2.3 .Trouble Shooting For Engine (2010 + )

Engine Trouble Shooting overseas a/s
section
Engine Trouble Shooting
page1
section
1-1 Engine won’t start
1. Check which starter turn or not 8. Check the air cleaner filter
9. Check the fuel level including gauge

2. Check the battery
10. Check the fuel line
3. Check the power relay & Aux fuse No.5

11. Check the engine stop motor system
12. Check the check valve

4. Check which gear stage is neutral
of injection pump
13. Check the fuel strainer

5. Check the starter or starter relay
14. Check the cap or check valve of
fuel tank
6. Check the harness earth status
15. Check the fuel filter
7. Check the harness line including

16. Check the injection pump & Injector
combination switch
page2
section
1-1 Check point regarding engine won’t start(1) MAIN MENU
No. : 1-1-1 Check which starter turn or not No. : 1-1-2 Check the battery
photo photo
Location : The left side of engine Location : The right side of frame
Checking Method : Checking Method :

1.Check which starter does turn or not 1.MF Battery : check the state of charge by test indi-
when turn the starter key to “START” position. cator(green color →normal, black →recharge,
transparent → replace)
2.PT Battery : check the voltage between (+) & (-)
(below 10.5V → replace, 12.5v ~ 10.6 → recharge
above 12.6V → normal)
Starter turn : go to No. 1-1-8 Normal : go to 1-1-3
Starter does not turn : go to No. 1-1-2 Abnormal : need to recharge or replace
page3
section
No. : 1-1-3 Check the power relay & Aux fuse No.5 No. : 1-1-4 Check which gear stage is neutral
Location : Power relay(in the grove box) Location : near drive seat(change lever)
Aux fuse No.5(in the aux fuse box) top side of transmission(neutral switch)
1.fuse : check which No.5 fuse is shortage. 1.change lever : Check which position is neutral
2.power relay : When supply power between termi- 2.When place the neutral position, check the resi-
nal No.86 & 85, check the resistance between ter- stance between GB terminal & G terminal.
minal No.87 & 30. If resistance value is unlimited, 3. If there is resistance value, it is normal.
it is abnormal. If not, need to replace the neutral switch
Normal : go to No.1-1-4 Neutral position : go to No.1-1-5
Shortage or damage : Need to replace Be not neutral : place change lever neutral stage
page4
section
No. : 1-1-5 Check the starter or starter relay No. : 1-1-6 Check the harness earth status
earth position
photo photo
Location : The left side of engine Location : The left side of engine

1.When supply power between GL & B harness, 1.Check that earth is clean & fixing bolt is tighten
check the resistance value between R harenss. 2.If it was dirty or loose, clear the earth & fasten
If there is resistance value, it is normal.
Normal : go to No.1-1-6 Normal : go to No.1-1-7
Abnormal : replace the neutral switch Abnormal : Fasten or clear the earth position
page5
section
No. : 1-1-7 Check the harness line No. : 1-1-8 Check the air cleaner filter
photo photo
Location : The right side of steering column Location : In the air cleaner

1.Check the harness line between fuse No.5 & Key 1.Check that element has been clogged severely
Box(LY color) with dust particles.
2.Check the harness line between ignition s/w &
engine stop motor(RL color)
Normal : Replace the ignition switch If filter is clean : go to No.1-1-9
Abnormal : Repair the harness line If filter is dirty : replace the air cleaner filter
page6
section
No. : 1-1-9 Check the fuel level including gauge No. : 1-1-10 Check the fuel line
photo
Location : The left side of meter cluster(fuel gauge)

Location : Between fuel tank and injection pump
The right side of frame(fuel tank)
1.Check that needle of fuel gauge indicates between 1.Check that fuel line has been clogged severely
F & E. If not, replenish fuel. with dust object between fuel tank and injection
2.Check that fuel is empty or not. pump.
If it is empty, replenish fuel.
When level is not empty : go to No.1-1-10 Normal : go to No.1-1-11
When level is empty, replenish fuel. If fuel line is clogged, clear the line
page7
section
No. : 1-1-11 Check the engine stop motor system No. : 1-1-12 Check the check valve of injection pump
photo photo
Location : The inside of sill inner panel,RH Location : The top of injection pump

1.Check which engine motor operate when turn the 1.Check the opening pressure of check valve.
starter key to “ON” position. 2.Specification of pressure : 1.6Bar
Normal : go to No.1-1-12 Normal : go to No. 1-1-13
Abnormal : replace the engine stop motor Abnormal : replace the check valve
page8
section
No. : 1-1-14 Check the cap or check valve of fuel
No. : 1-1-13 Check the fuel strainer
tank
photo photo
Location : In the fuel feed pump Location : The top of fuel tank

1.Check that fuel strainer has been clogged 1.Check that check valve has been clogged
severely with some particles. severely
with dust object.
2.Check which hose is bent or damaged.
If strainer is clean : go to No.1-1-14 Normal : go to No.1-1-15
If strainer is dirty : clear the strainer If is clogged, clear or replace the valve
page9
section
No. : 1-1-15 Check the fuel filter No. : 1-1-16 Check the injection pump & Injector
photo photo
Location : The right side of engine(DE engine)

Location : The rear of engine
The top of engine(DV engine)
1.Check that fuel line has been clogged severely 1.Check the injection timing, injection pressure &
with dust object at fuel filter. injection condition
2.Refer the engine service manual, if you want spec.
Normal : go to No.1-1-16
If be clogged, replace the fuel filter. Abnormal : repair the injection pump or injector
page10
section
1-2 Engine overheating
1. Check the coolant for level & color 11. Check the external leakage of coolant
2. Check the using condition

12. Check engine oil
3. Check the tighten condition of fan & fan

clutch 13. Check surge tank cap
4. Check which fan & fan guide is damaged

14. Check the internal leakage of coolant
5. Check which radiator is covered with
some objects
15. Check the oil cooler
6. Check the temperature gauge &
temperature sensor
16. Check the air compressor

7. Check the operation of fan & fan clutch
17. Check cylinder cavitation

8. Check the thermostat
10. Check the circulation line of coolant

9. Check the water pump
about blocking
page11
section
1-2 Check point regarding engine overheating(1) MAIN MENU
No. : 1-2-1 Check the coolant for level & color No. : 1-2-2 Check the using condition
photo photo
Location : The rear of cabin(surge tank) Location :

1.Check the level of coolant in the surge tank 1.Check the using condition
If coolant level is between “max” & “min”, (Overload, high temperature areas, high rpm,
it is normal. high mountain areas etc)
2.Check the color of coolant which be drained thro-
ugh drain cock of radiator.
Lack or discoloration of coolant: go to No.1-2-11 If using condition is abnormal, ask to buyer

page12
section
No. : 1-2-3 Check the bolting condition of fan & fan
No. : 1-2-4 Check which fan & fan guide is damaged
clutch
photo photo
Location : The front of engine Location : The rear of radiator

1.Check the bolting condition of fan & fan clutch. 1.Check which fan & fan guide is damaged.
Check which bolt is loose or not. 2.If damaged, must replace that.
2.If it be loose, fasten the bolt
If it be loose, fasten the bolt If damaged, replace the fan or fan guide
page13
section
No. : 1-2-5 Check which radiator is covered with No. : 1-2-6 Check the temperature gauge &
some objects temperature sensor
photo photo
Location : Temperature sensor(on the cooling pipe)

Location : The front of vehicle
Temperature gauge(on the instrument)
1.Check which radiator is covered with some 1.Check the operation of temperature gauge &
temperature sensor.
objects(cloth, vinyl, paper etc.) Water Temp.(℃) Resistance(Ω) Gauge angle( ˚)
2.If there is an obstacle for cooling, remove that. 50 231.0 0
85 63.5 20
105 35.8 40
125 21.3 60
If you find an obstacle for cooling, remove that Abnormal : Replace the sensor or gauge
page14
section
No. : 1-2-7 Check the operation of fan & fan clutch No. : 1-2-8 Check the thermostat
photo
Location : The front of engine Location : The front top of engine

1.Check the fan speed at hot(65 ℃) & cold(50 ℃) time 1.Check the operation of thermostat
2.Specification of fan speed. 2.Refer the above picture for test of thermostat.
Maker hot time cold time Specification of thermostat
BorgWarner 95% of E/S* Below 40% of E/S* Open at(℃) Full open temp.(℃)
Korea GMB 90% of E/S* Below 40% of E/S* general country 83 95
E/S* : Engine Speed hot country 71 85
Abnormal : Replace the fan clutch Abnormal : replace the thermostat

page15
section
No. : 1-2-10 Check the circulation line of coolant
No. : 1-2-9 Check the water pump
about blocking
photo photo
Location : The front of engine Location :

1.Check which impeller of water pump be rotated 1.Check the circulation line of coolant about block-
or not during rotation of pulley or gear. ing.
2.If not, check the belt, bearing or teeth of gear. 2.Check point : radiator core, engine cylinder block,
oil cooler, cylinder head, air compressor, water
pipe, etc.
If was damaged, replace the damaged parts. If was blocked by some things, clear that.
page16
section
No. : 1-2-11 Check the external leakage of coolant No. : 1-2-12 Check engine oil
photo photo
Location : Location : In the engine

1.Check the external leakage of coolant. 1.Check the level and color of engine oil.
2.Check point : radiator, cylinder gasket, coolant 2.Check which engine oil is mixed with coolant
pipe, coolant hose, etc) or not after draining engine oil through drain plug.
3.If found external leakage, tighten fitting or replace
the defect parts
Abnormal : tighten or replace Abnormal : go to No.1-2-15

page17
section
No. : 1-2-13 Check surge tank cap No. : 1-2-14 Check the internal leakage of coolant
photo photo
Location : The rear of cabin(Top of surge tank) Location : In the engine

1.Check the operation of surge tank cap. 1.Check the internal leakage of coolant.
Specification of surge tank cap. 2.Check point : engine cylinder block, heater core,
Pressure valve opening : 0.7±0.1 ㎏ / ㎠ cylinder gasket, etc.)
Vacuum valve opening : 0.1 ㎏ / ㎠
Abnormal : replace the surge tank cap Abnormal : Change the defected parts.
page18
section
No. : 1-2-15 Check the oil cooler No. : 1-2-16 Check the air compressor
photo photo
Location : The left side of engine(DE engine)

Location : The right side of engine
The rear of engine(DV engine)
1.Check which coolant is mixed with engine oil 1.Check which coolant is mixed with engine oil
through oil cooler. through air compressor.
2.If oil cooler was damaged, replace the oil cooler. 2.If oil compressor was damaged, replace the air
compressor.
If oil cooler was damaged, change the cooler. Abnormal : repair the injection pump or injector
page19
section
No. : 1-2-17 Check cylinder cavitation
photo
BLANK
Location : In the engine block
Checking Method :
1.Check which coolant is mixed with engine oil
through engine cylinder liner.
2.If happen cavitation of cylinder liner, replace the
cylinder liner and add the inhibitor at coolant.
(3% of coolant volume)
If happen cylinder cavitation, replace the cylinder

liner and add the inhibitor at coolant.
(See engine manual for detail information)
page20
section
1-3 Lack of power
Fuel system Air system ETC
8.Excessive resistance of
1.Low quality & grade of fuel 14.Using condition
inlet air
2.Air and/or moisture in fuel 9.Excessive back pressure 15.Cooling fan inoperative
of exhaust gas
16.Intake and/or Exhaust

3.High fuel temperature
valve leakage
10.Leak in air line
4.Foreign material in fuel 17.Push rod broken or

line bended
11.High ambient temperature

18.Broken, scored or worn
5.Rout of fuel line
piston ring
12. Turbo charger intake

6.Engine control cable impeller defective 19.Injection timing
7. Injection nozzle 13.Faulty intercooler 20.Slip of clutch pad

page21
section
1-3 Check point regarding lack of power(1) MAIN MENU
No. : 1-3-1 Low quality & grade of fuel No. : 1-3-2 Air and/or moisture in fuel
photo photo
Location : Top of filter(fuel tank)

Location : The right side of frame(fuel tank)
Front of injection pump(Feed pump)
1.Drain the fuel through drain hole of fuel tank 1.Drain the fuel through drain cock of fuel filter
2.Check the quality & grade of fuel 2.Check which there is moisture in fuel or not
▣ Specification of fuel: 3.Drain the fuel through pump filter after turning
Sulfur → less than 1%, the feed pump cap anti-clockwise.
Cetane Number : minimum 40 4.Check which there is air in fuel or not
If is poor quality, change the fuel If is air or moisture in fuel, remove that
page22
section
No. : 1-3-3 High fuel temperature No. : 1-3-4 Foreign material in fuel line
photo photo
Location : sub parts of injection pump(fuel pump) Location : Inside of frame

1.Check the temperature of fuel at fuel pump 1.Check that fuel line has been clogged severely
2.Specification : below 38℃ with dust object(fuel line, strainer of injection
pump, etc)
Abnormal : Change the fuel or fuel line route If fuel line is clogged, clear the line
page23
section
No. : 1-3-5 Rout of fuel line No. : 1-3-6 Engine control cable
Engine control lever
photo photo
Engine control cable

full
load idling
position position
Location : Inside of frame Location : sub parts of injection pump

1.Check that fuel line has been bended between 1.Check the angle of between full load position &
fuel tank and injection pump idling position
2.Specification
DE12 engine series : 34˚ ± 3 ˚
DV15 engine series : 32˚ ± 6 ˚
Abnormal : modify the rout of fuel line Abnormal : Adjust engine control cable
page24
section
No. : 1-3-7 Check the injection nozzle No. : 1-3-8 Excessive resistance of inlet air
nozzle spray patterns photo

▣ Specification of injection pressure
DE12, DE12T : 220 ㎏ / ㎠
DE12TI, DE12TIS : 160 ㎏ / ㎠ (1st), 220 ㎏ / ㎠
(2nd)
DV15, DV15T, DV15TI : 200 ㎏ / ㎠
DV15TIS : 250 ㎏ / ㎠
Location : In the head cover(Injection nozzle) Location :

1.Check injection pressure, and adjust the nozzle 1.Check the resistance of inlet air
using the adjusting shim if the pressure does Check point : air cleaner, air inlet hose, intake
not meet the specified limit. manifold, intercooler, etc
2.Check nozzle spray patterns and replace 2.Check the pressure of inlet air(at outlet pipe of air
if damaged cleaner)
3.Refer to engine manual for detail information Specification : below 300 ㎜ Aq,
Normal : check the air system or etc system Normal : go to No.1-3-9
Abnormal : Replace or adjust the nozzle Abnormal : clear the air line
page25
section
No. : 1-3-9 Excessive back pressure of exhaust gas No. : 1-3-10 Leak in air line
photo photo
Location : Exhaust manifold Location :

1.Check the back pressure of exhaust gas 1.Check which air line is leak or not.
2.Check point & specification: 2.Check point : intake duct, intake elbow, intake
NA type →Outlet port of exh. manifold(1000 ㎜ Aq) hose, intercooler, intake manifold,etc
TC type →Outlet port of turbo charger(600 ㎜ Aq)
Abnormal : Replace or repair the exhaust manifold If be leakage, replace or repair the defected part
page26
section
No. : 1-3-11 High ambient temperature No. : 1-3-12 Turbo charger intake impeller defective
photo photo
Location : Location :

1.Check the temperature of inlet air. 1.Check the turbo charger.
2.Check point & specification 2.Check point : Impeller was damaged
At intake manifold , ???? Leakage of engine oil
Abnormal : Ask to buyer Abnormal : Replace the turbo charger

page27
section
No. : 1-3-13 Faulty intercooler No. : 1-3-14 Using condition
photo photo
Location : Front of engine Location :

1.Check the temperature of deviation between 1.Check the using condition
outlet port and inlet port of intercooler. (Overload, high temperature areas, high mountain
2.Specification : ????? areas etc)
Normal : check the fuel system or etc system Normal : go to No.1-3-15
Abnormal : Clear the tube of intercooler If using condition is abnormal, ask to buyer
page28
section
No. : 1-3-15 Cooling fan inoperative No. : 1-3-16 Intake and/or Exhaust valve leakage
photo photo
Location : Front of engine Location : The top of engine

1.Check the fan speed at hot(65 ℃) & cold(50 ℃) time 1.Check the valve clearance and valve seat contact
2.Specification of fan speed.
Maker hot time cold time -
BorgWarner 95% of E/S* Below 40% of E/S* ing faces for scratches or wear
Korea GMB 90% of E/S* Below 40% of E/S* 2.Specification :
.Valve clearance → DE12 series : 0.3 ㎜ (IN,EX)
E/S* : Engine Speed DV15 series : 0.25(IN), 0.35(EX)
Abnormal : Replace the fan clutch Abnormal : Adjust clearance and replace valve seat
page29
section
No. : 1-3-17 Push rod broken or bended No. : 1-3-18 Broken, scored or worn piston ring
photo photo
Location : In the engine Location : Outside of piston

1.Check which push rod is broken or bended. 1.Check which piston ring is broken, scored or
2.The method of test worn.
:Refer the engine manual for detail. 2.Checking method
- After disassembling, visually check the ring
- Check the cylinder compression pressure
:Refer the engine manual for detail
Abnormal : Replace or correct the push rod If using condition is abnormal, ask to buyer
page30
section
No. : 1-3-19 Injection timing No. : 1-3-20 Slip of clutch pad
photo photo
Location : Front of engine Location : Between engine & transmission

1.Check the injection timing 1.Check the clutch pad
2.Check which install the idle gear by coinciding (excessive abrasion of disc facing, oil sticking to
the marks(2) impressioned on the crank gear,fuel disc facing,etc)
injection pump drive.
Normal : go to No.1-3-20 Normal : check the air system or fuel system
Abnormal : Install correctly Abnormal : Check the clutch system

page31
section
1-4 Low oil pressure
1.Check the oil pressure gauge and

9. Check the external leakage of oil
oil pressure sensor
2. Check the level & spec. of engine oil 10. Check the internal leakage of oil
3. Check which engine is overheated

8. Check the clearance of bearing
or not
4. Check the oil filter 7. Check the oil flow line
5. Check the oil relief valve 6. Check the oil pump

page32
section
1-4 Check point regarding low oil pressure(1) MAIN MENU
No. : 1-4-1 Check the oil pressure gauge and oil
No. : 1-4-2 Check the level & spec. of engine oil
pressure sensor
photo
Location : On the instrument(oil pressure gauge) Location : Below engine(drain plug)

Near oil filter(oil pressure sensor) Side of engine(oil level gauge)
1.Check the operation of oil pressure gauge & 1.Check the level and color of engine oil.
oil pressure sensor. 2.Check which engine oil is mixed with moisture
2.Specification : refer the above table or fuel after draining engine oil through drain
plug.
3.Specification : SAE 15W40
Abnormal : Replace sensor or gauge Abnormal : Replenish and go to No.1-4-9

page33
section
No. : 1-4-3 Check which engine is overheated or not No. : 1-4-4 Check the oil filter
photo photo
Location : The right side of engine(DE series)

Location : On the instrument(coolant temp. gauge)
The front of engine(DV series)
1.Check the position of temperature gauge 1.Check that filter has been clogged severely with
on driving. dust particles.
2.Below the red colored zone : normal 2.Check the opening pressure of bypass valve
H zone : Abnormal Specification : 1.8 ~ 2.3 bar
Normal : go to No. 1-4-4 Normal : go to No. 1-4-5
Abnormal : Check the item regarding overheating Abnormal : Replace filter or bypass valve
page34
section
No. : 1-4-5 Check the oil relief valve No. : 1-4-6 Check the oil pump
photo photo
Location : In the oil pan Location : In the oil pan

1.Check the opening pressure 1.Check the axial end play of the oil pump gear
Specification : Limit : 0.0025 ~ 0.089 ㎜
Relief valve of pump : 10±1.5 bar 2.Check the amount of back lash between oil pump
Bypass for oil cooler : 5+1 bar gear and driven gear
Adjusting valve for spray nozzle : 1.5 ~ 1.8 bar Limit : 0.50 ~ 0.64 ㎜
Refer to engine manual for more information
Abnormal : Repair or replace wrong part Abnormal : Replace oil pump

page35
section
No. : 1-4-7 Check the oil flow line No. : 1-4-8 Check the clearance of bearing
photo photo
Location : Location : In the engine

1.Check that oil flow line has been clogged severely 1.Check the clearance of bearing
with dust particles. 2.Checking point & specification
Conn. Rod bearing : 0.20 ㎜
Main bearing : 0.25 ㎜
Refer to engine manual for more information
Abnormal : Clear the oil line Abnormal : Replace the bearing

page36
section
No. : 1-4-9 Check the external leakage of oil No. : 1-4-10 Check the internal leakage of oil
photo photo

1.Check the external leakage of oil 1.Check the internal leakage of oil
Check point : Head gasket, Air compressor, 2.Check point : oil cooler, oil suction pipe, oil pipe
Turbo charger, breather housing etc.
Abnormal : Fasten bolt or replace gasket,seal Abnormal :Repair or replace the wrong part
page37
section
1-5 High fuel consumption
Fuel system ETC system
1.Low quality & grade of fuel 8.Using condition
2.Fuel external leakage
9.Air cleaner and intake system fouled
3.Moisture in fuel
4.Foreign material in fuel line 10.Intake and/or Exhaust valve clearance
5.Injection nozzle
11.Each gasket or seal leaky
6.Injection timing
7.Injection pump 12.Push rod broken or bended

page38
section
1-5 Check point regarding high fuel consumption(1) MAIN MENU
No. : 1-5-1 Low quality & grade of fuel No. : 1-5-2 Fuel external leakage
photo
Location : The right side of frame(fuel tank) Location :

1.Drain the fuel through drain hole of fuel tank 1.Check the fuel external leakage
2.Check the quality & grade of fuel 2.Check point :
▣ Specification of fuel: Fuel tank, Fuel line(supply & return), Fuel filter,
Sulfur → less than 1%, Feed pump, etc
Cetane Number : minimum 40
If is poor quality, change the fuel Abnormal :Repair or replace defected part
page39
section
No. : 1-5-3 Moisture in fuel No. : 1-5-4 Foreign material in fuel tank
photo photo
Location : The rear of engine(fuel filter) Location : The right side of frame(fuel tank)

1.Check which fuel is mixed with moisture after 1.Check which there is foreign material in the fuel
draining fuel through the drain plug tank.
2.If contains moisture in the fuel, change the fuel
Abnormal : change the fuel or fuel filter Abnormal :Clean or replace the fuel tank
page40
section
No. : 1-5-5 Injection nozzle No. : 1-5-6 Injection timing
nozzle spray patterns photo

▣ Specification of injection pressure
DE12, DE12T : 220 ㎏ / ㎠
DE12TI, DE12TIS : 160 ㎏ / ㎠ (1st), 220 ㎏ / ㎠
(2nd)
DV15, DV15T, DV15TI : 200 ㎏ / ㎠
DV15TIS : 250 ㎏ / ㎠
Location : In the head cover(Injection nozzle) Location : In the timing gear case

1.Check injection pressure, and adjust the nozzle 1.Check the injection timing
using the adjusting shim if the pressure does 2.Check which install the idle gear by coinciding
not meet the specified limit. the marks(2) impressioned on the crank gear,fuel
2.Check nozzle spray patterns and replace injection pump drive.
if damaged
3.Refer to engine manual for detail information
Abnormal : Replace or adjust the nozzle Abnormal :Repair or replace the wrong part
page41
section
No. : 1-5-7 Injection pump No. : 1-5-8 Using condition
photo photo
Location : The right side of engine(DE engine)

Location :
The top of engine(DV engine)
1.Make sure that servicing should be performed at 1.Cause according to operating condition
the professional maintenance shop as authorized - Overload
by Bosch or Zexel Company - Frequent use of low gear position at high speed
2.Refer to engine manual for specification - Frequent use of high gear position at low speed
- Clutch slip
- Too low tire inflation pressure
Normal : Check the etc system Normal : go to No.1-5-9
Abnormal : Adjust injection pump Abnormal :Observe the owner’s manual

page42
section
No. : 1-5-9 Air cleaner and intake system fouled No. : 1-5-10 Intake and/or exhaust valve clearance
photo photo
Location : Location : The top of engine

1.Check that intake system has been clogged 1.Check the valve clearance and valve seat contact
severely with dust object -
2.Check point : air cleaner, air duct, inlet hose etc ing faces for scratches or wear
2.Specification :
.Valve clearance → DE12 series : 0.3 ㎜ (IN,EX)
DV15 series : 0.25(IN), 0.35(EX)
Abnormal : Fasten bolt or replace gasket,seal Abnormal : Adjust clearance and replace valve seat
page43
section
No. : 1-5-11 Each gasket or seal leaky No. : 1-5-12 Push rod broken or bended
photo photo

1.Check which 1.Check which push rod is broken or bended.
2.The method of test
:Refer the engine manual for detail.
Normal : go to No.1-4-10 Normal : check regarding lack of power
Abnormal : Replace the gasket or seal Abnormal : Replace the push rod
page44
section
1-6 Excessive oil consumption
1.Verify the oil consumption rate 6.Check the condition of exhaust gas
2.Check the quality & grade of engine oil

7.Check that turbocharger oil seal is leaking
and change interval
8.Check that air compressor is pumping oil

3.Check the oil fouled or moisture
into the air system
4.Check the external oil leakage 9.Check that oil is contaminated with coolant
10.Check that boring parts broken damaged,

5.Check that crankcase ventilation is plugged
page45 or worn
section
1-6 Check point regarding Excessive oil consumption(1) MAIN MENU
No. : 1-6-2 Check the quality & grade of engine oil
No. : 1-6-1 Verify the oil consumption rate
and change interval
min
max photo
Location : The front of engine(oil level gauge) Location : In the engine

1.After operating the vehicle, check the oil level 1.Check the quality & grade of engine oil
2.Replenish the oil to max mark of level gauge 2.Specification :
3.After operating the vehicle about 10,000 T or TI engine series : API CF-4 ,SAE15W40,
㎞ ,recheck Every 10,000 ㎞
the level of oil. TIS engine series : API CH-4,SAE15W40,
4.If level is located between max and min mark, Every 20,000 ㎞
it’s normal
Abnormal : go to No.1-6-2 Normal : go to No.1-6-3
Normal : Abnormal : Change to the regulation oil

page46
section
No. : 1-6-3 Check the oil fouled or moisture No. : 1-6-4 Check the external oil leakage
photo
Location : The right side of frame(fuel tank) Location :

1.Check the oil fouled or moisture. 1.Check the external oil leakage
2.Check point :
Oil pan, Cylinder head, Exhaust manifold etc.

Abnormal :Tighten the cap screws, pipe plugs &
Abnormal : Change to the regulation oil fitting. Replace gaskets if necessary
page47
section
No. : 1-6-5 Check that crankcase ventilation is
No. : 1-6-6 Check the condition of exhaust gas
plugged
photo
Location : The top of engine Location :

1.Check that crankcase ventilation is plugged. 1.Check the condition of exhaust gas.
2.If it is plugged, clean the crankcase breather and 2.If there is black smoke, check the air cleaner
vent tube and ring kit.
Abnormal : Clean the crankcase Black smoke : go to No.1-6-10

page48
section
No. : 1-6-7 Check that turbocharger oil seal is No. : 1-6-8 Check that air compressor is
leaking pumping oil into the air system
photo
Location : Side of Engine(Turbocharger) Location : Left side of engine

1.Check the turbocharger compressor and turbine 1.After removing air pipe, check the oil leak through
seal is leaking air compressor.
2.If leaked, replace the turbocharger 2.If oil leaked excessively, replace the air
compressor.
Abnormal : Replace the turbocharger Abnormal : Replace the air compressor or ring
page49
section
No. : 1-6-9 Check that oil is contaminated with No. : 1-6-10 Check that boring parts broken
coolant damaged, or worn
photo
Location : Rear of cabin Location :

1.Check that oil is contaminated with coolant 1.Check that boring parts broken, damaged or
2.If mixed, need to overhaul the engine. worn.
2.Check point : bearing, valve stem seal, ring kit
etc.
Normal : Normal :
Abnormal : Overhaul the engine Abnormal :Repair defected parts

page50
section
1-7 Engine knocks(excessive)
1.Verify the oil consumption rate 6.Check the condition of exhaust gas
2.Check the quality & grade of engine oil

7.Check that turbocharger oil seal is leaking
and change interval
8.Check that air compressor is pumping oil

3.Check the oil fouled or moisture
into the air system
4.Check the external oil leakage 9.Check that oil is contaminated with coolant
10.Check that boring parts broken damaged,

5.Check that crankcase ventilation is plugged
page51 or worn

2.3 .Trouble Shooting For Engine (2010 + )

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2.3 .Trouble Shooting For Engine (2010 + )

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Engine Trouble Shooting overseas a/s

Engine Trouble Shooting

9. Check the fuel level including gauge

10. Check the fuel line

3. Check the power relay & Aux fuse No.5

12. Check the check valve

13. Check the fuel strainer

7. Check the harness line including

Checking Method : Checking Method :

Starter turn : go to No. 1-1-8 Normal : go to 1-1-3

Normal : go to No.1-1-4 Neutral position : go to No.1-1-5

Checking Method : Checking Method :

Normal : go to No.1-1-6 Normal : go to No.1-1-7

Checking Method : Checking Method :

Normal : Replace the ignition switch If filter is clean : go to No.1-1-9

Location : The left side of meter cluster(fuel gauge)

When level is not empty : go to No.1-1-10 Normal : go to No.1-1-11

Checking Method : Checking Method :

Normal : go to No.1-1-12 Normal : go to No. 1-1-13

Checking Method : Checking Method :

If strainer is clean : go to No.1-1-14 Normal : go to No.1-1-15

Location : The right side of engine(DE engine)

2. Check the using condition

3. Check the tighten condition of fan & fan

4. Check which fan & fan guide is damaged

16. Check the air compressor

17. Check cylinder cavitation

10. Check the circulation line of coolant

Location : The rear of cabin(surge tank) Location :

Checking Method : Checking Method :

Normal : go to No.1-2-2 Normal : go to No.1-2-3

Lack or discoloration of coolant: go to No.1-2-11 If using condition is abnormal, ask to buyer

Location : The front of engine Location : The rear of radiator

Checking Method : Checking Method :

Normal : go to No.1-2-4 Normal : go to No.1-2-5

Location : Temperature sensor(on the cooling pipe)

Location : The front of engine Location : The front top of engine

Normal : go to No.1-2-8 Normal : go to No.1-2-9

Abnormal : Replace the fan clutch Abnormal : replace the thermostat

Location : The front of engine Location :

Checking Method : Checking Method :

Location : Location : In the engine

Checking Method : Checking Method :

Normal : go to No.1-2-12 Normal : go to No.1-2-13

Abnormal : tighten or replace Abnormal : go to No.1-2-15

Location : The rear of cabin(Top of surge tank) Location : In the engine

Checking Method : Checking Method :

Location : The left side of engine(DE engine)

Normal : go to No.1-1-16 Normal : go to No.1-2-17

No. : 1-2-17 Check cylinder cavitation

If happen cylinder cavitation, replace the cylinder

16.Intake and/or Exhaust

4.Foreign material in fuel 17.Push rod broken or

11.High ambient temperature

12. Turbo charger intake

7. Injection nozzle 13.Faulty intercooler 20.Slip of clutch pad

Location : Top of filter(fuel tank)

Normal : go to No.1-3-2 Normal : go to No.1-3-3

Location : sub parts of injection pump(fuel pump) Location : Inside of frame

Checking Method : Checking Method :

Normal : go to No.1-3-4 Normal : go to No.1-3-5

Engine control lever

Engine control cable