1

1a. Engine Crankshaft Will Not Turn

When Start Switch Is On
Cause Correction

 Battery Has Low Output  Make Reference to Item 25.

 Wiring or Switches Have Defect  Make Reference to Item 25.
 Starting Motor Solenoid Has a  Make Reference to Item 25.
Defect  Make Reference to Item 25.
 Starting Motor Has A Defect  Make a replacement of defective
 Oil Pressure Switch For switch
Prelubrication Pump Has A Defect Repair or replace pump components
 Prelubrication Oil Pump Has a as needed.
Defect

2
1b. Engine Crankshaft Will Not Turn
When Start Switch Is On
Cause
 Inside Problem Prevents Engine
Crankshaft From Turning
Correction
 If the crankshaft can not be turned
after disconnecting the driven
equipment, remove the fuel nozzles
and check for fluid in the cylinders
while turning the crankshaft. If
fluid in the cylinders is not the
problem, the engine must be
disassembled to check for other
inside problems. Some of these
inside problems are bearing seizure,
piston seizure, wrong pistons
installed in the engine.
3
2a. Engine will not start
Cause
 Slow Cranking Speed
 Dirty Fuel Filter
 Dirty or Broken Fuel Lines
 Fuel Pressure is Low
Correction
 Make Reference to Item 26.
 Install new fuel filter
 Clean or install new fuel lines as
necessary
 At starting rpm, the minimum fuel
pressure from fuel transfer pump must
be 3 psi (20 kPa). If fuel pressure is
less than 3 psi (20 kPa), change the
fuel filter element. Look for air in the
fuel system. If fuel pressure is still
low, check the fuel control valve and
the fuel transfer pump for correct
operation.
4
2b. Engine will not start
Cause
 No Fuel to Cylinders
 Bad Quality Fuel
 Wrong Fuel Injection Timing
Correction
 Put fuel in fuel tank. “Prime” (remove
the air and/or low quality fuel from
the fuel system)
 Remove the fuel from the fuel tank.
Install a new fuel filter element. Put a
good grade of clean fuel in the fuel
tank.
 Make adjustment to timing.
5
3a. Misfiring Or Running Rough
Cause Correction

 Fuel Pressure is Low  Make sure there is fuel in the fuel

tank. Look for leaks or bad bends in
the fuel line between fuel tank and
fuel transfer pump. Look for air in the
fuel system, sticking, binding or
defective fuel control valve. Check
fuel pressure. The outlet pressure of
the fuel transfer pump must be a
minimum of 20 psi (140 kPa) at full
load speed.

 If fuel pressure is lower than the

above pressure, install a new filter
element. If fuel filter is still low, check
the fuel transfer pump.

6
3b. Misfiring Or Running Rough
Cause
 Air In Fuel System
 Leak or Break in Fuel Line Between
Injection Pump and Injection Valve
 Wrong Valve Clearance
Correction
 Find the air leak in the fuel system
and correct it. If air is in the fuel
system it will generally get in on the
suction side of the fuel transfer pump.
 Install a new fuel line.
 Make adjustment according to Testing
and Adjusting.
7
3c. Misfiring Or Running Rough
Cause Correction

 Run engine at rpm that gives

 Defect in Fuel Injection valve(s) or
maximum misfiring or rough running.
Injection Pump(s).
Then loosen a fuel line nut on the
injection valve for each cylinder, one
at a time. Find the cylinder where
loosening the fuel line nut does not
change the way the engine runs. Test
the injection pump and injection valve
for that cylinder. Install new parts
where needed.
 Wrong Fuel Injection Timing
 Make adjustment to timing.

8
4a. Stall At Low RPM
Cause Correction

 Fuel Pressure is Low  Make sure there is fuel in the fuel

tank. Look for leaks or bad bends in
the fuel line between fuel tank and
fuel transfer pump. Look for air in the
fuel system, sticking, binding or
defective fuel control valve. Check
fuel pressure. The outlet pressure of
the fuel transfer pump must be a
minimum of 20 psi (140 kPa) at full
load speed.

 If fuel pressure is lower than the

above pressure, install a new fuel filter
element. If fuel pressure is still low,
check the fuel transfer pump.

9
4b. Stall At Low RPM
Cause Correction

 Make adjustment to governor so idle

 Idle rpm Too Low rpm is the same as given in the RACK
SETTING INFORMATION.

10
4c. Stall At Low RPM
Cause Correction

 Defect in Fuel Injection Valve(s) or  Run engine at rpm that gives

Fuel Injection Pump(s) maximum misfiring or rough running.
Then loosen a fuel line nut on the
injection pump for each cylinder, one
at a time. Find the cylinder where
loosening the fuel line nut does not
change the way the engine runs. Test
the injection pump and injection valve
for that cylinder. Install new parts
where needed.
 Engine Accessories.
 Check engine accessories for damage
and correct adjustment. If necessary,
disconnect the accessories and test the
engine.

11
5. Sudden Changes In Engine Speed (rpm)
Cause Correction

 Failure of Governor or Fuel Injection  Look for damaged or broken springs,

Pump linkage or other parts. Remove the
governor. Check for free travel of the
fuel rack. Be sure fuel injection pumps
are installed correctly. Check for
correct governor spring. Install new
parts for those that have damage or
defects.

12
 6a. Not Enough
Cause
Power Correction

 Remove the fuel from the fuel tank.

 Bad Quality Fuel Install a new fuel filter element. Put a
good grade of clean fuel in the fuel
tank.

 Fuel Pressure is Low

 Make sure there is fuel in the fuel
tank. Look for leaks or bad bends in
the fuel line between fuel tank and
fuel transfer pump. Look for air in the
fuel system, sticking, binding or
defective fuel control valve. Check
fuel pressure. The outlet pressure of
the fuel transfer pump must be a
minimum of 20 psi (140 kPa) at full
load speed.
 If the fuel pressure is lower than the
above pressure, install a new fuel filter
element. If fuel pressure is still low,
check the fuel transfer pump.
13
6b. Not Enough Power
Correction
Cause

 Check the pressure in the air intake

 Leaks in Air Inlet System
manifold. Look for restrictions in the air
cleaner.

 Governor Linkage  Make adjustment to get full travel of

linkage. Install new parts of those that have
damage or defects.
 Wrong Valve Clearance
 Make adjustment according to
Specifications.

14
6c. Not Enough Power
Cause
 Defect in Fuel Injection Valve(s) or
Fuel Injection Pump(s)
 Wrong Fuel Injection Timing
Correction
 Run engine at rpm that gives
maximum misfiring or rough running.
Then loosen a fuel line nut on the
injection pump for each cylinder, one
at a time. Find the cylinder where
loosening the fuel line nut does not
change the way the engine runs. Test
the injection pump and injection valve
for that cylinder. Install new parts
where needed.
 Make adjustment to timing.
15
6d. Not Enough Power
Correction
Cause

 Make reference to the RACK SETTING

 Rack Setting Too Low
INFORMATION.
 Make adjustment to control. Check for
 Fuel Ratio Control Has Wrong bad diaphragm and weak or broken
Adjustment or Defect springs. Replace parts if needed.
 Inspect and repair turbocharger as
 Turbocharger has Carbon Deposit necessary.

16
7. Too Much Vibration
Cause
 Vibration damper or Pulley is Loose
 Vibration Damper Has A Defect
 Engine Supports Are Loose, Worn or
Have a Defect
 Driven Equipment is not in Alignment
or is Out of Balance
 Flexible Coupling Between Engine
and Driven equipment Has a Defect
 Misfiring or Running Rough
Correction
 Check vibration damper and pulley for
damage. Tighten bolts or nuts. If
vibration damper or pulley bolt holes
have damage or wear, replace with
new parts.
 Install a new vibration damper
 Tighten all mounting bolts. Install new
components if necessary.
 Check alignment and balance, correct
if needed.
 Repair or replace coupling
components.
 Make reference to item 3.
17
8. Loud Combustion Noise (Sound)
Cause
 Bad Quality Fuel
 Defect in Fuel Injection Valve(s) or
Fuel Injection Pump(s)
 Wrong Fuel Injection Timing
Correction
 Remove the fuel from the fuel tank.
Install a new fuel filter element. Put a
good grade of clean fuel in the fuel
tank.
 Run engine at rpm that gives
maximum misfiring or rough running.
Then loosen a fuel line nut on the
injection pump for each cylinder, one
at a time. Find the cylinder where
loosening the fuel line nut does not
change the way the engine runs. Test
the injection pump and injection valve
for that cylinder. Install new parts
where needed.
 Make adjustment to timing.
18
9. Valve Train Noise (Clicking)
Cause
 Broken Valve Spring(s) or Locks
 Not Enough Lubrication
 Too Much Valve Clearance
Correction
 Install new parts where necessary.
Broken locks can cause the valve to
slide into the cylinder. This will cause
much damage.
 Check lubrication in valve
compartment. There must be a strong
flow of oil at engine high rpm, but
only a small flow of oil at low rpm.
Oil passages must be clean, especially
those sending oil to the cylinder head.
 Make adjustment according to Testing
and Adjusting.
19
10. Oil In Cooling System
Cause Correction

 Defect In Core of Oil Cooler  Install a new core in the oil cooler

 Check cylinder liner projection.

 Failure of Cylinder Head Gasket Replace head gasket.

20
11. Mechanical Noise (Knock) In Engine
Cause Correction

 Failure of Bearing For Connecting  Inspect the bearing for the

Rod connecting rod and the bearing
surface (journal) on the
crankshaft. Install new parts
where necessary.

 Damaged Timing Gears  Install new parts where necessary.

 Defect in Attachment.  Repair or install new components.

21
12. Fuel Consumption Too High
Cause Correction

 Fuel System Leaks  Replacement of parts is needed at

points of leakage.

 Fuel and Combustion Noise (Knock)  Make Reference to Item 3 and Item 6.

 Make adjustment to timing.

 Wrong Fuel Injection Timing

22
13. Loud Valve Train Noise
Cause Correction

 Broken Valve Spring(s)  Make replacement of parts with damage

 Broken Camshaft  Make replacement of parts with

damage. Clean engine thoroughly.

23
14a. Too Much Valve Lash
Cause
 Not Enough Lubrication
 Rocker Arm Worn at Face That
Contacts End of Valve
Correction
 Check lubrication in valve
compartment. There must be a strong
flow of oil at engine high rpm, but
only a small flow at low rpm. Oil
passages must be clean, especially
those sending oil to the cylinder head.
 If there is too much wear, install new
parts or rocker arms. Make adjustment
of valve clearance according to
Testing and Adjusting.
24
14b. Too Much Valve Lash
Cause Correction

 If there is too much wear, install new

 End of Valve Stem Worn valves. Make adjustment to valve
clearance according to Testing and
Adjusting.
 Worn Push Rods
 If there is too much wear, install new
push rods. Make adjustment of valve
clearance according to Testing and
Adjusting.

25
14c. Too Much Valve Lash
Cause Correction

 Valve Lifters Worn  If there is too much wear, install new

valve lifters. Make adjustment of
valve clearance according to Testing
and Adjusting.
 Broken or Worn Valve Lifters
 Install new valve lifters. Check
camshaft for wear. Check for free
movement of valves or bent valve
stem. Clean engine thoroughly. Make
adjustment of valve clearance
according to Testing and Adjusting.

26
14d. Too Much Valve Lash
Cause Correction

 Worn Cams on Camshaft  Check valve clearance. Check for free

movement of valves or bent valve
stems. Install a new camshaft. Make
adjustment of valve clearance
according to Testing and Adjusting.

27
15. Valve Rotocoil Or Spring Lock Is Free
Cause Correction

 Broken Locks  Broken locks can cause the valve to

slide into the cylinder. This will cause
much damage.

 Broken Valve Spring(s)  Install new valve spring(s).

 Broken Valve  Replace valve and other damaged

parts.

28
16. Oil At The Exhaust
Cause Correction

 Too Much Oil in the Valve  Look at both ends of the rocker arm
Compartment shaft. Be sure that there is a plug in
each end.

 Worn Valve Guides  Reconditioning of the cylinder head is

needed.

 Worn Piston Rings  Inspect and install new parts as

needed.

29
17. Little Or No Valve Clearance
Cause Correction

 Worn Valve Seat or Face of Valve  Reconditioning of cylinder head is

needed. Make adjustment of valve
clearance according to Testing and
Adjusting.

30
18. Engine Has Early Wear
Correction
Cause

 Remove dirty lubrication oil. Install a

 Dirt in Lubricating Oil new oil filter element. Put clean oil in
the engine. Check oil filter bypass
valve for a weak or broken spring.

 Air Inlet Leaks  Inspect all gaskets and connections.

Make repairs if leaks are found.

 Fuel Leakage Into Lubrication Oil  This will cause high fuel consumption
and low engine oil pressure. Make
repairs if leaks are found. Install new
parts where needed.

31
19. Coolant In Lubrication Oil
Correction
Cause

 Install a new core for the oil cooler.

 Failure of Oil Cooler Core Drain crankcase and refill with clean
lubricant. Install new oil filter element.

 Failure of Cylinder Head Gasket  Check cylinder liner projection. Install a

new cylinder head gasket. Tighten the
bolts holding the cylinder head,
according to the specifications.

 Crack or Defect in Cylinder Head

 Install a new cylinder head.

 Crack or Defect in Cylinder Block

 Install a new cylinder block.

 Failure of Liner Seals

 Replace seals.

32
20. Too Much Black Or Gray Smoke
Correction
Cause

 Not Enough Air For Combustion  Check air cleaner for restrictions.

 Test fuel injection valves. Replace bad

 Bad Fuel Injection Valve(s)
valves.

 Wrong Fuel Injection Timing  Make adjustment to timing.

 Defect in Fuel Ratio Control  Make an adjustment to control. Check

for broken springs. Replace if needed.

33
21a. Too Much White or Blue Smoke
Cause Correction

 Remove extra oil. Find where extra oil

 Too Much Lubrication Oil in comes from. Put correct amount of oil
Engine in engine. Do not put too much oil in
engine.

 Misfiring or Running Rough

 Make reference to item 3.

 Wrong Fuel Injection Timing  Make adjustment to timing.

34
21b. Too Much White or Blue Smoke
Cause Correction

 Reconditioning of cylinder head is

 Worn Valve Guides needed.

 Worn Piston Rings  Install new piston rings.

 Failure of Turbocharger Oil Seal  Check inlet manifold for oil and
repair turbocharger if necessary.

35
22a. Engine Has Low Oil Pressure
Cause Correction

 Check the operation of bypass

 Dirty Oil Filter or Oil Cooler
 Diesel Fuel in Lubrication Oil
 Find the place where diesel fuel
valve for the filter. Install new oil
filter elements if needed. Clean or
install new oil cooler core.
Remove dirty oil from engine. Put
clean oil in engine.
gets into the lubrication oil. Make
repairs as needed. Remove the
lubrication oil that has diesel fuel
in it. Install a new oil filter
element. Put clean oil in the
engine.

36
22b. Engine Has Low Oil Pressure
Cause Correction

 Too much Clearance between Rocker  Check lubrication in valve

Arm Shaft and Rocker Arms compartment. Install new parts as
necessary.

 Oil Pump Suction Pipe Has A Defect  Replacement of pipe is needed.

 Pressure Regulating Valve Does Not  Clean valve and housing. Install new
Close parts as necessary.

37
22c. Engine Has Low Oil Pressure
Cause Correction

 Oil Pump Has A Defect  Repair or replace oil pump.

 Too Much Clearance Between  Check the oil filter for correct
Crankshaft and Crankshaft Bearings operation. Install new parts if
necessary.

 Too much Clearance between  Install new camshaft and camshaft

Camshaft and Camshaft Bearings. bearings if necessary.

 Defect in Oil Pressure Gauge  Install new gauge.

38
23a. Engine Uses Too Much Lubrication Oil
Cause Correction

 Remove extra oil. Find where extra oil

 Too Much Lubricating Oil In Engine comes from. Put correct amount of oil
in engine. Do not put too much oil in
engine.
 Oil Leaks
 Find all oil leaks. Make repairs as
needed. Check for dirty oil breather.

 Oil Temperature is Too High

 Check operation of oil cooler. Install
new parts if necessary. Clean the core
of the oil cooler.

39
23b. Engine Uses Too Much Lubrication Oil
Cause Correction

 Too Much Oil in the Valve  Look at both ends of the rocker arm
Compartment. shaft. Be sure that there is a plug in
each end.

 Worn Valve Guides  Reconditioning of the cylinder head is

needed.

 Worn Piston Rings  Inspect and install new parts as

needed.

40
24a. Engine Coolant Is Too Hot
Cause Correction

 Restriction To Flow of Coolant  Clean and flush radiator.

Through Radiator Core Tubes

 Restriction To Air Flow Through  Remove all restrictions of flow.

Radiator

 Low Fan Speed  Check for work or loose fan belts.

 Not Enough Coolant in System  Add coolant to cooling system. Check

for leaks.

 Pressure Relief Valve Has a Defect  Check operation of pressure relief

valve. Install a new pressure relief
valve if necessary.

41
24b. Engine Coolant Is Too Hot
Cause
 Combustion Gases in Coolant
 Water Temperature Regulators
(Thermostats) or Temperature Gauge
Has a Defect
 Water Pump Has A Defect
 Too Much Load On The System
 Wrong Fuel Injection Timing
Correction
 Find out where gases get into the
cooling system. Make repairs as
needed.
 Check water temperature regulators
for correct operation. Check
temperature gauge operation. Install
new parts as necessary.
 Make repairs to the water pump as
necessary.
 Make a reduction to the load.
 Make adjustment to timing.
42
25. Starting Motor Does Not Turn
Cause Correction

 Battery Has Low Output  Check condition of battery. Charge battery

or make replacement as necessary.

 Wiring or Switch Has Defect  Make repairs or replacement as necessary.

 Starting Motor Solenoid Has A Defect  Install a new solenoid.

 Starting Motor Has A Defect  Make repair or replacement of starting

motor.

43
26. Alternator Gives No Charge
Cause Correction

 Loose Drive Belt For Alternator  Make an adjustment to put the correct
tension on the drive belt.

 Inspect all cables and connections.

 Charging or Ground Return Circuit or Clean and tighten all connections.
Battery Connections Have A Defect Make replacement of parts with
defect.

 Install new brushes.

 Brushes Have A Defect

 Install a new rotor.

 Rotor (Field) Has A Defect

44
27a. Alternator Charge Rate Is Low Or Not Regular
Cause Correction

 Make an adjustment to put the

 Loose Drive Belt For Alternator correct tension on the drive belt.

 Inspect all cables and connections.

 Charging or Ground Return Circuit or Clean and tighten all connections.
Battery Connections Have A Defect Make replacement of parts with
defect.

 Make an adjustment or
 Alternator Regulator Has A Defect replacement of alternator
regulator.

45
27b. Alternator Charge Rate Is Low |Or Not Regular
Cause Correction

 Install new brushes.

 Alternator Brushes Have A Defect

 Rectified Diodes Have A Defect  Make replacement of rectifier

diode that has a defect.

 Rotor (Field Coil) Has A Defect  Install a new rotor.

46
28. Alternator Charge Too High
Cause Correction

 Tighten all connections to

 Alternator or Alternator Regulator Has
Loose Connections. alternator or alternator regulator.

 Alternator Regulator Has A Defect  Make adjustment or replacement

of alternator regulator.

47
29. Alternator Has Noise
Cause
 Drive Belt For Alternator is Worn Or
Has A Defect.
 Loose Alternator Drive Pulley
 Drive Belt and Drive Pulley For
Alternator Are Not in Alignment.
 Worn Alternator Bearings
Correction
 Install a new drive belt for the
alternator.
 Check groove in pulley for key that
holds pulley in place If groove is
worn, install a new pulley. Tighten
pulley nut according to Specifications.
 Make an adjustment to put drive belt
and drive pulley in correct alignment.
 Install new bearings in the alternator.
48
30. Exhaust Temperature Is Too High
Cause Correction

 Check pressure in the air intake

 Air Inlet System Has A Leak
manifold. Look for restrictions at
the air cleaner. Correct any leaks.

 Exhaust System Has A Leak

 Find cause of exhaust leak. Make
repairs as necessary.
 Air Inlet or Exhaust System Has A
Restriction  Remove restriction

 Wrong Fuel Injection Timing  Make an adjustment to the timing.

49