Diesel Engine Maintenance Training Manual

Chapter 1. Troubles: Their Symptoms and Their Causes

A. General Trouble Shooting Procedure

1A1. Recognizing and locating troubles

B. Engine

Fails to Start

1B1. Engine will not crank but can be barred over

1B2. Engine cannot be cranked and cannot be

1B3.

C. Unusual or Erratic Operation

1C1.

1C2.

Engine stops suddenly

1C3.

Engine overspeeds

1C4.

Engine will not carry load (loss of power).

1C5.

Engine will not shut off

1C6.

1C7.

1C8.

Cylinder safety valves pop frequently during engine operation

1C9.

Engine will not reach rated speed

1C10.

Engine hunts (speed varies at constant throttle setting)

D. Noises

1D1. Pounding

1D2. Knocking

1D3. Metallic clicking

1D4. Rattling

E. Instruments — Pressure

1E1. Low lube oil pressure

1E2. High lube oil pressure

1E3. Low fuel oil pressure (in low-pressure fuel supply system)

1E4. Low cooling water pressure (fresh)

1E5. Low cooling water pressure (salt)

1E6. High cooling water pressure (salt)

1E7. Low compression pressure

1E8. Low firing pressure 6

1E9. High firing pressure 6

1E10. Low scavenging air receiver pressure (super-charged engine) 6

1E11. High exhaust back pressure 6

R Instruments — Temperature

1F1. Low lube oil temperature 6

1F2. High lube oil temperature 6

1F3. Low cooling water temperature (fresh) 6

1F4. High cooling water temperature (fresh). 6

1F5. Low cylinder exhaust temperature 7

1F6. High exhaust temperature in one cylinder 7

G. Instruments — Correlation of Cylinder Exhaust Temperature and Cylinder Firing and Compression

Temperatures

1G1. Low firing pressure and low exhaust temperature 7

1G2. Low firing pressure and high exhaust temperature 7

1G3. High firing pressure and low exhaust temperature 7

1G4. High firing pressure and high exhaust temperature 7

1G5. Low compression pressure and low exhaust temperature 7

1G6. Low compression pressure and high exhaust temperature 7

1G7. High compression pressure and low exhaust temperature 7

1G8. High compression pressure and high exhaust temperature 7

H. Instruments — Speed

1H1. Idling speed not normal 7

1H2. Maximum speed not normal 7

I. Presence of Smoke

111. Black exhaust smoke 8

112. Bluish-white exhaust smoke 8

113. Smoke arising from crankcase 8

114. Smoke arising from cylinder head 8

115- Smoke arising from engine auxiliary equipment such as blower, pumps, etc 8

J. Excessive Consumption of Lube Oil, Fuel, or Water

1J1. Excessive lube oil consumption 8

1J2. Excessive fresh water consumption 8

1J3- Excessive fuel oil consumption 8

K. Contamination of Lube Oil, Fuel, or Water

1K1. Fuel oil in lube oil 8

1K2. Water in lube oil 9

1K3. Oil or grease in water 9

1K4. Water in fuel oil 9

1K5. Air or gas in water 9

1K6. Metal particles in lube oil . 9

Chapter 2. Air Intake System

A. Blowers

2A1. Introduction 11

2A2. Turbochargers 12

a. Possible trouble — Damaged shaft or thrust bearings 13

b. Possible trouble — Damaged turbine blading 14

c. Possible trouble — Damaged nozzle ring 15

d. Possible trouble — Damaged blower impeller 16

2A3. Roots type blowers 17

a. Possible trouble — Worn gears 17

b. Possible trouble — Scored rotor lobes and casing 18

c. Possible trouble — Blower shaft oil seals leaking 20

d. Possible trouble — Failure of serrated shafts 21

2A4. Hamilton-Whitfield blowers 21

B. Air Passages

2B1. Troubles in air passages 22

a. Possible trouble — Foreign bodies in manifold 22

b. Possible trouble — Excess accumulation of oil in manifold or air box 23

C. Air Heaters

2C1. Electrical air heaters 24

a. Possible trouble — Failure of electric air heater to operate 24

2C2. Flame primers for air heating 25

a. Possible trouble — Failure of flame