Reasons For Engine Failures

THE SERVICE IS IMPORTANT !
Years ago, technical literature would

have concentrated on one thing:
engines.
Today this approach would be
missing something out.
Good service, for example,
contributes just as much to success
on the sales as good product.
We must never loose sight of this if
we want to compete.
For us this means assisting the
customer at all stages before,
during and after the sale of any
engine.
IDENTIFY THE CAUSE,
NOT JUST THE EFFECT !
DUST IS THE GREATEST ENEMY
OF ALL ENGINES.
AIR & DUST.

All air contains contaminants (Dust) in various shapes and
sizes and is measured in parts per million or parts per billion.
The air that we can breath for many years can ruin an internal
combustion engine in a matter of hours.
And, in some applications, unfiltered air can render an engine
absolutely useless in thirty minutes running time.
While particles of dust in that amount of air is usually measured in parts
per million, in a 24 hour operation it can be virtually measured in
kilograms.
Make sure that all hoses, bellows and adapter pipes
are intact and no clips are missing.
Dust and dirt are the internal combustion engines
greatest enemy !
Unfiltered air entering an engine will cause
excessive wear
and
decrease the "life" of the engine in direct proportion to the
amount of dirt that it has to "eat".
Properly filtered combustion air is of vital importance

for satisfactory performance and long life of the engine
It is very important that
you keep the air intake system air tight and,
KEEP THOSE FILTERS CLEAN !
AIR CONTAMINATION, BY DUST.
Leads to:
- Piston ring wear.
Piston rings are worn on their faces and sides.
Maximum wear appears on the chamfers of the oil scraper ring.
Piston rings may broke because of the excessive wear.
- Cylinder wear.
At the reverse points of the piston rings, wear edges are produced on the
cylinder wall.
- Valve wear.
Wear on valve face.
Wear on inlet valve stem.
- Increased oil consumption.
- Starting problems.
- Lack of power.
- Carbon deposits in the exhaust port.
- Reduced engine life.
- Premature overhaul of the engine becomes
necessary.
Check for:
Crack in air filter element.
Correct air filter element positioning.
Filter case possible damages.
Connection hose possible damage.
Connection hose correct installation.
Possible deformation of the air-intake manifold.
Air-intake manifold tightness with cylinder head.
Use of original replacement parts.
AVOID COMBUSTION-AIR CONTAMINATION !
AIR CLEANER ELEMENT MUST BE CAREFULLY

CHECKED FOR CRACKS AND MUST SHOW
PERFECT INTEGRITY, BEFORE ITS
INSTALLATION.
LACK TO COMPLY
WITH THE
MAINTENACE
RECOMMENDATIONS
MUD !
POOR QUALITY
CARTRIDGE
THE
CONSEQUENCE !
NO OIL
INSIDE
YES
NO !
NO !
YES !
RUBBER PLUGS OF NON-USED ACCESSORIES

OF THE AIR-CLEANERS
MUST BE FIRMLY POSITIONED IN THEIR
LOCATION.
WHEN LOOSE, OR LOST, UNFILTERED AIR
ENTERS IN THE INLET SYSTEM F THE ENGINE.
CONSEQUENCES OF COMBUSTION- AIR
CONTAMINATION !
WEAR DUE TO
COMBUSTION-AIR
CONTAMINATED BY
DUST
DUST INGESTION
Cylinders & Pistons

CONSEQUENCES OF COMBUSTION- AIR
CONTAMINATION !
Valves & Pistons

CONSEQUENCES OF COMBUSTION-AIR
CONTAMINATION !
Y O IL
E A V N !
H P T IO
SU M
CON
CONTAMINATION !
CONTAMINATION !
NO ADEQUATE
COMPRESSION !
EL. STARTER
EXTENDED
CRANKING!
ELECTRIC STARTER
Evidence of
OVERHEATING !
STARTING
PROBLEMS !!!!!
CONTAMINATION !
CONTAMINATION !
DAMAGE DUE TO OIL QUALITY AND OIL
CHANGE INTERVALS.
Leads to:
Carbon build-up on piston rings and piston rings grooves.
Check for:
Lube oil quality according to API class as recommended
by the Manufacturer.
Recommended viscosity.
Recommended oil and filter change intervals.
DAMAGE DUE TO OIL CONTAMINATION

FROM OUTSIDE SOURCES.
Due to:
Dust contamination in the lube oil.
Leads to:
- General abrasive action internally of the engine.
- Premature wear of all moving parts of the engine.
- Cylinder wear.
- Oil scraper ring worn on the chamfers.
- Rocker arms wear.
- Valve guides wear.
- Thrust bearing wear.
- Rapid wear of the bearing shells.
- Oil pressure relief valve (bypass) incorrect
operation.
GOOD OIL QUALITY AND
CORRECT OIL CHANGE
INTERVALS !!!!.
POOR OIL
MAINTENANCE ?
CONSEQUENCES OF OIL QUALITY &
CHANGE INTERVALS !
MAJOR WEAR ON
LOWER PART !
WEAR DUE
TO
CONTAMINATED
OIL
CONSEQUENCES OF OIL QUALITY
& CHANGE INTERVALS !
WORN
CAM
WORN LUBE OIL

PUMP BODY
By-Pass
Valve
Clogged !
CONSEQUENTIAL
FAILURE
DAMAGE DUE TO FUEL SYSTEM
CONTAMINATION.
Due to:
Unfiltered fuel.
Water contamination.
Poor fuel quality.
Faulty injector.
Poor pump timing.
Too much fuel delivered per stroke.
Leads to:
Wear of the injector nozzle needle.
Damage to injector nozzle.
Injector nozzle clogging for
carbonization.
Poor fuel atomization.
Uncontrolled combustion
Piston crown damage and melting.
CONSEQUENCES OF FUEL
SYSTEM CONTAMINATION
SEIZED
DIRT SEIZURES
WATER
CONTAMINATION !
POSSIBLE SEIZURE !
POSSIBLE SEIZURE !
SEIZURE !
CLOGGING OF THE
FUEL FILTER
DAMAGE DUE TO INCORRECT
VALVE CLEARANCE.
TOO GREAT.
Leads to:
- Reduced time of the inlet, it reduces the air intake.
- Black smoke in the exhaust.
- Increased engine noise level.
- The rocker arm to strike the end of the valve stem at too
high velocity.
- Rocker arm hammer effect on the end of the
valve stem.
TOO SMALL.
Leads to:
- Extended opening times of the inlet.
- Loss of compression.
- Starting problem.
- Power is decreased.
NO-CLEARANCE.
Leads to:
- Preventing the heat exchange between valve face and
cylinder head.
- Combustion gases enter the air-intake
manifold.
- Burn the faces of the valve head and valve
seat insert.
DAMAGE DUE TO INCORRECT VALVE
CLEARANCE
TOO GREAT !
- REDUCES AIR INTAKE

- BLACK SMOKE
- HIGHER NOISE LEVEL
-HAMMERING EFFECT
ON VALVE STEM
CLEARANCE
TOO SMALL !
- EXTENDED OPENING TIME OF
INTAKE
- LOSS OF COMPRESSION
- STARTING PROBLEMS
- LOSS OF POWER
CLEARANCE
NO CLEARANCE !
- PREVENTS HEAT EXCHANGE BETWEEN
VALVES AND CYLINDER HEAD
- BURNS THE FACE OF THE VALVE HEAD
- COMBUSTION GASES ENTER INTO THE INTAKE
MANIFOLD
- POSSIBLE HIT ON THE TOP OF THE PISTON
-VALVES & PUSH RODS DAMAGES
- CAMSHAFT DAMAGES
CLEARANCE
CLEARANCE
BROKEN
ROCKER
ARM
CLEARANCE
!!
RY
TO
NA
P LA
E X
L F
SE
DAMAGE DUE TO OVERHEATING FOR
INEFFECTIVE COOLING.
Caused by:
Dirt build-up on cooling fins, on radiator ,on stator
rotor, on oil cooler.
Lack of lube oil.
Failure of cooling blower.
Leads to:
Piston seizure.
Cylinder-head & gasket damage.
Piston rings may be completely stuck in the grooves.
Signs of blow-by on the sealing surface of cylinder
head on the cylinder liner seal.
Combustion gases escape from the head sealing surface.
Cooling liquid into combustion chamber lube oil into the
cooling system
Hissing noise is emitted when engine in cold condition.
Injector nozzle stuck.
Oil becomes thick.
Lube oil looses the ability to lubricate.
Lube oil oxidizes and ages prematurely.
Starting problems.
Possible damage to internal alternator.
It is necessary:
New sealing on the cylinder head/liner.
Recondition sealing surfaces may be necessary.
Piston and piston rings may need to be replaced.
Cylinders must be replaced or re-machined.
CAUSES OF OVERHEATING
LUBE OIL
TOO LOW
POOR OIL QUALITY

AND
POOR OIL CHANGE
INTERVALS !!
CONSEQUENCES OF OVERHEATING or
INEFFECTIVE COOLING
INEFFECTIVE COOLING
INEFFECTIVE COOLING
INEFFECTIVE COOLING
INEFFECTIVE COOLING
INEFFECTIVE COOLING
Cooling System
leakage!
INEFFECTIVE COOLING
Cooling System
leakage!
INEFFECTIVE COOLING
BLOW-BY
FROM
CYLINDER-
HEAD GASKET
DAMAGES DUE TO INCORRECT OIL LEVEL.
TOO HIGH OIL LEVEL

Leads to:
- Oil flooding.
- Increases oil temperature.
- Oil foaming.
- Bearings damage because of
too much air in the lube oil.
It may be observed:
- White smoke.
- Engine over-speed
TOO LOW OIL LEVEL,

OR LACK OF OIL.
Leads to:
- Connecting rod big-end bolts to break off.
- Connecting rod big-end bearing, and main
bearing damage.
- Initial stage : signs of smearing of thin material.
- Advanced stage: signs of melted metal;
metal particles imbedded in the thin layer.
- Final stage : Due to bearing overheating the big
end bolts loose their torque.
DAMAGES DUE TO
EXCESSIVE OIL LEVEL.
TOO HIGH !
ENGINE OVER-SPEED
MAY BE EXPECTED
OIL FLUDING AIR
BUBBLES IN THE OIL
WITH BEARINGS
DAMAGE
ENGINE TEMPERATURE
INCREASES
WHITE SMOKE
DAMAGES DUE TO INCORRECT
OIL LEVEL or LACK of OIL.
DAMAGES DUE TO
LOW OIL LEVEL or LACK of OIL.
TOO LOW
DAMAGES DUE TO ENGINE
OVERSPEED.
Overspeed due to:
- Oil level too high.
- Air cleaner oil ingestion.
- Oil ingestion for high inclination
- Wrong adjustment of the high idle speed.
- Tampering with the governor.
Leads to:
- Piston strikes the valves (exhaust first).
- Valve stem bending (exhaust first).
- Valve deformation.
- Push rod damage and bending.
- Damage to push rod spherical sockets.
- Damage (or broken) tappet plate.
- Valve cone clamp becomes loose.
- Valve spring plate jump-out.
- Valve drops into the combustion chamber.
- Severe damage to the engine.
OVERSPEED
OVERSPEED
OVERSPEED
OVERSPEED
OVERSPEED
DAMAGES DUE TO LOADED ENGINE
OPERATION AT TOO LOW R.P.M.
DAMAGES DUE TO LOADED ENGINE
OPERATION AT TOO LOW R.P.M.
BREAKAGE
STARTING POINT
OVERHEATING
SIGNS !
HAMMERING
SIGNS !
OVERLOAD.
Overload due to:
- Excessive power take off.
- Excessive axial load.
- Engine use at excessive power
requirement at high elevation,
temperature.
Leads to:
- Black smoke.
- Engine overheating.
(See overheating consequences)
Then:
- Excessive exhaust temperature.
- Injectors damages and seizure.
- Injection pump damages and seizures.
- Pistons seizures.
- Bearings seizures.
- Lube oil solidification.
- Loss of lubricating capacity of the lube-
oil.
OVERLOAD.
OVERLOAD.
OVERLOAD.
OVERLOAD.
PROLONGED OPERATION
AT IDLE SPEED or NO-LOAD.
Due to:
Engine over-cooling.
Engine thermal conditions too-low.
Engine uncontrolled tolerances.
Leads to:
Increased oil consumption.
Oil-Carbon deposits in the exhaust port.
Oil leakage from exhaust.
Solidified oil deposits on piston rings.
Piston rings may be completely stuck in
the grooves.
Injector nozzle clogging for carbonization.
Exhaust clogged.
Lack of power.
White smoke.
Severe damage to the engine.
PROLONGED OPERATION
-OIL CONSUMPTION
SIGNIFICANTLY INCREASES
- OIL LEAKAGE FROM EXHAUST
- OIL CARBON DEPOSITS ON
PISTON, PISTON-RINGS and
EXHAUST PORT
- INJECTOR CLOGGING FOR
CARBONIZATION
- WHITE SMOKE
PROLONGED OPERATION
PROLONGED OPERATION
DAMAGES DUE TO
MISALIGNMENT,
POOR ASSEMBLY
AXIAL DISTORTION and
THERMAL EXPANSION OF THE DRIVEN
COMPONENTS.
Due to:
- Faulty mounting of driven components.
- Incorrect re-assembly of driven
components.
Leads to:
- Damage to thrust bearing ring halves.
- Severe damage to the engine.
- Extremely great crankshaft end-play.
- The non-thrust-loaded ring halves may drop into the
oil pan.
- Main bearing shells become severely damaged on
the edge.
- Severe damage may occur to the crankshaft
breakage!
- Break the crankshaft taper.
- Severe engine vibrations.
- Breaking of external components (muffler, air-
cleaner, etc.).
IS THIS A CORRECT COUPLING?
Is OK
the Distance from the crankcase?
Is the RADIAL LOAD

in between the allowed tolerances?
DAMAGES DUE TO MISALIGNMENT
MISALIGNMENT EXAMPLE
a a > b !!!
b
or
INCORRECT COUPLING
CRANKSHAFT
BROKEN TAPER
HERE !
DAMAGES DUE TO THERMAL EXPANSION OF
DRIVEN COMPONENTS
& INCORRECT COUPLING
ENGINE
PUMP GENERATOR ETC.

CAUSES OF INCORRECT COUPLING
CONTACT
NO-CONTACT
CONTACT &
PITTING
NO-CONTACT
DAMAGE DUE TO INCORRECT COUPLING

DAMAGES DUE TO INCORRECT COUPLING
DAMAGE DUE TO ENGINE PROLONGED
STORAGE.
When:
- New engine is not put into operation within 6
months of the delivery from the factory.
- If engine that has been already in operation is
kept out of operation for more then six months.
- All above, if engine is stored in the open or
exposed to climatic extremes.
Leads to:
- Rust in the cylinder walls.
- Corrosion in the cylinder walls.
- Rust on injection pump parts.
- General corrosion in the fuel system due to
water in the fuel.
- Deposits of varnish and resinous gummy
material on the lapped cylinders and plunger of
the injection pump.
It is necessary:
Replace all damaged parts.
Run the engine for a while on special
preservation fuel.
DAMAGES DUE TO UN-PROTECTED
PROLONGED STORAGE
RUST !
RUST !
HARD PUMP
CONTROL RACK
RUSTED
INSIDE or
STUCKED
NEEDLE
STUCKED
PROLONGED STORAGE
INTERNAL HARD
OPERATION
or
BLOCKED OPERATION
PROLONGED STORAGE
SLOW
REACTION
OF THE
GOVERNOR
SYSTEM !
PROLONGED STORAGE
RUST !
RUST !
RUST !
PROLONGED STORAGE
RUST !
RUST !

Reasons For Engine Failures

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Reasons For Engine Failures

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THE SERVICE IS IMPORTANT !

Years ago, technical literature would

AIR & DUST.

Properly filtered combustion air is of vital importance

AIR CLEANER ELEMENT MUST BE CAREFULLY

RUBBER PLUGS OF NON-USED ACCESSORIES

Cylinders & Pistons

Valves & Pistons

DAMAGE DUE TO OIL CONTAMINATION

WORN LUBE OIL

- REDUCES AIR INTAKE

POOR OIL QUALITY

TOO HIGH OIL LEVEL

TOO LOW OIL LEVEL,

Is the RADIAL LOAD

PUMP GENERATOR ETC.

DAMAGE DUE TO INCORRECT COUPLING

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