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SECTION 5 - ENGINE
5.1 ENGINE TROUBLESHOOTING
The following troubleshooting chart is to be used to
isolate engine problems and give possible causes and
corrective action responses.
TROUBLE
The troubleshooting key is generic and can be used for
several types of engines. Use only those possible
causes and corrective actions that apply to the
unit.
Black Exhaust
Blue/White Exhaust
Difficult Starting
Erratic Running
Excessive Fuel Consumption
Excessive Crankcase Pressure
High Oil Pressure
Knocking
Loss of Power or System
Low Cranking Power
Low Oil Pressure
Misfiring
Overheating
Poor Compression
Starts and Stops
POSSIBLE CAUSES
(Refer to Key Below)
1, 20, 22, 25, 29, 31, 32, 33
4, 20, 25, 31, 33, 34
1, 5, 7, 8, 9, 10, 20, 21, 22, 29, 31, 32, 33
1, 7, 8, 9, 10, 20, 21, 23, 26, 29, 33, 59, 62
1, 20, 22, 23, 25, 29, 31, 32, 33
25, 31, 33, 34, 45, 55
4, 41
22, 26, 29, 31, 33, 36, 46, 59
1, 8, 10, 20, 21, 22, 23, 25, 26, 31, 32, 33
2, 3, 4, 11
4, 36, 37, 39
10, 20, 25, 26, 28, 29, 32
1, 19, 25,
25, 28, 29, 31, 32, 33, 34,59,
1, 6, 10, 62
Vibration
Will Not Crank
Will Not Start
20, 23, 25, 26, 29, 33, 45, 49
2, 11, 45
1, 10, 62
CORRECTIVE ACTION
repair
repair
repair
repair
repair
or replace
or replace
or replace
or replace
or replace
repair or replace
repair or replace
repair or replace
repair or replace
repair or replace
repair or replace
repair or replace
repair or replace
repair or replace
see electrical systems
see engine service manual
repair or replace
charge battery or replace
repair or replace
see electrical systems
see engine service manual
TROUBLESHOOTING KEY
1
2
3
4
5
6
7
16
17
18
19
Restriction in air cleaner
Bad electrical connection
Faulty starter motor
Incorrect grade of lubricating oil
Low cranking speed
Fuel tank empty
Controls not in correct operation
position
Blocked fuel feed line
Faulty fuel lift pump
Choked fuel filter
Battery capacity low
Air in fuel system
Faulty fuel injection pump
Faulty fuel injectors or incorrect
type
Incorrect use of cold start
equipment
Faulty cold start equipment
Broken fuel injection pump drive
Incorrect fuel pump timing
Incorrect valve timing
20
21
Poor compression
Blocked fuel tank vent
8
9
10
11
12
13
14
15
22
23
24
25
26
27
28
Incorrect grade of fuel
Sticking throttle/restricted movement
Exhaust pipe restriction
Leaking cylinder head gasket
Overheating
Cold running
Incorrect tappet adjustment
43
44
45
46
47
48
49
29
30
31
32
33
34
35
Sticking valves
Incorrect high pressure pipes
Worn cylinder bores
Pitted valves and seats
Broken, worn or sticking piston ring(s)
Worn valve stems and guides
Restriction in air cleaner
50
51
52
53
54
55
56
36
Worn or damaged bearings
57
37
38
39
40
Insufficient oil in sump
Bad/defective oil temperature switch
Oil pump worn
Pressure relief valve sticking open
58
59
60
61
41
42
Pressure relief valve sticking closed
Broken relief valve spring
62
5 - 17
Faulty suction pipe
Choked oil filter
Bad solenoid switch
Incorrect piston height
Damaged fan
Faulty engine mounting
Incorrectly aligned flywheel and/or
flywheel housing
Faulty thermostat
Restriction in water jacket
Loose fan belt
Choked radiator
Faulty water pump
Choked breather pipe
Damaged valve stem oil deflector (if
fitted)
Coolant level too low
Blocked sump strainer
Broken valve spring
Exhaust or vacuum pipe leak
Bad or defective water temperature
switch
Bad spark plug(s)