Detroit Diesel Troubleshooting Diagrams

Series 60 Cylinder Pressure Losses

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A loss of cylinder pressure can cause increased oil consumption. The detection and elimination of cylinder pressure losses is vital to engine life and efficient operation. To assist the mechanic in effectively measuring the loss of cylinder pressure, and locating the source of abnormal leaks in individual cylinders, the following test procedure has been developed.

1. Move the vehicle requiring test to the chassis dynamometer; refer to OEM guidelines.
2. Disconnect air compressor.
3. Start the engine.
4. Run the engine and bring the engine coolant temperature to normal operating range.
5. Run vehicle to full load and rated speed.
6. Attach a manometer calibrated to read in inches of water, to the oil dipstick opening. Measure and record the crankcase pressure.
7. Shut down engine.
8. Remove the vehicle from the chassis dynamometer.
9. Review the crankcase pressure test results.
If the crankcase pressure exceeds 0.75 kPa (3 in. H 2 O), repair worn or damaged valve(s) or cylinder kit; r
If the crankcase pressure was less than or equal to 0.75 kPa (3 in. H 2 O), perform cylinder compression test.
10. Compare the cylinder compression test results to specifications.
If the cylinder compression is below specifications, repair worn or damaged valve(s) or cylinder kit;
If the cylinder compression is within specification, call Detroit Diesel Technical Service Group

Written by sam

June 12th, 2019 at 4:06 am

Series 60 Defective Turbocharger

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To determine if a defective turbocharger is causing excessive oil consumption, perform the following: ‪

1. Remove the turbocharger drain line connected to the crankcase and place the drain line into a suitable container.
2. Perform a crankcase pressure test.

If the engine crankcase pressure is less than 0.75 kPa (3 in. H 2 O), replace the turbocharger;
If the engine crankcase pressure is 0.75 kPa (3 in. H 2 O) or more, check for worn or damaged valve and cylinder kit;

 

Written by sam

June 9th, 2019 at 4:03 am

Series 60 Damaged Breather

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To determine if an obstructed or damaged breather is causing excessive crankcase pressure, perform the following: ‪

Perform a crankcase pressure test.

If the engine crankcase pressure is less than 3 in. H 2 O (0.75 kPa), check the air compressor.
If the engine crankcase pressure is greater than 3 in. H 2 O (0.75 kPa), replace wire mesh element.

Rocker Cover Breather Resolution

Perform the following steps to replace wire mesh element replacement: ‪

1. Remove the valve rocker cover(s);
2. Remove the wire mesh form the rocker cover;
3. Install a new wire mesh element to the rocker cover;
4. Install the rocker cover to the engine;
5. Verify replacement of wire mesh element;

 

Written by sam

June 7th, 2019 at 4:10 am

Series 60 Leaking Oil Cooler

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To determine if a leaking oil cooler core is causing excessive oil consumption, perform the following: ‪

1. Check for oil in the engine coolant or radiator.
If oil is present in either the engine coolant or radiator;
If no oil is present in either the engine coolant or radiator, check for a defective air compressor;
2. Remove the oil cooler core and housing;
3. Clean both the oil side and water side of oil cooler core;
4. Perform an oil cooler core pressure test;
5. Visually check to see if air bubbles are rising to the surface of the water within the container.
If air bubbles are present
If no air bubbles are present, complete a lube oil consumption report, call the Detroit Diesel Technical Service Group for a form.

Written by sam

June 6th, 2019 at 3:30 am

Series 60 Defective Air Compressor

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

1. Perform a crankcase pressure test and record the test results.
2. Disconnect the air outlet line from the air compressor;

Series 60 Defective Air Compressor 300x175 Series 60 Defective Air Compressor

3. Repeat step and record the test results.
4. Compare the results of test one with test two.

If the engine crankcase pressure remained the same, check the turbocharger;
If the engine crankcase pressure decreased, repair the air compressor;

Written by sam

June 3rd, 2019 at 4:13 am

Series 60 External Oil Leaks

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To determine if oil leaks are causing excessive oil consumption, perform the following:

1. Start and run the engine to operating temperature 88 ° C (190 ° F).
2. Check for leaks at oil lines, connections, mating joints, seals, and gaskets

If no oil leaks are found, shut down the engine and check for a leaking oil cooler core;
If oil leaks are found, shut down the engine;

Engine Oil Leak Repair

Perform the following steps, as necessary, to resolve engine oil leaks: ‪

1. Repair or replace components leaking oil;
2. Verify repairs made to correct oil leaks;

Written by sam

June 2nd, 2019 at 3:26 am

Series 60 Defective Air Compressor

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To determine if a defective air compressor is causing excessive oil consumption, perform the following: ‪

1. Perform a crankcase pressure test and record the test results.
2. Disconnect the air outlet line from the air compressor;

Series 60 Defective Air Compressor 300x175 Series 60 Defective Air Compressor

3. Repeat step and record the test results.
4. Compare the results of test one with test two.

If the engine crankcase pressure remained the same, check the turbocharger;
If the engine crankcase pressure decreased, replace the air compressor

Written by sam

May 12th, 2019 at 3:35 am

Series 40E Supply Manifold

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Drain the supply manifold oil rail before removing the fuel injectors to prevent leakage into the cylinder bore. ‪

NOTICE:

 

The supply manifold oil rail must be drained prior to removing the fuel injectors to prevent leakage into the cylinder bore. ‪

Drain Supply Manifold

Drain the supply manifold as follows: ‪

  1. Remove the supply manifold end plug from the supply manifold.
  2. Install a new O-ring and backup ring onto the end plug and install into the supply manifold. Torque plug.

Removal of Supply Manifold

Disconnect the supply manifold as follows: ‪

  1. Loosen the nuts and disconnect the high pressure oil supply hose from the Injection Control Pressure (ICP) Sensor elbow and the high pressure pump.
  2. Disconnect the fuel supply line from the fuel filter header to the supply manifold.
  3. If it is necessary to remove the supply manifold, disconnect the fuel return line and remove the 12 mounting bolts securing the supply manifold to the cylinder head.
  4. Remove the supply manifold and gasket. Discard the gasket.

Sensor Removal

Disconnect the sensor as follows: ‪

  1. Remove ICP sensor and O-ring from the front elbow of the supply manifold.
  2. Discard O-ring and replace.

Written by sam

November 28th, 2015 at 10:38 pm

Posted in Engine

Series 40E Valve Cover Intake Manifold

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Use the following procedure to remove the valve cover/intake manifold. ‪

  1. Disconnect the main wiring harness connector from the valve cover/intake manifold.
  2. Remove 13 valve cover/intake manifold capscrews.
  3. Lift the valve cover/intake manifold; bend back the tabs located in the wiring channel harness.
  4. Disconnect the six fuel injector solenoids from the wiring harness by spreading the tabs and pushing down. Or, release the retaining tabs of the wiring harness connector and push the connector body toward the inside of the valve cover/intake manifold. Remove the valve cover/intake manifold, leaving the wiring harness connected to the fuel injectors.

valve cover Series 40E Valve Cover Intake Manifold

5.       Remove valve cover/intake manifold and gasket from cylinder head. See Figure 31073 and see Figure 31074 .

valve cover removal 1024x597 Series 40E Valve Cover Intake Manifold

Written by sam

November 28th, 2015 at 10:35 pm

Posted in Engine

Road Draft Tube

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Use the following procedure to remove the road draft tube. ‪

  1. Remove two bolts securing the road draft tube to the crankcase.
  2. Pull road draft tube out from the valve cover/intake manifold and away from the crankcase.

Written by sam

November 28th, 2015 at 10:30 pm

Posted in Engine