1. D.SURESH SR.MGR. (MECH.) DONIMALAI.

2. TROUBLE SHOOTING 1. It is applicable in day to day life at any where any time without knowingly you would have solved the problem. 2. For trouble shooting some common sense and some basic knowledge is essential other wise instead of solving the problem will be creating another problem.

3. TROUBLE SHOOTING IN ENGINES. LISTION THE PROBLEM CAREFULLEY. CHECH OIL AND COOLENT LEVEL AND START ENGINE THEN OBSERVE SMOKE, SOUND IF THE ENGINE CAN START. ATTEMPT SIMPLE THINGS FIRST. DO NOT THINK ABOUT BIG WORKS FIRST. CHECK ANY WORKS CARRIEDOUT BEFORE THIS PROBLEM RISES. CHECK PERIODICAL MAINTENANCE IS DUE IF SO THINK ANY LINK TO THIS PROBLEM.

4. HEAVY SMOKE IN ENGINE OBSERVATION 1. BLACK SMOKE 2. WHITE SMOKE 3. BLUEISH SMOKE 4. CLEAR SMOKE

5. SYMPTOMS DUE TO Black smoke:- More fuel consumption, Diesel smell in smoke, engine not taking load. White smoke:- Radiator coolant level decreasing, engine cold boiling. Bluish smoke:- More lubricating oil consumption, More blow-by. Clear smoke:- Less fuel consumption, less engine rated speed, engine not taking load.

6. REASONS BLACK SMOKE WHITE SMOKE BLUEISH SMOKE CLEAR SMOKE BARELY VISIBLE EXCESS FUEL BURNING WATER BURNING LUB OIL BURNING LESS FUEL BURNING HEALTY SMOKE

7. TO BURN 1 GALLON OF FUEL 1250 TO 12500 GALLON OF AIR REQUIRED.

8. BLACK SOMKE IS DUE TO IMPROPER BURNING OF FUEL.

9. MINOR TECHNICAL CHECKS. AIR SYSTEM FUEL SYSTEM 1. CHECK PRE CLEANER FOR AIR RESTRICTION. 2. CHECK AIR SUCTION PIPES AND HOSES FOR AIR RESTRICTION. 3. CHECK AIR CLEANER FOR CHOKE. 4. CHECK TURBO FOR PROPER FUNCTION. 1. CHECK FUEL RETURN LINE FOR CHOCK. 2. CHECK FUEL PUMP PRESSURE AS PER OEM CHART. 3. CHECK VALVE CLEARANCE AND INJECTOR SETTING. 4. CHECK INJECTOR AND FUEL PUMP PART NUMBER FOR SUITABILITY.

10. MINOR REPAIRS TO BE DONE. AIR SYSTEM FUEL SYSTEM 1. REPLACE AIR CLEANER ASSEMBLIES. 2. REPLACE TURBOCHARGER ASSEMBLY. 1. INJECTORS AND FUEL PUMP CALIBRATION OR REPLACEMENT.

11. INJECTION TIMING TO BE CHECKED. ENGINE CYLINDER LINERS AND RINGS TO BE REPLACED / TOP OVERHAUL.

12. PROGRESSIVE DAMAGES IF ENGINE RUNNING IN SAME CONDITION. 1. MORE FUEL CONSUMPTION AND LESS POWER. 2. DUE TO IMPROPER COMBUSTION CARBON DEPOSITION ON PISTON TOP (CROWN). 3. PARTIALLY BURNT FUEL (LIQUID CARBON) FLOWING THROUGH RINGS GAP TO OIL PAN. 4. DUE TO LIQUID CARBON (EMERY PAST)IN RINGS AND LINER GAP EARLY WEAR AND TEAR OF RINGS AND LINERS.

13. 5 DUE TO MORE GAP IN RINGS AND PISTON INCREASE IN BLOW-BY (5” TO 12” OF MURCURY) 6 SLEDGE FORMATION DUE TO MIXING OF CARBON FUEL AND OIL IN OIL PAN. 7 DUE TO SLEDGE IN OIL, OIL FILTER GET CHOCKED EARLY. 8 RESULTING LOW OIL PRESSURE, LESS OIL SUPPLY TO MAIN AND CONNECTING ROD BEARINGS. 9 DUE TO OIL STARVATION CRANK SHAFT SEIZER. 10 FINNALY ENGINE NEEDS COMPLETE OVERHAULING.

14. THANKING YOU.