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SERIES 60 WORN OR DAMAGED VALVE OR CYLINDER KIT

To determine if a worn or damaged cylinder kit is causing excessive crankcase pressure, perform the following: ‪

  1. Move the vehicle requiring testing to the chassis dynamometer; refer to OEM guidelines.
  2. Disconnect air compressor; refer to section .
  3. Start the engine.
  4. Run the engine and bring the engine coolant temperature to normal operating range.
  5. Run the vehicle to full load and rated speed.
  6. Attach a manometer calibrated to read in inches of water, to the oil dipstick opening.
  7. Measure and record crankcase pressure.
  8. Shut down the engine.
  9. Remove the vehicle form the chassis dynamometer.
  10. Review the crankcase pressure test.
    1. If the crankcase pressure was greater than 3 in. H2 O (0.75 kPa), refer to section .
    2. If the crankcase pressure was less than 3 in. H2 O (0.75 kPa), perform a cylinder compression test.
  11. Compare the cylinder compression test results to specifications.
    1. If cylinder pressure is below specifications, refer to section .
    2. If cylinder pressure is within specifications, call Detroit Diesel Technical Service Group.

Worn or Damaged Valve or Cylinder Kit Repair

Perform the following steps for worn or damaged valve or cylinder kit: ‪

  1. Remove the cylinder head; refer to section .
  2. Inspect the cylinder head for worn or damaged valves; refer to section .
  3. Inspect the cylinder kit components for worn or damaged liners; refer to section ; pistons or piston rings, refer to section .
  4. Verify repair to cylinder valve(s) or cylinder kit components; refer to section .
Test Engine with Repairs Made to Correct Worn or Damaged Valve or Cylinder Kit

Perform the following to determine if the repaired valve or cylinder kit resolved the excessive crankcase pressure: ‪

  1. Refer to section for exhaust catuion before preceeding. Start the engine.
  2. Run the engine and bring the engine coolant temperature to normal operating range, 88-96C (190-210F).
  3. Run the vehicle to full load and rated speed.
  4. 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, call the Detroit Diesel Technical Service Group. Shut down the engine.