s/n Problems Possible causes

Checks by the user Checks by the skilled personnel

01 The starter motor turns  Battery capacity low,
the engine too slowly  Wrong grade of lubricating oil
 Bad electrical connection
 Fault in starter motor
02 The engine does not o The starter motor turns the engine
start too slowly
o Fuel tank empty
o Spare
o Restriction in a fuel pipe
o Fault in fuel lift pump
o Dirty fuel filter element
o Air in fuel system
o Fault in the fuel injector units
o Cold start system used incorrectly
o Fault in cold start system
o Wrong type or grade of fuel used
o Valve timing is incorrect
o Bad compression
o worn cylinder bores
o leakage b/n valves and seats
o piston rings are not free or they are worn or
broken
o faulty engine management system
o broken drive on the high pressure pump
o faulty injection control system
o faulty sensor

03 Engine is difficult to start  The starter motor turns the engine  Valve timing is incorrect
too slowly  Bad compression
 Spare  Valves are not free

Prepared by: Alex Berhane (Maintenance Engineer) Sig,________ Date: ________

PLEASE MAKE SURE THAT THIS IS THE CORRECT ISSUE BEFORE
  Restriction in a fuel pipe
 Fault in fuel lift pump
 Dirty fuel filter element
 Air in fuel system
 Fault in the fuel injector units
 Cold start system used incorrectly
 Fault in cold start system
 Restriction in fuel tank vent
 Wrong type or grade of fuel used
 Restriction in exhaust pope
04 Not enough power  Dirty fuel filter element
 Air in fuel system
 Fault in the fuel injector units
 Cold start system used incorrectly
 Fault in cold start system
 Engine temperature is too high
 Engine temperature is too low
Prepared by: Alex Berhane (Maintenance Engineer) Sig,________
PLEASE MAKE SURE THAT THIS IS THE CORRECT ISSUE BEFORE
 worn cylinder bores
 leakage b/n valves and seats
 piston rings are not free or they are worn or
broken
 faulty engine management system
 Valve timing is incorrect
 Bad compression
 Cylinder head gasket leaks
 worn cylinder bores
 leakage b/n valves and seats
 piston rings are not free or they are worn or
broken
 turbocharger impeller is damaged or dirty
 induction system leaks
 turbocharger waste-gate does not work
correctly, if one is fitted
 faulty engine management system
 faulty injection control system
 faulty sensor
Date: ________
05 misfire Dirty fuel filter element
Air in fuel system
Fault in the fuel injector units
Air in fuel system
Fault in the fuel injector units
Fault in cold start system
Engine temperature is too high
Incorrect valve tip clearance
06 High fuel consumption  Restriction in air induction system
 Fault in the fuel injector units
 Fault in cold start system
 Wrong type or grade of fuel used
 Restricted movement of engine
speed control
 Restriction in exhaust pipe
 Too much oil or oil of the wrong
type is used in wet type air
cleaner, if one is fitted
 Incorrect valve tip clearances
Prepared by: Alex Berhane (Maintenance Engineer) Sig,________
PLEASE MAKE SURE THAT THIS IS THE CORRECT ISSUE BEFORE
Valve timing is incorrect
Bad compression
Cylinder head gasket leaks
Valves are not free
leakage b/n valves and seats
faulty engine management system
faulty sensor
 Valve timing is incorrect
 Bad compression
 Cylinder head gasket leaks
 Valves are not free
 worn cylinder bores
 leakage b/n valves and seats
 piston rings are not free or they are worn or
broken
 faulty engine management system
 Induction system leaks
Date: ________
07 Black exhaust smoke  Restriction in air induction system
 Fault in the fuel injector units
 Fault in cold start system
 Wrong type or grade of fuel used
 Restriction in exhaust pipe
 Engine temperature is too low
 Incorrect valve tip clearance
08 Blue or white exhaust  Wrong grade of lubricating oil
smoke  Fault in cold start system
 Engine temperature is too low
 Too much oil or oil of the wrong
type is used in wet type air
cleaner, if one is fitted
Prepared by: Alex Berhane (Maintenance Engineer) Sig,________
PLEASE MAKE SURE THAT THIS IS THE CORRECT ISSUE BEFORE
 Valve timing is incorrect
 Bad compression
 Cylinder head gasket leaks
 Valves are not free
 worn cylinder bores
 leakage b/n valves and seats
 piston rings are not free or they are worn or
broken
 faulty engine management system
 Induction system leaks
 Turbocharger impeller is damaged or dirty
 Valve timing is incorrect
 Bad compression
 Cylinder head gasket leaks
 worn cylinder bores
 leakage b/n valves and seats
 piston rings are not free or they are worn or
broken
 valve stems and/or guides are worn
 piston is damaged
 valve stem seal is damaged
 lubricating oil seal of turbocharger leaks
 faulty engine management system
 faulty injection control system
Date: ________
09 The pressure of the low  Wrong grade of lubricating oil
pressure lubricating oil  Not enough lubricating in sump
system is too low  Defective gauge
 Dirty lubricating oil filter element
10 The engine knocks o Air in fuel system
o Fault in the fuel injector units
o Fault in cold start system
o Wrong type or grade of fuel used
o Engine temperature is too high
o Incorrect valve tip clearance
o Too much oil or oil of the wrong
type is used in wet type air
cleaner, if one is fitted
11 The engine runs o Dirty fuel filter element
erratically o Air in fuel system
o Fault in the fuel injector units
o Air in fuel system
o Fault in the fuel injector units
o Fault in cold start system
o Engine temperature is too high
o Incorrect valve tip clearance
o Restriction in air induction system
Prepared by: Alex Berhane (Maintenance Engineer) Sig,________
PLEASE MAKE SURE THAT THIS IS THE CORRECT ISSUE BEFORE
 Crank shaft bearings are worn or damaged
 Lubricating oil sump is worn
 Relief valve does not close
 Relief valve spring is broken
 Restriction in sump strainer
o Valve timing is incorrect
o Piston rings are not free or they are worn or
broken
o Valves are not free
o Worn cylinder bores
o crank shaft bearings are worn or damaged
o Piston is damaged
o Piston height is incorrect
o Valve spring is broken
o Faulty engine management system
o Faulty injection control system
o Bad compression
o Valves are not free
o broken drive on the high pressure pump
o faulty injection control system
o faulty sensor
o Valve spring is broken
o Worn cylinder bores
o Piston is damaged
Date: ________
 o Restriction in fuel tank vent
o Restricted movement of engine
speed control
o Too much oil or oil of the wrong
type is used in wet type air
cleaner, if one is fitted
12 vibration  Fault in the fuel injector units
 Restricted movement of engine
speed control
 Engine temperature is to high
 Fan damaged
 Fault in engine mounting or fly
wheel hosing
13 The pressure of the low  Wrong grade of lubricating oil
pressure lubricating oil  Defective gauge
system is too high
14 The engine oil Restriction in air induction system
temperature is too high Fault in the fuel injector units
Fault in cold start system
Restriction in exhaust pipe
Fan damaged
Too much lubricating oil in sump
 Bad compression
 Cylinder head gasket leaks
valves are not free
 Piston rings are not free or they are worn or
broken
 Piston is damaged
 Flywheel housing or flywheel is not aligned
correctly
 Relief valve does not open
Valve timing is incorrect
Cylinder head gasket leaks
Piston is damaged
Restriction in coolant passages
Fault in water pump
Turbocharger waste- gate does not work

Prepared by: Alex Berhane (Maintenance Engineer) Sig,________ Date: ________

PLEASE MAKE SURE THAT THIS IS THE CORRECT ISSUE BEFORE
 Restriction in air or water passages correctly if one is fitted
of radiator Faulty sensor
Insufficient coolant in system
Faulty engine management system
15 Crankcase pressure  Restriction in breather pipe  Cylinder head gasket leaks
 Fault in exhauster  Worn cylinder bores
 Piston rings are not free or they are worn or
broken
 Valve stems and/or guides are worn
 Piston is damaged
16 Bad compression  Restriction in air reduction system  Valve timing is incorrect
 Incorrect valve tip clearance  Cylinder head gasket leaks
 Valves are not free
 Worn cylinder bores
 Leakage b/n valves and seats
 Piston rings are not free or they are worn or
broken
 Valve stems and/or guides are worn
 Piston height is incorrect
 Valve spring is broken
17 The engine starts and  Dirty fuel filter element  faulty engine management system
stops  Air in fuel system  faulty injection control system
 Fault in the fuel injector units  o faulty sensor

Prepared by: Alex Berhane (Maintenance Engineer) Sig,________ Date: ________

PLEASE MAKE SURE THAT THIS IS THE CORRECT ISSUE BEFORE
18 The pressure of the lo  Wrong grade of lubricating oil  faulty engine management system
pressure lubricating oil  not enough lubricating oil in sump  faulty injection control system
system is too low  defective gauge  faulty sensor
 dirty lubricating oil filter element

Prepared by: Alex Berhane (Maintenance Engineer) Sig,________ Date: ________

PLEASE MAKE SURE THAT THIS IS THE CORRECT ISSUE BEFORE