TROUBLESHOOTING

The purpose of troubleshooting is investigating the fundamental causes of troubles and preventing the re-occurrence of the same trouble
after repairs are made. In trouble shooting, an intimate knowledge of the mechanism of the devise and its operating principle is of essential
importance. With this knowledge, you can check the various functions in the proper sequence and locate the cause.

Procedures Before Investigating the Cause of the Problem

Early Detection of Problems
Engine failure is usually preceded by certain signs. Therefore, whenever even a minor or negligible abnormality is observed, the suspected
parts must be immediately checked for early detection of the trouble area and for minimizing accidents.

Preliminary Work
Before attempting troubleshooting, keep watch for the following and make a complete study of the parts involved. Was there an alarm
before the trouble occurred? Had there been a similar problem in the past? Were any repairs or maintenance work carried out before? Is it
safe to continue operating while troubleshooting?

Investigating the Cause

Begin investigation of the cause with obvious answers. First check those easy and obvious, then proceed to those complicated gradually to
save time.

Re – Inspection Before Overhaul

In many cases, a trouble may be related to not only one part but to other parts as well. Carry out an additional inspection before
disassembling the device to confirm that the approach is correct and to prevent missing of evidence in related parts.

Correcting the Source of the Problem

Make it a rule to not only remedy the trouble but to identify the cause of the trouble. For example, a stuck fuel injection pump plunger can
be remedied by repairing the plunger or replacing it with a new one. However the cause of the trouble remains yet to be eliminated.

Causes of Problems & Countermeasures

The following chart gives a listing of probable troubles during diesel operation and their causes as well as remedies against them. It should
be borne in mind that the chart does not provide answers to all possible causes.
 Starting air pressure low Replenish and check the pressure gauge

Starting air not available

Either main valve or intermediate valve from air receiver is closed Open the valve

Air is not available at

Turning apparatus has not been disengaged Disengage
distributor

Starting air valve malfunction (sticking) Repair or replace

Incorrect distributor timing Reset distributor timing

Crankshaft
Defective starting air spring Replace
does not turn
or insufficient
RPM Defective starting air valve seating Repair by lapping or replace
Starting air
Starting air
leakage
is available
Defective distributor valve seating Repair by lapping or replace

Air is
available at Piping system leakage Check & repair
distributor

High lube oil viscosity Warm or change oil

Piston & Liner sticking Check, repair or replace

Increased
resistance of
sliding parts Open indicator cock, check for leaks
Cylinder full of water
& repair or replace

Crankshaft or bearing
Check, repair or replace
stuicking

Empty Fuel
Replenish fuel
Tank

Water is mixed with fuel or poor

Analyse fuel or change fuel
quality fuel

Air inhalation from pipe

Check, repair or vent air
Fuel oil not joints
available to
the injection Clogged Overhaul, clean or
pump filter replace

Defective supply pump Check, repair or replace

Piping is clogged or
Check, repair or open valve
valves closed

Worn plunger Replace

Fuel oil
does not Defective plunger spring Replace
deliver
Abnormal
Engine fails fuel injection Defective delivery valve Replace
to start pump
Crankshaft
turns Decreased delivery rate caused by Replace
worn plunger

Injection admission angle Readjust fuel cam

Incorrect timing incorrect lift

Good fuel oil Incorrect meshing of cam Correct gear

quality drive gears messhing

Seized needle valve or poor Test injector, clean or

spray replace parts

Defective fuel injector Test or replace

Abnormal fuel
injector
Excessive oil leakage from
Test or replace
injector

Fuel oil
available to Injection pressure drop Test & re- adjust
the fuel
injection
pump Clogged nozzle holes Test, clean or replace

Loose or broken injector pipe Tighten or replace

Normal fuel Air in fuel line Vent air

injection
pump
Check & reset
Incorrect valve timing
timing

Normal fuel
Repair by lapping or
injector Defective valve seats
replace

Seized piston rings Repair or replace

Seized control rack Check & repair

 Un-intentional
Sticking of either main starting air valve or air stop valve
engine start

Empty fuel tank Replenish

Insufficient supply Feed pump failure Check, repair or replace

of fuel oil

Clogged filter Check, clean or replace

Insufficient supply
pressure Clogged piping system (valves, cocks etc.) Check, repair or open

Air in pipe system Vent air

Water in fuel Drain water

Abnormal governor
Check & repair
drive

Seized links or
Check & repair
disconnected links

Fuel control linkage Governor failure

closes (out of control)
Governor failure Check, repair or replace

Air in fuel system Vent air

Seized plunger Replace

Engine stalls Abnormal fuel pump
shortly after Seized delivery
Replace
start valve

Seized control rack Repair or replace

Fuel pump control rack

Abnormal engine Check & repair
assembled incorrectly
start Abnormal firing or
Fuel not injected to
misfiring of some
all cylinders Incorrect injection
cylinders Reset timing
timing

Stuck needle valve Test and replace

Abnormal nozzle hole (clogged Test and

or broken) replace

Abnormal fuel injector Injection pressure Test injector &

drop reset

Broken spring Replace

Broken nozzle Test and replace

Fuel collects in
Check & repair
cylinder

Sticking of fuel
pump rack for Check & repair
specific cylinders

Sudden Abnormal governor

increase in Check & repair
drive
engine
revolution
Seized fuel rack
Governor out of
links or Check & repair
control
disconnected links

Check, repair or
Governor failure
replace

Abnormal fuel
control

Fuel oversupplied at
Readjust
start

Abnormal fuel
control at start Inadequate control
release (abnormal Check & repair
control air system)
 Abnormal feed Check, repair or
pump replace

Incorrect adjustment of Check, adjust or

governor link or failure repair

Exhaust gas is Clogged fuel pipe Clean

Insufficient fuel
colourless or
supply
pale blue
Normal feed pump Clogged filter Clean or replace

Loose fuel pipe

Tighten or replace
joints

Worn plunger Replace

Defective fuel
injector pump
Damaged delivery
Replace
valve

Injection timing retarded Adjust

Incorrect fuel
injection timing
Injection timing advanced Adjust

Abnormal fuel Worn or seized plunger Replace

injection system
Defective fuel Defective delivery valve Replace
injection pump
Defective delivery valve gasket Replace

Seized needle valve Replace & test

Worn, damaged or clogged valve seat Clean or replace

Defective fuel Defective fuel injector spring Replace & test

injector
Clogged nozzle holes Clean or replace

Worn liner & piston rings Repair or replace

Seized piston rings Repair or replace

Insufficient
engine power

Repair by lapping/
Defective valve seats
cutting seats

Tappet clearance too small Adjust

Abnormal operation
of engine itself

Broken valve springs Replace

Tighten or replace
Gas leakage from cylinder head
gaskets

Tighten or replace
Leakage from inlet & exhaust manifolds
gasket

Exhaust gas
blackish or Increased resistance of moving parts Check & repair
contains soot

Clogged inlet filter Clean

Compressor impeller or turbine Clean & wash by

Abnormal
blades choked injection
turbocharger

Damaged bearings Replace

Improper fuel quality Replace

Improper fuel

Air or water present in fuel Vent air or replace

 Abnormal propeller
(rapid increase in Repair or replace
temperatures)
Overload
Increase hull
Clean
resistance

Increased engine
Ventilate
room temperature

Compressor choked Clean by injection

Turbocharger Decreased RPM & Turbine blades

Clean by injection
performance drop charge air pressure choked

Temperature of all
cylinder too high Intake filter clogged Clean

Charge air cooler

Clean
Air cooler Increase charge air unclean
performance drop temperature
Increased
Control water
temperature of
quantity
secondary water

Accumulation of
Reduced inlet
carbon in cylinder Clean
passage area
head inlet port

Exhaust
gastemperatures
Check exhaust
too high Increased exhaust
manifold & silencer
back pressure
system & clean

Temperature probe
Replace
out of order

Exhaust valve
Repair or replace
burning

Fuel pump rack

scale out of order Readjust
(advanced)

Temperature of
specific cylinders Incorrect fuel
too high Readjust
injector timing

Abnormal exhaust
gas temperature
Abnormal nozzle Test injector &
(enlarged holes) replace

Underload Normal

Temperature of all
cylinders too low

Charge air Secondary water Control water

temperature drop temperature drop quantity

Temperature probe
Replace
out of order

Exhaust
temperature too
low Rack scale out of
Readjust
order (retarded)

Abnormal fuel
Sticky plunger Replace
injector pump

Broken plunger
Replace
spring

Clogged nozzle Test injector or

Temperature of holes replace
Abnormal fuel
specific cylinders
injector
too low Stuck nozzle needle Test injector or
valve replace

Fractured pipe Replace

Leakage from fuel
injector pipe
Defective joints Repair or replace

Water leakage from Check, repair or

cylinder head replace
Water leaking into
cylinders
Water leakage from Check, repair or
liner replace
 Peak pressure Recalibrate or
meter out of order replace

Overload Reduce load

Increased pressure
in all cylinders

Clogged turbine
Maximum cylinder Increased charge air Increased RPM of Overhaul, clean or
nozzle (deformed
pressure too high pressure turbocharger replace
or carbon build up)

Fuel injection timing

Camshaft drive
incorrect (advanced Reset or replace
gears misaligned
camshaft)

Wrong fuel injection

timing Readjust
Advanced fuel cam

Abnormal fuel Jammed control

Repair or replace
injection pump rack in high position
Increased pressure
in specific cylinders
Enlarged nozzle
Replace & Test
holes
Abnormal fuel
injector
Missing nozzle tip Replace

Recalibrate or
Peak pressure
replace
meter out of order

Abnormal maximum
cylinder pressure
Underload Normal

Decreased pressure
in all cylinders

Fuel injection timing

Camshaft drive
incorrect (Retarded Check and adjust
gears misaligned
camshaft)

Compressor side Clean by water

unclean washing
Turbocharger
performance drop
(decreased RPM)

Rurbine side Clean by water

unclean washing

Charge air pressure

Maximum pressure drop
too low
Increased charge air
Clean
cooler resistance

Inlet & exhaust

Repair or replace
valves burning
Compression
pressure drop
Polished liners Hone

Decreased pressure
in specific cylinder
Worn or sticky
Clean or replace
piston rings

Incorrect fuel
injection timing Readjust
(retarded)

Normal
compression Abnormal fuel Stuck rack at low
pressure Repair or replace
injection pump position

Test, repair or
Stuck needle valve
replace
Abnormal fuel
injector
Test, clean or
Clogged nozzle
replace

Cracked piping Replace

Leakage from fuel
injection pipe
Defective joint Repair or replace
 Underload Normal

Compressor side Clean by water

unlean washing
Turbocharger
Pressure too low
performance drop

Turbine side Clean by water

unclean washing

Air leakage from

inlet manifold Repair
system

Abnormal charge air

pressure

Overload Reduce load

Pressure too high

Abnormal Clogged turbine Overhaul, clean or

turbocharger nozzle replace

Cooling water side Clean

Air cooler choked

Air side Clean

Increased air inflow
temperature

Cooling water pump

Check & repair
failure
Increased
temperature of air
Decrease air inflow cooler cooling water
rate Cooling water Increase water
shortage quantity

Inlet filter unclean Clean

Turbocharger Compressor side Water Wash by

unclean unclean injection

Turbine side
Surging of Overhaul & clean
unclean
turbocharger

Reduced nozzle
Increased RPM of
area (nozzle Overhaul & clean
turbocharger
unclean)

Avoid rapid load

Sudden load change
change

Not all cylinders

Lower RPM
operating

Overload Reduce load

Overload

Check, repair or
Seized moving parts
replace
 Increased cooling Cooling water Cooling water pump Check, repair or
water temperature failure failure replace

Overheated Cooling water Control water

cylinders shortage quantity

Temperature
Check, reset, repair
control valve failure

Jacket water cooler

Clean
blocked

Seized pistons & Check, repair or

liners replace

Cooling water
Check, repair or
stoppage or
replace
shortage

Overheated
turbocharger

Damaged bearings Replace

Stuck plunger Replace

Overheated fuel
injection pump

Clogged fuel Test, clean or

injector nozzle replace

Overheated engine

Inlet valve burning

Repair or replace
or stuck

Overheated inlet
manifold

Air cooler
Clean
performance drop

Cam and cam roller

Repair or replace
seized

Overheated cam &

Cam bearing seized Repair or replace
crank case doors

Main bearing & Check, repair &

crank pin seized replace

Increased
Overheated Lube oil cooler
temperature of lube Clean cooler
bedplate performance drop
oil

Overheated cam Cam drive gears

Repair or replace
drive casing seized

Combustion gas
Overheated starting
leaking from Repair or replace
air main or pipes
starting air valve
 Fuel injection timing
Readjust
too early

Fuel oil Cetane

Change fuel oil
number too low

Irregular injection
Readjust
quantity
Knocking

Improper fuel spray Test, repair or

pattern replace

Defective fuel
injector

Broken fuel injector

Replace
spring

Control water
Overcooled engine
temperature

Foreign matter in
Repair or replace
gear train

Abnormal noise
generated within Abnormal gears Damaged gear Replace
can drive casing

Excessive backlash Check & repair

Loose fasteners Check & tighten

Engine produces
abnormal noise

Abnormal noise
Stuck inlet & Check, repair or
generated around
exhaust valve replace
cylinder head

Excessive tappet
Readjust
clearance

Abnormal noise in Stuck or damaged Check repair or

air inlet manifold inlet valve replace

Damaged cam &

Repair or replace
cam roller

Abnormal noise
generated within
cam case

Damaged roller
Repair or replace
guide

Damaged bearings Replace

Abnormal noise &

vibration of
turbocharger

Ingress of foreign
Damaged rotor Replace
matter
 Overload Reduce load

Piston seized with

liner

Undercooled Clogged cooling oil

Check & clean
pistons passage

Increased mist
quantity
Improper lube oil Analyse oil &
properties change

Excessively worn Check & control

Blow by Overcooled cylinder
liners & rings water quantity

If after recent
overhaul has Check liner bore re-
running in process hone, replace rings
been followed
Abnormal crankcase
mist
Lube oil pressure
Check & adjust
drop
Main bearing &
crankpin bearing
seized
Improper lube oil Analyse oil &
Water mixed in oil
properties change

Check fitting of
If after recent
main bearing & Repair or replace
overhaul
large end bearing

Abnormal oil Excessive wear or

Check & replace
scraper ring breakage

Burning lube oil

Excessively worn Measure wear &

scraper replace liner
Colour change
(pale blue)

Incorrect lube oil Change oil

Relief valve set

Test & reset valve
pressure dropped

Cylinder safety
valve is actuated
Sudden increase in
Check & reduce
engine revolution &
load
overload

Excessive maximum
cylinder pressure

Maximum firing Injection timing

Readjust
pressure too high advanced

Seized pistons and Check, repair or

liners, blow by replace

Crankcase safety Increased crankcase Seized main bearing Check, repair or

valve is actuated mist pressure & crankpin bearing replace

Seized bearings
(camshaft, cam Check repair or
drive, free end replace
pump drive)
 Load fluctuation Stabilise the load

Clogged filter Clean or replace

Check, repair & vent

Air in fuel pipe
air

Irregular fuel supply

Clogged piping Clean

Defective fuel Check, repair or

supply pump replace

Drain water or
Water in fuel
replace

Diesel knocking due

to low Cetane Change fuel
number
Improper fuel
properties

Carbon flower on Clean & test, change

nozzle oil

Abnormal
combustion

Stuck plunger Replace

Defective fuel Broken plunger

Replace
injection pump spring

Unstable engine
(Hunting)
Pump rack
Repair
malfunction

Roller guide
Check & repair
malfunction

Fuel pump roller

guide failure

Damaged cam roller Check & repair

Test & replace

Seized needle valve
nozzle

No load fluctuation Defective fuel

injector

Damaged injector Replace

Control linkage
malfunction Check, repair or
(excessive backlash replace
in linkage)

Normal govenor

Normal combustion Check backlash &

Abnormal governor
bearing clearance.
drive
Repair, or replace

Abnormal governor Check & repair

 Air mixed into fuel pump Vent air

Worn plunger or plunger sticky Repair or replace

Defective fuel pump

Defective delivery valve Replace

Improper fuel injection timing Readjust

Uneven cylinder
outputs
Clogged nozzle holes Test , clean or replace

Defective fuel
Significant difference in injection pressure Test, adjust or repair
injector

Improper fuel spray Test, correct or replace

Excessive fuel leaks Check & repair

Worn cylinder liners & piston rings Repair or replace

Seized piston rings Repair or replace

Abnormal operation
of engine itself Defective inlet & exhaust valve seats Recut or replace

Excessively small tappet clearance Adjust

Black or dark grey Broken inlet & exhaust valve springs Replace

Increased resistance of moving parts Check & repair

Overload Overload Reduce load

Charge air pressure drop by turbo failure Check & repair

Choked inlet filter Clean

Turbocharger failure Compressor & turbine unclean Clean

Damaged bearings Replace

Overcooled charge
Unsuitable air cooler cooling water control By pass control
air

Seized or worn rings Repair or replace

Oversupply of lube
Excessive clearance between
oil to combustion Replace
cylinder liner & piston
chamber
Abnormal exhaust
gas colour
Lube oil viscosity too low Replace

Irregular injection Test injectors,

into some cylinders adjust or repalce

Seized piston rings Replace

Insufficient
compression Damaged piston Repair or replace
pressure

Seized inlet & exhaust valves Repair or replace

White or pale blue

Control water
Overcooled
temperature

Incorrect fuel
Adjust
injection timing
 Empty fuel tank Replenish

Abnormal fuel Defective feed Check, repair or

supply pump replace

Supply pipe valve

Clean / Open valve
clogged / shut

Clogged piping or Check, repair or

leakage clean

Fuel tank full Air in piping system Vent air

Water mixed with Discharge water or

fuel replace

Fuel shut off due to

governor linkage Check or repair
failure

Clogged filter Clean or change

Check, repair or
Seized moving parts
replace

Engine stalls Engine cannot be

abrubtly turned

Broken moving
Replace
parts

Broken governor
Replace
spring

Check, repair or
Engine can be Sticking piston ring
Normal fuel supply replace
turned

Seized piston Repair or replace

Emergency stop
Check or repair
actuated

High load Excessive load

Apply correct load
fluctuation applied
 Improper fuel oil properties Replace

Leakage from fuel piping system Check & repair

Incorrect fuel
Readjust
injection timing

Defective fuel Check, repair or

Excessive fuel oil Defective fuel injection pump replace
consumption injection system

Defective injector Test injector, reset

nozzle or replace

Overhaul, check &

Turbocharger defective & unclean
repair

Overload Reduce load

Lube oil pressure

Adjust
too high

Overheated engine Check or repair

Excessive clearance
Excessive lube oil Incorrect operation Check, repair or
between piston &
consumption of engine itself replace
liner

Worn or seized
Repair or replace
piston rings

Worn or polished
Hone or replace
liners

Leakage from lube

oil piping system
Repair or replace
(Including internal
pipes)

Leakage on water
Repair or replace
side of oil cooler

Improper lube oil

Replace
properties
 Lube oil shortage Replenish

Libe oil viscosity too low Replace

Defective lube oil pressure gauage Replace

Clogged pressure gauge/piping Clean

Pressure gauge
pointer does not
rise after engine
start

Excessive bearing clearance Check, repair or replace

Air inhalation into suction Check, repair or replace

Clogged suction piping or filter Clean, change filter elements

Lube oil pump

malfunction

Worn pump gear drive Check & replace

Abnormal Lube oil

pressure
Pressure regulating valve failure Check, repair or replace

Clogged filter Clean

Excessive oil leakage caused by

Check, repair or replace
damaged piping or cooler

Pressure gauge
pointer drops
Loose or missing plugs Check & refit plugs
suddenly during
operation

Cracked lube oil pipework or leaking

Check, repair or replace
joints

Pressure gauge Air inhalation

pointer oscillates through inlet due to Replenish
during operation lube oil shortage

Clogged lube oil piping Clean

Poorly adjusted pressure regulating valve Adjust

 Engine speed rises spontaneously or
cannot be controlled

Fuel scale pointer abnormally

advanced and engine speed drops

Bearings or other moving parts

overheated

Engine produces abnormal vibration

Case where engine requires

Engine produces abnormal noise
emergency shutdown

Mist in crankcase is abnormally high

or colour changes (breather)

Lube oil pressure suddenly drops

Cooling water temperature suddenly

rises

Turbocharger produces abnormal

noise, vibration or heat