Man D 2840 LE 301, Repair Manual

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Troubleshooting table
12
1. Starter turns over engine only slowly or not at all
2. Starter turns, engine does not start, engine does not start / difficult to start when cold
3. Engine stalls (dies) during operation, no longer starts (starter turns),
engine does not start / starts with difficulty when hot
4. Sudden, temporary engine shutdown, engine does not reach full revs
5. Engine only runs at idle speed, no throttle response
6. Engine only runs at increased idle speed, no throttle response
7. Rated engine speed distinctly reduced (even under no load)
8. Reduced output in all ranges
9. Irregular engine operation, traction loss
10. Unstable idle speed, engine hunting, misfiring, knocking in engine
11. Engine judder
12. Unusual combustion noise
13. Excessive smoke emission: White smoke / blue smoke
14. Excessive smoke emission: Black smoke
15. Engine temperature too high (coolant loss)
16. Intermediate speed control cannot be activated / does not switch off;
engine running at an excessively high speed
17. Fuel consumption too high
18. Lubricating oil pressure too low
19. Lubricating oil pressure too high
20. Lubricating oil consumption too high
21. Engine too “loud” / mechanical noise
Possible causes
x x Batteries discharged, battery lead connections loose or corroded,
break in power circuit
x Crank gear blocked
x x Starter solenoid switch sticks (clicks) / defective, cable connection loose or
damaged
x x Starter / starter interlock relay defective (carbon brushes worked loose / worn,
winding defective, short to ground)
x x x x Engine oil viscosity unsuitable, not suitable for ambient temperature, lubricating oil
quality does not correspond to specifications
x 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 defective
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 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 defective (does not open), oil lines / oil galleries clogged
x Leaks in lubricating oil circuit, particularly at turbocharger and oil cooler
x x Piston rings heavily worn, broken
x x Piston pin or crankshaft bearing loose
x Valve stems worn, bent
x x x Valve clearance not correct
x x Valves jam
x x x x Compression deficient, or more than 3 − 4 bar pressure difference between individual
cylinders
x x x Valve seats leaking
o x x Increased power intake due to defective secondary consumers such as
hydraulic pumps, fan etc., power take-off engaged
x x x x x Air cleaner soiled or clogged, turbo air system leaking,
air inlet / exhaust line clogged / leaking
x x x x x x x x x Fuel low pressure system: Fuel tank, prefilter, water trap faulty / clogged / mould / fungal
attack, fuel unsuitable / contaminated (paraffin added)
x x x x x x x x Fuel low pressure system: Fuel lines leaking, broken, clogged