When people talk about durability, they talk about the DD15

The industry standard measurement for engine durability is the B50 rating.

The DD15 has a B50 rating of 1.7 million km’s.

This means that 50% of engines will get to 1.7 million km’s before a major repair (Head and
or sump off). That’s the highest of any heavy duty engine on the market.

(03) 376 4305
DD15 engine preview
0
kilometres before a major repair
0
Engines made since 2007

Top Secret

The failure rate for the Series 60 EGR was quite consistent throughout the life of the engine. Now look at the DD15. When the engine was released there were some failures, but these were quickly addressed with a corrective action plan, not just replacing the part. And as the product matured, the failures dropped dramatically. Look at the lack of dots in the last few years. This suggests nearly all the issues have been fixed. This is very impressive, and a key reason why Heavy Trucks is excited about the DD15.

The best free warranty in the market

Detroit put their money where their mouth is too with the best free warranty in the market, 1 million km/5 year/15,000 hours including turbos, and with no midlife. How can Detroit afford to cover such a warranty? Simple: they have designed the engine from the ground up to be durable, so they don’t see many failures.

DD15 Blocks and liners

Blocks and Liners

Normally in a heavy diesel engine the cylinder liner hangs in the block from the top on a flange/lip with nothing holding it from below. This can lead to cylinder liners dropping, sending you off the road: head off, counter bore and re-line, new gasket, head back on. This physically can’t happen in a DD15, the bottom is tapered and sits in the block, meaning it can’t fall. The cylinder liners on a DD15 are located and clamped at both the top and the bottom.

Competitor engines and the Series 60 are only clamped at the top, meaning it allows the cylinder liner to rock every time the piston moved up and down. In the DD15 the cylinder liner is clamped and located top and bottom, so forces hold it steady in its locators. And the locators and shape make it physically impossible for the liner to drop.

 

Since 2007 Detroit have made over 300,000 DD engines, and they have never had a liner drop. Ever. They haven’t even made a counter bore tool yet, since they have never needed one.

Block, Cylinder Bore And Liner Design

The foundation of an engine, the block and head have been designed with more coolant, more fuel and more oil gallery passages. Keeping internal temperatures down and longer life to internal components.

Cylinder Block Cooling

There are large cooling holes at the top of the cylinder block to cool the cylinder liners and block which is the most important point.

These are called Top Liner Cooling ports. Many major engine failures you see today are related to parts getting too hot. Cooling is very important. Keep it cool and you keep it from failing. Others only cool at the bottom, but it’s the top that gets hot and needs it the most!

Head Gasket

Head gaskets are under a lot of pressure, and are known to fail. Just looking at the DD15 gasket you can see the durability, and the additional sealing. This doesn’t look like a gasket that will give trouble. The gasket is two ply and is riveted at the sealing grommets to maintain torque load. The gasket does not include a compression ring at the centre of each cylinder, further enhancing durability.

You can also see the carbon scraper ring in this picture here, more on that later.

Carbon, Oil And Engine Life

Head gaskets are under a lot of pressure, and are known to fail. Just looking at the DD15 gasket you can see the durability, and the additional sealing. This doesn’t look like a gasket that will give trouble. The gasket is two ply and is riveted at the sealing grommets to maintain torque load. The gasket does not include a compression ring at the centre of each cylinder, further enhancing durability.

You can also see the carbon scraper ring in this picture here, more on that later.

Wiring Loom & Harness

Wiring looms and harnesses give a lot of problems on heavy duty engines. Looking at the wiring looms and harnesses on a DD15 and you can see that this is a quality loom and harness, built properly to avoid the wiring issues we have seen so often in New Zealand conditions.

Features of the harness include:

  • No longer split to ensure that no splash or debris can no longer penetrate the harness.
  • All of the sensors have lock engagements to ensure proper pin contact to the harness.
  • No more zip ties located at the harness avoiding pinching or chafing concerns and preventing false electronic codes.
  • Connectors have been added to the harness for proper alignment at parts.
  • Front of harness molded to sit properly within the frame to avoid interference at the rail to engine.

Cylinder Liners

The cylinder liners in a DD15 are machined to a biocratic finish (criss/cross pattern); this avoids oil settling in one spot creating a hot spot, which is a major cause of an expensive failure.

A very precise cut of cross-hatch marks within the cylinder bore of the liner allow the oil to be evenly distributed, ensuring longer life of the piston kit and less wear.

Conrods/Connecting Rods

The tops and bottoms of the connecting rods (conrods) are cast as one complete unit, laser etched and then cracked apart. The resulting random rough pattern makes them grip better together as an exact matched pair (unique to each pair).
They are barcoded to ensure the pairs are fitted together. This matching allows for a true torque position over the life of the engine allowing higher strength, precision location and longer life to the internal components of the engine. This means there is less opportunity for relaxation of torque at the mating surface of the connecting rod, making the engine more durable.

Detailed Barcoding – DMC “Data Matrix Codes”

Note the detailed barcodes, called Data Matrix Codes (DMC). All parts on the DD13/15 engine assembly have a Data matrix Code (DMC) which is scanned to a specific engine. This DMC now allows traceability from each engine to the supplier and the build of the product. The DMC holds casting information, machining measurements and torque measurements; on every single engine.

In a past real example, a supplier reported to Detroit to advise the furnace for their cast parts
did not reach the critical temperature on a batch of heads supplied. These parts were already assembled to engines. Detroit had no way of knowing which engine serial numbers were affected.

With DMC it can be identified which specific major part is assembled to which engine. This means Detroit can identify exactly which engines are affected, exactly which specific trucks those engines are in, and can issue a specific recall to get them fixed fast.