Trouble Shooting SW

Engine Related Troubleshooting
Problem - Hard starting / Failure to start

Reasons ( Air System )
• Restricted air intake
- Inlet cap restriction
- Air cleaner choked
- Non genuine air cleaner element
1
LOS S OF POWER WITH BLACK S MOKE
* AIR INTAKE RES TRICTED

* DEFECTIVE TURBO.
* AMBIENT TEMP. HIGH
* AFTERCOOLER CHOCKED
* COMPRES S ION LEAKAGE
* INCORRECT VALVE CLEARANCE
* HIGH EXHAUS T BACK PRES S URE
* INJECTOR S PRAY HOLES ENLARGED
* ENGINE OVERLOADED
* AIR LEAKAGE BETWEEN TURBO.
AND INTAKE MANIFOLD
* ENGINE OPERATING AT HIGH ALTITUDE
2
LOW LUBRICATING OIL PRES S URE
* DEFECTIVE PRES S URE GAUGE

* WRONG GRADE OF LUB. OIL
* OIL TEMP. HIGH
* LUBRICATING OIL DILUTED WITH FUEL
* IMPROPER OIL LEVEL
* PLUGGED OIL FILTER
* DEFECTIVE PUMP / PRES S URE REGULATOR
* PIS TON COOLING NOZZLES ORIFICE TOO LARGE
* EXTERNAL OIL LKG. OR AIR IN S YS TEM
* EXCES S IVE BEARING CLEARENCE
3
HIGH LUBRICATING OIL CONS UMPTION
* EXTERNAL / INTERNAL OIL LKG.

* WRONG GRADE OF OIL
* OIL TEMP. HIGH
* LUBRICATING OIL DILUTED WITH FUEL
* TURBO. S EAL DEFECTIVE
* EXTENDED OIL CHANGE PERIOD
* EXCES S OIL PRES S URE
* HIGH CRANK CAS E PRES S URE
* GLAZED CYLINDER LINERS
* EXCES S IVE VALVE / VALVE GUIDE CLEARANCE
* PIS TON RING WORN OUT
* WORN OUT AIR COMP. CYLINDER / RINGS
4
LUBRICATING OIL TEMP. HIGH
* DEFECTIVE TEMP. GAUGE

* ENGINE OVERHEATING
* WRONG GRADE OF OIL
* PLUGGED OIL COOLER
* COOLANT IN OIL
* ENGINE OVERLOADED
* OIL COOLER "O" MARK MIS ALINGED
* ENGINE EXTERIOR CAKED WITH DIRT
* EXTENDED OIL CHANGE PERIOD
5
LUBRICATING OIL DILUTED WITH DIES EL
* EXCES S IVE ENGINE IDLING

* COLD OPERATION
* INADEQUATE INTAKE AIR
* LKG. AT COPPER WAS HERS (FUEL CONNECTION)
* FUEL CONNECTION CRACKED
* INJECTOR "O" RINGS DAMAGED ( CYLINDRICAL TYPE)
* EXCES S IVE CLEARENCE BETWEEN
BARREL AND PLUNGER
* INJECTOR CUPS CRACKED
* FUEL PUMP S EAL DAMAGED (PTR)
* POROUS CYLINDER HEADS
6
COOLANT MIXING WITH LUBE OIL
* LEAKY OIL COOLER
* POROUS CYLINDER HEADS
* LEAKY INJECTOR S LEEVE
* LEAKY LINER CREVICE S EAL
* PIN HOLE IN CYLINDER LINER
* MUTILATED OIL COOLER "O" RINGS
* LEAKY OIL COOLER S UPPORT GAS KET
* BROKEN OR LOOS E CYL. HEAD CAPS CREW
* CRACKED OR POROUS CYLINDER BLOCK
7
Reasons ( Starting System )
• Improper use of starting aids
- Discharged Battery
- Long cables
- Wrong size of cables
- Loose contacts in circuit - high resistance
8
Reason ( Fuel System )
• Out of fuel
• Fuel shut off closed
• Poor quality fuel
• Air leaks in suction line
• Restricted fuel lines
• Stuck drain valve
. . . contd
9
Reason ( Fuel System )
• Injector spray holes choked
• Fuel pump drive shaft broken
• Scored / worn gears of gear pump
• Loose injector inlet or drain connection
• Cracked injector body or cup
• Water in fuel
• Aneroid check valve stuck open
10
Reason ( Operation & Maintenance practices )
• Extended idle periods
11
Reason (Mechanical Adjustments or Repair )
• Valve leakage
• Broken or worn piston rings
• Engine due for overhaul
• Incorrect valve & Injection adjustment
12
Problem - Engine misses
Reason (Fuel system )
• Air leaks in suction lines
• Plugged injector spray holes
• Water in fuel
13
Reason (Operation & Maintenance practices )
14
Reason (Mechanical adjustments or repair )
• Valve leakage
• Injectors need adjustment
15
Problem - Excessive smoking at idling
• Wrong injector cups
16
Reason (Lubricating system )
• Faulty cylinder oil control
17
Reason (Operation & maintenance practices )
18
Reason (Mechanical adjustments or repair )
• Incorrect valve and injection timing
• Worn or scored liner or pistons
19
Problem - Excessive smoke under load
Reason (Air system )
• High exhaust back pressure
• High ambient temperature or high altitude
• Dirty turbocharger compressor
20
Reason (Fuel system)
• Aneroid set improperly
21
Reason (Lubricating system)
22
Reason (Operation and Maintenance practices)
• Engine overloaded
23
Reason (Mechanical adjustments or repair)
• Gasket blow by or leakage
• Worn or scored liners or pistons
24
Problem - Low power or loss of power
Reason (Air system)
• Thin air in hot weather or high altitude
25
• External or internal fuel leaks
• Scored gear pump or worn gears
.. Contd..
26
• Throttle linkage or adjustment
• High speed governor set too low
• Aneroid set improperly
• Fuel pump out of adjustment
• Injector flow incorrect
27
• Oil level too high
28
Reason (Cooling system)
• Insufficient coolant
• Worn water pump
• Faulty thermostat
• Insufficient coolant capacity
29
Reason (Operation and maintenance practices)
• Dirty filters and screens
30
• Valve leakage
• Incorrect bearing clearences
.. Contd..
31
32
Problem - Cannot reach governed RPM
• High speed governor set too low
• Water in fuel
33
Problem - Low air output
Reason (Air system)
• Thin air in hot weather or high altitude
• Air leaks between cleaner and engine
34
Problem - Excessive fuel consumption
Reason (Air system)
35
..contd..
36
• Mutilated injector cup O ring
37
38
39
• Misalignment of engine with driven unit
40
Problem - Poor deceleration
• Incorrectly assembled idle springs
41
Problem - Erratic idle speeds
•Throttle linkage or adjustment
• Governor weights assembled incorrectly
42
Problem - Engine dies
• Out of fuel or fuel shut off closed
• Broken fuel pump drive shaft
..contd..
43
Problem - Engine dies
• Governor weights assembled incorrectly
• Water in fuel
44
Problem - Surging at governed RPM
45
Problem - Excessive lube oil consumption
Reason (Air system)
46
• External and internal oil leaks
• Wrong grade oil for weather conditions
47

48
Problem - Crankcase sludge
• Dirty oil filter
49
• Faulty thermostats
• Radiator shutters stuck open
• Coolant temperature low
50
Reason (Operation and maintenance practices )

• Oil needs changing
51
Problem - Dilution
• Loose injector inlet or drain connection
• Mutilated injector cup O ring
52
Problem - Dilution
Reason (Lubricating system )
• External and internal oil leaks
53
Problem - Dilution
Reason (Cooling system )
• Internal water leaks
54
Problem - Dilution
55
Problem - Dilution
56
Problem - Low lubricating oil pressure
57
• Oil suction line restriction
• Faulty oil pressure regulator
• Crankcase low or out of oil
• Wrong grade oil for weather conditions
58
• Insufficient coolant
• Worn water pump
• Damaged water hose
• Loose fan belts
• Clogged water passages
.. Contd..
59
• Clogged oil cooler
• Radiator core openings dirty
• Air in cooling system
• Exterior water leaks
60
• Engine exterior caked with dirt
61
• Damaged main or rod bearings
62
Problem - Coolant temperature too low
• Radiators shutters stuck open
63
Problem - Coolant temperature too high
Reason (Air system)
64
65
•Insufficient coolant
• Worn water pump
• Loose fan belts
..contd..
66
•Radiator core openings dirty
67
68
Problem - Lube oil too hot
69
•Insufficient coolant
• Worn water pump
• Loose fan belts
..contd..
70
•Radiator core openings dirty
• Internal water leaks
71
72
Problem - Piston ,liner and ring wear
Reason (Air system)
73
• Clogged oil drillings
74
75
76
Problem - Wear of bearings and journals
Reason (Air system)
77
78
79
• Excessive crankshaft end clearence
• Main bearing bore out of alignment
80
Problem - Worn valves and guides
Reason (Air system)
81
82
83
• Valve leakage
84
Problem - Fuel knocks
Reason (Air system)
• Improper use of starter aid / air temp
85
86
87
88
89
Problem - Mechanical knocks
90
• Faulty vibration damper
• Unbalanced or loose flywheel
• Excessive crankshaft end clearence
..contd..
91
• Broken tooth in gear train
• Excessive gear back lash
• Loose mounting bolts
92
Problem - Gear train whine
• Excessive crankshaft end clearences
• Broken tooth in gear train
• Excessive gear back lash
93
Problem - Excessive engine vibration
• Faulty vibration damper
• Unbalanced or loose flywheel
• Loose mounting bolts
94

Trouble Shooting SW

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Trouble Shooting SW

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Engine Related Troubleshooting

Problem - Hard starting / Failure to start

* AIR INTAKE RES TRICTED

* DEFECTIVE PRES S URE GAUGE

* EXTERNAL / INTERNAL OIL LKG.

* DEFECTIVE TEMP. GAUGE

* EXCES S IVE ENGINE IDLING

• Broken or worn piston rings

• Dirty filters and screens

• Extended idle periods

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