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Troubleshooting a problem depends on an in-depth analysis of the problem. Gather as much information as
possible to make solving it faster and easier. Attempt the easiest logical solution first. If that solution does not
work, then go to the next one in sequence. Although the troubleshooting table attempts to cover as many
common problems as possible, it is not possible to include all solutions to all problems. Factors that aid in
solving a problem include: gathering all the facts, analyzing the problem, relate problem symptoms to systems
and components and consider any recent maintenance worked performed related to the problem.
POWERPACK
Engine Assembly
Excessive blow-by
Engine breather oil leak and or high oil 1. Check breather connection sealing.
steam pressure. 2. Check breather body for cracks.
3. Check engine compressibility (need
ST-100 certified Tech.) for high oil
steam pressure.
Air compressor malfunction Check air compressor blow-by (). Repair or
replace as necessary.
Turbocharger oil seal leaking Check turbocharger turbine and compressor
seals ().
Check turbocharger blow-by contribution ().
Repair or replace as necessary.
Valve stem clearance is excessive, or seals Check valve stems and seals ().
are excessively worn
Cylinder head valve guides are excessively Check the valve guides for wear (). Replace
worn cylinder head if necessary.
Piston or piston rings are excessively worn Check pistons and piston rings for wear or
or damaged. damage.
Engine difficult to start or will not start
Low fuel level. Check fuel tank level. Verify fuel gauge is
accurate. Refuel as needed.
Low fuel rail pressure Engage starting the engine for continuous 30
seconds then check fuel pressure value with
INSITE. If fuel pressure remains low, refer to
fuel system table.
Malfunctioning ECM Check for the battery voltage at the ECM
power and ground circuits. Check for faults
using INSITE
Low battery voltage Check the battery voltage gauge. Replace
battery if necessary.
Slow cranking speed Minimum cranking speed must be greater
than 150 rpm.
Excessive fuel drain. Check suction side line and filter for loose
connections that allow air inside the fuel
system.
Check for air in the fuel system See section ().
Plugged fuel tank vent. Remove fuel tank cap. If engine starts,
inspect fuel tank vent for obstructions.
Poor fuel quality. Operate the engine with a known good fuel
supply.
Excessive engine noise
Air intake or exhaust leaks Inspect air intake and exhaust systems for
leaks.
Fan is loose or damaged. Check the fan.
Lubricating oil is above or below Add or drain oil as necessary.
specification.
Lubricating oil pressure is low Refer to Low lubricating oil pressure
problem.
High coolant temperature Refer to coolant system table.
Engine mounts worn or damaged. Replace engine mounts.
Incorrect overhead adjustments Measure and adjust the overhead settings.
Injector malfunction Perform cut-out test (). Replace the injectors
as necessary.
Turbocharger is worn or damaged. Check the turbocharger for damage.
Measure the turbine and compressor wheel
clearances.
Engine power output low
Air leaks Inspect the air intake and exhaust systems
for leaks.
Fuel injector malfunction Perform cylinder cut-out test with INSITE.
Replace injectors as necessary.
Secondary fuel filter clogged. Inspect and replace secondary fuel filter.
Turbocharger seized or damaged Inspect turbocharger. Repair or replace if
necessary.
Air in the fuel Find and repair air leak. Bleed fuel system ().
Incorrect overhead adjustments Measure the overhead valve lash settings.
Adjust if necessary ().
Malfunctioning accelerator pedal Use INSITE to monitor accelerator pedal
position while depressing and releasing the
accelerator pedal. Verify the reading is 0
when pedal is released and 100 when pedal
is fully depressed.
Poor fuel quality. Operate engine with known high-quality fuel.
Engine running rough or misfires
Poor fuel quality. Operate engine with known high-quality fuel.
Fuel injector malfunction Perform cylinder cut-out test with INSITE.
Replace injectors as necessary.
Fuel pump actuator malfunction Remove actuator electric plug while the
engine is idling, if engine runs normally,
replace the actuator.
Secondary fuel filter clogged. Inspect and replace secondary fuel filter.
Air in the fuel Find and repair air leak. Bleed fuel system ().
Incorrect overhead adjustments Measure the overhead valve lash settings.
Adjust if necessary ().
Engine speed surge
Air in the fuel Find and repair air leak. Bleed fuel system ().
Fuel pump actuator malfunction Remove actuator electric plug while the
engine is idling, if engine runs normally,
replace the actuator.
Secondary fuel filter clogged. Inspect and replace secondary fuel filter.
Fuel injector malfunction Perform cylinder cut-out test with INSITE (6-
26). Replace injectors as necessary.
Turbocharger damaged Inspect turbocharger. Repair or replace if
necessary.
Engine starts but does not keep running
Fuel level low. Refuel.
Low battery voltage. Check battery voltage. Replace battery if
necessary.
Fuel leak. Check fuel lines, filters and connections for
leaks.
Fuel filter or fuel suction line restricted Check filter and suction line for restrictions.
Clean suction line. Replace fuel filter.
Air in the fuel. Find and repair air leak. Bleed fuel system ().
Fuel lift pump malfunction Measure fuel lift pump output pressure.
Replace if necessary.
Poor fuel quality. Operate engine with known high-quality fuel.
Engine will not shut of
Turbocharger oil seal leaking Check the turbocharger turbine and
compressor oil seals.
Fuel fumes entering air intake Check the air intake ducts. Locate the source
of the fumes. Repair as necessary.
ECM malfunction Replace ECM.
FUEL SYSTEM
Fuel in coolant
Coolant is contaminated Drain and refill with non-contaminated coolant.
Cylinder head is cracked or porous Pressure test the cylinder head ().
Fuel in lubricating oil
Engine idling for too long Engine should not remain idling for more than
10 minutes. Shut down engine or raise idle
speed.
Fuel drain line restriction Check fuel drain lines for restrictions. Clear or
replace the fuel lines, check valves or fuel tank
vents as necessary.
Fuel injector malfunction Perform a high-pressure injector return flow test
(). Replace injectors as necessary.
Internal fuel leaks Inspect for leaks. Add fluorescent dye to fuel
system to locate source of fuel leaks.
COOLING SYSTEM
EXHAUST SYSTEM
Gearbox Assembly
DRIVELINE
Transfer Case
Drive Shaft s
Noise from wheel hubs. Insufficient lubrication. Check for leaks then fill
to the correct level.
Worn bearings. Replace bearings.
Splined shaft worn. Replace shaft.
Noise Insufficient lubrication. Check for leaks then fill
to the correct level.
Noise at release. Improper fitting backlash
between pinion and ring
bevel gear.
Noise during acceleration Insufficient lubrication. Check for leaks then fill
to the correct level.
Noise when cornering. Improper backlash Replace the unit.
between planetary gears
and crown wheels.
Final Drive
SUSPENSION
STEERING
PNEUMATIC
Brake
Problem Solution
2 Air Reservoir
Leaks. Repair or replace.
4 Safety Valve
Excessive Check system pressure.
venting Valve operating properly when venting at 140/150 [psi].
Check unloader/governor.
Vents at less Replace.
than 140 [psi]
Leaks Replace.
Does Not Periodic Test: Remove and test above 150 [psi] with
Function external air. Replace if non-functional.
4a Drain Valve
(Manual)
Leaks Replace.
4b Drain Valve
(Automatic)
Does Not Drain Repair or replace.
Does Not Drain Replace with heated unit.
In Cold
Weather
Leaks or Periodic Test: with system pressure stabilized
Malfunctions (compressor unloaded) no leak evident at discharge port
- make several foot brake applications to reduce wet
tank pressure. Moisture should drain from discharge
port. Repair or replace.
6 Check Valve
Allows flow Periodic Test: bleed supply reservoir and observe
back to air gauges. Check valves should maintain primary and
reservoir secondary reservoir pressure. Replace if test results are
negative.
8 Air Pressure
Gauge
Shows only Replace.
one reading
9 Foot Brake CAUTION
Valve Chock wheels then repair and/or replace items as
necessary.
Leaks from Check seal of parking brake chamber for back-flow of spring
vent port when “hold-off” pressure through service port to open exhaust on
all brakes are
valve.
released.
Replace parking brake chamber.
Leaks from Foot valve defective. Repair or replace.
vent port when
service brake
applied.
Leaks from Foot valve defective. Repair or replace.
vent port when
parking brakes
applied and
service brakes
released.
10 Quick Release
Valve
Leaks when Repair or replace.
service brakes
are applied
11 Service Brake
Chamber
12 Parking Brake CAUTION
Chamber Service only service brake side of parking brake
chamber.
Auxiliary
Problem Solution
DRIVELINE CONTROL
Problem Solution
AIR CONDITION
FIRE SUPPRESSION