Chapter
11
Troubleshooting
_I._T_ro_u_b_l_es_h_o_o_tin_g;;....
________________________
~4JH3(BXC)E
TROUBLE
AND
TROUBLESHOOTING
I
Cl>
( I
-1)
Tighten.
~
( l
•2)
Repair
usmg
sandpaper
or
..-eplace.
:E
( I
-3)
Replace.
E ( I
-4)
Repair using sandpaper and
~
then
grease.
-@
( J
-5)
Adjust.
a ( I
-6)
Adjust.
c,
( I -
7)
Replace.
\
11
}
Pinion
gears
do
not
mesh
\
(i I
Loos•
oaiecy
eOQaoe
\
m.a9~ei
lermmal
\
15)
EC9es
ol
\;lei'
10-1:1ri-
!2}
Fa-L.by
corinecM~
1n
\
m1ss~ap,i1-11
sian'"9
sw,ch
\
(6)
Faaly
pos!~ninQ
ol
f3)
Cui
baiter,
e,~.a~a
\
pmion
and
n~
geau:
(
11
-1)
Tighten.
( H
-2)
Repair
using
sandpaper.
(
ll
-3)
Replace.
( n
-4)
Repair
using
sandpaper(Type 500-600).
( n
-5)
Replace.
(
□
-6)
Undercut and repair or replace.
(
ll
-
7)
Replace.
(
IJ
TB)
Replace
with
thicker
or
ShOrt8f
wire.
( n
-9)
Charge.
.......
I
Chart
7
I
TROUBLE WITH STARTING
(
Ill
-1
) Prime well.
( Ill
-2)
Adjust.
(
111-3)
Clean out matter causing clogging.
(
111-4)
Add fuel to fuel
tanl<.
(
111-5)
Open
cock.
(
Ill
-6)
Clean.
(
111-7)
Disassemble and repair
or
replace.
(
111-8)
Drain
water
from
fuel
system
and
prime.
(IV-1) Lap.
(IV-2) Lap.
( IV-3) Replace.
( N-4)
Clean
or
replace.
( IV-5) Adjust.
\
(!}Ring
gears
do
not
mesh
\ \
(m}
Fuel
oil
nol injected \ I
!WI
Faulty
fuel
injection
valve
I
1
11
Loosa
baltery
\ \
(11
lmperlect
priming
oflual
o,I
system \
(t)
Faul!yvalva
sear
(5) Cul slarter
coil
starter
tarminal
.....
.-------
\ {2) Injection cut
oll
d~
to t.aully governor \
12
t Sticking
ol
valve
ne9dlo
(2) Faulty
conneclion
in I (6) Worn
commutalor
\ (3) Clogging of luel ,ntol
foliar
\
{31
Worn valve needle
engage
magnel
sw~ch
\
[?
51
. f
I
h \ [4) tnsulhc,ent lual
011
,n
tank \
--------~_:~
1
.:::'.::!'P~P:::•~
9
:•.:'.
0
:..:''.'.'.
1
.:'.:"r'.::
1
e:'.'.r~c:'.'.u'.::
1
c::'..'
\
(5)
Fuel
0,1
tank cock
cJosad
(
4
)
CIOQged
ouuer
(3)
Worn
brushes
\ (8) Excessive res~stance \
(G)
Clogging
in
tuel
011
pipe
\ (5)
Low
1nJec11cn
i:iressvre-
t3
2
uJ
magne1
coil
-\
- m
Ss1zure
ol
Stii~EII
mel3~
(4) Commu1alor
ro~h
\ betw&an batter,, ar.d
Slarter
\ (7) Darnagec! luet
011
supply
pump
\
and
d~rly
\ {9) lnsuWeierit
baltery
ch•HQ0
\ (8)
Water
Ln
lual
oil tank j I
"C
C
(lj
(4)
Aoug:ri
cap
movement
\
\
(1) Worn
plunger
/
-~,
/
(31
Plunger ShCl<s
\
..
STARTING
TROUBLE
/
/ (
1)
Air leakage from suchoniexhaust v.alves /
.,..
l~--~-----~
/ (2)
No
I
appal
clesvance
/ { l )
fncorrt-11:I
thickness
of
ga
sl(et
11}
Fuel miec:t,on purnp
1rrn1ng
irtaguiar
/'~'(3,FauUy
gasket
paciong /
packmg
(I)
UJ
::::i
(lj
(.)
(2) Damaged-
plunger
spr1n-g
/ (4} Oil leak.age lrom e)jhawst
11alve
/
l2}
Loose high pressure
hJe~
pipe / • {4} Upper part o,
cylinder
liner worn
/,__(2-J~F-a-ul-ly-,~ns-t-al-la-1,-0-n_o_l
g-o-,-.-,n-o-,
/ nng and l9vt:ir
/ (5) Air
111side
pump
/
(6)
Dam
aQed e,:Mau-st
11alve
spring
I
I
(V}
Faulty
fuel
injeclion
pump
I
........
~
( V -1) Replace plunger and barrel as a unit.
)fl ( V -2} Replace.
~
(V-3)
Disassemble
and repair
or
replace.
$ ( V
-4}
Lap
valves.
§
(V-5}
Bleed air.
8 ( V
-6}
Replace,
TROUBLE
AND
TROUBLESHOOTING
~
( I
-1)
Replace.
~
( I
-2)
Disassemble and repair
or
replace.
ffi
( f
-3)
Lap
valves.
E ( I
-4)
Tighten firmly.
$ ( I
-5)
( I
-6)
Adjust.
§ ( I
-7)
( I
-8)
Clean"
0
u
( I
-9)
Replace.
( I
-10)
Repair.
I
/
131
Oamaged high pressure luel
pipe
/ (4)
Air
In
high
prass1.Jra
fuel pfpa
/
(5!
Warn piston ring
/ (6)
P1S!Or'\
rir'\Q
Slicks
/ (7)
insuifjcienl
!IQhlomng
ol
head
bolts
/ (8) OamaQod
v~ive
spnni;;i
(~)
Faulty
fuel
injection
system
\
(W)
Leakage
of
pressurized
air
\
------
('.H)
Adjust
(Vl-1)
Lap
valves.
(VI
-2)
Adjust.
(\111-1
) Replace.
(Vll-2) Adjust.
/ (3)
Governof
handie is
In
ttop
pos~hon
/
/ I Si ciooi;w,g
01
s.ue1ion1e1haus1 pJpes
I
(\l()
Miscellaneous
I
-----
Count-ermeasurA
(
VI
-2) Tighten firmly.
(
VI
-3) Replace.
(VIA)
Bleed air.
(V11-3)(Vll
-4)
(VU
-5)
Replace.
(VI
-6)
Disassemble
and
repafr
or
replace_
(Vl-7)
Tighten
tightening
nuts
uniformty.
(VII-BJ Replace.
(Vl-3)
Move
governor
handle to
acceleration
position.
(Vl-4)
Check
and
repair.
(
IT
-1) Clean nozzle
hole
or
replace.
(
IT
-2) Lap or replace.
(
JI
-3) Lap
or
replace.
(
JI
-4) Tighten firmly.
(
JI
-5) Replace.
(
JI
-6) Clean.
( I }
Amount
of
fuel
injection
inadequate
(Vl-5) Clean.
Chart
8
INSUFFICIENT POWER OUTPUT
l
lll-1j
Replace.
111-2
Repair.
1_
1
_1
_w_o_m_pl_u_ng_e_r
__
-...._(6)
Inaccurate
posi~fOnir.g
of
adJLlstmenl
rack
(I)
Clogglng o! nozzle hole
[2) Faul,y valve seal
ti
2
uJ
"C
C
CCI
(l)
UJ
:::I
(lj
(.)
(2) Sticking,
ct
plunger
{7) C!cog,nc
ol
fuel oil tiller
(31
011 lea-ka.ge 1,om e:rt1aus1
valve
(4) Oil
leakage
from
jo1n1
of
hiQh
.pressure
pipe
(9)
Damaged
\/alve spring
~:S)
Faully
adjuslmen1
of
iuol
pump
PO)
Faulty
supply
pump
(
1)
Leak.age
at
gas rrom
suct1on/.exhausl
va1ves
{3) Worn
upper
par!
o~
eylinder
liner
(2) lnaoaQuale lappet
(4f
Worn
p1s1on
ring
ciearance
(3)
St1cktr,.g
ct
valve needro
(4)
Loosa
hJQh
p1essu1a
pipe
(5)
Worn
valve
noodle
i
I)
Early
lnjeclion
(2) Lal& injection
(1) Damaged
governor
Oear111g
{2) l11accurat-e
leng!h
of
governor
l1n1i£.
INSUFFICIEN1
POWER
OUTPUT
l 1 / Poor quatJty luel oil
(2)
Clogg,ng
ol
oxhausl line
(J) Seizure
ol
moviog parts
(4) lnsuthcienl coohng waier
[51
lnsullicient
lube
oil
supplied
(V]
Irregular
fuel
Injection
timing
(VJ)
Cio99ed
intake
air
filter
~
(
IV
-1)
Lap
valves.
g;
{
IV
-2}
Adjust.
a,
(
IV
-3) Replace.
~
(N-4)
Replace.
§ (
IV
-5)
Disassemble
and
repair
or
replace.
8
( V-1)
Adjust
timing to (
VI
-1) Clean.
delay
injection.
( V -2)
Adjust
timing
to
speed
injection.
11-4
(Vl-1 ) Replace
with
good
fuel oil.
(Vl-2) Clean.
(Vl-3)
Disassemble,
check
and
repair.
(Vl-4) Lap cooling
waler
pump
suction/exhaust valves.
(Vl-5)
Disassemble
and
clean
lube oil
pump
and
filter.
Printed in japan
HINSHI·H8009
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