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Tips For Troubleshooting Engine

The document provides troubleshooting guidance for diesel generators. It lists common problems like black smoke, white smoke, engine overheating, lack of power, and hard starting. For each problem, it suggests checking specific systems and identifies potential causes like faulty fuel injectors, air filters, thermostats, or electrical components. The document aims to help technicians systematically diagnose issues by considering different failure points in key engine systems.

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Sandeep Nikhil
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575 views22 pages

Tips For Troubleshooting Engine

The document provides troubleshooting guidance for diesel generators. It lists common problems like black smoke, white smoke, engine overheating, lack of power, and hard starting. For each problem, it suggests checking specific systems and identifies potential causes like faulty fuel injectors, air filters, thermostats, or electrical components. The document aims to help technicians systematically diagnose issues by considering different failure points in key engine systems.

Uploaded by

Sandeep Nikhil
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPT, PDF, TXT or read online on Scribd
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Trouble Shooting

How to trouble shoot effectively


• Listen to the complaints carefully.
• Check and confirm that the problem exists.
• Check the log book. (verify whether problem existed
earlier)
• Collect all the informations. Walk around the DG set
for clues.
• Solve the problem by detection and elimination
method.
• Check for simple things first.
• Make a through repair
Problems that occcur in the engine
Black smoke
White smoke.
Bluish smoke
Gray or Ash colour smoke
Loss of engine Power.
Hard starting or engine does not start.
Excessive fuel consumption.
Engine stops.
Excessive Lube oil consumption
Problems that occcur in the engine
0. Engine oil dilution
1. Lube oil contaminated with Coolant.
2. Low lube oil pressure.
3. Coolant temperature too high.
4.Lube oil temperature high.
5.Excessive engine Vibration.
6.Lube oil sludge formation more.
7.Engine misfires.
8.Mechanical knocks/ unusal sounds
Black Smoke
Inference: Excessive un-burnt fuel.
Probable Causes:
•Operation of engine at High altitude.
•High ambient temperature.
•Excessive engine idling
•Operation of engine without thermostat.
•Chocked air cleaner.
•Defective turbocharger.
•Incorrect fuel pump timing/ Defective fuel pump.
•Incorrect valve clearance.
•Excessive blow- bye.
•Defective fuel injection nozzle.
•Defective after cooler.
•High exhaust restriction.
White smoke
Inference : Water vapourises in the combustion
chamber, will lead to white smoke. After starting the
engine in the morning, white smoke can be observed
for some time till the engine warms up, If it
continues it can lead to serious problem.
Probable Causes :
1. After cooler leakage
2. Fuel injection nozzle adapter cracked.
3. Cylinder head cracked.
4. Cylinder head gasket burnt.
5. Liner pitted and pin holes
Bluish Smoke
ence : Engine oil burns in the combustion chamber.

able Causes:
ngine oil level above the full mark in the dip stick.
urbocharger return line is choked
urbocharger seal is leaking
alve and Valve guide clearance is excessive
ow- bye is more (piston rings and liner are worn out)
r cleaner choked.
Gray or Ash colour smoke
Inference: It is a mixture of bluish and White smoke,
both oil and water are burning in the combustion
chamber.

Probable Causes:

( Note : the causes for bluish smoke and cause for


white smoke should be checked).
Loss of Power
ch : Check the fuel system and the air induction system.
e causes:
quality of fuel
ages in the fuel system
larator to throttle linkages loose.
pump line elbow wrong.
supply pipe line choked.
filters / air filters choked.
rrect injection timing
sfer pump defective
rrect valve clearance.
ctive fuel injection nozzles.
ctive fuel injection pump.
Hard starting/ Engine does not start
h : Checking starting system, air system and the fuel system.
e causes:
ry not charged fully.
battery connections
it breaker in the starting circuit defective.
er motor – defective, solenoid functioning
ck or Air filter choked.
ilter choked.
sfer pump defective.
pump defective
njection nozzles choked.
ng pin is not removed after checking valve lash.
raulic lock.
e drop
train damage
Excessive Fuel consumption
roach : Check the fuel system, air system

able causes:
xcessive Idling
ngine overloaded
eakages in the fuel system
njector dribbling
ncorrect fuel pump timing
estricted air intake
urbocharger rotating at lower speeds
alves and valve seats wear
ncreased engine blow – bye.
Engine stalls or stops
ach: Check the fuel system, Electrical system .

ble causes:
l tank exhausted
ply hose leaks
ply hose collapsed
eign bodies in the fuel tank.
ergency shutoff –operation
ectors choked
ctrical junction box defective
rgised to run solenoid – supply defective
mage to the drive train.
Excessive Lub oil consumption
proach: Check the lube oil system and air system.

bable causes:
Wrong engine oil
Leakages in the lubricating system
Excessive engine Idling
Level in the lub oil sump more than the full mark.
mproper method of checking lub oil level.
Engine oil dilution.
Excessive blow bye (lube oil burns in the combustion chamber
Oil not changed at recommended intervals
Air cleaner choked
Turbocharger seal worn out.
Engine Oil dilution
ach : Check the Lub oil system and Fuel system.

ble causes:
cessive Engine idling
or load factor on the engine.
el injector dribbling.
el pump - leakages
Coolant in Lube oil
pproach –Cooling system and the Lube oil system (interfaces)
obable causes:
After cooler puncture.
Oil cooler defective
Plugged waterpump weep hole.
Cylinder head gasket burnt.
Failed or Defective spacer plate.
Failed or defective cylinder head
Fuel injection nozzle adapter cracked/ damaged.
Water deflectors in spacer plate defective.
Cracked liner.
Liner seal “O” rings mutilated or damaged.
Cracked or porous casting.
Low Lub oil pressure
pproach : Lub oil system, oil and the cooling system.
obable causes:
Defective pressure guage
Wrong brand and grade of oil
Engine oil dirty and not changed at regular schedule mainten
Ambient temperature inside the room too high.
Operation of engine at higher than specified altitudes.
Poor ventilation
Over heating due to cooling system problem.
High engine oil temperature, Incorrect oil level, Wrong dip st
Engine oil dilution, Engine oil contaminated with water.
Leakages in lube oil system.
Lube oil filter choked.
Engine over loaded, Defective pressure relief valve
Low Lub oil pressure
3. Lube oil cooler bypass is always open.
4.Defective lub oil cooler.
5.Strainer choked.
6.Defective lube oil pump
7.Plugs omitted in crankshaft or loose.
8.Main bearings or bushings worn out.
gine overheating or coolant temperature h
Approach: Cooling system, Airsystem, Coolant.
Probable causes:
1. Defective temperature guage.
2. Excessive addition
3. Radiator choked externally or internally.
4. Ventillation to the room is poor/ High ambient
temperature.
5. Air cleaner choked./ Exhaust restriction high
6. Low coolant level
7. Absence of cowl/ shroud for fan. Wrong or dented blades
or fans.
8. Fan belts are not tight, one of them damaged.
9. Engine overloaded.
10.Defective thermostat (thermostat is stuck in closed
position)
Excessive Vibration
roach : Mounting, rotating components, timing and firing.
bable causes:
Engine is not grouted properly or fixed properly.
Loose or defective vibration damper.
Loose or unbalance flywheel.
Cooling fan unbalance.
Choked and not firing injectors
Alignment not proper.
Hunting by the governor.
Lubricating oil sludge formation is more
oach : Lubricating oil, luboil system, air system,
able causes:
mproper brand / grade of engine oil
ngine oil level above the full mark.
ngine oil diluted with coolant(glycol)
ngine oil diluted with fuel oil
xcessive blow- bye.
xcessive engine idling.
ow load factor.
or quality of fuel
estricted exhaust system.
efective fuel injection nozzles
alves wear
Engine misfires
roach: Fuel system injectors, quality of diesel, Valve setting.
able causes:
uality of Diesel
ented or leaking high pressure lines
roken valve bridges
hoked fuel injector
ailed or choked plunger and barrel.
eaking or sticking valves.
Mechanical knocks/ unusual sound
Approach : Check all the mechanical components for
loose connection and metal rubbing
Probable causes:
1. Bad quality of fuel.
2. Turbine wheels rubbing against the housing
3. Too much of valve clearance
4. Valve slapping noise
5. Defective fuel injection nozzles
6. Defective fuel pump.
7. Crankshaft end clearance increased.
8. Connecting rod big end bearing knock.
9. Connecting rod small end bearing knock.
10. Piston slap sound
11. Gear train whine noise.

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