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Diagnosis and repair



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To perform the engine performance diagnostic procedure it will be necessary to connect the pressure test kit, Rotunda 014-00761 or equivalent, to the various components.

The engine performance diagnostic procedure begins with those items which are the high frequency, easy to diagnose problems, and progresses to the low frequency, hard to diagnose problems. Use of this procedure will promote rapid as well as accurate diagnosis.

If the concern is hard starting, follow the procedures for troubleshooting the glow plug system prior to troubleshooting the fuel system.

Under no circumstances should the fuel injection pump be replaced until the engine performance diagnostic procedure has been completed. The only exceptions to this are in the case of excessive black smoke (Diagnostic Charts Procedure H) and external leaks. In these cases, only those steps specified need to be completed.

Service each concern detected before going on to the next step. If service corrects the original complaint, it will not be necessary to proceed to the next test step. However, if the complaint is not corrected, continue with the test until the complaint is corrected.

The following explanations refer to the basic test steps of the engine performance diagnostic procedure. They give a brief description of how these problems can affect performance and an understanding of the importance of each test step.

1.External leakage: Fuel leakage may cause diesel fuel smell or low economy. Oil leakage may cause high oil consumption. An air intake system leak can shorten engine life, especially under dusty conditions. Coolant leakage can result in engine overheating.
2.Exhaust system condition: Kinks or dents in the exhaust system can cause high exhaust back pressure. This can result in loss of power and high smoke levels.
3.Fuel quality: Diesel engines need clean fuel, free of air, dirt and water. Any contamination may result in poor engine performance.
4.Fuel system condition: Kinks in the fuel lines or hoses can block or restrict fuel flow. Loose connections can leak air into the fuel. This can result in loss of power and high smoke levels.

NOTE: The fuel supply system must deliver the proper quantity of fuel with no pressure loss or air leaks in chassis fuel system.

5.Fuel system return line restriction: A restriction in the fuel return line will raise the pressure in the injection pump causing an adverse effect on injection pump timing. This results in excessive smoke levels or loss of power.
6.Air cleaner restriction: A dirty air cleaner may result in low power, excessive smoke and poor fuel economy.
7.Transfer pump pressure: This is the pressure which is available to charge the injection plunger. Low pressure will result in low power, and excessive smoke levels.
8.Accelerator linkage: If the accelerator linkage is improperly adjusted, the engine cannot reach full rated rpm. Top speed and pulling power will be reduced, or curb idle speed will be excessive.
9.Engine idle speed: Low engine idle speed may cause stalling or rough running.
10.Injection timing: Incorrect timing can be responsible for poor fuel economy, rough idling or hard starting and excessive smoke.
11.Injection nozzle test: The injection nozzles must be removed from the engine for this test. This is a functional test of injection nozzle performance. Incorrect nozzle performance will cause missing, poor fuel economy, loss of power and excessive smoke.
12.Crankcase pressure: This test measures the amount of crankcase blow-by. More blow-by will create high pressures. Crankcase pressure readings, plus rate of oil consumption, should be used to evaluate engine mechanical condition.
Pressure Test KitPressure Test Kit


To perform the engine performance diagnostic procedure it will be necessary to connect the pressure test kit, Rotunda 014-00761 or equivalent, to the various components.

The engine performance diagnostic procedure begins with those items which are the high frequency, easy to diagnose problems, and progresses to the low frequency, hard to diagnose problems. Use of this procedure will promote rapid as well as accurate diagnosis.

If the concern is hard starting, follow the procedures for troubleshooting the glow plug system prior to troubleshooting the fuel system.

Under no circumstances should the fuel injection pump be replaced until the engine performance diagnostic procedure has been completed. The only exceptions to this are in the case of excessive black smoke (Diagnostic Charts Procedure H) and external leaks. In these cases, only those steps specified need to be completed.

Service each concern detected before going on to the next step. If service corrects the original complaint, it will not be necessary to proceed to the next test step. However, if the complaint is not corrected, continue with the test until the complaint is corrected.

The following explanations refer to the basic test steps of the engine performance diagnostic procedure. They give a brief description of how these problems can affect performance and an understanding of the importance of each test step.

1.External leakage: Fuel leakage may cause diesel fuel smell or low economy. Oil leakage may cause high oil consumption. An air intake system leak can shorten engine life, especially under dusty conditions. Coolant leakage can result in engine overheating.
2.Exhaust system condition: Kinks or dents in the exhaust system can cause high exhaust back pressure. This can result in loss of power and high smoke levels.
3.Fuel quality: Diesel engines need clean fuel, free of air, dirt and water. Any contamination may result in poor engine performance.
4.Fuel system condition: Kinks in the fuel lines or hoses can block or restrict fuel flow. Loose connections can leak air into the fuel. This can result in loss of power and high smoke levels.

NOTE: The fuel supply system must deliver the proper quantity of fuel with no pressure loss or air leaks in chassis fuel system.

5.Fuel system return line restriction: A restriction in the fuel return line will raise the pressure in the injection pump causing an adverse effect on injection pump timing. This results in excessive smoke levels or loss of power.
6.Air cleaner restriction: A dirty air cleaner may result in low power, excessive smoke and poor fuel economy.
7.Transfer pump pressure: This is the pressure which is available to charge the injection plunger. Low pressure will result in low power, and excessive smoke levels.
8.Accelerator linkage: If the accelerator linkage is improperly adjusted, the engine cannot reach full rated rpm. Top speed and pulling power will be reduced, or curb idle speed will be excessive.
9.Engine idle speed: Low engine idle speed may cause stalling or rough running.
10.Injection timing: Incorrect timing can be responsible for poor fuel economy, rough idling or hard starting and excessive smoke.
11.Injection nozzle test: The injection nozzles must be removed from the engine for this test. This is a functional test of injection nozzle performance. Incorrect nozzle performance will cause missing, poor fuel economy, loss of power and excessive smoke.
12.Crankcase pressure: This test measures the amount of crankcase blow-by. More blow-by will create high pressures. Crankcase pressure readings, plus rate of oil consumption, should be used to evaluate engine mechanical condition.



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