s/n Problems Possible causes
Checks by the user Checks by the skilled personnel
01 The starter motor turns Battery capacity low,
the engine too slowly Wrong grade of lubricating oil
Bad electrical connection
Fault in starter motor
02 The engine does not o The starter motor turns the engine o Valve timing is incorrect
start too slowly o Bad compression
o Fuel tank empty o worn cylinder bores
o Spare o leakage b/n valves and seats
o Restriction in a fuel pipe o piston rings are not free or they are worn or
o Fault in fuel lift pump broken
o Dirty fuel filter element o faulty engine management system
o Air in fuel system o broken drive on the high pressure pump
o Fault in the fuel injector units o faulty injection control system
o Cold start system used incorrectly o faulty sensor
o Fault in cold start system
o Wrong type or grade of fuel used
03 Engine is difficult to start The starter motor turns the engine Valve timing is incorrect
too slowly Bad compression
Spare Valves are not free
Prepared by: Alex Berhane (Maintenance Engineer) Sig,________ Date: ________
PLEASE MAKE SURE THAT THIS IS THE CORRECT ISSUE BEFORE
Restriction in a fuel pipe worn cylinder bores
Fault in fuel lift pump leakage b/n valves and seats
Dirty fuel filter element piston rings are not free or they are worn or
Air in fuel system broken
Fault in the fuel injector units faulty engine management system
Cold start system used incorrectly
Fault in cold start system
Restriction in fuel tank vent
Wrong type or grade of fuel used
Restriction in exhaust pope
04 Not enough power Dirty fuel filter element Valve timing is incorrect
Air in fuel system Bad compression
Fault in the fuel injector units Cylinder head gasket leaks
Cold start system used incorrectly worn cylinder bores
Fault in cold start system leakage b/n valves and seats
Engine temperature is too high piston rings are not free or they are worn or
Engine temperature is too low broken
turbocharger impeller is damaged or dirty
induction system leaks
turbocharger waste-gate does not work
correctly, if one is fitted
faulty engine management system
faulty injection control system
faulty sensor
Prepared by: Alex Berhane (Maintenance Engineer) Sig,________ Date: ________
PLEASE MAKE SURE THAT THIS IS THE CORRECT ISSUE BEFORE
05 misfire Dirty fuel filter element Valve timing is incorrect
Air in fuel system Bad compression
Fault in the fuel injector units Cylinder head gasket leaks
Air in fuel system Valves are not free
Fault in the fuel injector units leakage b/n valves and seats
Fault in cold start system faulty engine management system
Engine temperature is too high faulty sensor
Incorrect valve tip clearance
06 High fuel consumption Restriction in air induction system Valve timing is incorrect
Fault in the fuel injector units Bad compression
Fault in cold start system Cylinder head gasket leaks
Wrong type or grade of fuel used Valves are not free
Restricted movement of engine worn cylinder bores
speed control leakage b/n valves and seats
Restriction in exhaust pipe piston rings are not free or they are worn or
Too much oil or oil of the wrong broken
type is used in wet type air faulty engine management system
cleaner, if one is fitted Induction system leaks
Incorrect valve tip clearances
Prepared by: Alex Berhane (Maintenance Engineer) Sig,________ Date: ________
PLEASE MAKE SURE THAT THIS IS THE CORRECT ISSUE BEFORE
07 Black exhaust smoke Restriction in air induction system Valve timing is incorrect
Fault in the fuel injector units Bad compression
Fault in cold start system Cylinder head gasket leaks
Wrong type or grade of fuel used Valves are not free
Restriction in exhaust pipe worn cylinder bores
Engine temperature is too low leakage b/n valves and seats
Incorrect valve tip clearance piston rings are not free or they are worn or
broken
faulty engine management system
Induction system leaks
Turbocharger impeller is damaged or dirty
08 Blue or white exhaust Wrong grade of lubricating oil Valve timing is incorrect
smoke Fault in cold start system Bad compression
Engine temperature is too low Cylinder head gasket leaks
Too much oil or oil of the wrong worn cylinder bores
type is used in wet type air leakage b/n valves and seats
cleaner, if one is fitted piston rings are not free or they are worn or
broken
valve stems and/or guides are worn
piston is damaged
valve stem seal is damaged
lubricating oil seal of turbocharger leaks
faulty engine management system
faulty injection control system
Prepared by: Alex Berhane (Maintenance Engineer) Sig,________ Date: ________
PLEASE MAKE SURE THAT THIS IS THE CORRECT ISSUE BEFORE
09 The pressure of the low Wrong grade of lubricating oil Crank shaft bearings are worn or damaged
pressure lubricating oil Not enough lubricating in sump Lubricating oil sump is worn
system is too low Defective gauge Relief valve does not close
Dirty lubricating oil filter element Relief valve spring is broken
Restriction in sump strainer
10 The engine knocks o Air in fuel system o Valve timing is incorrect
o Fault in the fuel injector units o Piston rings are not free or they are worn or
o Fault in cold start system broken
o Wrong type or grade of fuel used o Valves are not free
o Engine temperature is too high o Worn cylinder bores
o Incorrect valve tip clearance o crank shaft bearings are worn or damaged
o Too much oil or oil of the wrong o Piston is damaged
type is used in wet type air o Piston height is incorrect
cleaner, if one is fitted o Valve spring is broken
o Faulty engine management system
o Faulty injection control system
11 The engine runs o Dirty fuel filter element o Bad compression
erratically o Air in fuel system o Valves are not free
o Fault in the fuel injector units o broken drive on the high pressure pump
o Air in fuel system o faulty injection control system
o Fault in the fuel injector units o faulty sensor
o Fault in cold start system o Valve spring is broken
o Engine temperature is too high o Worn cylinder bores
o Incorrect valve tip clearance o Piston is damaged
o Restriction in air induction system
Prepared by: Alex Berhane (Maintenance Engineer) Sig,________ Date: ________
PLEASE MAKE SURE THAT THIS IS THE CORRECT ISSUE BEFORE
o Restriction in fuel tank vent
o Restricted movement of engine
speed control
o Too much oil or oil of the wrong
type is used in wet type air
cleaner, if one is fitted
12 vibration Fault in the fuel injector units Bad compression
Restricted movement of engine Cylinder head gasket leaks
speed control valves are not free
Engine temperature is to high Piston rings are not free or they are worn or
Fan damaged broken
Fault in engine mounting or fly Piston is damaged
wheel hosing Flywheel housing or flywheel is not aligned
correctly
13 The pressure of the low Wrong grade of lubricating oil Relief valve does not open
pressure lubricating oil Defective gauge
system is too high
14 The engine oil Restriction in air induction system Valve timing is incorrect
temperature is too high Fault in the fuel injector units Cylinder head gasket leaks
Fault in cold start system Piston is damaged
Restriction in exhaust pipe Restriction in coolant passages
Fan damaged Fault in water pump
Too much lubricating oil in sump Turbocharger waste- gate does not work
Prepared by: Alex Berhane (Maintenance Engineer) Sig,________ Date: ________
PLEASE MAKE SURE THAT THIS IS THE CORRECT ISSUE BEFORE
Restriction in air or water passages correctly if one is fitted
of radiator Faulty sensor
Insufficient coolant in system
Faulty engine management system
15 Crankcase pressure Restriction in breather pipe Cylinder head gasket leaks
Fault in exhauster Worn cylinder bores
Piston rings are not free or they are worn or
broken
Valve stems and/or guides are worn
Piston is damaged
16 Bad compression Restriction in air reduction system Valve timing is incorrect
Incorrect valve tip clearance Cylinder head gasket leaks
Valves are not free
Worn cylinder bores
Leakage b/n valves and seats
Piston rings are not free or they are worn or
broken
Valve stems and/or guides are worn
Piston height is incorrect
Valve spring is broken
17 The engine starts and Dirty fuel filter element faulty engine management system
stops Air in fuel system faulty injection control system
Fault in the fuel injector units o faulty sensor
Prepared by: Alex Berhane (Maintenance Engineer) Sig,________ Date: ________
PLEASE MAKE SURE THAT THIS IS THE CORRECT ISSUE BEFORE
18 The pressure of the lo Wrong grade of lubricating oil faulty engine management system
pressure lubricating oil not enough lubricating oil in sump faulty injection control system
system is too low defective gauge faulty sensor
dirty lubricating oil filter element
Prepared by: Alex Berhane (Maintenance Engineer) Sig,________ Date: ________
PLEASE MAKE SURE THAT THIS IS THE CORRECT ISSUE BEFORE
