- Cause of malfunction - Remedy
Engine won't start:
- The starter does not turn the crankshaft or rotates it very slowly
Check the state of charge and serviceability of the batteries and, if necessary, charge or replace them
Check the starter power contacts, clean the wire terminals.
Check the condition of the starter relay contacts, if there is a burn, clean the contacts in the circuit, tighten them if necessary.
Check the contacts of the starter brushes with the commutator and the absence of sticking of the brushes in the brush holders, if necessary, wipe and clean the commutator, clean the side edges of the brushes, replace worn brushes with new ones or replace faulty brush springs.
If the defects cannot be repaired, replace the starter.
- Clogged fuel lines or intake in the fuel tank
Rinse intake, flush and blow out fuel lines
- Freezing of water in the fuel lines or on the grid of the fuel tank intake
Carefully warm up the fuel pipes, filters and tank
- Clogged fuel filter elements
Replace the fuel with another one that matches the season and bleed the system
- Wrong fuel injection advance angle
Adjust fuel injection advance angle
- The presence of air in the fuel system
Bleed the system, fix leaks
- The fuel priming pump does not work
Disassemble the pump and troubleshoot
- Jamming of the rail of the high pressure fuel pump at zero flow
Repair the fuel pump in a workshop or replace it with a good one
- Difficulty moving the injection pump rail due to thickening of the lubricant
Carefully warm up the fuel pump
Replace filter elements
The engine does not develop power:
- Dirty air filters
Clean air filters
- Clogged exhaust tract
Clean the exhaust path
- Contamination of fuel filter elements
Replace filter elements
- The regulator control lever does not reach the maximum speed bolt. The stop lever does not reach the end working position
Check and adjust drive lever system
- The presence of air in the fuel system
Bleed the fuel supply system and fix it
- Wrong fuel injection advance angle
Adjust fuel injection advance angle
- Leaks in the gas distribution valves
Adjust the thermal gaps in the valve mechanism, grind the valves if necessary
- Low air pressure
The air supply system is leaking. Repair leaks.
If there is increased resistance in the exhaust pipe, clean the exhaust pipe.
Faulty turbocharger.
Repair.
- Violation of adjustment or clogging of nozzles
Adjust the nozzles and, if necessary, flush and clean them
- Faulty fuel priming pump valves
Rinse the seats and valves of the pump, grind the valves if necessary
- Breakage of the springs of the pushers of the high pressure fuel pump
Change the springs and adjust the pump on the stand in a special workshop
- Broken springs or leaks in the injection valves of the fuel pump
Replace the spring or repair the leak in the valve (have it done in a specialist workshop)
- Piston ring wear
Replace piston rings, if necessary, pistons and cylinder liners
Diesel knocking:
- Early fuel injection into cylinders
Adjust fuel injection advance angle
- Clearances in the valve mechanism are misaligned
Adjust valve clearances
Uneven diesel operation:
- The fastening is loose or the high-pressure pipe has burst
Tighten fitting or replace tube
- The uniformity of the fuel supply by the sections of the high pressure pump is broken. Unsatisfactory operation of individual nozzles
Adjust the feed on a special stand
Remove the injectors and check in the workshop, if necessary, repair or replace defective injectors
- Faulty speed controller
Removed in a special workshop
Lower oil pressure:
- Contamination of the oil filter element (light bulb on)
Change oil filter elements
- Faulty pressure gauge
Replace the pressure gauge with a good one
- Clogged oil pump intake
Remove the pan, rinse the intake
- Clogging or malfunction of the pressure reducing or differential valves of the oil pump
Disassemble, wash and reassemble the valve. If the spring breaks, replace it and adjust the valve on the bench
- Leakage of oil pipeline connections
Check the connections and gaskets of filters and tubes.
- Oil dilution due to fuel ingress
If necessary, tighten connections or replace gaskets
Check the tightness of the connections of the drain pipeline, high pressure pipes of the nozzle 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
Elevated fluid temperature in the cooling system:
- Loosening the tension of the water pump drive belt
Adjust belt tension
- Water pump belt wear
Change the belt
- Violation of the tightness of the liquid path of the cooling system
Troubleshoot
- Radiator cap gasket rupture
Replace gasket
- Faulty thermostats
Replace thermostats
- Radiator pollution
Clean the radiator
- The fan does not turn on
Check the position of the fan control lever and set it to the "B" position.
If the fan does not turn on, the switch is faulty.
- Faulty fan clutch switch
Replace TC103 temperature sensor
- The fan does not turn off
Set the switch to the "0" position. If the fan does not turn off, the drain holes in the fan drive are clogged. Repair or replace the drive.
Water gets into the lubrication system:
- Leakage on rubber rings of cylinder liners
Replace defective O-rings
- Destruction of the cylinder head gasket
Replace defective gasket
- Violation of the tightness of the liquid-oil heat exchanger
Remove the heat exchanger from the engine and eliminate leakage
- Violation of the tightness of the sealing gasket of the cylinder head of the pneumatic compressor
Replace gasket
Extraneous noises in the turbocharger:
- Rotor touching on stationary parts
Remove turbocharger for repair or replacement