The “Remedy” column is only filled in when it is not clear from the "probable cause" what needs to be done.
Fault Possible cause Remedy
Engine does not start D Fuel tank empty D Fuel valve shut off D Air in fuel system
D Fuel lines leak, broken or clogged D Fuel filter/prefilter clogged
D Condensation in fuel D Air filter clogged D Exhaust clogged
(exhaust back pressure too high) D Electric circuit interrupted
D Battery dead
D Starter/solenoid switch faulty D Injectors clogged
D Valves do not close or are stuck D Crank assembly is externally blocked
D Inner engine damage (piston seizure, possibly caused by water in fuel)
D Drain water from fuel filter and tank
D Set main switch to "on"
D Set transmission shift lever to
"N"
D Replace faulty fuses
D Repair any loose, corroded and broken wires and contacts D See information at "Starter"
D Remove objects that interfere with the movement of the fan, power output, alternator, etc.
Engine starts but does not reach idle speed or stalls
D Power take-off is on D Fuel filter clogged
D Fuel grade does not meet the specifica
tions or is contaminated D Air filter clogged
D See "Fluids and Lubricants...."
Engine does not start or poorly starts in war
med up condition
D Engine shutoff faulty
D Insufficient compression in cylinder or more than 3-4 bar pressure difference between the cylinders
Engine does not start or poorly starts in cold condition
D Fuel filter clogged with paraffin D Replace filter.
Rough idle with engine warm, misfires
D Air in fuel system
D Fuel lines leak, broken or clogged D Fuel filter clogged
D Lower idle speed is set too low D Valve clearance not OK D Injectors or injection lines leak D Turbocharger faulty
D Insufficient compression in cylinder or more than 3-4 bar pressure difference between the cylinders
D Help from the manufacturer ser
vice
Faults
Fault Possible cause Remedy
Engine speed fluctua
tions during operation
D Not enough fuel in tank D Air in fuel system D Tachometer faulty D Injectors faulty
Poor performance D Too much power is demanded from the engine than it can produce
D Air in fuel system
D Fuel filter/air filter clogged
D Fuel grade does not meet the regu
lations
D Insufficient fuel supply D Oil level in oil pan too high
D Exhaust pipe clogged D Air intake pipe leaks
D Turbocharger leaks or faulty
D Insufficient compression in cylinder or more than 3-4 bar pressure difference between the cylinders
D Rated speed incorrectly set
D See "Fluids and Lubricants..."
D Fuel feed pump worn or faulty D Check whether the guide tube is
correctly installed and the cor
rect oil dipstick is being used D If coolant or fuel is discovered in
the engine oil, check cylinder head gasket, cylinder liner gas
ket and piston rings
Coolant temperature too high, loss of coolant
D Coolant level too low D Air in coolant circuit
D Radiator very dirty, fins clogged D V-belt for coolant pump not correctly
tightened (slips)
D Cap with work valves on expansion reservoir/radiator is faulty or leaks D Temperature display faulty
D Coolant pump leaks, defective (bearing damage)
D Thermostat faulty, does not open D Coolant lines leak, clogged or twisted Lube-oil pressure too
low
D Oil level in oil pan too low D Engine temperature to high D Oil filter clogged
D Oil pressure indicator faulty
D Selected oil viscosity is inappropriate for ambient temperature (too thin)
D Oil in oil pan is too thin (contains con
densation or fuel) D Bearing heavily worn D Oil pump gears heavily worn
D Safety valve in oil circuit faulty (does not close, spring is worn or broken)
D See "Fluids and Lubricants..."
Faults
74
Carefully read the Operating Instructions before starting any work!
This is especially valid for the chapter on General Safety Instructions and the safety instructions in each of the chapters.
Fault Possible cause Remedy
Lube-oil pressure too high
D Engine cold
D Selected oil viscosity is inappropriate for ambient temperature (too thick)
D Oil pressure indicator faulty
D Safety valve in oil circuit faulty (does not open)
D Oil lines/oil ducts clogged
D See "Fluids and Lubricants..."
Lube-oil consumption too high
D Lube-oil quality does not meet the regu
lations
D Oil level in oil pan too high
D Leaks in lube-oil circuit especially at the turbocharger and oil cooler
D Piston rings heavily worn D Valve stems heavily worn, bent
D See "Fluids and Lubricants..."
D Check whether the guide tube is correctly installed and the cor
rect oil dipstick is being used D If coolant or fuel is discovered in
the engine oil, check cylinder head gasket, cylinder liner gas
ket and piston rings
Fuel consumption too high
D Fuel grade does not meet the regu
lations
D Fuel loss due to leaks in system D Valve seat leaks
D See "Fluids and Lubricants..."
Black smoke accom
panied by loss of power
D Air filter clogged
D Air intake duct leading to turbocharger leaks
D Exhaust clogged (exhaust back pressure too high)
D Turbocharger faulty D Intercooler leaks, faulty D Injectors faulty, carbonised
D Help from the manufacturer ser
vice
Blue smoke D Engine/coolant/intake air still too cold D Lube oil penetrates into combustion
chamber (pistons/piston rings worn or piston rings broken)
D Valve stem/guide worn
D Overpressure in crankcase (crankcase ventilation system clogged)
White smoke D Engine/coolant/intake air still too cold D Fuel tank empty
D Air in fuel system
D Fuel lines leak, broken or clogged D Coolant penetrates into combustion
chamber (cylinder head/gasket leaks) D Fuel filter clogged
D Fuel grade does not meet the regu
lations
D Injectors faulty
D See "Fluids and Lubricants..."
Faults
Fault Possible cause Remedy
Engine knocking D Engine not at correct operating tempe
rature
D Valve clearance not OK D Valves stick
D Piston pin or crankshaft bearing loose D Piston ring broken
D Let engine warm to operating temperature before running at full load
D Check thermostat
Engine too "loud" D Intake or exhaust pipe leaks
D Timing gears worn, gear backlash too large
D Valve clearance too large
D Turbine and compressor impeller in tur
bocharger dirty (rough running, out of balance)
D Poly-V-belt slips
D Help from the manufacturer ser
vice
Faults
76
Carefully read the Operating Instructions before starting any work!
This is especially valid for the chapter on General Safety Instructions and the safety instructions in each of the chapters.
Starter
Fault Possible cause Remedy
(This column is only filled in when it is not clear from the "probable cause"
what needs to be done)
D Pinion gear does not turn or turns slowly
D Pinion gear does not engage
D Pinion gear does not disengage after en
gine starts
D Battery has insufficient charge D Terminal is loose, oxidised, poor
connection to ground
D Starter terminal or carbon brushes are short circuited to ground
D Carbon brushes stick or have poor con
tact
D Pinion gear or starter ring gear are very dirty or damaged
To be repaired by a vehicle elec
trician or by the manufacturer service
D Immediately shut down engine
Decommissioning and Recommissioning
10 Decommissioning and Recommissioning 10.1 Prerequisite
Before starting any work read and observe the General Safety Instructions and the safety information in this chapter.
Strictly observe these instructions and act prudently to avoid accidents, personal injury and property damage.
Personal Protective Equipment
The following protective equipment must be worn:
S Protective Clothing S Safety Shoes S Safety Gloves
10.2 Safety Instructions
Personnel
S Decommissioning and recommissioning of the engine may only be made be trained and qualified per
sonnel.
Ground Rules
WARNING!
Risk of injury caused by improper work.
Improper work can case serious injuries or considerable property damage.
For this reason:
S Ensure that the engine cannot be started be unauthorised persons.
S Perform all work steps in accordance with the instructions in these Operating Instructions.
S Ensure adequate work space before starting any work.
S Make sure work space is kept clean and orderly! Any unused parts or components lying around are potential sources of accidents.
Decommissioning and Recommissioning
78
Carefully read the Operating Instructions before starting any work!
This is especially valid for the chapter on General Safety Instructions and the safety instructions in each of the chapters.