DIESEL ENGINE TROUBLE SHOOTING

CAUSES 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

Air System Restricted air intake * * * *

High exhaust back * * * *

pressure
Thin air in hot weather or * *
high altitude
Fuel System Out of fuel or fuel shut * *
off closed
Poor quality fuel * * * * * *

Air leaks in suction lines * * * *

Restricted fuel lines/stuck * * * * * * * * * *

drain valve
External or internal fuel *
leaks
Plugged injector spray * * * * * * *
holes
Broken fuel pump drive * *
shaft
Scored gear pump or * *
worn gears
Loose injector inlet or * *
drain connection
Wrong injector cups * * * *

Cracked injector body or * *

cup
Mulitilated injector cup O * *
ring
Throttle linkage * *

Incorrectly assembled * *
idle spring
Governor weight *
assembled incorrectly
High speed governor set * *
too low
Water in fuel * * * *

Lubricating External and internal oil * *

System leaks
Dirty lube oil strainer *

Faulty cylinder oil control * * * *

Oil suction line restriction *

Faulty oil pressure *

regulator
Crankcase low or out of * * *
oil
Wrong grade oil for * *
weather conditions
Oil level too high * * * *

Cooling Insufficient coolant * * *

System
Worn water pump * * *

Faulty thermostats * * * * *

Damaged water hose * * *

 Loose fan belts * * *

Radiator shutters stuck * *

open
Clogged water passages * * *

Internal water leaks *

Clogged oil cooler * *

Radiator core openings * * *

dirty
Air in cooling system * * *

Exterior water leaks * * *

Insufficient coolant * * *
capacity
Operation Dirty filters and screen * *
and
Maintenance Long idle periods * * * * * * *
practices
Engine overloaded * * * * *

Engine exterior caked * * *

with dirt
Mechanical Gasket blow by or * * * *
Adjustment leakage
or Repair Faulty vibration damper *

Unbalanced or loose *
flywheel
Valve leakage * * *

Broken or worn piston * * * *

rings
Incorrect bearing * * *
clearance
Engine due for overhaul * * * * * *

Damaged main or rod *

bearing
Misalignment engine to *
driven unit
Loose mounting bolts * *

Incorrect valve and * * * *

injection timing
Worn or scored lines or * * *
piston
Injectors need adjustment * * * * * * * *

No Complaints No Complaints

1 Hard starting or failure to start 14 Low lubricating oil pressure

2 Engine misses 15 Coolant temperature too low
3 Excessive smoking at idling 16 Coolant temperature too high
4 Excessive smoke under load 17 Engine oil too hot
5 Low power or loss of power 18 Mechanical knocks
6 Cannot reach govern RPM 19 Excessive engine vibration
7 Excessive fuel consumption
8 Poor deceleration
9 Erratic idle speed
10 Engine stop
11 Excessive engine oil consumption
12 Crankcase sludge
13 Dilution