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VI. Component Failure Analysis

Fuel System

Nozzle Holder component failure

Description:

Broken coil on the holder spring directly

related to large amounts of carbon build

up on the nozzle spring. Carbon build-up

can also be seen on the push rod. This

condition is directly related to combustion

gases passing through the nozzle holder

spring chamber. Problem can be avoided be

routine inspection of the nozzles.

Description:

Broken coil due to oxidation caused by

moisture or high sulfur content in the fuel.

Condition can be prevented through routine

inspection of the fuel and filter.

Description:

Sulfuric acid corrosion at the pintal caused

by high sulfur content in the fuel. This is a

result of water reacting with the sulfur to

form sulfuric acid.

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Содержание 4IRJ7N

Страница 1: ...e to Ingersoll Rand Company or use of trademarks service marks logos or other proprietary identifying marks belonging to Ingersoll Rand Company in this manual is historical or nominative in nature and is not meant to suggest a current affiliation between Ingersoll Rand Company and Doosan Company or the products of either Revised 10 12 ...

Страница 2: ...g 22 III Engine Servicing Procedures Oil Filter Change 23 Injection System Air Bleeding 24 Spill Port Timing 25 26 Valve Adjustment 27 Injector Service 28 30 Injector Pop Off Test 31 Injector Leak Test 32 Glow plug Inspection 33 IV Engine Repair Specifications 4IRJ7N 34 35 V Component Failure Analysis 36 40 VI Appendix Misc Service Information Turbo Diagnosis 41 Exhaust Temperature 42 Crankcase Pr...

Страница 3: ... and reassembly of the engine Section three is the engine service section which illustrates important information regarding fuel injection operation and routine fuel injection service items Section four provides a listing of some of the critical engine specifications A broad range of component failures are illustrated in section five This training manual outlines the important aspects of the repai...

Страница 4: ...iet Two stage injection pump cam Dampened crank pulley 8 counter balance crankshaft with a fine module gear Large mesh area on gear driven components Auto thermatic pistons that reduce engine noise at start up and after warm up Small size Overhead valve to reduce engine height Full siamese engine block design reduces length Ease of Maintenance All service points of engine are placed on the same si...

Страница 5: ...e 4IRJ7N engine use a gear driven in line injection pump to supply fuel to the injection nozzles The injection pump is mounted to a cradle that is mounted to the engine block II Engine Component Description ...

Страница 6: ... flange on the back side of the timing gear case This drawing shows the relationship between injector pump cam lift and cam angle when pre stroke length is changed The stroke length represented as L is always constant When the injection pump is advanced by moving the pump away from the block the timing sleeve is lowered sooner and the start of injection occurs at the beginning of the cam lift Conv...

Страница 7: ...port flows back into the fuel reservoir via the spill port hole Pump Injection Sequence Beginning of Injection As the plunger rises it blocks the spill port hole in the timing sleeve The plunger blocks the inlet port preventing additional fuel from entering the high pressure chamber It is during this transition that pressure inside the chamber begins to develop II Engine Component Description ...

Страница 8: ...zed fuel flows through the spill port and into the oil reservoir At this moment pressure in the chamber drops which ends the injection cycle Pressure Feeding Since the intake port and helix are kept closed by the timing sleeve fuel pressure continues to rise the delivery valve opens and fuel flows to the injector Pump Injection Sequence continued ...

Страница 9: ...for servicing by simply removing the shaft bracket fixing bolts The rocker shaft is oil pressure fed through a galley machined in the cylinder head This galley intersects with the main oil galley in the block to provide full pressure oiling to the rocker arms II Engine Component Description Valve Train ...

Страница 10: ...three marks 7 o clock lines up with crank s mark X XX 10 o clock lines up with camshaft gear Y YY 2 o clock lines up with idler gear Z ZZ The camshaft and injection pump gears each have an addition mark 0 for fuel injection timing IMPORTANT The initial timing of these gears is absolutely essential Due to the combination of different gear ratios the timing marks will not line up with their respecti...

Страница 11: ...haft bushing placement is critical The oiling hole must be placed in the 12 o clock position for proper lubrication With the central timing gear installed an oiling jet provides additional lubrication to the idler and injection pump gears mesh areas The idler gear that meshes with the injection pump gear has an oil passage drilled through the teeth to allow the oil from the center of the gear to f...

Страница 12: ...g cm 2 IR allows an 8 variance between neighboring cylinders on compression tests but there can be no more than a 15 difference between any two cylinders Letters A F represent the different measurements that need to be taken to determine head warpage Lower face warpage specifications Standard 0 05 mm 0 002 in Limit 0 2 mm 0 008 in Max Grinding Allowance 0 3 mm 0 0118 in Head Height Standard 91 95 ...

Страница 13: ...res The cylinder head gasket is available in three grades thickness identifiable by the punched Grade Mark The appropriate head gasket grade is selected according to the average measured piston projection A good rule of thumb is that unless you are machining the deck replace with the same grade thickness of gasket that came out During installation the TOP mark of the gasket must be facing up and n...

Страница 14: ...ine s serial number is stamped on the front of the engine block This number is used by parts technical personnel to track an engine s application or verify a specification Serial The engine block uses chromard cylinder liners that are removable for servicing ...

Страница 15: ...the letters on the piston s the pistons have been replaced The number stamped on the block deck is the liner grading referencing the outside diameter of the liner to fit the block The 4J block contains 5 main bearings The caps are identified as detailed below 1 1 2 2 3 3 Cast in cap 4 4 5 5 Cast in cap When installing the bearing caps ensure that the arrows face forward ...

Страница 16: ...four digits of that piston s part number The letter stamped in the piston should match the letter stamped on the block deck surface If it doesn t the piston has been replaced The 4IRJ7N engine uses replaceable cylinder liners A kit containing a new piston and liner is used when servicing engines under warranty This liner and piston kit needs to be sized according to the number stamped on the block...

Страница 17: ...onent Description Piston Ring Installation Piston rings are installed on the piston with the N mark facing up The piston ring gaps are placed 120 apart 1st top compression ring 2nd compression ring 3rd Oil control ring ...

Страница 18: ...orged steel I beam connecting rod is used NOTE When removing and replacing the connecting rod assemblies be sure to install the connecting rod with the Logo facing the same direction as the piston s notch Both of these should face the front of the engine ...

Страница 19: ...y balancing and help reduce crankshaft vibrations Certain 4IRJ7N engines are externally balanced with the use of weights on the crankshaft damper NOTE The dampers should NEVER be interchanged Excessive engine vibration and damage will occur IMPORTANT The crank is hardened using Tufftriding IR does not recommend grinding or polishing the crankshaft undersize Removal of the rear oil seal is achieved...

Страница 20: ...a conventional wet sump oiling system Internally the oil pump uses a single rotor instead of spur gears or a set of rotors The pump is mounted under the engine block and driven by the camshaft The journal oil feed routing is as follows Main Rod 1 1 2 2 3 Sump Screen ASM 4 3 5 4 ...

Страница 21: ...llowing valve opening pressures For the oil filter bypass valve Relief Valve 14 PSI is where the valve begins to open For the oil pump relief valve Regulating Valve 64 PSI is where the valve begins to open NOTE Conversions to above pressure specifications 20 kPa 2 9 PSI 98 kPa 14 21 PSI 441 kPa 63 96 PSI ...

Страница 22: ...n hot spots to the cooling system It is absolutely required that you use a low silicate formula anti freeze Do not add any additional water pump lubricants to the cooling system Refer to the Workshop Manual for radiator cap and cooling system testing and specifications Use a commercially available antifreeze tester when testing for coolant water mixture Testing for pH is recommended as too high an...

Страница 23: ... normal operating temperature 2 Loosen the oil drain bolt see arrow one full turn to allow the oil to drain out of the filter and down to the crankcase The time it takes to drain the oil from the oil pan is sufficient to thoroughly drain the filter 3 Once drained remove the drain bolt entirely and replace the O ring on the bolt which is supplied with each Genuine IR oil filter 4 Install the oil dr...

Страница 24: ...feed pump priming knob and prime up the system Loosen the air bleeding screws on the injection pump Pump the feed pump priming knob to force the air out of the system Once the air is bled tighten the bleeding screws Clean up any excessive spills Start engine and check for leaks ...

Страница 25: ... from the nozzle and fuel pump First clean the fuel pump to prevent any foreign materials to enter the pump Then remove the delivery valve holder from the injection pump Then disassemble the delivery valve holder to remove the valve and valve spring Replace the delivery valve holder Tighten to 29 33 Ft lbs Place the stop solenoid in the on or up position to allow full fuel flow Bring the TDC mark ...

Страница 26: ...n pump cradle bolts and all fuel lines from pump to injectors at both ends Pull the pump away from the block to advance the timing push towards the block to retard NOTE Refer to the proper specification sheet for timing adjustment information After spill port is performed be sure to reassemble all components and install correctly for proper operation Refer to appropriate Workshop Manual for proced...

Страница 27: ... or 4 This adjustment should not be made with the engine running Loosen the adjuster jam nut insert a 0 40 mm 0 016 feeler gauge in between the rocker tips and the valve stems to adjust the valves NOTE Proper adjustment is obtained when there is a slight drag against the feeler gauge Jam nut torque is 5 8 8 7 lbs ft 0 8 1 2 kg m Rotate the crankshaft 360 so that the opposing piston is now on its e...

Страница 28: ...carbon residue and carbon build up on the surface of the nozzle Soak all parts other than the nozzle in cleaning oil Use a soft wire brush to clean excessively dirty parts IMPORTANT Do not use metal or abrasive cleaning media to clean the nozzle holder Their abrasive nature will leave scars on the ground surface and may cause fuel leaks ...

Страница 29: ...e needle valve from the nozzle Clean the seat s surface and shaft section using the piece of hardwood from the cleaning kit or a clean soft cloth dipped in oil Likewise clean the spray hole Re wash the injector components to remove any final debris Reassemble the injector ...

Страница 30: ...on that could cause a fuel leak Insert the body nozzle holder to center the nozzle in the retaining nut For reassembly torque specifications see Appendix Nozzle Holder Tightening Standards NOTE Use a flare nut crowfoot socket on the torque wrench Install the nozzle assembly back into the head Tighten the retaining nut with a torque wrench to 29 36 lb ft 39 49 Nm ...

Страница 31: ...and pump the lever at a rate of one stroke per second Then check the opening pressure When the pressure gauge pointer decreases rapidly read pop off value Refer to engine s specification sheet for values An Indirect Injection will have lower readings than a Direct Injection engine IMPORTANT If the nozzle opening pressure is not steady or cannot be checked the trouble is with the nozzle assembling ...

Страница 32: ...zzle opening pressure adjustment check Wipe the nozzle with a clean shop towel Decrease the tester pressure about 20 kg cm 2 less than the pop off pressure and maintain the position There should be no fuel discharge from the nozzle for at least 10 seconds Re clean or replace any nozzle that doesn t meet the criteria ...

Страница 33: ...resistance value should be 0 9 ohms On engine service Remove the buss bar from the glow plug Attach the DVOM red lead to the to the tip of the glow plug Attach the DVOM black lead to a good ground source Verify the ground integrity by testing it with the DVOM Off engine service Disconnect and remove glow plug Place DVOM leads across glow plug one lead at each end to obtain resistance reading ...

Страница 34: ...d Maximum grinding allowance is 0 3 mm 0 0118 in Measurement is established by measuring from the head s sealing surface to the rocker bracket surface area Dimension taken from the cylinder head surface to the top of the valves Specification is for both intake and exhaust valves Refer to the Operation Maintenance Manual that came with the unit ...

Страница 35: ...35 IV Engine Repair Specifications 4IRJ7N Lubrication and Sealant Specifications During Installation of the rocker arm bracket be sure not to cover the rocker shaft oil passage ...

Страница 36: ...related to combustion gases passing through the nozzle holder spring chamber Problem can be avoided be routine inspection of the nozzles Description Broken coil due to oxidation caused by moisture or high sulfur content in the fuel Condition can be prevented through routine inspection of the fuel and filter Description Sulfuric acid corrosion at the pintal caused by high sulfur content in the fuel...

Страница 37: ...hamber Description Nozzle seat damage caused by metal contaminants in the fuel that pressed onto the seat area The condition can cause leaks or distorted spray patterns from improper nozzle seating Description Pintal valve abrasion caused by sulfuric acid This condition will cause the nozzle to stop functioning Description Foreign material build up on the nozzle seat surface This condition will ca...

Страница 38: ...ole sections when the nozzle holder is over tightened Description Damaged head gasket cylinder head pistons connecting rods and crankshaft caused by poor cylinder block casting cooling system cavitation or cooling system electrolysis Description Low oil pressure readings or premature engine bearing wear due to missing internal oil galley plugs ...

Страница 39: ...e piston to wall clearance Creates piston slap sound Description Seized piston skirt due to insufficient piston to wall clearance a k a piston galling Description Failed piston due to lack of oil in the engine at the time of failure Heat failure can be identified by 4 point scoring resulting in vertical scoring on the sides of the pin boss on both sides of the piston ...

Страница 40: ...40 VI Component Failure Analysis Piston Failure Description A wrist pin seized in this bore due to a previously used bent wrist pin or damaged piston pin bore Description Normal piston skirt wear ...

Страница 41: ...leaking gaskets 4 Check the intake and exhaust systems for restriction i e dirty air cleaner collapsed hose or crushed exhaust pipe 5 Check the fuel system i e air in the fuel dirty fuel inlet screen rock stopper dirty fuel filter contaminated fuel or reduce fuel delivery to the injection pump 6 Check the valve clearance adjustment 7 Check the injection nozzles i e popping pressure spray pattern o...

Страница 42: ...l Pressure should never measure more than 2 in The manometer pickup tube is inserted into the oil level gauge tube from which the level gauge has been removed Do not insert the tube into the oil Do not attempt to seal engine openings The reading is taken with the engine operating at rated output Inlet Manifold Pressure Boost Pressure Test Boost pressure is to be measured with a mercury manometer A...

Страница 43: ...ax B Heptane Insoluble Wt 3 max Resin Insoluble Wt Reference 1 max Ash Sulfate Wt Reference 0 5 max Diesel Fuel Content Wt 5 max Water Content Wt 5 max Worn Metal particle Fe PPM 150 Worn Metal particle Cu PPM 50 Worn Metal particle PB PPM 50 Worn Metal particle Cr PPM 20 or 80 Cr plated liner Worn Metal particle Al PPM 20 40 Worn Metal particle Si PPM 20 Based on testing a new oil sample of exact...

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