Troubleshooting chart x = Probable o = Possible 27 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 elevated 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 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 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 elevated 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 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 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 elevated 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 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 6. Engine only runs at idle speed, no throttle response 7. Engine only runs at elevated 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 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 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 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 10. Irregular engine operation, traction loss 11. Unstable idle speed, engine hunting, misfiring, knocking in engine 12. Engine judder 13. Unusual combustion noise 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 12. Engine judder 13. Unusual combustion noise 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 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 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 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 20. Lubricating oil pressure too high 21. Lubricating oil consumption too high 22. Engine too loud / mechanical noise Possible causes 22. Engine too loud / mechanical noise Possible causes x x x x x x x Fuel low pressure system:
Air in system (turn on ignition when bleeding system) x x x x x x x x x Fuel low pressure system: Fuel pump, overflow valve, main filter x x x x x o x x Fuel high pressure system: Jets defective / clogged / leaking / coked x x x x o Fuel high pressure system: Pressure lines – constriction, cavitation, leaking x x o x x x x o Fuel high pressure system: Injection pump worn/set incorrectly o x o o Fuel high pressure system: Injection pump constant-pressure control valve / return flow restrictor defective x x x o x Safty relay defective, drive faulty o o o x o x x x Injection pump-engine allocation:
Start of delivery incorrect (basic installation), start of delivery set incorrectly x x x x o x o Injection pump–controller: Stiff movement-fuel delivery controller (control deviation) x x x x o Control rod position transducer in controller: Connection lines, break, short-circuit o o o Control rod position transducer in controller: Set incorrectly x x o Control rod position transducer in controller: Capacitance reserve of wiring harness too low (e.g. water penetrated wiring harness) x o x o o Injection pump: Delivery set incorrectly / uniform delivery, lower idle speed set too low x o x x x x Delivery actuating solenoid in controller:
Connection lines, break, short–circuit, or CAN–Bus x x x x x o Drive stage selection defective: Connection lines, break, short-circuit x EDC rpm sensor faulty, implausible with auxiliary rpm sensor, line fault x o EDC rpm sensor, polarity reversed x EDC rpm sensor faulty, implausible with auxiliary rpm sensor, line fault x x x x o o o o EDC detects incorrect engine speed (interference signal on rpm sensor line) x x x x o Both rpm sensors faulty, line fault x x x EDC boost pressure sensor:
faulty, incorrect, implausible with atmospheric pres- sure sensor, line fault x x o x Exhaust turbocharger leaking or faulty x Turbine and compressor rotor in turbocharger dirty (out-of-balance, irregular run- ning) x Intercooler leaking, faulty x x Flame starting system defective x o x x o x EDC coolant temperature sensor: faulty, line fault x x x EDC charge-air temperature sensor: faulty, line fault o x x Radiator dirty or cooling system failure (temperatures too high) x Coolant level too low, air in coolant circuit x V-belt for water pump drive not tensioned correctly x Incorrect V-belt tension