Troubleshooting Chart - Man D 2866 LUE 605 Repair Manual

1. EDC self-diagnosis or flash code output
2. Starter turns over engine only slowly or not at all
3. Starter turns, engine does not start, engine does not start / difficult to start when cold
4. Engine stalls (dies) during operation, no longer starts (starter turns), engine does not start / starts with difficulty when hot
5. Sudden, temporary engine shut-down, engine does not reach full revs
6. Engine only runs at idle speed, no throttle response
7. Engine only runs at increased idle speed, no throttle response
8. Rated engine speed distinctly reduced (even under no load)
9. Reduced output in all ranges
10. Irregular engine operation, traction loss
11. Unstable idle speed, engine hunting, misfiring, knocking in engine
12. Engine judder
13. Unusual combustion noise
x x
x
x x
x x
x
x
x
x
x
x x
x x
x x x x
x x
o x
x x
x x x x x x x
x = Probable
o = Possible

Troubleshooting chart

14. Excessive smoke emission: White smoke / blue smoke
15. Excessive smoke emission: Black smoke
16. Engine temperature too high (coolant loss)
17. Intermediate engine speed control cannot be activated / does not switch off,
engine revs too high
18. Fuel consumption too high
19. Lubricating oil pressure too low
20. Lubricating oil pressure too high
21. Lubricating oil consumption too high
22. Engine too loud / mechanical noise
Possible causes
Batteries discharged, battery lead connections loose or corroded, break in power
circuit
Crank gear blocked
Starter solenoid switch sticks (clicks) / defective, cable connection loose or dam-
aged
Starter / starter interlock relay defective (carbon brushes worked loose / worn,
winding defective, short to ground)
x x x Engine oil viscosity unsuitable, not suitable for ambient temperature, lubricating
oil quality does not correspond to specifications
x Oil level in sump too high
x Oil level in sump too low, oil in sump too thin (mixed with condensate or fuel)
x Engine temperature too high
x Oil filter clogged
x x Oil pressure gauge faulty
x Safety valve in oil circuit defective (does not close, spring fatigued or broken)
x x Bearing wear
x Oil pump gears worn
x Crankshaft timing gears worn, tooth flank backlash too great
x x Engine cold
x Lubricating oil entering combustion chamber (piston rings worn, piston rings
broken) - valve stem guide worn - overpressure in crankcase (crankcase vent
clogged)
x Relief valve in oil circuit faulty (does not open), oil lines / oil galleries clogged
x Leaks in lubricating oil circuit, particularly at turbocharger and oil cooler
x Piston rings heavily worn, broken
x Piston pin or crankshaft bearing worn
x Valve stems worn
x Valve clearance not correct
Valves jam
Compression deficient, or more than 3-4 bar pressure difference between individ-
ual cylinders
x Valve seats leaking
x Increased power consumption due to faulty secondary consumers such as hy-
draulic pumps, fan, etc, power take-off engaged
x x x Air cleaner soiled or clogged, charge-air system leaking, air inlet / exhaust lines
clogged / leaking
x x Fuel low pressure system: fuel tank, prefilter, water trap faulty / clogged / mould /
fungal attack, fuel unsuitable / heavily contaminated (paraffin added)
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