FAILURE

ANALYSIS
Some Basics
350 C 300C

220C

180C

150C

140C
 Influence Of Operating
Conditions
TEMPERATURE VARIATION
CONDITION VARIATION AT THE 1st RING GROOVE

Speed n (Pe = constant) 100 rpm 2…4 C

Load 1 bar Approx. 10 C
(Bowl rim aprox. 20 C)
Start of injection 1 crank angle + 1…2 C
(Bowl rim less than 4.5 C)
Compression by one unit 4...12 C
Coolant temperature (water) 10 C 8…10 C
Lubrication oil temperature 10 C 1…3 C
(oil sump)
 Important facts
• Piston alloy casting temp. -- 750 c
• Fuel burning temp. -- > 2000 c
• Piston softening temp. -- 530 c
• Engine oil turns into carbon -- 220 C
 Important fact

Piston takes only 20 seconds to

fully expand
Whereas cylinder liner takes
20 minutes .
RING ACTION

SUCTION

COMPRESSION

POWER
EXHAUST
INLET VALVE EXHAUST VALVE
 KEY FACTORS
• AIR • CLEAN
• ADEQUATE

• WATER •
•
CLEAN
ADEQUATE
•
• GOOD QUALITY
• FUEL • RIGHT QUANTITY

• • FULLY ATOMISED

• GOOD QUALITY
• CORRECT QUANTITY
• CORRECT PRESSURE

• OIL
LOW PISTON-LINER CLEARANCE
PISTON SEIZURE AT 45
 ENGINE

OVERHEATING
LACK OF OIL
BIG END BRG.
FAILURE
DIAGONAL WEAR PATTERN
TAPPET COVER OF TATA 407
PISTON RING WEAR
THANK YOU
 CRANK CASE DILUTION
POSSIBILITIES

1.Engine overcooled
FROM FUEL INJECTION FROM PISTON ASSEMBLY
PUMP SIDE 2.Poor compression SIDE
pressure

INJECTOR DRIBBLING
OIL SEAL LEAKAGE DIESEL LEAKAGE
(ON TIMING GEAR SIDE) DUE TO WORNOUT
PLUNGERS OF FIP
SYMPTOMS DETERIORATION IN ENGINE
PERFORMANCE wrt. SMOKE, FUEL
LEVEL OF OIL IN STARTING CONSUMPTION & POWER
FIP SUMP WILL REDUCE PROBLEM CHECK POINTS
• CHECK OIL LEVEL IN • CHECK FIP FD SETTING • CHECK INJECTORS FOR DRIBBLING
FIP SUMP • CHECK FIP PLUNGERS FOR SPRAY PATTERN, CHATTERING &
• CHECK CRANKCASE WEAR (POLISHING/WEAR NOZZLE SEAT LEAKAGE ON
SUMP OIL QUALITY ( IT MARKS JUST ABOVE PLUNGER INJECTOR TESTER
WILL NOT SHOW DIESEL HELIX) • CHECK SUMP OIL QUALITY (IT
CONTENT • CHECK SUMP OIL QUALITY (IT WILL SHOW DIESEL CONTENT)
• CHECK OIL SEAL WILL SHOW DIESEL CONTENT) • CHECK ENGINE PERFORMANCE
 INDUCTION
MANIFOLD

INDIRECT DIRECT MULTI-

SINGLE POINT INJECTION
POINT (DMP)
INJECTION
(ISPI)

THROTTLE
VALVE

INDIRECT
MULTI-POINT
INJECTION
(IMPI)

SHRIRAM PISTONS & RINGS LTD.

ROVER KV 6 ENGINE

SHRIRAM PISTONS & RINGS LTD.

SHRIRAM PISTONS & RINGS LTD.
SAAB’S RADICAL ENGINES

SHRIRAM PISTONS & RINGS LTD.

FOUR VALVES PER CYLINDER – DOHC

SHRIRAM PISTONS & RINGS LTD.

 A presentation
by
Shriram Pistons & Rings
Ltd
(an ISO 9001 company)
ELETROMAGNETIC VALVE
ACTUATION SYSTEM

SHRIRAM PISTONS & RINGS LTD.