Maintenance
Fault-Finding
125 9831/0650-3 125
One or more fuel injector worn or malfunctioning. Check the electrical connections at the injectors.
Worn or malfunctioning high pressure fuel pump. Do all the necessary fault finding checks before re-
moval of the high pressure fuel pump.
Table 32. Engine - RPM Surges
Cause Remedy
Replace defective high pressure fuel lines.
WARNING: DO NOT repair defective fuel lines. If
there is a fuel leak remove and discard the neces-
sary components and install new ones.
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 tank cap vent/breather blocked. Inspect and rectify as required - replace cap if neces-
sary.
Fuel is aerated. Check the low pressure fuel system for loose con-
nections and possible air ingress points. Rectify and
bleed the fuel system.
Electrical sensor fault. Check the electrical connections at the sensors.
One or more fuel injector worn or malfunctioning. Check the electrical connections at the injectors.
Worn or malfunctioning high pressure fuel pump. Do all the necessary fault finding checks before re-
moval of the high pressure fuel pump.
Table 33. Engine - Vibration Excessive
Cause Remedy
Engine not running smoothly/misfiring. Refer to Table 27.
Oil level over-full. Check oil level.
Fan damaged or accessories faulty. Check/replace the vibrating component.
Fan hub faulty. Inspect/replace the fan hub. Refer to workshop man-
ual.
Engine mounts loose or broken. Check/replace engine mounts. Refer to the
machine's service manual for correct installation and
torque figures.
Inlet and exhaust valve clearances set incorrectly. Set the valve clearances to the recommended clear-
ances.
Engine compression low in one or more cylinders. Check the engine compression.
Alternator bearing worn or damaged. Check/replace the alternator.
Flywheel housing misaligned. Check/correct flywheel alignment.
Electrical sensor fault. Check the electrical connections at the ECU (Elec-
tronic Control Unit) and sensors.
Drive line components worn or unbalanced. Check and inspect drive line components such as
propshafts. Refer to workshop manual.
Table 34. Engine - Exhaust Smoke Excessive (Black Smoke)
Cause Remedy
Engine being lugged down. Use appropriate gear for task.
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.
Air leak between the turbocharger and the intake
manifold (Turbocharged machines only).
Check/correct leaks in the air crossover tube, hoses,
or manifold cover.
Exhaust leak at the Manifold or Turbocharger (Tur-
bocharged machines only).
Check/correct leaks in the manifold or turbocharger
gaskets. Look for a cracked manifold.
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