High Horsepower Marine
Engine Troubleshooting
Basics
Session 7 - Troubleshooting Basics
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High Horsepower Marine Engine
Troubleshooting
High Horsepower Marine Engine
Troubleshooting
High Horsepower Marine Engine
Troubleshooting
The Marine Technician should have a working knowledge of Marine gears
so as to understand the effects of marine gear problems on engine
operation.
High Horsepower Marine Engine
Troubleshooting
The Marine Technician must possess the required mechanical skills to
correctly diagnose and repair systems that have been found defective.
Removal and replacement skills are outlined in Cummins Service
Literature.
Part and equipment rigging skills are needed to remove and install
engines and components that cannot be handled by hand.
High Horsepower Marine
Engine Troubleshooting
Basic Troubleshooting
Basic Troubleshooting Steps
Get all the facts concerning the problem.
Analyze the problem thoroughly.
Relate the symptoms to the basic engine and
components.
Consider any recent maintenance or repair action
that can relate to the problem.
Basic Troubleshooting Steps
Double-check before doing any disassembly.
Solve the problem by using the logic charts and
doing the easiest things first.
Determine the cause of the problem and make a
thorough repair.
After repairs have been made, operate the engine to
make certain the cause of the problem has been
corrected.
Basic Troubleshooting Steps
Listen to the customer’s complaint.
Talk with the captain if possible.
Get the engine model and rating-- Know
what you will be looking at.
What are the symptoms?
What were the warning signs preceding
the trouble?
Were any other changes noticed (even if
they seem unrelated)?
Basic Troubleshooting Steps
Was the problem gradual or immediate?
How was the boat being operated at the
time of trouble and under what conditions?
Has this problem ever been experienced on
the boat before?
What previous repair and maintenance
work has been done?
Basic Troubleshooting Steps
Preliminary Analysis
What would cause the symptoms?
What engine systems would be involved?
What changes in those systems would result in the
symptoms observed?
What other symptoms would these changes cause?
Basic Troubleshooting Steps
Preliminary Analysis
Relate these possibilities to the conditions under
which the problem occurred.
Order the possible problems from least to most
likely based on information available.
Use the troubleshooting logic charts where
applicable.
Form a plan of action before leaving.
Basic Troubleshooting Steps
Plan of Action
Avoid Assumptions
Take a complete test kit
List possible causes from preliminary analysis
List an appropriate test to confirm or eliminate each
possibility.
List other possible symptoms for each possible problem
Basic Troubleshooting Steps
Plan of Action
Decide what the possible causes are.
Decide which tests are appropriate from simplest to most
difficult.
Perform these tests in the order of likelihood based on
preliminary analysis.
Basic Troubleshooting Steps
Arrival/Action
Get additional information from the Captain about
the problem.
Ask questions developed in your preliminary
analysis.
Follow your plan of action --always look at the
simplest solution first.
Don’t forget the obvious, no matter how simple.
Basic Troubleshooting Steps
Arrival/Action
Use, but don’t rely on past experience.
Things to
Do:
1.
2.
There are sometimes more than one problem.
Once a problem has been identified and corrected, test the
appropriate systems to be sure the problem is corrected and
will not reoccur.
Performance Troubleshooting
VESSEL LOW POWER
A vessel with a low power complaint is a difficult to
troubleshoot because of different interpretations of
what low power may really be like.
Low Engine RPM
Full Throttle
The time it takes to accelerate to rated speed
Low Vessel Speed
Knots
Engine Speed vs. Vessel Speed
Engines operating at different full throttle RPMs
Performance Troubleshooting
CONDITIONS THAT AFFECT VESSEL PERFORMANCE
Boat Weight
Number of people aboard
Water, fuel tank levels
Cargo
Additional equipment and gear added to vessel
Weather conditions
Vessel Bottom Condition
Performance Troubleshooting
CONDITIONS THAT AFFECT VESSEL PERFORMANCE
Sea Current
Wind Conditions
Water Density
Vessel Trim
Engine and Shaft Alignment
Propeller Size and Condition
Performance Troubleshooting
•Frontal Area of Vessel
•Marine Gear Ratio
•Vessel Design
Engine Room Air Inlet and
Exhaust
Exhaust Restriction
Fuel System Sizing
Fuel Lines
Valves
Vents
Performance Troubleshooting
Engine Not Reaching Rated RPM at No Load
Throttle Linkage Incorrectly Set or Adjusted Cable
Adjustment
Throttle Control Head Adjustment Upper and Lower
Station Not Set At Same Position
Air In Hydraulic Control System
Binding of Throttle Cable
Cable Outer Jacket Worn Through
Performance Troubleshooting
Fuel Injection Pump Related Malfunctions
Engine Not reaching Rated RPM at
Rated Load
Throttle Linkage Incorrectly Set or Adjusted.
Cable Adjustment
Throttle Control Head Adjustment for Upper and Lower
Stations Not Set at Same Position
Air In Hydraulic Control Systems
Binding of Throttle Cable
Engine Not reaching Rated RPM at
Rated Load
Partially Engaged Mechanical Shutdown
Solenoid Binding In Housing
Solenoid Adjustment
Low Supply Voltage To Solenoid
Start / Stop Spring on Fuel Pump Binding, Broke or
Corroded
Engine Not reaching Rated RPM at
Rated Load
Malfunctioning Tachometer
Tachometer Not Set To Proper Engine Configuration
Tachometer Not Set To Proper Tooth Count On Flywheel
Ring Gear
Tachometer Not Adjusted Correctly With Engine Speed
Corroded Connections At Alternator Or Harness
Magnetic Pickup Dirty or Not Adjusted Correctly
Engine Not reaching Rated RPM at
Rated Load
Air Leak Between Turbocharger and Intake Manifold
Turbocharger Crossover Tube Hoses Loose or Blown Off
Tee Bolt Clamps Should Be Used In All Locations Except
At the Turbocharger Compressor Outlet
Engine Not reaching Rated RPM at
Rated Load
Lubricating Oil Level Too High
Oil Level On Dip Stick May Be incorrectly marked
A High Oil Level Can Cause The Connecting Rods To
Contact Oil In The Pan, Creating Foam and Reducing
Power
Engine Not reaching Rated RPM at
Rated Load
Intake System Restrictions
Air Cleaner Plugged With Foreign Material
Air Cleaner With Black Coated Paper Element May Be As
A Result Of Leak In The Exhaust System
Air Cleaner Filter Element Soaked With Water
Vessel Air Inlet And Exhaust Duct Work Undersized For
Engine And Ancillary Gear
Engine Not reaching Rated RPM at
Rated Load
Fuel Quality Poor
Cetane Rating Less Than #40 Can Affect Engine
Performance
Water Or Growth Of Algae In Fuel System
Algae In Marine Applications Can Appear As Black Grit
(Coal Dust) In The Filter Element
Engine Not reaching Rated RPM at
Rated Load
Fuel System Restriction
Fuel System Restriction
Fuel Supply / Return Valves Not Fully Open
Fuel Tank Vent Plugged
Fuel Lines Pinched
Plugged Fuel Filter
Water Or Algae Growth Plugging Filter
Gasoline In Diesel Fuel Will Break Down Filter Coating
and Plug Filter Media
Engine Not reaching Rated RPM at
Rated Load
Air In Fuel System
Fuel Pick-Up Tube In Fuel Tank Cracked / Broken
Fuel Fittings / Clamps Not Tight
Fuel / Water Separator Filter Gasket Not Sealed
Fuel Line Control Valve Packing Seal Defective / Loose
Engine Not reaching Rated RPM at
Rated Load
High Intake Air Temperature > 17°C (30°F)
Above Ambient Air Temperature
Inlet Air Temperature Entering The Turbocharger Can Be A
Major Factor in Horsepower Loss
High Inlet Air Temperatures Will Increase The Cylinder
Temperatures and Reduce The Life Of The Engine.
MAB 0.10.00 – 07/17/2000 Engine Air Intake Systems
MAB 0.23.00 – 03/28/2001 Engine Room Ventilation
Engine Not reaching Rated RPM at
Rated Load
High Intake Air Temperature > 17°C (30°F)
Above Ambient Air Temperature
For internal air supply – The difference between combustion air
intake temperature and ambient air temperature (outside the
engine room) must not exceed 17o C (30o F).
For an external air supply – The difference between engine
room temperature and ambient temperature (outside the engine
room) must not exceed 17o C (30o F).
Engine Not reaching Rated RPM at
Rated Load
High Fuel Temperature Above 43°C (110°F)
Fuel return Line Restriction
Return Line Pinched
Fuel Return Valve Not Fully Open
Fuel Return Line Undersized
Fuel Return Check Valve Plugged / Stuck In The Closed
Position.
Engine Not reaching Rated RPM at
Rated Load
Malfunctioning Lift Pump
Injection Pump Supply Line, Lift Pump Pressure
Check (Low Pressure) Restricted Fuel Filter
Injection Fuel Pump, Fuel Gallery Pressure Regulator (Check
Valve) Dirty / Foreign Material In Check Valve
Sticking Valve Shut check Valve Incorrectly Adjusted
High Fuel Drain Line Restriction
Engine Not reaching Rated RPM at
Rated Load
Exhaust System Restriction
Exhaust System Defect
Muffler Baffle Breakage
Exhaust System Hanger Breakage Causing Piping To
Flex And Restrict Flow
Exhaust Components Having Material Defect
Marine Growth In The Exhaust System
Undersize Exhaust System
Engine Not reaching Rated RPM at
Rated Load
Exhaust Leak From Exhaust Manifold or Turbocharger
Loss Of Exhaust Gases Will Reduce The Force Placed On
The Turbine Blades, Which Will Decrease Turbo Boost
Pressure
Check For Leakage At The Cylinder To Manifold To Cover
Plate, And Manifold To Turbocharger
Engine Not reaching Rated RPM at
Rated Load
Low Intake Manifold Pressure
Turbocharger Worn Or Malfunctioning
Turbocharger Side Of Aftercooler Dirty Or Plugged (If Oil,
Check Compressor Seal)
If The Engine Can Not Reach Rated Speed Under Full
Load, Maximum Intake Manifold Pressure Cannot Be
Reached
Lack Of Fuel For Combustion Will Also Cause Low Intake
Manifold Pressure
Engine Not reaching Rated RPM at
Rated Load
Injector Nozzles Worn Or Malfunctioning
As The Springs In Injectors Work, They Lose Some
Tension.
Injectors Should Be Checked On Calibrated Tester.
A Stuck Injector Needle Valve Will Cause Misfiring And
Low Power
An Incorrect Thickness Of Injector Sealing Washer Can
Cause Low Power And Smoke
Engine Not reaching Rated RPM at
Rated Load
Engine Not reaching Rated RPM at
Rated Load
Valves Not Set Properly
Incorrect Valve Adjustment Can Reduce Air Flows
Resulting In Low Power
Injection Pump Worn / Malfunctioning
Injection Pump Not Timed Correctly
Defective AFC Control Valve
AFC Sensing Line Plugged
Defective Hydraulic Rack Lock-Out System
Injection Pump Damaged From Water, Debris
Internal Fuel Rack Binding
Engine Not reaching Rated RPM at
Rated Load
Excessive Engine Noises
Drive Belt Squeal, Insufficient Tension Or
Abnormally High Charging Load
Intake Air Or Exhaust Leaks
Turbocharger Noise
Bearing Clatter
Idle Gear Clatter
Noise In Marine Gear
Vibration Excessive
Engine Not Running Smoothly
Incorrectly Installed, Loose, Or Broken Vibration Isolators
Marine Gear Not Aligned To Prop Shaft
Bent Or Damaged Propeller or Prop Shaft
Worn Or Damaged Alternator Bearing
Malfunctioning Vibration Damper
Vibration Generated By Driven Auxiliary Equipment
Cooling System Temperature Below
Normal
Operating In Cold Weather
Malfunctioning Temperature Gauge, Sender, Or Wiring
Harness
Thermostats Incorrect or Malfunctioning - Debris Can
Prevent A Thermostat From Closing
Cooling System
Contaminated Coolant
Rusty Coolant, Operation Without Correct Mixture Of Coolant
And Additives
Minimum 25% glycol/water mixture required
Poor quality makeup water
Mixing DCA 2 and DCA 4 (Using DCA 2 makeup filter with
DCA 4 coolant)
Oil Leaks From Oil Cooler, Head Gasket, Head and Cylinder
Block
Cooling System Temperature
Above Normal
Coolant Loss
Overfilling Of Expansion Tank
Hose Leaking
External Engine Leak
Cooling System Temperature
Above Normal
Coolant Loss
Leaking Compression Gases From Head, Exhaust
Manifold Gaskets, Causing Coolant Loss Through
Expansion Tank Overflow.
Lubricating Oil Cooler Leak
Exhaust Manifold/Water-cooled Turbo Crack Can Cause
Coolant Leakage Through Exhaust System.
Cooling System Temperature
Above Normal
Low Coolant Level
Air Trapped In Coolant
Low Coolant Level
Check Expansion Tank and Recovery Bottle
Air Trapped In Coolant
Improper Venting/De-aeration During Initial Fill
Cooling System Temperature
Above Normal
Impeller
Blades
Sea Water pump impeller blades can fail.
Cooling System Temperature
Above Normal
Malfunctioning Sea (Raw) Water Pump
Improper Oil Level
Loose Drive Belt On Engine Water Pump
Incorrect / Broken Pressure Cap
Malfunctioning Sender, Gauge, Harness
Malfunctioning / Incorrect Thermostat
Cooling System Temperature
Above Normal
Plugged Heat Exchanger
Malfunctioning Engine Water Pump
Air In Cooling System
Plugged Cooling Passages In Cylinder
Head, Gasket, Cylinder Block
Malfunctioning Keel Cooler
Lubrication System
Low Oil Pressure
Dip Stick
Incorrect Oil Level
FULL MARK
Do not Over
Oil Diluted With Fuel, Engine fill
Operation Normal
Incorrect Oil Level
ADD MARK add
Verify Dip Stick Markings oil when level is at
or below this mark
Oil Diluted With Fuel, Engine Operation Normal
Fuel Lift Pump Plunger Seal Or Diaphragm Leaking
Injection Pump Front Seal On CAV & Bosch-VE Fuel
Pumps
Lubrication System
Low Oil Pressure
Oil Pressure Sender Or Gauge Malfunction
Oil Diluted With Water
Plugged Oil Filter
Regulating Valve Stuck Open Or Broken Spring
Oil Diluted With Coolant (Antifreeze)
Incorrect Oil Specifications
Loose Or Missing Pipe Plug
Lubrication System
Low Oil Pressure
Oil Viscosity Low Due To High Coolant Temperature
[Above 93°C (205°F)]
Oil Diluted With Fuel Accompanied By Rough Engine
Operation Or Low Power
Shipping Plugs Left In Oil Cooler When Replaced
Oil Pan Gasket Leak Affects Pick-Up Seal To Block
Pick-Up Tube Broken Or Incorrectly Installed
Pick-Up Gasket Leaking
Lubrication System
High Oil Pressure
Engine Operating Too Cold
Oil Viscosity Too High
Malfunctioning Pressure Gauge, Sender, Or Harness
Relief Valve Stuck Closed
Lubrication System
Oil Loss
External Leak
Crankcase Being Overfilled
Incorrect Oil (Specification or Viscosity)
Rear Oil Seal Leak (Can Appear As Starter
Motor)
Front Oil Seal Leak
Lubrication System
Oil Loss
Internal Leak
Oil Cooler Leak
High Blowby Forcing Oil Out The Breather
Turbocharger Leaking Oil To The Air Intake
Or Exhaust
Lubrication System
Contaminated Oil
Coolant In The Oil: Internal Engine Component Leaks
Excessive Oil Sludge
Fuel In The Oil: Engine Operation Too Cold
Lift Pump Seal Leaking
Injector Needle Valve Not Sealing
Worn Injection Pump Plungers
Exhaust Smoke - Black
Air Cleaner Plugged
Air In Fuel System
Air Cleaner Plugged
Air In Fuel System
Air Leak Between Turbocharger and Intake Or Exhaust
Manifold
Air Fuel Control Line Leak
Exhaust Smoke - Black
More Than One Or Incorrect Sealing Washer Under
Injector Nozzle
Injection Pump Timing Incorrect
Injector Nozzle Malfunctioning
Air Flow Through Aftercooler Restricted
Malfunctioning Or Over Fueled Injection Pump
Malfunctioning Turbocharger
Exhaust Smoke - White
Engine Running Too Cold
Coolant Temperature Too Low
Fuel Quality Poor
STC System Malfunction
Intake Air Temperature Too Low
Air System Troubleshooting
Fuel Or Oil Leaking From Exhaust Manifold
Intake Air Restriction
Obstructed Turbocharger Drain Line
Turbocharger Seals Leaking Oil
Injector Failure
Cold Starting Troubleshooting
Engine Will Not Crank Or Cranks Slowly
Battery Voltage Falls Below 9 Volts For 12 Volt Systems,
Below 19 Volts For 24 Volt Systems
Crankshaft Rotation Restricted
Marine Gear Clutch Pack Welded Together Causing Drag
Defective Key Switch
Defective Start Push Button
Cold Starting Troubleshooting
Engine Hard To Start Or Will Not Start (Exhaust Smoke Present)
Engine Cranking Speed Too Slow (Below 175 RPM)
Temperatures Below 16°C (60°F) Starting Aid Needed, Or
not Working
No Fuel In Supply Tank
Air In The Fuel System
Check Fuel Pick-up In Tank
Fuel Supply Restricted
Cold Starting Troubleshooting
Engine Hard To Start Or Will Not Start (Exhaust Smoke Present)
Check Supply And Return Fuel Line Values
Intake Air System Restricted
Fuel Contaminated
One Or More Injectors Worn Or Malfunctioning
Valves Incorrectly Adjusted
Cold Starting Troubleshooting
Engine Cranks But Will Not Start -
No Smoke From Exhaust
Fuel
No Fool In the Tank
