Mechanical Diesel Engine / Common Failure Analysis

[Bearing 1 of 2]
Bearing is one of the important parts for troubleshooting mechanical failure of diesel engine because engine operates all the time with the
bearing to withstand presuure and lubricate in all rotating parts (It may not cover all the possible causes to check on the mechanical engine,
but you can refer to below possible causes to troubleshoot the diesel engine mechanical problems)

Scoring / Embedded

Possible Causes
Metal chips or debris contamination
Extended oil maintenance interval
Improper cleaning of the engine and parts prior to assembly

Corrective Action
Find the source for contamination
Maintenance Oil and filters

Seizure / Hot Short

Possible Causes
Insufficient lubrication / clearance
Clogged Oil Passage
Oil level or oil pressure too low
Blocked oil filter
Overheating phenomena, such as discolouration, offten occur together with seizure

Corrective Action
Find the source for oil starvation such as pump or external/internal leak

Technical Publication & Training Part

Doosan Infracore Global R&D Center
 Mechanical Diesel Engine / Common Failure Analysis
[Bearing 2 of 2]
Bearing is one of the important parts for troubleshooting mechanical failure of diesel engine because engine operates all the time with the
bearing to withstand presuure and lubricate in all rotating parts (It may not cover all the possible causes to check on the mechanical engine,
but you can refer to below possible causes to troubleshoot the diesel engine mechanical problems)

Corrosion

Possible Causes
Coolant in the oil
Oil dilution
Extended oil maintenance interval

Corrective Action
Find the source for contamination
Maintenance Oil

Acidic attack will be accelerated by high load/stress ; Engine bearings will be shown corrosive damage in the following order
Rod bearings
Piston pin bushings
Camshaft bushings
Main Bearings

Overloading

Possible Causes
Excessive Load to be exerted upon the bearings
Metal Fatigue

Corrective Action
Check the clearance of bearing assembly
Engine Horsepower is correct for the application

Technical Publication & Training Part

Doosan Infracore Global R&D Center
 Mechanical Diesel Engine / Common Failure Analysis
[Piston]
Piston is mostly working in tough condition that operate the engine by making changed reciprotating force to rotating motion of engine. It
would be main consequence for failure fuel system and/or timing problem (It may not cover all the possible causes to check on the mechanical
engine, but you can refer to below possible causes to troubleshoot the diesel engine mechanical problems)

Piston Melting

Possible Causes
Leakage of the nozzle
Incorrect Fuel Injection Timing
Incorrect Valve Timing

Corrective Action
Find the source to get too much heat inside of chamber
Warm up and Cool down time
ONLY Single Piston : Possible Nozzle or Valve Timing
Several Pistons : Possible Fuel Injection Timing

Piston Cracks in the crown

Possible Causes
Lack of piston cooling by piston cooling nozzle
Engine Brake Frequently Using OR Failure
Installation of pistons with incorrect bowl shape
Thermal Overload

Corrective Action
Find the source to prevent cooling to the piston

Technical Publication & Training Part

Doosan Infracore Global R&D Center
 Mechanical Diesel Engine / Common Failure Analysis
[Cylinder Liner]
Cylinder Liner is the wall which is used to radiate heat and make lubricate film to move piston up and down inside of it. It would be maintained
by coolant and/or operator behavior like idling time of machine (It may not cover all the possible causes to check on the mechanical engine, but
you can refer to below possible causes to troubleshoot the diesel engine mechanical problems)

Cylinder Liner Cavitation

Possible Causes
Lack of Coolant Additives (Coolant Maintenance Interval : 2YRS.)
Used Tap Water
Used Radiator Cap with Low Oil Pressure

Corrective Action
Maintenance for Coolant Additives in Coolants
Short Idle Time

Cylinder Liner Scuffing

Possible Causes
Incorrect installation of piston rings
Carbon stuck on piston crown

Corrective Action
Short idle time to prevent building the carbon soot on the crown
Piston Ring Installation Check and Replacement if it needed

Technical Publication & Training Part

Doosan Infracore Global R&D Center