Troubleshooting
Engine
Low Power Output
Possible Cause
Correction
Low Engine RPM
Adjust governor linkage to rest against the high idle
stop when accelerator pedal is depressed.
Adjust high idle rpm with adjustment screw.
Restriction in air inlet
system
Inspect air cleaner element and ductwork for
damage and excessive bends air turns.
Water in fuel
Drain fuel tank as needed to remove water.
Faulty shut-off solenoid
Remove solenoid and start engine to see if it has full
power. If there is full power, replace solenoid and/or
adjust linkage.
Misfiring and Rough Running
Possible Cause
Correction
Air in fuel system
Bleed air from lines.
Valve clearance
incorrect
Adjust intake and exhaust valves to specifications.
Fuel injection timing
incorrect
Check and adjust if necessary
Automatic timing
advance malfunction
Check for correct timing, if a timing light is not
available, check for smooth acceleration from low to
high idle. Replace timing mechanism if defective.
Misfiring and Rough Running
Possible Cause
Correction
Defective fuel nozzles
Locate misfiring injector; clean and service.
Engine valve leaking,
worn, or damaged
pistons and/or rings,
worn or damaged
cylinder liners
Check leakage with compression pressure tester.
Fuel leakage at nozzle
nut or adapter
Tighten nut to specifications.
Black or Gray Smoke (Engine runs smooth)
Possible Cause
High altitude operation at
762m or higher
Correction
Adjust fuel injection amount.
Dirty air cleaner
Replace dirty air cleaner element.
Air inlet system
restriction
Inspect air cleaner element and ductwork for
damage and excessive bends and turns.
Exhaust system
restriction
Inspect system piping and muffler. Locate and
correct source of any restriction.
Black or Gray Smoke (Engine runs smooth)
Possible Cause
Fuel injection timing
incorrect
Valve adjustment
incorrect
Leaking fuel nozzles
Correction
Check and adjust if necessary.
Adjust intake and exhaust valves clearance
Locate misfiring injector and clean and service as
required
Black or Gray Smoke (Engine runs rough)
Possible Cause
Misfiring cylinders
Automatic timing
advance malfunction
Air in fuel system
Correction
See misfiring and rough running.
Check for correct timing. If light is not available,
check for smooth acceleration from to high idle.
Check for leaks and bleed air from system.
White Smoke
Possible Cause
Cold outside
temperatures
Correction
Normal condition until engine warms to operating
temperature, as not all fuel is burning.
Long idle periods
Reduce unnecessary idling or use fuel heating
system
Air in fuel system
Check for leaks and bleed air from system.
Fuel injection timing
incorrect
Check and make necessary adjustments.
White Smoke
Possible Cause
Automatic timing
advance malfunction
Correction
Check for correct timing. If light is not available,
check for smooth acceleration from to high idle.
Valve adjustment
incorrect
Adjust intake and exhaust valves clearance
Bad fuel nozzles
Locate misfiring injector. Clean and service
Misfiring cylinders
See misfiring and rough running
Blue Smoke
Possible Cause
Correction
Engine oil level too high
Do not overfill crankcase. Check oil for fuel dilution.
Worn valve guides
Check for maximum permitted wear and service as
needed.
Worn piston rings and/or
cylinder walls
Check cylinder compression and leakage. Visually
inspect piston rings and cylinder walls.
Worn or damaged
pistons
Check piston ring to groove clearance. Make sure
return holes under oil control rings are open
Excessive Fuel Consumption
Possible Cause
Correction
External fuel system
leakage
Check fuel system external piping and tubing for
signs of leaks. Repair as needed.
Fuel injection timing
incorrect
Check and make necessary adjustments.
Leaking fuel nozzles
Locate leaking injector and service as required.
Fuel injection pump
calibration incorrect
Remove injection pump and nozzle assemblies from
engine. Check calibration and adjust.
Internal engine wear
Overhaul engine
Excessive Oil Consumption
Possible Cause
External oil leaks
Correction
Check engine for visible signs of leaks. Replace
defective parts.
Clogged crankcase
breather pipe
Remove obstruction
Worn valve guides
Replace valve guides
Internal engine wear
Overhaul engine
Engine Stalls at Low Speed
Possible Cause
Idle speed too low
Fuel tank vent plugged
Low fuel supply
Defective fuel injection
nozzle or pump
Correction
Adjust idle as required
Check vent arrangement and repair as required
Check tank for fuel. Check fuel lines or sharp bends
and restrictions. Check fuel pressure. If pressure is
low, replace fuel filters. If pressure is still low,
replace injection pump. Bleed fuel system.
Inspect, test, and replace nozzle parts or injection
pump
Hard to start(Crankshaft turns)
Possible Cause
Cold outside temperature
Air in fuel
Water in fuel
Low fuel pressure
Fuel injection timing
incorrect
Correction
Use starting aids.
Bleed air from lines.
Test for water in fuel. Drain fuel tank as need to
remove water. Install new fuel filter and fill tanks with
clean fuel.
Check leakage.
Check and adjust if necessary.
Hard to start(Crankshaft turns)
Possible Cause
Correction
Valve adjustment
incorrect
Adjust intake and exhaust valve.
Bad fuel nozzles
Locate misfiring injector and clean and service.
Low compression
See misfiring and rough running.
No exhaust smoke
visible while starting
Exhaust system
blockage
No fuel from injection pump due to cold weather
waxing or fuel line restriction. Faulty fuel injection
pump shut-off solenoid.
Loosen exhaust pipes at manifolds. If engine starts,
check for blockage or restriction in exhaust piping.
Hard to start(Crankshaft will not turn)
Possible Cause
Low or no battery voltage
Correction
Recharge battery or replace
Faulty relay switch or
wiring connection in
starting circuit
Check for voltage at switch connection on starter
solenoid. Repair as needed.
Bad starter solenoid
Replace
Bad starter motor
Repair or replace
Hard to start(Crankshaft turns slowly)
Possible Cause
Low battery voltage
Correction
Check voltage and recharge/replace battery as
needed.
Poor electrical
connections
Inspect, clean, and tighten electrical connections.
Lubricating oil too thick
Use proper grade oil for temperature conditions.
Bad starter motor
Repair or replace.
Extra outside loads
Check transmission.
Internal engine problem
Overhaul the engine.
Cooling System(Overheating)
Possible Cause
Low coolant level
Bad temperature gauge
Clogged radiator
Loose fan or water pump
belts
Bad hoses
Shunt line restriction
Correction
Check for leaks and repair as needed.
Inspect, repair or replace
Clean and flush radiator core.
Tighten to specifications.
Check for leaks and collapsed hoses
Check for restrictions from the radiator top tank to
the engine front-cover.
Cooling System(Overheating)
Possible Cause
Bad thermostat
Bad temperature gauge
Bad water pump
Air in cooling system
Correction
Test thermostat and replace as needed.
Inspect, repair or replace
Check for loose water pump pulley or impeller.
Remove pump and check for impeller damage and
proper impeller clearance.
Air can enter when coolant level is low combustion
gases ca also enter through cracks or a bad cylinder
head gasket
Cooling System(Overheating)
Possible Cause
Correction
Undersize fan, fan and/or
shroud in incorrect
position
Fan must be large enough to send air through most
of the radiator area. Fan and shroud must be
positioned as specifications
Undersize radiator
Fuel injection timing
incorrect
Make certain radiator is sized to specifications.
Check and make necessary adjustments.
