Causes of Engine Starting & Running Faults With Remedies:-
If the engine is maintained as per the instructions given in the earlier sections of this booklet, normally there will be no trouble. However, if a fault occurs, the following table would help the engine user to remove the faults of elementary nature and keep the idle time of the engine to minimum. If even after attending to the engine as per the following instructions, the working is still unsatisfactory, it is advisable that our nearest authorized dealer/distributor be consulted.
Fault |
– Cause |
Remedy |
| Dirty/clogged air cleaner. | Clean air cleaner, change oil in air cleaner. | |
| High exhaust back pressure. | Clean exhaust silencer and manifold | |
| Fuel tank empty | Fill up tank and air vent | |
| Fuel tank cock closed | Open the cock and air- vent if necessary | |
| Air in fuel line | Bleed fuel system | |
| Strainer in feed pump | Clean the strainer | |
| inlet banjo bolt choked | ||
| Engine fails | Fuel line leaking | Check all fuel line connections for tightness, |
| to start | change copper washers. | |
| Faulty fuel injection nozzle | Check the nozzle spray, if necessary change the nozzle | |
| Dirty/choked fuel filter | Change the filter elements and clean fuel | |
| filter bowls. | ||
| Feed pump not working | Operate feed pump, if not working, send it | |
| to your dealer. | ||
| Wrong adjustment of valve | Re-adjust the valve clearances correctly. | |
| clearance | ||
| Incorrect fuel timing | Set to correct fuel timing. | |
| Battery runs down | Recharge battery | |
| Battery of wrong capacity | Use battery of correct capacity | |
|
Faulty starter |
recommended in Maintenance manual.
Repair starter |
|
| Loose or dislodged wiring | Tighten all loose wiring
|
|
| High exhaust back pressure | Clean exhaust silencer and manifold | |
| Dirty/Clogged air cleaner | Clean air cleaner, change oil in air cleaner | |
| Air in fuel line | Bleed fuel system | |
| Engine difficult to start | Fuel line leaking | Check all fuel line connections for tightness change copper washers |
| Faulty fuel injection nozzle | Check the nozzle spray, if necessary change the nozzle | |
| Engine used after a long time | Flush and service engine thoroughly | |
| Incorrect fuel timing | Set it to correct fuel timing |
Fault |
Cause |
Remedy |
| Run down battery, terminals loose or oxidized causing starter motor to turn slowly. | Have battery inspected, clean terminals, tighten and coat with acid-free grease. | |
| Grade of lub. oil used is too viscous
(applies particularly at very low temp. in winter) |
Use correct grade of lub. oil as Recommended(in lub. Oil Specifications) | |
| Fuel supply not sufficient | Renew fuel filter and then air-vent, clean strainer in fuel lift pump | |
| Engine starts but stops after some time
but stops Download
after some time |
Dirty/Clogged air cleaner | Clean air cleaner, change oil in |
| air cleaner | ||
| No fuel | Replenish with clean fuel | |
| Air in fuel line | Bleed fuel system, tighten all fuel | |
| connections | ||
| Choked fuel injector holes | Clean holes | |
| Dirty/Choked fuel filter | Clean fuel filter bowls and | |
| replace the fuel filter elements | ||
| Water mixed with fuel | Change fuel and clean fuel tank | |
| Wrong adjustment of valve clearance | Re-adjust valve clearances correctly | |
| Engine seized | Contact nearest distributor | |
| One or more cylinders not working | Contact nearest distributor | |
| Engine gives | Dirty/clogged air cleaner |
Clean air cleaner, refill lub. oil in air cleaner |
poor |
High exhaust back pressure | Clean exhaust silencer and manifold |
| performance Or engine | De-rating due to altitude And temperature | Calculate de-rating due to altitude and temperature and Put correct load on engine |
| Lacks power | Choked fuel injector holes or nozzle needle sticking | Clean injector and fuel line, Have inspected by a specialist |
| Control lever setting wrong | Adjust to correct setting | |
| Faulty fuel pump | Send pump for recalibration | |
| Fuel supply not sufficient | Renew fuel filter elements and air-vent, clean strainer in fuel lift pump, tighten fuel line connections | |
| Overflow valve on fuel | Have inspected by a specialist | |
| injection pump not working properly |
Fault |
Cause |
Remedy |
| Engine gives poor performance or engine lacks power | Valve clearance out of adjustment, valve spring broken | Re-adjust valve clearance, renew valve spring. |
| Dirty air cooling fins on cylinder heads | Clean air fins | |
| Loose fan belt | Tighten belts | |
| Valve leakages | Regrind the valves | |
| Broken/seized/worn out piston rings | Replace with new piston rings | |
| Worn out liner and piston | Replace with new one | |
| Damaged main and connecting rod bearings | Change bearings | |
| Incorrect valve and fuel timings | Set to correct settings | |
| Faulty governor setting | Set governor properly | |
| One or more cylinders not working | Contact nearest distributor | |
| Exhaust smokes badly | Too much oil in sump | Drain off until level reaches low mark on dipstick |
| Oil level in oil bath air cleaner too high | Pour off until level agrees with mark hole | |
| Inefficient compression due to sticking or broken compression rings or incorrect valve clearance | Have compression rings and pistons inspected by a specialist, readjust valve clearance | |
| De-rating due to altitude and temperature | Calculate de-rating due to altitude and temperature and reduce load on the engine if necessary | |
| Poor quality of fuel | Change to quality fuel | |
| Engine overheats
(shut down engine Immediately) |
Cooling fins on cylinders and cylinder heads, very dirty | Clean cooling fins, particularly the vertical ones on the cylinder heads |
| Injectors defective | Have inspected by a specialist | |
| Injection pump delivery out of | Have adjusted by a specialist | |
| adjustment | ||
| Insufficient cooling air input to blower | Ensure the cooling air flow | |
| Blower V-belt broken | Renew V-belt
|
|
| FAULT | CAUSE | REMEDY |
| Engine oil
pressure too low (shut down engine immediately |
Wrong grade of lub oil used
Dirty/choked suction tube strainer Dirty/clogged oil filter |
Use lub. oil of recommended grade
Clean strainer thoroughly Clean oil filter and replace filter element by new one |
| Engine oil pressure too low (shut down engine immediately) | Clogged oil passages
Defective relief valve in lub. oil filter Leaks in lub. oil system
Faulty oil pump Engine oil not changed at recommended period Excessive play on main bearing |
Flush oil passages
Replace with new one
Check connections on pump, lines, filter, pressure gauge and cooler for tightness Replace with new one Change the oil
Change bearings, consult specialist |
| Battery runs down frequently | Faulty starter
Faulty generator Faulty cut-out
Loose wiring |
Repair starter
Repair generator Clean the contact points, if necessary replace it Tighten all loose wiring |
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