Series 60 DDEC V Troubleshooting – Section 9.1 Defective Turbocharger

Section 9.1
Defective Turbocharger

To determine if a defective turbocharger is causing excessive exhaust smoke, perform the following:‪

1. Remove the charge air cooler inlet duct connected between the turbocharger and charge air cooler; see Figure "Charge Air Cooler and Related Parts" .
   

   1. Flexible Coupling‪	4. Charge Air Cooler‪
   2. Charge Air Cooler Outlet Duct‪	5. Turbocharger‪
   3. Charge Air Cooler Inlet Duct‪	6. Coupling Hose Clamp‪

   Figure 1. Charge Air Cooler and Related Parts

2. Visually inspect the charge air cooler outlet duct.
   1. If excessive engine lube oil is present, refer to "9.1.1 Turbocharger Replacement" .
   2. If no engine lube oil is present, check for worn or damaged valve or cylinder kit, refer to "9.2 Worn or Damaged Valve or Cylinder Kit" .

Section 9.1.1
Turbocharger Replacement

Perform the following steps to replace a defective turbocharger:‪

1. Remove defective turbocharger from the engine; refer to appropriate service manual, air intake system chapter.
2. Tag removed turbocharger for remanufacture.
3. Install a replacement turbocharger to the engine; refer to appropriate service manual, air intake system chapter.
4. Verify replacement of new turbocharger; refer to "9.1.1.1 Test Engine with Replaced Turbocharger" .

Section 9.1.1.1
Test Engine with Replaced Turbocharger

Perform the following steps to determine if a replaced turbocharger resolved the excessive exhaust smoke condition:‪

1. Start and run the engine.
2. Run the engine at idle with a no-load for approximately 5 minutes, allowing the engine coolant to reach normal operating range, 88-96°C (190-210°F).
3. Visually inspect exhaust for excessive smoke.
   1. If the engine exhaust smoke emission appears normal, no further troubleshooting is required. Shut down the engine.
   2. If the engine exhaust smoke is excessively black or gray, shut down the engine. Check for worn or damaged valve or cylinder kit; refer to "9.2 Worn or Damaged Valve or Cylinder Kit" .