Section 503

TrouE. shoot

Description

Starting Failures 503.01

Faults in Fuel Oil System 503.02
Disturbances during Running 503.03
Ignition in Crankcase 503.04
Trouble Shooting Guide for Centrifugal By-pass Filter 503.05
Trouble Shooting Guide for Air Starter 503.06
Trouble Shooting for Cooling Water System 503.09
Trouble Shooting for Lubricating Oil Cooler 503.10
 Description
Starting Failures 503.01
Page 1 (1)
Edition 02

General

Trouble Possible cause Troubleshooting

Engine turns as soon as shut- Faults in electrical system. Check electrical parts.
off valve is opened, without
start button being activated.

Engine does not turn when Air pressure in starting air Start compressors, re-charge
start button is activated. receiver too low. air receiver.

Main valve(s) closed. Open valve at receiver and stop

valve interposed in line between
receiver and engine.

Pinion does not engage with Check the air starter.

the flywheel.

Air motor runs, pinion engages Check the air motor for broken
but does not rotate. shafting, bearing or clutch
jaws,
see Working Card 513-01.30.

Faults in electrical system. Check electrical parts.

Engine turns too slowly or ir- Worn air motor parts. Remove and disassemble the
regularly when start button is air motor. Examine all parts
activated. and replace any that are worn
or damaged. Use the guidelines
for determining unserviceable
parts, see Working Card 513-
01.30.

Start valve is sticking in closed Check start valve.

position.

Low air pressure. Raise the air receiver pres-

sure.

Air starter works, but the drive Clutch or drive shaft broken. Dismantle the air starter and
shaft does not rotate. repair it.
08028-0D/H5250/94.08.12

04.31 - ES0
 Description
Faults in Fuel Oil System 503.02
Page 1 (2)
Edition 05

L16/24 L27/38
V28/32S L21/31

Trouble Possible cause Troubleshooting

Engine turns, but ignition fails. Fuel Sluggish movement of manoeuvering Lubricate and mobilize rod connections
pumps are not actuated. gear. in manoeuvering gear.

Incorrect adjustment of manoeuver- Check rod connec. Check that fuel pump
ing gear. index corresponds to "Adjustments after
trials" in testbed chart.

Safety system stop activated. Reset safety system stop.

Piston in Lambda controller is ac- Check that piston is not sticking. Check
tuated. that pressure in cylinder is relieved.
Check that the shutdown trip is not
actuated.

Check pressures and temperatures.

Piston in Lambda controller cylinder Check for faults in shut-down devices:
is actuated due to stop function or Check for faults in fuel limitation de-
fuel limitation. vices.
Check adjustment according to
Working Card 509-10.00.

Incorrect adjustment of Lambda con- Adjust setting of adjustment screw, see

troller's adjustment screw. Working card 509-10.00.

Governor setting incorrect. Adjust governor, see special instruction

manual.

Failures in governor. Check that governor is working properly.

For further fault location, see special
instruction manual in section 509.

Sticking fuel pumps. Dismantle and clean.

Engine turns, but no fuel is injected Fuel oil service tank empty. Pump oil into the tank.
owing to failure in fuel system.
If Then
Air in fuel pumps. Loosen hexagon
socket screw on
fuel pumps until air
disappears.

Engine runs, but does not ignite on Air in fuel valves. Ignition fails on Vent the respective
08028-0D/H5250/94.08.12

all cylinders. one or more fuel valves.

cylinders due to
air in the fuel
valves.

Ignition fails on Change the fuel

one or more valves and check
cylinders and them for sticking
no air bubbles spindle or broken
appear. spring. Check for
collecting oil on
piston top.

Air appears in Check stuffing box

the entire system. and sealing in the
fuel system.

Cont.

02.40 - ES0
503.02 Faults in Fuel Oil System Description
Edition 05 Page 2 (2)

L16/24 L27/38
V28/32S L21/31

Trouble Possible cause Troubleshooting

Worn-out fuel pump. Change fuel pumps.

If Then
Pressure before Clean fuel filter.
pumps is too low. Check that by-pass
valve for feed pump
is not open.

Pressure is still Increase the fuel

too low. oil feed pump
pressure.

Engine turns, fuel is injected, but Water in the fuel. Drain off water and repeat venting of fuel
ignition fails. pumps by loosening the hexagonal socket
screw until air disappears.

Fuel valves or nozzles defective. Change defective fuel valves, see working
card 514-01.10.

If Then
Compression Check intake and
during start too exhaust valve for
low. tight closing.
Check piston rings.

Timing of fuel Check fuel cam-

camshaft is shaft adjustment,
incorrrect. see Working card
507-01.20.

Major alteration Adjust camshaft,

of the fuel de- see Working card
mand adjustment 507-01.20.
of the fuel pump
timing.

Oil has collected Slow turning to

on piston crown. remove oil. Locate
and change defec-
tive fuel valve.
08028-0D/H5250/94.08.12

First ignitions are too violent. Engine Sluggish movement of manoeuvering Lubricate and mobilize rod connections
runs erratically. gear. and bearings in manoeuvring gear.

Fuel pump index to high. Check rod connection in manoeuvring

gear. Check that governor is working
properly.

02.40 - ES0
 Description 503.03
Page 1 (3) Disturbances During Running Edition 06

L21/31
L27/38
V28/32S

Trouble Possible cause Troubleshooting

Exhaust gas temperatures Increased charging air temperature Clean air coolers, see working card 512-01.00.
increased on all cylinders. due to ineffective air coolers.

Fouling of air and gas passages. Clean air and gas passages, see working cards in section
512.

Insufficient cleaning of fuel oil or Check separator and fuel filters.

changed combustion characteristics.

Wrong maximum combustion pressure Check camshaft adjustment, see working card
/fuel injection timing 507-01.20.

Poor fuel quality. Change fuel.

Exhaust gas temperature Fuel valve or valve nozzle defective. Overhaul fuel valve, see working card 514-01.10.
increased on one cylinder.
Leaky exhaust valves. Check the valve clearance, see working card 514-01.10
or
change the leaky valve and recondition the exhaust valve,
see working card 505-01.05.

Note: This manifests itself by a rise If Then

in the exhaust temperature and faill- Stopping of the The fuel pump of the cylinder con-
ing of the compression and maximum engine is not cerned should be put out of opera-
combustion pressure of the respective possible or tion by moving the index to stop
cylinder. convenient. and locking it in this position.

Blow-by = leaky combustion cham- Check piston rings, see working card 506-01.35.
ber.
Blow-by means a serious danger of piston seizure, and
the engine must if possible be stopped and the piston in
question pulled. Leaky piston rings will normally result in
heavy excess pressure in the crankcase.

If Then
Stopping of the The fuel pump of the cylinder con-
engine is not cerned should be put out of opera-
possible or tion by moving the index to stop
convenient. and locking it in this position.
08028-0D/H5250/94.08.12

Damaged fuel pump cam. Replace camshaft section, working card 507-01.05.

Exhaust gas temperature Decreased charging air temperature. Check the thermostatic valve in the cooling water system,
decreases on all cylinders. see working card 516-04.00.

Exhaust gas temperature Spindle in fuel valve is sticking. Change and overhaul defective fuel valve, see working
decrease on one cylinder. card 514-10.00.

Fuel pump plunger is sticking or Change fuel pump plunger/barrel assembly, see working
leaking. card 514-10.00.

Cont.

05.08 - ES0
503.03 Description
Edition 06
Disturbances During Running Page 2 (3)

L21/31
L27/38
V28/32S
Trouble Possible cause Troubleshooting

Engine speed decreases. Pressure before fuel pumps too low. Raise fuel oil feed pump pressure to normal.
or
check filter, see working card 514-01.15.

Fuel valve defective. Change defective valve, see working card 514-01.10.

Fuel injection pump defective. Change or overhaul.

Water in the fuel. Drain off water from service and setting tanks. Check fuel
oil centrifuge.

Governor defective. See governor manual.

Linkage adjustment wrong

Engine stops. Shut-down for overspeed. Check fuel pumps, see working card 514-10.00.
Check governor, see governor manual.
Check movement of regulating mechanism.

Shut-down for low lubricating Check pressostat, see working card 509-05.00.
oil pressure. Check lubricating oil filter, see working card 515-01.10.
Check lubricating oil pump, see working card 515-01.00.

Shut-down for high lubricating Check lub. oil flow and pressure,
oil pressure. see working card 515-01.20.
Clean lubricating oil cooler, see working card 515-06.00.

Shut-down for high HT cooling water Check HT system and pumps.

temperature.

Smoky exhaust. Turbine speed lagging behind engine Clean turbine(s), see turbocharger manual
speed.

Air supply too low. Clean air cooler, see working card 512-01.00.
Clean air filter, see working card 512-35.00.
Clean compressor, see turbocharger manual
Clean turbine, see turbocharger manual

Fuel valves or nozzles defective. Check fuel valves, see working card 514-01.10.

Exhaust valve knocking. Adjusting screw for valve setting Inspect and replace defective parts, see working card
08028-0D/H5250/94.08.12

clearance loose. Push rod thrust disc 508-01.00.

damaged.

Rising cooling water Thermostatic function Check thermostat.

temperature.
Pump defective Stop the engine and repair the pump.

Decreased flow Check valves.

If Then
The cooling water Open the test cocks (if
fitted
temperature for the on the discharge from
entire engine has cylinders).
risen to 90-100°C. Cont.

05.08- ES0
 Description 503.03
Page 3 (3) Disturbances During Running Edition 06

L21/31
L27/38
V28/32S

Trouble Possible cause Troubleshooting

Check whether steam has

developed.

Steam has developed. Stop the engine.

Leave the engine to cool
while the discharge valve
is closed.

After 15 minutes open the

discharge valve a little to
allow the water to rise
slowly in the cooling
jackets.

Check filling at test cocks.

Lubricating oil pressure Lubricating oil pump defective. Check lubricating oil pump, see working card 515-01.00.
fails.
Filters fouled. Clean filter, see working card 515-01.10.

Cooler fouled. Clean cooler, see working card 515-06.00.

If Then
The lubricating oil Stop the engine: find the
pressure drops below cause of the pressure drop
the minimum stated and remedy the defect
before
in the Data sheet. restarting the engine.

Note: Feel over 5-15-30 minutes after starting, and again

when full load is achieved.

See section 502.

Alternator (GenSet only) Short circuit Flywheel must be dismounted and guide pin replaced
08028-0D/H5250/94.08.12

05.08 - ES0
 Description 503.04
Page 1 (1) Ignition in Crankcase Edition 03

General

Cause 1) Stop the Engine

During running the atmosphere in the crankcase 2) Leave the engine room. Shut doors and keep
contains the same gases (N2-O2-CO2) in the same away from them. Make ready fire-fighting equip-
proportions as in the ambient air, but an intense ment.
spray of oil drops is slung around everywhere. If
undue friction, and thus heating, arises between Warning: Do not open crankcase until 10 minutes
sliding surfaces, or heat is otherwise transmitted to after stopping the engine. When opening up, keep
the crankcase, the heated surface will cause eva- clear of possible flames. Do not use naked light and
poration of the lubricating oil splashed onto it. When do not smoke.
the oil vapours condense they form milky white oil
mist which can ignite. Such ignition may be caused 3) Cut off starting air.
by the same "hot spot" that produced the oil mist. Set the control panel in "Blocking Mode" see
If a large quantity of oil mist has developed before description 501.01.
ignition, the burning may cause considerable pres- Take off all doors on one side of the crank-
sure rise in the crankcase, forcing the relief valves case.
to open. In a few cases, presumably when the whole
crankcase has been filled with oil mist, a subsequent 4) Locate the hot spot. Powerful lamps should be
explosion has thrown off the crankcase doors and employed at once (in explosion-proof fittings).
caused fire in the engine room. Feel over all sliding surfaces (bearings, liners,
pistons, roller guides, etc.).
Every precaution should therefore be taken to (A)
avoid "hot spots" and (B) discover oil mist in time. Look for squeezed-out bearing metal and discol-
oration by heat (blistered paint, burnt oil, heated
steel).
"Hot spots" in Crankcase
5) Prevent further heating, preferably by making
Overheating of bearings is a result of inadequate or a permanent repair. Special attention should be
failing lubrication, possibly caused by pollution of paid to ensuring lubricating oil supply and the
the lubricating oil. satisfactory condition of the frictional surfaces
involved. It is equally important to replace filter
It is therefore important that the lubricating oil filtration elements in time.
equipment is in perfect condition. Filter cartridges may
not be used again if they have been removed from 6) Start electrically driven lubricating oil pump
the filter. Checking of the oil condition by analysis is and check oil flow from all bearings and spray
recommended. pipes in crankcase while turning the engine
through at least two revolutions.

7) Stop and feel over. Look out for oil mist.

08028-0D/H5250/94.08.12

Oil Mist in Crankcase

The presence of oil mist may be noted at the vent Especially the frictional surfaces that caused the
pipe which is usually fitted to the top of the engine heating should be felt over (5-15-30 minutes after
frame. starting, and again when full load is obtained). Sec-
tion 501.10.
Measures (in case of white oil mist).
8) If it has not been possible to locate the hot spot,
Warning: Keep away from doors and relief valves on step 7 should be intensified and repeated until
crankcase. Do not stay unnecessarily in doorways the cause of the oil mist has been found and
near the doors of the engine room casing. remedied. In very rare cases oil mist could be
due to "atomization" of lubricating oil by the
action of an air jet (for instance blow-by, or
blow-by through cracked piston).

00.12 - ES0
 Description
Trouble Shooting Guide for Centrifugal By-pass Filter 503.05
Page 1 (1)
Edition 03

L21/31
L27/38
Tabulated below are the remedial actions to be taken
if the following faults are observed:

Trouble Possible cause Trouble shooting

Oil leakage through cover nut. Missing or damaged O-ring Replace O ring.
(see Item 158, Plate 51515).

Seal face damaged. Replace cover assembly.

Excessive vibrations. Rotor out of balance owing to uneven

build-up of deposit on rotor walls
resulting from:

Missing or damaged O ring (see Item Replace O ring.

109, Plate 51515), allowing leakage.

O-ring seat on rotor joint faces Replace rotor assembly.

damaged.

Rotor assembly inadequately Tighten and bring to notice of maintenance

tightened. staff.

Standtube incorrectly seated or da- Refit or replace if damaged.

maged.

Dirt deposit not completely removed. Clean and bring to notice of maintenance
staff.

Rotor castings distorted through Replace rotor assembly.

maltreatment.

Rotor assembly components fitted in Follow sequence in Working card 515-15.00

wrong sequence. in section 515.

Bushes loose or worn in tube as- Fit new bearing tube assembly.
sembly.
08028-0D/H5250/94.08.12

99.25 - ES0
 Description 503.06
Page 1 (2) Trouble Shooting Guide for Air Starter Edition 04

L21/31
L27/38

Trouble Possible Cause, see Plate 51309 Trouble Shooting

On pressing push-button, starter - Empty air receiver(s) Charge receiver(s)

does not respond and no air flow - Flow valve(s) close Open flow valve(s)
seems to exist in control circuit. - Control circuit blocked Disconnect and clean out

On pressing push-button, starter - Leak in control duct Repair or replace

does not respond, although air - Insufficient air pressure Increase pressure in receiver
flows through control circuit. - Push button stuck Remove and clean same
- Excessive length of main air Approach push-button to starter
pipework or install a solenoid valve near the
latter

Pinion revolves and advances, but - Ring gear and/or pinion burrs or Clean burrs or replace if necessary
does not engage the ring gear. damage
- Lack of clearance between pinion Replace pinion by a more adequate
and ring gear one. Check for distortion of ring
gear

Pinion revolves but does not - Follower Item 130 inoperative Disassemble, check, smoothen
advance. guide diameter, clean or replace if
rusted
- Insufficient air pressure Increase pressure in receiver
- Splined shaft Item 11 sticking Disassemble, clean, check spring
Item 13 and reassemble
- Excessive length of control pipe Approach push-button to the starter
or install a solenoid valve near the
latter

Pinion advances but does not - Pneumatic motor inoperative Disassemble, inspect rotor for
revolve foreign matters between teeth and
for possible wear of gears.
- Check valve Item 131 Clean and reassemble. Replace
worn parts
Disassemble, clean and reassem-
ble

Pinion engages gear ring, but will - Main valve Item 133 blocked Disassemble, clean and reassem-
08028-0D/H5250/94.08.12

not turn the engine ble or replace

- Rotors worn or blocked Disassemble, clean and reassem-
ble or replace rotors
- Insufficient air pressure Increase pressure in receiver
- Main air pipework restricted or of Check all pipework and replace it if
insufficient bore it necessary

Starter starts working upon ope- - Incorrect connection of control Connect control pipes as per instal-
ning the flow valve of the feed line, pipes (with separate solenoid- lation instruction
although push-button (or solenoid valve)
valve) are not actuated. - Main valve Item 133 blocked and Disassemble, clean and replace
open joint if needed

00.13 - ES0
503.06 Description
Edition 04
Trouble Shooting Guide for Air Starter Page 2 (2)

L21/31
L27/38

Trouble Possible Cause, see Plate 51309 Trouble Shooting

Lack of starter power - Main pipework choked or is bore Check entire pipework for correct
is less than stipulated for the bore and replace if incorrect
starter
- Insufficient air pressure Increase pressure in receiver
- Badly worn rotors Disassemble, replace and reassem-
ble

08028-0D/H5250/94.08.12

00.13 - ES0
 Description
Trouble Shooting for Cooling Water System 503.09
Page 1 (1)
Edition 03

General

Description The pump bearings are lubricated automatically with

oil from the lubricating oil system of the engine.
The built-on fresh water pumps in the high and low
temperature circuits are of the centrifugal type. They If the pump leaks and the shaft sealing rings are
are mounted in the front end box and are driven worn, it is recommended to replace the shaft seal,
through the gearing. see Working card 516-02.00.

Trouble Possible cause Troubleshooting

Oil or water flows out of the inspec- Worn rotating sealing. See working card 502-05.00.
tion holes.

The pump does not work after start. Pump draws in air at suction side. Check packings and pipes for tightness.

The system is not filled-up. Check the level in the expansion tank.

Air cannot escape on delivery side. Vent the system.

Leaking shaft seal. Check the shaft seal.

Pump capacity drops after normal Air leakages from shaft seal. Overhaul the shaft seal.
operation.
Fouled impeller. Clean the impeller.

Pump does not give maximum Suction valve not fully open. Open the suction valve.
delivery.
Defective seals. Replace the seals.

Worn impeller and worn wear rings. Overhaul the pump.

Note: Running trouble with the pump, apart from

mechanical faults, is most often due to leaks in the
08028-0D/H5250/94.08.12

suction line. It is therefore essential that all packings

and gaskets are in order and that they are renewed
when necessary. Even a tiny hole in the suction line
will reduce the pump capacity.

98.20 - ES0
 Description 503.10
Page 1 (2) Trouble Shooting for Lubricating Oil Cooler Edition 01

General
Trouble Shooting Fatigue fracture will normally necessitate replace-
ment of all plates and gaskets as there may be a
It is necessary to replace damaged plates or ga- risk of fatigue fracture in all the material.
skets. In case of corrosion, all plates must be examined
carefully!
First examine the external conditions around the Concerning the work to be carried out see Working
plate heat exchanger in order to localize the cause card 515-06.00.
of the damage. Do this very carefully.

Visible Leakage

Trouble Possible cause Troubleshooting

Leakage. Too high pressure. Reduce the pressure to the correct work-
ing pressure, see page 500.30 "Operating
Data & Set Points".

Leakage. Insufficient tightening. Tighten up the plate heat exchanger, but

(Phase 1) not below the minimum dimension and
never when the plate heat exchanger is
under pressure or over 40°C.

If the plate heat exchanger is still leaky,

proceed to phase 2.

Leakage. Fouled or deformed plates. Separate the plate heat exchanger and
(Phase 2) Inelastic or deformed gaskets. check if the plates are deformed or
fouled.
Check that the gaskets are elastic and
non-deformed, and that the faces of the
joints are clean.
Replace deformed plates and gaskets,
if any.
Before assembling clean all plates and
gaskets very carefully.
Assemble the plate heat exchanger and
start it up again.
Note: Even tiny impurities such as sand
grains may cause leakage.

Leakage. Gaskets. Separate the plate heat exchanger.

(Even after tightening of the plate heat Clean the plates very carefully.
exchanger to minimum dimension.) Replace the gaskets.
08028-0D/H5250/94.08.12

Assemble the plate heat exchanger and

start it up again.

Leakage. Defective gasket or badly corroded Separate the plate heat exchanger.
(Through the drain holes of the gas- plate. Replace defective plates and gaskets,
kets.) if any.
Assemble the plate heat exchanger and
start it up again.

98.20 - ESO
503.10 Description
Edition 01 Troubleshooting for Lubricating Oil Cooler Page 2 (2)

General

Non-Visible Leakage

Trouble Possible cause Troubleshooting

Reduced heat transmission and/or Fouled plates or choked plate chan- Separate the plate heat exchanger and
increasing pressure drop. nels. check if the plates are fouled.
Clean the plates very carefully.
Assemble the plate heat exchanger and
start it up again.

Leakage. Holes in plates. A suspected leakage can be localized in

(The fluids get mixed.) Corrosion or fatigue fracture. the following way:
(Phase 1) Remove one of the lower pipe connec-
tions.
Then put the opposite side under pres-
sure.
If the medium continues to run out of the
lower pipe connections after the pressure
has stabilized one or several plates are
leaking.
Close down the plate heat exchanger.
Separate the plate heat exchanger and
check the plates very carefully.
Check suspected plates with a dye pen-
etrant.
Check defective plates and gaskets.
Before assembling, clean all plates and
gaskets.
Assemble the plate heat exchanger and
check to find more defective plates, if any,
by putting one side under press.
Start up again.

Leakage. Holes in plates. Close down the plate heat exchanger.

(The fluids get mixed.) Corrosion or fatigue fracture. Separate the plate heat exchanger.
(Phase 2) Put all plates to dry. Suspend the plates
in the plate heat exchanger again and
tighten it.
Circulate medium at full capacity on one
plate side (every second plate channel).
Keep the other plate channels unpres-
surised and free from liquid!
Stop the circulation after a few minutes
of operation and open the plate heat ex-
changer again. Take care to avoid water
spraying onto the dry plate side!
By a careful study of the plates it will be
08028-0D/H5250/94.08.12

possible to find moist areas, if any, on the

otherwise dry plate sides.
Check these areas with a dye penetrant!
Replace defective plates and gaskets.
Before assembling, clean all plates and
gaskets.
Assemble the plate heat exchanger and
check to find more defective plates, if any,
by putting one side under press.
Start up again.
If the unit is still leaking, check all plates
with a dye penetrant!

98.20 - ES0