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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 for sound of air entering tank. Replace cap.
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No electrical power to injection pump solenoid
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Turn key switch to ON position. Must hear click at injection pump. Replace fuse. Repair wiring.
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Water in fuel or water frozen in fuel line.
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Drain water from fuel tank. Inspect fuel filter for water. Change filter.
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Debris in fuel or wrong grade of fuel
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Check fuel tank outlet strainer for type of fuel debris. Check bottom of fuel tank for debris. Clean tank. Add fuel. Check grade of fuel. Add correct fuel. (See Fuels and Lubricants chapter.)
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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. Incorrect engine oil (cold weather).
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Restricted air filter
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Check air filter restriction indicator and air filters. Clean.
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Stuck injection pump metering valve
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Tap injection pump housing (lightly) if engine now starts. Replace metering valve. See your authorized dealer.
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Faulty electric shutoff
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Test shutoff solenoid. See your authorized dealer.
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Improper 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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TX,100,BG336 -19-09JAN97-1/11
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| Symptom |
Problem |
Solution |
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Injection nozzle(s)
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Remove and test nozzles. See your authorized dealer.
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Worn compression rings or low compression
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See your authorized dealer.
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Blown head gasket
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See your authorized dealer.
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TX,100,BG336 -19-09JAN97-2/11
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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 for 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 bottom of fuel tank for debris. Clean tank. Add fuel. Check grade of fuel.
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Water in fuel
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Drain fuel tank and inspect filter element for water. Replace filters.
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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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Fuel injection pump out of time
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See your authorized dealer.
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Check return oil fitting on top of injection pump control cover 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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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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Improper valve clearance
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Check and adjust valve clearance.
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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 or cylinder head gasket leaking
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See your authorized dealer.
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TX,100,BG336 -19-09JAN97-3/11
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| Symptom |
Problem |
Solution |
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Engine Misses
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Air in fuel
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Check for evidence of air in filter. Tighten connections and bleed fuel system.
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Debris in fuel or wrong grade of fuel
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Check fuel tank for water. Check fuel tank strainer and fuel filter for debris. Clean. Check grade of fuel.
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Idle speeds out of adjustment (too low)
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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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Fuel transfer pump
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See your authorized dealer.
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Injection pump governor faulty or metering valve sticking
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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.
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Bent 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) plugged
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See your authorized dealer.
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TX,100,BG336 -19-09JAN97-4/11
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| Symptom |
Problem |
Solution |
|
Engine Does Not Develop Power
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Fuel tank outlet strainer plugged
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Check fuel tank for water or debris. Remove and clean.
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Fuel filter plugged
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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 and air filters. Clean.
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Incorrect high idle speed (too low) or linkage out adjustment
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Adjust linkage. Check high idle speed. See your authorized dealer.
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Incorrect engine or injection pump timing
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See your authorized dealer.
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Incorrect valve clearance
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Adjust valve clearance.
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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 brake system
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See your authorized dealer.
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Excess drag in axle
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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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Injection pump delivery or governor faulty
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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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Worn camshaft
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See your authorized dealer.
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TX,100,BG336 -19-09JAN97-5/11
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| Symptom |
Problem |
Solution |
|
Engine Emits Excessive Black or Gray Exhaust Smoke
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Restricted air filter
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Check air filter restriction and air filters. Clean or replace.
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Incorrect grade of fuel
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Drain and add correct 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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Engine Emits Excessive Blue or White Smoke
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Cranking speed too slow
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Check batteries and connections.
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Incorrect grade of fuel
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Drain and add correct 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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Wrong grade of fuel
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Drain and add correct fuel.
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Injection nozzle(s)
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See your authorized dealer.
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Fuel injection pump
|
See your authorized dealer.
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Detonation (Excess Engine Knock)
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Low engine oil level
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Add oil.
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Stuck cold weather starting aid
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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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Low coolant temperature
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See your authorized dealer.
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TX,100,BG336 -19-09JAN97-6/11
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| Symptom |
Problem |
Solution |
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Abnormal Engine Noise
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Low or incorrect engine oil (too thin)
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Add correct oil to proper level.
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Loose or worn hydraulic pump drive coupling
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See your authorized dealer.
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Engine oil diluted with fuel
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Inspect engine oil. See your authorized dealer.
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Incorrect fuel injection pump timing
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See your authorized dealer.
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Excessive valve clearance
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Adjust valve clearance.
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Bent push rods
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See your authorized dealer.
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Worn rocker arm shafts
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See your authorized dealer.
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Loose connecting rod caps
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See your authorized dealer.
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Loose main bearing caps
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See your authorized dealer.
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Worn main bearings
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See your authorized dealer.
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Worn connecting rod bearings
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See your authorized dealer.
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Incorrect cam timing
|
See your authorized dealer.
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Scored piston
|
See your authorized dealer.
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Worn piston pin bushings and pins
|
See your authorized dealer.
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TX,100,BG336 -19-09JAN97-7/11
|
| Symptom |
Problem |
Solution |
|
Low Oil Pressure (Oil Pressure Light On-Red "Stop" Flashing)
|
Low oil level
|
Add oil to proper level. Inspect engine oil.
|
|
|
Wrong viscosity oil/oil diluted with diesel fuel
|
Change oil and see your authorized dealer.
|
|
|
Oil pressure switch or indicator
|
See your authorized dealer.
|
|
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Oil pressure regulating valve
|
See your authorized dealer.
|
|
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Plugged or broken oil pump intake screen
|
See your authorized dealer.
|
|
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Loose oil pump drive gear
|
See your authorized dealer.
|
|
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Worn oil pump gear or housing
|
See your authorized dealer.
|
|
|
Excessive main bearing, connecting rod or balance shaft clearance
|
See your authorized dealer.
|
|
|
Cracked cylinder block
|
See your authorized dealer.
|
|
|
Leakage at internal oil passage.
|
See your authorized dealer.
|
|
|
TX,100,BG336 -19-09JAN97-8/11
|
| Symptom |
Problem |
Solution |
|
Engine Overheats (Engine Coolant Indicator Light On and Red "Stop" Flashing)
|
Low coolant level
|
Fill cooling system and check for leaks.
|
|
|
Low engine oil level
|
Add oil.
|
|
|
Loose or broken fan belt
|
See your authorized dealer.
|
|
|
Engine overloaded, operating in wrong gear
|
Reduce load.
|
|
|
Fan on backwards
|
See your authorized dealer.
|
|
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Radiator dirty or plugged
|
See your authorized dealer.
|
|
|
Radiator shroud missing, damaged or baffles missing
|
See your authorized dealer.
|
|
|
Improper fuel
|
Drain and add correct fuel.
|
|
|
Radiator cap
|
Replace cap.
|
|
|
Faulty temperature sender
|
See your authorized dealer.
|
|
|
Incorrect injection pump timing
|
See your authorized dealer.
|
|
|
Excessive axle drag
|
Check axle drag. See Operational Checkout chapter.
|
|
|
Excessive brake drag
|
Check brake drag. See Operational Checkout chapter.
|
|
|
Faulty thermostat (Stuck closed)
|
See your authorized dealer.
|
|
|
Thermostat missing, cooling system coated with lime deposits
|
See your authorized dealer.
|
|
|
Water pump
|
See your authorized dealer.
|
|
|
Excessive fuel delivery
|
See your authorized dealer.
|
|
|
Scored piston
|
See your authorized dealer.
|
|
Engine Runs Cold
|
Thermostat (stuck open)
|
See your authorized dealer.
|
|
|
TX,100,BG336 -19-09JAN97-9/11
|
| Symptom |
Problem |
Solution |
|
Oil In Coolant Or Coolant In Oil
|
Leaking cylinder head gasket
|
See your authorized dealer.
|
|
|
Leaking cylinder liner packing
|
See your authorized dealer.
|
|
|
Cracked cylinder liner
|
See your authorized dealer.
|
|
|
Oil cooler
|
See your authorized dealer.
|
|
|
Cracked cylinder block
|
See your authorized dealer.
|
|
Excessive Fuel Consumption
|
Air system restricted
|
Check filter restriction indicator and air filters. Replace
|
|
|
Leakage in fuel system
|
Inspect. Repair.
|
|
|
Incorrect grade of fuel
|
Refill with correct fuel.
|
|
|
Operator holding hydraulics over relief.
|
Return control levers to neutral position.
|
|
|
High system relief valve setting
|
See your authorized dealer.
|
|
|
High power limiter setting on hydraulic pump
|
See your authorized dealer.
|
|
|
Incorrect injection pump timing
|
See your authorized dealer.
|
|
|
Faulty injection nozzle(s)
|
See your authorized dealer.
|
|
Turbocharger Excessively Noisy Or Vibrates
|
Bearings not lubricated
|
See your authorized dealer.
|
|
|
Worn bearings
|
See your authorized dealer.
|
|
|
Air leak in engine, intake or exhaust manifold
|
See your authorized dealer.
|
|
|
Improper clearance between turbine wheel and turbine housing
|
See your authorized dealer.
|
|
|
Broken blades on turbine
|
See your authorized dealer.
|
|
|
TX,100,BG336 -19-09JAN97-10/11
|
| Symptom |
Problem |
Solution |
|
Oil Dripping From Turbocharger Adapter
|
Damaged or worn bearings and/or worn seals
|
See your authorized dealer.
|
|
|
Excessive crankcase pressure
|
See your authorized dealer.
|
|
|
Turbocharger oil return line carbon buildup where line passes exhaust manifold
|
See your authorized dealer.
|
|
Excessive Drag In Turbocharger Rotating Members
|
Carbon build-up behind turbine wheel caused by combustion deposits
|
See your authorized dealer.
|
|
|
Dirt build-up behind compressor wheel caused by air intake leaks
|
See your authorized dealer.
|
|
|
Bearing seizure or dirty or worn bearings caused by excessive temperature, unbalanced wheel, dirty oil, oil starvation, or insufficient lubrication
|
Check for plugged air filters.
|
|
|
TX,100,BG336 -19-09JAN97-11/11
|
|