Troubleshooting Engine

1Troubleshooting
SAFETY INSTRUCTIONS
WARNING
AVOID DEATH OR SERIOUS INJURY
Instructions are necessary before operating or servicing
machine. Read and understand the Operation &
Maintenance Manual and signs (decals) on machine. Follow
warnings and instructions in the manuals when making
repairs, adjustments or servicing. Check for correct
function after adjustments repairs or service. Untrained
operators and failure to follow instructions can cause death
or serious injury.
DX225LCA Troubleshooting
4-1
ENGINE
ENG01 Engine Start Fault .................................................................................................4-332
ENG02 Graphite Generated ..............................................................................................4-336
ENG03 Excessive Engine Oil Consumption ......................................................................4-340
ENG04 Abnormal Engine Knocking Noises.......................................................................4-342
ENG05 Low Engine RPM for Operation Mode ..................................................................4-344
ENG06 Coolant Reduction and Mixture with Engine Oil....................................................4-347
ENG07 Fuel Mixed with Engine Oil ...................................................................................4-348
ENG08 Engine and Coolant Overheated...........................................................................4-353
4-331
ENG01 Engine Start Fault
Failure Engine Start Fault
• For troubleshooting, refer to E2 on how to diagnose and resolve failures with
the electrical system.
• If an EPOS error code is displayed on the gauge panel, start troubleshooting
Related Information the part indicated first.
• Have a dialog with the customer before inspecting (about the operation time,
time of failure occurrence, whether the failure occurred after replacing parts or
taking measures, etc.)
No. Cause Procedure, Measuring Location, Criteria and Remarks

Battery 1. Turn starting switch to "OFF" position and check that battery disconnect switch
Disconnect is in "ON" position.
Switch and
2. Be ready with starting switch at "OFF", then perform troubleshooting without
1 Battery Voltage
turning starting switch to "ON" position.
Level Check
During Engine Reference
Battery voltage (2 pieces)
Cranking voltage: 24 V
1. Check the battery relay 
(Positions: R01, R02)
• Refer to E2
2. Check the interconnectors. on how to
Loose Terminal
or Open Circuit • H05 and H12 troublesho
2 At Terminal  ot failures
• H03 and H38
(Inspect the • Reference
Interconnector) • E07 and H41 voltage:
24 V
• H02 and H33
• H17 and H35
Turn starting switch to "OFF" position  Turn starting switch to "START" position
and perform troubleshooting.
• Grating noise is heard from starter motor pinion. 
(When starting switch is turned to "START" position,
starting motor pinion is pushed out.)
Refer to E2 on
Defective • Starting motor pinion disengages during operation. how to
3 (When starting switch is turned to "START" position troubleshoot
Starting Motor
starting motor pinion is pushed out) failures with the
• Rattling noise is heard and starting motor does not rotate. starter relay.
(When starting switch is turned to "START" position,
starting motor pinion is pushed out) 
(Reference: Rattling noise is caused when starting motor
pinion is repeatedly pushed and pulled).
Troubleshooting DX225LCA
4-332
1. The warning display indicates that the air cleaner is clogged. 
If there is a warning indicated on this warning display, immediately stop
operating the machine and replace the part indicated.
2. To replace an element, check the paper filter for any folded part and the rubber
sealing condition as well as for deformation prior to re-assembling.
3. Never re-use a damaged part; in case of doubt, replace with a new one.
Outer element: Clean every 500 hours and replace every
2,000 hours
Checking the air
Malfunction of cleaner elements Inner element: Replace every 2,000 hours.
4
the Air Cleaner (if the machine is operated in a dusty workplace, clean it more
frequently than every 500 hours.)
1. The air cleaner indicator is displayed when an air cleaner
is clogged. This indicator prompts the user to clean or
replace the air cleaner. If it is on, ensure that the air
cleaner element is cleaned or replaced and confirm if the
Check indicator warning indicator is off.
2. Connector No.: S02
Check the voltage between EPOS CN2-17 Reference
(+) and ground (-) terminals. voltage: 24 V
1. Intake air heater mount does not warm up during Refer to E3 on
Defective Air preheating operation. how to
5 troubleshoot
Heater 2. When engine is preheated or when temperature is low, or
failures.
the preheating monitor does not indicate it properly.
Clogged Fuel Check how long the fuel filter has been used. If the replacement Replacement inte
6
Filter Element interval is exceeded, the fuel filter element may be clogged. rval: 500 hours
If the spring pressure set for the valve gets weaker, the pressure of the fuel supplied
to the nozzle is reduced, the injection spray condition becomes poor, and the engine
Defective is not cranked normally.
7 Delivery Valve
• Valve's variable pressure: 20.4 bar (20.8 kg/cm2, 295.8 psi) spring constant (k):
(Injection Pump)
1.63 kg/mm
• Delivery valve holder tightening torque: 41.7 N.m (4.25 kg.m, 30.7 ft lb)
4-333
Pump and deliver more fuel than required by the diesel engine and always maintain
the fuel return line pressure constant during engine operation.
To maintain the performance of the fuel pump, a fuel pressure-regulating valve with
a spring incorporated is provided to respond actively to the changes in engine load
and maintain fuel pressure at a constant level.
The pressure on the delivery side
(injection pump discharge) is reduced.
1. Stuck open Tip: The pressure may be more severely
Defective reduced depending on the aging of the
8 Overflow Valve injection pump. Overflow relief
(Injection Pump) valve setting
The internal pressure remaining in the
injection pump increases. pressure: 
1.6 bar 
Tip: Consider factors including mixing with (1.6 kg/cm2,
the engine oil (injection pump lubrication), 23.2 psi)
2. Stuck closed difficulty generating high-pressure on the
delivery side, poor fuel injection due to the
back pressure at the fuel return line of the
fuel injection nozzle, and possibility of oil
leak of the fuel return line.
The performance of the fuel injection nozzle may affect the fuel consumption,
emissions, and power.
• When the fuel is supplied to the cylinder, the atomization performance affects
engine startability.
• The fuel injection nozzle tip may be clogged with particles as the filter fails to
filter out byproducts of post-combustion and pollutants contained in the fuel.
Fuel Injection • The fuel injection nozzle should be inspected every 200 hours.
9
Nozzle
1. If power is found to be continuously weak, inspect the
nozzle for inappropriate injection pressure or stuck Fuel injection
condition. nozzle pressure:
186 bar 
2. If power is not sufficient during acceleration, inspect the (190 kg/cm2,
nozzle injection pressure and injection angle for any 2,702.4 psi)
inadequacy.
Fuel injection nozzle locking nut torque 2.2 kg.m
4-334
If the piston's compression pressure drops below the specification, it may affect the
compression ignition of the diesel engine and cause engine start fault accordingly.
Cylinder compression pressure test
The low compression pressure of the (Engine temperature: 75 ~ 80°C)
cylinder may be caused by:
1. Valve closure fault or bent stem 28 bar (28 kg/
cm2, 398.3 psi)
2. Damaged valve spring Standard Value
Over (at 200
3. Leak of the cylinder head gasket rpm)
24 bar (24 kg/
4. Worn piston, piston ring, or liner Limit Value
cm2, 341.4 psi)
Checking the
• Compression pressure Different
Cylinder
10 checking interval: Every Between Each Within ±10%
Compression
1,200 hours Cylinder
Pressure
• Adapter for compression
pressure measurement:  (For information on measurement, refer
EU.2-0529 to the Operation & Maintenance
Manual.)
Compression pressure measurement.
1. Normal compression pressure: Specified pressure 27.5 bar 
(28 kg/cm2, 398.3 psi)
2. For example, if it is 23.5 bar (24 kg/cm2, 341.4 psi), which is below the
specification, the engine cylinder's compression pressure is reduced, and the
valve system, piston compression ring, and cylinder liner require inspection.
If the plunger is worn due to pollutants
Inspecting the
inside the FIP and moisture in the fuel, the
Worn plunger FIP plunger for
fuel injection pressure and fuel volume
wear.
decrease and cause poor startability.
• Feed pump piston tappet stuck Inspecting
Performance fault
• Poor adhesion of feed pump valve performance of
Mechanical of feed pump
11 surface FIP feed pump.
Factors in FIP
• Engine stop cable/stop lever stuck
• Inspect whether the FIP control rack Inspecting the
Engine stop cable is stuck engine stop
motor.
• Inspect where the FIP control rack is
located during start
4-335
ENG02 Graphite Generated
Failure Graphite Generated
• For troubleshooting, refer to "E2 Engine Start Fault (Starter Motor)" on how to
diagnose and resolve failures with the electrical system.
• If an error code is displayed on the gauge panel, start troubleshooting the part
Related Information indicated first.

Even when the country-specific fuel quality
requirements are met, use of fuel
Make sure that only the fuels specified
containing moisture and pollutants on the
1 Fuel Quality in the Operation and Maintenance
job site or stored in the customer's fuel
Manual are used.
tank may cause problems in the fuel
system for the machine.
1. Since an air cleaner element, if polluted, may limit the inlet air flow and cause
fumes to be emitted, check the outer and inner parts for pollution. (Inspect the
element not only when you see the air cleaner clogged indicator but also at
other times if needed.)
2. To replace the air cleaner element, check the paper filter for any folded part
and the rubber sealing condition as well as for any deformation prior to re-
assembling.
Outer element: Clean every 500 hours and replace every 2,000
Checking the hours
Defective Air air cleaner Inner element: Replace every 2,000 hours.
2
Cleaner elements (if the machine is operated in a dusty workplace, clean it more
• The air cleaner indicator is displayed when an air cleaner is
clogged, in which case the air cleaner element concerned
should be cleaned or replaced. Afterward, reset the indicator
and confirm if the warning indicator is off.
Check
indicator • Connector No.: S02
Check the voltage
between EPOS CN2-17
Reference voltage: 24 V
(+) and ground (-)
terminals.
4-336
If the spring set for the valve gets weaker, the pressure of the fuel supplied to the
nozzle is reduced, which prevents atomization and ignition and causes incomplete
combustion, increased fume emissions, reduced power, and other effects such as
the following:
1. Increased fuel consumption and fumes emitted from the machine
Defective 2. Reduced engine power and fuel efficiency
3 Delivery Valve
(Injection Pump) 3. Changes in the delivery valve spring preventing it from becoming closely
attached to the valve sheet surface, which causes reversed fuel flow, reduced
pressure, and re-startability.
• Valve's variable pressure: 20.4 bar (20.8 kg/cm2, 295.8 psi), 
spring constant (k): 1.63 kgf/mm
• Delivery valve holder tightening torque: 41.7 N.m (4.25 kg.m, 30.7 psi)
The performance of the fuel injection nozzle may affect the fuel consumption,
emissions, and power.
• When the fuel is supplied to the cylinder, the atomization performance affects
engine startability.
• The fuel injection nozzle tip may be clogged with particles as the filter fails to
filter out byproducts of post-combustion and pollutants contained in the fuel.
• The fuel injection nozzle should be inspected every 200 hours.
Fuel Injection
4 1. If power is found to be continuously
Nozzle
weak, inspect the nozzle for
inappropriate injection pressure or
stuck condition. Fuel injection nozzle pressure:
2. If power is not sufficient during 186.3 bar (190 kg/cm2, 2,702.4 psi)
acceleration, inspect the nozzle
injection pressure and injection angle
for any inadequacy.
Fuel injection nozzle locking nut torque 21.6 N.m (2.2 kg.m, 15.9 ft lb)
4-337
If the performance of the turbo charger is reduced, it may cause a lack of air inside
the combustion chamber as well as fumes during combustion.
Tip: Any negative pressure caused by the polluted air filter may exacerbate the turbo
seal damage.
1. Check the breather hose, blow
by hose for bending or clogging
(indicated by increased pressure
inside the engine)
2. Soldering of the turbo charger
Checking the oil supply to bearing (indicated by low oil level
the turbo charger. and reduced lubrication and
cooling effects)
Turbo • Oil leak lowers the oil
3. Checking the oil pressure (if too
charger oil pressure, and oil loss
low, it may cause abnormal wear
leak causes bearing
or soldering of the bearing; if too
soldering.
high, it may cause oil leak)
• Idling: 1.5 ~ 3.0 bar 
(1.5 ~ 3.1 kg/cm2, 21.8 ~
43.5 psi) or higher
• Preload: 3.0 ~ 5.5 bar 
Defective Air
5 (3.1 ~ 5.6 kg/cm2, 43.5 ~
Heater
80.0 psi)
• Check the cleanliness of the air
• Damaged turbine or cleaner.
Poor power compressor wings.
• Check the air hose for tear
or • Reduced inlet air (causing pollutants to enter).
acceleration flow in the turbo
charger. • Inspect the air cleaner for
extreme pollution or wet state.
Damaged turbine or
compressor wings.
Damaged turbo charger • Check the contact state of the
caused by exceeding the rotary part.
turbo charger's allowed
Abnormal • Check the rotor's rotary part for
max. RPM.
noises during imbalance.
acceleration • Turbine speed at
• Soldering state.
max. power: 
105,000 rpm • Check each assembly part for
laxity.
• Allowed max.
revolutions: 
127,500 rpm
Defective
6 Inspect the intake manifold pipe and intercooler for cracks.
Intercooler
4-338
Worn piston ring and wrong ring gap cause the engine oil to enter the cylinder and
burn engine oil that produces white fumes.
• If the gap between the cylinder and piston is too large, it causes piston slack
and heavy blowby gas; if it is too small, the piston and ring may be sintered.
• The piston ring does three things: air-tightening, heat conduction (compression
ring), and oil control (oil ring).
• The compression ring and oil ring prevent the combustion gas of the piston ring
from leaking and control the oil lubricating the space between the cylinder wall
and piston, respectively.
• To make sure the engine performs optimally over a long period of time and
maintains optimized performance, the cylinder block, liner, and piston to
assemble should have the same rating or engraved number. For the number
and location engraved, refer to the Operation & Maintenance Manual.
• Gap between the cylinder liner
and piston: 0.053 ~ 0.077 mm
• Gap between the piston ring and
Defective Piston
7 piston ring groove:
Ring
Standard Limit
Worn piston, piston ring, or liner Increased (mm) (mm)
piston gap due to worn piston or piston ring Top Ring 0.007 ~ 0.120 0.2
2nd Ring 0.050 ~ 0.085 0.15
Excessive oil consumption due to the large
gap between the cylinder liner and piston Oil Ring Gap 0.030 ~ 0.070 0.15
Damaged, stuck, or inappropriately • Piston ring gap

positioned piston ring
Standard Limit
• Piston ring assembly flyer No:
(mm) (mm)
T7621010E
Top Ring 0.25 ~ 0.45 1.50
2nd Ring 0.80 ~ 1.00 2.00
Oil Ring Gap 0.20 ~ 0.40 0.15
(For information on how to measure,

refer to the Operation & Maintenance
Manual)
This intentional gap helps the valve surface and valve sheet adhere together when
the temperature rises and the valve apparatus is expanded. It refers to the gap
between the valve stem end and rocker arm, and it may be adjusted with the
adjusting screw.
Valve gap fault and resulting cylinder compression fault and graphite generation
Checking the If the valve gap is changed, it affects the
8
Valve Gap timing of the valve opening and closing. If it
is too large, it causes noises and impact on Inlet and outlet valve gap: 0.4 mm
the valve apparatus. Therefore, it should (For information on how to adjust the
be kept at an appropriate level. valve gap, refer to the Operation &
Maintenance Manual)
• Inlet and outlet valve gap adjustment:
Every 50 hours
4-339
ENG03 Excessive Engine Oil Consumption
Failure Excessive Engine Oil Consumption
1. Engine oil may be reduced during the machine operation time due to:
• Gap between the piston ring and cylinder liner and inevitable oil
consumption in the engine (as it gets older, the piston ring and liner get
worn and increase oil vaporization).
• Blowby gas and oil vapor from explosion in the engine mix and get into
the inlet pipe via the PCV system.
• Oil leak via the valve stem seal (may be replaced).
• Engine oil leak caused by damaged turbo charger seal (as the engine oil
circulation system circulates engine oil with the turbo charger, the
Related Information damaged turbo charger seal causes oil leak and excessive engine oil
consumption).
• A damaged gasket, which is visually identifiable, must be immediately
replaced. (Note that leaking engine oil attached to the heated outlet pipe
area may cause fire.)
2. If an engine-related error code is displayed on the gauge panel, start
troubleshooting the error code first.
3. Have a dialog with the customer before inspecting (about the operation time,

1. Since an air cleaner element, if polluted, may limit the inlet air flow and cause
fumes to be emitted, check the outer and inner parts for pollution. (Inspect the
element not only when you see the air cleaner clogged indicator but also at
other times if needed.)
2. To replace the air cleaner element, check the paper filter for any folded part and
the rubber sealing condition as well as for any deformation prior to re-
assembling.
Outer element: Clean every 500 hours and replace every 2,000
Checking the hours.
Defective Air air cleaner Inner element: Replace every 2,000 hours.
1 elements
Cleaner (if the machine is operated in a dusty workplace, clean it more
• The air cleaner indicator is displayed when an air cleaner is
clogged, in which case the air cleaner element concerned
should be cleaned or replaced. Afterward, confirm if the
warning indicator is off.
Check • Connector No.: S02
indicator
Check the voltage
between EPOS CN2-17
Reference voltage: 24 V
(+) and ground (-)
terminals.
If the air filter is faulty, fine dust or pollutants that enter may wear out the cylinder
liner wall, which may allow blowby gas to increase.
Inspecting Increased blowby gas mixed with oil vapor may consume engine oil.
2
Blowby Gas • Inspecting the compression pressure and blowby gas volume.
Reference: Piston ring gap and cylinder compression pressure under "Engine
Start Fault".
4-340
Check the
cylinder head Inspect if there is oil leak between the cylinder block and cylinder head (with gasket)
3 gasket and as well as the cylinder head and cylinder head cover.
cylinder head • Refer to ENG6 Coolant Decrease and Engine Oil Corruption
cover for oil leak.
If the piston's compression pressure drops below the specification, it may affect the
compression ignition of the diesel engine and cause engine start fault accordingly.
The low compression pressure of the Cylinder compression pressure test
cylinder may be caused by: (Engine temperature: 75 ~ 80°C (167 ~
1. Valve closure fault or bent stem 176°F))
2. Damaged valve spring 28 bar
3. Leak of the cylinder head gasket (28 kg/cm2,
Standard Value
4. Worn piston, piston ring, or liner 398.3 psi) Over
Compression pressure checking (at 200 rpm)
interval: Every 1,200 hours 24 bar
Checking the Adapter for compression pressure Limit Value (24 kg/cm2,
Cylinder measurement: EU.2-0529 341.4 psi)
4
Compression Different
Pressure Between Each Within ±10%
Cylinder
(For information on measurement,

refer to the Operation & Maintenance
Manual.
Compression pressure measurement
1. Normal compression pressure: Specified pressure 27.5 bar (28 kg/cm2,
398.3 psi)
2. For example, if it is 23.5 bar (24 kg/cm2, 341.4 psi), which is below the
specification, the engine cylinder's compression pressure is reduced, and the
valve system, piston compression ring, and cylinder liner require inspection.
1. Check the breather hose, blowby
hose for bending or clogging
(indicated by increased pressure
inside the engine).
2. Soldering of the turbo charger
bearing (indicated by low oil level
Checking the oil supply to and reduced lubrication and
the turbo charger. cooling effects).
Oil leak and 3. Checking the oil pressure (if too
Defective Turbo • Oil leak lowers the
5 excessive low, it may cause abnormal wear
Charger oil pressure, and oil
consumption or soldering of the bearing; if too
loss causes bearing
soldering. high, it may cause oil leak).
• Idling: 1.5 ~ 3.0 bar 
(1.5 ~ 3.1 kg/cm2, 21.8 ~
43.5 psi) or higher
• Preload: 3.0 ~ 5.5 bar 
(3.1 ~ 5.6 kg/cm2, 43.5 ~
80.0 psi)
Check the valve 1. Inspect the current state of the valve guide and stem seal
guide and stem 2. Disassemble the cylinder head, check inside the valve guide, and check the
6 seal for stem seal for any damage
mounting and • For information on how to inspect the valve guide, refer to the Operation &
damage. Maintenance Manual.
4-341
ENG04 Abnormal Engine Knocking Noises
Failure Abnormal Engine Knocking Noises
• Engine knocking may cause metal noises, reduced thermal efficiency, increase
of wear and tear, piston damage (con-rod bushing wear) and decrease in
engine power when it occurs.
• Engine knocking is caused by delayed ignition and large amount of fuel
Related Information
injected during this time.

If the fuel injection, piston operation cycle, and valve timing are all correct, efficiency
increases. If not, engine power and fuel efficiency decrease, and engine vibration
and noise occur.
Wrong Timing • If metal powder is found in the oil pan and oil filter,
1 (Valve, Piston disassemble the engine and check the piston ring.
Interference) Worn piston rings or
cylinder • Check the cylinder's compression pressure.
(Refer to "Check Piston Ring Gap" and "Cylinder
Compression Pressure" in Engine Start Fault.)
Check the engine for any fault caused by improper valve gap when:
1. The engine does not maintain normal power;
2. The valve connection creates extreme noises; and
3. The fuel injection system is not faulty, but the engine generates abnormal
noises and vibration.
• The engine may have improper valve gap after a long period of use. If the
engine has been used for a long time, check the valve gap to maintain
engine power and prevent noises and vibration.
• For information on how to adjust and inspect the valve gap, refer to the
Operation & Maintenance Manual.
Inspecting
2 Adjusting the valve gap
Blowby Gas Specified inlet and outlet
• Adjust the gap while 0.4 ±0.02 mm
valve gap
the engine is cooled.
How to check the valve gap
Always check the valve gap at the piston's top dead point of the compression stroke.
In other words, measure the gaps of the inlet and outlet valves with the piston at the
uppermost point when the valves on both ends are closed.
• If the valve gap is too large: Noises, engine overheating, graphite, and push rod
bending occur.
• If the valve gap is too small: Compression gas leak causes faulty start,
abnormal cam & tappet wear, and valve system damaged.
4-342
• Inside the cylinder of the piston engine, the unburned part of the mixture of fuel
and air gets burnt quickly, causing abnormal increase of pressure and
temperature and special metal noises.
Abnormal
Cylinder • If the fuel is burned first in the cylinder, the temperature reaches an appropriate
3
Explosion and level to cause ignition. If ignition takes longer, however, knocking efficiency is
Combustion reduced.
• For diesel, use fuel with high cetane number to prevent ignition delay and
facilitate fuel injection.
4-343
ENG05 Low Engine RPM for Operation Mode
Failure Low Engine RPM for Operation Mode
• The engine RPM for the respective operation mode decreases over the entire
range.
• Due to its mechanical mechanism, the mechanical injection pump should be
Related Information reset on a regular basis if RPM drops. (TPS Calibration)

• Adjust the injection pump's low idle
• Check the positions of the control
RPM and high idle RPM adjusting
lever and stopper gap.
screw.
• RPM drops over high RPM and low
• Check the fixing screw condition of
RPM as well as the entire range.
the acceleration cable.
Wrong Timing • Check the cable for bending,
1 (Valve, Piston • If the cable has a fault, check the
interference, and damage.
Interference) engine control motor.
Check the RPM with the Starter Switch "ON" Power Mode "ON", and Auto Idle
"OFF".
• Low Idle RPM: 900 ±50 rpm
• High Idle RPM: 2,030 ±50 rpm
Check the injection pump governor
spring for change in tension. Check the governor's condition.
Inspecting
2 (Repair it in a shop capable of calibrating
Blowby Gas Check the injection pump governor the FIP performance)
tension lever & link for wear.
4-344
Control Lever & Stopper (High and Low RPM)
• Low RPM: Governor Lever Condition
Low Idle rpm Control Screw
High Idle rpm Control Screw
Control Lever
DS1602124
Figure 367
• High RPM: Governor Lever Condition

rpm Cable Control Nut Accelerate Cable
DS1602123
Figure 368
Idle Stop
Max Speed
Shut off Stop

Max
Stop lever
Starting Shut off
Governor Spring
Guide lever
Starting Shut off
Support Idle
Speed Spring
Tension lever
Perturbation Volt
Idle Speed Position

DS1602125
Figure 369
4-345
Governor Structure Diagram
Link
Guide Lever
Governor Spring
Tension Lever
Swivel Lever
DS1602126
Figure 370
4-346
ENG06 Coolant Reduction and Mixture with Engine Oil
Failure Coolant Reduction and Mixture with Engine Oil
• If the coolant is reduced and mixed with the engine oil, the existing coolant line
runs out of coolant and sharply reduces the engine cooling effect.
• When the engine oil is mixed with the coolant, it also loses its lubricating effect,
causing rapid internal wear and deformation of the piston, piston ring, and
Related Information
engine head inside the cylinder.

1. The compression gas may leak due to the deformation of the cylinder head and
damage of cylinder head gasket, causing the coolant to escape.
2. While the engine is running, check the radiator for bubbles or coolant escape
due to entry of emissions.
Checking for
• If the compression gas escapes the radiator, the mixed gas leaks from the
1 Compression
cylinder head gasket when the cylinder is compressed.
Gas Leak
3. How to check:
• Open the radiator cap and check the coolant for bubbles when the engine
is running (check at room temperature or check the thermostat-opening
temperature while the engine is idling).
1. If the oil cooler is cracked and damaged, the engine oil gets into the coolant,
and you can visually confirm that oil mixed inside the coolant reserve tank.
Damaged 2. Tightening force is reduced due to the damaged oil cooler gasket and bolt (Bolt:
2 Engine Oil M8)
Cooler Tube • Torque: 21.6 N.m (2.2 kg.m, 15.9 ft lb)
Oil pressure: Approximately. 4.5 ~ 5.0 bar (4.6 ~ 5.1 kg/cm2, 65.3 ~ 72.5 psi), Coolant
pressure 0.7 ~ 1.0 bar (0.7 ~ 1.0 kg/cm2, 10.2 ~ 14.5 psi) (relative pressure)
• If this condition is left unresolved for a long time, the lubrication effect is
reduced, and the engine may get overheated.
• If the head gasket gets damaged and causes the coolant to enter the engine oil
part, the engine oil level may seem to go up.
• If the head gasket is damaged, the coolant gets into the combustion chamber
and causes mixture with the engine oil and reduced coolant.
Damaged Note for assembling the cylinder head gasket
3 Cylinder Head
Gasket • If it is fastened at an extremely high torque, the cylinder head gasket,
cylinder liner flange, and cylinder head bolt may be damaged; therefore,
maintain the specified torque.
• When assembling the cylinder head gasket, make the "TOP" head face
upward and "FRONT" face the front of the engine.
– For information on how to assemble the cylinder head gasket, refer
to the cylinder head Operation & Maintenance Manual.
Checking the • The engine oil level goes up, and the engine oil turns ivory.
4 Cylinder Block
for Crack • Check the inside of the cylinder block for engine block crack and pitting.
4-347
ENG07 Fuel Mixed with Engine Oil
Failure Fuel Mixed with Engine Oil
• If the engine oil is mixed with fuel, the fuel decreases the viscosity of the engine
oil and causes a lot of wear.
• If the engine oil is mixed with fuel, the engine oil volume increases, and the oil
Related Information vapor in the blowby gas builds up.

• Dribbling occurs when fuel drops from the nozzle tip in the combustion
chamber after the fuel is burned completely by the injection nozzle.
• When dribbling occurs, back pressure is generated, reducing engine power
Injection Nozzle and causing engine overheating as the remaining fuel is burned after the
Needle Valve explosion stroke.
Check (Leak Or • When the amount of dribbling increases, the engine oil increases via the inside
1
Open) for of the cylinder; therefore, check using the engine oil level gauge.
Injection Fault
and Dribbling Injection occurs when the fuel pumped by the injection pump has enough pressure to
push away the spring tension blocking the nozzle. The pressure spring and adjusting
screw of the injection nozzle adjust and determine this pressure. If the nozzle tension
is reduced, High-pressure cannot be generated, and fuel dribbles, preventing normal
explosion. The drops of fuel reach the cylinder wall and get mixed with the engine oil.
If the plunger inside FIP is worn or cracked, the fuel inside the plunger flows to the
FIP camshaft side and gets mixed.
The plunger is a cylinder inside the barrel, moving vertically to generate fuel
Worn Injection pressure of over 98 bar (100 kg/cm2, 1,422.3 psi)
2 Pump Plunger &
Plunger Barrels On top of the plunger and barrel is a hole for the fuel inlet and outlet, and the plunger
moves vertically inside the barrel and works as a piston that pressurizes the fuel
directly. On the head part is a hole for the escaping fuel and a lid (groove) to regulate
the injection volume.
The piston attached to a side of the injection pump and operated by the injection
Faulty FIP Feed pump cam pumps out fuel from the fuel tank and sends this fuel to the injection pump
Pump Seal and via the fuel filter.
3 Abnormal Wear
of Feed Pump When the feed pump starts, it pushes the feed pump tappet roller and the push rod
Push Rod contacting the tappet. This push rod slides along with the feed pump body, causing
abnormal wear and making fuel flow to the camshaft and get mixed.
4-348
Structure of the Injection Nozzle
Return Pipe
Control Screw
Supply Connector Nozzle Spring
Nozzle Holder Body

Fuel Supply
Push Rod
Needle Valve
Nozzle Body
Injection Hole
DS1602127
Figure 371
4-349
Injection Pump Plunger
Injection Pipe
Valve Holder
Valve Spring
Delivery Valve
Plunger Barrel
Plunger
Plunger Control Lack
Control Pinion
Control Sleeve
Plunger Spring
Tappet
Fuel Feed Pump
Cam Shaft
DS1602128
Figure 372
4-350
Deliver Valve
Plunger Barrel
Plunger
Control Rod
Control Sleeve
Return Spring
Tappet Gap Control Scren

Roller Tappet
Cam Shaft
Cam
DS1602129
Figure 373
4-351
Feed Pump Push Rod
Priming Pump
Piston
Piston Spring
Spring
Inhalation Valve Exhaust Valve
Filter
Fuel Tank
Piston
Push Rod
Tappet
Tappet Roller
Cam Shaft
Figure 374
DS1602130
4-352
ENG08 Engine and Coolant Overheated
Failure Engine and Coolant Overheated
• The engine and coolant may be overheated by malfunctioning thermostat,
excessive operation of the cooling fan and belt, loss of cooling due to a polluted
radiator, pollution of the air cleaner (insufficient air flow), and other various
causes around the engine.
• If the gauge panel displays an over temperature signal, check the following:
Related Information
• Troubleshoot the error code for the coolant temperature sensor (V223)
displayed on the gauge panel first.
taking measures, etc.).

If the thermostat does not function under the
Non-functioning normal temperature range. Checking for normal functioning
1
Thermostat • Thermostat cracking temperature:  (Parts no.: 65.06402-5015)
71.0 ±2.0°C (159.8 ±3.6°F)
• V-belt tension: 10 ~ 15 mm
• Check the belt for any • Checking the poly belt for
crack, oil pollution, thermal tension: Refraction amount
Belt deformation, and wear. with defined force (kg)
applied (Refer to the
• Check the belt's tension.
additional documentation
Checking the below.)
Operation of the
2 • Inspect the belt tension every 2,000 hours of operation.
Cooling Fan and
Belt • Check the cooling fan for
thermal deformation or
damage.
Check the cooling fan and the
Cooling Fan • Check if the gap between radiator's installation condition.
the cooling fan and radiator
shroud is maintained at
360˚.
3 Coolant Leak Check the coolant piping for coolant leak. Replace the coolant pipe.
• Check the air cleaner element's condition.
• Check the air cleaner for tear (allowing
Faults with Inlet pollutants).
(Insufficient Air
• Check the air cleaner for excessive Refer to the main items of the
4 Flow) and Outlet
pollution or wet condition. engine start fault.
(Emission Back
Pressure) • Check the turbo charger and intercooler
and its connections (hoses, clamps).
• Check the muffler for clogging.
4-353
• If the anti-freezing liquid's concentration is
too high, it may have adverse influence on
the engine cooling performance.
• To maintain the concentration of the anti- Amount of anti-freezing liquid for
freezing liquid and additives, inspect the winter: Refer to the table below.
Defective Air
5 coolant every 500 hours.
Heater
(For information on how to check, refer to
DB58TIS Operation & Maintenance
Manual.)
You may check the concentration of the anti-freezing liquid and anti-corrosion agent
with the coolant inspection strip.
• Check the water pump's condition and normal functioning visually.
(Check the shaft seal, the impeller for breakage, and the shaft for any water
Reduced Water
pump leak.)
6 Pump
Functionality • If the internal coolant circuit is polluted by corrosion or contaminants, the
cooling effect is reduced, and the resistance inside the coolant circuit damages
the pump performance.
Check the inside of the radiator core (for
pollutants) and the radiator fin for clogging
caused by impact from outside.
Radiator Core Once the clogging is confirmed,
7 TIP: You may check for radiator core clogging
Clogged clean the radiator core.
(pollutants) with the temperature variance
between the radiator inlet and outlet with the
thermostat opened.
Overheating may be caused by reduced coolant
Defective
and bubbles created and resulting reduction of Refer to the section on the
Cylinder Head
8 the cooling power, which may be the reduction of coolant and mixing
or Cylinder
consequences of the damages in the cylinder of engine oil.
Head Gasket
head or cylinder head gasket.
How to Check the Belt Tension with the Hands

1. V-belt
• The tension of the V-belt is correct if you can press it
until its thickness becomes 10 ~ 15 mm. Press here
"Y"
(Press the pulley and pulley center)
• For more correct tension measurement of the V-belt,
use the V-belt tension gauge. Coolant
pump pulley
Alternator pulley
Crank pulley
V-belt EA9O2006
Figure 375
4-354
2. Poly belt
The poly belt tension should be adjusted to the refraction
(T) = 0.015 × S (1.5 mm per 100 mm) under the defined
force (F kg).
• T = 0.015 × *S (mm)
(D-d)2
*S = C2 - (mm)
2
(T: Refraction, S: Distance)

EB5O6001
(C: Distance between axes (mm), Large pulley diameter Figure 376
(mm), Small pulley diameter (mm))
Poly Belt Tension
Belt Arithmetic (PK) Tension (kgf)

3 20 ~ 27
4 27 ~ 38
5 34 ~ 45
Belt (reinforcing shim rubber)
6 41 ~ 57
Adhesive rubber
7 48 ~ 88
Cord
8 59 ~ 73
Cover
EB5O6002
Figure 377
Amount of Anti-freezing Liquid During Wintertime
Ambient
Cooling Water Antifreeze
Temperature
(%) (%)
(°C (°F))
over -10 (14) 85 15
-10 (14) 80 20
-15 (5) 73 27
-20 (-4) 67 33
-25 (-15) 60 40
-30 (-22) 56 44
-40 (-40) 50 50
4-355
4-356

Troubleshooting Engine

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Troubleshooting Engine

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1Troubleshooting

No. Cause Procedure, Measuring Location, Criteria and Remarks

No. Cause Procedure, Measuring Location, Criteria and Remarks

Damaged, stuck, or inappropriately • Piston ring gap

(For information on how to measure,

No. Cause Procedure, Measuring Location, Criteria and Remarks

(For information on measurement,

No. Cause Procedure, Measuring Location, Criteria and Remarks

No. Cause Procedure, Measuring Location, Criteria and Remarks

Low Idle rpm Control Screw

High Idle rpm Control Screw

• High RPM: Governor Lever Condition

Shut off Stop

Idle Speed Position

No. Cause Procedure, Measuring Location, Criteria and Remarks

No. Cause Procedure, Measuring Location, Criteria and Remarks

Supply Connector Nozzle Spring

Nozzle Holder Body

Plunger Control Lack

Fuel Feed Pump

Tappet Gap Control Scren

Inhalation Valve Exhaust Valve

No. Cause Procedure, Measuring Location, Criteria and Remarks

How to Check the Belt Tension with the Hands

(T: Refraction, S: Distance)

Poly Belt Tension

Belt Arithmetic (PK) Tension (kgf)

Amount of Anti-freezing Liquid During Wintertime

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