6.1.5. Diagnostics and troubleshooting
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MAINTENANCE OF MAJOR COMPONENTS
Complaints Possible causes Corrections
1. Engine won’t start
1) Fuel not being pumped Fuel pipes clogged or air into Correct
out from feed pump pipe fine
Feed pump valve defective Replace
Feed pump piston or Push rod Disassemble, correct
sticking
2) Fuel not being injected Fuel filter element restricted Clean
from injection pump
Air in fuel filter or injection Bleed
pump
Plunger and/or delivery valve Disassemble, correct
sticking or defective
3) Fuel injection timing Injection pump not properly Check, correct
incorrect
installed on pump bracket
Injection pump tappet Check, correct
incorrectly adjusted
Cams on cam shaft worn Replace
excessively
4) Injection nozzles Needle valves sticking Correct or replace
inoperative
Fuel leaking past clearance Correct or replace
between nozzle and needle valve
Injection pressure incorrect Adjust
2. Engine starts but stalls Pipe from feed pump to Clean
immediately injection pump clogged or filter
clogged
Air in fuel Bleed
Feed pump delivery insufficient Disassemble, correct
Fuel delivery insufficient due to Replace breather
clogging of fuel tank air breather
3. Engine lacks power Plunger worn excessively Replace
Injection timing incorrect Adjust
Delivery valves defective Replace
Nozzle leaks excessively Correct or replace
Nozzle not working normally Disassemble, correct
4. Engine knocking Injection timing too fast Adjust
Nozzle injection pressure too Adjust
high
Nozzles not working normally Disassemble, correct
5. Engine knocks seriously Injection timing incorrect Adjust
producing excessive
Nozzle Injection Pressure too Adjust
exhaust smoke
low
Nozzle spring broken Replace
Nozzles not working normally Replace
Plungers worn excessively Adjust
Delivery valves seat defective Replace
Supply of fuel excessively Check feed pump
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