INDEX

Sr No Description Page Nos.

1 Engine Overheating 2–6
2 Exhaust Red hot 7 – 10
3 Oil Dilution With Fuel 11 – 12
4 High Fuel Consumption 13 – 15
5 Oil in Coolant 16
6 Diesel In Coolant 17
7 High Lubricating Oil Consumption 18 – 20
8 Coolant In Oil 21 – 23
9 Oil Throw From Discharge Line Of Air Compressor 24
10 Engine Cranks But Does Not Start 25 – 27
11 Engine Hunting 28 – 29
12 Engine Emitting White Smoke 30
13 Abnormal Sound From Engine 31 – 32
14 Engine Over racing 33 – 34
15 Engine Late Stopping 35
16 Engine Not Taking Load 36 – 41
17 Low Lub Oil Pressure 42 – 43
18 Excessive Engine Vibrations 44 – 45

-1-
 1. Engine overheating
Symptoms

1. Coolant Temp. gauge indicate temperature more that operating range.

2. Electronic control panel will show LED in red colour.
3. ECP (New) fault lamp will glow for high coolant temperature.
4. ECM will have lit up indicator lamp and will lodge fault code.
5. Steam will come out of radiator pressure cap.
6. Oil temperature will shoot up than nominal. In extreme conditions oil
burning smell will be emitted.
7. High water temperature safety control will trip, fault will be indicated by
audio visual annunciation panel.
8. In few cases engine will be too hot and Radiator / Heat exchanger will be
cold.
9. Radiator coolant level will drop when engine RPM is raised and will give
surge in top tank while decelerating.

-2-
 Engine Overheating ( High Coolant Temperature )
Defective Gauge / Malfunction/ • Replace the gauge, relocate capillary or
Gauge Capillary touching the replace sensor and check.
exhaust manifold. Sensor faulty.

Low Coolant level in Radiator / Check coolant level .

H.E top tank • Coolant level should be up to bottom of
fill neck.

Check for visible external leaks Results in coolant loss.

from gaskets, O rings, seals, hoses, • Inspect and arrest leaks.
Radiator core etc.
Missing top tank pressure cap.

Choked / excessive length / • Restriction in the coolant line, make up

routing of coolant vent line hoses. line, engine vent, radiator vent, hoses can
Make up line hose / pipe choked. result in improper filling of cooling
system and false indication of coolant
level.
• Clean or replace / re-route vent line
hoses.

Loose fan belt / water pump belt / • Check belt tension by thumb pressure /
Slippery belts due to spillage of oil Belt Tension Gauge. Deflection should
or grease. Viscous / be as per thumb rule i.e. centre distance
Electromagnetic / Hydraulic of pulleys in feet multiplied by belt pitch.
Clutch of Fan not engaging at • Adjust belt tension Or replace belts if
preset temperature. found worn excessively. Clean fan belts /
pulleys. Check for Belt Squealing noise.
• Check Fan Clutch Operation. Change
Fan Clutch Sensor / clutch assembly.

Radiator shroud missing / No • Results in by-passing fan air flow and

sealing or improper Shroud and reduces cooling system efficiency.
fan alignment relation. Maintain 1/3 , 2/3 ratio of fan to shroud
as per sucker / blower fan.

Radiator core choked externally Clean radiator fins.

with oil,dust,debris,insects etc. • Use 60 psi air pressure to blow the dirt
from the fins. Blow the air in the
opposite direction of fan air flow. For
oily core use kerosene / diesel to remove
-3-
 oily dirt then wash the radiator core with
water jet. Use soft Nylon brush to clean
the fins.

Check the coolant capacity of • If radiator capacity is less than specified,

radiator as specified by than replace the radiator with correct part
manufacturer. number.

Insufficient opening / obstruction • Re-circulation of hot air over the radiator

in front of radiator. core. Check for missing air re-circulation
prevention baffle or its sealing condition.

Less / No raw water flow through • Check valves for opening position.
heat exchanger. • Check raw water level in the cooling
Excessive raw water inlet tower pond.
temperature. • Check operation of raw water pump.
• Check raw water pump suction strainer if
choked.
• Check cooling tower water sprinklers for
choking / fins clogging / operation of
cooling tower fan etc.
• Confirm the temperature difference in
incoming and outgoing raw water to heat
exchanger is as per specifications.

Thermostat/s not opening at its • Check thermostat operation and replace

specified temperature. if not functioning properly. For single
thermostat engine, engine block will be
too hot and radiator core will be cold.
• (Should operate within specified limits of
temperature and open fully)

Water pump impeller pitted / • Results in reduction in coolant flow.

impeller loose on shaft. Excessive Check and replace pump if necessary.
clearance between Water Pump
Housing and Impeller.

Water pump drive coupling broken • Results in water pump not rotating and
(K series) no circulation of coolant. Replace drive
coupling.

Choked engine oil cooler ( N & V • Choked lub oil cooler can cause less
-4-
series ) coolant flow. Main reason is dirt entry
through filler neck caused by missing
radiator cap or too hard water used as
coolant.
• Clean or replace LOC element.

Radiator / H.E tubes choked • Check for temperature difference across

internally / Excessive plugging of radiator / coolant inlet and outlet across
tubes (i.e. more than 20 %) H.E.
• Difference should be 7 – 10 deg C
• Clean Heat exchanger / Radiator tubes
internally. Use Fleetguard Restore Plus,
Ready Wash or Clean Flow 14.

High ambient temperature / • Check ambient temperature near engine

improper ventilation which should not exceed LAT.
(Limiting Ambient Temperature)

Engine overloaded • Check kW output as per engine rating

and confirm.
• For Compressor application – Check air
discharge pressure settings / RPM,
unloader valve setting, Air Oil Separator
condition.
• For Earth moving applications – Check
fuel pump pressure / excessive gradient /
excessive load factor.
• Check Retarder Brake Operation
• Check for Torque Converter
malfunctioning
• Check for brake binding.
• Check for Hydraulic Oil Pressure
settings.
• For Marine engines check for propeller
damage, Sea Growth on propeller,
foreign object such as fishing net stuck to
propeller.

-5-
High engine oil temperature • Check oil temperature
• Check for too high oil level.
• If oil temperature is too high, it leads to
engine overheating

Clogged radiator oil cooler (ROC) • Clean the ROC assembly. Clogged oil
assembly ( Comp application) cooler leads to high compressor oil
temperature raising the coolant
temperature

Punctured Radiator Top Tank • The coolant flows to top tank from
Baffle. Radiator Top header through hole and
goes back un-cooled via Make Up Line
towards water pump. Repair baffle by
welding or replace top tank.

High transmission oil temperature • Dissipates excess heat to engine coolant

raising coolant temperature

High torque convertor oil • Dissipates excess heat to engine coolant

temperature raising coolant temperature

Fan fitted in reverse direction • Confirm sucker / blower type fan as per
engine application.

Damaged Fan blade profile /angle/ • Results in less air flow. Check and
dents confirm

Excessive Fan tip to shroud • Reduces fan efficiency.

clearance. • Adjust fan position in the shroud.

-6-
 Exhaust red hot
Symptoms

1. Exhaust manifold and Turbo casing will glow and emit light /
sparkles.
2. Engine may / may not take full load.
3. Exhaust manifold will appear whitish in cold condition.
4. Burnt / cracked exhaust bellows / flexible piping.
5. Occasional flame through from exhaust slip joints.
6. Exhaust tail pipe will emit flame, which will be visible at night.
7. Too hot engine surroundings.
8. Early damages to exhaust insulation.

-7-
Exhaust Manifold And Turbo Getting Red hot / High Exhaust Temperature
Check exhaust temperature on full • Check and confirm the temperature is
load . within specified range by using
calibrated temperature gauge. If not in
specified range then proceed as below :

Excessive air intake restriction. • Choked air cleaner element/s

• Clogged Pre-cleaner tubes / hood /
collapsed or improperly seated hood.
• Collapsed hump hose.
• Excessive length of air intake pipe
• Poor DG room ventilation – Causing
excessive room temperature Or
insufficient air quantity.

Excessive exhaust back pressure • Maximum allowable exhaust back

pressure is 3” Hg and 2” Hg for Quntum.
(Normally when the system is new it
should be less than 2.5” Hg. And for
QSK-60 1.5'' Hg) If it is more check
following points.
• Diameter of pipe is less than specified.
• More number of bends / sharp bends /
exhaust piping too long.
• Faulty rain cap.
• Choked / defective silencer. Incorrect
fitment of silencer.

Turbo boost pressure less / Less • Check turbo boost pressure / Boost
intake manifold pressure. pressure drop across aftercooler.

Check and correct following.

• Choked after cooler fins externally.

• Defective turbocharger – Excessive
radial / axial play, Sluggish rotation of
turbo, incorrect turbo fitted.
• Foreign material entry such as welding
spatter, dust, cotton waste, Carbon from
leaky exhaust.

-8-
High intake manifold temperature. • Check IMT and confirm whether within
specified limit. If not check and correct
following.

• High coolant temperature

• Choked LTA heat exchanger.
• Less coolant flow through after cooler.
• Choked after cooler tubes internally.
• Improper rubber sealing of after cooler
provided in air passage. As applicable.

Improper valve / injector settings. • Recheck / adjust valves & injector

settings.

Engine overloading • Check and limit load as applicable.

• Excessive fuel pump pressure.
• Excessive hydraulic pump pressure
settings / Compressor air discharge
pressure settings. (As applicable)

Excessive fuelling • May be due to excessive fuel pump

pressure.
• Injector cup hole enlarged. Change
Injector Cups.
• Nozzle Pop Setting Low, Stuck Nozzle
needle in open condition. Repair
Nozzles.
• Gas – Air mixture too lean. Set
Carburetor / Gas Pressure Regulators.
• Damaged Injector Cam Lobe.

Recalibrate injector and fuel pump as per

specified calibration code.

Cylinder head valves leakage • Improper valve clearances.

• Recondition the cylinder heads.
(In case of excessive / uneven wear of valve
seat / inserts, Valve channeling, worn valve
guides, Excessive Carbon deposition on
valve stem etc.)

Incorrect injection timing Check and correct injection timing as

-9-
 specified for the engine.
• Check and ensure camshaft lobes / rollers
are not worn / pitted.
• Correct injection timing
• STC Valve / Injector malfunctioning.
Check for STC Valve plumbing. Check
& Calibrate STC Injector.

Weak compression Combustion chamber air can leak through

Valve seat, Piston ring gap which can results
in weak compression.
Measure blow-bye with proper tool and
confirm whether it is excessive.
• Worn out piston rings / cylinder liner
• Stuck or broken piston rings.
• Cylinder head valve leakage.

- 10 -
 OIL DILUTION (Mixing With Fuel)
Symptoms

1. Abnormal drop in oil pressure.

2. Lower viscosity of oil.
3. No top up required / rise in oil level.
4. Two rings of oil drop colour on DDO paper / blotting paper.

Oil Dilution ( Diesel In Oil )

Check oil level in oil pan and Can be confirmed by following.
confirm • Increase of oil level
• Drop in oil pressure
• Reduction in lub oil viscosity
• Two different layers on blotting paper

Excessive idling • Find out the reason for excessive idling

and stop / reduce idling of the engine e.g.
LOCO engines.

Prolonged operation of the engine • Check air intake restriction and ensure
with restricted air intake can cause that it is within limit. E.g. Basement
incomplete combustion. (The mounted DG sets, Fire fighting pump
engine will also have the black engines.
smoke / low power problem.)

S.D valve in manual mode • Check & replace S.D Coil if required
Diesel level above injector level • Check & Clean / Replace NRV if
Supply line NRV Failed / leak required.
• Check AMF Relay providing power to S
D Valve for proper operation.

PT pump front flange seal • Check and replace seal.

damaged (PTR Pumps)

Improper sealing of fuel inlet / • Replace copper washers and tighten fuel
drain connections of injector. connections properly.
• Check fuel inlet / drain connectors for
pin hole / crack.
Improper sealing of injector ‘O’ • Cut / damaged top ‘O’ ring – Replace
- 11 -
rings. injector ‘O’ rings and also check the ‘O’
ring seating area for cleanliness, finish
and correct if required.

Fuel dribbling from injector • Bend injector push tube / Loose injector
settings.
• Barrel – plunger clearance excessive.
• Re calibrate the injector.
• Injector cup crack / enlarged injector cup
holes – Replace cup & re-calibrate
injectors.

Injector cup retainer loose / crack • Check and correct – Recalibrate the
injector.

Injector body porosity / crack near • Identify and replace the defective
fuel inlet / outlet passage. injector.
• Test injector on leakage tester for leaky /
Injector Barrel Plugs Loose / missing plugs.
missing.

Defective STC valve – (Engines • Worn STC valve internal ‘O’ rings /
fitted with STC injectors) worn STC valve housing inside.
• Stuck fuel return line NRV fitted on STC
valve (Elbow type).

- 12 -
 High fuel consumption
Symptoms

1. Visible external leaks.

2. Black smoke from the exhaust.
3. High exhaust temperature with exhaust manifold red hot problem.
4. Excessive carbonization
5. Diesel dilution in few cases.
6. Engine may / may not take full load.
7. For gensets running in parallel, improper load sharing, with
different individual power factor.
8. Persistent engine coolant temperature lower than operating
temperature despite engine running on rated load.
9. Under load operation entries in Log book.

High Fuel Consumption

Check for external fuel leaks • Arrest all external leakages from
• Fuel tank, supply line, Manual valves,
Fuel filter, Water separator, Fuel pump,
Fuel tubings, Return line hoses etc.

Check the fuel consumption • Compare the results with manufacturer’s

accurately with proper measuring specifications and decide whether it is
device. more Or OK.
• Faulty KWH meter • Compare the Exhaust Temperature
• Faulty fuel flow meter / wrong reading v/s Load with earlier readings on
method of checking. the engine OR Cummins data.
• If exhaust temperatures are more, Rectify
Also measure exhaust temperature High Exhaust Temperature problem first.
with ‘K’ type thermocouple and Ref – High Exhaust Temperature
calibrated thermometer. steps.

Check load cycle / average load on • Excessive idling / fluctuating load can
the DG set. result in high SFC.
• Average load is less (i.e. below 70%) can
- 13 -
 result in less Units / lit.
• Ref. Load v/s Specific Fuel Consumption
data.
(Operating DG sets @ 80% load factor give
better fuel efficiency and optimum engine
life.)

Improper load sharing during • Set load sharing by adjusting engine

parallel operation. speed droop.

Faulty cooling system. • Oversize Radiator.

• High Raw Water Flow.
• Faulty Thermostat.
• Overcooling causing low oil temperature
and more oil viscous drag.

Drop in main alternator efficiency. • Check the Load v/s Alternator efficiency
chart provided by alternator
manufacturer.
• DG set running with lower power factor
(less than 0.8) draws more current on
same kW out put and increases heat
losses in alternator which can reduce
alternator efficiency.

For other applications like Normally the fuel consumption is measured

dumper, dozer, excavator, in terms of Litres / hour. ( Tons-KM / Litre
compressors etc. for dumper application.)
Check load cycle / load factor. Higher load factor can cause high fuel
consumption.

For drilling rigs / Air compressors – Restrict load factor to 80 %.

Improper flushing / drilling cycles.

- 14 -
Bad quality of fuel • Contaminated fuel
• Adulterated fuel
• Low fuel density / low calorific value

Check the fuel quality from authorised

laboratory and compare the results with
Cummins fuel specifications.

- 15 -
 Oil in coolant
Symptoms
1. Oil will float on coolant in radiator top tank.
2. Oil traces will be observed from overflow tube of top tank.

Oil in Coolant
Check for oil in top tank of • Check and confirm the problem. If yes,
Radiator / Heat Exchanger. proceed further. Check if oil containers
were used to top up coolant without
proper cleaning.

Oil cooler element tubes punctured • Check and replace Oil Cooler element /
/ ‘O’ ring cut / mutilated. ‘O’ ring.

Oil cooler housing gasket cut / • Check and replace the gasket.
damaged.

Porosity / crack at lub oil cooler • Replace complete Lube Oil Cooler
housing. assembly.

Porosity / crack at lub oil gallery • Following are the possible locations,
near coolant passages. - For V12 – Rear end of the cylinder
block from where the oil transfer tube is
connected.
- For NH / NT – LOC mounting area.

Cylinder liner cracked / pin hole • Check all cylinder liners for excessive
pitting / corrosion which can result in
through pinhole at water jacket area.

For construction application • Check coolers for leak and repair /

Torque Converter Oil / Brake oil replace.
may come to Radiator in case of
respective cooler failures.

Head gasket failure in case ‘B’, • Check for cold boiling in radiator and
‘C’ or S 3.8 G engines. replace head gasket.

- 16 -
 Diesel in coolant
Symptoms: -

1. Smell of diesel from coolant.

2. Diesel will float on coolant.
3. Coolant will be bluish in colour.

Diesel in Coolant
Check for diesel in top tank of • If traces found, check the possible area of
Radiator / H.E fuel leakage, which is mixing with water.

Cracked / Porous cylinder head • Check all cylinder heads for crack in fuel
(NT , V , K series ) gallery which is connected to water
jacket.
• Injector sleeve crack in NT engines at
injector ‘O’ ring area. Replace Injector
sleeve.
• On HM 101 M Shovel, check TC cooler
for leakage.

- 17 -
 High lubricating Oil consumption.
1. Visible external oil leaks.
2. Blue smoke from exhaust.
3. Oil in air receiver tank for engines mounted with air
compressor.
4. Excessive blow bye.
5. Oil in air cross over.
6. Torque converter / Gear box oil will rise.
7. Oil will come out of breather in few cases.

High Lube Oil Consumption

Understand the customer’s • First arrest all external oil leakages and
complaint and how he measures use correct dipstick / correct profile of
the oil consumption. dipstick guiding tube of OG bracket for
KV engines.
• External leakages may cause • Clean / replace breather and draft tube.
high lub oil consumption. • Carry out minimum 24 hrs load trial and
• Excessive oil level due to confirm the oil consumption in terms of
wrong dipstick / Defective OG Lit / Hr.
bracket. • Compare the actual consumption with
• Crankcase breather choked or Cummins specification.
Breather draft tube restricted. • If the consumption is just above the limit,
then monitor the consumption between
two ‘B’ Checks. (300 hrs). If found more,
proceed further.

Check lub oil quality • Ensure that the lub oil used is as per
Cummins recommendations. Refer
• Extended oil change interval Cummins latest SPT –
• bad quality of oil / • Ensure that the oil has been procured
unauthorised source. from genuine source.
• Wrong brand / grade of oil • Check the fresh and used oil properties
on DYNA OTS-5 kit and if doubt check
The complete history of engine from authorised laboratory.
history should be checked from • If oil quality is found bad, conduct trial
log book, various records, with recommended brand, grade of oil
customer interview so as to find and confirm the oil consumption again.
out any evidence of extended oil
change, bad quality of oil used,
- 18 -
wrong grade / brand of oil used in
past.

Such type of abuse happened in

past which might have resulted
permanent damage of engine
performance components, that can
not be corrected by simply using
good quality oil / filters now.

Oil throw from turbocharger • Check any traces of oil in the air intake
• Intake side cross-over pipe to confirm turbo intake
• Exhaust side seal leakage. Confirm and repair / replace
turbocharger and ensure no oil throw
from turbo.

• Check any traces of oil throw from turbo

exhaust outlet. If yes then check
following possibilities,

• Turbocharger exhaust seal ring damaged

/ worn out. In this case repair / replace
turbocharger.

Oil throw from cylinder head 1. Damaged / hardened / worn valve stem
exhaust ports indicates, seals. (If provided)
Excessive clearance between valve
1. Oil leakage from valve guides. Stem and guide due to excessive wear.
2. Oil leakage from piston rings. 2. Excessive wear of piston rings, broken
3. Damaged / burnt piston. piston rings, wrong fitment of piston
4. Cylinder liner scoring / worn rings, improper staggering of piston
out. rings, piston rings sticky in the ring
grooves, wrong / defective piston rings
used.
3. Excessive wear of piston ring grooves,
crack or physically damaged piston,
piston crown burnt. (Due to excessive
idling, over fueling, improper injector
cup spray angle etc.)
4. Cylinder liner scoring may occur due to
piston scuffing, dust entry, entrapment of
foreign material into combustion
chamber.
5. Sticky piston rings due to carbon
accumulation caused by bad quality of oil or
in case of ‘B’ & ‘C’ low nozzle POP [Peak
Opening Pressure] setting.

- 19 -
Extended oil and filter change • For extended period beyond the specified
period / Engine running with limit confirm with the help of engine
clogged or ruptured lub oil filters / Logbook.
Non Cummins filters used. • Check for evidence of sludge formation
in the oil filter / tappet cover / lube oil
pan etc.
• Additive package in the • Check used oil quality with the help of
lubricating oil gets depleted DYNA OTS – 5 Kit and in case of doubt
because of its use. This also get detailed analysis from authorised lab.
results increase in the rate of The used oil properties should not exceed
lub oil consumption. specified limits. Ref. O & M Manual
• Check the previous history / present
• Repetitive extended oil change condition of engine components and after
intervals can cause permanent getting confirmation advise customer for
damage of engine components reconditioning of the complete engine.
due to excessive soot / sludge
formation resulting clogging of
lub oil filter and circulation of
unfiltered oil.

Air compressor throwing oil • Air compressor piston rings worn out
• Air compressor cylinder bore scoring /
worn out.
• Repair / replace air compressor.
• Excessive air compressor intake
restriction.
• Check air intake piping / air cleaner for
choking.

- 20 -
 Coolant in oil.
Symptoms: -

1. Lub oil will be whitish in colour.

2. Oil level will rise / oil will not require regular top-up.
3. Rocker Arm Housing covers will have whitish butter deposits inside.
4. Traces of moisture will be found inside Rocker arm covers / Rocker
arm housings.
5. In operating condition, Blow by Gasses will be too hot because of
presence of steam in it.
6. More than regular coolant top-up will be required.
7. In few cases cold boiling cold boiling in top tank will be noticed.
8. In few cases there may be presence of oil in radiator / heat exchanger
top tank.

Coolant In Oil
Confirm the complaint • Oil level has increased more than ‘H’
mark
• Oil becomes milky white.
• Already water contaminated oil might
have been poured in the engine.
• Traces of oil in the radiator / H.E top
tank.

• Already contaminated oil • Drain the complete contaminated oil

poured in the engine from oil pan and lub oil filters. Flush the
unknowingly. lub oil system with little fresh oil and
conduct trial with fresh oil and lub oil
filters.
• Also flush the cooling system and top up
with fresh coolant in case of Oil Cooler
Failure.
• Observe the symptoms like,
• White fumes coming out from breather
initially and stops after some time OR
coming out continuously.

• • Check all the possibilities and ensure that

water has not entered through exhaust.
- 21 -
 • In case of any doubt take suitable
corrective action to prevent recurrence.

• Check and replace water cooled exhaust

manifold gaskets / Turbo Gasket. (If
applicable)

• Check the water cooled exhaust manifold

for internal crack / porosity. Replace if
found defective.

• Check the water cooled turbine casing for

crack / porosity. Replace if found
defective.

• Check for Exhaust port Water Jacket

Porosity.

If oil traces are seen in the • Test Lub oil cooler element with air
Radiator / H.E top tank then, pressure and confirm for the puncture. In
case of element puncture replace it along
• Remove oil cooler element . with new ‘O’ rings / gaskets etc.
Check for tube puncture or • In case of LOC element OK – replace
mutilated O rings. only ‘O’ rings / gaskets etc.
• Ensure ‘O’ ring seating area / gasket
• Check LOC housing, gasket seating area is clean / not damaged – If
surface, ‘O’ ring seating yes then clean the seating area or change
surface worn out / damaged LOC housing if required.
etc. • After correction again fill the system
with fresh coolant and take trial for
sufficient hrs as per the complaint.

If no oil in the coolant as well as no coolant

in the oil is observed that indicates problem
has been resolved.

If not proceed further.

• After cooler element tube • Remove and check aftercooler element

puncture / leak from header for leakage with pressurised air.
plate joints. In case of leak, replace the after cooler
element.

• If the engine is equipped with • Check and replace head and gasket.
air compressor, head Or head
- 22 -
 gasket leaking.

• If engine is fitted with water • Check the turbo oil drain tube for coolant
cooled bearing housing traces. If coolant traces are observed
turbocharger, coolant mixing check the bearing housing and replace if
through crack or porous found defective.
bearing housing.

• Cracked injector sleeve, • Remove all tappet covers and check for
• Cylinder head casting crack / traces of coolant, if possible try to
porous, identify any particular cylinder head
• Leakage from internal having problem. Otherwise remove all
expansion plugs. the cylinder heads and test out side.
( water pressure test ).
• Rectify the leakage or replace the
defective cylinder head if necessary.

• Cylinder liner puncture • Remove the oil pan and inspect the
• Cylinder liner seal rings cylinder liners from bottom. Try to
mutilated , cut or damaged due identify the cylinder from which coolant
to overheating. is leaking and replace that particular liner
• ‘K’ series water pump seal and seal rings.
leak with plugged bleed hole. • If it is difficult to pin point any particular
• ‘KV’ series water header plug cylinder, remove all the cylinder liners
area corroded inside and check for crack, pin hole due to
Camfollower cover area. excessive pitting /mutilated seal rings.
• Liner first bore / third bore • If seal ring seating area is damaged due
area damage. to corrosion / pitting, rectify with proper
salvaging techniques.

• Internal coolant leakage from • Pressure test the block by water pressure
coolant passages in the block and check for traces of water leaks from
coolant passages.

- 23 -
 Oil Thrown from Discharge Line of
Air Compressor
Oil Throw From Discharge Line of Air Compressor
Disconnect the discharge line from Confirm whether oil is coming from
air compressor and start the compressor discharge line
engine.

Air compressor throwing oil is due 1. Dust entry, Oil starvation, and Bad
to quality of lube oil.
1. Compressor rings worn out 2. Accumulation of carbon inside the
2. Back pressure in discharge line discharge line more than 1/16”.
3. Piston rings broken 3. Improper installation or excessive wear.
4. Sticky piston rings 4. Water entry or excessive carbon deposits.
5. Compressor bore worn out. 5. Same as point #1.
6. Restricted oil drain (KV) to 6. Excessive sludge in oil.
cylinder Block. 7. Use of old piston.
7. Worn / broken piston ring
grooves.

- 24 -
 Engines cranks but does not start
Symptoms:-

1. Smoke may not be visible.

2. Cranking RPM low.
3. Fault indication on panel.
4. Battery leads sparking.
5. No supply to S. D. coil.
6. Power OK Lamp not glowing on controller.
7. No output from magnetic pickup while cranking. Pickup OK lamp
not glowing.
8. ECM in flashout mode. i.e., yellow lamp glowing continuously.
9. High speed rotation sound from starter.

Engine Cranks But Does Not Start

Crank the engine and confirm the
complaint. If the engine fails to
start the problem may be due to

Fuel Lines empty. • Low fuel level / no fuel in tank

• Fuel drain back from lines for faulty
check valve, faulty cooling kit valve.
• Air entry in fuel lines through leaky
joints, Fuel filter ‘O’ rings.
• Too high suction lift of fuel ( More than
6 feet )
• Week and worn out Fuel Pump Gear
Pump.
• Problem in engine Safety • Open/Lossen SD Valve Bleeding
Control or Wiring so that Shut Capscrew & check weather Diesel comes
Down Coil is not energised. out while cranking.
• Failed SD Solenoid Coil. If not
• Restricted fuel supply / • Check Supply to SD Solenoid Coil while
Insufficient fuel supply. / Cranking engine & ensure SD Valve
opens.
• Stuck closed fuel suction valve if
provided.
• Choked strainer as applicable.
- 25 -
 • Choked fuel filter.
• Collapsed suction hose or blocked drop
tube.
• Fuel supply and drain tubing in NT 855
series interchanged at Cylinder head fuel
inlet.
• Excessively worn gear pump. Broken
gear pump shaft.
• Choked magnetic screen filter / wrongly
fitted.
• Defective solenoid valve.
• Defective safety control / loose – open
electrical wiring.
• Seizure of governor plunger in PT pump.
• PT pump coupling slipping on shaft
• Pressure regulator plunger seized in PTR
pump
• Actuator stuck in closed position
• Governor controller defective

• Engine cranking speed is less • Low battery voltage / discharged battery.

• Loose battery terminal connections.
• Excessive length / inadequate capacity
of battery cable.
• Defective starter / magnetic switch.
• Out of 2 starters, 1 No starter failed on
KV12, KV 16, & 1 MW.
• Excessive parasitic load (e.g. defective
unloader valve setting in compressor
application, alternator shaft bearing
seized in genset)

• Contaminated / bad quality of • Check the fuel for water contamination

fuel. and adulteration.

• Engine low idle RPM set too • Set the low idle speed as per engine
low. application.
• Weak / no signal from • Excessive gap between flywheel ring
Magnetic Pick Up unit. gear and MPU.
• Defective MPU. Loose / open / short
circuit wiring from MPU.
• Loose connection in wiring harness.

- 26 -
• Restricted air intake / exhaust. • Choked air cleaner.
• Pre-cleaner hood damaged / depressed.
• Blocked exhaust piping.

• Improper valve setting. Excessive valve clearances.

• Dribbling / Malfunction of • Choked fuel inlet screen.

injectors • Cracked injector cup / or choked injector
cup holes / enlarged cup holes.
• Seized injector barrel & plunger.

• Improper injection timing. • Too much advanced / retarded injection

timing.

• Weak compression. • Excessive valve leakage.

• Worn out piston rings / cylindrical liners.
• Sticky piston rings.

- 27 -
 ENGINE HUNTING
Crank the engine and confirm the • Bleed air from the fuel pump SD valve.
complaint. Install fuel sight glass • Check for loose hose connections,
to detect air in the system damaged water separator O ring and fuel
filter O ring
• Gear pump suction adapter O ring
damaged
• Magnetic filter screen partially choked
Dirt / Water in Fuel Tank causing fuel
filter choking.

Cracked / defective pulsation • Replace pulsation damper assembly and

damper check

In case of EFC governor check for • Loose connection in wiring

• Shielding is not proper
• Incorrect wiring
• Battery voltage too low
• MPU gap more
• MPU lock nut loose
• Dirt / Dust on MPU tip / Dirt on flywheel
ring gear

Improper gain setting • Adjust the Gain pot

In case of imported controller • Short link A& B and readjust gain

Damaged actuator O ring • Remove actuator , inspect O rings,

springs,
• Check for stickiness, clean all the
components & refit as per procedure.
Replace the O rings and springs if
damaged.

Wear marks on actuator shaft / • Replace the actuator

Actuator sticky / weak springs

Scored actuator housing • Replace actuator housing if ‘O’ ring

seating area is damaged
- 28 -
Controller faulty • Replace the controller & refit the old
housing and check for hunting.
• Remote pot defective

Improper Droop Setting in  Adjust the droop.

Hydraulic Governor  In SG governor screw in the Allen screw
on top of droop bracket to correct
hunting at High Idle RPM

Sticky pressure regulator in Remove the pressure regulator assembly

hydraulic governor clean and refit the assembly.

PT pump calibration / repair Check for calibration / repairs / replacement

of PT pump

Alternator winding weak Alternator winding to be checked and

repaired.

- 29 -
 Engine Emitting White Smoke
Improper starting procedure in Ensure use of cold starting aid as per
cold weather. recommendations.

Intake air temperature too low. • Take intake air from appropriate location.

Poor fuel quality. • Procure good quality of fuel as per O &

M manual specification from authorised
source.

Low coolant temperature. • Check thermostat for proper operation.

• Control heat exchanger raw water flow.

In correct valve adjustment. • Recheck and correct valve adjustment.

Injection timing incorrect. { Too • Recheck and correct injection timing..

retarded}

Malfunctioning of injectors. • Inspect and repair injector / STC valve.

Light load operation. • Optimized the load to minimum 60% of

the rated capacity.

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 Abnormal Sound from Engine
Note: Do not start the engine to confirm the problem.
First open full flow filter and check for presence of metal particles.
If only copper is present in the Lub Oil Filter, Connecting Rod Big End Bearing or Roller
Tappet pin is failed.
If Aluminium and steel particles are found in filter, Liner Piston scoring may be the
reason.
If only Aluminum particles are present in the filters, Thrust Bearing or Air Compressor
connecting rod may have failed.

If no metal particles are found in the filter, bar the crankshaft in opposite direction to
check hydraulic lock by coolant / diesel.

Disconnect supply to shut down valve coil and crank the engine. Carefully listen for
abnormal sound.

Abnormal sound from If there is whistling sound then check for

Turbocharger. compressed air leaks through gasket, ‘O’
rings, torn hose.
If there is metallic noise then check for
foreign material entry such as pipe welding
flux, washers etc.

Abnormal sound from Air • Check air compressor connecting rod for
Compressor. damage. Check unloader valve setting for
higher setting more that 10 Kg per Sq.
Cm.

Abnormal sound from connecting • Remove oil pan and check for excessive
rod big end bearing. radial clearance.

Abnormal sound from combustion • Metallic knocking sound caused by

chamber. advance engine timing, sudden burning
of dribbled fuel, fuel starvation during
load change.
• Valve drop. Open Rocker arm housing
covers and inspect over head valve
mechanism.

Noise from tappet roller pin. • Cyclic metallic sound from Cambox
covers. Open Cam box covers and carry
- 31 -
 out visual inspection and check for
excessive Roller play.

Abnormal sound from counter • Open oil pan and check for correct
balancer. installation, loosening of mounting
Hardware.

Abnormal sound from gear train. • Check for whining sound from Gear Case
Cover.
• Excessive gear backlash.
• Idler Gear shaft looseness.
• Gear teeth pitting caused by ineffective
vibration damper.
• Gear walkover caused by overspeeding.

Abnormal sound from flywheel • Improper fitment of starter i.e. spacer

housing. fitment, correct hardware.

- 32 -
 14. ENGINE OVER SPEEDING
Symptoms –

1. Engine RPM raises with out activation of throttle.

2. Engine may develop problem of late stopping [More than 8
sec.]
Reason for over speeding:

Load throw
Return fuel line restriction
Governor card faulty
Incorrect droop setting
Excessive down slop operation.
PT fuel pump Governor Bypass plunger stuck
Improper load sharing between generator synchronizing
Mining – Engine brake, Auto retarder brake.

Execssive fuel return line • Check for fuel return line restriction with
restriction. Hg manometer / gauge. Maximum fuel
return restriction should be less than 4 ”
of Hg.

Defective non return valve in fuel • Specified rating of non-return valve is ¼

return line. inch of Hg. Confirmed pressure rating
stamped on valve body.
• Clean non return valve {NRV} and
check for proper working.

Choked fuel tank breather. • Inspect and clean the fuel tank breather.

Stuck / seized MVS or PTG auto • Inspect the PT pump for water in fuel,
governor plunger. dirt entry and take corrective action.

EFC Actuator assembly stuck in • Open and inspect the actuator for dirt,
open position. wear or broken stud / spring.
• Reinstall the actuator as per specified

- 33 -
 procedure.
• Check actuator functioning by applying
V DC supply for clicking.

Defective EFC controller. • The EFC controller characteristic

changes with respect to temperature and
RPM shoots up than the set RPM.
Confirm the problem and replace the
controller.

In locomotive application - • Malfunctioning of master control

activating MUTC unit. [Multiple Unit
Throttle Control.]

In Marine application, Air • Malfunctioning of throttle control

compressors, large capacity mechanism. [ Wire rope, pneumatic &
dumpers. electric]

- 34 -
 15. Engine late stopping
Symptom –
Engine will take more than 8 seconds to shut off.

Execssive fuel return line • Check for fuel return line restriction
restriction. with Hg manometer / gauge. Maximum
fuel return restriction should be less than
4” of Hg.

Defective non return valve in fuel • Specified rating of non-return valve is ¼

return line. inch of Hg. Confirmed pressure rating
stamped on valve body.
• Clean non return valve {NRV} and
check for proper working.

Choked fuel tank breather / fuel • Inspect and clean the fuel tank breather.
tank placed at more than specified • Rectify the location of fuel tank.
height.

Fuel shut down valve disc sealing • Inspect and clean / replace SD valve
rubber eroded / entrapment of dirt . disc.

High Injector check ball leakage. • Check and repair injector.

- 35 -
 16. Engine Not Taking Rated Load
Symptoms

1. Engine RPM will lug down.

2. Engine may / may not have Black Smoke Problem.
3. Equipment will operate at slow speed.
4. In case of DG set, AC Output Voltage (<380 V& Frequency <50) of
Main Alternator will reduce below specified .
5. Engine may stall on load and shut down.

NOTE

If the engine is not taking load and there is black smoke problem, engine is
starving for air to burn the fuel injected in combustion chamber completely.
As a result the engine will not develop rated power and un-burnt fuel will
come through Exhaust as Black Smoke. In this case Air System is having
problem.

If the engine is not taking load and smoke is clear, required amount of fuel is
not being supplied by fuel system. The fuel system needs to be
troubleshooted. Check EFC Governor as per EFC Troubleshooting Tree if
the Fuel System do not have mechanical problem.

In case of Electronic engines fitted with Electronic Control Modules, there is

a feature which derates the engine whenever serious performance problem
like Low Oil Pressure or High Coolant Temperature is detected by ECM.
The ECM cuts fuel to engine to reduce the power.

While attending problems on this type of engine, check for any active fault
codes.

- 36 -
BEFORE ATTEMPTING ENGINE REPAIRS, CHECK THE
APPLICATION SIDE FOR ENGINE OVERLOADING AS
DETAILED BELOW

Engine overloaded • For Genset application, check kW output

as per engine rating and confirm.
• For Compressor application – Check air
discharge pressure settings / RPM,
unloader valve setting, Air Oil Separator
condition.
• For Earth moving applications – Check
fuel pump pressure / excessive gradient /
excessive load factor.
• Check Retarder Brake Operation
• Check for Vehicle Parasitic loads are
excessive i.e. vehicle brakes for
dragging, transmission malfunctioning,
cooling fan operation cycle time, or
Drive Train is not matched with engine (
New / Repower Applications only)

• Check for Torque Converter

malfunctioning. Measure Stall Speed. If
Stall speed is less than specified, engine
is faulty. If it is more than specified,
Transmission is defective.
• Check for brake binding.
• Check for Hydraulic Oil Pressure
settings.
• For Marine engines check for propeller
damage, Sea Growth on propeller,
foreign object such as fishing net stuck to
propeller.

- 37 -
 17. Engine Not Taking Rated Load (Black Smoke from Exhaust)
Choked Air Cleaner Element or  Check whether Vacuum Indicator is
Air Inlet Hood / Pre-cleaner showing Red indication. Clean Air
Cleaner Element. If Vacuum indicator
still shows Red Indication, check Air
Inlet Hood Screen for restriction or
insufficient Air Inlate Passage caused by
dislocation of Hood ( Old Design
Hoods.) For Air Cleaners with Cyclonic
Tubes, check the tubes for cleanliness.

Air Intake Piping obstructed /  Check the Air Intake Piping & hoses for
Damaged. obstruction caused by damage or foreign
material such as cloth rag left inside
during maintenance / repairs.

High Intake Air Temprature  Check for proper ventilation

 Check for Air Temprature Drop across
Aftercooler. After cooler choked
internally will not cool the air to desired
temperature.

Turbocharger not delivering  Inspect the Turbocharger Air discharge

desired boost pressure. piping for compressed air leaks and arrest
leaks.
 Inspect the turbocharger for free rotation.
 Inspect the Turbo Compressor Wheel and
Turbine Wheel for dirt / carbon
accumulation or damage.
 Measure the Turbo Boost Pressure.

Choked Aftercooler fins.  Restriction will be created to air flow if

the Aftercooler is choked externally.
Clean the Aftercooler and measure Turbo
boost pressure before and after the
Aftercooler.
 Check After Cooler Housing Air Inlet
Fins for damage causing restriction to air
flow.

Exhaust Back pressure more than  Excessive Exhaust Back Pressure will
specified. affect engine Fresh Air Aspiration and
- 38 -
 easy combustion smoke clearing. Check
Exhaust Back Pressure and take
corrective action as appropriate.

Leaky Cylinder Head Valves  Repair the Cylinder Heads

ENGINE NOT TAKING LOAD ENGINE NOT EMITTING BLACK

SMOKE

Improper Throttle adjustment.  Check and adjust throttle travel. For

Engines with Speed Governors activating
the throttle, check the throttle linkage
adjustments and governor droop setting.

Check whether EFC Controller ‘Actuator

OK’ LED is glowing Red indicating high
current drawn for fuel starvation.
Choked Fuel Filter  Check Fuel Filter Restriction. Replace
Fuel Filter if found choked.
 Clean the Fuel Tank if Fuel Filters are
found dirty.

Fuel Inlet Restriction  Check Fuel Supply Valve at Fuel Tank

for full opening.
 Check Fuel Suction Line Strainer
 Check Fuel Lines & hoses for restriction.
 Check Fuel Line Non-return Valves for
choking / correct orientation.
 Check Fuel Tubing for Field Repairs eg
brazing leading to blockage of fuel
passage.
Dirty / Improper Grade Fuel.  Check Fuel visualy for dirt &
adulteration. If suspected collect sample
for analysis.

Choked Magnetic Filter Screen of  Check & clean / repalce the Magnetic
PT Pump Filter screen.

Choked Injector Fuel Connection  Check & clean / repalce the Injector Fuel
screens in case of PT Flanger Connection screens
Injectors
Choked Fuel Inlet Screens on  Check which cylinders are misfiring by
Cylindrical Injectors touching the Exhaust ports immediately
after starting cold engine. Remove the
Injectors of Cylinders which are

- 39 -
 suspected to be misfiring and clean the
screens. Check Injector cup holes for
choking.

Improper Valve & Injector  Check and adjust Valves & Injectors.
Adjustment / Stuck Injector
Plunger

Low Fuel Manifold Pressure.  Measure the Fuel Manifold Rail Pressure.
If found out of specification, recalibrate
the Fuel Pump.

AFC Plumbing Leak / Blocked.  Check & rectify.

High Pressure Fuel System –

Engine Shut Off Lever partially  Check & adjust Fuel Shut Off Lever.
engaged.
Fuel Return Overflow Valve  Check Fuel Return Valve on Fuel Pump
Malfunctioning. Body for dirt or malfunctioning.

AFC Air signal line crack,  Check AFC Signal Line, Wastegate
blocked. Wastegate Cylinder plumbing & Cylinder.
Diaphragm / sensing line damage.

Lift Pump Malfunctioning.  Check Lift Pump Delivery volume at the

time of cranking. The values are listed in
Troubleshooting & repair Manuals.

Nozzles malfunctioning.  Check for double sealing washer fitment

to Injectors erroneously.
 Check and Repair the nozzles.

Quantum Engines: Chocked Fuel  Check and clean the Actuator Screens.
Metering & Timing Actuator
Screens.

Incorrect ECM Calibration  Check and download correct calibration

data to ECM.

- 40 -
High ambient temperature /  Check ambient temperature near engine
improper ventilation which should not exceed LAT.
(Limiting Ambient Temperature)

GENERAL REASONS

Very high lub oil level.  Correct the oil level.

High Fuel Inlet temperature  Clean the Fuel Cooler.

(Engines having Return Line Fuel
Coolers)

Engine operating above  Derate the engine as per recommendation

recommened altitude. in engine data sheet.

High Blow By  Check and correct the Blow by problem.

Injection Timing incorrect  Check & correct Injection Timing.

Damage to Camshaft or Tappets  Check conditions of Camshaft & tappets.

- 41 -
 18. Low Lube Pressure
Symptom –

1. Gauge will indicate lower than specified lub oil pressure.

2. In case of EIP, LEDs will glow red.
3. In case of ECP LED will indicate low lub oil pressure fault.
4. ECM / PCC / EGPC will log low lub oil pressure fault code.
5. Genset Panel will show Audio-Visual Low Lub Oil pressure alarm.

Low Lube oil pressure indicated on oil pressure gauge.

Engine Oil level low.  Check / Replenish engine oil level. If it
is less than ‘L’ mark, top up the oil and
correct the same.

 Check for a severe external oil leak that

could reduce the oil pressure.

Grade / Viscosity of oil used by  Verify grade of engine oil used.

the customer. Thin, Diluted or
does not meet the specification.

Oil Dilution with fuel.  Check oil level.

 Check for oil dilution.
 Test the oil for DDO test on Dyna OTS
Kit.
 Take corrective actions for Oil Dilution
with Fuel.

Engine Coolant Temperature  Refer to trouble shooting logic for

High. ( Above 93 Deg. C.) Engine ‘Overheating’.

Oil pressure Switch / Gauge is  Verify the pressure switch is functioning

malfunctioning. correctly.

Lube oil filter is choked.  Check / replace lube oil filter.

 Verify the change interval.

- 42 -
Lub Oil Pump Suction Tube ‘O’  Verify and correct.
Ring Damaged or Suction Tube
Loose / Cracked.
Oil Pan Adapter loose ( K-6  Check and correct.
engines )

Choked lube oil cooler.  Inspect Element lube oil cooler for any
deposition of material.
 Clean or Replace Element.

Pressure Regulator valve is stuck  Check thoroughly lubricating oil pump

open. assembly. Check / Replace valve.

Check for correct lube oil pump. .  Verify that the correct lubricating oil
pump is used.

Cylinder block / Cylinder head  Check / replace expansion plugs.

plug loose or missing..

Piston Cooling Nozzle.  Check for any damages to PC Cooling

Nozzle.

Lubricating Oil Pump is worn out.  Check / replace lubricating oil pump.

Main / Con Rod Bearings Worn  Inspect / replace bearings.

out.

- 43 -
 19. Engine Vibration Excessive
Symptoms

Engine may have Lateral and or Vertical Movement more than

generally observed.

NOTE

If the engine is vibrating more than normally observed and the problem
could not sorted out by normal troubleshooting steps, measure the
vibrations with Vibration Meter available at Regional Offices.

The engine Vibration Level varies with the speed as well as the load.

- 44 -
 20. ENGINE VIBRATIONS EXCESSIVE

Engine not running smoothly.  Check & correct Air Entry to Fuel
System.
Injectors Misfiring.  Check and correct Injector Misfiring
EFC Actuator Sticky. problem / Actuator problem.

Engine Low Idle set too low. Verify and set the Low Idle RPM to correct
specifications.

Radiator Fan Loose / Damaged or  Check Radiator Fan, Main Alternator

rotating accessory damage. Fan and all rotating accessories for
damage and correct if any.

Engine Mounting Supports to  Check and correct.

Flywheel Hsg / Base Rail Bolts
Loose and not torqued to
specification.

Engine to Main Alternator  Verify and correct the alignment.

Alignment out of specification.

Engine Mounts / Anti Vibration  Check AVM for their condition and
Mounts damaged / loose specified compressed height. Check
whether there is Gap in AVM and
Foundation surface. Provide shims if
gap is found.
 Verify and replace the damaged engine
mounts in equipments other than
Gensets.

Flywheel / Coupling or Alternator  Correct Flywheel / Coupling or

Hub loose / Vibration Damper Alternator Hub / Vibration Damper
damaged. problem.
Flywheel Housing Misaligned. Check TIR and Face Run Out for Flywheel
Housing.

Drive Line Components Loose or  Check & correct.

Broken or improperly assembled.

- 45 -