M13_ICE Internal Combustion Engine

Engine Troubleshooting Guide - Lubrication System

Complaint Possible Causes Remedy
Low lubricating Oil leak-line gasket etc check oil level and top up as required. Oil must be
oil pressure Insufficient lube oil level be to recommended specs. Check for oil leaks

Wrong oil viscosity Drain lubricating oil. Change oil filters and fill with
oil meeting specifications

Defective oil pressure Check operation of oil gauge. If defective, replace

gage gauge

Dirty oil filter(s) Check operation of bypass valve for the filter.
Install new oil filter elements. Clean or install new
oil cooler core. Drain oil from engine and install oil

Lubricating oil diluted Check fuel system for leaks. Repair if necessary.
with fuel oil Drain diluted lube oil. Install new filter elements
and fill crankcase with recommended oil

Defective oil pump relief Remove valve check for seat condition and sticking
valve relief valve spring tension and cap. Check assy parts
The use of incorrect parts will result improper oil
pressure. Repair or install new relief valve
 M13_ICE Internal Combustion Engine
Engine Troubleshooting Guide - Lubrication System
Complaint Possible Causes Remedy
Low lubricating Excessive clearance Overhaul engine and replace worn/defective parts
oil pressure between crankshaft and
bearings

Excessive oil External oil leaks Check engine for visible signs of oil leakage. Look for
consumption loose/stripped oil drain plug, broken gaskets
(cylinder head cover etc), front and rear oil seal
leakage. Replace all defective parts

Clogged crankcase Remove obstruction

breather/pipe

Excessive exhaust Check exhaust pressure and make necessary

black pressure corrections

Air compressor passing Repair or replace air compressor

oil

Failure of seal rings in check inlet manifold for oil and make repairs as
turbocharger necessary

Internal engine wear Overhaul engine

 M13_ICE Internal Combustion Engine
Engine Troubleshooting Guide - Cooling System
Complaint Possible Causes
Loss of coolant Leaking pipe plugs, eg core plugs, which seal off coolant passages. Core hole
due to external plugs are sometimes loosened by corrosion or vibration
leakage
Loose clamps, faulty hose and piping

Leaking radiator or cab heater core

Leaking radiator deaeration top tank or surge tank

Leaking gaskets due to improer tightening of capscrews, uneven gasket

surfaces, or faulty gasket installation

Leaking drain cocks

Leaking water pump. Badly worn of deteriorated seals are the cause of leaks
at the pumps. Premature failure of the pump seals often result from suspended
abrasive materials in the cooling system, excessive heat from lack of coolant or
cavitation

Leaks at engine or air compressor cylinder heat gasket

 M13_ICE Internal Combustion Engine
Engine Troubleshooting Guide - Cooling System
Complaint Possible Causes
Loss of coolant Leaks at upper cylinder liner counterbore
due to external
leakage Leaking engine or auxilliary oil cooler

Leaking air intake aftercooler (intake air heater in some cases)

Leaking coolant-cooled exhaust manifold

Leaking water manifold and/or connections

Loss of coolant Leaking engine or air compressor cylinder head gasket. Coolant passes into the
due to internal cylinders or the crankcase
leakage
Cracked engine or air compressor cylinder head. Coolant passes into the
cylinders and is blown out the exhaust or out the air compressor discharge

Deteriorated, severed or chafed liner packing; defective liner packing bore.

Cooling passes into the engine crankcase

Improperly seated or defective injector sleeves. Coolant can pass into the
cylinder or crankcasen and can enter the fuel system if it gets past the injector
body O-ring
 M13_ICE Internal Combustion Engine
Engine Troubleshooting Guide - Cooling System
Complaint Possible Causes
Loss of coolant Porous cylinder block or head casting. Coolant can pass into the crankcase via
due to internal holes in the cooling system jacket. In case of the cylinder heads having internal
leakage fuel passages, coolant can enter the fuel system via holes in the wall of the
fuel rifle, which adjoins coolant passages

Cracked or porous water coolant exhaust and faulty manifold to head mounting
gasket. Coolant passes into the cylinder or out through the exhaust system

Leaking engine air intake after cooler or intake air heater. Coolant passes into
the cylinders on naturally aspirated engine; also on turbocharted and super-
charged engines when the intake manifold pressure is less than the coolant
pressure

Engine overheating Poor circulation of coolant caused by collapse of soft hose and restriction

Overfuelling the engine

Radiator shutter malfunction or improper adjustment of the thermal controls

Incorrect adjustment or malfunction of variable pitch or modulating fans

 M13_ICE Internal Combustion Engine
Engine Troubleshooting Guide - Cooling System
Complaint Possible Causes
Engine overheating Crankcase oil level too high. Crankshaft dips in oil and causes a corresponding
increase in temperatures due to friction and parasitic load on the engine. Crank-
shaft oil dipping can also be encountered when operating engine beyond the
angles for which the oil pan was originally designed

Dirty engine exterior; heavy accumulation of dirt and grease can severely
hinder normal heat dissipation through the exterior walls of all the engine
components

Pressure of air in the cooling system. The following are the most common
causes of air entrainment:

a) low coolant level due to a leaking water pump or leaks at hose and coolant
accessories
b) Insufficient venting of the coolant system or plugging of vent lines
c) Leaking air intake aftercooler
d) Inadequate cooling system deaerating top tank. Allows air entrapement of the
coolant by failing to control the top level of coolant
e) Leaking engine or air compressor cylinder head gasket
f) Improperly seated injector sleeves (where applicable)

Improper fanbelt tension

 M13_ICE Internal Combustion Engine
Engine Troubleshooting Guide - Cooling System
Complaint Possible Causes
Engine operating An altered horpower rating of an engine or new engine installation, which exceed
too hot or over- the original design of the cooling system or the equipment
heating when
loaded and coolant Clogged radiator air passages
is known to be at the
proper level Dmaged radiator core fins

Heat exchanger element, which contains heavy lime and scale deposits

Thermostat not opening fully

Fan shrouding missing, damaged or improperly positioned w.r.t. the fan

Recirculation baffles on the sides of the radiator missing or damaged

Fan drive belts slip. Impeller slips on the water pump shaft

Excessive heat load from the torque converter operating below 0.3 speed ratio

Clogged coolant passages, radiator and engine

 M13_ICE Internal Combustion Engine
Engine Troubleshooting Guide - Cooling System
Complaint Possible Causes
Engine operating Faulty automatic radiator shutters. Shutter only open paritally or open too late
too hot or over-
heating when Faulty thermatic or modulate fan drive. Fan engages too later or operates too
loaded and coolant slowly
is known to be at the
proper level Faulty variable pitch fan. Fan operates with the blades at an insufficient pitch

Engine coolant Thermostat stuck in open position or malfunctions to allow premature opening
temperature too low
Thermostat seal lip deteriorating and hardening, allowing the coolant to bypass
the closed thermostat and enter the radiator, heat exchanger or keel cooler

Excessive bypassing of coolant to the radiator or heat exchanger with the

thermostat closed and properly sealed

Engine exposed to very low temperature and high wind with a low load factor
 M13_ICE Internal Combustion Engine
Engine Troubleshooting Guide - Fuel System
Complaint Possible Causes Remedy
Engine misfiring Poor qualilty fuel Drain fuel from tank. Install new fuel filters and fill tank
Water or dirt in fuel with recommended diesel fuel

Air in fuel system Check system for air leaks and rectify. Air will
generally get into the fuel system on the suction side
of the fuel transfer pump

Broken or leaking high Check for fuel leaks and replace defective parts
pressure fuel lines

Restrictions in fuel Check for fuel flow. If no flow, replace lines

lines /drain lines

Low fuel supply Check to be sure that there is fuel in fuel tank. Look
pressure for leaks or sharp bends or kinks infuel line between
fuel tank and fuel transfer pump, also clogged suction
pipe in tank and plugged fuel suction hose. Look for
air in the system. Check fuel pressure, if lower than
specified, change filters and recheck. If still low,
replace or repair transfer pump.

Improper valve lash Check and make necessary adjustment

 M13_ICE Internal Combustion Engine
Engine Troubleshooting Guide - Fuel System
Complaint Possible Causes Remedy
Engine stalling Idle speed too low Check idle setting and make the necessary
speeds adjustments

Fuel tank vent plugged Check vent arrangement and make necessary repairs
or partly plugged

Low fuel supply Check to be sure tank is in fuel tank. Look for leaks,
sharp bends or dents in the fuel supply lines. Check
for air in fuel system. Check fuel pressure, it must be
within the recommeded specs. If not, check filters,
replace, transfer pump

Injection pump overflow Repair or replace valve

valve leaky, stuck open
or closed

Defective fuel injection Isolate defective fuel injection nozzle and replace
nozzle

Defective fuel injection Remove injection pump. Test and make repairs as
pump required. Reinstall pump
 M13_ICE Internal Combustion Engine
Engine Troubleshooting Guide - Fuel System
Complaint Possible Causes Remedy
Erratic engine Air leaks in fuel suction Check for air leaks and make rectifications as required
speed line

Throttle linkage loose or Check for air leaks and adjust accordingly
out of adjustment

Injection pump governor Remove injection pump and look for damaged or
failure broken springs or other components. Check for correct
governor spring. Install new parts in place of those
having damage or defects. Recalibrate injection pump
and install

Engine not Air in fuel system Check system for air leaks and remedy. Air will
reaching no-load generally get into the fuel system on suction side of
governed rpm fuel transfer pump

Accelerator linkage loose Cheak all linkage and adjust accordingly

or out of adjustment

Restricted fuel lines / Check flow in fuel and overflow valve for defective
stuck overflow valve spring, poor valve, valve setting or sticking. Adjust as
necessary
 M13_ICE Internal Combustion Engine
Engine Troubleshooting Guide - Fuel System
Complaint Possible Causes Remedy
Excessive smoke Broken outlet line to air Check and replace broken/faulty air line
during cylinder
acceleration
Plugged or broken Check and replace broken or faulty air line
pressure-sensing line

Inoperative air cylinder Check operatin of air cylinder; replace if defective

Air cylinder improperly Remove air cylinder and check operation, dimension
shimmed and shim pack. Make corrections and install injection
pump

Defective or stuck Correct sticking or replace valve

reversing relay valve

Excessive black Insufficient air for Check for air cleaner restrictions. Check inlet manifold
or gray smoke combustion pressure and inspect turbocharger for correct
operation. Make necessary repairs

High exhaust back Check for faulty exhaust piping or muffler obstructions.
pressure Repair/replace defective parts
 M13_ICE Internal Combustion Engine
Engine Troubleshooting Guide - Fuel System
Complaint Possible Causes
Excessive black High idle adjustment set
or gray smoke too low
Internal fuel pump
governor wear
Fuel injection pump
calibration incorrect
Air leaks in the air supply
line or defective control
valve
Remedy
Check high idle adjustment. Adjust as necessary
Remove injection pump from engine. Make all
necessary repairs, recalibrate and install on engine
Remove injection pump and nozzle asemblies from
engine. Check calibration. Make necessary adjustment
and install on engine
If the air supplly to the transmission or air line from the
transmission to the fuel injection pump governor leak,
the maximum engine rpm would automatically be
restricted for all load conditions. Check all connecting
hoses and make necessary repairs. Replace control
valve if required
 M13_ICE Internal Combustion Engine
Engine Troubleshooting Guide - Air Intake System
Possible Causes

- Dirty air cleaner element

- Plugged crankcase breathers

- Air cleaner element missing, leaking, not sealing correctly. Loose connections to turbocharger

- Collapsed or restricted air tube before turbocharger

- Restricted-damaged crossover pipe turbocharger to inlet manifold

- Foreign object between air cleaner and cleaner and turbocharger

- Foreign object in exhaust system (if from engine, check engine)

- Turbocharger flanges, clamps or bolts loose

- Inlet manifold cracked; gaskets loose or missing; connections loose

- Exhaust manifold cracked, burned, gaskets loose, blown, or missing

- Restricted exhaust system

 M13_ICE Internal Combustion Engine
Engine Troubleshooting Guide - Air Intake System
Possible Causes

- Oil lag (oil delay to turbocharger at start-up)

- Insufficient lubrication

- Lubricating oil contaminated with dirt or other material

- Improper type lubricating oil used

- Restricted oil feed line

- Restricted oil drain line

- Turbine housing damaged or restricted

- Turbocharger seal leakage

- Worn journal bearings

- Excessive dirt buildup in compressor housing