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6.7. Possible errors and their solutions
6.7.1. Engine does not start
Problem
Cause
Solution
Electrical problem in option “E”
main switch switched off
Turn on the main switch
Battery broken or too weak
Charge battery externally and check the state of the battery
again.
Wiring damaged or loose
Check the battery cables to the starter as well as the control
cables to the starting relais
Electric starter is broken
Test electric starter according to maintenance instructions
Surrounding temperature too low
Use the decompressor
Bad fuel delivery
Too little fuel in the tank
Refuel
Air in the fuel delivery
Ventilate the injection pump
Wrong fuel
Remove all fuel from the system and refuel with diesel
Fuel filter clogged
Change the fuel filter
Injection nozzle clogged
Check nozzle spray outcome and injection pressure
Wrong timing
Check the injection pump
Bad air intake
Air filter or air intake clogged
Clean or replace the air filter
Clean the air-intake
Wrong timing
Wrong valve clearance
Check valve clearance of both valves
Too little compression
Intake valve doesn’t close properly
Check the valve-clearance as well as whether the intake-valve
is leak-free
Piston or piston rings worn
Send in device for repair
6.7.2. Abnormal colour of exhaust gas
Problem
Cause
Solution
Black smoke
Generally the motor is overloaded when it is releasing black smoke. On the one hand it can be caused by overload –
in this case lower the load. Note that the motor does not perform as well over temperatures over 25°C or at heights
above 1.000m (see derating chart). Another cause is a flaw in the motor – but here the motor is overloaded as well, for
example if the air filter is clogged and the motor is getting too little air and therefor has low performance.
air filter clogged
Clean or replace the air filter
Clean air filter housing and intake manifold
Wrong fuel
Remove all fuel from the tank and replace it with diesel
Too little fuel
Refuel. Check whether the injection nozzle is getting enough
fuel.
Wrong valve clearance
Check valve clearance
Injection nozzle clogged
Clean and check injection nozzle
Wrong timing
Check injection pump position/mounting
Intake valve does not close correctly
Check valve clearance and proper closing of intake valve
Piston or piston rings worn
Send in device for repair
Blue smoke
When the motor is releasing blue smoke, motor oil is being burnt. This flaw has to be treated with special care as it
could destroy the entire motor.
In rare cases blue smoke can be caused by the timing (position of injection pump) having been set up incorrectly.
Too much oil (oil level too high)
Check the oil level and if necessary drain some oil via the drain
screw
Breather gasket of the crankcase broken or wron-
gly adjusted
Check breather gasket of the crankcase
valve gaskets worn
Check valve gaskets (primarly intake valve gasket)
Cylinder head gasket worn
Change cylinder head gasket.
Allways take also rubber gasket for tunnel of push-rods
Rubber gasket for tunnel of push-rods worn
Change rubber gasket for tunnel of push-rods.
Clean and check cylinder head gasket
Wrong timing
Check injection pump position/mounting
White smoke
When the engine releases white smoke there is water in the fuel. Reasons see below
Ambient temperature < 5°C
At low temperatures white smoke is normal during starting. As
soon as the motor has the heat it usually operate on, the white
smoke has to stop.
Water in the fuel
Water can be in the tank because of condensation. That’s what
causes the white smoke. Drain the tank and refuel with fresh
diesel.
