Maintenance
Fault-Finding
124 9831/0650-3 124
Inspect and correct as required leaks in the high
pressure lines, fittings injector sealing washers, or
delivery valves.
Fuel injection lines leaking.
WARNING: Fine jets of fluid at high pressure can
penetrate the skin. Keep face and hands well clear of
pressurised fluid and wear protective glasses. If fluid
penetrates your skin, get medical help immediately.
Fuel filter(s) blocked, fuel supply restricted. Check/replace the fuel filter(s). Check fuel lines for
restriction.
Fuel is aerated. Check the fuel system for loose connections and
possible air ingress points. Rectify and bleed the fuel
system.
Fuel lift pump not operating correctly (fuel supply in-
adequate).
Check that the lift pump operates and delivers fuel to
the fuel injection pump. Check the correct electrical
wires for open or short circuits.
Air intake or exhaust system blocked. Visually check the air intake and exhaust system for
blockage or obstruction - remove as required. Check
the air filter elements for signs of blocking - replace
as required.
One or more fuel injector worn or malfunctioning Check the electrical connections at the injectors.
Exhaust leak at the manifold or turbocharger (if ap-
plicable).
Check/correct leaks in the manifold or turbocharger
gaskets. Look for a cracked manifold.
Extra injector sealing washer installed under injector. Remove extra injector sealing washer.
Inlet and exhaust valve clearances set incorrectly. Set the valve clearances to the recommended clear-
ances.
Worn or malfunctioning fuel injection pump. Do all the necessary fault finding checks before re-
moval of the fuel injection pump.
Engine compression low in one or more cylinders. Check the engine compression.
Engine in reduced torque or limp home mode. Investigate the fault using ServiceMaster.
Electrical engine fault. Investigate the fault using ServiceMaster.
Table 31. Engine - Will Not Reach Maximum RPM
Cause Remedy
Tachometer faulty. Verify engine speed with hand tachometer. Correct
as required.
Engine overloaded. Verify high idle speed without load. Investigate oper-
ation to be sure correct gear is being used.
Throttle position sensor (TPS) system defective. Check the throttle assembly.
Fuel is aerated. Check the low pressure fuel system for loose con-
nections and possible air ingress points. Rectify and
bleed the fuel system.
Fuel lift pump not operating correctly (fuel supply in-
adequate).
Check that the lift pump operates and delivers fuel to
the high pressure fuel pump. Check the correct elec-
trical wires for open or short circuits.
Stop the engine.
Replace the fuel filters. Operate the engine with a
temporary supply of the correct grade of clean fuel.
Monitor the engine performance.
Fuel is contaminated or incorrect grade diesel fuel
used.
WARNING: Dirty fuel will cause damage to the high
pressure fuel pump and injectors.
Check/replace the fuel filter(s).Fuel filter(s) blocked, fuel supply restricted.
Check fuel lines for restriction.
Turbocharger wastegate actuator diaphragm rup-
tured. (turbocharged machines only)
Repair of replace turbocharger.
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