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Engine Will Not Start or Starts Hard
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Fuel tank empty.
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Check fuel quantity.
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Fuel tank vent plugged.
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Remove cap and listen to sound of air entering tank.
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No electrical power to injection pump solenoid.
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Turn key switch to ON. Must hear "click" at injection pump. Replace fuse. Repair wiring. See your authorized dealer.
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Water in fuel or water frozen in fuel line.
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Drain water from fuel tank trap. Change filter. Inspect fuel filter for water.
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Debris in fuel or wrong grade of fuel.
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Check outlet strainer for debris. Check water trap for debris with a flashlight through the filler neck toward bottom of right corner of fuel tank. Check fuel grade.
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Air leak on suction side of fuel system.
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Check for bubbles in fuel filter and tighten connections. Inspect fuel lines for damage.
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Fuel transfer pump diaphragm leaking.
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Check engine oil for fuel dilution.
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Slow cranking speed.
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Check battery and connections.
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Restricted air filter.
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Check air filter restriction indicator and air filters.
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Injection pump metering valve.
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Tap injection pump housing (lightly). If engine now starts, see your authorized dealer.
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Electric shut off solenoid.
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See your authorized dealer.
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Injection pump timing.
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See your authorized dealer.
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Injection pump.
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See your authorized dealer.
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Injection nozzle(s).
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See your authorized dealer.
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| Symptom |
Problem |
Solution |
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Engine Surges or Stalls Frequently
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Air in fuel.
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Inspect filter for evidence of air in fuel. Tighten connections and bleed fuel system.
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Fuel tank vent plugged.
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Remove cap and listen to sound of air entering tank. Replace cap.
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Debris in fuel or wrong grade of fuel.
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Check fuel tank outlet strainer for debris. Check water trap for debris with a flashlight through filler neck toward bottom right corner of fuel tank. Check fuel grade.
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Water in fuel.
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Drain water trap and inspect filter element for water.
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Fuel filter plugged.
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Replace filter.
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Return line from injection pump to tank restricted.
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See your authorized dealer.
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Restrictor fitting on top fitting in injection pump plugged.
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See your authorized dealer.
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Injection pump metering valve sticking.
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See your authorized dealer.
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Fuel injection pump out of time.
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See your authorized dealer.
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Engine overheating.
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See your authorized dealer.
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Fuel transfer pump.
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See your authorized dealer.
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Fuel injection pump.
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See your authorized dealer.
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Injection nozzle(s).
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See your authorized dealer.
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Valve clearance.
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Check and adjust valve clearance. See Maintenance-Every 1000 Hours or Every 2000 Hours.
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Low lubricity of fuels.
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Check fuel grade. (See Lubricity of Diesel Fuels in Fuels and Lubricants chapter.)
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Valves sticking or burned.
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See your authorized dealer.
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| Symptom |
Problem |
Solution |
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Worn or broken compression rings or cylinder head gasket leaking.
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See your authorized dealer.
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Engine Misses
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Air in fuel.
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Check for evidence of air in fuel. Tighten connections and bleed fuel system.
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Debris in fuel or wrong fuel grade.
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Check fuel tank strainer with flashlight and examine fuel. Check fuel filter for debris. Clean. Check grade of fuel.
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Idle speeds out of adjustment (too low).
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Check engine speeds. See Maintenance-Every 1000 Hours.
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Fuel injection pump out of time.
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See your authorized dealer.
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Fuel transfer pump.
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See your authorized dealer.
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Injection pump governor
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See your authorized dealer.
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Engine overheating.
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See your authorized dealer.
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Incorrect valve clearance.
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Check and adjust valve clearance. See Maintenance-Every 1000 Hours or Every 2000 Hours.
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Push rods.
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See your authorized dealer.
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Cylinder head gasket leaking.
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See your authorized dealer.
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Valve sticking or burned.
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See your authorized dealer.
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Worn or broken compression rings.
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See your authorized dealer.
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Fuel injection pump.
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See your authorized dealer.
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Injection nozzle(s).
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See your authorized dealer.
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| Symptom |
Problem |
Solution |
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Engine Does Not Develop Full Power
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Fuel tank strainer plugged.
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Check water trap for debris with a flashlight through filler neck toward bottom right corner of fuel tank.
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Fuel filter clogged.
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Replace fuel filter.
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Wrong grade of fuel.
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Drain and add correct fuel.
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Air system restricted.
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Check air filter restriction indicator and air filters.
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Incorrect high idle speed (too low).
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Linkage out of adjustment. Adjust. See Maintenance-Every 1000 Hours.
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Injection pump timing.
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See your authorized dealer.
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Valve clearance.
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Adjust valve clearance. See Maintenance-Every 1000 Hours or Every 2000 Hours.
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Injection pump return fuel tube or fittings are restricted.
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See your authorized dealer.
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Fuel transfer pump.
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See your authorized dealer.
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Fuel line restricted.
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See your authorized dealer.
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Excess drag in brakes.
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See your authorized dealer.
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Engine temperature.
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Check thermostat or see your authorized dealer.
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Excess drag in transaxle.
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See your authorized dealer.
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Injection pump.
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See your authorized dealer.
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Injection nozzle.
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See your authorized dealer.
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Muffler restricted.
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See your authorized dealer.
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Low compression.
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See your authorized dealer.
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Turbocharger
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See your authorized dealer.
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Air leak between turbocharger and manifold.
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See your authorized dealer.
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| Symptom |
Problem |
Solution |
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Worn camshaft.
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See your authorized dealer.
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Engine Emits Excessive Black or Gray Exhaust Smoke
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Restricted air filter.
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Check air filter restriction indicator and air filters. Replace.
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Incorrect grade of fuel.
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Use correct grade of fuel.
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Incorrect injection pump timing.
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See your authorized dealer.
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Excessive fuel delivery.
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See your authorized dealer.
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Injection nozzle(s).
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See your authorized dealer.
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Turbocharger.
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See your authorized dealer.
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Air leak between turbocharger and manifold.
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See your authorized dealer.
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Engine Emits Excessive Blue or White Smoke
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Incorrect grade of fuel.
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Use correct grade of fuel.
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Engine running too cold.
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Check thermostat operation. See your authorized dealer.
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Injection pump out of time.
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See your authorized dealer.
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Injection nozzle(s).
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See your authorized dealer.
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Low compression.
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See your authorized dealer.
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Excessive wear in liners and/or piston rings stuck.
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See your authorized dealer.
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Slow Acceleration
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Improper fuel.
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Use correct grade of fuel.
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Fuel injection pump.
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See your authorized dealer.
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Injection nozzle(s).
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See your authorized dealer.
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Detonation (Excess Engine Knock)
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Stuck ether application.
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See your authorized dealer.
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Injection pump out of time.
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See your authorized dealer.
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Incorrect injection pump timing.
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See your authorized dealer.
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| Symptom |
Problem |
Solution |
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Engine Overheats
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Faulty thermostat (stuck closed).
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See your authorized dealer.
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Cooling system coated with lime deposits.
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Flush cooling system. See your authorized dealer.
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Water pump.
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See your authorized dealer.
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Excessive fuel delivery.
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See your authorized dealer.
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Scored piston.
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See your authorized dealer.
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Engine Runs Cold
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Thermostat (stuck open).
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See your authorized dealer.
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Oil In Coolant or Coolant In Oil
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Leaking cylinder head gasket.
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See your authorized dealer.
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Leaking cylinder liner packings.
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See your authorized dealer.
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Cracked cylinder liner.
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See your authorized dealer.
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Cracked cylinder block.
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See your authorized dealer.
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Excessive Fuel Consumption
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Air system restricted.
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Check air filter restriction indicator and air filters. Replace.
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Leakage in fuel system.
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Inspect. Repair.
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Incorrect grade of fuel.
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Refill with correct fuel.
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Operator holding hydraulics over relief.
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Return control levers to neutral position.
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Incorrect injection pump timing.
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See your authorized dealer.
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Faulty injection nozzles.
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See your authorized dealer.
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Turbocharger.
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See your authorized dealer.
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