Mechanical Diagnosis
|
CONDITION |
POSSIBLE CAUSE |
REMEDY |
|---|---|---|
| Unit Switch ON; Controller display does not come on |
Corroded battery terminals / cable Battery discharged Fuse S13 open Defective ON / OFF Switch Open Circuit |
Clean and tighten Charge or replace battery Check circuit and replace fuse Check switch Check 2, 2B, 2C, and 8 circuit |
| Unit Switch ON; Controller display ON, but engine does not crank |
Battery discharged Corroded battery terminals / cable Defective starter relay or open circuit Defective starter solenoid Defective starter Water in cylinders |
Charge or replace battery Clean and tighten Replace relay; check 2A, 8S, SR, and PSR circuits Replace solenoid Repair starter Check for hydrostatic lock. Remove injectors and manually turn engine slowly. |
|
Engine will not crank |
Electrical problem |
Check and repair electrical system |
|
Defective starter solenoid |
Replace solenoid |
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Defective starter |
Repair starter |
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Water in cylinders |
Check for hydrostatic lock. Remove injectors and turn engine slowly |
|
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Starter motor turns but engine does not crank |
Starter clutch defective |
Replace |
|
Engine cranks but fails to start |
Voltage falls below 6 Vdc at ECU while starter cranking |
Repair cause of low voltage at ECU while starter cranking |
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Problem with ECU controlled engine function |
Use EXXODiag diagnostic tool to diagnose problem |
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Electric fuel pump not energized |
Check FP+ and GND circuits |
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Electric fuel pump defective |
Replace electric fuel pump |
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Air in fuel system |
Bleed air |
|
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Compression low |
Overhaul engine |
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Air cleaner clogged |
Replace air filter |
|
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Exhaust plugged |
Clean exhaust |
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Engine stops after starting |
Alarm LED Flashing |
Check alarm code and repair fault |
|
Air in fuel system |
Bleed fuel system |
|
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Fuel filter obstructed |
Replace filter element |
|
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Vent of fuel tank obstructed |
Unclog vent |
|
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Clogged fuel tank or fuel lines |
Clean fuel tank and fuel lines |
|
|
High head pressure |
Eliminate cause of high head pressure |
|
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Engine does not develop full power |
Air intake system clogged |
Clean air intake system |
|
Fuel tank vent clogged |
Unclog vent |
|
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Clogged fuel tank or fuel lines |
Clean fuel tank and fuel lines |
|
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Insufficient fuel volume leaving filter |
Check for dirty filter or air in system |
|
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Air cleaner clogged |
Replace air filter |
|
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Delivery of electric fuel pump insufficient |
Repair pump |
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Problem with ECU controlled engine function |
Use EXXODiag diagnostic tool to diagnose problem |
|
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Compression low or unbalanced |
Overhaul engine |
|
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Engine speed too high |
Problem with ECU controlled engine function |
Use EXXODiag diagnostic tool to diagnose problem |
|
Engine fails to stop when unit is OFF |
Problem with ECU controlled engine function |
Use EXXODiag diagnostic tool to diagnose problem |
|
Engine knocks heavily |
Air in system |
Bleed fuel system |
|
Wrong fuel |
Change fuel |
|
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Compression too low |
Overhaul engine |
|
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Valve out of adjustment |
Adjust valves |
|
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Fuel return line plugged |
Remove return line restriction |
|
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Rod or main bearing worn |
Replace rod or main bearings |
|
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Engine runs hot |
Dirty radiator |
Wash radiator |
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Coolant level is low |
Add coolant |
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Cooling system heavily scaled |
Cleaning cooling system |
|
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Cylinder head gasket leaks |
Replace cylinder head gasket. Use correct gasket |
|
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Faulty thermostat |
Check or replace thermostat |
|
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Oil pressure low |
Insufficient oil in pan |
Add oil |
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Faulty oil pressure switch |
Check oil pressure switch. Replace if necessary |
|
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Oil control valve defective |
Check oil pressure control valve |
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Worn oil pump, camshaft, main or connecting rod bearings, loose oil gallery plug |
Repair engine |
|
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High oil consumption |
10 hour engine break in running was not successfully completed |
Run unit for 10 hours in continuous high speed with varying load. |
|
Oil leakage |
Check and eliminate possible causes at rocker arm cover, oil lines, oil filter, front timing cover or crankshaft seals |
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Damaged valve seals |
Replace seals on valve stem |
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Worn valve stem |
Replace valves |
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Broken piston rings or cylinder bore worn or scored |
Have engine repaired and rebored. Replace broken piston rings |
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Clogged air cleaner system |
Unclog air cleaner |
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White Smoke |
Black Smoke |
Blue Smoke |
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Fuel is not burning |
Excessive Fuel to Air Ratio |
Oil Consumption |
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