QSV Diesel Engines

Module 7 - Trouble-shooting

Cummins Corporate Training

QSV Diesel CUMMINS CORPORATION

Cummins Corporate Training

D / Trouble / BMG / 01-01 / Rev. 03

 Trouble-shooting Module

Learning Objectives
After completing this module you will understand the importance of a
logical approach to trouble-shooting and possible causes relating to
specific faults.

Agenda
• Trouble-shooting Approach,
• Trouble-shooting Tips,
• Trouble-shooting Symptom Charts - O & M Section 08,
• System Analysis Chart.

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 Trouble-shooting Approach

“ Refresh our memory

Sir. What was the
problem with your car ” ?

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 Trouble-shooting

Trouble-shooting Tips:

• Always make reference to the trouble-shooting section in the O&M

manual.
• Remember - Warranty will only pay for a diagnosis that has been
approached logically.
• Look for and eliminate the simple things first in a logical
progression.
• Be thorough when undertaking each step, never make
assumptions!
• Use trouble-shooting aids where appropriate, e.g. Fluorescent
Coolant tracer.
• Use all relevant information available; Engine Temperature, Oil
Pressure, Load Conditions, Air Manifold Pressure, etc. Refer to
the full maintenance history for information.
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 Trouble-shooting Symptom Charts

Possible Causes and Symptoms

Diesel Series O&M Manual

Section 08

Exhaust gas blue/white/gray High Exhaust Temperature High Lube Oil Temperature
(Page 08 - 2) (Page 08 - 3) (Page 08 - 4)

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 Fuel System Notes

• Fuel System Suction Leaks

All diesel engine fuel systems require a solid, airless supply of
fuel, available at all times. Suction leaks which permit air to
become entrained in the fuel system are indicated by poor
actuator response, slow deceleration, intermittent misses and loss
of power. Trouble-shooting is complicated by the fact that a
particular engine symptom may have more than one cause.
Remember ! Such leaks can be internal, on the engine, or
external supply to the engine.

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 System Analysis - Air Start Engines
F a u lt P o s s ib le C a u s e
L o w c ra n k in g s p e e d 1, 2, 3, 4
W ill n o t s ta rt 5, 6, 7, 8, 9, 10, 12, 13, 14 15, 16, 17, 18, 19,
20, 22, 31, 32, 33, 35, 56, 60
D iffic u lt s ta rtin g 5, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19,
20, 21, 22, 24, 29, 31, 32, 33
Lack of power 8, 9, 10, 11, 12, 13, 14, 18, 19, 20, 21, 22, 23,
24, 25, 26, 27, 31, 32, 33, 61, 63, 64, 65
M is firin g 8, 9, 10, 12, 13, 14, 16, 17, 18, 19, 20, 25, 26,
28, 29, 30, 32
E xc e s s iv e fu e l
c o n s u m p tio n
11, 13, 14, 18, 19, 20, 22, 23, 24, 25, 27, 28,
29, 31, 32, 33, 63
For Chart Codes:
B la c k e xh a u s t 11, 13, 14, 16, 18, 19, 20, 22, 24, 25, 27, 28,

B lu e /w h ite e xh a u s t
29, 31, 32, 33, 61, 63
4, 16, 18, 19, 20, 25, 27, 31, 33, 34, 45, 62
Reference Handout
L o w o il p re s s u re
K n o c k in g
4, 36, 37, 38, 39, 40, 42, 43, 44, 46, 58
9, 14, 16, 18, 19, 22, 26, 28, 29, 31, 33, 36, 45,
Sheet.
59
E rra tic ru n n in g 7, 8, 9, 10, 11, 12, 13, 14, 16, 20, 21, 23, 26,
28, 29, 30, 33, 45, 59
V ib ra tio n 13, 14, 20, 23, 25, 26, 29, 30, 33, 45, 47, 48,
49
H ig h o il p re s s u re 4, 38, 41
O v e rh e a tin g 11, 13, 14, 16, 18, 19, 24, 25, 45, 50, 51, 52,
53, 54, 57
E xc e s s iv e c ra n k c a s e 25, 31, 33, 34, 45, 55, 62
p re s s u re
P o o r c o m p re s s io n 11, 19, 25, 28, 29, 31, 32, 33, 34, 46, 59
S ta rts a n d s to p s 2, 10, 11, 12
 1. Insufficient reserve air in tank 34. Worn valve stems and guides
System Analysis - Air Start 2. External conditions affecting
engine crankshaft
35. Engine barring mechanismengaged

rotation/overload
Engines 3. Faulty starter motor
4. Incorrect grade of lubricating oil/oil
36.
37.
Worn or damaged bearings
Insufficient oil in sump
diluted with fuel or coolant
5. Lowcranking speed 38. Inaccurate gauge
6. Fuel tank empty 39. Oil pump worn
7. Faulty stop/control operation 40. Pressure relief valve sticking open
8. Blocked fuel feed pipe 41. Pressure relief valve sticking closed
9. Faulty fuel lift pump 42. Broken relief valve spring
10. Choked fuel filter 43. Faulty suction pipe
11. Restriction in air cleaner or 44. Choked oil filter
induction system
12. Air in fuel system 45. Piston seizure/pick up
13. Faulty fuel injection pump 46. Lube oil 3-way valves wrong position
14. Faulty atomisers or incorrect type 47. Damaged fan on cooling system
15. Incorrect use of cold start 48. Faulty engine mounting (housing)
equipment
16. Faulty cold starting equipment 49. Incorrect aligned flywheel housing, or
flywheel

Chart Codes: 17. Broken fuel injection pump

drive/camfollower
50. Faulty thermostat

18. Incorrect fuel pump timing 51. Restriction in water jacket

19. Incorrect valve timing 52. Cooling fan motor/drive failure

Handout Sheet. 20. Poor compression

21. Blocked fuel tank vent
53.
54.
Choked radiator
Faulty water pump
22. Incorrect type or grade of fuel 55. Choked breather pipe
23. Sticking throttle, restricted 56. Engine governor malfunction
movement or incorrect
adjustments
24. Exhaust pipe restriction 57. Coolant level too low
25. Cylinder head gasket leaking 58. Blocked sump strainer
26. Overheating 59. Broken valve spring
27. Cold running 60. Hydraulic lock-in cylinder
28. Incorrect tappet adjustment 61. Turbocharger impeller damaged or
dirty
29. Sticking valves 62. Turbocharger lubricating oil seal leaks
30. Incorrect high pressure pipes 63. Induction systemleaks (turbocharged
engines)
31. Worn cylinder bores 64. High fuel temperature (above
50°C/122°F)
32. Pitted valves and seats 65. High intake temperature (above
38°C/100°F)
33. Broken, worn or sticking piston
ring/s
 1. Insufficient reserve air in tank 34. Worn valve stems and guides
System Analysis - 2. External conditions affecting
engine crankshaft
35. Engine barring mechanismengaged

rotation/overload
Air Start Engines 3. Faulty starter motor 36. Worn or damaged bearings
4. Incorrect grade of lubricating oil/oil 37. Insufficient oil in sump
Fault Possible Cause diluted with fuel or coolant
Low cranking speed 1, 2, 3, 4
5. Lowcranking speed 38. Inaccurate gauge
6. Fuel tank empty 39. Oil pump worn
W ill not start 5, 6, 7, 8, 9, 10, 12, 13, 14 15, 16, 17, 18, 19, 7. Faulty stop/control operation 40. Pressure relief valve sticking open
20, 22, 31, 32, 33, 35, 56, 60 8. Blocked fuel feed pipe 41. Pressure relief valve sticking closed
9. Faulty fuel lift pump 42. Broken relief valve spring
Difficult starting 5, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19,
10. Choked fuel filter 43. Faulty suction pipe
20, 21, 22, 24, 29, 31, 32, 33 11. Restriction in air cleaner or 44. Choked oil filter
Lack of power 8, 9, 10, 11, 12, 13, 14, 18, 19, 20, 21, 22, 23, induction system
12. Air in fuel system 45. Piston seizure/pick up
24, 25, 26, 27, 31, 32, 33, 61, 63, 64, 65
13. Faulty fuel injection pump 46. Lub oil 3-way valves wrong position
Misfiring 8, 9, 10, 12, 13, 14, 16, 17, 18, 19, 20, 25, 26, 14. Faulty atomisers or incorrect type 47. Damaged fan on cooling system
28, 29, 30, 32 15. Incorrect use of cold start 48. Faulty engine mounting (housing)
equipment
Excessive fuel 11, 13, 14, 18, 19, 20, 22, 23, 24, 25, 27, 28, 16. Faulty cold starting equipment 49. Incorrect aligned flywheel housing, or
consumption 29, 31, 32, 33, 63 flywheel
Black exhaust 11, 13, 14, 16, 18, 19, 20, 22, 24, 25, 27, 28,
17. Broken fuel injection pump 50. Faulty thermostat
drive/camfollower
29, 31, 32, 33, 61, 63 18. Incorrect fuel pump timing 51. Restriction in water jacket
Blue/white exhaust 4, 16, 18, 19, 20, 25, 27, 31, 33, 34, 45, 62 19. Incorrect valve timing 52. Cooling fan motor/drive failure
20. Poor compression 53. Choked radiator
Low oil pressure 4, 36, 37, 38, 39, 40, 42, 43, 44, 46, 58
21. Blocked fuel tank vent 54. Faulty water pump
Knocking 9, 14, 16, 18, 19, 22, 26, 28, 29, 31, 33, 36, 45, 22. Incorrect type or grade of fuel 55. Choked breather pipe
59 23. Sticking throttle, restricted 56. Engine governor malfunction
movement or incorrect
Erratic running 7, 8, 9, 10, 11, 12, 13, 14, 16, 20, 21, 23, 26, adjustments
28, 29, 30, 33, 45, 59 24. Exhaust pipe restriction 57. Coolant level too low
Vibration 13, 14, 20, 23, 25, 26, 29, 30, 33, 45, 47, 48, 25. Cylinder head gasket leaking 58. Blocked sump strainer
26. Overheating 59. Broken valve spring
49 27. Cold running 60. Hydraulic lock-in cylinder
High oil pressure 4, 38, 41 28. Incorrect tappet adjustment 61. Turbocharger impeller damaged or
dirty
Overheating 11, 13, 14, 16, 18, 19, 24, 25, 45, 50, 51, 52,
29. Sticking valves 62. Turbocharger lubricating oil seal leaks
53, 54, 57 30. Incorrect high pressure pipes 63. Induction systemleaks (turbocharged
Excessive crankcase 25, 31, 33, 34, 45, 55, 62 engines)
31. Worn cylinder bores 64. High fuel temperature (above
pressure
50°C/122°F)
Poor compression 11, 19, 25, 28, 29, 31, 32, 33, 34, 46, 59 32. Pitted valves and seats 65. High intake temperature (above
Starts and stops 2, 10, 11, 12 38°C/100°F)
33. Broken, worn or sticking piston
ring/s
 Module 7 - Trouble-shooting

End

Cummins Corporate Training

QSV Diesel CUMMINS CORPORATION

Cummins Corporate Training

D / Trouble / BMG / 01-01 / Rev. 03