Ww Section 5 - Fault Finding Contents Contents Page No. Fault Finding Introduction 5-1 Fault Finding Charts, 5-2 A Charts - Engine 5-3 8 Charts - Fuel 5-19 C Charts - Lubricating Oil 5-21 Charts - Coolant... 5-25Section 5 - Fault FindingSB Section 5 - Fault Finding Fault Finding Introduction “The fault finding procedures are given in the form af flow charts. There are a number of charts, each one dedicated 10 2 particular fault catagory. ‘The charts are designed to identity possible causes by performing checks and where applicable, specific tests on the engine, Having identified @ cause the suggested remedy is given, The charts are designed to identify causes through a process of elimination, starting with the ‘simplest, most easily rectified fauts, Due to the time and effort involved in removing, ismanting, assembling and replacing an engine, it is recommended that fault finding procedures are carried out Until a fault can be identified with a good degree of certainty. ‘There are many reasons why an engine may maifunction, time and effort will be saved by following basic ‘troubleshooting steps: — Do not make assumptions. — If possibte, talk to the operator for a description of the ‘ault. Also, check if any recent maintenance or repair has been completed on the engine. — Start simple - for instance many starting and running faults can be attributed to low fuel level = Systematically work through each of the possible = Confirm your diagnosis before dismanting and assembling, — Follow the recommended repair procedures in this manual 5-1 808:3000-02SB Section § - Fault Finding Fault Finding Fault Finding Charts ‘A Charts @ Engine - Will Noi Start or Difficult to Start Exhaust Smoke) ([1 5-3) = Engine - Will Not Start or Difficult to Start (Exhaust Smoke) (115-4) ‘S Slow) = Engine - Poor Running (15-7) = Engine - Poor Running at Idle ([)5- @ Engine - Noise Excessive (15-9) = Engine - Compression Knocks (() 6-10) Engine - Reduced Power Output ((\5-11 = Engine - Will Not Reach Maximum RPM ([\5-13) = Engine - RPM. Eo) = Engine - Vibration Excessive (1)&-16) @ Engine - Exhaust Smoke Excessive (Black Smoke) (1)5-16) = Engine - Exhaust Smoke Excessive (White/Blue Smoke) (15-17) = Engine - Will Not Shut OF ([\6-78) B Charts = Fuel - Consumption Excessive ([\6-19) @ FuelOil- Leaking from Exhaust Manifold ([) 5-20) Consumption Excessive (1) 5-21) = Lubrleating Oil- Contaminated ([\5-22) @ Lubricating Oil- Pressure Low (5-23) = Lubricating Oil- Pressure High (75-24 D Charts = Coolant - Loss ([)6-26) @ Coolant - Over Temperature ([) 6-26) = Coolant - Under Temperature (35-27) = Coolant - Contaminated (7) 5-26) Introduction 5-2 808:3000-02SB Section § - Fault Finding Fault Finding ‘A Charts - Engine A Charts - Engine ‘Table 4. Engine - Will Not Start or Difficult to Start (No Exhaust Smoke) Cause Remedy No fuel in supply tank ‘Check the levelin the fuel tank, use sight gauge or dipstick Replenish as required, Electrical fuel shut-off solencia (ESOS) valve not functioning propetly. ‘Check for correct operation of the electric shutoff eolenaid (ES08}, Refer to Test Procedures, Section 6. Improper starting procedure, Veiily proper starting procedure. Refer to Starting the Engine, Section 1. Fuel Filter blocked with water or other contamination, Fuel lift pump not operating correcty (fuel supply inadequate) ‘Drain fualiwater separator or replace fuel fiter Refer to Engine Fuel System, Section 3. ‘Check that the lif pump is operating and delivering fuel to ‘the injection pump. Refer to Test Procedures, Section 6. Fuelis aerated (Check the fuel system for loose connections and possible air ingress points, Rectfy and bleed the fuel system. Refer to Engine Fue! System, Section 3. ‘Check fuel inlet restriction Maximum inlet restiiion to fuel transfer pump must not exceed 100 mm Hg (4 in. Ha). Air intake or exhaust system blocked Visually check the air intake and exhaust system for blockage or obetruction -remove as required. Check the air iter elements for signs of blocking - replace a8 required. Fuel drain return line blocked, not connected properly, Verify thatthe fuel retumn line is not obstructed and connected to the top of the ‘vel tank. Refer to System Descriptions, Section 4. ‘War oF malfunctioning fuel injection pump Unjaction pump ‘not delivering fue. ‘Check for operation of the fuel injection pump, refer to Test Procedures, Section 6. The fuel injection pump must be take to@ local FIE specialist ‘to have the fuel delivery timing checked. Ensure that all obvious causes have been eliminated bafore removing the injection pump. Refer to Fuel Injection Pump, Section 7 for removal and replacement procedures. Injection pump timing incorrect Ifthe pump has recently been removed and replaced, the timing could be incorrect if the correct removel procedures were not followed, The timing can only be checked by a local FIE specialist, using the appropriate equipment. Refer to Fue! injection Pump, Section 7 for removal and replacement procedures, ‘One oF more engine injector worn or malfunctioning, ‘Check and externally clean the injector. Ifthe problem sill persists, the injector must be checked by a local FIE Specialist, or they can be replaced with new. 808:3000-02SB Section § - Fault Finding Fault Finding ‘A Charts - Engine Table 2. Engine - Will Not Start or Difficult to Start (Exhaust Smoke) Cause Remedy ‘iarling procedure incorrect Veiily proper starting procadure. Refar to Starting the Engino, Section 1. Cold staring aid not working (if fited) ‘Check for correct operation of te cold start advance, Refer to Test Procedures, Section 6. Airintake system blocked or resticted ‘Visually check the air intake for blockage or obstruction remove as required. Check the air filter elements for signs, of blocking - replace as required. Fuclis aerated ‘Check the fuel system for loose connections and possible air ingress points. Recty and blead the fuel system. Refer to Engine Fuel System, Section 3. Fuel ift pump not operating carreally fuel supply inadequate), ‘Check that the Ii pump is operating and delivering fuel to the injection pump. Refer to Test Procedures, Section 6. Fuels contaminated or incorrect grade diesel fuel used Refer to Fuel Systems Data, Section 7 for recommended diesel fuels. If the fue is suspect, verify by operating the | engine with recommended clean fuel from a temporary tank. Fuel fiter(s) blocked, fuel supply restricted ‘Chacldreplace the fual iter). Refer to Engine Fuet ‘System, Section 3, Check fuel lines for restriction Fuel drain return line blocked, not connected properly. Verify thatthe Tuel retuin line is not obstructed and ‘connected to the top of the vel tank, Refer to System Descriptions, Section 4. ‘Ghedk fuel inlet restriction ‘Maximum inlet restriction to fuel transfer pump must not exceed 100 mm Hg (4 in. Ha). Injection pump timing incorrect. Ifthe pump hes recently been removed and replaced, the ‘timing could be incorrect if the correct removal procedures were not followed, The timing can only be checked by a local FIE specialist using the appropriate equipment. Refer to Fuel Injection Pump, Section 7 for removal and raplacement procaduras. Tnlet and exhaust valve Gearances setincorrecty, ‘Set the valve clearances to the recommended clearances Refer to Valve Clearances, Section 12 ‘One oF more engine injector worn oF malfunctioning, ‘Check and externally clean the injector. f the problem stil persists, the injector must be checked by a local FIE specialist, or they can be replaced with new. Engine compression low in one ar more cylinders Check the engine compression. Refer to Engine Compression Check, Section 6. ranking speedtoo slow Refer to > Table 3, Engine - Will Noi Crank or Cranks ‘Slowly ([5-5) for possible low cranking speed faults, (Worn or malfunctioning fuel injection pump (injection pump not delivering fue). ‘Check for operation of the fuel injection pump, refer to Test Procedures, Section 6. ‘The fuel injection pump must be take toa local FIE specialist to have the fuel delivery timing checked. Ensure that all ‘obvious causes have been eliminated before removing the injection pump. Refer to Fuel Injection Pump, Section 7 or removal and replacemant procedures, 808:3000-02SB Section § - Fault Finding Fault Finding A Charts - Engine Table 3. Engine - Will Not Crank or Cranks Slowly Cause Remedy ‘iarling electrical aroult connections loose or carrodad Clean and ighten connections: Refer to Electrical Circuit Chocks, Section 6. Battery charge low, ‘Check battery voltage, charge the battery or replace as required. Make sure that the alternator is functioning correctly and charging the battery, Refer to Electrical Circuit Checks, Section 6. No electrical connection fo starter solenoid Check voltage to solenoid Refer to Electrical Circuit Checks, Section 6. Grankshaft rotation restricted Use spacial tool 882/07147 (crankshaft turning too)) to ‘manual turn the engine and check for any severe rotational resistance. ‘Solenid or Sartor motor Fault Replace starter motor. Reter to Elecirical Circuit Checks, Section 6. ‘Slarier motor operating but net cranking, Remove the starter motor and check for broken teeth on the ting gear or broken starter motor spring, Refer to Starter Motor, Section 10, 5-5 808:3000-02 5-5SB Section § - Fault Finding Fault Finding ‘A Charts - Engine Table 4. Engine - Starts then Stops. Cause Remedy No Tuelin supply tank (Check the lavelin the fuel tank, use sight gauge or dipstick Replenish as required, Engine starting under load. ‘Check for addedioading from malfunctioning accessories or liven units, brakes dragging and other changes in vehicle leading, Disengage the hydraulic controls, Ide speed too low for accessories ‘Adjust the idle speed. Refer to the machine's service ‘manual for correct adjustment piogedutes and idling speed Airintake or exhaust system blocked ‘Visually check the air intake and exhaust eystem for blockage or obstruction - remove as required. Check the air filter elements for signs of biacking - replace as required, Fuclis aerated ‘Check the fuel eystem for lcose connections and possible air ingress points. Rectfy and bleed the fuel system. Refer {to Engine Fuel System, Section 3 Fuel lift pump not operating correct (fuel supply inadequate), ‘Check that the lif pump is operating and delivering fuel to ‘the injection pump. Refer to Test Procedures, Section 6. Fuelis waxing due to extremely cold weather Verify by inspecting the fue iter Clean the system and use climatised fuel, Refer to Fuel Systems Data, Section 1 for recommended diesel fuels. Fuels contaminated or incorrect grade diesel fuel used Refer to Fuel Systems Data, Section 7 for recommended diesel fuels. Ifthe fue is suspect, veify by operating the engine with recommended clean fuel from a temporary tank, Fuel fiter(s) Blocked, fuel Supply resticted. CChecidrepiace the fuel fiters). Refer to Engine Fuel ‘System, Section 3. Check fuel lines for restiction. Fuel drain return line Blocked, not connected properly. Verify thatthe fuel retumn line ig not obstructed and connected to the top of the ‘vel tank. Refer to System Descriptions, Section 4. 808:3000-02SB Section § - Fault Finding Fault Finding ‘A Charts - Engine Table 5. Engine - Poor Running Cause Remedy Condition only occurs at ile Referto=> Table 6. Engine- Poor Running at lle ([) 5-8) {or possible poor running at idle faults. Engine is cold, cold starting aid not working ‘Check for correct operation of the cold start advance, Refer to Test Procedures, Section 6, If engine wil not reach ‘operating temperature, = Table 24. Coolant - Under Temperature ([) 5-27) Fuel injection lines leaking Inspect and correct as required leaks in the high pressure lines, fittings injector sealing washers, or delivery valves. WARNING: Fine jets of fludat high pressure can penetrate the skin, Keep face andhands wel clear of pressurised uid and wear protective glasses. If fluid penetrates your skin, get medical help immediately Fuelis aerated ‘Check the Tuel system for loose connections and possible air ingress points. Rectfy and bleed the fuel system. Refer to Engine Fuel System, Section 3 Fuel lift pump not operating correctly (fuel supply inadequate), ‘Check that the lif pump is operating and delivering fuel to ‘the injection pump. Refer to Test Procedures, Section 6, Fuel fiter(s) blocked, fuel supply restricted CCheclirepiace the fuel ites), Refer to Engine Fuel ‘System, Section 3. Check fuel lines for restriction. Fuel is contaminated or incorrect grade diesel fuel used Refer to Fuel Systems Data, Section 1 for recommended diesel fuels. If the fue is suspect, verify by operating the engine with recommended clean fuel from a temporary tank. Tnlet and exhaust valve dearances setincorredly. ‘Set the valve clearances to the recommended clearances. Refer toValve Clearances, Section 12. Engine compression low in one ar mare oylidners ‘Check the engine compression. Referto Engine Compression Check, Section 6. Injection pump timing inoorrect TFthe pump has recently bean removed and replaced, the ‘timing could be incorract i tha correct removal procadures ‘were not followed The timing can only be checked by a local FIE specialist sing the appropriate equipment. Refer to Fuel Injection Pump, Section 7 for removal and replacement procedures. ‘One oF more engine injector worn or malfunctioning, (Check and externally clean the injector. Ifthe problem stil persists, the injector must be checked by a local FIE specialist, or they can be replaced with new, Worn or malfunctioning fuel injection pump (injection pump not delivering fuel). (Check for operation ofthe fuel injection pump, refer to Test Procedures, Section 6. ‘The fuel injection pump must be take to @ local FIE specialist ‘to have the fuel delivery timing checked. Ensure thet all obvious causes have been eliminated before removing the injection pump. Refer to Fuol Injection Pump, Section 7 {or removal and replacement procedures. Camshaft or tappets damaged Inspect camshaft and tappets. Refer to Camshaft and Tappets, Section 12 808:3000-02SB Section § - Fault Finding Fault Finding ‘A Charts - Engine ‘able 6. Engine - Poor Running at Idle Cause Remedy Engine is cold, cold starting aid not working Ide speed too low for the accessories. ‘Chack for carreat operation of the cold Siar advance, Refer 10 Tost Procedures, Section 6. If engine will not reach operating temperature, = Table 24. Coolant - Under Temperature ([ 5-27) ‘Adust the idle speed, Refer to the machine's service ‘manual for correct adjustment procedures and idling speed Engine mounts oversightened, damaged or loose Verily condition of mounts. Refer to the machine's service ‘manual for correct adjustment procedure. Fuel injection lines leaking Inspact and correct as required leaks in the high pressure lines, ttungs injector sealing washers, of delivery valves. WARNING: Fine jet of fluid at high pressure can penetrate ‘the skin, Keep face and hands wall clear of pressurised fluid and wear protective olasses. If fluid penetrates your skin, get medical help immediately Fuelis aerated ‘Check the fuel eystem for leose connections and possible air ingress points, Rectty and bleed the fuel system. Refer 10 Engine Fuel System, Section 3. Fuel lft pump not operating correct (fuel supply inadequate), ‘Check that the lit pump is operating and delivering fuel to the injection pump. Refer to Test Procedures, Section 6. Fuel fiter(s) blocked, fuel supply restricted ‘Chackireplace the fuel fiters), Refer to Engine Fuel ‘System, Section 3. Check fuel lines for restriction Fuels contaminated or incorrect grade diesel fuel used Refer to Fuel Systems Data, Section 1 for recommended diesel fuels. If the fue is suspect, vetify by operating the engine with recommended clean fuel from a temporary tank. Tnlat and exhaust valve dearances setincorredty, ‘Sat the valve clearances to the recommended clearances: Refer to Valve Clearances, Section 12. Engine compression low in ona ar mare oyiindars Chock the engine compression. Refer to Engine Compression Check, Section 6. Tnjection pump timing incorrect. Ifthe pump has recently been removed and replaced, the timing could be incorrect if the correct removal procedures. ‘were not followed The timing can only be checked by a local FIE specialist, sing the appropriate equipment Refer to Fue! Injection Pump, Section 7 for removal and replacement procedures. ‘One oF more engine injectors worn or malfunctioning. (Ghack and externally Glean the injector. I the problem etl persists, the injector must be checked by a local FIE specialist, or they can be replaced with new. Worn or malfunctioning fuel injection pump (injection pump not delivering fue). ‘Check for operation of the fuel injection pump, refer to Test Procedures, Section 6. ‘The fuel injaction pump must be take to a local FIE specialist {to have the fuel delivery timing checked. Ensure that all ‘obvious causes have been eliminated before removing the injection pump. Refer to Fuel Injection Pump, Section 7 or removal and replacement procedures, 808:3000-02SB Section § - Fault Finding Fault Finding ‘A Charts - Engine Table 7. Engine - Noise Excessive Cause Remedy [Brive belt squeal, insufficient tension or abnormally high leading ‘Check the tensioner and inspect the diiva belt for loading. deterioration, Make sure water pump, tensioner pulley, fan alternator turn freely Check for paintoll or other material on pulleys. Check the tension of accessory drive belts Coie ata advance not operating corecty ‘Check for correct operation of the cold start advance. Refer to Test Procedures, Section 6, If engine wil not reach ‘operating temperature, => Tablo 24. Coolant - Undor Temperature (() 5 Tatake air or exhaust leaks. ® Table 13. Engine - Exhaust Smoke Excessive (Black ‘Smoke) ([\5-16) and > Table 14. Engine - Exhaust ‘Smoke Excessive (White/Blue Smoke) (6-17) Fuel is contaminated or incorrect grade diesel fuel used Refer to Fuel Systems Data, Section 1 for recommended diesel fuels. If the fue is suspect, verify by operating the | engine with recommended clean fuel from a temporary tank. Inlet and exhaust valve Gearances setincorredty, ‘Set the valve clearances to the recommended clearances Refer toValve Clearances, Section 12 Make sure the push rods are not bent or the rocker levers are not severely wor, Turbocharger noise. ‘Chack turbocharger impeller and turbine wheel for housing contact Inlet and exaust valve spings broken. ‘Check and ftnew valve spings, Refer to Valves, Valve and Springs and Stem Seals, Section 12. Worn crankleonnecting red bearings (knocking under load). ‘Checkireplace rodand main bearings. Refarto Crankshaft, Section 12, Excessive camehatt beating wear. (Check bearings (engine overhaul required), refer to Section 12. ‘Worn or damaged pistons and/or piston tings. ‘Check piston assembles (engine overhaul required), refer 10 Section 12, ‘Gne oF mare engine Injectors worn or malfunetoning. Check and externally clean the injector. the problem ei persists, the injector must be checked by a local FIE Specialist, or they can be replaced with new. Gear tain noise, Visually inspect and measure gear backlash, Replace gears a8 required. 5-9 808:3000-02 5-9SB Section § - Fault Finding Fault Finding ‘A Charts - Engine ‘Table &. Engine - Compression Knocks Cause Remedy Fuelis aerated ‘Check the fuel system for lease connections and possible air ingress points. Rectfy and bleed the fuel system. Refer to Engine Fuel System, Section 3. Fuel is contaminated or incorrect grade diesel fuel used Refer to Fuel Systems Data, Section 1 for recommended diesel fuels, If the fue is suspect, verity by operating the engine with recommended clean fuel from a temporary tank, Injection pump timing incorrect. Ifthe pump has recently been removed and replaced, the timing could be incorrect if the correct removal procedures were not followed, ‘The ming can only be checked by a local FIE specialist using the appropriate equipment. Refer to Fue! Injection Pump, Section 7 for removal and replacement procedures, Tnlet and exhaust valve spings broken Check and ftnew valve spings, Refer to Valves, Valve ‘Springs and stem Seals, Section 12. ‘One oF more engine injector worn or malfunctioning, ‘Check and externally clean the injector. I the problem stil persists, the injector must be checked by a local FIE specialist, or they can be replaced with new. ‘Coolant operating temperature incorrect. /@ Table 23. Coolant - Over Temperature (P\6-26) and | Table 24. Coolant - Under Temperature ([) 5-27). 808:3000-02SB Section § - Fault Finding Fault Finding ‘A Charts - Engine Table 9. Engine - Reduced Power Output Cause Remedy No Tuelin supply tank (Check the lavelin the fuel tank, use sight gauge or dipstick Replenish as required, Gillevel incorrect Check oll evel, refer io Engine Oil, Section 3. Engine overload ‘Check for addedicading irom malfunctioning accessories or siven units, brakes dragging and other changes in vehicle loading. Disengage the hydraulic controls, Thrcttle adjustment incorreclly set of Binding ‘Check the engine maximum rpm setting is a6 specified in the machine's service manual. Check the throttle linkage and cable for binding etc Fuels contaminated or incorrect grade diesel fuel used Refer to Fuel Systems Data, Section 7 for recommended diceel fuels. If the fue is euspect, verify by operating the engine with recommended clean fuel from a temporary tank. Turbocharger boost control pipe leaking of damaged, or ‘wastegate diaphragm ruptured (Turbocharged machines only) ‘Check boost control pressure, refer to Test Procedures, ‘Section 6, Inspect and tighten fitings, repair pipes, replace ‘wastegate assembly. Fuel injection lines leaking Inspect and correct as required leaks in the high pressure lines, fitings injector sealing washers, or delivery valves. WARNING: Fine jets of flud at high pressure can penetrate ‘the skin, Keep face and hands well clear of pressurised uid and wear protective glasses. If fluid penetrates your skin, get medical help immediately Fuel fiter(s) Blocked, fuel Supply resticted. CChecldrepiace the fuel fiters). Refer to Engine Fuel ‘System, Section 3. Check fuel lines for restiction. Fuelis aerated ‘Check the fuel eystem for cose connections and possible air ingress points. Rectfy and blead the fuel system. Refer to Engine Fue! System, Section 3. Fuel ift pump not operating correctly (fuel supply inadequate) ‘Ghedk that the lif pump © operating and dalivering fuel to ‘the injection pump. Refer to Test Procedures, Section 6. Air intake or exhaust system blocked Visually check the air intake and exhaust system for blockage or obstruction - remove as required. Check the iter elements for signs of blocking - replace as required, ‘One oF mare engine injectors worn or malfunctioning. (Check and externally clean the injector. Ifthe problem stil persis, the injector must be checked by a local FIE ‘specialist, or they can be replaced with new. ‘Worn or malfunctioning fuel injection pump (injection pump not delivering fue). ‘Check for operation of the fuel injection pump, refer to Test Procedures, Section 6 ‘The fuel injection pump must be take toa local FIE specialist {to have the fuel delivery timing checked. Ensure that all obvious causes have been eliminated before removing the injection pump. Refer to Fuel Injection Pump, Section 7 {or removal and replacement procedures. Exhaust leak at the manifold or turbocharger (if applicable). CCheck/correct leaks in the manifold or turbocharger ‘gaskets. Look for a cracked manifold Exira injectar sealing washer installed under injector Remove extia injector sealing washer 808:3000-02SB Cause Section § - Fault Finding Fault Finding A Charts - Engine Remedy Tnlet and exhaust valve dearances setincorredty, ‘Set the valve clearances to the recommended clearances Refer to Valve Clearances, Section 12. Injection pump timing incorrect. Ifthe pump has recently been removed and replaced, the timing could be incorrect ifthe correct removal procedures were not followed, Engine compression low in one er mere cylinders. The timing can only be checked by a local FIE specialist using the appropriate equipment. Refer to Fuel injection Pump, Section 7 for removal and replacement procedures ‘Check the engine compression. Refer to Engine Compression Check, Section 6. 808:3000-02 5-12SB Section § - Fault Finding Fault Finding ‘A Charts - Engine Table 10. Engine - Will Not Reach Maximum RPM Cause Remedy Tachometer fauly, Verily engine speed with hand tachomater Correct a8 required Engine overloaded Verity high idle speed without oad. Investigate operation to be sure correct gear is being used. Throttle adjustment incorrectly set or binding, ‘Check the engine maximum rpm setting is as specified in ‘the machine's service manual. Check the throtte linkage and cable for binding etc Fuclis aerated ‘Check the fuel system for loose connections and possible air ingress points. Recty and blead the fuel system. Refer to Engine Fuel System, Section 3. Fuel ift pump not operating correally fuel supply inadequated) ‘Check that the Ii pump is operating and delivering fuel to the injection pump. Refer to Test Procedures, Section 6 Fuels contaminated or incorrect grade diesel fuel used Refer to Fuel Systems Data, Section 1 for recommended diesel fuels. If the fue is suspect, verify by operating the | engine with recommended clean fuel from a temporary tank. Fuel fiter(s) blocked, fuel supply restricted ‘Chacldreplace the fual iter). Refer to Engine Fuet ‘System, Section 3, Check fuel lines for restriction (Turbocharged machines oniy) Turbocharger wasiegate ‘actuator diaphragm ruptured, Repair of replace turbocharger. ‘Gne oF mare engine injectors worn or malfunctioning: (Ghack and externally Glean the injector. I the problem stil persists, the injector must be checked by a local FIE Specialist, or they can be replaced with new. ‘Worn or malfunctioning fuel injection pump (injection pump not delivering fue). ‘Check for operation ofthe fuel injection pump, refer to Test Procedures, Section 6. ‘The fuel injection pump must be take to local FIE specialist ‘to have the fuel delivery timing checked. Ensure that all ‘obvious causes have baon aliminated before removing the injection pump. Refer to Fuel Injection Pump, Section 7 {or removal and reptacerent procedures. 808:3000-02SB Section § - Fault Finding Fault Finding ‘A Charts - Engine Table 11. Engine - RPM Surges Cause Remedy Fuel levellow Ifthe condition cocurs at ide, the idle speed set too low for accessories, ‘Chackfill uel tank Check the engine idle rpm setting is as specified in the machine's service manual Throttle adjsutment incorrectly set or binding ‘Ghack the engine maximum rpm seiting is as specifiedin ‘the machine's service manual. Check the throtte linkage and cable for binding etc Fuel injection lines leaking. Tnspact and correct as required leaks in the high pressure lines, fitings injector sealing washers, or delivery valves, WARNING: Fine jets of dat high pressure can penetrate ‘the skin, Keep face and hands well clear of pressurised fuid and wear protective glssses. If fluid penetrates your skin, get medical help immediately Fuel tank cap vent/breather blocked Inspect and rectly 6s required - replace cap if necessary. Fuclis aerated ‘Check the fuel eystem for lease connections and possible air ingress points, Rectty and bleed the fuel system. Refer {to Engine Fuel System, Section 3. ‘Gre or more engine injector worn oF malfunctioning (Check and externally clean the injector. Ifthe problem sill persists, the injector must be checked by a local FIE specialist, or they can be replaced with new. ‘Worn or malfunctioning fuel injection pump (injection pump not delivering fue). ‘Check for operation of the fuel injection pump, refer to Test Procedures, Section 6. ‘The fuel injection pump must be take to a local FIE specialist ‘to have the fuel delivery timing checked. Ensure thet all obvious causes have been aliminated before removing the injection pump. Refer to Fuel Injection Pump, Section 7 for removal anc replacement procedures. 808:3000-02SB Section § - Fault Finding Fault Finding ‘A Charts - Engine Table 12. Engine - Vibration Excessive Cause Remedy Engine not running smeothiyimistiing Oi level overful Ifthe condition cccurs at ide, the idle speed set too low for accessories. '@ Table 6. Engine - Poor Running at late ([) 5-6). ‘Check oil level, refer to Engine Oil, Section 3. ‘Check the engine idle rpm setting is as specified in the machine's service manual. | Fan damaged or accessories faulty Check/replace the vibrating component. Refer to the ‘machine's service manual for correctinstellation and torque figures. Fan nub raulty Inspactreplace the fan hub. Refer to the machine's service ‘manual for correct installation and torque figures. Engine mounts loose or broken, ‘Checkireplace engine mounts. Refer to the machine service manual for correct installation and torque figures Inlet and exhaust valve dlearances setincorretl. ‘Set the valve clearances to the recommended clearances. Refer to Valve Clearances, Section 12. Engine compression low in one ar more cylinders ‘Gheck the engine compression. Refer to Engine Compression Check, Section 6. Alternator bearing worn or damaged. CChackireplace the altemator. Refer to Alternator, Section 10. Fiywhee! housing misaligned CChecklcorrect fywheel alignment. Refer to Flywheel Housing, Section 12 Injection pump timing incorrect. Tf the pump hes recently been removed and replaced, the ‘timing could be incorrect if the correct removal procedures ‘were not followed The timing can only be checked by a local FIE specialist using the appropriate equipment. Refer to Fuel Injection Pump, Section 7 for removal and replacement procedures. Dive line components worn or unbalanced ‘Check and inspect drive line components such a8 propshafts. Refer to the machine's service manual for ‘correct installation and torque figures. 808:3000-02SB Section § - Fault Finding Fault Finding ‘A Charts - Engine Table 13, Engine - Exhaust Smoke Excessive (Black Smoke] Cause Remedy Engine being lugged dawn Air intake or exhaust system blocked. Use appropriate gear or task Visually check the air intake and exhaust system for blockage or obstruction - remove as required. Check the air fiter elements for signs of blocking - replace as required, Airleak between the turbocharger and the intake manifold (Turbocharged machines oniy} ‘Checkicorrect leaks in the air crossover tube, hoses, oF manifold cover. Refer to Section 11, Tateresoler faulty ‘Check for Blocked cooler matrix Exhaust leak at he Maniford or Turbocharger (Turbocharged machines oniy) ‘Gheck/correct leaks In the manifold or turbocharger gaskets. Look for a cracked manifold Turbocharger wastegate fauly. Repair of replace wastegate. Refer to Turbocharger, Section 11. Turbocharger malfunction Replace Turbocharger. Refer to Turbocharger, Section 11 ‘One or more engine injector worn oF malfunctioning ‘Ghack and externally clean the injector 1 tha problem sill persists, the injector must be checked by a local FIE specialist, or they can be replaced with new, ‘Worn or malfunctioning fuel injection pump (injection pump not delivering fue). ‘Check for operation of the fuel injection pump, refer to Test Procedures, Section 6. ‘The fuel injection pump must be take toa local FIE specialist to have the fuel delivery timing checked. Ensure that all ‘obvious causes have been eliminated before removing the injection pump. Refer to Fuel Injection Pump, Section 7 {for removal and replacement procedures. Injection pump timing incorrect. Retardadif smokes under load and engine quieter than normal Ifthe pump has recently been removed and replaced, the timing could be incorrect i the correct removal procedures ‘were not followed Injection pump timing incorrect. Advanced if smokes under load and engine noisier than usual "The timing can only be checked by a local FIE speaalst using the appropriate equipment. Refer to Fue! injection Pump, Section 7 for removal and replacement procedures Engine compression low in one or more cylinders. Smokes under load at all speeds, but mainly jw to mid speed range. hack the engine compression. Refer to Engine Compression Check, Section 6. 808:3000-02SB Section § - Fault Finding Fault Finding ‘A Charts - Engine Table 14, Engine - Exhaust Smoke Excessive (White!Blue Smoke) Cause Remedy Tmpropar starting procedure, Verily proper staring pocadure. Refar to Starting the Engino, Section 1. Fuels contaminated or incorrect grade diesel fuel used Refer to Fuel Systems Data, Section 7 for recommended diesel fuels. If the fue is suspect, verify by operating the engine with recommended clean fuel from a temporary tank. Gillevel incorrect. Check ol evel, refer to Engine Oil, Section 3. Diesel or hydraulic olin eum. ‘Check oll consistency, fol contamination is suspected ‘check equipment such as PTO pump for hydraulic ol leaks pass the seal into the engine. Drain, fush and{il with clean oll Coolant temperature too low (over-cooling) - ight Blue or white high speedfight oad /= Table 24, Coolant - Under Temperature (7) 5-27) Injection pump timing incorrect. Retarded if smokes under light load at high speed. Note that this is a normal function of the cold start advance, Tf the pump has recently been removed and replaced, the timing could be incorrect if the correct removal procedures ‘were not followed ‘The timing can only be checked by a local FIE specalst using the appropriate equipment. Refer to Fue! injection Pump, Section 7 for removal and replacement procedures. ‘One oF more engine injector worn or malfunctioning, -white/ blue smoke at operating temperature, ‘Check and externally Gean the injector Ifthe problem stil persists, the injector must be checked by a local FIE specialist, or they can be replaced with new, Coojant leaking into combustion chamber. '@ Table 22, Coolant -Loss (115-25) Leaking valve stem seals - evidert ater longidle peodand ‘then acceleration, Replace valve seals, refer to Valves, Vaive Springs and ‘Stem Seals, Section 12. ‘Worn or malfunctioning fuel injection pump (injection pump not delivering fuel). ‘Check for operation of the fuel injection pump, refer to Test Procedures, Section 6. ‘The fuel injection pump must be take toa local FIE specialist {to have the fuel delivery timing checked. Ensure that all obvious causes have been eliminated before removing the injection pump. Refer to Fuel Injection Pump, Section 7 {or removal and replacement procedures. Piston rings not sealing- evident with persistent blue smoke at all speeds/icad Check the engine compression. Refer to Engine Compression Check, Section 6. 808:3000-02SB Table 15. Engine Cause Section § - Fault Finding Fault Finding A Charts - Engine = Will Not Shut Off Remedy Electrical fuel shut-off solenoid (ESOS) valve not functioning prope. ‘Check for correct operation of the eleciic shutoll solenoid (ESOS), Refer to Test Procedures, Section 6. ‘Worn or malfunctioning fuel injection pump. ‘Check for operation of the fuel injection pump, refer to Test Procedures, Section 6. ‘The fuel injection pump must be take to a local FIE specialist {to have the fuel delivery timing checked. Ensure that all obvious causes have been eliminated before removing the injection pump. Refer to Fuel Injection Pump, Section 7 for removal and replacement procedures. 808:3000-02SB Section § - Fault Finding Fault Finding B Charts - Fuel B Charts - Fuel Table 16. Fuel - Consumption Excessive Cause Remedy ‘Additonal oad on engine. ‘Checkfrepair accesories and vehicle components, Refer to the equipment manufacturer's procedures, ‘Operator technique Review operation for correct gear shifts, deceleration and idling, Fuel leaks. (Check for external leaks and engine lubricating ofl diution. For fuel dilution, check for internal leaks at the fuel trensier pump and injection pump. Inspect and correct as required leaks in the high pressure lines, ftings injector sealing washers, or delivery valves. WARNING: Fine jets of fluid a high pressure can penetrate ‘the skin, Keep face andhande well clear of pressurised fuld and wear protective glasses. If fluid penetrates your skin, get medical help immediately Fuel is contaminated or incorrect grade diesel fuel used Refer to Fuel Systems Data, Section 1 for recommended diesel fuels. If the fue is suspect, verity by operating the engine with recommended clean fuel from a temporary tank. Tntake air oF exhaust leaks. '@ Table 13. Engine - Exhaust Smoke Excessive (Black ‘Smoke) ([15-16) and > Table 14. Engine - Exhaust ‘Smoke Excessive (White/Blue Smoke) ([\6-17) Engine compression low in ona er mare cylinders ‘Check the engine compression. Refer to Engine Compression Check, Section 6. Tnjection pump timing incorrect. Ifthe pump has recently been removed and replaced, the ‘timing could be incorrect i the correct removal procedures ‘were not followed The timing can only be checked by a local FIE specialist Using the appropriate equipment Refer to Fuel Injection Pump, Section 7 for removal andreplacement procedures, ‘One oF more engine injector worn oF malfunctioning (Check and externally clean the injector. I the problem stil persist, the injector must be checked by a local FIE specialist, or they can be replaced with new. ‘Worn or malfunctioning fuel injection pump (injaction pump not delivering fue). ‘Check for operation of the fuel injection pump, refer to Test Procedures, Section 6. ‘The fuel injection pump must be take toalocal Fle specialist ‘to have the fuel delivery timing checked. Ensure thet all obvious causes have been eliminated before removing the injection pump. Refer to Fuel Injection Pump, Section 7 {for removal and replacement procedures. Inlet and exhaust valve clearances set incorrectly, ‘Set the valve clearances to the recommended clearances Refer to Valve Clearances, Section 12, 808:3000-02SB Section § - Fault Finding Fault Finding B Charts - Fuel ‘Table 17. Fuel/Oil - Leaking from Exhaust Manifold Cause Remedy ‘Operating far extended periods under ight or no load conditions. Review operation for correct gear shifts, deceleration and idling Intake air or exhaust leaks. Table 13. Engine - Exhaust Smoke Excessive Smoke) ([) 6-16) and > Table 14. Engine - Exhaust ‘Smoke Excessive (White/Blue Smoke) ([) 5-1 Turbocharger lubricating ol drain line obstructed (Check/cean line Exhaustleak al the Manifold or Turbocharger turbocharged machines only) ‘Checklcorrect leaks in the manifold or turbocharger gaskets. Look for a cracked manifold Valve guide seals are leaking, Replace valve guide stem seals as required. Use the ‘special tool in Service Too/s, Section 1 to ensure the seals are fitted correctly, ‘One or more engine injector worn oF malfunctioning, (Check and externally clean the injector Ifthe problem sill persist, the injector must be checked by a local FIE specialist, or they can be replaced with new. Injection pump timing incorrect. Ifthe pump has recently been removed and replaced, the ‘timing could be incorrect i the correct removal procedures /were not followed The timing can only be checked by a local FIE specialist Using the appropriate equipment. Refer to Fuel injection Pump, Section 7 for removal and replacement procedures 808:3000-02SB Section § - Fault Finding Fault Finding C Charts - Lubricating Oil C Charts - Lubricating Oil ‘Table 18. Lubricating Oil - Consumption Excessive Cause Remedy OilTeaks, Tnspect the engine for visible signs of leaks. Pay particular altentions to seats, gaskets oll cooler anc extemal connections. Oillevel over ful Check oil level, refer to Engine Oil, Section 3. Incorrect lubscating oil (specification of viscosiy) Make sure the correct lubricating oll is being used. Refer to Lubricants and Capacities, Section 1. Look for reduced viscosity from dilution with fuel. Fuel ution in lubvicating oll can originate from fuel injection ump driveshatt seel or fuel transfer pump, Review/reduce the lubricating ol change intervale, Excessive leaking out ofthe breather tube (system blocked) (turbocharged machines only), ‘Check the breather tube area or signs of lubricating ol loss. If necessary, repiace the breather gauze, refer to Engine Breather, Section 3. Lubricating of cooler leak (Check forlubjicating llin the coolant Refer to Lubricating Oil Cooler, Section 8. “Turbocharger leaking lubricating Ol to the alrintake or exhaust (f ited). Tnspect the alr crossover tube for evidence of lubricating of transfer Valve guide seals are leaking. Replace valve guide stom seals as required. Use the special ool in Service Tools, Section 1 to ensure the seals are fitted correctly, Piston rings not Sealing -lubrioating oll bing consumed by ‘the engine (blue smoke from exhaust) Chedk the engine compression. Rafer to Engine Compression Check, Section 6. ‘Wor cylinder bores - lubricating ol being consumed by the engine (blue smoke from exhaust). Check the engine compression, Refer to Engine compression Check, Section 6. Glazed cylinder bares De-glaze bores as required 808:3000-02SB Section § - Fault Finding Fault Finding Table 19. Lubricating C Charts - Lubricating Oil Oil - Contaminated Cause Remedy ‘Coolant in the lubricating oll, internal engine companant leaks, '@ Table 22, Coolant -Loss ([) 5-25) Lubricating of sludge excessive ‘Change ail and fiter. Refer to Engine Oil and Filter, Section 3. Review oil and fier change period. I operating in arduous applications, change more frequently. Refer to Maintenance Procedures, Section 3, {or a definition of “arduous applications. Make sure the correct lubricating ol s being used, refer to Lubricants and Capacities, Section 1 Fuelin the lubricating ol, engine operating too cold. Review the operation for excessive iding resulting in he engine running below normal temperature Fuel ift pump leaking, Repair or replace fuel lit purmp. Refer to Fuel Lift Pump, ‘Section 7. ‘One or more engine injector worn or malfunctioning ‘Check and externally clean the injector the problem etl persists, the injector must be checked by a local FIE specialist, or they can be replaced with new. ‘Worn or malfunctioning fuel injecion pump (injection pump not delivering fue). ‘Check for operation of the fuel injection pump, refer to Test Procedures, Section 6. Internal bearing or component damage, The fuelinjection pump must be take toa local FIE specialist to have the fuel delivery timing checked. Ensure thet all ‘obvious causes have been eliminated before removing the injection pump. Refer to Fuel Injection Pump, Section 7 {or removal and replacement procedures, Have oll sample analysed. Repair engine as required 808:3000-02SB Section § - Fault Finding Fault Finding Cause C Charts - Lubricating Oil Table 20. Lubricating Oil - Pressure Low Remedy Gillevel incorrect Incorrect lubricating oil (specification of viscosity). Check oil evel, refer io Engine Oil, Section 3 Make sure the correct lubricating oll s being used Referto Lubricants and Capacities, Section 1 Look for reduced viscosity from dilution with fuel. Fuel dition in lubricating oll can originate from fuel injection ump driveshaft seal or fuel transfer pump, Review oil and fiter change period. if operating in arduous applications, change more frequently. Refer to Maintenance Procedures, Section 3, tor a definiton of ‘arduous applications! Pressure witch or gauge fauk. Verily the prosaure ewiich is functioning corel, Refer Tost Procedures, Section 6 Lubricating of fiter Blocked ‘Change lubricating oll fiter, refer to Engine Olfand Filter, Section 3. Review oil and fier change period. If operating in arduous applications, change more frequently. Refer to Maintenance Procedures, Section 3, {or a definiton of “arduous applications’ Lubricating ol filter drain down valve not fitted (refer to ‘System Description, Section 4). ‘Change lubricating ol Titer, refer to Engine Olland Filter, Section 3. ‘Suction pump pressure relief valve stuck open. (Gheckireplace seal, Refer to Oil Pan (Sump), Section 9. Gil pump pressure relief valve stuck open. Replace oll pump assembly. Refer to Oi Pump, Section 9. Lubricating of’ pump warn Replace oll pump assembiy Refer to Oi! Pump, Section 9. 808:3000-02SB Section 5 - Fault Finding Fault Finding C Charts - Lubricating Oil Table 21. Lubricating Oil - Pressure High Cause Remedy Tacorrect lubricating oil (specification of viscosity) ‘Make sure tha correct lubicating oll is being used Refer to Lubricants and Capacities, Section 1 Review oil and fiter change period. if operating in arduous applications, change more frequently. Refer to Maintenance Procedures, Section 3, for a definiton of “arduous applications’ Pressure switch or gauge fault Verily the pressure switch is functioning correct, Refer to Test Procedures, Section 6, Engine running too cold /3 Table 24. Coolant - Under Temperatura (75-27) Gil pump pressure relief valve stuck closed Replace oil pump assemby Refer to Oif Pump, Section 9. 808:3000-02 5-24SB Section § - Fault Finding Fault Finding D Charts D Charts - Coolant - Coolant Table 22. Coolant - Loss Cause Remedy Tncorrect coolant level Check the level, referto Engine Cooling System, Section 3 Coolant leaking from engine radiator or cab heater. Visually inspect te radiator heater, hoses and connection to locate the leak. Ifollis presentin the coolant, check for a transmission or engine oil cooler leak External engine coolant leak ‘Visually inspect the engine and components forseal, gasket hose connection leaks, Make sure all hose clips are in good condition and torqued to the recommended figure. ‘Overheating or compression gases leaking, reculting Inloes ‘through the radiator overtiow, = Table 23, Coolant - Over Temperature (1) 6-26) TF equipped, transmission cooler leak, ‘Check for mixing of coolant and transmission Tu, Ifthe engine is coolant aftercooled, aftercooler leak ‘Checiireplace the aftercooler. Look for coolantin the intake manifold and in the ol Lubricating of cooler leak CChecidreplace the ail cooler. Look for coolant in the ol ‘ylinder head gasket leak Checidreplace the head gasket Refer to Cylinder Head, Section 12, Gylinder head cracked or porous (Ghackreplace the head. Refer to Cylinder Head, Section 12. ‘Gylinder Block coolant passagas leaking ‘Ghadliraplace the oylinder block 808:3000-02SB Section § - Fault Finding Fault Finding Table 23. Coolant - D Charts - Coolant Over Temperature Cause Remedy Tncorreat coolant level (low) ‘Chack the level, refer to Engine Cooling System, Section 3 Ensure low level is not as a result of coolant leak, = Table 22, Coolant - Loss ([) 6-28). External radiator matrix blocked with drt or chaff [Air flow to the radiator inadequate or restricted. Glean exterior or radiator matrix. ‘Checi/repair fan shroud, anti-recirculaton sealing, shutters, fan sensors, fan speeds as required. Refer to the machine manufacturer's documentation for detailed information. ‘Coolant pump or fan drive belts loose. ‘Check/correct belt tension Radiator hose collapsed, resticted or leaking Checkdreplace hose. Gillevel over ful ‘Ghack aillevel, refer to Engine Oil, Section 3. Cooling system pressure cap incorrect or faulty Replace cap with the correct rating for the system ‘Over concentration of anti-freeze, Remove parr ofthe coolant from cooling system and replace with water. Refer to Coolant Mixtures, Section 3. ‘Temperature sensor gauge fauly, Verify that the gauge and temperature sensor are accurate Refer to Test Procedures, Section 6. Thermostat fauly, incorrect or missing, Gheclireplace the thermostat. Refer to Thermostat, Section 8. ‘Bir or combustion gases in the cocling system. Wake sure the fil rate Ie not exceeded and the correct vented thermostat is installe. Ifaeration continued, check for @ compression leak through ‘the head gasket ‘Coovant pump fauly. ‘Checidreplace the coolant pump. Refer to Coolant Pump, Section 8. Ventline from engine and/or radiator blocked or incorrectly routed (sudden overheating). ‘Check routing and operation or vent ine, Leak between the top tank and the auxiliary tank (sudden overheating). Check for coolant leakage between radiator aualiary tank and radiator top tank. Cooling passages in radiator, cyinder head, head gasket or block blocked, Flush the system and fil with clean coolant Fuel injection pump timing incorrect Thjection pump timing incorrect I the pump has recenty been removed and replaced, the timing could be incorrectif ‘the correct removal procedures were not followed. The timing can only be checked by a local FIE specialist using the appropriate equipment Refer to Fuel Injection Pump, Section 7 for removal and replacement procedures 808:3000-02SB Section § - Fault Finding ‘Table 24, Coolant - Under Temperature Cause Remedy Fault Finding D Charts - Coolant Air flow acrass the radiator excessive ‘Chackirepairfan shroud, ani-redrculaliansealing, shutters, an sensors, fan speeds as required, Refer to the machine manufacturer's documentation for detailed information. Temperature sensor gauge faulty. ‘Verify that the gauge and temperature sensor are accurate, Refer to Test Procedures, Section 6. Thermostat faulty, (open - not sealing). Section 8. CChecldreplace the thermostat. Refer to Thermostat, Coolant not lowing by temperature sensor" ‘Checkdslean coolant passages, (1) Atolal coolant loss may result nthe gauge showing low temperature intially In which case, check the i Engine Cooling System, Section 3. 808:3000-02SB Section § - Fault Finding Fault Finding D Charts - Coolant Table 2. Coolant - Contaminated Cause Remedy ‘Coolant rusly, operation without correct mocture of antifreeze and water. ‘Drain and fush the cooling system, Fill with correct maxture of antireaze and water Review the coolant change interval. Refer to the Operation and Maintenance Manual Engine oll cooler, or cooler housing allowing cross contamination of coolant with engine ol. Remove the oll cooler assembly and check relevant sealing elements for damage. See Lubricating Oi Cooler and Filter Head, Section 9 Transmission lubricating of cooler leaking (if applicable). ‘Chackireplace lubricating oll cooler, Refer to equipment manufacturers procedures. Lubricating oll leaks from lubricating ol cooler, head gasket, head and oylinder block. 'B Table 22, Coolant -Loss ([\5-25) 808:3000-02