Troubleshooting

Engine

Low Power Output

Possible Cause

Correction

Low Engine RPM

Adjust governor linkage to rest against the high idle

stop when accelerator pedal is depressed.
Adjust high idle rpm with adjustment screw.

Restriction in air inlet

system

Inspect air cleaner element and ductwork for

damage and excessive bends air turns.

Water in fuel

Drain fuel tank as needed to remove water.

Faulty shut-off solenoid

Remove solenoid and start engine to see if it has full

power. If there is full power, replace solenoid and/or
adjust linkage.

Misfiring and Rough Running

Possible Cause

Correction

Air in fuel system

Bleed air from lines.

Valve clearance
incorrect

Adjust intake and exhaust valves to specifications.

Fuel injection timing

incorrect

Check and adjust if necessary

Automatic timing
advance malfunction

Check for correct timing, if a timing light is not

available, check for smooth acceleration from low to
high idle. Replace timing mechanism if defective.

Misfiring and Rough Running

Possible Cause

Correction

Defective fuel nozzles

Locate misfiring injector; clean and service.

Engine valve leaking,

worn, or damaged
pistons and/or rings,
worn or damaged
cylinder liners

Check leakage with compression pressure tester.

Fuel leakage at nozzle

nut or adapter

Tighten nut to specifications.

Black or Gray Smoke (Engine runs smooth)

Possible Cause
High altitude operation at
762m or higher

Correction
Adjust fuel injection amount.

Dirty air cleaner

Replace dirty air cleaner element.

Air inlet system

restriction

Inspect air cleaner element and ductwork for

damage and excessive bends and turns.

Exhaust system
restriction

Inspect system piping and muffler. Locate and

correct source of any restriction.

Black or Gray Smoke (Engine runs smooth)

Possible Cause
Fuel injection timing
incorrect

Valve adjustment
incorrect

Leaking fuel nozzles

Correction
Check and adjust if necessary.

Adjust intake and exhaust valves clearance

Locate misfiring injector and clean and service as

required

Black or Gray Smoke (Engine runs rough)

Possible Cause
Misfiring cylinders

Automatic timing
advance malfunction

Air in fuel system

Correction
See misfiring and rough running.

Check for correct timing. If light is not available,

check for smooth acceleration from to high idle.

Check for leaks and bleed air from system.

White Smoke
Possible Cause
Cold outside
temperatures

Correction
Normal condition until engine warms to operating
temperature, as not all fuel is burning.

Long idle periods

Reduce unnecessary idling or use fuel heating

system

Air in fuel system

Check for leaks and bleed air from system.

Fuel injection timing

incorrect

Check and make necessary adjustments.

White Smoke
Possible Cause
Automatic timing
advance malfunction

Correction
Check for correct timing. If light is not available,
check for smooth acceleration from to high idle.

Valve adjustment
incorrect

Adjust intake and exhaust valves clearance

Bad fuel nozzles

Locate misfiring injector. Clean and service

Misfiring cylinders

See misfiring and rough running

Blue Smoke
Possible Cause

Correction

Engine oil level too high

Do not overfill crankcase. Check oil for fuel dilution.

Worn valve guides

Check for maximum permitted wear and service as

needed.

Worn piston rings and/or

cylinder walls

Check cylinder compression and leakage. Visually

inspect piston rings and cylinder walls.

Worn or damaged
pistons

Check piston ring to groove clearance. Make sure

return holes under oil control rings are open

Excessive Fuel Consumption

Possible Cause

Correction

External fuel system

leakage

Check fuel system external piping and tubing for

signs of leaks. Repair as needed.

Fuel injection timing

incorrect

Check and make necessary adjustments.

Leaking fuel nozzles

Locate leaking injector and service as required.

Fuel injection pump

calibration incorrect

Remove injection pump and nozzle assemblies from

engine. Check calibration and adjust.

Internal engine wear

Overhaul engine

Excessive Oil Consumption

Possible Cause
External oil leaks

Correction
Check engine for visible signs of leaks. Replace
defective parts.

Clogged crankcase
breather pipe

Remove obstruction

Worn valve guides

Replace valve guides

Internal engine wear

Overhaul engine

Engine Stalls at Low Speed

Possible Cause
Idle speed too low

Fuel tank vent plugged

Low fuel supply

Defective fuel injection

nozzle or pump

Correction
Adjust idle as required

Check vent arrangement and repair as required

Check tank for fuel. Check fuel lines or sharp bends
and restrictions. Check fuel pressure. If pressure is
low, replace fuel filters. If pressure is still low,
replace injection pump. Bleed fuel system.
Inspect, test, and replace nozzle parts or injection
pump

Hard to start(Crankshaft turns)

Possible Cause
Cold outside temperature

Air in fuel

Water in fuel

Low fuel pressure

Fuel injection timing
incorrect

Correction
Use starting aids.
Bleed air from lines.
Test for water in fuel. Drain fuel tank as need to
remove water. Install new fuel filter and fill tanks with
clean fuel.
Check leakage.

Check and adjust if necessary.

Hard to start(Crankshaft turns)

Possible Cause

Correction

Valve adjustment
incorrect

Adjust intake and exhaust valve.

Bad fuel nozzles

Locate misfiring injector and clean and service.

Low compression

See misfiring and rough running.

No exhaust smoke
visible while starting
Exhaust system
blockage

No fuel from injection pump due to cold weather

waxing or fuel line restriction. Faulty fuel injection
pump shut-off solenoid.
Loosen exhaust pipes at manifolds. If engine starts,
check for blockage or restriction in exhaust piping.

Hard to start(Crankshaft will not turn)

Possible Cause
Low or no battery voltage

Correction
Recharge battery or replace

Faulty relay switch or

wiring connection in
starting circuit

Check for voltage at switch connection on starter

solenoid. Repair as needed.

Bad starter solenoid

Replace

Bad starter motor

Repair or replace

Hard to start(Crankshaft turns slowly)

Possible Cause
Low battery voltage

Correction
Check voltage and recharge/replace battery as
needed.

Poor electrical
connections

Inspect, clean, and tighten electrical connections.

Lubricating oil too thick

Use proper grade oil for temperature conditions.

Bad starter motor

Repair or replace.

Extra outside loads

Check transmission.

Internal engine problem

Overhaul the engine.

Cooling System(Overheating)
Possible Cause
Low coolant level
Bad temperature gauge
Clogged radiator
Loose fan or water pump
belts
Bad hoses
Shunt line restriction

Correction
Check for leaks and repair as needed.
Inspect, repair or replace
Clean and flush radiator core.
Tighten to specifications.
Check for leaks and collapsed hoses
Check for restrictions from the radiator top tank to
the engine front-cover.

Cooling System(Overheating)
Possible Cause
Bad thermostat
Bad temperature gauge

Bad water pump

Air in cooling system

Correction
Test thermostat and replace as needed.
Inspect, repair or replace
Check for loose water pump pulley or impeller.
Remove pump and check for impeller damage and
proper impeller clearance.
Air can enter when coolant level is low combustion
gases ca also enter through cracks or a bad cylinder
head gasket

Cooling System(Overheating)
Possible Cause

Correction

Undersize fan, fan and/or

shroud in incorrect
position

Fan must be large enough to send air through most

of the radiator area. Fan and shroud must be
positioned as specifications

Undersize radiator

Fuel injection timing

incorrect

Make certain radiator is sized to specifications.

Check and make necessary adjustments.