01:00-01

Issue 2 en-GB
program 96

Troubleshooting diagram
Industrial and Marine Engines

The troubleshooting diagram is intended to serve as a guide and source of

ideas for the practical troubleshooting carried out on site by experienced
mechanics. The diagram contains the fault causes that Scania has
experienced over the years and will be supplemented with new fault causes
as they come to light.
Please use the form on the last page to report anything missing from the
troubleshooting diagram. This is the best way of keeping the
troubleshooting diagram up to date.
The "Troubleshooting" and "Action" columns of the diagram provide
descriptions not found in other parts of the Workshop Manual. If the
columns are empty, instructions can be found in other sections.

! WARNING!

This troubleshooting must not be applied to XPI

engines. This could cause serious accidents.

1 588 534
©
Scania CV AB 1997-06
 Search list/index
Page Page
Blue smoke . . . . . . . . . . . . . . . . . . . . . . . . . .5 Oil in the coolant . . . . . . . . . . . . . . . . . . . . . 6
Fuel in the oil. . . . . . . . . . . . . . . . . . . . . . . . .5 Oil is pressed out via the crankcase
ventilation. . . . . . . . . . . . . . . . . . . . . . . . . . 27
Contaminated coolant . . . . . . . . . . . . . . . . .23 Abnormal wear (lining, piston rings, etc.). 10
High exhaust gas temperature. . . . . . . . . . .24 Black smoke during operation/when under
load. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
High fuel consumption . . . . . . . . . . . . . . . .19 Black smoke during start attempt . . . . . . . . 5
High oil consumption . . . . . . . . . . . . . . . . .18 Engine difficult to start . . . . . . . . . . . . . . . 14
High oil temperature . . . . . . . . . . . . . . . . . .23 Thermostat oscillation, 14 series engine . . 16
High system voltage . . . . . . . . . . . . . . . . . .25 Pneumatic system . . . . . . . . . . . . . . . . . . . 28
High oil pressure (engine at operating Pressure pipe breaks. . . . . . . . . . . . . . . . . . 14
temperature). . . . . . . . . . . . . . . . . . . . . . . . . .9
Cold engine . . . . . . . . . . . . . . . . . . . . . . . . .22 Turbocharger malfunction . . . . . . . . . . . . . 27
Knocking/noise . . . . . . . . . . . . . . . . . . . . . .16 External corrosion on cylinder liner . . . . . 14
Coolant/water in the oil. . . . . . . . . . . . . . . . .6 External fuel leakage . . . . . . . . . . . . . . . . . 26
Coolant loss . . . . . . . . . . . . . . . . . . . . . . . . .22 External coolant leakage . . . . . . . . . . . . . . 26
Low compression . . . . . . . . . . . . . . . . . . . .19 External oil leakage . . . . . . . . . . . . . . . . . . 25
Low engine power. . . . . . . . . . . . . . . . . . . .19 Hot engine . . . . . . . . . . . . . . . . . . . . . . . . . 21
Low system voltage. . . . . . . . . . . . . . . . . . .25 Hunting. . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Low fuel pressure . . . . . . . . . . . . . . . . . . . .25 Vibrations. . . . . . . . . . . . . . . . . . . . . . . . . . 11
Low charge air pressure . . . . . . . . . . . . . . .24 White smoke . . . . . . . . . . . . . . . . . . . . . . . . 3
Low oil pressure . . . . . . . . . . . . . . . . . . . . . .7 White smoke - water vapour . . . . . . . . . . . . 3
Engine heater. . . . . . . . . . . . . . . . . . . . . . . .23 Liquid slugging . . . . . . . . . . . . . . . . . . . . . 15

2 © Scania CV AB 1997-06 01:00-01

White smoke
Effect Cause Troubleshooting Action
- If possible: reduce
the engine speed or
put the engine under
load
Incomplete The white smoke turns
- Install a white smoke
combustion of Cold engine blue and disappears once
limiter (exhaust
fuel the engine is warm
brake)
- Install a flame heater
- Install an engine
heater
Injection time is too late
The intake valve opens
too little. Valve
adjustment has slipped
Detach one pressure pipe at a time and listen for
Too much fuel in engine noise changes.
relation to air at
low combustion
temperature
Broken delivery valve
spring, uncontrolled
! WARNING!

injection Take care when detaching the pressure pipes.

The pressure is extremely high and could cause
injury or damage

Leaking injector, drips?

White smoke - water vapour

Effect Cause Troubleshooting Action
Pressure test (air 0.5 bar,
Leaking charge air cooler
fluid 4 bar)
Leaking cylinder head
gasket The fault type also exists
Cracked fluid-cooled when the engine is warm
Water in the
exhaust pipe
combustion
chamber If the fault is difficult to locate:
Crack in cylinder head Change all cylinder heads to exchange cylinder
(does not apply to cracks heads.
between the valve seats). (Or pressure test all cylinder heads. Heat the
cylinder heads before pressure testing!)
Crack in cylinder liner

01:00-01 © Scania CV AB 1997-06 3

 Black smoke during operation/when under load
Effect Cause Troubleshooting Action
Injection pump tampered
Check sealing - Test run in test bench
with, attempt at trimming
Injection time is too late
The intake valve opens
too little. Valve
adjustment has slipped
Detach one pressure pipe at a time and listen for
engine noise changes.

Broken delivery valve

spring, uncontrolled
! WARNING!

injection Take care when detaching the pressure pipes.

The pressure is extremely high and could cause
injury or damage
Too much fuel in
relation to air at
high combustion Leaking injector, drips?
temperature
Seized nozzle
Incorrect spray pattern
from injection nozzle
More than 1 washer under
injector
Check the charge air
Fault in turbocharger
pressure
Blocked air filter
High exhaust back
See page 24
pressure
Worn intake valves
Blocked intake port

4 © Scania CV AB 1997-06 01:00-01

Black smoke during start attempt
Effect Cause Troubleshooting Action
Open the hatch (RQ/RQV)
or hexagon (RSV) on the
governor and use a finger
to check that the control - Submit the pump to a
Engine difficult to
Seizing control rack rack goes to the max. stop Bosch workshop for
start
bracket. repair
(Applies to engines
without smoke limiter on
the governor housing)

Blue smoke
Effect Cause Troubleshooting Action
Oil carryover past the
piston rings
Check whether there is oil
in the intake manifold
Oil leak in turbocharger
downstream of the
turbocharger
Damaged piston cooling - Renew any damaged
nozzles nozzles
Petrol in the diesel

Fuel in the oil

Effect Cause Troubleshooting Action
- Normally approx. 1%
Non-combusted fuel
fuel in lubricating oil
passes the piston
per 200 h
Defective injector
Internal leak in injection
Dilution of oil in
pump (worn pump
the sump
element or crack in pump
housing)
Worn/defective O-ring at
feed pump pushrod
Many cold starts
continued

01:00-01 © Scania CV AB 1997-06 5

 Fuel in the oil, continued
Effect Cause Troubleshooting Action
Check blow-by in the crankcase
Correct value for new engine: 0 - +10 mm wc
Dilution of oil in Worn engine
(flow 60-100 l/min)
the sump Closed crankcase ventilation: -50 - +20 mm wc
Intake valve does not open

Oil in the coolant

Effect Cause
Oil cooler leaks during
operation
Defective cylinder head
gasket
Crack in cylinder head
(does not apply to cracks
between the valve seats).
(On 11 series engines:
search for cracks between
the water jacket and the
oil duct)
Troubleshooting Action
Pressure test the oil cooler
Note: classed oil cooler, pressure tested: 10 bar oil
on the oil side, 0.5 bar air on the water side,
submerged in water 25-27°C
If the fault is difficult to locate:
Change all cylinder heads to exchange cylinder
heads.
(Or pressure test all cylinder heads. Heat the
cylinder heads before pressure testing!)

Coolant/water in the oil

Effect Cause Troubleshooting Action
The oil cooler is leaking
Pressure test the oil cooler;
when the engine is
see above
stationary
Leaking O-rings at Leakage in the overflow
- Renew liner seals
cylinder liner hole?
Dilution of oil in Condensed water is
the sump deposited in the crankcase
ventilation and runs down
into the sump
14-series engine: Blocked
drain hole in coolant
pump in combination with
leaking pump seal
continued

6 © Scania CV AB 1997-06 01:00-01

Coolant/water in the oil, continued
Effect Cause
Crack in cylinder head
Crack in water jacket on
cylinder block/cylinder
head. (Coolant runs down
through the pushrod hole)
Crack in water jacket on
cylinder head. (Coolant
runs down via the oil duct
for rocker arm lubrication)
Dilution of oil in
the sump
Cracked fluid-cooled
exhaust pipe
Leakage in the charge air
cooler core
Water penetrates via the
exhaust/intake system
Low oil pressure
Effect Cause
Fault in the
sensor/instrument
The gauge
indicates a low Improperly adjusted relief
value valve
Broken spring in oil relief
Max. oil pressure 2 bar at
valve (14-series engine,
2,000 rpm
earlier design)
The piston in the oil relief
valve is stuck in the open
position
01:00-01
Troubleshooting Action
Run the engine until it
reaches normal operating
temperature.
Remove the oil sump and - Renew the cylinder
all side covers. head with an
Pressure test the cooling exchange cylinder
system. head
If coolant penetrates - If no leakage can be
behind the side covers or found, renew all of
at the camshaft bearing, the cylinder heads
there is probably a crack in with exchange
one of the cylinder heads. cylinder heads
It is usually possible to see
which cylinder head or
heads are leaking.
Pressure test (air 0.5 bar,
fluid 4 bar)
- Install a self-closing
cover on the exhaust
pipe
- Position the air
cleaner so that water
cannot run in
Troubleshooting Action
Measure the oil pressure with the engine warm
using a mechanical pressure gauge directly on the
engine:
Min. 1 bar at 800 rpm. Max. 6 bar > 800 rpm.
Note: Single-speed engines must not be tested at
800 rpm. Risk of damage to the elastic
coupling
- 1 shim = 0.2 bar
(screw adjustment on
14 series engines)
- Check/remedy the
relief valve
continued
© Scania CV AB 1997-06 7
 Low oil pressure, continued
Effect Cause Troubleshooting Action
The incorrect size
- Change to bearings of
connecting rod
Max. oil pressure 2 bar, correct size.
bearings/main bearings
including for cold engine Check the bearing
were fitted on a reground
seats before fitting
crankshaft
Connecting rod bearing
and main bearing play is
too large
The oil pressure lamp
comes on if the bush slides
out of the bearing seat
Seizing in camshaft
completely.
bearing
The engine sprays out oil
through the crankcase
ventilation
A piston cooling nozzle
has come loose
The oil pressure may be
Seizing in bearing on
increased ~ 1 bar when the
engine power take-off
power take-off is under
ED140 (14 series engine)
load
The gauge Loosened oil duct screw
indicates a low plugs at the camshaft
value bearing seats, under the The pressure drops to 0 bar
protective plate in the V
(14 series engine)
The suction pipe of the oil
pump has come loose; the
pump sucks in air
Engine too hot
- Choose a viscosity
Extremely low lubricating
suitable for the
oil viscosity
ambient temperature
- Renew the rotor if
Worn bushes or loose bush has been worn
shaft in the lubricating oil to an oval
cleaner - Renew
worn/damaged shaft
Broken O-ring in cyclone
component of lubricating
oil cleaner
Defective oil pump drive
Internal leakage in the Check that the cleaner is
lubricating oil cleaner correctly assembled
continued

8 © Scania CV AB 1997-06 01:00-01

Low oil pressure, continued
Effect Cause Troubleshooting Action
Loosened guide plates in
oil cooler prevent the oil
from passing
Worn/damaged oil pump
Plug in the cylinder block
under the relief valve has
The gauge come loose (11 series
indicates a low engine)
value Blocked oil cooler
Seized/worn bearings in The pressure varies when
air compressor; see also the compressor
page 28 charges/relieves pressure
Loose screws in the
timing gear's intermediate
gear
The plug of the main oil
The oil pressure at
The gauge shows port (for the piston
idling/low engine speed is
a low value at full cooling nozzles) at the
not affected since the
speed, but not at rear edge of the engine has
pressure valve closes at
idling loosened (also front edge,
3 bar
9 series engine)
The oil valve sleeve is
- Tighten the oil valve
No oil pressure unscrewed out of the oil
Check that the oil valve sleeve
when idling pump housing (produces a
sleeve is properly seated - Renew the sleeve if
(14 series engine) bypass and disables the
damaged
overflow valve)

High oil pressure (engine at operating temperature)

Effect Cause Troubleshooting Action
Measure the oil pressure with the engine warm
using a mechanical pressure gauge directly on the
engine:
Fault in the
Min. 1 bar at 800 rpm. Max. 6 bar > 800 rpm.
The gauge sensor/instrument
Note: Single-speed engines must not be tested at
indicates a high 800 rpm. Risk of damage to the elastic
value coupling
- Choose a viscosity
Lubricating oil viscosity is
suitable for the
too high
ambient temperature
continued

01:00-01 © Scania CV AB 1997-06 9

 High oil pressure (engine at operating temperature), continued
Effect Cause Troubleshooting Action
- 1 shim = 0.2 bar
Improperly adjusted relief
(screw adjustment on
valve
14 series engines)
The gauge The piston in the relief
indicates a high valve is stuck in the closed
value position
The valve in the oil duct to
the piston cooling nozzles
is seizing

Abnormal wear (lining, piston rings, etc.)

Effect Cause Troubleshooting Action
Dirty intake air due to Wear ridge (cylinder wear
- Fit a more efficient
insufficient filtering ridge) at the upper turning
air filter
(wrong size air filter) point of the piston
Dirty intake air due to
leakage in the intake line
Wrong oil grade,
polishing damage
Filter renewal and oil
changes were not handled
properly
Short service life
Low coolant temperature
(cold engine)
- Switch fuel
- Switch to oil with a
Sulphur content in the fuel higher total base
is too high number
- Shorter oil change
intervals
Faulty injector (leads to
rinsing away of oil film)

10 © Scania CV AB 1997-06 01:00-01

Vibrations, no driven components connected
Effect Cause Troubleshooting Action
Incorrect injection timing
Broken delivery valve Detach one pressure pipe at a time and listen for
spring engine noise changes.

! WARNING!
Individual injectors not Take care when detaching the pressure pipes.
working The pressure is extremely high and could cause
injury or damage

Fan imbalance
Flywheel has come loose
Crankshaft hub has come
loose
Abnormally worn main
bearings
Vibrations or
noise at
1,500-1,700 rpm Defective vibration
insulator
Drive belts come
off
The compressor is
Only when the air
working with too high a
compressor is
back pressure
charging, worst at
(e.g. blocked lines/air
approx.
dryer) or the safety valve
1,000 rpm; see
has too high an opening
also page 28
pressure
Check the engine
Alignment fault
alignment
- Change to rubber
Unsuitable rubber
elements of a
mountings and positioning
different hardness
Movements at engine - Reinforce the engine
Weak engine bed
attachment bed

01:00-01 © Scania CV AB 1997-06 11

 Vibrations when clutch or reverse gear is engaged
Effect Cause Troubleshooting Action
Imbalance in the driven
- Balance the unit
unit
Clutch imbalance
Insufficient alignment
- Align more
between the engine and Check the alignment
accurately
the driven unit
Unsuitable suspension for
engine or driven unit
- Reinforce the engine
Weak engine bed Movements at attachments
bed
- Renew the rubber
Defective elastic coupling
element in the elastic
between clutch/reverse
coupling
gear and driven unit
(consumable)
- Move the engine or
Improperly fitted the driven unit so that
propeller shaft, e.g. too the working range of
large an angle or too large the propeller shaft is
a deviation from parallel in accordance with
between the flanges the recommended
values
Too long and weak
propeller shaft

Vibrations during alternator operation

Effect Cause Troubleshooting Action
Alternator imbalance
Disassemble the coupling. Fit the coupling halves
Coupling imbalance
offset one half turn in relation to each other.
Bearing damage in
alternator
Defective elastic coupling - Renew the rubber
between engine and element or change
alternator coupling type
Fault in reduction gear

12 © Scania CV AB 1997-06 01:00-01

Hunting - single-speed engines with RQ governor
Effect Cause Troubleshooting Action
Free play in elastic - Renew rubber
Put under light load; at
coupling between engine element/check
approx. 20 kW load
and alternator (worn coupling hub and
hunting ceases
coupling) flange
- Select a coupling
New coupling with free without free play,
play e.g. Scania std.
coupling
Too little flyweight in the
- Fit extra flyweight
driven unit, e.g. alternator
Hunting when Skewed engine brackets - Switch to harder
engine under light (unit mounting) could rubber elements in
load (15-20 kW) worsen hunting in the engine/alternator
or unladen unfavourable conditions mountings
Incorrect injection timing
Detach one pressure pipe at a time and listen for
engine noise changes.

Individual injectors not ! WARNING!

working
Take care when detaching the pressure pipes.
The pressure is extremely high and could cause
injury or damage

Hunting – single-speed engines with RSV governor

Effect Cause Troubleshooting Action
- Replace the injection
The RSV governor is no
pump delivery valves
Hunting at 4-5% longer used for single-
(1- or 2-hole) with
deviation speed operation (except
0-hole delivery
on 9 series engines)
valves
- Fit an idling spring
Governor incorrectly
and adjust the
adjusted
rotational speed
Hunting when
idling Under 700 rpm, the std - Fit a weaker start
start spring, 282 544 spring, part number
(Bosch 1 424 650 006) is 268 866 (Bosch
too strong 1 424 650 056)

01:00-01 © Scania CV AB 1997-06 13

 Pressure pipe breaks
Effect Cause Troubleshooting Action
No clamping
Negligent handling of
pressure pipe
Inner cavitation in the
Fit 0-hole delivery
pressure pipe
valves for single-speed
Note: A single-pipe
operation
system is not permitted

External corrosion on cylinder liner

Effect Cause Troubleshooting Action
- Clean the cooling
Unsuitable corrosion system and fill
inhibitor, glycol or water coolant as specified
in coolant in the maintenance
and care instructions

Engine difficult to start

Effect Cause Troubleshooting Action
Leakage in the suction
pipe
The highest fuel level in
the tank is lower than the
feed pump. During long - Install a day tank,
Air in the fuel
stationary periods (days), which is positioned
system
the fuel in the suction pipe higher than the feed
can run back to the tank pump
due to a leaking overflow
valve
Leaking overflow valve
Low battery voltage
- Starting aids are not
Ambient temperature too
normally needed over
low
-15°C
Lubricating oil viscosity is
too high
Paraffin precipitation in
the fuel
continued

14 © Scania CV AB 1997-06 01:00-01

Engine difficult to start, continued
Effect Cause Troubleshooting Action
Blocked intake or exhaust
system
Out of fuel
- Check the stop
Stop lever in stop position
magnet and links
Incorrect injection timing
Fault in the injectors
Open the hatch (RQ/RQV)
or hexagon (RSV) on the
Control rack/pump governor and use a finger
element does not assume to check that the control - Submit the pump to a
cold start position. rack goes to the max. stop Bosch workshop for
Seizing control rack/pump bracket. repair
element (Applies to engines
without smoke limiter on
the governor housing)
- Pre-heat the engine
combustion chamber
by running the starter
motor with the stop
control in the stop
position for about
15 sec. Then start as
normal.

Liquid slugging
Effect Cause Troubleshooting Action
Pressure test (air 0.5 bar,
Leaking charge air cooler
fluid 4 bar)
The starter motor
is not able to pull Leaking cylinder head
the piston over the gasket
compression If the fault is difficult to locate:
stroke (if the Change all cylinder heads to exchange cylinder
engine fires, a Crack in cylinder head heads.
connecting rod (Or pressure test all cylinder heads. Heat the
may become bent) cylinder heads before pressure testing!)
Crack in cylinder liner
continued

01:00-01 © Scania CV AB 1997-06 15

 Liquid slugging
Effect Cause Troubleshooting Action
- Install a self-closing
The starter motor cover on the exhaust
Water has penetrated the
is not able to pull pipe
engine via the
the piston over the - Position the air
exhaust/intake system
compression cleaner so that water
stroke (if the cannot run in
engine fires, a
Crack in fluid-cooled
connecting rod
exhaust pipe
may become bent)
Injector is open

Thermostat oscillation, 14 series engine

Effect Cause Troubleshooting Action
- Fit an external
Lines between the
thermostat
thermostat housing and
- Try drilling two
radiator are too long
∅ 2.5 mm holes in
(more than 0.5 m)
the thermostat plate

Knocking/noise
Effect Cause Troubleshooting Action
Timing gears incorrectly
meshed
The exhaust
valves close too The crankshaft gear has Check the valve timing;
late and strike the come loose see "Service data, engines"
piston tops
Valve mechanism not
working
Quickly
Disruption in the supply
increasing valve
of rocker arm lubrication
clearance
The piston is Loose connecting rod cap - Tighten to the torque
striking the (wrong tightening torque specified in the
cylinder head used after repair) Workshop Manual
Foreign objects in the
piston crown
continued

16 © Scania CV AB 1997-06 01:00-01

Knocking/noise, continued
Effect Cause Troubleshooting Action
Piston seizing (may be
caused by blocked piston
cooling nozzles)
Incorrect injection timing
Worn exhaust valve
collets
Incorrectly set injection Detach one pressure pipe at a time and listen for
pump engine noise changes.

Broken upper Broken delivery valve ! WARNING!

piston rings spring (post-injection)
Take care when detaching the pressure pipes.
The pressure is extremely high and could cause
injury or damage

Connecting rod bearing

seizing
Faulty injector (seized,
worn, faulty or broken tip,
worn-out spring)
Incorrectly adjusted
injector
More than 1 washer under
injector
Check for leaks. (Remove the flame start and run
Fuel leakage in flame start
the engine with the fuel pipe connected)
Loosened connecting rod
cap
Injection timing extremely
Check the injection timing
Melting damage early, 30° or more BTDC
to piston crown Incorrectly adjusted
injector

01:00-01 © Scania CV AB 1997-06 17

 High oil consumption
Effect Cause Troubleshooting Action
Piston ring seizing
Is combustion temperature
Piston seizing
too high?
Cylinder seizing
Liner wear Unclean intake air?
Carbon polishing
(in spots)
Poor oil quality?
Piston ring wear
Pistons are stuck
Tapered piston rings are
facing the wrong way
Individual piston rings broken = incorrect fitting
Several upper piston rings broken = starter gas
facing the wrong way, wrong injection timing (too
Broken piston rings
early)
Several intermediate rings broken = worn rings or
ring grooves
Check the clearance
Blue smoke when between the valve and
under load guide.
Worn valve guides
High exhaust gas
temperature?
Poor oil quality?
Oil level too high
Check for oil in the
Defective shaft seals in
compressor component or
turbocharger
the intake manifold
Blocked air filter
Too great a vacuum in the Measure the vacuum
air intake upstream of the (max. 500 mm wc)
turbocharger Check the air filter
Oil viscosity too low
Deformed/incorrectly
positioned piston cooling
nozzles
External leakage
Leakage in the sea water-
cooled oil cooler
(11 series marine engines)

18 © Scania CV AB 1997-06 01:00-01

High fuel consumption
Effect Cause Troubleshooting Action
Faulty injectors
Low charge air pressure
In a pump test bench,
Injection pump tampered check that the quantity
with (Q-mm3/stroke) is in line
with the specification
Driving style,
operating/load conditions

Low compression
Effect Cause Troubleshooting Action
Worn engine Check the compression
Broken piston rings
Incorrectly
adjusted/defective valves
Liquid slugging/bent
connecting rod
Measure on a warm engine, with all injectors
removed, at starter motor speed
Measurement performed Measure cylinders 1-6, then cylinder 1 again
incorrectly Check that the starter motor speed does not drop
Correct value: 20-30 bar
Max. 3 bar difference between the cylinders

Low engine power

Effect Cause Troubleshooting Action
Check the integrity of the feed pump and overflow
valve as specified in the Workshop Manual
Low fuel supply pressure
Search for leaks in the suction pipe between the
(below 0.3 bar)
tank and feed pump
Blocked fuel filter/paraffin precipitation in the fuel
Faulty injectors
Fuel too hot
continued

01:00-01 © Scania CV AB 1997-06 19

 Low engine power, continued
Effect Cause
Wrong fuel specification
Low charge air pressure
Abnormal pressure drop
in the intake line
Worn engine
Leaking valves
Incorrect injection timing
Incorrectly adjusted
governor/throttle control
Intake air temperature is
too high
Exhaust back pressure is
too high
Intake back pressure is too See "Low charge air
high pressure", page 24
Incorrectly set injection
pump
Blocked fuel consumption
gauge
Seizing injector
Exhaust
brake/environmental
damper in closed position
20 © Scania CV AB 1997-06
Troubleshooting Action
Check the density and
viscosity
Check the charge air
pressure
Measure the vacuum upstream of the turbocharger,
max. 500 mm wc
Check the air filter
Check blow-by in the crankcase
Correct value for new engine: 0 - +10 mm wc
(flow 60-100 l/min)
Closed crankcase ventilation: -50 - +20 mm wc
Measure and compare the
compression in the
cylinders
Check that the governor
begins to deregulate at the
intended rotational speed
Check that the gas control
goes to the max. stop
Check the air temperature
upstream of the engine.
Over + 25°C reduces
engine power
Measure, recommended
back pressure:
500 mm wc, max.
1,000 mm wc
Check in a pump test
bench
The injection nozzle nut of
the injector is tightened
too hard
01:00-01
Hot engine
Effect Cause Troubleshooting Action
Check that the sensor and instrument are suited to
Fault in the
each other (120 and 150°C respectively)
sensor/instrument
Measure with a separate instrument
Low coolant level
Blocked sea water
strainer/filter
Blocked fresh/sea water - Clean the cooling
cooling system system inside and out
Pressure cap not working Pressure test
Impeller on fresh/sea
water pump worn or
damaged
Instrument shows
high temperature Wrong cam/worn
cam/worn cover on sea
water pump
Restriction of coolant
flow, e.g. rubber pieces
from sea water impeller
Measure the cooling
Cooling capacity too low
capacity
Gas leakage (produces
coolant loss)
Check the opening
Defective thermostats temperature of the
thermostats
Drive belts slipping or
pump impeller loose on
pump shaft
- Bleed at the highest
point of the cooling
system
Reduced coolant Air pockets in the engine's
- Check that the
flow outer cooling circuit
ventilation pipe to the
expansion tank is not
blocked.
Too high a pressure drop
Measure with forcibly-
in the external cooling
opened thermostats
system
Blocked radiator
continued

01:00-01 © Scania CV AB 1997-06 21

 Hot engine, continued
Effect Cause Troubleshooting Action
Check by measuring the
Circulation of cooling air
temperature
Cavitated impeller in
coolant pump
Leakage in the charge air
cooler

Cold engine
Effect Cause
Fault in the
sensor/instrument
Thermostat stuck in open
position
Instrument shows Low power at low
low temperature ambient temperature
(large external cooling
surface)
Large leakage flow in the
thermostat housing (9 and
11 series marine engines)
Troubleshooting Action
Check that the sensor and instrument are suited to
each other (120 and 150°C respectively)
Measure with a separate instrument
Check thermostat
operation
- Fit a thermostat fan
- Fit a smaller fan
- Install KLAFFO radiator rolling shutter.
Note: NOT A RADIATOR BLIND. Risk of fan
blade breakage
- Reduce the air flow
- Reduce the gear ratio for the fan/coolant pump

Coolant loss
Effect Cause Troubleshooting Action
Defective cylinder head
gasket (external leakage)
External leakage
The turbocharging
Coolant is forced
pressure enters the cooling Pressure test (air 0.5 bar,
out of the radiator
system via leaking charge fluid 4 bar)
on DSI engines
air element
continued

22 © Scania CV AB 1997-06 01:00-01

Coolant loss, continued
Effect Cause Troubleshooting Action
If the fault is difficult to locate:
Crack in cylinder head Change all cylinder heads to exchange cylinder
(does not apply to cracks heads.
White smoke with between the valve seats) (Or pressure test all cylinder heads. Heat the
a warm engine cylinder heads before pressure testing!)
indicates water
vapour Grey oil = coolant in the oil
Locate the leak by removing the oil sump and
Cracked cylinder liner
pressure test the cooling system while cranking the
engine by hand

Contaminated coolant
Effect Cause Troubleshooting Action
Faulty inhibitor - Clean the cooling
system and fill
Overdose of corrosion coolant as specified
inhibitor in the maintenance
and care instructions

Engine heater
Effect Cause Troubleshooting Action
Wrong mixture or type of
- Clean the cooling
glycol and/or corrosion
system and fill
Scaling on engine protection
coolant as specified
heater Antifreeze with
in the maintenance
phosphate-based inhibitor
and care instructions
must not be used.
The heater is not designed
for continuous operation.
Short service life Suitable temperature for
thermostat control
= 40-60°C

High oil temperature

Effect Cause Troubleshooting Action
- Fault in the Check with a separate
- Instrument sensor/instrument instrument
shows too high a
temperature - Poor water flow in the
oil cooler

01:00-01 © Scania CV AB 1997-06 23

 High exhaust gas temperature
Effect Cause
Injection pump tampered
with
Incorrect injection timing Check the injection timing
Injection nozzle dripping
High exhaust back
pressure
High intake air
temperature
Low charge air pressure
Blocked air filter
Low charge air pressure
Effect Cause
Dirty/damaged
turbine/compressor wheel
in turbocharger
Leakage between the
turbocharger and cylinder
head
Bearing seizure in
turbocharger
Blocked air filter
High exhaust back
pressure
High fuel temperature
24 © Scania CV AB 1997-06
Troubleshooting Action
Check the sealing; test the - Test in a pump test
RV governor if necessary bench
Check type, opening
pressure and condition
Measure, recommended back pressure:
500 mm wc, max. 1,000 mm wc
Check the silencer, spark suppressor, exhaust pipe
length and inside diameter
Troubleshooting Action
- Check/clean
- Check/renew gaskets
- Recondition/renew
Check bearing play
turbocharger
Measure the vacuum
upstream of the
turbocharger,
max. 500 mm wc
Measure, recommended back pressure:
500 mm wc, max. 1,000 mm wc
Check the silencer, spark suppressor, exhaust pipe
length and inside diameter
01:00-01
Low fuel pressure
Effect Cause Troubleshooting Action
Blocked fuel filter
Defective overflow valve
Defective feed pump
Air leakage in the suction
pipe
High pressure drop in the
suction pipe

Low system voltage

Effect Cause Troubleshooting Action
Alternator belt rupture
Slipping alternator drive
belt

(Normal charging Batteries in poor condition

voltage: Fault in the alternator
27-28 V)
Fault in the voltage
regulator
Fault in the battery
charger

High system voltage

Effect Cause Troubleshooting Action
Fault in the voltage
(Normal charging regulator
voltage:
27-28 V) Fault in the battery
charger

External oil leakage

Effect Cause Troubleshooting Action
Check blow-by in the crankcase
Crankcase pressure is too Correct value for new engine: 0 - +10 mm wc
high (flow 60-100 l/min)
Closed crankcase ventilation: -50 - +20 mm wc
continued

01:00-01 © Scania CV AB 1997-06 25

 External oil leakage, continued
Effect Cause Troubleshooting Action
Leaking crankshaft seal
Leakage at lining seal via
overflow hole in cylinder
block
Defective cylinder head
gasket
Leakage in a
Light load
manifold joint

External fuel leakage

Effect Cause Troubleshooting Action
Damaged
connections/gaskets to
injectors and injector
pump
Defective pulsation
damper
- Switch to Bosch
Leakage at high rotational
Blocked overflow valve overflow valve
speed and low power
(with ball)

External coolant leakage

Effect Cause Troubleshooting Action
Leakage in cylinder lining
seal
- Change hose quality
Cold leakage (preferable to silicone
hoses)
Defective cylinder head
gasket
Check the overflow hole
Water pump leakage
of the water pump housing
Leaking at charge air
cooler connection
continued

26 © Scania CV AB 1997-06 01:00-01

External coolant leakage, continued
Check that the self-venting
Coolant losses in
valve is not positioned
stationary
Coolant is pressed out of higher than the highest - Renew the valve or
installations with
the expansion tank coolant level and that air is fit a manual air screw
self-venting
not drawn through the
valves
valve

Oil is pressed out via the crankcase ventilation

Effect Cause Troubleshooting Action
Hole in piston crown Increases when the white
Bearing seizure in smoke limiter or exhaust
turbocharger brake is applied

Oil bleeding via pistons -

liner
Oil bleeding in air
compressor

Turbocharger malfunction
Effect Cause Troubleshooting Action
Bearing play in
turbocharger too large
Power loss Improperly connected
lubricating oil lines - Check the
between the turbocharger connections
and filter

01:00-01 © Scania CV AB 1997-06 27

 Pneumatic system
Effect Cause Troubleshooting Action
Too much carbonisation
in the compressor cylinder Empty the compressed air
tank, allow the air to
head or outlet line
remain in connected
Outlet valves leaking pneumatic components. - If the charging time
Run the engine at exceeds the specified
The compressor Worn pistons and 1,200 rpm and measure the values:
does not maintain cylinders time until the compressor - Repair any leakage
sufficient pressure Leaking/stuck intake is relieved; - Check/repair the
in the system valves 3-3.5 min. for 9/11-series pressure regulator
engine with 90-110 dm3 - Check/repair the
Defective pressure tank volume compressor
regulator 2.5-3 min. for 14 series
engine with 90-110 dm3
Leakage in compressed air tank volume
lines
Too much carbonisation
in the compressor cylinder
head or outlet line
Check/repair the
Worn connecting rod compressor as described in
bearings/main bearings the Workshop Manual
Noise Worn pistons and
cylinders
Compressor gear loose on
the shaft; see also
"Knocking/noise",
page 16
Worn pistons and
Compressor cylinders
allows oil to pass;
Incorrectly fitted piston
see also "High oil
rings
consumption",
page 18 Overpressure in engine
crankcase
Defective seals on the
relief pistons
The compressor
The relief mechanism
does not relieve
seizes
the load
Defective pressure
regulator
Check the operation of the
air dryer, change the
Moisture/oil in the Operational problems in desiccant.
pneumatic system the air dryer If the desiccant is oily, see
"Compressor allows oil to
pass" above

28 © Scania CV AB 1997-06 01:00-01

 Suggestions and opinions?

One of the aims of the troubleshooting diagram is for it to be continually updated and the best source
of updated information comes from where the diagram is used.
If you have any suggestions for improvements or additions, please make a copy of this page, write
your comments and send it by fax or post to the address below.
Your comments are the help we need to improve future issues.
Thanks in advance for your contribution.

Sender:

Suggestion/Note:

Address Scania CV AB Fax +46 8 - 55 38 31 80

Industrial and Marine Engines
Dept. ISAC Telephone +46 8 - 55 38 10 00
151 87 Södertälje, Sweden

29 © Scania CV AB 1997-06 01:00-01