Engine

Engine Hard To Start, Will Not Start

Battery disconnect switch off.

Turn switch on.

Hydraulic tank shut-off lever closed.

Open shut-off lever.

Solenoid on injection pump does not "click" when key is turned to RUN.

Check fuse. Test shut-off solenoid. See your authorized dealer.

Fuel tank empty.

Add fuel.

Fuel tank vent cap clogged.

Loosen cap and listen for air entering tank. Install new cap.

Water in fuel tank, or fuel frozen in line.

Drain water from fuel tank. Inspect fuel filter for water. Change filter.

Debris in fuel, or wrong grade of fuel.

Check fuel tank outlet for type of fuel debris. Check fuel tank for debris with a flashlight through the filler neck toward bottom of tank. Check grade of fuel.

Fuel pump primer lever left up.

Push primer lever down.

Air leak on suction side of fuel system.

Check for bubbles in fuel filter and tighten connections. Inspect fuel lines for damaged lines.

Fuel pump diaphragm leaking.

Check engine oil for fuel dilution. Replace fuel pump.

Slow cranking speed.

Check battery and connections. Incorrect engine oil (cold weather).

Restricted air filter.

Check air filter restriction indicator and air filters. Clean.

Stuck injection pump metering valve.

Tap injection pump housing (lightly). If engine now starts, replace metering valve. See your authorized injection pump service center.

Improper injection pump timing.

Check timing. See your authorized dealer.

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Injection pump.

Remove and test pump.

Injection nozzle(s).

Remove and test nozzle(s).

Worn compression rings or low compression.

Check compression. Repair. See your authorized dealer.

Starting ether used excessively.

Remove nozzles and add small amount of oil to each cylinder. See your authorized dealer.

Blown head gasket.

Remove. Route radiator overflow into container of fluid, and check for bubbles. Bubbles indicate head gasket leakage. See your authorized dealer.

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Engine Knocks, Runs Irregularly Or Stops

Engine oil low.

Add oil.

Air in fuel.

Inspect filter for evidence of air in fuel. Tighten connections and bleed fuel system.

Clogged air intake system.

Clean filter and system.

Fuel tank vent cap clogged.

Remove cap and listen for sound of air entering tank. Install new cap.

Debris in fuel or wrong grade of fuel.

Check fuel tank outlet for debris. Check fuel tank for debris with a flashlight through filler neck toward bottom of tank. Check grade of fuel.

Water in fuel.

Drain fuel tank and inspect filter element in water. Replace filters.

Fuel filter clogged.

Replace filter.

Return line from injection pump to tank restricted.

Route return line at the pump into a separate container. If engine now operates normally, check return line to tank for restriction. Replace.

Fuel injection pump out of time.

Time injection pump. See your authorized dealer.

Restrictor fitting on top fitting in injection pump clogged.

Remove, inspect and clean. Determine source of debris. See your authorized injection pump service center.

Injection pump metering valve sticking.

Remove pump top cover and inspect. Replace metering valve. See your authorized injection pump service center.

Idle speed adjustment too low.

Test slow idle speed. See your authorized dealer.

Engine overheating.

Verify engine temperature. See your authorized dealer.

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Fuel pump.

Test pump pressure. See your authorized dealer.

Fuel injection pump.

Remove and test fuel injection pump. See your authorized injection pump service center.

Faulty injection nozzle(s).

Remove and test nozzle(s).

Improper valve clearance.

Check and adjust valve clearance. See your authorized dealer.

Valve sticking or burned.

Do Compression Pressure Test. See your authorized dealer.

Bent push rods.

Inspect. Replace. See your authorized dealer.

Worn or broken compression rings or cylinder head gasket leaking.

Route radiator overflow hose into a container of fluid and check for bubbles. Bubbles indicate head gasket leakage. See your authorized dealer.

Turbocharger malfunction.

Inspect and repair. See your authorized dealer.

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Engine Has Little Power

Fuel tank vent in cap clogged.

Inspect. Install new cap.

Fuel tank shut-off valve not fully open.

Open shut-off valve.

Fuel tank strainer clogged.

Clean.

Fast idle speed incorrect.

Do Fast Idle Speed Adjustment. See your authorized dealer.

Fuel filter clogged.

Replace fuel filter.

Grade of fuel wrong.

Use correct grade of fuel.

Hydraulic system leakage.

Do Hydraulic System Leakage Check. See your authorized dealer.

Fuel line to pump or pump return to tank restricted.

Check, repair.

Fuel pump malfunction.

Do Fuel Pump Test. See your authorized dealer.

Air intake system restricted.

Clean or replace air cleaner element.

Intake air overheating.

Clean or replace inlet screens.

Timing incorrect.

Check injection pump timing. See your authorized dealer.

Injection nozzle(s) clogged or faulty.

Repair injection nozzle(s). See your authorized dealer.

Manifold has air leak.

Do Air Intake System Test for leakage. See your authorized dealer.

Compression low.

Do Compression Pressure Test. See your authorized dealer.

Injection pump delivery or governor faulty.

Repair pump. See your authorized injection pump service center.

Valves burned, warped.

Repair valves. See your authorized dealer.

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Charged air cooler restricted.

Inspect charge air cooler inlet screen. Clean or replace. Check motor and fan assembly for proper operation.

Turbocharger malfunction.

Inspect and repair. See your authorized dealer.

Area between turbocharger and manifold has air leaks.

Do Air Intake System Test for leakage. See your authorized dealer.

Camshaft worn.

Do Valve Lift Test. See your authorized dealer.

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Engine Overheats

Coolant level low.

Refill.

Radiator, oil cooler, and charge air cooler cores clogged with dirt, or fins bent.

Clean, straighten.

Gauge or sender faulty.

Test gauge and sender. See your authorized dealer.

Fan belts loose, belts soaked with oil, or pulleys worn excessively.

Adjust, inspect, replace. See your authorized dealer.

Fan shroud or baffles missing.

Inspect, repair.

Fan blade on backward.

Reinstall. See your authorized dealer.

Thermostat stuck closed.

Check and/or reinstall.

Radiator cap faulty, or water in radiator.

Check, replace.

Hydraulic system overheating.

Verify, repair. See your authorized dealer.

Cooling system limed up.

Flush cooling system.

Water pump faulty.

Repair. See your authorized dealer.

Fuel injection pump timing incorrect.

Check injection pump static timing. See your authorized dealer.

Fuel delivery excessive.

Remove and adjust fuel injection pump. See your authorized injection pump service center.

Head gasket leaking.

Check, replace. See your authorized dealer.

Coolant Temperature Too Low

Thermostat faulty (stuck open).

Replace thermostat. See your authorized dealer.

Temperature gauge faulty.

Install new gauge or sending unit. See your authorized dealer.

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Oil In Coolant Or Coolant In Crankcase

Oil cooler leaking.

Test, repair. See your authorized dealer.

Head gasket leaking.

Inspect, repair. See your authorized dealer.

Cylinder head cracked.

Check, replace. See your authorized dealer.

Liner packing leaking, and/or cracked cylinder block.

Remove pan, inspect bottom end, repair. Verify and replace if necessary. See your authorized dealer.

Low Engine Oil Pressure

Oil level low.

Fill.

Wrong grade of oil or fuel dilution.

Use correct grade of oil. Do Fuel Transfer Pump Test. See your authorized dealer.

Oil pressure regulating valve malfunction.

Repair valve. See your authorized dealer.

Internal oil passages leak, and/or spray cooling jet missing.

Check, repair.

Oil pump intake screen clogged or loose.

Check. See your authorized dealer.

Pressure pipe from oil pump leaking.

Check. See your authorized dealer.

Oil pump drive gear loose.

Check, repair drive gear. See your authorized dealer.

Oil pump gear and/or housing worn.

Repair. See your authorized dealer.

Excessive main or connecting rod bearing clearance.

Replace main bearings or connecting rod bearings. See your authorized dealer.

Seal(s) leaking in turbocharger.

Repair. See your authorized dealer.

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High Engine Oil Pressure

Oil level too high.

Drain. Check for other fluid leaking into oil.

Oil viscosity wrong (too thick).

Drain, refill. See Fuels and Lubricants chapter.

Pressure regulating valve stuck or misadjusted.

Verify, repair. See your authorized dealer.

Piston cooling jet orifices clogged.

Verify, clean. See your authorized dealer.

Engine oil has anti-freeze.

Verify, repair, change oil.

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Engine Uses Too Much Oil

Wrong grade of oil.

Use correct grade of oil. See Fuels and Lubricants chapter.

Oil level too high.

Correct. Check to see if some other fluid is leaking into oil.

Oil leaks externally.

Check, repair.

Air intake restricted.

Check, clean air cleaner elements if necessary.

Crankcase breather restricted.

Remove, clean.

Engine operating too hot, or oil cooler water passage clogged.

Test cooling system. Test thermostat. See your authorized dealer.

Main or connecting rod bearing clearance excessive.

Replace main bearings or connecting rod bearings. See your authorized dealer.

Pistons or liners scored.

Check, repair pistons or liners. See your authorized dealer.

Piston rings worn, broken, or stuck.

Do Compression Pressure Test. See your authorized dealer.

Oil return slots in piston clogged.

Clean. See your authorized dealer.

Crankshaft thrust bearing worn (misaligned piston and rod).

Check piston and rod assembly. See your authorized dealer.

Valve guides or valve stems worn.

Check, repair. See your authorized dealer.

Engine Uses Too Much Fuel

Fuel system leakage.

Tighten connections. See your authorized dealer.

Air system restricted.

Repair, clean filters.

Wrong grade of fuel.

Use correct grade of fuel.

Injection pump static timing incorrect.

Check injection pump static timing. See your authorized dealer.

Injection nozzle(s) faulty.

Test, repair nozzle(s). See your authorized dealer.

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Excessive Black Smoke

Wrong grade of fuel.

Use correct grade of fuel.

Air system restricted.

Check, repair air cleaner elements if necessary.

Injection pump static timing incorrect.

Check injection pump timing. See your authorized dealer.

Over-fueling.

Remove and adjust fuel injection pump. See your authorized injection pump service center.

Injection nozzle orifice clogged or faulty nozzle.

Check and repair. See your authorized dealer.

Excessive Blue Or White Smoke

Cranking speed too slow.

Check batteries and connections.

Injection pump static timing incorrect.

Check injection pump static timing. See your authorized dealer.

Wrong grade of fuel.

Use correct grade of fuel.

Liners have wear, and/or piston ring stuck.

Do Compression Pressure Test. See your authorized dealer.

Detonation

Fuel injection pump static timing incorrect and/or injection pump advance faulty.

Check injection pump static timing. See your authorized dealer.

Oil in air system.

Check turbocharger oil seals. Check valve guides for wear. See your authorized dealer.

Ether starting aid solenoid stuck.

Check and repair.

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Abnormal Noise

Oil level low.

Check and add oil.

Grade of engine oil wrong.

Use correct grade of oil.

Fuel dilution.

Do Fuel Pump Pressure Test. See your authorized dealer.

Valve clearance excessive.

Check, adjust valve. See your authorized dealer.

Push rods bent.

Inspect, replace push rods. See your authorized dealer.

Main and/or connecting rod bearing caps loose or worn.

Inspect main bearing and connecting cap screws. See your authorized dealer.

Piston scored.

Replace piston. See your authorized dealer.

Piston pin bushings worn.

Replace pins and bushings. See your authorized dealer.

Rocker arm shafts worn.

Check. See your authorized dealer.

Crankshaft end play excessive.

Check, repair. See your authorized dealer.

Balancer shafts out of time.

See your authorized dealer.

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