Failure Diagnosis Table

Engine stall Engine Noise and Cooling Intake

Symptoms and conditions of failure Starting failure Speed control error Lubricating oil Exhaust gas Fuel Electrical parts
after start up output low vibration water air
Starter does Starter Work Smoke Work
Smoke No load

ECU failure lamp stops flashing immediately (within 2 secinds) after turning off the key
not rotates rotates load color load

Revolution speed cannot be changed with accelerator (stays at a constant speed)

ECU failure lamp goes in immediately(within 2 seconds) after turning on the key
ECU failure lamp does not go on immediately after turning on the key

Engine does not start up (it stops immediately after initial ignition)

Abnormal sound (other than combustion sound) from engine

Fuel mixed with water (oil-water separator warning lamp lit)

Engine does not start up (without initial ignition)

Oil pressure low (oil pressure warning lamp lit)

Overheat (water temperature warning lamp lit)

Corrective Action Referenced page number

It takes longer than before to start up engine

Pressure low (air cleaner warning lamp lit)

High knocking sound at combustion time

Fuses get blown or broken (repeatedly)

Does not smoothly return to low speed

Battery charge error (charge lamp lit)

Too much lubricating oil consumed

Specific Ecu control functions fail.

Cannot be set to particular speed

Lubricating oil mixed with water

Lubricating oil diluted with fuel

Exhaust gas ternperature high

Uneven combustion sound

Too much fuel consumed

ECU failure lamp flashes

Fuel filter fouled shortly
Engine vibrates heavily

Water temperature low

Too much blow-bye

White exhaust gas

Black exhaust gas

Poor acceleration

Hunting occurs

Hunting occurs

Pressure high
Remarkable

Normal

White
slight

Black
None

Possible causes

See “Measuring and Adjusting

Intake/exhaust valves with improper clearances O O O O O O Adjust the valve clearances.
Valve Clearance” on page -123

Compressed air leaks from a valve seat • O O O O O O O O Lap the valve seat.

Repair or replace the intake/

Intake/exhaust valve seized O O O O O O O O O O O
exhaust valves.
Cylinder head gasket blown O O O Replace the gasket.
Piston ring stuck or broken O O O O O O O O O O O O Replace the piston rings.
Apply honing, and use See “Honing and Boring” on
Piston ring joint not correctly positioned O O O O O O O
oversized parts. page -147
Crank pin metal and bearing seized O O O O O O O Repair or replace.
Engine system

Piston ring joint not correctly positioned O O O O Correct the joint position.
Piston ring reverse-installed O O O O Reinstall.
Crank pin metal and journal metal worn O O O O O O Measure and replace.
Connecting rod bolt loose O O O Tighten with specified torque.
Foreign matter in a combustion chamber O O O O Disassemble and repair.
Gear backlash too large O Adjust the gear engagement.
Intake/exhaust valve guide worn O O O Measure and replace.

Governor not properly adjusted • O O O O O Adjust.

Intake/exhaust valves with improper opening/ See “Measuring and Adjusting

O O O O O O Adjust the valve clearances.
closing timings Valve Clearance” on page -123

Engine’s mounting loosened or damaged O O • • Repair or replace the faulty

part(s).

Floor fouled O O • Clean the floor.

Supercharger

Waste gate malfunctioning O O • Disassemble and inspect.

Radial metal worn O • O Disassemble and inspect.

Engine SP001434
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 Lubricating oil system Cooling water system

Engine
Possible causes

Thermostat faulty
Cooling water low

Lubricating oil low

Fan belt elongated
Radiator overcooling

Water jacket cracked

Improper lubricating oil

Radiator cooling insufficient

Lubricating oil filter clogged

Pressure regulator valve faulty

Crank case excessively lubricated

Leakage from lubricating oil system
Trochoid pump discharge rate insufficient
Symptoms and conditions of failure

ECU failure lamp does not go on immediately after turning on the key

ECU failure lamp goes in immediately(within 2 seconds) after turning on the key
not rotates
Starter does

O
Engine does not start up (without initial ignition)
Starting failure

Engine does not start up (it stops immediately after initial ignition)
Starter
rotates

It takes longer than before to start up engine

O
O
None

slight
Smoke
Engine stall
after start up

Remarkable

Revolution speed cannot be changed with accelerator (stays at a constant speed)

Cannot be set to particular speed

Poor acceleration

Does not smoothly return to low speed

No load

Hunting occurs
Speed control error

load

Hunting occurs
Work

Normal

White
color
Smoke
Engine
output low

O
O
O
O

Black

High knocking sound at combustion time

Uneven combustion sound

Abnormal sound (other than combustion sound) from engine

vibration
Noise and

Engine vibrates heavily

Too much lubricating oil consumed

O
O

Lubricating oil diluted with fuel

O

Lubricating oil mixed with water

Lubricating oil

O
O
O
O
O

O
O

Oil pressure low (oil pressure warning lamp lit)

O
O
O
O

Overheat (water temperature warning lamp lit)

water

O
Cooling

Water temperature low

Pressure low (air cleaner warning lamp lit)

air
Intake

Pressure high
O

White exhaust gas

load
Work

Black exhaust gas

O

Too much blow-bye

Exhaust gas

O
O
O

Exhaust gas ternperature high

O

Too much fuel consumed

Fuel mixed with water (oil-water separator warning lamp lit)

Fuel

Fuel filter fouled shortly

Battery charge error (charge lamp lit)

ECU failure lamp flashes

ECU failure lamp stops flashing immediately (within 2 secinds) after turning off the key

Specific Ecu control functions fail.

Electrical parts

Fuses get blown or broken (repeatedly)

Repair.
looseness.

Clean or replace.
Repair or replace.

Inspect or replace.

Inspect and repair.

Inspect the engine oil.

Adjust the belt tension.
Replace the thermostat.
Replace the thermostat.

Clean, adjust, or replace.

Corrective Action

system for water leakage.

Fill the proper lubricating oil.

Use the proper lubricating oil.
Check the cooling water
Or check the fan belt for
Referenced page number

Page 270
SP001434
 Engine stall Engine Noise and Cooling Intake
Symptoms and conditions of failure Starting failure Speed control error Lubricating oil Exhaust gas Fuel Electrical parts
after start up output low vibration water air
Starter does Starter Work Smoke Work
Smoke No load

ECU failure lamp stops flashing immediately (within 2 secinds) after turning off the key
not rotates rotates load color load

Revolution speed cannot be changed with accelerator (stays at a constant speed)

ECU failure lamp goes in immediately(within 2 seconds) after turning on the key
ECU failure lamp does not go on immediately after turning on the key

Engine does not start up (it stops immediately after initial ignition)

Abnormal sound (other than combustion sound) from engine

Fuel mixed with water (oil-water separator warning lamp lit)

Engine does not start up (without initial ignition)

Oil pressure low (oil pressure warning lamp lit)

Corrective Action Referenced page number

Overheat (water temperature warning lamp lit)

It takes longer than before to start up engine

Pressure low (air cleaner warning lamp lit)

High knocking sound at combustion time

Fuses get blown or broken (repeatedly)

Does not smoothly return to low speed

Battery charge error (charge lamp lit)

Too much lubricating oil consumed

Specific Ecu control functions fail.

Cannot be set to particular speed

Lubricating oil mixed with water

Lubricating oil diluted with fuel

Exhaust gas ternperature high

Uneven combustion sound

Too much fuel consumed

ECU failure lamp flashes

Fuel filter fouled shortly
Engine vibrates heavily

Water temperature low

Too much blow-bye

White exhaust gas

Black exhaust gas

Poor acceleration

Hunting occurs

Hunting occurs

Pressure high
Remarkable

Normal

White

Black
slight
None

Possible causes

Stop solenoid faulty O O Inspect and replace. See “Stop Solenoid” on page -171
Fuel injection pump's injection timing
O O O O Inspect and adjust.
advanced excessively
Fuel injection pump's injection timing
O O O O O O Inspect and adjust.
advanced excessively

Improper fuel oil O O O O O O • • Use the proper fuel oil.

Water flown into the fuel system O • O O O O O O • Drain the fuel filter.

Fuel filter clogged O • O • O Clean or replace.

Air contained in the fuel system O • O • • O Bleed.

Fuel pipe clogged or cracked O O O Clean or replace.

Fuel system

Inspect the fuel tank cock, fuel

Insufficient fuel supply to the fuel injection pump O • O • O filter, fuel pipe, and fuel feed
pump.
Uneven injection by the fuel injection pump O O O O O O O O O Inspect and adjust.
Fuel injected excessively O O O O O O O Inspect and adjust.
Fuel injection nozzle spray failure O O O O O O O O O Inspect and adjust.
Remove dirt caught in the
See “Fuel System Components” on
Priming fails O priming pump internal valve
page -178
(disassemble and clean).

Feed pump inlet strainer clogged • • O Clean the strainer.

CSD valve malfunctioning O O • Replace the pump.

Replace the CSD valve.
Inspect the fuel tank and lid;
Fuel tank airtightness deteriorated • • replace with the genuine parts
if necessary.

Air filter clogged O • O O • O O • Clean the air filter.

Intake/exhaust
gas system

Examine the relationship

Engine used at high temperatures or high altitudes O O O O O between output reduction and
load.

Exhaust pipe clogged • • O O O O Clean the exhaust pipe.

Engine SP001434
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 Engine stall Engine Noise and Cooling Intake
Symptoms and conditions of failure Starting failure Speed control error Lubricating oil Exhaust gas Fuel Electrical parts
after start up output low vibration water air
Starter does Starter Work Smoke Work
Smoke No load

ECU failure lamp stops flashing immediately (within 2 secinds) after turning off the key
not rotates rotates load color load

Revolution speed cannot be changed with accelerator (stays at a constant speed)

ECU failure lamp goes in immediately(within 2 seconds) after turning on the key
ECU failure lamp does not go on immediately after turning on the key

Engine does not start up (it stops immediately after initial ignition)

Abnormal sound (other than combustion sound) from engine

Fuel mixed with water (oil-water separator warning lamp lit)

Engine does not start up (without initial ignition)

Oil pressure low (oil pressure warning lamp lit)

Corrective Action Referenced page number

Overheat (water temperature warning lamp lit)

It takes longer than before to start up engine

Pressure low (air cleaner warning lamp lit)

High knocking sound at combustion time

Fuses get blown or broken (repeatedly)

Does not smoothly return to low speed

Battery charge error (charge lamp lit)

Too much lubricating oil consumed

Specific Ecu control functions fail.

Cannot be set to particular speed

Lubricating oil mixed with water

Lubricating oil diluted with fuel

Exhaust gas ternperature high

Uneven combustion sound

Too much fuel consumed

ECU failure lamp flashes

Fuel filter fouled shortly
Engine vibrates heavily

Water temperature low

Too much blow-bye

White exhaust gas

Black exhaust gas

Poor acceleration

Hunting occurs

Hunting occurs

Pressure high
Remarkable

Normal

White

Black
slight
None

Possible causes

Fuse blown or broken O O O • • Replace the fuse.

Starter faulty O O Repair or replace the starter.

Repair or replace the
Alternator faulty O O
alternator.
Repair or replace the
Wires disconnected O O O O O O O O disconnected wire(s) of the
harness.
Inspect, repair, or replace the
Wires short-circuited (sheathing broken);
overloaded by the power consumption
additional devices
by • • harnesses and wires as needed.
Reexamine the additional
devices.
Battery voltage low O O - Inspect and charge the battery.
Repair or replace the harness.
Key switch faulty or disconnected O O O
Replace the key switch.
Key switch instantly cut off O O Replace the key switch.
Starter relay faulty, disconnected, or short- Repair or replace the harness.
Electrical system

O
circuited Replace the starter relay.
Main relay faulty
Repair or replace the harness.
(except for sticking of the contact, which is O O
Replace the main relay.
undetectable by ECU)
Actuator relay faulty
? ? O Replace the actuator relay.
(contact failure undetectable by ECU)
Start assist relay faulty
(contact failure undetectable by ECU)
O O • Δ Replace the start assist relay.

Accelerator sensor signal error Repair or replace the

O O O O
(an error undetectable by ECU) accelerator sensor.
Water temperature sensor signal error
(an error undetectable by ECU)
O O • • • Replace the water temperature
sensor.
Speed sensor signal error (an error undetectable
by ECU, such as caused by noise)
O • O O O O
Repair or replace the fuel
injection pump.
Monitor the engine speed using
the diagnosis tool.
Rack position sensor signal error
(an error undetectable by ECU) • O • O O O
Repair or replace the fuel
injection pump.
Monitor the rack position sensor
signal using the diagnosis tool.
Rack actuator malfunctioning
(an error undetectable by ECU) • O • O O O
Repair or replace the fuel
injection pump.
Monitor the rack actuator using
the diagnosis tool.
ECU failure lamp disconnected O Replace the lamp.
ECU faulty (ECU self diagnosis failure) O O O O O Replace the ECU.

Engine SP001434
Page 272
 Engine stall Engine Noise and Cooling Intake
Symptoms and conditions of failure Starting failure Speed control error Lubricating oil Exhaust gas Fuel Electrical parts
after start up output low vibration water air
Starter does Starter Work Smoke Work
Smoke No load

ECU failure lamp stops flashing immediately (within 2 secinds) after turning off the key
not rotates rotates load color load

Revolution speed cannot be changed with accelerator (stays at a constant speed)

ECU failure lamp goes in immediately(within 2 seconds) after turning on the key
ECU failure lamp does not go on immediately after turning on the key

Engine does not start up (it stops immediately after initial ignition)

Abnormal sound (other than combustion sound) from engine

Fuel mixed with water (oil-water separator warning lamp lit)

Engine does not start up (without initial ignition)

Oil pressure low (oil pressure warning lamp lit)

Corrective Action Referenced page number

Overheat (water temperature warning lamp lit)

It takes longer than before to start up engine

Pressure low (air cleaner warning lamp lit)

High knocking sound at combustion time

Fuses get blown or broken (repeatedly)

Does not smoothly return to low speed

Battery charge error (charge lamp lit)

Too much lubricating oil consumed

Specific Ecu control functions fail.

Cannot be set to particular speed

Lubricating oil mixed with water

Lubricating oil diluted with fuel

Exhaust gas ternperature high

Uneven combustion sound

Too much fuel consumed

ECU failure lamp flashes

Fuel filter fouled shortly
Engine vibrates heavily

Water temperature low

Too much blow-bye

White exhaust gas

Black exhaust gas

Poor acceleration

Hunting occurs

Hunting occurs

Pressure high
Remarkable

Normal

White

Black
slight
None

Possible causes

ECU control function active O O O • This is not a failure.

Switch to the normal mode.
Refer to the control manual.

Repair or replace the harness.

Water temperature sensor disconnected or short-
O O O Replace the water temperature
circuited
sensor.
Repair or replace the harness.
Accelerator sensor disconnected or short-
O O Replace the accelerator
circuited
Engine stopped or restricted by ECU failure diagnosis function

sensor.
Repair or replace the harness.
Speed sensor signal error O O O Repair or replace the fuel
injection pump.
Repair or replace the harness.
Rack position sensor signal error O O O O O Repair or replace the fuel
injection pump.
Repair or replace the harness.
Rack actuator malfunctioning O O O Repair or replace the fuel
injection pump.
Check for idle rotations caused
by the working machine.
Engine overspeed occurs O O
Check the speed sensor
signal.
Repair or replace the harness.
CAN Communication error O O O
Replace the ECU.
The EGR valve motor disconnected or short- Repair or replace the harness.
O O O
circuited. Replace the EGR valve.
Repair or replace the harness.
CSD solenoid valve disconnected or short-
O O O Replace the CSD valve
circuited.
solenoid.
Repair or replace the harness.
Start assist relay disconnected or short-circuited. O O Δ O
Replace the relay.
Main relay cannot be turned off O O Replace the relay.
Rack actuator relay disconnected or short- Repair or replace the harness.
O ? O
circuited Replace the relay.
Error detected by ECU self diagnosis O ? O Replace the ECU.

Engine SP001434
Page 273