Section 4.4 Defective Air Compressor

Section 4.4
Defective Air Compressor

Check as follows:‪

  1. Check for oil present in the airdryer or air tanks.
    1. If no oil is present, check for a worn or damaged cylinder kit. Refer to "4.5 Worn or Damaged Valve Guide/Seal or Cylinder Kit" .
    2. If oil is present, go to the next step.
  2. Perform a crankcase pressure test and record the test results using the following: Crankcase pressure — Full load, maximum KPa (in. H2 O) operating limits @ Rated speed = 1.25 KPa (5.0 in. H2 O column). For test procedures, refer to "4.4.1 Crankcase Pressure Test" .
  3. Disconnect the air outlet line (2) from the air compressor; refer to "10.1 Air Compressor" in the “Special Equipment” chapter of the EPA07 DD15 Workshop Manual (DDC-SVC-MAN-0002).
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  4. Repeat the first step and record the test results.
  5. Compare the results of test one with test two.
    1. If the engine crankcase pressure remained the same, check the turbocharger; refer to "4.3 Defective Turbocharger" .
    2. If the engine crankcase pressure decreased, replace the air compressor; .
  6. Remove the air compressor from the engine; refer to appropriate service manual, special equipment chapter.
  7. Replace the air compressor; refer to OEM guidelines.
  8. Install the air compressor to the engine; refer to "10.1 Air Compressor" in the “Special Equipment” chapter of the EPA07 DD15 Workshop Manual (DDC-SVC-MAN-0002).
  9. Start and run the engine.
  10. Perform a crankcase pressure test. Refer to the DD15 Service Manual (DDC-SVC-MAN-0002), preventive maintenance chapter.
    1. If the engine crankcase pressure exceeds 1.25 kPa (5 in. H2 O), refer to "4.3 Defective Turbocharger" . Shut down the engine.
    2. If the engine crankcase pressure is less than 1.25 kPa (5 in. H2 O), shut down the engine; no further troubleshooting is required.

Section 4.4.1
Crankcase Pressure Test

Check the engine crankcase pressure as follows:‪

caution

To avoid injury before starting and running the engine, ensure the vehicle is parked on a level surface, parking brake is set, and the wheels are blocked.‪

warning

ENGINE EXHAUST

To avoid injury from inhaling engine exhaust, always operate the engine in a well-ventilated area. Engine exhaust is toxic.‪

  1. Start the engine.
  2. Run the engine and bring the engine coolant temperature to normal operating range, 88-96°C(190-205°F).
  3. Install J-48540–1 from the J-48540 kit on to the oil fill opening. Attach the gauge from kit J-48540, calibrated to read pressure in inches of H2 O, on to the adaptor.
  4. Run the vehicle to full load and rated speed. Use either chassis dynamometer or a trailer have the truck at full load.
  5. Measure and record crankcase pressure.
  6. Shut down the engine.
  7. Remove the adaptor from the port.


EPA07 DD15 Troubleshooting Guide - DDC-SVC-MAN-0029
Generated on 10-13-2008

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