- Cause of malfunction - Solution
The engine does not start:
- The starter does not turn the crankshaft or turns it very slowly
Check the charge level and serviceability of the batteries and, if necessary, charge or replace them
Check the power supply contacts of the starter, clean the wire terminals for serviceability.
Check the condition of the starter relay contacts, if there is any burning, clean the contacts in the circuit, tighten them if necessary.
Check the contacts of the starter brushes with the collector and the absence of sticking of the brushes in the brush holders, if necessary, wipe and clean the collector, clean the side edges of the brushes, replace worn brushes with new ones or replace faulty brush springs.
If it is impossible to eliminate the defects, replace the starter.
- - Clogged fuel lines or intake in the fuel tank - Flush the intake, flush and blow out the fuel lines
- - Freezing of water in the fuel lines or on the fuel tank intake screen - Carefully warm up the fuel lines, filters and tank
- - Clogged filter elements of the fuel filters - Replace the fuel with another one that matches the season and bleed the system
- - Incorrect fuel injection advance angle - Adjust the fuel injection advance angle
- - Air in the fuel system - Bleed the system, eliminate leaks
- - The fuel priming pump does not work - Disassemble the pump and eliminate the malfunctions
- - Seizure of the high-pressure fuel pump rack in zero supply - Repair the fuel pump in a workshop or replace it with a serviceable one
- - Difficulty in moving the fuel injection pump rack due to thickening of the lubricant - Carefully warm up the fuel pump. Replace the filter elements
The engine does not develop power:
- - Contaminated air filters - Clean the air filters
- - Clogged exhaust tract - Clean the exhaust tract
- - Contaminated filter elements of the fuel filters - Replace the filter elements
- - The regulator control lever does not reach the maximum speed bolt. The stop lever does not reach the extreme operating position. Check and adjust the drive lever system
- - Air in the fuel system - Bleed the fuel supply system and eliminate
- - Incorrect fuel injection advance angle - Adjust the fuel injection advance angle
- - Loose valve timing - Adjust the thermal clearances in the valve mechanism, grind the valves if necessary
- - Low charge air pressure - The air supply system is leaky. Eliminate the leak. If the resistance of the exhaust pipe is increased, clean the exhaust pipe. Turbocharger is faulty. Repair.
- - Injector adjustment or clogging - Adjust the injectors and, if necessary, flush and clean them
- - Fuel injection pump valves are faulty - Flush the pump seats and valves, grind the valves if necessary
- - High-pressure fuel pump pusher springs are broken - Replace the springs and adjust the pump on a stand in a specialized workshop
- - Fuel pump discharge valves are broken or leaky - Replace the spring or eliminate the valve leak (carry out in a specialized workshop)
- - Piston ring wear - Replace the piston rings, pistons and cylinder liners if necessary
Diesel knocking:
- - Early fuel injection into cylinders - Adjust the fuel injection advance angle
- - Misadjusted clearances in the valve mechanism - Adjust the thermal clearances in the valve mechanism
Uneven operation of the diesel engine:
- - Loose fastening or burst high-pressure pipe - Tighten the fastening or replace the pipe
- - Uniform fuel supply by sections of the high-pressure pump is disrupted. Unsatisfactory operation of individual injectors. Adjust the supply on a special stand. Remove the injectors and check them in a workshop, if necessary, repair or replace faulty injectors
- - Malfunction of the speed controller - Repaired in a specialized workshop
Low oil pressure:
- - Contamination of the filter element of the oil filter (light comes on) - Change the filter elements of the oil filter
- - Faulty pressure gauge - Replace the pressure gauge with a working one
- - Clogged oil pump intake - Remove the pan, flush the intake
- - Clogged or faulty pressure reducing or differential valves of the oil pump - Disassemble, flush and assemble the valve. If the spring breaks, replace it and adjust the valve on the stand
- - Leaky oil line connections - Check the connections and gaskets of the filters and pipes side.
- - Oil dilution due to fuel contamination - If necessary, tighten connections or replace gaskets. Check the tightness of the connections of the drain pipe, high-pressure pipes of the injector under the cylinder head covers and eliminate the leak
- - Increased clearances in the main and connecting rod bearings of the crankshaft as a result of wear or destruction of the liners - Replace the crankshaft bearing shell, grind the shaft journals if necessary
Increased fluid temperature in the cooling system:
- - Loose tension of the water pump drive belt - Adjust the belt tension
- - Wear of the water pump belt - Replace the belt
- - Loss of tightness of the liquid path of the cooling system - Eliminate the malfunction
- - Rupture of the radiator cap gasket - Replace the gasket
- - Faulty thermostats - Replace thermostats
- - Radiator contamination - Clean the radiator
- - Fan does not turn on - Check the position of the fan switch and set it to position "B". If the fan does not turn on, the switch is faulty.
- - Fan clutch switch is faulty - Replace the TC103 temperature sensor
- - Fan does not turn off - Set the switch to position "0". If the fan does not turn off, the drain holes in the fan drive are coked. Repair or replace the drive.
Water is getting into the lubrication system:
- - Leakage along the rubber rings of the cylinder liners - Replace the faulty sealing rings
- - Destruction of the cylinder head gasket - Replace the faulty gasket
- - Loss of tightness of the liquid-oil heat exchanger - Remove the heat exchanger from the engine and eliminate the leak
- - Loss of tightness of the cylinder head gasket of the pneumatic compressor - Replace the gasket
Extraneous noises in the turbocharger:
- - The rotor touches stationary parts - Remove the turbocharger for repair or replacement