AJAX Engine Troubleshooting Guide

Effect
(1)
Engine will not fire

Cause

(2)
Lubricator fails to pump

(3)
Excessive crankcase oil
consumption

(4)
Racing or irregular operation

(5)
Detonation or pinging

Electrical & Ignition Systems.

- Check spark plug gap.
- Check Altronic Ignition.
- Check timing.
- Check for incorrect ignition coil.
- Shutdown switch grounding out ignition.
Fuel System
- Faulty gas regulator.
- Linkage between governor and throttle valve set improperly.
- Fuel pressure to high or to low.
- Fuel pressure to tank shut off.
- Volume tank filled with fluid.
- Air in hydraulic system.
- Regulator flow off or to small orifice.
- Needle bypass valve open.
- Injection valve not adjusted properly.
- Improper hydraulic fluid in injection system.
Air Intake & Exhaust Systems
- Air cleaner plugged.
- Air flow restricted.
- Reed valve (s) broken in air mixing valve.
- Blind gasket between exhaust flange & cylinder not removed at installation.
Mechanical
- Lack of compression due to cylinder / piston / rings.
Air lock in lubricator pump.
Check valves to the cylinders plugged.
Faulty check valve in lubricator.
No /Low oil level in lubricator box.
Lubricator drive failure.
Lubricator pump suction strainer plugged.
Oil level to high.
Worn stuffing box packing.
Scored piston rod.
Air filter plugged.

Note: When the lubricator and crankcase are both connected to the auxiliary oil supply,
check to ensure that the excess oil consumption is not a result of excess oil through the
lubricator.

Improper sparkplug gap.

Gas volume tank too small.

Faulty gas regulator.

Governor binding / sticking.

Throttle valve binding / sticking.

Worn connection in governor linkage.

Excessive backlash between layshaft drive & driven gears.

Overloading.

Oil used in power cylinder is too light and is burning.

Fuel gas pressure to high.

Wet fuel.

High ambient air temp.

Ignition timing too early.

Fuel / Air mixture to rich.

Air filter plugged.

Inadequate fuel anti-knock properties.

AJAX Engine Troubleshooting Guide (cont.)

Effect
(6)
Knock in engine.

(7)
Engine slows down. (while firing
regularly)

(8)
Engine will not pull load.

(9)
Over heating.

(10)
Excessive carbon deposits in ports
and rings.
(11)
Hot main or crank pin bearings.

(12)
Burning of engine piston.

(13)
Engine backfiring.

(14)
Engine out of balance.

(15)
Cylinders will not stay balanced.

Cause

Restriction of air through the air cleaner.

Fuel gas pressure to high.
Wet fuel.
Air / fuel mixture to rich.
Injection valve adjusted to far closed.
Improper timing.
Loose crank pin bearings or crosshead pin bearings.
Excessive load.
Piston & rings sticking due to improper lubrication.
Hot bearings.
Intake / exhaust ports carboned up.
Insufficient fuel system.
Faulty ignition coil.
Excessive load.
Fuel pressure too low.
Improper air / fuel mixture.
Throttle valve linkage improperly adjusted.
Volume bottle and/or fuel line regulator & orifice in regulator improperly sized.
Loss of compression due to worn or stuck rings.
Improper timing.
Intake / exhaust ports carboned up.
Exhaust pipe improper size / length.
Air cleaner plugged.
Muffler to small or carboned up.
Muffler baffles collapsed.
Excessive load.
Improper exhaust pipe length.
Air filter plugged.
Muffler or exhaust ports pugged.
Air passage through the cooler restricted.
Recirculation of hot air through the cooler.
Improper timing.
Cooler plugged.
Ports and rings carboned up.
Entrained liquids in the fuel gas.
Entrained liquids in the fuel gas.
Lubricator feed rates to power cylinders set too high.
Leakage of crankcase oil through the piston rod oil wiper packing.
Oil too heavy or used too long.
Water in oil.
Crankcase oil level too low.
Insufficient bearing clearance given after an inspection or overhaul.
Gas pressure too high.
Air / fuel mixture too rich.
Excessive carbon deposits.
Oil in lubricator to high.
Improper timing.
Replacement alternator, wrong design.
Excessive carbon deposits in ports.
Fuel gas pressure too high.
Reed valves in air mixing valve.
Fuel injection valves incorrectly adjusted.
Sparkplugs fouling and/or ignition problems.
Intake / exhaust ports carboned up.
Improper hydraulic fluid.
Injection valve stem not lubricated.
Leaks in the hydraulic system.
2

AJAX Engine Troubleshooting Guide (cont.)

Effect
(16)
Engine stops running

(17)
Injection valve stays open.

(18)
Higher fuel pressure than
recommended needed to pull load.

(19)
Muffle glowing red.

Cause

Excessive sparkplug gap.

Air cleaner plugged.
Faulty ignition.
Excessive load.
Loss of fuel gas pressure.
Fuel regulator frozen.
Safety switch grounding out ignition.
Broken sparkplug wire (s).
Loose valve seat in injection valve.
Injection valve stem not lubricated.
Fuel gas pressure too high.
Valve spring weak or broken.
Insufficient fuel system.
Regulator to small or equipped with the wrong orifice.
Regulator spring wrong size.
Volume tank too small or the pressure drop across between the tank and throttle valve
too great.
Plugged muffler.
Excessive load.
Over-fueling.
Using oil with too high flash point.
Defective fuel gas regulator.