1 KEYS TO TORUBLESHOOTING CHART FOR DIESEL ENGINE

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. 41. 42. 43. 44. 45. 46. 47. 48. 49. 50. 51. 52. Battery capacity low/ discharge Bad/ Loose electrical connection Faulty starter Motor Incorrect grade of Engine Oil Excessive cold weather Engine partially seized Engine needs overhauling Low cranking speed Fuel tank empty Filter clogged Pulled engine stop lever Faulty FIP feed pump Clogged fuel filter Restriction in air cleaner Air in fuel system Faulty FIP pump Faulty injector/ hole chocked Spray not proper/ Dribbling Incorrect use of cold starting grove Incorrect fuel injection timing Incorrect fuel timing Poor compression Incorrect grade of fuel worm out of cylinder liner Pitted and worm valves seat Broken/sticky/partially seized piston rings Leakage in high pressure pipe joints Leakage between injector and cylinder head Spurious diesel filter Excessive engine back pressure/restrictions in exhaust system Wrong tappet setting Head gasket leakage Main/big end bearing worn out and excessive play in crank shaft Hole of fuel tank cap blocked FIP over flow valve leakage/ jam Water in diesel Engine seized One or more cylinder not working Engine running cold Not proper setting of accelerator linkages Maximum speed less Do rating due to heat Do rating due to height/ low atmospheric pressure Wrong governor setting Injector tips protrusion not proper Bumping clearance not proper Sticky valve Inside/ outside leakage of diesel Idling speed more Low opening pressure of injector Engine overloading Brake jam No proper use of speed according to implement 53. 54. 55. 56. 57. 58. 59. 60. 61. 62. 63. 64. 65. 66. 67. 68. 69. 70. 71. 72. 73. 74. 75. 76. 77. 78. 79. 80. 81. 82. 83. 84. 85. 86. 87. 88. 89. 90. 91. 92. 93. 94. 95. 96. 97. 98. 99. 100. 101. 102. 103. 104. 105. 106. Clutch plate worn out Tyre pressure less Continue running of idling speed FIP delivery valve jam/ spring broken More engine oil in sump Worn out valve steam and valve guide Breakage of cylinder liner Overfull of air cleaner/ pullover of engine oil Engine overheating Hot running of engine Incorrect type of HP pipes Bearing clearance more Fly wheel loose FIP coupling gear mounting nut loose Damaged fan/ incorrect fan Faulty thermostat Restriction in water jacket Loose fan belt Chocked radiator Faulty water pump Coolant level low Radiator cap pressure incorrect Spring /rubber ring sealing broken of radiator cap Excess carbon in combustion chamber Oil passage closed Chocked air fins of radiator No proper setting of radiator coolant Faulty temp gauge No oil change at proper time Faulty oil pressure gauge Pressure relief valve sticks closed Less oil in sump Oil pump gear worn-out Pressure relief valve stick open Broken relief valve spring Suction strainer chocked Suction pipe joint loose Chocked oil filter Reverse fitment of piston rings Incorrect gap of piston rings Crank shaft balancing weight interchanged Excess capacity of water pump fan Excess oil in sump Leakage of oil from engine part /seal Excessive depth and improper honing FIP facing out Breakage of delivery valve spring/ jammed Injector opening pressure more Dirty oil filter/spurious filter Engine oil not change Loose / missing air hose clamps Burst/damaged air hoses No oil top-up / replaced, in time in FIP Excessive hot weather

2 KEYS TO TORUBLESHOOTING CHART FOR DIESEL ENGINE

S.N o 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23

Trouble Low Cranking speed Engine will not Start Difficulty starting Engine Start but Stop Lack of Power Misfiring Excessive Fuel Consumption Black Smoke White Smoke Erratic Running Vibration Overheating High Oil Pressure Low Oil Pressure Blue Smoke Excessive Back Pressure Poor Compression Knocking Engine Starts and Stop Crank Case Dilution Excessive Oil Consumption Earlier failure of Cylinder Liner/ Piston Rings Earlier failure of Fuel Injection Equipment 1,2,3,4,5,6,

Possible cause

7,8,9,10,11,12,13,14,15,16,17,19,20,21,22,23,24,25,26,27,29,30,31,32,36,46 5,8,10,12,13,14,15,16,17,18,19,20,21,22,23,24,25,26,27,29,30,31,33,34,35 7,9,13,14,15,16,17,25,30,31,32,34,35,36,37 4,7,10,12,13,14,15,16,17,19,20,21,22,23,24,25,26,29,30,31,32,33,34,35,37,38,39,40,41 ,42,43,44,45 10,12,13,15,17,19,20,24,30,31,35,44,46 12,16,17,19,20,21,22,23,24,25,26,27,28,29,30,31,38,40,41,42,44,45,47,48,49,50,51,52, 53,54,55 14,16,17,19,20,21,22,23,25,29,31,32,37,42,44,46,50,56 19,35,36,59 10,11,12,13,14,15,16,17,21,25,30,37,46,61,66,93 16,17,21,23,25,30,31,32,46,61,63,64,65,93 4,14,16,17,19,20,25,29,31,46,50,51,52,53,54,67,68,69,70,71,72,73,74,75,76,77,78,79,8 0,81,106 4,77,82,83 4,7,32,82,84,85,86,87,88,89,90 4,23,25,57,58,60 23,25,31,58,91,92 14,20,23,24,25,30,45,46,58,92 17,19,20,22,23,25,30,32,37,45,46,60,61,98,99,100 13,14,15,25 5,14,16,17,19,20,22,23,25,37,38,55,66,94 4,23,25,58,91,92,95,96,97 4,14,17,19,20,21,22,35,38,50,55,62,101,102,103,104 13,22,28,35,105