01:00-01

Issue 1 en
Industrial & Marine Engines program 96

Trouble-shooting
schedule
Industrial and Marine engines

The trouble shooting schedule is intended as a guide and source of ideas

for practical trouble shooting carried out on the spot by experienced
mechanics. The schedule contains the causes of faults which we at Scania
have encountered over the years and it will be expanded with new causes
of faults as they occur and as we gather knowledge about them.
If you like, use the form on the last page to report anything you think is
missing from the trouble shooting schedule. That is the best way of keep-
ing it up-to-date.
The columns in the trouble shooting schedule headed “Trouble shooting”
and “Action” describes such matters that are not covered in other parts of
the workshop manual. If these columns are empty, instructions can be
found in other sections.

1 588 534
© Scania CV AB 1997-09
2 ©
Scania CV AB 1997-09 01:00-01
 Index
Page
Abnormal wear (liner, piston rings, etc.) 11
Black smoke on starting . . . . . . . . . . . . . . 6
Black smoke when running/under load . . 5
Blue smoke . . . . . . . . . . . . . . . . . . . . . . . . 6
Cold engine. . . . . . . . . . . . . . . . . . . . . . . 24
Compressed air system . . . . . . . . . . . . . . 30
Coolant loss . . . . . . . . . . . . . . . . . . . . . . 24
Coolant/water in oil . . . . . . . . . . . . . . . . . 7
Delivery pipe fractures . . . . . . . . . . . . . . 16
Engine difficult to start. . . . . . . . . . . . . . 16
Engine heater . . . . . . . . . . . . . . . . . . . . . 25
Engine speed hunting . . . . . . . . . . . . . . . 14
External coolant leakage . . . . . . . . . . . . 28
External corrosion on cylinder liner. . . . 16
External fuel leakage . . . . . . . . . . . . . . . 28
External oil leakage . . . . . . . . . . . . . . . . 27
Fluid stroke. . . . . . . . . . . . . . . . . . . . . . . 17
Fuel in the oil . . . . . . . . . . . . . . . . . . . . . . 6
High exhaust temperature. . . . . . . . . . . . 26
High fuel consumption . . . . . . . . . . . . . . 21
01:00-01 ©
Scania CV AB 1997-09
Page
High oil consumption . . . . . . . . . . . . . . .20
High oil pressure (engine warmed up) . .10
High oil temperature . . . . . . . . . . . . . . . .25
High system voltage . . . . . . . . . . . . . . . .27
Hot engine . . . . . . . . . . . . . . . . . . . . . . . .23
Knocking/noise . . . . . . . . . . . . . . . . . . . .18
Low charge air pressure. . . . . . . . . . . . . .26
Low compression. . . . . . . . . . . . . . . . . . .21
Low engine output . . . . . . . . . . . . . . . . . .21
Low fuel pressure . . . . . . . . . . . . . . . . . .27
Low oil pressure . . . . . . . . . . . . . . . . . . . .8
Low system voltage . . . . . . . . . . . . . . . . .27
Oil in coolant . . . . . . . . . . . . . . . . . . . . . . .7
Oil pressed out via crankcase ventilation 29
Polluted coolant . . . . . . . . . . . . . . . . . . . .25
Thermostat hunting, 14-series engine . . .18
Turbocharger breakdown. . . . . . . . . . . . .29
Vibration . . . . . . . . . . . . . . . . . . . . . . . . .12
White smoke . . . . . . . . . . . . . . . . . . . . . . .4
White smoke, water vapour . . . . . . . . . . . .4
3
 White smoke
Effect Cause Trouble shooting Action
- If possible: reduce
engine speed or put the
The white smoke starts engine under load
Incompletely burnt to turn blue and disap- - Install a white smoke
Cold engine
fuel pears when the engine is limiting device
warmed up (exhaust brake)
- Install flame heater
- Install an engine heater
Injection timing too late
Inlet valve does not open
properly. Valve adjust-
ment disturbed
Disconnect one delivery pipe at a time and listen
Too much fuel in for changes in the engine sound.
relation to air at low
combustion temper- Broken delivery valve
atures spring, uncontrolled
! WARNING!

injection Be careful when disconnecting the delivery

pipes as the pressure is extremely high and
could cause injury

Leaky injector, drip-

ping?

White smoke, water vapour

Effect Cause
Leaky charge air cooler
Leaky cylinder head
gasket
Cracked water-cooled
Water in the com- exhaust manifold
bustion chamber
Cracked cylinder head
(not cracks between
valve seats).
Crack in cylinder liner
Trouble shooting Action
Test pressure (air
0.5 bar, liquid 4 bar)
The fault is also present
when the engine is hot
If the fault is hard to trace:
Change all cylinder heads for exchange cylinder
heads.
(Or test pressurize all cylinder heads. Heat the cyl-
inder heads before pressurizing them.)

4 ©
Scania CV AB 1997-09 01:00-01
Black smoke when running/under load
Effect Cause Trouble shooting Action
“Adjusted” injection
Check the lead seal - Test in test bench
pump, attempt to boost
Injection timing too late
Inlet valve does not open
properly. Valve adjust-
ment disturbed
Disconnect one delivery pipe at a time and listen
for changes in the engine sound.

Broken delivery valve

spring, uncontrolled
! WARNING!

injection Be careful when disconnecting the delivery

pipes as the pressure is extremely high and
could cause injury
Too much fuel in
relation to air at high
Leaky injector, drip-
combustion temper-
ping?
atures
Nozzle tip jams
Incorrect spray pattern
from nozzle
More than 1 washer
under injector
Check charge air pres-
Fault in turbo
sure
Clogged air filter
High exhaust counter-
See page 26
pressure
Worn intake valves
Clogged intake port

01:00-01 ©
Scania CV AB 1997-09 5
 Black smoke on starting
Effect Cause Trouble shooting Action
Open the cover
(RQ/RQV) or hexagon
(RSV) on the governor
and check with a finger
on the control rod that it - Take the pump to a
Engine difficult to
Binding control rack goes to the maximum Bosch workshop for
start
stop bracket. repair
(This applies to engines
without a smoke limiter
on the governor hous-
ing.)

Blue smoke
Effect Cause Trouble shooting Action
Oil coating past piston
rings
Check for oil in the
Oil leakage in turbo-
intake manifold after the
charger
turbocharger
Damaged piston cooling - Change damaged
nozzles nozzles
Petrol in diesel oil

Fuel in the oil

Effect Cause Trouble shooting Action
- Normally about 1% of
Unburnt fuel passes the
fuel in the lubricating
piston
oil per 200 h
Defective injector
Internal leakage in injec-
Dilution of oil in
tion pump (worn pump
sump
element or crack in
pump housing)
Worn/broken O-ring at
feed pump pushrod
Frequent cold starts
Cont.

6 ©
Scania CV AB 1997-09 01:00-01
Fuel in oil, cont.
Effect Cause Trouble shooting Action
Check “blow-by” in crankcase
Correct value for new engine: 0 - +10 mm wc
Dilution of oil in Worn engine
(flow rate 60 - 100 l/min.)
sump Closed crankcase ventilation: -50 - +20 mm wc
Intake valve not opening

Oil in coolant
Effect Cause Trouble shooting Action
Test pressurize the oil cooler
Oil cooler leaks when Note: classed oil cooler, test pressurized: 10 bar oil
engine is running on the oil side, 0.5 bar air on the water side,
immersed in water 25 - 27 °C
Defective cylinder head
gasket
Crack in cylinder head
(not cracks between If the fault is hard to trace:
valve seats). Change all cylinder heads for exchange cylinder
(On 11-series engines: heads.
look for cracks between (Or test pressurize all cylinder heads. Heat the cyl-
the water jacket and oil inder heads before pressurizing them.)
duct.)

Coolant/water in oil
Effect Cause Trouble shooting Action
Oil cooler leaks when Test pressurize the oil
engine is not running cooler, see above
Leaky O-rings at cylin-
Leakage in telltale hole? - Change liner seals
der liner
water is condensed in
Dilution of oil in crankcase ventilation
sump and runs down into the
sump
14-series engine:
Clogged drain hole in
coolant pump in combi-
nation with leaking
pump seal
Cont.

01:00-01 ©
Scania CV AB 1997-09 7
 Coolant/water in oil, cont.
Effect Cause Trouble shooting Action
Crack in cylinder head Run the engine until
warm.
Crack in water jacket on Remove the oil sump
cylinder block/cylinder and all side covers.
head. (Coolant runs Test pressurize the cool- - Change the cylinder
down through the push- ing system. head for a exchange
rod hole.) If coolant seeps out cylinder head
behind side covers or at - If no leakage can be
the camshaft bearing found, change all cylin-
Crack in water jacket on there is probably a crack der heads for exchange
cylinder head. (Coolant in one of the cylinder cylinder heads
runs down via the oil heads.
duct for rocker arm As a rule it is possible to
Dilution of oil in lubrication.) see which cylinder head
sump or heads are leaking.
Cracked water-cooled
exhaust manifold
Leakage in charge air Test pressure (air
cooler core 0.5 bar, liquid 4 bar)
- Install a self-closing
cover on the exhaust
Water enters via the pipe
exhaust/intake system - Position the air cleaner
so that water cannot
run into it

Low oil pressure

Effect Cause Trouble shooting Action
Take a reading of the oil pressure on warmed-up
engine using a mechanical pressure gauge directly
on the engine:
Defective sensor/instru- Minimum 1 bar at 800 r/min.
ment Maximum 6 bar > 800 r/min.
Obs! Single-speed engines must not be tested
at 800 r/min. Risk of damage to the flexi-
ble coupling
Gauge shows low - 1 shim = 0.2 bar
Incorrectly adjusted oil (screw adjustment on
pressure relief valve 14-series engines)
Broken spring in oil Max. oil pressure 2 bar - Check/remedy
relief valve (14-series
engines, earlier version) at 2000 r/min relief valve

The piston in the oil

relief valve has jammed
in open position
Cont.

8 ©
Scania CV AB 1997-09 01:00-01
Low oil pressure, cont.
Effect Cause Trouble shooting Action
Crankshaft bear- - Change to bearings of
ing/main bearing of
wrong size has been fit- Max.
also
oil pressure 2 bar
when engine cold
the correct size. Check
the bearing seats before
ted on reground crank- assembly
shaft
Excessive play in big-
end and main bearings
If the bushing slides all
the way out of the bear-
ing seat, the oil pressure
Seizing in camshaft warning lamp will come
bearings on.
The engine throws out
oil through the crank-
case ventilation
Piston cooling nozzle
has come loose

Seizing in the bearing on Oil pressure can be

engine power take-off increased ~ 1 bar when
ED140 (14-series engine) the power take-off is
under load
Loosened oil duct plugs
Gauge shows low at camshaft bearing
pressure seats, under Pressure drops to 0 bar
the protection plate in
the V (14-series engine)
Suction pipe to oil pump
has come loose, the
pump sucks air
Engine too hot

Extremely low lubricat- - Choose a viscosity that

ing oil viscosity is suitable for the ambi-
ent temperature
- Change rotor if bush-
Worn bushings or loose ing is worn oval
shaft in oil cleaner - Change worn/dam-
aged shaft
Broken O-ring on
cyclone part of oil
cleaner
Defective oil pump drive

Internal leakage in oil Check that the oil

cleaner cleaner is correctly
assembled
Cont.

01:00-01 ©
Scania CV AB 1997-09 9
 Low oil pressure, cont.
Effect Cause Trouble shooting Action
Loosened guide plates in
the oil cooler prevent
passage of the oil
Worn/damaged oil pump
Plug in cylinder block
under the relief valve
Gauge shows low has come loose (11-
pressure series engine)
Clogged oil cooler
Seized/worn bearings in Pressure varies when
compressed air compres- compressor
sor, see also page 30 charges/relieves
Loose screws in timing
gear’s intermediate gear
The main oil duct (to
Oil pressure at
Gauge indicates low piston cooling nozzles)
idling/low engine speed
pressure at maxi- plug in the rear of the
is not affected since the
mum speed but not engine has come loose
delivery valve closes at
at idling speed (also at front of engine,
3 bar
9-series engine)
Oil valve sleeve screwed
- Tighten the oil valve
No oil pressure at out of oil pump housing Check that the oil
sleeve
idling speed (gives “by-pass” and valve sleeve is correctly
- If damaged, change the
(14-series engine) disables the overflow fitted
sleeve
valve)

High oil pressure (engine warmed up)

Effect Cause Trouble shooting Action
Take a reading of the oil pressure on the warmed-
up engine using a mechanical pressure gauge
directly on the engine:
Defective sensor/instru- Minimum 1 bar at 800 r/min.
ment Maximum 6 bar > 800 r/min.
Gauge indicates Note! Single-speed engines must not be tested
high pressure at 800 r/min. Risk of damage to the
flexible coupling
- Choose a viscosity that
Oil viscosity too high is suitable for the ambi-
ent temperature
Cont.

10 ©
Scania CV AB 1997-09 01:00-01
High oil pressure (engine warmed up), cont.
Effect Cause Trouble shooting Action
- 1 shim = 0.2 bar
Incorrectly adjusted oil
(screw adjustment on
relief valve
14-series engines)
Piston in oil relief valve
Gauge indicates
jammed in closed posi-
high pressure
tion
Valve in oil duct to pis-
ton cooling nozzles is
binding

Abnormal wear (liner, piston rings, etc.)

Effect Cause Trouble shooting Action
Unclean induction air
Wear ridge (ring travel
due to inadequate filter- - Fit a more efficient air
shoulder) at piston top
ing (wrongly dimen- filter
dead centre
sioned air filter)
Unclean intake air due to
leakage in intake piping
Wrong grade of oil, pol-
ishing damage
Changing of filters and
oil has been neglected
Short service life
Low coolant tempera-
ture (cold engine)
- Change the fuel
- Change to oil with a
Excessive sulphur con-
higher base number
tent in fuel
- Shorter oil change
intervals
Defective injector
(causes oil film to be
washed off)

01:00-01 ©
Scania CV AB 1997-09 11
 Vibration, no driven components engaged
Effect Cause Trouble shooting Action
Wrong injection timing
Broken delivery valve Disconnect one delivery pipe at a time and listen
spring for changes in the engine sound.

! WARNING!
Individual injectors not Be careful when disconnecting the delivery
operating pipes as the pressure is extremely high and
could cause injury

Fan imbalance
Flywheel has come
loose
Crankshaft hub loosened
Abnormally worn main
bearings
Vibration or unusual
noise at
1500 - 1700 r/min Defective vibration
damper
Drive belts run off
pulleys
Compressor operates
Only when com-
with excessive counter-
pressed air compres-
pressure (e.g. clogged
sor is charging, worst
piping/air dryer) or
at about 1000 r/min,
excessively high safety
see also page 30
valve opening pressure
Alignment fault Check engine alignment
Unsuitable rubber sus- - Change to rubber ele-
pension and location of ments of different
same hardness
Movement at engine - Reinforce the engine
Weak engine bed
attachment points bed

12 ©
Scania CV AB 1997-09 01:00-01
Vibration when the clutch or reverse gear is engaged
Effect Cause Trouble shooting Action
Imbalance in driven unit - Balance the unit
Imbalance in clutch
Inadequate alignment
- Carry out alignment
between engine and Check alignment
more accurately
driven unit
Unsuitable suspension
of engine or driven unit
Movement at attachment - Reinforce the engine
Weak engine bed
points bed
Defective flexible - Change rubber ele-
coupling between ment in flexible cou-
clutch/reverse gear and pling (consumption
driven unit item)
Unsuitably mounted - Reposition the engine
propeller shaft, e.g. or driven unit so that
excessive deflection the propeller shaft’s
angle or excessive devi- working range is in
ation in parallelism accordance with rec-
between flanges ommendations
Propeller shaft too long
and weak

Vibration when alternator is in operation

Effect Cause Trouble shooting Action
Imbalance in generator
Dismantle the coupling. Assemble the coupling
Imbalance in coupling
halves rotated half a turn relative to each other
Bearing damage in alter-
nator
Defective flexible cou- - Change the rubber ele-
pling between engine ment or type of cou-
and alternator pling
Fault in reduction gear

01:00-01 ©
Scania CV AB 1997-09 13
 Engine speed hunting - single-speed engines with RQ governor
Effect Cause Trouble shooting Action
Play in flexible cou-
Apply a light load, at a - Change the rubber ele-
pling between engine
load of about 20 kW the ment/check the cou-
and alternator (worn
hunting disappears pling hub and flange
coupling)
- Choose a coupling
without play, e.g.
Play in new coupling
Scania standard cou-
pling
Not enough flywheel
- Mount extra flywheel
mass in the driven unit,
mass
e.g. alternator

Hunting when Skew engine brackets

engine is running (engine suspension) - Change to harder rub-
under light load could under unfavoura- ber elements for the
(15 - 20 kW) or ble circumstances engine/alternator sus-
no-load conditions worsen engine speed pension
hunting
Incorrect injection tim-
ing
Disconnect one delivery pipe at a time and listen
for changes in the engine sound.

Individual injectors not ! WARNING!

operating
Be careful when disconnecting the delivery
pipes as the pressure is extremely high and
could cause injury

Engine speed hunting - single-speed engines with RSV governor

Effect Cause Trouble shooting Action
The RSV governor - Change the injection
Engine speed hunt- should not nowadays be pump delivery valves
ing at 4-5% speed used for single-speed (1-hole or 2-hole) for
droop operation (except on 9- 0-hole valves
series engines)

14 ©
Scania CV AB 1997-09 01:00-01
 Governor incorrectly - Tighten the idling
adjusted spring and adjust
engine speed
Engine speed hunt-
ing at idling Below 700 r/min the - Fit a weaker starter
standard starter spring, spring, part number
282 544 (Bosch 1 424 268 866
650 006) is too strong (Bosch 1 424 650 056)

01:00-01 ©
Scania CV AB 1997-09 15
 Delivery pipe fractures
Effect Cause Trouble shooting Action
No clamping
Carelessly handled
delivery pipe
Internal cavitation in
Fit 0-hole delivery
delivery pipe
valves for single-speed
Note: Single-pipe sys-
operation
tem is not permitted

External corrosion on cylinder liner

Effect Cause Trouble shooting Action
- Clean the cooling sys-
Unsuitable corrosion tem and fill up with
protection agent, glycol coolant as described in
or water in coolant the maintenance
instructions

Engine difficult to start

Effect Cause Trouble shooting Action
Leakage in suction pipe
The highest fuel level in
the tank is lower than the
feed pump. A longer - Install a ”daily supply
Air in fuel system standstill (days) the fuel tank” at a higher loca-
in the suction pipe may tion than the feed pump
run back to the tank
because of a leaky over-
flow valve
Leaky overflow valve
Low battery voltage
- Starting aids are not
Ambient temperature normally needed at
too low temperatures above
-15 °C
Oil viscosity too high
Paraffin precipitation in
the fuel
Cont.

16 ©
Scania CV AB 1997-09 01:00-01
Engine difficult to start, cont.
Effect Cause Trouble shooting Action
Blocked intake or
exhaust system
No fuel
Stop lever in stop posi- - Check the stop
tion solenoid and links
Wrong injection timing
Faulty injector
Open the cover
(RQ/RQV) or hexagon
(RSV) on the governor
Control rack/pump ele- and check with a finger
ment will not go into the on the control rod that it - Take the pump to a
cold start position. goes to the maximum Bosch workshop for
Binding control stop bracket. repair
rack/pump element (This applies to engines
without smoke limiter
on the governor hous-
ing.)
- Preheat the engine
combustion chambers
by running the starter
motor with the stop
control in stop position
for about 15 seconds.
Then start in the usual
way.

Fluid stroke
Effect Cause Trouble shooting Action
Test pressure (air
Leaky charge air cooler
0.5 bar, liquid 4 bar)
Starter motor not Leaky cylinder head
powerful enough to gasket
pull the piston over
the compression If the fault is hard to trace:
stroke (if the engine Change all cylinder heads for exchange cylinder
fires a connecting Crack in cylinder head heads.
rod could be bent) (Or test pressurize all cylinder heads. Heat the cyl-
inder heads before pressurizing them.)
Crack in cylinder liner
Cont.

01:00-01 ©
Scania CV AB 1997-09 17
 Fluid stroke
Effect Cause Trouble shooting Action
- Install a self-closing
cover on the exhaust
Starter motor not Water has entered the
pipe
powerful enough to engine via the
- Position the air cleaner
pull the piston over exhaust/intake system
so that water cannot
the compression run into it
stroke (if the engine
fires a connecting Crack in water-cooled
rod could be bent) exhaust manifold
Injector open

Thermostat hunting, 14-series engine

Effect Cause Trouble shooting Action
- Fit an external thermo-
Piping between thermo-
stat
stat housing and radia-
- Try drilling 2 holes,
tor too long (more than
∅ 2.5 mm, in the ther-
0.5 m)
mostat disc

Knocking/noise
Effect Cause Trouble shooting Action
Timing gears incor-
rectly meshed
Exhaust valves close Check the valve timing,
The crankshaft gear has
too late and strike see “Service data,
come loose
the piston crowns engines”
Valve mechanism not
operating
Disturbances in the sup-
Rapidly increasing
ply of lubricant for the
valve clearances
rocker arms
Loosened big end cap - Tighten to the torque
The piston strikes
(wrong tightening torque specified in the Work-
the cylinder head
after repair) shop manual
Foreign objects in the
piston crown
Cont.

18 ©
Scania CV AB 1997-09 01:00-01
Knocking/noise, cont.
Effect Cause Trouble shooting Action
Piston seizure (may be
caused by clogged pis-
ton cooling nozzles)
Wrong injection timing
Worn collets on exhaust
valves
Incorrectly adjusted Disconnect one delivery pipe at a time and listen
injection pump for changes in the engine sound.

Broken upper pis- Broken delivery valve ! WARNING!

ton rings spring (after-injection)
Be careful when disconnecting the delivery
pipes as the pressure is extremely high and
could cause injury

Connecting rod bearing

seizure
Faulty injector (seized,
worn, incorrect or
cracked tip, fatigued
spring)
Incorrectly adjusted
injector
More than 1 washer
under injector
Fuel leakage in flame Check whether it leaks. (Take out the flame start
start and run the engine with fuel pipe connected)
Loosened big end cap
Injection timing
Check the injection tim-
extremely advanced,
ing
Melting damage on 30 °BTDC or more
piston crown
Incorrectly adjusted
injector

01:00-01 ©
Scania CV AB 1997-09 19
 High oil consumption
Effect Cause Trouble shooting Action
Piston ring seizure
Combustion tempera-
Piston seizure
ture too high?
Cylinder seizure
Liner wear Unclean intake air?
Carbon polishing
(in patches)
Poor grade of oil?
Piston ring wear
Piston rings stuck
Tapered piston rings fit-
ted wrong way
Individual piston rings broken = incorrectly fitted
Several upper rings broken = start spray used
Broken piston rings wrongly, wrong injection timing (too early)
Several intermediate rings broken = worn rings or
grooves
Check the clearance
between valve and
Blue smoke under guide.
load Worn valve guides
High exhaust tempera-
ture?
Poor grade of oil?
Oil level too high?
Check whether oil is
Defective shaft seals in
present in the compres-
turbocharger
sor or intake manifold
Clogged air filter
Excessive vacuum in the Measure the vacuum
air intake before the tur- (max. 500 mm wc)
bocharger Check the air filter
Oil viscosity too low
Deformed/incorrectly
directed piston cooling
nozzles
External leakage
Leakage in seawater-
cooled oil cooler (11-
series marine engines)

20 ©
Scania CV AB 1997-09 01:00-01
High fuel consumption
Effect Cause Trouble shooting Action
Faulty injector
Low charge air pressure
Check in a pump test
bench that the amount
Adjusted injection pump
(Q-mm3/stroke) corre-
sponds to specification
Manner of driving, oper-
ating/load conditions

Low compression
Effect Cause Trouble shooting Action
Worn engine Check the compression
Broken piston rings
Incorrectly adjusted/
defective valves
Hydrostatic lock/bent
connecting rod
Take compression readings on a hot engine, with
all injectors removed, at starter motor speed
Readings not taken cor- Check cylinders 1 - 6, then cylinder 1 again
rectly Check that starter motor speed does not drop
Correct reading: 20 - 30 bar
Max. 3 bar difference between cylinders

Low engine output

Effect Cause Trouble shooting Action
Check the feed pump and overflow valve for leak-
age as described in the workshop manual
Low fuel supply pres-
Look for leakage in the suction pipe between tank
sure (below 0.3 bar)
and feed pump
Clogged fuel filter/Paraffin precipitation in fuel
Faulty injector
Fuel too hot
Cont.

01:00-01 ©
Scania CV AB 1997-09 21
 Low engine output, cont.
Effect Cause Trouble shooting Action
Incorrect fuel specifica- Check density and vis-
tion cosity
Low charge air pressure Check charge air pressure

Abnormal pressure drop Check

500 mm
the vacuum before the turbocharger, max.
wc
in intake piping Check the air filter
Check “blow-by” in crankcase
Worn engine Correct value for new engine: 0 - +10 mm wc
(flow rate 60 - 100 l/min.)
Worn crankcase ventilation: -50 - +20 mm wc
Take compression read-
Leaky valves ings and compare those
of the different cylinders
Wrong injection timing
Check that the governor
starts deregulating at the
Incorrectly adjusted intended speed
governor/throttle control Check that the throttle
control goes to the maxi-
mum stop bracket
Check the temperature
Intake air temperature of the air before the
too high engine.
Above +25 °C reduces
engine power
Take a reading, recom-
Exhaust counterpres- mended counterpres-
sure too high sure:
500 mm wc,
max. 1000 mm wc
Intake counterpressure See “Low charge air
too high pressure”, page 26
Incorrectly adjusted Check in a pump test
injection pump bench
Blocked fuel consump-
tion gauge

Binding injector Injector’s nozzle nut

tightened too hard
Exhaust brake/white
smoke limiter throttle in
closed position

22 ©
Scania CV AB 1997-09 01:00-01
Hot engine
Effect Cause Trouble shooting Action

Defective sensor/instru- Check

(120
that sensor and instrument suit each other
and 150 °C)
ment Check with a separate instrument
Low coolant level
Clogged seawater filter

Clogged freshwater/sea- - Clean the cooling sys-

water cooling system tem internally and
externally
Pressure cap not operat- Test pressurize
ing
Impeller on freshwa-
Instrument shows ter/seawater pump worn
high temperature or damaged
Incorrect cam/worn
cover on seawater pump
Restriction in coolant
flow, e.g. pieces of rub-
ber from seawater
impeller
Cooling capacity too Take a reading of the
low cooling capacity
Gas leakage (causes loss
of coolant)

Defective thermostats Check opening tempera-

ture of thermostats
Drive belts slip or pump
wheel loose on pump
shaft
- Vent at the cooling sys-
tem’s highest point
Reduced coolant Air pockets in engine’s - Check that the ventila-
flow outer cooling circuit tion piping to the
expansion tank is not
clogged
Excessive pressure drop Check with forcibly
in the external cooling opened thermostats
system
Clogged radiator
Cont.

01:00-01 ©
Scania CV AB 1997-09 23
 Hot engine, cont.
Effect Cause Trouble shooting Action
Circulation of cooling Check by taking temper-
air ature readings
Cavitation damaged
impeller in coolant
pump
Leakage in charge air
cooler

Cold engine
Effect Cause Trouble shooting Action
Check that sensor and instrument match each other
Defective sensor/instru-
(120 and 150 °C)
ment
Check with a separate instrument
Thermostat jammed in Check operation of ther-
open position mostat
- Fit a thermostat fan
Instrument indi- - Fit a smaller fan
Low power output at
cates low tempera- - Install a KLAFFO radiator shutter
low ambient temperature
ture NOTE: NOT A RADIATOR BLIND
(large external cooling
Risk of fan blade breakage
surface)
- Reduce the air flow
- Reduce fan/coolant pump gear ratio
Large leakage flow in
thermostat housing
(9- and 11-series marine
engines)

Coolant loss
Effect Cause Trouble shooting Action
Defective cylinder head
gasket (external leakage)
External leakage
Turbocharging pressure
Coolant pressed out
enters cooling system Test pressure
of radiator on DSI
via leaking charge air (air 0.5 bar, liquid 4 bar)
engines
element
Cont.

24 ©
Scania CV AB 1997-09 01:00-01
Coolant loss, cont.
Effect Cause Trouble shooting Action
If the fault is hard to trace:
Crack in cylinder head Change all cylinder heads for exchange cylinder
(not cracks between heads.
White smoke when valve seats) (Or test pressurize all cylinder heads. Heat the cyl-
engine hot indicates inder heads before pressurizing them.)
water vapour Grey oil = Coolant in oil
Locate the leak by removing the oil sump and pres-
Cracked cylinder liner
surizing the cooling system while turning the
engine over by hand

Polluted coolant
Effect Cause Trouble shooting Action
Faulty inhibitor - Clean the cooling sys-
tem and fill it with
Overdosed corrosion coolant as described in
inhibitor the maintenance
instructions

Engine heater
Effect Cause Trouble shooting Action
Incorrect mixture or type
- Clean the cooling sys-
of glycol and/or corro-
tem and fill it with
Boiler scale on sion inhibitor
coolant as described in
engine heater Anti-freeze with phos-
the maintenance
phate-based inhibitor
instructions
must not be used
The heater is not
designed for continuous
Short service life engagement. Suitable
temperature for thermo-
stat control = 40 - 60 °C

High oil temperature

Effect Cause Trouble shooting Action
- Defective sen- Check with separate
- Instrument indi- sor/instrument instrument
cates too high tem-
perature - Poor water flow in oil
cooler

01:00-01 ©
Scania CV AB 1997-09 25
 High exhaust temperature
Effect Cause
Adjusted injection pump
Wrong injection timing
Nozzle drips
High exhaust counter-
pressure
High inlet air tempera-
ture
Low charge air pressure
Clogged air filter
Low charge air pressure
Effect Cause
Dirty/damaged tur-
bine/compressor wheel
in turbocharger
Leakage between turbo-
charger and cylinder
head
Bearing seizure in turbo-
Check bearing play
charger
Clogged air filter
High exhaust counter-
pressure
High fuel temperature
26 ©
Scania CV AB 1997-09
Trouble shooting Action
Check the lead seal,
- Test in test bench
check CRO if necessary
Check the injection tim-
ing
Check type, opening
pressure and general
condition
Take a reading, recommended counterpressure:
500 mm wc, max. 1000 mm wc
Check silencer, spark arrester, length and inside
diameter of exhaust pipe
Trouble shooting Action
- Check/clean
- Check/change gaskets
- Recondition/change
turbocharger
Check the vacuum
before the turbocharger,
max. 500 mm wc
Take a reading, recommended counterpressure:
500 mm wc, max. 1000 mm wc
Check silencer, spark arrester, length and inside
diameter of exhaust pipe
01:00-01
Low fuel pressure
Effect Cause Trouble shooting Action
Clogged fuel filter
Defective overflow
valve
Defective feed pump
Air leakage in suction
pipe
High pressure drop in
suction pipe

Low system voltage

Effect Cause Trouble shooting Action
Broken alternator drive
belt
Slipping alternator drive
belt
(Normal charging
voltage: Batteries in poor condi-
27 - 28 V) tion
Alternator fault
Voltage regulator fault
Battery charger fault

High system voltage

Effect Cause Trouble shooting Action
(Normal charging Voltage regulator fault
voltage:
27 - 28 V) Battery charger fault

External oil leakage

Effect Cause Trouble shooting Action
Check “blow-by” in crankcase
Crankcase pressure too Correct value for new engine: 0 - +10 mm wc
high (flow rate 60 - 100 l/min.)
Closed crankcase ventilation: -50 - +20 mm wc
Cont.

01:00-01 ©
Scania CV AB 1997-09 27
 External oil leakage, cont.
Effect Cause Trouble shooting Action
Leaky crankshaft seal
Leakage at liner seal via
overflow hole in cylin-
der block
Defective cylinder head
gasket
Leakage in manifold
Low load
joint

External fuel leakage

Effect Cause Trouble shooting Action
Damaged injector and
injection pump connec-
tions/gaskets
Defective pulsation
damper
Leakage at high engine
- Change to Bosch over-
Blocked overflow valve speed and low power
flow valve (with ball)
output

External coolant leakage

Effect Cause Trouble shooting Action
Leakage in cylinder liner
seal
- Change to hoses of bet-
Cold leakage ter quality (preferably
silicone hoses)
Defective cylinder head
gasket
Check at the water pump
Water pump leakage
housing’s telltale hole
Leakage at charge air
cooler connection
Cont.

28 ©
Scania CV AB 1997-09 01:00-01
External coolant leakage, cont.
Effect Cause Trouble shooting Action
Check that the self-vent-
Loss of coolant in ing valve is not situated
stationary installa- Coolant pressed out of higher than the highest - Change the valve or fit
tions with self-vent- expansion tank coolant level and that air a manual air screw
ing valves is not drawn in through
the valve

Oil pressed out via crankcase ventilation

Effect Cause Trouble shooting Action
Hole in piston crown Increases when white
smoke limiting device is
Bearing seizure in turbo- engaged or exhaust
charger brake applied
Oil seepage via pistons -
liner
Oil seepage in air com-
pressor

Turbocharger breakdown
Effect Cause Trouble shooting Action
Excessive bearing play
in turbocharger
Loss of power Lubrication piping
between turbocharger
- Check the connections
and filter incorrectly
connected

01:00-01 ©
Scania CV AB 1997-09 29
 Compressed air system
Effect Cause Trouble shooting Action
Too much carbon in
compressor cylinder Empty the compressed
head or discharge air tank, retain the air in
piping connected compressed
air components. - If charging time
Exhaust valves leak Run the engine at exceeds specified val-
Worn pistons and cylin- 1200
Compressor does r/min and note the ues:
not maintain suffi- ders time it takes for the com- - Rectify leakage, if any
cient pressure in the pressor to discharge: - Check/rectify pressure
system 3 - 3.5 min.
Leaking/jammed intake series engines for 9/11- regulator
valves with - Check/rectify compres-
90-110 dm3 tank capac- sor
Defective pressure regu- ity
lator 2.5 - 3 min. for 14-series
engine with 90-110 dm3
Leakage in compressed tank capacity
air piping
Too much carbon in
compressor cylinder
head or discharge piping
Check/rectify compres-
Worn big end/main sor as described in the
bearings Workshop Manual
Noise Worn pistons and cylin-
ders
Compressor gear loose
on shaft, see also
“Knocking/noise”,
page 18
Worn pistons and cylin-
ders
Compressor allows
passage of oil, see Piston rings fitted
also “High oil con- wrongly
sumption”, page 20
Overpressure in engine
crankcase.
Defective seals on dis-
charge pistons
Compressor does Discharge mechanism
not discharge binding
Defective pressure regu-
lator
Check operation of air
Moisture/oil in com- Air dryer not working dryer, change desiccant.
pressed air system properly If desiccant is oily, see
“Compressor allows
passage of oil” above

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Scania CV AB 1997-09 01:00-01
01:00-01 ©
Scania CV AB 1997-09 31
32 ©
Scania CV AB 1997-09 01:00-01
33 ©
Scania CV AB 1997-09 01:00-01
 Suggestions and views?

One of the objectives of the trouble shooting schedule is that it should be continuously updated and
the best source of updating is where the schedule is actually used.
If you have any suggestions for improvements and additions to the trouble shooting schedule, please
copy this page and write down your comments on it. Then send it by fax or mail to the address
below.
Your comments are the help we need to improve future issues.
Thank you in advance for your cooperation.

From:

Proposal/Remarks:

Address Scania CV AB Telefax +49 8 55 38 31 80

Industrial and Marine Engines
Dept. ITS Telephone +49 8 55 38 10 00
151 87 Södertälje, Sweden

34 ©
Scania CV AB 1997-09 01:00-01