not easily removed, that is an indication that the gears are not timed. 10. Check the gear lash between idler gear No. 3 and idler gear No Install a dial indicator onto gear case and position the stem to rest between the teeth on idler gear No. 3; zero out the dial indicator. 12. Hold idler gear No. 5 with a screwdriver to check gear lash. 13. The lash reading on the dial indicator should be mm ( in.). 14. When correct gear lash is established, torque idler gear No. 3 to N m (44-48 lb ft).

9 15. Install spindle and idler gear No. 2 onto cylinder block with three bolts. Torque bolts to 100 N m (73 lb ft). NOTE: For ease of installation on idler gear No. 1, roll the gear into crankshaft gear. 16. Install the spindle and idler gear No. 1 and thrust washers onto cylinder block with three bolts. Torque the bolts to 100 N m (73 lb ft). NOTE: When installing No. 4 idler gear, verify that the part number on the gear is facing the block. 17. Install spindle and idler gear No. 4 and thrust washers onto cylinder block with four bolts. Torque the bolts to 100 N m (73 lb ft). 18. With J and J48630 installed and the gear train completely assembled, use timing tool (W ) installed into the holes in the rear of the camshaft frame. Verify camshaft gear timing marks are aligned with marks on the timing tool. 19. Remove timing tools from gears and camshaft frame.

10 CHECKING AND ADJUSTING GEAR LASH WITH CYLINDER HEAD AND CAMSHAFT FRAME REMOVED This is performed with camshaft housing removed. Check and adjust as follows: 1. Remove the camshaft housing if not already removed. Refer to section "Removal of Camshaft Housing." 2. Install a magnetic base-dial indicator gauge on engine block. 3. Set the dial indicator on the number 5 gear tooth. 4. Turn idler gear number 5 counterclockwise (viewed from front of engine) until 0 lash is present, then zero the gauge on the dial indicator. 5. Check the gear lash by turning the idler gear number 5 stop to stop, verify that the lash reading on the dial indicator is mm ( in.). 6. If gear lash is incorrect, continue with the following steps to adjust. 7. Remove access cover to the number 3 idler bolts. 8. Loosen the two number 3 idler gear bolts and then snug by hand. 9. Turning idler gear number 5 by hand will change gear lash from zero lash to maximum lash.

11 NOTE: Rotating idler gear number 5 counterclockwise (viewed from front of engine) will result in 0 lash. Rotating idler gear number 5 clockwise (viewed from front of engine) will result in maximum lash. 10. Install a magnetic base-dial indicator gauge on engine block. 11. Set the dial indicator on the number 5 gear tooth.

12 12. Turn idler gear number 5 counterclockwise (viewed from front of engine) until 0 lash is present, then zero the gauge on the dial indicator. 13. Push idler gear number 5 clockwise (viewed from front of engine) till desired gear lash is present. 14. Tighten the two bolts on the number 3 gear. 15. Check gear lash by turning idler gear number 5 stop to stop; verify the lash reading on the dial indicator should be mm ( in.). 16. If gear lash is OK, then final torque idler number 3 bolts to N m (44-48 lb ft). 17. Install access cover and tighten. 18. Install the camshaft housing as needed. Refer to section "Installation of Camshaft Housing."

13 CAMSHAFT TIMING VERIFICATION Time the camshaft as follows: 1. Remove the rocker cover. Refer to section 1.9 "Removal of Rocker Cover.". 2. Bar the engine to top dead center (TDC) with J (3), #1 with the #6 valve in overlap and the dot (2) that is located inside the flywheel tone ring is aligned with the edge of the pointer (1). 3. Locate the mark on the camshaft and mark the top of the correspondinggeartoothwith a light colored paint pen. 4. Remove the Crankshaft Position Sensor from the flywheel housing.

14 5. Install the TDC locating pin (W ) through the crankshaft position sensor hole in the flywheel housing and engage into the flywheel notch. 6. Install the rear timing tool (1) (W ) onto the camshaft housing.

15 7. Install the front timing tool (1) (W ) into the grooves cut into the cams and pinitintothecamshafthousingwithabolt. 8. Verify that the marks on the gear teeth match the marks on the timing tool. [a] If the marks do not match, research the root cause of incorrect camshaft timing. Refer to section 1.16.

16 TIMING THE CAMSHAFTS WITH THE GEAR TRAIN INSTALLED Time as follows: 1. Bar the crankshaft over to TDC cylinder No. 1 and lock with W through the crankshaft position sensor hole. 2. Install timing tool No. 1 onto the rear of the cam frame. 3. Locate the mark on the camshafts and mark the top of the corresponding gear tooth with a light colored paint pen. 4. Lubricate the camshafts and camshaft housing journals with clean engine oil. NOTE: The intake camshaft has the tone wheel and must be installed on the intake side of the engine. 5. Install the camshafts into the camshaft housing in their respective locations lining up the marked cam gear teeth with the mark on the timing plate. 6. Install the front timing tool (1) (W ) into the grooves cut into the camshafts to verify correct cam timing. Any resistance felt while installing or removing could indicate the camshafts being out of time. Install a bolt into the tool to hold it into place. 7. To install the camshaft and rocker assemblies, refer to section 1.4 Camshaft and Rocker Shaft Assemblies.

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18 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.