Engine

Engine Will Not Crank

Battery disconnect switch off.

Turn switch on.

Hydraulic tank shut-off lever(s) in closed position.

Move shut-off lever(s) to open position.

Low battery power.

Check charging circuit. Charge or install new batteries.

Resistance in starting circuit.

Clean and tighten battery and starter connections. Check ground connections.

Starter malfunction

Replace starter. See your authorized dealer.

Start circuit.

Check start cable relay, key switch and wiring harness connections. Replace as required. See your authorized dealer.

Hydraulic tank shut-off valve switches.

Replace switch. See your authorized dealer.

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Engine Hard To Start, Will Not Start

Slow cranking speed.

Check battery and connections.

Incorrect engine oil (cold weather).

Replace engine oil. (See Fuels and Lubricants chapter.)

Incorrect hydraulic oil (cold weather).

Replace hydraulic oil. (See Fuels and Lubricants chapter.)

Starting aid malfunction.

Inspect lines. Clean nozzle. Listen for click from solenoid.

Fuel tank empty.

Add fuel.

Fuel tank vent cap clogged.

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

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.

Water in fuel tank, or fuel frozen in line.

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

Fuel pump primer lever left up.

Push primer lever down.

Fuel pump diaphragm leaking.

Check engine oil for fuel dilution. Replace fuel pump.

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

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

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.

Injection pump worn.

See your authorized dealer.

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Starting ether used excessively.

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

Injection nozzle(s).

Remove and test nozzle(s). See your authorized dealer.

Worn compression rings or low compression.

Check compression. Repair. See your authorized dealer.

Blown head gasket.

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

Hydraulic pump in stroke.

See your authorized dealer.

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Engine Knocks, Runs Irregularly Or Stops

Engine oil low.

Find source of oil consumption and repair as required.

Fuel tank vent cap clogged.

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

Water in fuel.

Drain fuel tank and inspect filter elements for water. Replace filters.

Fuel filter clogged.

Replace filter.

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.

Air in fuel.

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

Air intake system restricted.

Clean filter and system.

Fuel pump.

Test pump pressure. See your authorized dealer.

Idle speed adjustment too low.

Test slow idle speed. See your authorized dealer.

Fuel injection pump out of time.

Time injection pump. See your authorized dealer.

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.

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.

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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). See your authorized dealer.

Engine overheating.

Verify engine temperature. See your authorized dealer.

Improper valve clearance.

Check and adjust valve clearance. See your authorized dealer.

Valve sticking or burned.

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.

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Engine Has Little Power

Air intake system restricted.

Clean or replace air cleaner element.

Fuel filter clogged.

Replace fuel filter. Clean fuel tank screen.

Grade of fuel wrong.

Use correct grade of fuel.

Clogged vent in fuel tank cap.

Inspect. Install new cap.

Fuel tank strainer clogged.

Clean.

Fuel pump malfunction.

See your authorized dealer.

Fuel line to pump or pump return to tank restricted.

Check, repair. See your authorized dealer.

Timing incorrect.

Check injection pump timing. See your authorized dealer.

Air leak at intercooler or manifold.

See your authorized dealer.

Area between turbocharger and manifold has air leaks.

See your authorized dealer.

Fast idle speed incorrect.

Do Fast Idle Speed Adjustment. See your authorized dealer.

Charge air cooler restricted (200 hp engine)

Inspect charge air cooler inlet screen. Clean or replace.

Improperly adjusted hydraulic system.

See your authorized dealer.

Injection nozzle(s) clogged or faulty.

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

Injection pump delivery or governor faulty.

Repair pump. See your authorized injection pump service center.

Turbocharger malfunction.

Inspect and repair. See your authorized dealer.

Compression low.

See your authorized dealer.

Valves burned, warped.

Repair valves. See your authorized dealer.

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Camshaft worn.

See your authorized dealer.

Engine Overheats

Check for coolant leaks. Add coolant.

Refill.

Radiator, oil cooler or charge air cooler (200 hp engine) cores clogged, or fins bent.

Clean, straighten, or replace if fin bending is severe.

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

Adjust, inspect, replace. See your authorized dealer.

Fan shroud or baffles missing.

Inspect, repair, replace.

Radiator cap (170 hp engine) or surge tank cap (200 hp engine) does not hold pressure.

Replace cap.

Thermostat stuck closed.

Test and/or reinstall.

Fan blade on backward.

Reinstall. See your authorized dealer.

Gauge or sender faulty.

Test gauge and sender. See your authorized dealer.

Water pump.

See your authorized dealer.

Cooling system limed up.

Flush cooling system.

Hydraulic system overheating.

Verify, repair. See your authorized dealer.

Fuel injection pump timing incorrect.

See your authorized dealer.

Fuel delivery excessive.

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

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.

See your authorized dealer.

Intercooler leaking.

See your authorized dealer.

Head gasket leaking.

Inspect, repair. See your authorized dealer.

Cylinder head cracked.

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

Wrong grade of oil or fuel dilution.

Use correct grade of oil. See your authorized dealer.

Excessive engine temperature.

Check cooling system.

Oil pressure regulating valve malfunction.

See your authorized dealer.

Oil pump intake screen clogged or loose.

Check. See your authorized dealer.

Oil pump gear and/or housing worn.

See your authorized dealer.

Pressure pipe from oil pump leaking.

Check. See your authorized dealer.

Excessive main or connecting rod bearing clearance.

See your authorized dealer.

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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.

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

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

Pistons or liners scored.

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

Piston rings worn, broken, or stuck.

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.

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.

See your authorized injection pump service center.

Injection nozzle orifice clogged or faulty nozzle.

Check and repair. See your authorized dealer.

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Exhaust Smoke is White

Wrong grade of fuel.

Use correct grade of fuel.

Cold engine.

Run engine until warm.

Thermostat faulty or too cool.

See your authorized dealer.

Injection pump out of time.

See your authorized dealer.

Head gasket leaking.

See your authorized dealer.

Intercooler leaking.

See your authorized dealer.

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