Service manual
ENGINE
TROUBLESHOOTING
PROBLEM
PROBABLE
CAUSE
VERIFICATION/REMEDY
KNOCKING
ENGINE
KNOCKS
WITHOUT
MUCH
SMOKE
1.
Main
engine
troubles.
a.
Overheated
cylinder.
a.
See
OVERHEATING;
LOW
OUTPUT.
b.
Carbon
deposits
in
cylinder.
b.
Clean.
2.
Too
early
injection
timing.
2.
Correct.
3.
Too
high
injection
pressure.
3.
Correct.
4.
Improper
fuel.
4.
Replace
with
proper
fuel.
KNOCKING
WITH
DARK
SMOKE
1.
Poor
compression.
1.
See
LOW
COMPRESSION;
HARD
STARTING.
2.
Injection
pump
malfunctioning.
a.
Check
valve
worn/sticking.
a.
Replace
check
valve.
3.
Improper
nozzle.
a.
Poor
spray.
a.
Clean
or
replace
nozzle.
b.
Poor
chattering.
b.
Repair
or
replace
nozzle.
C.
After-injection
drip.
c.
Repair
or
replace
nozzle.
d.
Nozzle
needle
valve
seized.
d.
Replace.
INTERMITIENT
1.
Fuel
filter
clogged.
1.
Clean
or
replace.
EXHAUST
SOUND
2.
Air
leak
in
fuel
supply
side
of
system.
2.
Retighten
pipe
joints
or
replace
pipe.
3.
Water
mixed
in
fuel
3.
Replace
fuel.
OVERHEATING
1.
V-belt
slackening
or
slippery
with
oil.
1.
Adjust,
replace
or
clean.
2.
Damaged
water
pump.
2.
Replace.
3.
Lack
of
coolant
3.
Add.
4.
Low
oil
level
or
poor
oil
quality.
4.
Add
or
change.
5.
Knocking.
5.
See
KNOCKING.
B.
Moving
parts
seized
or
damaged.
B.
Replace.
7.
Defective
thermostat.
7.
Replace.
LOW
OIL
PRESSURE
1.
Wom
Bearings.
1.
Engine
overhaul
replace
bearings.
2.
Relief
valve
malfunction.
2.
Overhaul
oil
pump.
3.
Clogged
oil
cooler.
3.
Repair.
4.
Diesel
dilution
of
the
oil.
4.
Injection
pump
repair.
Engines
&
Generators
6