ENGINE TROUBLESHOOTING Task Guidelines

_______________________________________________________________________________________________________________________

Task (Job Code) : 035 – Troubleshooting

Model : Cat
Serial No : XXX
CC - MC : 1000 - Engine

JOB SUMMARY

Budget Budget Skill Level Complete

Activity Activity Description
Man hours Duration Yes / No

1 General Troubleshooting Preparation

2 Engine Low Power

3 Engine Overheating

4 High Oil Consumption

5 High Fuel Consumption

6 Engine Unusual Noises

7 Excessive Black Smoke

8 Excessive White Smoke

9 Excessive Blue Smoke

10 Engine Hard Starting

11 Oil Level Over Fill

12 Debris on Oil Filter

13 Engine Excessive Vibration

14

BUDGET TOTAL:

Special Tools Bill of Material Ref

Qty Part Number Description Qty Part Number Description
ET Tool
Engine Compression Test

Cooling Test Pressure

Tool Adjust Valve

Temperature Gauge

Belt Tension Gauge

Hand Tool

Workscope Reference Material

No Description Task Guidelines Doc. No Task Record Doc. No
1 Engine Troubleshooting CAT_ALL_1000_035_TG_000_ENG CAT_ALL_1000_035_TR_000_ENG
2

Ref No MSDS Reference

CAT_ALL_1000_035_TG_000_ENG 1 of 9 7148
 ENGINE TROUBLESHOOTING Task Guidelines
_______________________________________________________________________________________________________________________

Document No: Process: Issued Inspected Approved

CAT_ALL_1000_035_TG_000_ENG Troubleshooting Strategy
Section Model: Safety
Contamination
Rev/Date December 2019
Control
Page 9 CAT_ALL Planning
Daily Ops

TASK DESCRIPTION DISCLAIMER

Scope of Work
karyawan PT. Trakindo Utama yang berkualifikasi dalam hubungannya dengan manual service Caterpillar dan
• Perform Engine
Troubleshooting
• Create repair option
or recommendation
Dokumen ini adalah intelektual properti PT. Trakindo Utama dan diproduksi untuk digunakan oleh
juga di bawah pengawasan PT. Trakindo Utama. Penggunaan dokumen dan informasi yang terkandung di
dalamnya, oleh karyawan bukan PT. Trakindo Utama menjadi resiko pengguna. PT. Trakindo Utama tidak
bertanggung jawab atas segala kerusakan, kerugian, cedera atau masalah lain yang dapat terjadi pada
pengguna pihak ke-3, peralatan atau lingkungan yang disebabkan oleh penggunaan dokumen ini.
DISCLAIMER
This document remains the intellectual property of PT Trakindo Utama and was produced to be used by
qualified PT. Trakindo Utama employees in conjunction with Caterpillar service manuals and under
supervision of PT. Trakindo Utama Supervision. Use of this document and the information contained
therein, by non-PT. Trakindo Utama employees, is solely at the risk of the user. PT. Trakindo Utama is not
responsible for any damage, loss, injury or other such issue occurring to the user 3rd party, equipment
or the environment caused by using this document.

Key to Symbols

Memulai tugas • Menunjukkan, tugas dimulai dengan aktivitas ini.

START Starting of Task
Melanjutkan
Continue
Keputusan
Decision
Akhir sebuah tugas
FINISH
End of task
Membutuhkan tool khusus
Special Required Tools
Penggantian part
Parts Replacement
Literature pendukung
Support Literature
Workscope tertentu
Refer to other workscope
Peringatan
WARNING
Indicates that the task is begun with this activity.
• Menunjukkan aktivitas masih dilanjutkan.
Indicates that the activity continues.
• Menunjukkan bahwa tugas harus disetujui oleh supervisor sebelum melanjutkan aktivitas berikutnya.
Indicates that the task must be approved by supervisor before continuing the next activity.
• Menunjukkan bahwa tugas telah selesai.
Indicates that the task has finished.
• Menunjukkan bahwa ada tool tertentu yang di butuhkan untuk aktivitas tersebut.
Indicates that there is a special tool to perform the activity.
• Menunjukkan bahwa ada penggantian part yang di butuhkan pada aktivitas ini.
Indicates that there is parts replacement required in this activity.
• Menunjukkan bahwa ada literature pendukung yang dibutuhkan.
Indicates that there is support literature to perform the task.
• Menunjukkan bahwa ada workscope tertentu untuk tugas tersebut.
Indicates that there is a certain workscope to perform the task.
• Tanda ini digunakan untuk mengingatkan bahaya dan praktek-praktek yang tidak aman yang dapat
menyebabkan luka parah atau kematian jika prosedure yang benar tidak di ikuti.
This prompt is used to warn against hazards and unsafe practices that COULD result in severe
personal injury or death if correct procedures are not followed.

• Tanda ini digunakan ketika sebuah operasi, kondisi atau informasi penting untuk warrant highlighting.
Catatan
This prompt is used when an operation, condition, or information is of sufficient importance to warrant
NOTE
highlighting.

CAT_ALL_1000_035_TG_000_ENG 2 of 9 7148
 ENGINE TROUBLESHOOTING Task Guidelines
_______________________________________________________________________________________________________________________

Text Color Legend:

Semua Instruksi safety

All Safety instructions

Semua spesifikasi torque, tekanandan berat.

All Torque Specification, Pressure and weight

Instruksi umum
General Instruction

Contamination Control
Contamination Control

STEP PROBLEM INDICATOR ACTION OPTION REPAIR

Preparation

1. 8 step troubleshooting 1. Make sure the problem really does exist

process. 2. State the problem by writing it down
3. Visually inspect the engine or machine
4. List all possible causes
5. Run the test & record data
6. Find the root cause (eliminate everything
that could not create the problem)
7. Repair the fault & fix the problem
8. Analyze faulire why did the problem occur

ENGINE

2. Engine Low Power. A. Check primary & secondary air filter for
dirt or plugged:
1. Air filter indicator (red zone) 1. Reset air filter indicator
2. Primary & Secondary air filter (plugged, 2. Clean or replace primary air
wet, damaged) filter
Probable Causes Replace secondary air filter
(don’t clean secondary filter)
3. Dust valve (plugged) 3. Clean dust valve
Dirty primary/secondary 4. Seal cover (damaged) 4. Replace seal cover
A
air cleaner
5. Housing filter (leak, corrotion, damaged) 5. Repair or replace housing

B Exhaust restriction/leak B. Check exhaust manifold for leak or

damage:
1. Mounting bolts (loose or broken) 1. Repair loose or broken
C Faulty turbocharger
exhaust bolts
2. Test Exhaust bypass valve (if equipped) 2. Adjust exhaust baypass valve
D Faulty unit injector as specification
3. Compare actual exhaust temperature vs 3. Replace exhaust temperature
sensor sensor (if necessary)
E Fuel restriction
C. Check turbocharger for:
1. Clamps (loose or missing) 1. Repair/replace loose or
F Electrical problem
missing clamps
2. Mounting bolts (loose or broken) 2. Replace mounting bolts
3. Induction lines (leaks) 3. Repair leak
4. Wheel compressor (damage) 4. Repair or replace
Turbocharger (flush air
induction if necessary)
D. Check fuel unit injector:
1. Use ET tot est solenoid injector (low 1. Repair injector (harness) or
sound/klik) replace injector
2. Check rocker arm (for damage) 2. Replace damaged
mechanism for injector
3. Check Injector (for oil or fuel leak) 3. Reseal injector or replace unit
injector
E. Check fuel restriction:
1. Test fuel pressure & compare with 1. Repair (adjust) or replace fuel
specification regulator
2. Check output fuel tank and suction lines to 2. Clean or flush line (if
fuel priming pump restricted)
3. Check primary/water separator fuel filter 3. Drain water separator & clean
primary filter
4. Check secondary fuel filter (for plugged) 4. Replace with new filter (if
plugged)
5. Check damaged fuel hose (bent, twist) 5. Reposition or reroute bent or
twist fuel hoses

CAT_ALL_1000_035_TG_000_ENG 3 of 9 7148
 ENGINE TROUBLESHOOTING Task Guidelines
_______________________________________________________________________________________________________________________

STEP PROBLEM INDICATOR ACTION OPTION REPAIR

F. Check electrical problem:

1. Test atmospheric pressure sensor 1. Repair wiring or replace
sensor. Calibrate pressure
sensor
2. Test oil pressure sensor 2. Repair wiring or replace
sensor
3. Test coolant temperature sensor 3. Repair wiring or replace
sensor
4. Test air inlet temperature sensor (if 4. Repair wiring or replace
equipped) sensor
5. Check correct/updated flash file installed 5. Install updated flash file meet
(for electronic engine) to prefix (serian number)

3. Engine Over Heating. A. Check coolant level:

Probable Causes
A Low coolant level
Faulty temperature
B 1.
gauge
C Dirty radiator
D Loose belts
1. Actual level (low) 1. Levelling coolant (add coolant)
2. Display coolant level (low) 2. Repair or replace gauge level
indicator
3. External coolant leak 3. Repair external coolant leak
(hose & lines connection, cap
/relief valve, water pump, head
gasket)
4. Internal coolant leak 4. Check & repair crack on
cylinder head or block
B. Check gauge temperature:
Check gauge as (fail) 1. Replace gauge as (if
necessary)
2. Check wiring (problem) 2. Repair or replace wiring
C. Check dirty radiator:
1. Radiator cores (dirt) 1. Clean radiator cores & area

D. Inspect lose belts:

E Faulty hoses 1. Visual check condition 1. Replace for worn belt
2. Check tension 2. Readjust belt tension
3. Check bolts & nuts (tightening) 3. Tighten bolts & nut as
F Faulty thermostat
specification
E. Check faulty hoses:
G Faulty water pump 1. Visual check hoses, tubes (crack or 1. Replace cracked or damaged
damage) tubes & hoses
2. Check hose clamps (loose) 2. Tighten all coolant hose clamps
H Faulty fan as specification
F. Chek faulty thermostat:
Radiator duct/air 1. Check inlet & outlet temperature (delta T) 1. Replace thermostat (if
I necessary)
separator
G. Check faulty water pump:
1. Check coolant flow (if equipped with flow 1. Repair or replace flow switch
switch)
2. Check impeller (looseor bent shaft as) 2. Repair water pump

H. Check faulty fan:

1. Check blade (crack, damage, bend) 1. Replace damaged fan as
2. Check for wrong position of fan 2. Reposition fan as

I. Check radiator duct/air separator:

1. Check for correct radiator duct installation 1. Install radiator duct correctly
2. Check radiator duct (for damage or 2. Repair or replace damaged
missing) radiator duct

4. Engine High Oil A. Test worn or broken rings/ liners (engine

Consumption (blowby). blowby):
1. Carry out test blowby or compression 1. Repair (replace ring pistons,
(running test) liners)
2. Check engine oil filter (soot filter condition) 2. Change engine oil & filters

Probable Causes B. Test turbo (seal) leak:

1. Check endplay 1. Replace seal & bearing
2. Pressurize test for turbocharger 2. Make necessary repair (if found
Worn or broken rings / lubrication lines & check internal leak leak)
A
liners
Worn turbocharger C. Check worn valve guides:
B 1. Inspect the valve guide seals (wear or 1. Replace valve guide seals (if
seals
other damage) necessary)
2. Inspect the valve guides (for excessive 2. Recondition cylinder head (if
C Worn valve guides
wear) necessary)

D Hours on engine D. Engine hours:

CAT_ALL_1000_035_TG_000_ENG 4 of 9 7148
 ENGINE TROUBLESHOOTING Task Guidelines
_______________________________________________________________________________________________________________________

STEP PROBLEM INDICATOR ACTION OPTION REPAIR

Oil engine leak to HEUI 1. Check actual engine life relate 1. Perform planned component
E components (Ref. to Maintenace Interval) replacement as engine life
(fuel system)

E. Check oil transfer to HEUI (fuel system):

1. Test internal leak injector (HEUI) 1. Reseal or replace injector
2. Check lip seal on transfer pump 2. Replace lip seal (recondition
transfer pump if necessary)

5. Engine High Fuel A. External fuel leak:

Consumption. 1. Check fuel system lines (leak) 1. Make necessary repair

B. Excessive Idle or hight load:

1. Connect ET “current totals” for excessive 1. Coaching & Counselling the
idle time or high idle (indicate operator operators (share knowledge
Probable Causes habit) operational procedure)

C. Check damaged accessory:

A External fuel leak 1. Isolate the source of damage. Inspect the 1. Repair or replace engine
suspect accessory accessory in any defect is
Excessive idle or hight found
B D. Check dirty air cleaner:
Load
1. Check air filter indicator (red zone) 1. Reset air filter indicator
Check damaged 2. Primary & secondary air filter (plugged, wet, 2. Clean or replace primary air
C
accessory damaged) filter & replace secondary air
filter if necessary (don’t clean
D Dirty air cleaner secondary filter)
3. Dust valve (plugged) 3. Clean dust valve
Malfunction 4. Seal cover (damaged) 4. Replace seal cover
E 5. Housing filter (leak, corrotion, damaged) 5. Repair or replace housing
turbocharger
Malfunction fuel E. Malfunction turbocharger
F
nozzles/injectors 1. Clamps (loose or missing) 1. Repair loose or missing
clamps
2. Mounting bolts (loose or broken) 2. Replace mounting bolts
3. Induction lines (leaks) 3. Repair leak
4. Wheel compressor (damage) 4. Repair or replace
Turbocharger (flush air
induction if necessary)
F. Check malfunction nozzles/Injectors:
1. Solenoid Injector (fail) 1. Repair injector (harness) or
replace injector
2. Rocker arm (damage) 2. Replace damaged
mechanical injector
3. Injector (Oil or fuel leak) 3. Replace Injector (complete
installation)

6. Engine Unusual Noises. A. Check accessoriy equipment:

Probable Causes
A Accecory equipment
Damage valve train
B 1.
components
C Faulty engine bearing
1. Isolate the source of noises. Inspect the 1. Repair or replace engine
suspect accessory accessory in any defect is
found
B. Check valve train components:
1. Check valve lash 1. Adjust valve if necessary
2. Inspect rocker arms, pushrods, camshaft, 2. Replace components with
valve steams, rocker shaft (damage, bent) new if any damage
3. Inspect piston (damage and wear) 3. Replace piston or parts if
found any damage
C. Check rod & main bearings:
Inspect rod & main bearings (damage, 1. Replace main & conrod
abnormal wear) bearings
2. Inspect crankshaft journals (damage, 2. Repair or replace crankshaft
abnormal wear)

D Faulty Injector D. Test faulty injector:

1. Test solenoid injector (low sound/klik) 1. Repair injector (harness) or
replace injector
E Electrical problem 2. Check injector mechanism (for damage) 2. Replace damaged
mechanism for injector
3. Test injector (for oil or fuel leak) 3. Reseal injector or replace unit
injector

E. Check electrical problem: 1. Repair loose electrical

1. Connect ET & perform wiggle test (while connector or damaged
shake the engine harness) harness.

CAT_ALL_1000_035_TG_000_ENG 5 of 9 7148
 ENGINE TROUBLESHOOTING Task Guidelines
_______________________________________________________________________________________________________________________

STEP PROBLEM INDICATOR ACTION OPTION REPAIR

7. Engine Excessive Black A. Check diagnostic codes:

Smoke. 1. Connect ET & check active codes or 1. Investigate & repair active
check active code on cat display codes

B. Check software ECM:

1. Connect ET & check for the correct (Serial 1. Install correct flash files &
Probable Causes number, arrangement, software) perform calibrating (timing)

C. Check air intake & exhaust system:

A Diagnostic codes 1. Check air filtr restriction indicator (if 1. Reset after repair intake
equipped) system
2. Ensure air filtetr is clean & servicabel 2. Clean or replace primary air
B Software ECM filter & replace secondary air
filter if necessary
Intake & Exhaust 3. Check air intake & exhaust for blockage, 3. Make necessary repair to the
C
system restrictions, any damages components intake & exhaust system.

D Valve lash D. Check valve lash:

1. Ensure valve lash is correct 1. Adjust Valve (if necessary)
Turbochargers (If
E E. Check turbo (if equipped):
equipped)
1. Ensure mounting bolts are tight 1. Replace loose or broken bolts
Low compression 2. Check oil drain turbocharger is not 2. Repair blocked or restricted (if
F
(cylinder pressure) blocked or restricted necessary)
3. Check compressor & turbine housing 3. Repair or replace
Electrical problem (debris, dirt, and damage) turbocharger
G
(Atmospheric sensor) 4. Check turbine blades rotate freely 4. Repair or replace
turbocharger
H Fuel quality 5. Check wastegate is adjusted correctly (if 5. Adjust wastegate valve (if
equipped) equipped)
I Wrong timing dimension F. Check Low compression:
1. Perform compression test 1. Perform all necessary repairs.
J Faulty Injector 2. If compression is noted on any cylinder, 2. Ensure that the repairs have
investigate causes (loose glowplugs, eliminated the faults
faulty piston, rings, worn cylinder bores,
K FIP timing too advance worn valves, faulty head gasket, damaged
cylinder head)
Incorrect fuel rack
L G. Check atmospheric pressure sensor:
setting
1. Test atmospheric pressure sensor (supply 1. Replace faulty sensor
& return signal)
2. Check wiring harness for atmospheric 2. Repair wiring harness (if
pressure sensor (resistance) resistance is out of
specification)
H. Check fuel quality:
1. Determine if water is present in the fuel 1. Drain the water separator
2. Visual inspect the fuel for contaminant 2. Flush or change the fuel from
system
3. Obtain fuel & send to laboratory 3. Follow up sos result

I. Check timing dimension (MEUI & EUI):

1. Check timing dimension for the injectors 1. Adjust timing dimension meet
to specification
J. Check fuel unit injector:
1. Test solenoid injector (low sound/klik) 1. Repair injector (harness) or
replace injector
2. Check Rocker arm (damage) 2. Replace damaged
mechanism for injector
3. Check Injector (for oil or fuel leak) 3. Reseal injector or replace unit
injector

K. Check FIP timing (too advance):

1. Check static timing for FIP 1. Adjust static timing for FIP to
camshaft timing
L. Check incorrect fuel rack setting:
1. Measure fuel rack setting 1. Set fuel rack correctly

CAT_ALL_1000_035_TG_000_ENG 6 of 9 7148
 ENGINE TROUBLESHOOTING Task Guidelines
_______________________________________________________________________________________________________________________

STEP PROBLEM INDICATOR ACTION OPTION REPAIR

8. Engine Excessive White A. Check diagnostic codes:

Smoke. 1. Connect ET & check active codes or 1. Investigate & repair active
check active code on cat display (check codes (calibrate engine speed
engine speed timing sensor) timing sensor if necessary)

B. Check low coolant temperature:

Probable Causes 1. Ensure thermostat operating is correctly 1. Replace water regulator (if
faulty)
C. Check internal coolant leak:
A Diagnostic codes 1. Use external air pressure to pressurize 1. Replace aftercooler, air
cooling system & check intake manifold & compressor, or Turbocharger
Low coolant aftercooler for coolant leakage (if necessary)
B 2. Inspect air compressor (outlilnes) for 2. Repair or replace air
temperature
coolant leakage compressor
3. Inspect turbocharger for internal coolant 3. Repair or replace
C Cooling system
leakage turbocharger

D Glow plugs D. Check glow plugs:

1. Inspect electrical connector & wiring 1. Repair electrical connector &
wiring
E Fuel quality 2. Test continuity of glow plugs 2. Replace glow plugs (if
necessary)
E. Check fuel quality:
F Valve lash
1. Obtain SOS for fuel to analize (low cetane 1. Perform recommended action
fuel can create white smoke) from interpreter laboratory
Low compression (replace fuel with higher
G
(cylinder pressure) cetane if necessary)
Malfunction of automatic 2. Check water separator (if equipped). 2. Replace fuel filter & flushing
H Inspect fuel condition for contamination & fuel system (if necessary)
timing advance
abnormal colour
I Flash file F. Check valve lash:
1. Remove valve cover & inspect valve 1. Replace any damaged
J Turbocharger oil leak mechanisms components
2. Check valve lash & record measurement 2. Adjust valve within
specification
G. Check cylinder compression:
1. Perform compression test 1. Repair procedures must be
taken if the compression is
lower than the repair limit
H. Check automatic timing advance:
1. Test automatic timing advance 1. Replace malfunction
automatic timing advance

I. Check flash file is installed:

1. Verify that the correct flash file is installed
J. Check turbocharger oil leak:
1. Remove exhaust pipe from turbocharger
& visually inspect for the presence of oil
1. Install the correct flash file
(complete timing calibration)
1. Replace oil seal turbocharger
(recondition turbocharger if
necessary)

9. Engine Excessive Blue A. Check failure of turbocharger seal:

Smoke (Oil Consumption). 1. Check the inlet manifold for oil 1. Repair Turbocharger if oil
present on the inlet manifold
B. Check worn valve guides:
1. Inspect the valve guide seals (wear & 1. Replace valve guide seals (if
Probable Causes other damage) necessary)
2. Inspect the valve guides (wear) 2. Recondition cylinder head (if
necessary)
Worn turbocharger
A C. Check worn rings/liner:
seals 1. Perform testing blowby 1. Repair (replace ring pistons,
liners)
B Worn valve guides 2. Check soot on engine oil filter 2. Change engine oil & filters

D. Check engine hours:

C Worn rings/liners
1. Check actual engine life relate 1. Perform planned component
components (Ref. to Maintenace Interval) replacement as engine life
D Hours on engine

10. Engine Hard Starting. A. Check battery or air pressure low:

1. Test battery 1. Recharge or replace Battery
2. Check air system pressure drop 2. Repair external air leak &
charge air pressure
Probable Causes

CAT_ALL_1000_035_TG_000_ENG 7 of 9 7148
 ENGINE TROUBLESHOOTING
_______________________________________________________________________________________________________________________
STEP PROBLEM INDICATOR
Low battery or air
A 1.
pressure
B Low fuel & oil pressure
C Check ECM
Low cylinder
D 1.
compression
E Faulty nozzle or Injector
Malfunction shutdown
F
switch
Starting aid (if
G than the repair limit
applicable)
H Electrical problem
11. Engine Oil Level Over Full.
Probable Causes
A Improper oil fills
Internal leak engine oil
B 2.
cooler
Internal leak water
C
pumps
Internal leak cylinder
D
head, gasket, & block
E Injector fuel leak
Internal fuel leak (base
F
cover)
CAT_ALL_1000_035_TG_000_ENG
Task Guidelines
ACTION OPTION REPAIR
B. Check fuel & oil level:
Visual check for fuel & engine oil level. 1. Add fuel & engine oil
Verify minimum fuel & engigne oil
pressure.
2. Check IAP pressure (for HEUI) 2. Repair or replace fuel transfer
pump
3. Remove air in fuel system (bleeding) 3. Repair or replace HEUI pump
(if necessary)
C. Check ECM input & output:
Check ECM is receiving correct voltage 1. Repair wiring or replace
Check engine RPM while cranking speed/timing sensor
2. Use ET to check faults & logged events 2. Repair active codes
3. Ensure shutdown switch (if equipped) is 3. Reset shutdown switch (move
off position to position not ACTIVE)
D. Check cylinder compression:
1. Perform compression test 1. Repair compression is lower
E. Test nozzle or fuel injector:
1. Perform testing nozzle or injectors 1. Replace nozzle or injectors
F. Check malfunction shutdown switch:
1. Test shutdown switch “ON & OFF” 1. Replace failed switch
position
2. Check shutdown switch wiring & 2. Repair wiring & connector
connector
G. Check starting aid (if equipped):
1. Ensure the ether canister is not low or 1. Replace the ether canister
empty with new one (if low or empty)
2. Actuate the system manually after start-up 2. Replace coolant temperature
& observe results. The ether system will sensor (if failed)
not operate if the coolant temperature is
too high
3. Inspect electrical wiring & connector (for 3. Repair or replace wiring
damage) harness or electrical
connector (if damage)
H. Check electrical problem:
1. Check failed pressure sensor 1. Replace failed pressure
(atmospheric, oil pressure, coolant sensor & perform calibration
temperature, air inlet temperature)
2. Check failed engine speed timing sensor 2. Adjust clearance speed timing
sensor or replace failed
sensor
A. Check improper oil fills:
1. Check for correct part number on level 1. Replace with correct part
gauge number for level gauge. Drain
engine oil to correct level
B. Check engine oil cooler:
1. Disconnect inlet & outlet oil lines on cooler 1. Replace engine oil cooler if
& pressurize cooling system (check there is evidence of leaks
coolant leakage) coolant. Flush engine
lubrication system
C. Check internal leak water pump:
1. Check weep hole (for oil or coolant leak) 1. Repair water pumps.
Remove access cover on oil pan for 2. Flush engine lubrication
inspectiong internal leakage (pressurize system
cooling system)
D. Check cylinder head & gasket:
1. Remove access cover crankshaft & 1. Make necessary repair
camshaft. Pressurize cooling system (reseal, replace liner, repair or
(check coolant leakage): water seals, replace cylinder block
crack head, crack liner, crack cylinder
block
E. Check faulty injector:
1. Check seal injector for damage 1. Replace seal with new one
2. Check injector rocker arm (for damage 2. Replace damaged
solenoid) mechanism & replace
injectoro
3. Check injector (for oil or fuel leak) 3. Reseal injector or replace unit
injector
F. Check internal fuel leak at base cover:
1. Remove valve cover & inspect jumper 1. Replace jumper tube with new
tube may crack on the injector side one
8 of 9 7148
 ENGINE TROUBLESHOOTING Task Guidelines
_______________________________________________________________________________________________________________________

STEP PROBLEM INDICATOR ACTION OPTION REPAIR

12. Engine Debris on Oil Filter. A. Check dirty entry:

Probable Causes
A Dirty entry
Extended oil change
B D.
period
C Wrong oil used
Coolant/fuel leak into
D
crankcase
E Damaged bearings
F Leak combustion
1. Check leak on filler cap & breather 1. Reseal or replace filler cap
2. Inspect valve mechanism cover (for leak) 2. Reseal or replace valve
mechanism cover
B. Extended oil change period:
1. Ensure the oil change within interval 1. Change the engine oil & filter
if necessary
C. Check wrong oil used:
1. Ensure the engine oil is correct 1. Change engine oil if
specification necessary (flush lubricatin
system if necessary)
Check coolant/fuel leak into crankcase:
1. Remove access cover crankshaft & 1. Make necessary repair
camshaft. Pressurize cooling system (reseal, replace liner, repair or
(check coolant leakage): water seals, replace cylinder block
crack head, crack liner, crack cylinder
block
E. Damaged bearings:
1. Check engine bearing (wear or other 1. Replace damaged bearings &
damage) flush lub. lines if necessary

13. Engine Excessive Vibration. A. Check loose mounts:

1. Look for any loose or broken mounts, 1. Repair & tighten any fixtures
brackets & fasteners

B. Check vibration damper, flywheel, fan

Probable Causes blade:
1. Check debris & vibration damperrd for any 1. Repair & tighten vibration
damage. Check mounting bolts for damper bolts. Replace
A Loose mounts damage vibration damper (if
necessary)
Vibration damper, 2. Check run out of flywheel 2. Replace flywheel (if
B necessary)
flywheel, fan blade
3. Check fan blade fo imbalance (bent or 3. Replace fan blade (if
broken) necessary)
C Driven equipment
C. Check driven equipment:
Individual malfunction 1. Inspect mounting bolts for drive 1. Replace damaged mounting
D
cylinder equipment (loose or broken) bolts
Faulty crankshaft 2. Inspect coupling 2. Replace coupling if necessary
E
(counterweight)
D. Test individual malfunction cylinder:
1. Connect ET & perform individual injector 1. Repair faulty cylinder
F Engien misfiring
cut out with engine fast idle. Notice
cylinder operating below normal

E. Check faulty crankshaft (counterweight):

1. Look for any loose or broken bolts 1. Replace bolt with new one &
torque properly
2. Check for damaged counterweight 2. Replace damaged
counterweight
F. Check engine misfiring:
1. Use ET & perform solenoid test injector 1. Repair connector between
harness & solenoid. Replace
injector (if solenoid damage)
2. Test cut out test injector 2. Replace the bad injector
3. Check engine speed timing sensor 3. Adjust sensor clearance or
replace sensor (if failed)
4. Perform wiggle test (while shake the 4. Repair engine wiring harness
engine wiring harness) for intermittent connection
problem

CAT_ALL_1000_035_TG_000_ENG 9 of 9 7148