TROUBLE SHOOTING

AN ABNORMAL ENGINE INDICATION

• Abnormal circumstances will disrupt the operation of an engine.
• Good engine operation depends on the main things including :
1. The supply of air compression until high pressure is reached.
2. Sufficient fuel injection at the right time.
• Loss of power is caused by several factors:
– Unstable of Engine speed
– excessive vibration,
– faltering (too long) idle time
– The engine difficult to start is an indication that the
compression pressure is too low
– Poor quality of Injection on one or more cylinders, or
– Supply of air is very poor.
 LOOKING FOR MISFIRING LOCATION
1. Start engine and turn on the part load to normal
engine temperature conditions.
2. Stop the engine and open the valve rocker cover.
3. Check the clearance of valve (follow manual guide).
4. Start engine. Press the follower injector with screw
driver to prevent injector operation. If the cylinder
happens misfire then there will be no change of
engine sound and engine operation. Conversely, if
there is a change in sound and operation then the
cylinder in a normal working condition.
Check incjector follower with screw
driver
5. If the first cylinder is running normally, repeat
again on the next cylinder until the cylinder is
found misfire.
6. In case of misfire then it needs to be checked :
a. Check the timings of injectors.
b. Check the compression pressure.
c. Replace the new injector if it is damaged.
d. If there is still a jam, loose cam follower and check
worn cam roller, camshaft lobe , bent rod or worn
cocker arm bushing.
 Check Compression Pressure
1. Start engine and turn on the part load to normal engine
temperature conditions.
2. Turn off the engine and remove the fuel pipe from the
fuel injector and connector on the cylinder no 1.
3. Remove the injector and plug in the adapter and pressure
gage.
4. Use one of the fuel pipes as the connecting jumper
between the fuel inlet and the return manifold connector.
To return the fuel flow to the return manifold.
5. Start engine, turn the engine at 600 rpm. Observe and
note the compression pressure on the indicator.
Remember do not rotate engine with starting motor to
measure compression pressure!
 Check Compression Pressure (cont.)
6. Repeat processes 2 to 5. Pressure should be
adjusted to the table on the reference project
guide. If anyone does not meet the requirement
then it needs to be checked.
Low pressure may be caused by:
a. Possible piston ring stuck (sticky?) Or damaged.
Inspection of piston ring. For checking depending of
the engine brand. Open the air box cover, and check
each one and check with the blunt tool.
b. Possible damage from gaskets (torn, perforated etc.).