Common Faults and Solutions for Air-Cooled Engines 3

Fault cause

Solution

The engine uses high gear when it is heavily loaded

Use low gear

Air filter element clogged

Clean or replace the air filter element.

Muffler is squeezed, deformed or blocked

Replace the muffler.

Leakage at the joint between turbocharger and cylinder head

Tighten the clamp between the turbocharger and the cylinder head, and repair the leak at the connection between the turbocharger and the cylinder head.

Air leakage between turbocharger and exhaust manifold

Check and replace gasket.

Turbocharger does not rotate freely

Replace the turbocharger.

The fuel injector is defective or clogged

Replace defective or clogged injectors.

Incorrect adjustment of the fuel injection pump causes excessive fuel injection

Adjust or replace the fuel injection pump.

Piston ring or cylinder wear (blue smoke exhaust)

Replace worn piston rings or cylinders.

Incorrect injection timing

Adjust the injection timing.

Improper adjustment of the overhead mechanism

Measure and adjust the overhead mechanism settings.

Fault cause

Solution

Oil leak (external)

Check for oil leaks from the outside of the engine. Tighten the bolts, plugs and joints. Replace the gasket if necessary.

The air intake system is contaminated by dust

Remove and clean the intake manifold.

The oil dipstick is not calibrated correctly

Verify that the mark on the oil dipstick is correct.

The respirator or respirator hose is blocked

Clean the respirator and respirator hose.

Turbocharger compressor or turbine oil seal leakage

Replace the compressor or turbine oil seal.

The crankshaft rear oil seal or sealing surface is damaged

Repair or replace oil seal and sealing surface.

Damage to valve stem, valve guide or seal

Repair or replace damaged parts.

Piston ring or cylinder is worn or broken

Replace worn or broken piston rings or cylinders.

Fault cause

Solution

Respirator or respirator hose is clogged

Clean the respirator and respirator hose.

Oil filter clogged

Replace the filter.

Turbocharger oil return pipe is blocked

Clean the oil return pipe.

Turbocharger turbine oil seal damaged

Replace turbine oil seal.

The engine emits black smoke

Refer to black smoke exhaust (incomplete combustion).

Poor contact between the valve and the valve seat, resulting in a drop in compression pressure

Repair valves or valve seats

Wear of piston ring or cylinder causes compression pressure to drop

Replace worn piston rings or cylinders.