Series 60 DDEC VI Troubleshooting – Section 7.3 Defective Turbocharger

Section 7.3
Defective Turbocharger

To determine if a defective turbocharger is causing excessive crankcase pressure, perform the following: ‪

1. Remove the turbocharger drain line connected to the crankcase and place the drain line into a suitable container; refer to appropriate service manual, air intake system chapter.
2. Perform a crankcase pressure test. Refer to appropriate service manual, preventive maintenance chapter. For crankcase pressure guidelines refer to Service Information Letter 02 TS-20 found on the DDC extranet.
   1. If the engine crankcase pressure is less than 1.25 kPa (5 in. H₂ O), replace the turbocharger; refer to "7.3.1 Turbocharger Replacement" . Shut down the engine.
   2. If the engine crankcase pressure indicates no change, check for a worn or damaged valve or cylinder kit; refer to "7.4 Worn or Damaged Valve or Cylinder Kit" . Shut down the engine.

Section 7.3.1
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 "7.3.1.1 Test Engine with New Turbocharger" .

Section 7.3.1.1
Test Engine with New Turbocharger

To determine if a new turbocharger resolved the excessive crankcase pressure, perform a crankcase pressure test. Refer to appropriate service manual, preventive maintenance chapter. For crankcase pressure guidelines refer to Service Information Letter 02 TS-20 found on the DDC extranet.‪

1. If the engine crankcase pressure is 1.25 kPa (5 in. H₂ O) or less, no further troubleshooting is required.
2. If the engine crankcase pressure is greater than 1.25 kPa (5 in. H₂ O), check for a worn or damaged valve or cylinder kit; refer to "7.4 Worn or Damaged Valve or Cylinder Kit" .