NUMBER: 6 2–09Rev S.M.RE F.: Listed in Table ENGINE: DD15 DATE: November 2009 SUBJECT: CYLINDER HEAD LEAK TEST ADDITIONS, REVISIONS, OR UPDATES Publication Number Platform Section Title Change Page Number(s) DDC-SVC-MAN-0002 DD15 1.2.5 Cylinder Head Leak Test has been added. 1–27 NOTE: Page numbers are based on the most recent version of the individual publication and may be adjusted throughout the annual print cycle. CYLINDER HEAD LEAK TEST Utilize the following procedure to test for a leaking cylinder head using special tool W470589002500. NOTE: This tool is not required, but is useful for detecting a possible leaking cylinder head. 1. Cup Plug Caps 5. Manifold Opening Cover 2. Nut 6. Manifold Opening Cover 3. Reinforcement Plate (Optional) 7. Air Connector Quick Coupling 4. Cylinder Head Sealing Plate 8. Bolt 9. Cylinder Head Bolt Figure 1 DD15 Cylinder Head Leak Tool W470589002500 1. Thoroughly clean the cylinder head. 2. Inspect the sealing surfaces of the cylinder head and the tool. If damage is found, repair as necessary. 3. Using the supplied hardware and the original cylinder head bolts, install the leak test tool W470589002500 onto the head gasket surface of the cylinder head with the rubber side toward the head. Torque to 13 N·m (10 lb·ft) until the rubber starts to bulge out from in between the tool and the head. 4. Install the water manifold opening covers with the supplied hardware in the same fashion. Tighten the bolts to 13 N·m (10 lb·ft). The rubber should be starting to bulge from between the cylinder head and the tool. 5. Install the cup plug caps onto the cup plugs using the supplied hardware with the cutout side facing the cup plug. Torque to 15 N·m (11 lb·ft). 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. 6. Attach the air pressure gauge and regulator J-45982-7 or equivalent. 7. Turn regulator counterclockwise until it stops. 8. Connect shop air to the regulator and turn it clockwise until the gauge reads 30 psi. 9. Allow the air pressure to stabilize for one minute. 10. Close the ball valve on the regulator and disconnect the shop air hose. 11. Wait 30 minutes. 12. The air pressure should not drop over 30 minutes. If the pressure drops, use a soap and water solution to determine where the possible leak is coming from. Once the leak has been identified, repair as necessary. 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.
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