SECTION 5 - ENGINE
5.1 ENGINE TROUBLESHOOTING
The following troubleshooting chart is to be used to isolate engine problems and give possible causes and corrective action responses.
The troubleshooting key is generic and can be used for several types of engines. Use only those possible causes and corrective actions that apply to the
unit.
TROUBLE | POSSIBLE CAUSES | CORRECTIVE ACTION |
| (Refer to Key Below) |
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Black Exhaust | 1, 20, 22, 25, 29, 31, 32, 33 | repair or replace |
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Blue/White Exhaust | 4, 20, 25, 31, 33, 34 | repair or replace |
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Difficult Starting | 1, 5, 7, 8, 9, 10, 20, 21, 22, 29, 31, 32, 33 | repair or replace |
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Erratic Running | 1, 7, 8, 9, 10, 20, 21, 23, 26, 29, 33, 59, 62 | repair or replace |
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Excessive Fuel Consumption | 1, 20, 22, 23, 25, 29, 31, 32, 33 | repair or replace |
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Excessive Crankcase Pressure | 25, 31, 33, 34, 45, 55 | repair or replace |
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High Oil Pressure | 4, 41 | repair or replace |
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Knocking | 22, 26, 29, 31, 33, 36, 46, 59 | repair or replace |
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Loss of Power or System | 1, 8, 10, 20, 21, 22, 23, 25, 26, 31, 32, 33 | repair or replace |
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Low Cranking Power | 2, 3, 4, 11 | repair or replace |
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Low Oil Pressure | 4, 36, 37, 39 | repair or replace |
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Misfiring | 10, 20, 25, 26, 28, 29, 32 | repair or replace |
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Overheating | 1, 19, 25, | repair or replace |
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Poor Compression | 25, 28, 29, 31, 32, 33, 34,59, | repair or replace |
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Starts and Stops | 1, 6, 10, 62 | repair or replace |
|
| see electrical systems |
|
| see engine service manual |
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Vibration | 20, 23, 25, 26, 29, 33, 45, 49 | repair or replace |
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Will Not Crank | 2, 11, 45 | charge battery or replace |
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Will Not Start | 1, 10, 62 | repair or replace |
|
| see electrical systems |
|
| see engine service manual |
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TROUBLESHOOTING KEY
1 | Restriction in air cleaner | 22 | Incorrect grade of fuel | 43 | Faulty suction pipe |
2 | Bad electrical connection | 23 | Sticking throttle/restricted movement | 44 | Choked oil filter |
3 | Faulty starter motor | 24 | Exhaust pipe restriction | 45 | Bad solenoid switch |
4 | Incorrect grade of lubricating oil | 25 | Leaking cylinder head gasket | 46 | Incorrect piston height |
5 | Low cranking speed | 26 | Overheating | 47 | Damaged fan |
6 | Fuel tank empty | 27 | Cold running | 48 | Faulty engine mounting |
7 | Controls not in correct | 28 | Incorrect tappet adjustment | 49 | Incorrectly aligned flywheel and/or |
| operation position |
|
|
| flywheel housing |
8 | Blocked fuel feed line | 29 | Sticking valves | 50 | Faulty thermostat |
9 | Faulty fuel lift pump | 30 | Incorrect high pressure pipes | 51 | Restriction in water jacket |
10 | Choked fuel filter | 31 | Worn cylinder bores | 52 | Loose fan belt |
11 | Battery capacity low | 32 | Pitted valves and seats | 53 | Choked radiator |
12 | Air in fuel system | 33 | Broken, worn or sticking piston ring(s) 54 | Faulty water pump | |
13 | Faulty fuel injection pump | 34 | Worn valve stems and guides | 55 | Choked breather pipe |
14 | Faulty fuel injectors or incorrect | 35 | Restriction in air cleaner | 56 | Damaged valve stem oil deflector (if |
| type |
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| fitted) |
15 | Incorrect use of cold start | 36 | Worn or damaged bearings | 57 | Coolant level too low |
| equipment |
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16 | Faulty cold start equipment | 37 | Insufficient oil in sump | 58 | Blocked sump strainer |
17 | Broken fuel injection pump | 38 | Bad/defective oil temperature switch | 59 | Broken valve spring |
| drive |
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18 | Incorrect fuel pump timing | 39 | Oil pump worn | 60 | Exhaust or vacuum pipe leak |
19 | Incorrect valve timing | 40 | Pressure relief valve sticking open | 61 | Bad or defective water temperature |
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| switch |
20 | Poor compression | 41 | Pressure relief valve sticking closed | 62 | Bad spark plug(s) |
21 | Blocked fuel tank vent | 42 | Broken relief valve spring |
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