3500 Series Engines

Problems, Main Causes & Correction

1
1. Engine Crankshaft Will not turn when start switch is
on
Cause
• Battery has Low Output
• Wiring or Switches have defect
• Problem with Engine Protective System
• Starter Motor Solenoid has a defect
• Starter Motor has a defect
Correction
• Check condition of battery. Charge
battery or make replacement as
necessary
• Make Repairs or replacements as
necessary.
• Make reference to ELECTRIC
PROTECTIVE SYSTEM, in Form
SENR2984 or Form SENR2985, or
make reference to HYDRA-
MECHANICAL PROTECTIVE
SYSTEM Form SENR3078.
• Install a new solenoid
• Make repair or replacement of starter
motor
2
1. Engine Crankshaft Will not turn when start switch is
on
Cause
• Oil Pressure Switch for Pre-lubrication
Pump has a defect
• Pre-lubrication Oil Pump has a defect
• Inside problem prevents Engine
Crankshaft from Turning
Correction
• Make a replacement of defective switch
• Repair or replace pump components as
needed
• If the crankshaft can not be turned after
disconnecting the driven equipment,
remove the fuel injectors and check if
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, or
valves making contact with the pistons.
3
2a. Engine will not start - Actuator Terminal Shaft does
not move to open Injector Racks

Cause Correction

• Too much Binding in Control Linkage • Engine can start, but with hot oil,
actuator does not develop enough pump
pressure to move linkage. Check
linkage effort and correct

• No Signal to Actuator Solenoid • Make reference to 2301 WOODWARD

GOVERNOR in Form SENR 2928
• Low Oil Pressure in Actuator • The actuator oil pump relief valve may
be stuck open or leaking. Correct by
governor disassembly and cleaning

4
2b. Engine will not start - Actuator Terminal Shaft opens
at least half way or more at cranking as observed by
outboard shaft rotation
Cause Correction

• Slow Cranking Speed • Make reference to Item 28

• Bad quality fuel or water in fuel
• Remove fuel from the tank, lines and
fuel manifolds. Install new fuel filters
and put a good grade of clean fuel in the
fuel tank. Use priming pump to fill
system with fuel and to remove air.

5
2b. Engine will not start - Actuator Terminal Shaft opens
at least half way or more at cranking as observed by
outboard shaft rotation
Cause Correction

• No fuel to injectors • Check fuel level in fuel tank and fill if

necessary. Use priming pump to
remove any air from the fuel system
• Install new fuel filters if necessary.
Blocked or broken fuel lines should be
cleaned or replaced.
• Check the fuel transfer pump for
damage or wear and make replacements
as needed
• Governor linkage not connected to
internal rack linkage (such as improper
assembly during overhaul). Make sure
governor linkage is correctly engaged.

6
2b. Engine will not start - Actuator Terminal Shaft opens
at least half way or more at cranking as observed by
outboard shaft rotation
Cause Correction

• Fuel pressure is Low • At starting rpm, the minimum fuel

• Wrong Fuel Injection Timing
pressure from fuel transfer pump must
be 20 kPa (3 psi). If fuel pressure is
less than 20 kPa (3 psi) change the fuel
filters. Look for air in the fuel system.
If fuel pressure is still low, check the
fuel by pass valve and the fuel transfer
pump for correct operation.
• Make adjustment to timing

7
3. Engine over-speeds on start

Cause Correction

• Fuel Control Linkage • Improper assembly after overhaul,

linkage not free, bound up in fuel on
piston, actuator output lever not
connected to rack form lever. Make
repairs or replacements as needed.

• Governor or Actuator problem • Make reference to 2301 WOODWARD

GOVERNOR in Form SENR 2928

8
4. Engine Speed does not have stability

Cause Correction

• Engine misfiring • Make reference to Item 5

• Linkage is binding, or worn with flat • Inspect and repair or replace linkage as
spots and high clearances needed
• Governor problem • Make reference to 2301 WOODWARD
GOVERNOR in Form SENR 2928

9
5. Engine 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 bypass
valve. Check fuel pressure. The outlet
pressure of the fuel transfer pump must be
a minimum of 415 kPa (60 psi) at full load
speed. The pressure in both fuel
manifolds must be 415 to 450 kPa (60 to
65 psi). If fuel pressure is lower than the
above pressure, install new filters. If fuel
pressure is still low, check the fuel
transfer pump and fuel pressure regulator
valve at the fuel manifold.

10
5. Engine misfiring or running rough
Cause Correction

• Find the air leak in the fuel system and correct

• Air in Fuel System
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 line.

• Leak or break in Fuel Line between

• Temperature of an exhaust manifold port, when
Fuel Manifold and Cylinder Head
• Defect in Fuel Injector (s)
the engine runs at low idle speed, can be an
indication of the condition of a fuel injector.
Low temperature at an exhaust manifold port is
an indication of no fuel to the cylinder. This
can possibly be an indication of an injector
with a defect. Extra high temperature at an
exhaust manifold port can be an indication of
too much fuel to the cylinder, also caused by
an injector with a defect.

11
5. Engine misfiring or running rough
Cause
• Wrong Valve Clearance
• Wrong fuel injection timing
• Bent or broken push rod
• Fuel has “Cloud Point” higher than
atmospheric temperature (Cloud point =
Temperature which makes wax form in
fuel)
Correction
• Make adjustment according to subject, VALVE
CLEARANCE.
• Make adjustment to timing
• Replacement of push rod is necessary
• Drain the fuel tank, lines and fuel manifolds.
Change the fuel filter. Fill the tank with fuel
which has the correct “cloud point”, and
remove the air from the system with the
priming pump.
• In some installations it can be necessary to use
the fuel heaters to insure proper fuel flow and
to prevent filter blockage from fuel wax. The
fuel temperature at which flow is reduced and
filter blockage occurs is usually dependent
upon the amount of wax in the fuel (its could
point).
12
6. Engine 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
bypass valve. Check fuel pressure. The
outlet pressure of the fuel transfer pump
must be a minimum of 415 kPa (60 psi)
at full load speed. The pressure in both
fuel manifolds must be 415 to 450 kPa
(60 to 65 psi). If fuel pressure is still
low, check the fuel transfer pump and
fuel pressure regulator valve at the fuel
manifold.

13
6. Engine stall at low RPM
Cause
• Idle RPM too low
• Engine Accessories
• Defect in Fuel Injector (s)
Correction
• Make adjustment to governor so idle
RPM is the same as given in the FUEL
SETTING INFORMATION.
• Check engine accessories for damage
and make repair or replacement. If
necessary, disconnect the accessories
and test the engine.
• Make reference to Item 5
14
7. Not Enough Power
Cause
• Dirty Fuel Filters
• Bad quality Fuel or Water in Fuel
• Fuel Temperature is high
Correction
• Install new fuel filters
• Remove the fuel from the fuel tank.
Install new fuel filters. Put a good
grade of clean fuel in the fuel tank.
• Excess fuel flow temperature should be
65.6 to 82.2°C (160 to 180°F). If
excess fuel flow temperature exceeds
82.2°C (180°F), the use of a fuel cooler
is recommended to prevent excessive
engine power loss and to maintain an
acceptable injector life.
15
7. Not Enough Power
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 bypass
valve. Check fuel pressure. The outlet
pressure of the fuel transfer pump must be
a minimum of 415 kPa (60 psi) at full load
speed. The pressure in both fuel
manifolds must be 415 to 450 kPa (60 to
65 psi). If fuel pressure is lower than the
above pressure, install new filters. If fuel
pressure is still low, check the fuel
transfer pump and fuel pressure regulator
valve at the fuel manifold.

16
7. Not Enough Power
Cause
• Defect in Fuel Injector
• Leaks in Air Inlet System
• Actuator and Control Linkage
• Wrong Valve Clearance
Correction
• Make a reference to Item 5.
• Check the pressure in the air intake
manifold. Look for restriction sin the air
cleaner.
• Make sure actuator is opening injector
rack linkage against fuel setting stop.
Make adjustment to get full travel of
linkage. Install new parts for those that
have damage or defects. If control
linkage is not against stop and engine is
puled below rated speed under load,
check high idle and adjust if necessary.
• Make adjustment according to subject,
VALVE CLEARANCE.
17
7. Not Enough Power
Cause
• Wrong Fuel Injection Timing
• Fuel setting incorrect
• Defect in Aftercooler
• Turbocharger has Carbon deposits or
other causes of friction
Correction
• Make adjustment to timing.
• Make an adjustment of the fuel setting.
Se Fuel Setting Information for the
correct fuel setting and FUEL
SETTING procedure in TESTING
AND ADJUSTING section.
• Check temperature of inlet and outlet
water supply. Remove any external or
internal restrictions.
• Make inspection and repair of
turbocharger as necessary.
18
8. Too much Vibration
Cause
• Vibration Damper Loose
• Vibration Damper has a defect
• Engine supports are loose, wrong or
have a defect.
• Driven equipment is not in alignment or
is out of balance.
• Misfiring or Running Rough
Correction
• Check vibration damper for damage.
Tighten bolts. If vibration damper 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.
• Make reference to Item 5
19
9. Loud Combustion Noise (Sound)
Cause Correction

• Bad quality Fuel • Remove the fuel from the fuel tank.
Install new fuel filters. Put a good grade
of clean fuel in the fuel tank.
• • Make adjustment to timing
Wrong Fuel Injection Timing
• Make reference to Item 5
• Defect in Fuel Injector(s)

20
10. Valve Train Noise (Clicking)
Cause Correction

• Damage to Valve Spring(s) locks, or • Install new parts where necessary.

Broken or worn Valve Lifter Broken locks can cause the valve to get
into the cylinder. This will cause much
damage.
• Check lubrication in valve compartment.
• Not enough lubrication
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 that send oil tot
he cylinder head.
• Make adjustment according to the
• Too much Valve Clearance
subject. VALVE CLEARANCE.
• Make a replacement of the valve(s) and
• Damage to Valve(s) make an adjustment as necessary.

21
11. Oil in Cooling System
Cause Correction

• Defects in core of Engine Oil Cooler • Install a new engine oil cooler

• Failure of Cylinder Head Gasket or • Check cylinder liner projection. Install

Water Seals a new cylinder head gasket and new
water seals in the spacer plate. Tighten
the bolts that hold the cylinder head
according to the Specifications.

22
12. Mechanical noise (Knock) in Engine
Cause
• Failure bearing for connecting rod
• Damaged Gears
• Damaged Crankshaft
• Defect in attachment
Correction
• Inspect the bearings for the connecting
rods and the bearing surfaces (journals)
on the crankshaft. Install new parts
where necessary.
• Install new parts where necessary
• Make replacement of the crankshaft
• Repair or install new components
23
13. Fuel Consumption too high
Cause Correction

• Fuel system leaks • Tighten or make replacement of parts at

points of leakage.
• Fuel and Combustion Noise (knock) • Make reference to Item 5 and Item 7
• Wrong Fuel Injection Timing • Make adjustment to timing
• Defect in Fuel Injector(s) • Make reference to Item 5.

24
14. Loud Valve Train Noise
Cause
• Damage to Valve Spring(s)
• Damage to Camshaft
• Damage to Valve Lifter
Correction
• Make replacement of parts with damage
• Make replacement of parts with
damage. Clean engine thoroughly. If
replacement of camshaft is made, new
valve lifters are also necessary.
• Clean engine thoroughly. Make a
replacement of the damaged valve
lifters. Inspect camshaft lobes for
damage. Look for valves that do not
move freely. Make an adjustment to
valve clearance according to the
subject. VALVE CLEARANCE.
25
15. Too much Valve Lash
Cause
• Not enough lubrication
• Rocker Arm Worn at Face that makes
contact with Bridge
• Bridges for Valves worn
• End of Valve Stem worn
Correction
• Check lubrication in valve compartments.
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 subject, VALVE
CLEARANCE.
• Make an adjustment or replacement as
necessary
• If there is too much wear, install new
valves. Make adjustment of valve clearance
according to Subject, VALVE
CLEARANCE
26
15. Too much Valve Lash
Cause Correction

• • If there is too much wear, install new valves.

Worn Push Rods
Make adjustment of valve clearance
according to Subject, VALVE
CLEARANCE.
• Install new valve lifters. Check camshaft for
wear. Check for free movement of valves or
• Broken or worn Valve Lifters
bent valve stem. Clean engine thoroughly.
Make adjustment of valve clearance
according to subject, VALVE CLEARANCE.
• Check valve clearance. Check for free
movement of valves or bent valve stems.
Install new camshaft. Install new valve
• Worn Cams on Camshaft lifters. Make adjustment of valve clearance
according to subject, VALVE CLEARANCE.

27
16. 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
17. Oil at the exhaust
Cause
• Too much oil in the Valve
Compartment
• Worn Valve Guide
• Worn Piston Rings
Correction
• Be sure that the dowel is installed in the
left bolt hole of the rocker shaft.
• Reconditioning of the cylinder head is
needed
• Inspect and install new parts as needed
29
18. 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 the subject,
VALVE CLEARANCE.

30
19. Engine has early wear
Cause Correction

• Dirt in Lubrication Oil • Remove dirty lubrication oil. Install

new filters. Put clean oil in the engine.
Check oil filter bypass valve for a weak
or broken spring.
• Inspect all gaskets and connections.
• Air inlet leaks
Make repairs if leaks are found.
• This will cause high fuel consumption
• Fuel Leakage into Lubrication Oil and low engine oil pressure. Make
repairs if leaks are found. Install new
parts where needed.

31
20. Coolant in Lubrication Oil
Cause
• Failure of Oil Cooler Core
• Failure of Cylinder Head Gasket or
Water Seals
• Crack or defect in Cylinder Head
• Crack or defect in Cylinder Block
• Failure of Liner Seals
Correction
• Install a new core for the oil cooler.
Drain crankcase and refill with clean
lubricant. Install new oil filter element.
• Check cylinder liner projection. Install a
new cylinder head gasket and new
water seals in the spacer plate. Tighten
the bolts that hold the cylinder head
according to the specifications.
• Install a new cylinder head
• Install a new cylinder block
• Replace seals
32
21. Too much black or gray smoke
Cause Correction

• Not enough air for combustion • Check air cleaner for restrictions

• Bad fuel injectors • Install new fuel injectors

• Wrong Fuel injection timing • Make adjustments to timing

33
22. Too much white or blue smoke
Cause
• Too much Lubrication Oil in Engine
• Engine misfires or runs rough
• Wrong fuel injection timing
• Worn valve guides
• Worn piston rings
• Failure of Turbocharger Oil Seal
Correction
• Remove extra oil. Find where extra oil
comes from. Put correct amount of oil
in engine.
• Make reference to item 5
• Make adjustment to timing
• Reconditioning of cylinder head is
needed
• Install new piston rings
• Check inlet manifold for oil and repair
turbocharger if necessary.
34
23. Engine has low oil pressure
Cause
• Dirty oil filters or oil cooler
• Diesel Fuel in Lubrication Oil
• Too much clearance between Rocker
Arm Shaft and Rocker Arms
• Oil pump suction pipe has a defect
Correction
• Check the operation of bypass valve for
the filter. Install new oil filters if
needed. Clean or install new oil cooler
core. Remove dirty oil from engine. Put
clean oil in engine.
• Find the place where diesel fuel gets into
the lubrication oil. Make repairs as
needed. Remove the lubrication oil that
has diesel fuel in it. Install new oil
filters. Put clean oil in the engine.
• Check lubrication in valve
compartments. Install new parts as
necessary
• Replacement of pipe is needed
35
23. Engine has low oil pressure
Cause
• Oil pressure relief does not close
• Oil Pump has a defect
• Too much clearance between
Crankshaft and Crankshaft Bearings
• Too much clearance between Camshaft
and Camshaft Bearings
• Defect in Oil Pressure Gauge
Correction
• Clean valve and housing. Install new
parts as necessary.
• Repair or replace oil pump
• Inspect the bearings and make
replacement as necessary.
• Install new camshaft and camshaft
bearings if necessary.
• Install new gauge
36
24. Engine uses too much lubrication oil
Cause
• Too much Lubrication Oil in Engine
• Oil Leaks
• Oil Temperature is too high
• Too much oil in the Valve Compartment
• Worn valve guides
• Worn Piston Rings
• Failure of seal rings in Turbocharger
Correction
• Remove extra oil. Find where extra oil
comes from. Put correct amount of oil in
engine.
• Find all oil leaks. Make repairs as needed.
Check for dirty crankcase breather.
• Check operation of oil cooler. Install new
parts if necessary. Clean the core of the oil
cooler.
• Be sure that the dowel is installed in the left
bolt hole of the rocker shaft.
• Reconditioning of the cylinder head is needed
• Inspect and install new parts as needed
• Check inlet manifold for oil and make repairs
to the turbocharger if necessary.
37
25. Engine Coolant is too hot
Cause
• Restriction to flow of coolant through
radiator core tubes or heat exchanger
• Restriction to air flow through radiator
• Low fan speed
• Not enough coolant in system
• Pressure cap has a defect
• Combustion gases in coolant
Correction
• Clean and flush radiator or heat
exchanger
• Remove all restrictions of flow.
• Check for worn or loose fan belts
• Add coolant to cooling system. Check
for leaks.
• Check operation of pressure cap. Install
a new pressure cap if necessary.
• Find out where gases get into the
cooling system. Make repairs as
needed.
38
25. Engine Coolant is too hot
Cause
• 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
• Check water temperature regulators for
correct operation. Check temperature
gauges operation. Install new parts as
necessary
• Make repairs to the water pump as
necessary
• Make a reduction to the load
• Make adjustment to timing
39
26. Starter motor does not turn
Cause
• Battery has low output
• Wiring or Switch has defect
• Starter motor solenoid has a defect
• Starter motor has a defect
Correction
• Check condition of battery. Check
alternator charging output. Charge
battery or make replacement as
necessary.
• Make repairs or replacement as
necessary
• Install a new solenoid
• Make repair or replacement of starter
motor.
40
27. Alternator gives no charge
Cause
• Loose drive belts for alternator
• Charging or ground return circuit or
battery connections have a defect
• Rotor (field coil) has a defect
Correction
• Make an adjustment to put the correct
tension on the drive belts
• Inspect all cables and connections.
Clean and tighten all connections.
Make replacement of parts with defect.
• Install a new rotor.
41
28. Alternator charge rate is low or not regular
Cause
• Loose drive belts for alternator
• Charging or ground return circuit or
battery connections have a defect.
• Alternator regular needs adjustment or
has a defect
• Rectifier Diodes have a defect
• Rotor (Field Coil) has a defect
Correction
• Make an adjustment to put the correct
tension on the drive belts
• Inspect all cables and connections.
Clean and tighten all connections.
Make replacement of parts with defect.
• Make an adjustment to the alternator
regulator. If a replacement of the
regulator is needed, the alternator must
be disassembled.
• Make replacement of rectifier diode that
has a defect.
• Install a new rotor.
42
29. Alternator charge too much
Cause Correction

• Alternator or Alternator Regulator has • Tighten all connections to alternator or

loose connections. alternator regulator
• Alternator Regulator needs adjustment • Make an adjustment of the alternator
or has a defect regulator. If a replacement of the
regulator is needed, the alternator must
be disassembled.

43
30. Alternator has noise
Cause
• Drive Belts for Alternator are worn or
have a defect
• Loose Alternator Drive Pulley
• Drive belts and Drive Pulley for
Alternator are not in alignment.
• Worn Alternator Bearings
Correction
• Install new drive belts 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
44
31. Exhaust Temperature is too high
Cause
• Air inlet system has a leak
• Exhaust system has a leak
• Air inlet or Exhaust system has a
restriction
• Wrong Fuel Injection timing
Correction
• Check pressure in the air intake
manifold. Look for restrictions at the
air cleaner. Correct any leaks.
• Find cause of exhaust leak. Make
repairs as necessary
• Remove restriction
• Make an adjustment to the timing
45
32. Air Starter motor turn slowly or has a loss of power
Cause
• Low supply air pressure
• Pressure Regulator Adjustment not
correct
• Oiler not working correctly
Correction
• Make an increase to the air supply
pressure.
• Make an adjustment to the air pressure
regulator
• Check the oiler, inlet hose, fitting and
oil supply hose to make sure they are
vacuum tight and free of leaks. Clean,
make adjustment, tighten all fittings, fill
oiler or make a replacement, if
necessary.
46
32. Air Starter motor turn slowly or has a loss of power
Cause Correction

• Disassemble the motor and make an

• Worn motor parts
inspection of the parts. A guide for
determining worn parts that cannot be used
again is as follows:
– Install a set of new vanes if any vane is
cracked, damaged or worn to the extent
that its width is 32mm (1.25 in.) at either
end.
– Replace rotor bearings if any roughness
or looseness is apparent in the bearings
– Replace rotor if the body has deep
scoring that cannot be removed with the
use of emery cloth
– Replace cylinder if there are any cracks
or deep scoring.
– Clean up end plate scoring with emery
cloth placed on a flat surface

47
32. Air Starter motor turn slowly or has a loss of power
Cause Correction

• Air Leakage • Check the motor for worn seals. Plug

the exhaust. Apply 205 kPa (30 psi) air
to the inlet and put the unit in
nonflammable fluid for 30 seconds. If
bubbles appear, make a replacement of
the motor seals.

48
33. Air starter motor pinion does not engage with the
flywheel
Cause Correction

• Broken clutch jaws or other parts • Make a replacement of the parts

49
34. Air starter motor runs, pinion engages but does not
turn the flywheel
Cause Correction

• Broken shafts, gears or clutch jaws • Make a replacement of the parts

50
35. Air starter motor pinion does not engage correctly
with the flywheel
Cause Correction

• Dry pinion shaft • Remove the drive pinion and put clean
grease on the drive shaft splines and
drive pinion

51