Diagnose Engine Malfunctions

NOTE:

Diagnostic charts are arranged from most probable and simplest to verify, to least likely
and more difficult to verify. Remember the following steps when diagnosing a problem:

Step 1. Operational Checkout Procedure (See Group 9005-10).

Step 2. Adjustments and/or Tests (See Group 9010-20 and/or 9010-25).

Symptom Problem Solution

Engine Will Not Start Or
Starts Hard
 
 
 
 
 
 
 
Fuel tank empty
Fuel tank vent plugged
No electrical power to
injection pump solenoid
Water in fuel or water frozen Drain water from fuel tank.
in fuel line.
Debris in fuel or wrong
grade of fuel
Air leak on suction side of
fuel system
Fuel transfer pump
diaphragm leaking
Slow cranking speed
Check fuel quantity
Remove cap and listen for
sound of air entering tank.
Replace cap.
Turn key switch to "On".
Must hear click at injection
pump. Replace fuse. Repair
wiring.
Inspect fuel filter for water.
Change filter.
Check fuel tank outlet
strainer for type of fuel
debris. Check bottom of fuel
tank for debris. Clean tank.
Add fuel. Check grade of
fuel. Add correct fuel. See
Backhoe Loader Drain and
Refill Capacities .
(Operator's Manual.)
Check for bubbles in fuel
filter and tighten
connections. Inspect fuel
lines for damage.
Check engine oil for fuel
dilution. Replace fuel pump.
Check battery and
connections. Incorrect
engine oil (Cold weather).
Symptom Problem Solution
  Restricted air filter Check air filter restriction
indicator and air filters.
Clean.
  Stuck injection pump Tap injection pump housing
metering valve. (lightly) if engine now starts.
Replace metering valve. See
your authorized injection
pump service center.
  Faulty electric shut-off Test shut-off solenoid. See
System Functional
Schematic (S.N. 913479—
951252) (Group 9015A-15.)
or see System Functional
Schematic and Section
Legend (S.N. 951253— ) .
(Group 9015B-10.) Inspect
solenoid wiring and linkage.
  Improper injection pump Check timing. See
timing CTM104 .
  Injection pump Remove and test pump. See
CTM104 .
  Injection nozzle(s) Remove and test nozzles.
See CTM104
  Worn compression rings or Check compression. Repair.
low compression See CTM104
  Blown head gasket Remove. Route radiator
overflow into container of
fluid and check for bubbles.
Bubbles indicate head gasket
linkage. See CTM104 .
Engine Surges Or Stalls Air in fuel Inspect filter for evidence of
Frequently air in fuel. Tighten
connections and bleed fuel
system.
  Fuel tank vent plugged Remove cap and listen for
sound of air entering tank.
Replace cap.
  Debris in fuel or wrong Check fuel tank outlet
grade of fuel strainer for debris. Check

  Water in fuel
  Fuel filter plugged
  Return line from injection
pump to tank restricted
  Fuel injection pump out of
time
  Check return oil fitting on
top of injection pump
control cover plugged.
  Injection pump metering
valve sticking
  Engine overheating
  Fuel transfer pump
  Fuel injection pump
  Injection nozzle(s)
  Improper valve clearance
bottom of fuel tank for
debris. Clean tank. Add fuel.
See Backhoe Loader Drain
and Refill Capacities .
(Operator's Manual)
Drain fuel tank and inspect
filter element for water.
Replace filters.
Replace filter.
Route return line at the
pump into a separate
container. If engine now
operates normally, check
return line to tank for
restriction. Replace.
Time injection pump. See
CTM104 .
Remove, inspect and clean.
Determine source of debris.
See your authorized
injection pump service
center.
Remove pump top cover and
inspect. Replace metering
valve. See your authorized
injection pump service
center.
Test cooling system. See
CTM104 .
Test transfer pump pressure.
See CTM104 .
Remove fuel injection pump.
See CTM104 . Test pump.
See your authorized
injection pump service
center.
Remove and test nozzle(s).
See CTM104 .
Check and adjust valve
clearance. See CTM104 .
  Valve sticking or burned Do compression pressure
test. See CTM104 .
  Worn or broken Route radiator overflow
compression rings or hose into a container of fluid
cylinder head gasket leaking and check. Check for
bubbles. Bubbles indicate
head gasket leakage. See
CTM104 . Do compression
pressure test. See CTM104.
Engine Misses Air in fuel Check for evidence of air in
filter. Tighten connections
and bleed fuel system.
  Debris in fuel or wrong Check fuel tank for water.
grade of fuel Check fuel tank strainer and
fuel filter for debris. Clean.
Check grade of fuel.
  Idle speeds out of Test slow idle speeds. See
adjustment (too low) CTM104 .
  Fuel injection pump out of Time injection pump. See
time CTM104 .
  Fuel transfer pump Test fuel system pressure.
See CTM104 .
  Injection pump governor Inspect. Repair. See your
faulty or metering valve authorized injection pump
sticking service center.
  Engine overheating Verify engine temperature.
See CTM104 . Test
thermostat. Replace. See
CTM104 .
  Incorrect valve clearance Check and adjust valve
clearance. See CTM104 .
  Bent push rods Inspect. Replace.
  Cylinder head gasket leaking Route radiator overflow hose
into container of fluid and
check for bubbles. Bubbles
indicate head gasket leakage.
See CTM104 .
  Valve sticking or burned Do compression pressure
test. See CTM104 .
  Worn or broken Do compression pressure
compression rings test. See CTM104 .
  Fuel injection pump Remove and test fuel
injection pump. See
CTM104 .
  Injection nozzles(s) plugged Remove and test nozzles.
See CTM104 .
Engine Does Not Develop Fuel tank outlet strainer Check fuel tank for water or
Power plugged debris. Remove and clean.
  Fuel filter plugged Replace fuel filter.
  Wrong grade of fuel Drain and add correct fuel.
  Air system restricted Check air filter restriction
and air filters. Clean.
  Incorrect fast idle speed (too Adjust linkage. See Engine
low) or linkage out Speed Control Linkage
adjustment. Adjustment (S.N. —910055)
. In this Group. Check fast
idle speed. See Slow and
Fast Idle (S.N. —910055) .
In this Group.
  Incorrect engine or injection Check. Adjust timing. See
pump timing CTM104 .
  Incorrect valve clearance Adjust valve clearance. See
CTM104 .
  Injection pump return fuel Route return line at the
tube or fittings are restricted pump into a separate
container. If engine now
operates normal, check
return line for restriction.
Replace.
  Fuel transfer pump Test fuel transfer pump
malfunction pressure. See CTM104 .
  Fuel line restricted Route an external fuel source
to fuel transfer pump. If
engine operation is normal
clean fuel line.
  Excess drag in brake system Check park brake drag. See
Brake System Checks .
(Group 9005-10.)
  Excess drag in axle Test drag. See Brake System
Checks (Group 9005-10.)
  Muffler restricted Operate without muffler. If
engine operation is now
normal, replace muffler.
  Injection pump delivery or Remove pump and test. See
governor faulty your authorized injection
pump service center.
  Injection nozzle(s) Remove and test nozzle(s).
See CTM104 .
  Low compression Do compression pressure
test. See CTM104 .
  Worn camshaft Do valve clearance check.
Replace. See CTM104 .
Engine Emits Excessive Restricted air filter Check air filter restriction
Black or Gray Exhaust and air filters. Clean or
Smoke replace.
  Incorrect grade of fuel Drain and add correct fuel.
  Incorrect injection pump Time injection pump. See
timing CTM104 .
  Excessive fuel delivery Remove fuel injection
pump. See your authorized
injection pump service
center.
  Injection nozzle(s) Remove and test nozzle(s).
See CTM104
  Turbocharger not Repair. See CTM104 .
functioning.
Engine Emits Excessive Cranking speed too slow Check batteries and
Blue or White Smoke connections.
  Incorrect grade of fuel Drain and add correct fuel.
  Engine running too cold Check thermostat operation.
Replace.
  Injection pump out of time Time injection pump. See
CTM104 .
  Injection nozzle(s) Remove and test nozzle(s).
  Low compression Do compression test. See

  Excessive wear in liners
and/or piston rings stuck
Slow Acceleration Wrong grade of fuel
  Injection nozzle(s)
  Fuel injection pump
Detonation (Excess Engine Low engine oil level.
Knock)
  Stuck cold weather starting
aid
  Incorrect injection pump
timing.
  Low coolant temperature.
Abnormal Engine Noise Low or incorrect engine oil
(too thin).
  Loose or worn hydraulic
pump drive coupling
  Engine oil diluted with fuel
  Incorrect fuel injection
pump timing
  Excessive valve clearance
  Bent push rods
  Worn rocker arm shafts
  Loose connecting rod caps
  Loose main bearing caps
  Worn main bearings
  Worn connecting rod
CTM104 .
Disassemble, inspect, repair.
Drain and add correct fuel.
Remove and test nozzle(s).
Remove and test fuel
injection.
Add oil.
Repair.
Time injection pump. See
CTM104 .
Remove and check
thermostat. See CTM104 .
Add correct oil to proper
level.
Inspect. Repair.
Inspect engine oil.
Determine cause of fuel
dilution.
Time injection pump. See
CTM104 .
Adjust valve clearance. See
CTM104 .
Inspect. Replace.
Replace.
Inspect, tighten connecting
rod cap screws. See
CTM104 .
Inspect, tighten main bearing
cap screws. See CTM104 .
Replace bearings. See
CTM104 .
Replace bearings. See
 bearings CTM104 .
  Incorrect cam timing Check engine timing.
Repair.
  Scored piston Inspect. Replace.
  Worn piston pin bushings Inspect. Replace pins and
and pins bushings. See CTM104 .
Low Oil Pressure (Oil Low oil level Add oil to proper level.
Pressure Light on—Red Inspect engine oil.
"Stop" Flashing)
  Wrong viscosity oil/oil Change oil. Check injection
diluted with diesel fuel pump shaft seals and transfer
pump diaphragm. See
CTM104 .
  Oil pressure switch or Check engine oil pressure
indicator switch. See Display
Monitor/Indicator
Diagnostics (S.N. —
951252) . (Group 9015A-15.)
  Oil pressure regulating Test or replace. See CTM104
valve .
  Plugged or broken oil pump Inspect. Clean.
intake screen
  Loose oil pump drive gear Inspect. Repair. See CTM104
.
  Worn oil pump gear or Remove, inspect and repair.
housing See CTM104 .
  Excessive main bearing, See CTM104 .
connecting rod or balance
shaft clearance
  Cracked cylinder block Replace cylinder block. See
CTM104 . Inspect piston
cooling jets.
  Leakage at internal oil Check all possible internal
passage. leakage paths. Repair.
Engine Overheats (Engine Low coolant level Fill cooling system and
Coolant Indicator Light check for leaks.
On and Red "Stop"
Flashing)
  Low engine oil level Add oil.
  Loose or broken fan belt. Inspect belt tensioner or
replace belt. See CTM104 .
  Engine overloaded, Reduce load.
operating in wrong gear
  Fan on backwards Check for correct fan
installation. See CTM104 .
  Radiator dirty or plugged Check air flow. See Radiator
Air Flow Test . (Group 9010-
25.) Clean radiator. See
CTM104 .
  Radiator shroud missing, Inspect. Repair or replace.
damaged or baffles missing
  Improper fuel Drain and add correct fuel.
  Radiator cap Replace cap.
  Faulty temperature sender Test, repair or replace
converter oil temperature
sender. See Display
Monitor/Indicator
Diagnostics (S.N. —951252)
. (Group 9015A-15.) or See
Monitor Display Unit
(MDU) Circuit Theory of
Operation (S.N. 951253— ) .
(Group 9015B-15.)
  Incorrect injection pump Time injection pump. See
timing CTM104.
  Excessive axle drag Check axle drag. See Brake
System Checks . (Group
9005-10.)
  Excessive brake drag Check Brake drag. See Brake
System Checks . (Group
9005-10.)
  Faulty thermostat (Struck Inspect thermostat. Replace.
closed) See CTM104 .
  Thermostat missing, cooling Replace thermostats Flush
system coated with lime cooling system. See CTM104
deposits .
  Water pump Remove, inspect and repair.
See CTM104 .
  Excessive fuel delivery Remove. Check for proper
fuel delivery, adjust. See
CTM104 .
  Scored piston Replace piston. See CTM104
.
Engine Runs Cold Thermostat (stuck open) Replace. See CTM104 .
Oil in Coolant Or Coolant Leaking cylinder head Replace gasket. See
in Oil gasket CTM104 .
  Leaking cylinder liner Replace packings. See
packing CTM104 .
  Cracked cylinder liner Replace liner. See CTM104 .
  Oil cooler Replace oil cooler. See
CTM104 .
  Cracked cylinder block Replace block. See CTM104
.
Excessive Fuel Air system restricted Check filter restriction
Consumption indicator and air filters.
Replace
  Leakage in fuel system Inspect. Repair.
  Incorrect grade of fuel Refill with correct fuel. See
Backhoe Loader Drain and
Refill Capacities .
(Operator's Manual.)
  Operator holding hydraulics Return control levers to
over relief. neutral position.
  High system relief valve Test system relief valve
setting pressure. See Loader System
Relief Pressure Test—
310SG (S.N. —910055) .
(Group 9025-25.)
  Incorrect injection pump Time injection pump. See
timing CTM104 .
  Faulty injection nozzle(s) Test nozzle(s). Repair. See
CTM104 .
Turbocharger Excessively Bearings not lubricated Insufficient oil pressure.
Noisy or Vibrates Check for restricted
turbocharger oil line.
  Worn bearings Replace. See CTM104 .
  Air leak in engine, intake or Inspect and repair. See
exhaust manifold CTM104 .
  Improper clearance between Remove exhaust elbow and
turbine wheel and turbine air inlet hose. Inspect and
housing repair. See CTM104 .
  Broken blades on turbine Remove exhaust elbow and
air inlet hose. Inspect and
repair. See CTM104 .
Oil Dripping From Damaged or worn bearings Inspect compressor and
Turbocharger Adapter and/or worn seals turbine wheel for damaged
blades. Check for proper
engine service intervals or
dirt entering engine. See
CTM104 .
  Excessive crankcase Check for plugged oil drain
pressure line. Clean.
  Turbocharger oil return line Remove line. Inspect and
carbon buildup where line clean.
passes exhaust manifold.
Excessive Drag In Carbon build-up behind Inspect and clean. See
Turbocharger Rotating turbine wheel caused by CTM104 .
Members combustion deposits
  Dirt build-up behind Inspect and repair. See
compressor wheel caused by CTM104 .
air intake leaks
  Bearing seizure or dirty or Check for plugged air
worn bearings caused by filters. See CTM104 .
excessive temperature,
unbalanced wheel, dirty oil,
oil starvation, or insufficient
lubrication

TX,15,SS3184-19-20100115