Fault Diagnosis

Beschnitt Beschnitt
U1_Textwechsler_F.SLM_0297 9742 en_lang
Fault Diagnosis
High-Speed Engines
U1_Titel_FSM_lang
Beschnitt CYAN = HKS 49K MAGENTA = HKS 14K SCHWARZ Beschnitt

Fault Diagnosis
High-Speed Engines
0297 9742
© 05/00
Foreword
Notes on the brochure
The subject brochure is a tool for diagnosing possible sources of faults during engine operation.
The user can select relevant malfunction symptoms and is then guided via a fishbone diagram
(fault source, cause, remedy) in logical order, if possible (simple checks to be carried out first)
to the remedy.
The brochure should be considered to serve as a general tool. Due to design-specific differences
of the engine series and their variants, the procedure may vary for the different engines and
versions.
Electronic components (e.g. ECUs) are for the time being not considered in the fishbone dia-
grams. The notes in the relevant special documentation must be observed in this connection.
Benefits of a methodical fault diagnosis
The benefits of a methodical fault diagnosis for DEUTZ Service and the customer are:
– Long engine repairs and downtimes are avoided.
– Unnecessary parts replacements are excluded.
– Recurrent malfunctions following a repair are avoided.
– Service competence is substantiated towards customers.
Systematic troubleshooting
In principle, there are no objections against spontaneous troubleshooting which, based on

know-how and expertise, may often lead to quick results if the labour input remains within
reasonable limits. However, parts replacements due to incorrect assumptions are time-consum-
ing and expensive. In case of difficult, unknown faults and malfunctions, a systematic
troubleshooting procedure will substantially simplify the job.
The fishbone diagram is so structured that the checks which consume the least time and costs
are performed first. Troubleshooting in the individual construction groups should be conside-
red as a second possibility.
Questions on marginal conditions
Before really entering into the troubleshooting process, as many marginal conditions as pos-
sible should be determined by asking relevant questions, e.g.:
– When did the malfunction occur for the first time (e.g. after servicing, repair, etc.)?
– How often was the malfunction noticed since then (continuously, sporadically)?
– Under what conditions does the malfunction occur (empty battery, in the morning,
full load, etc.)?
– What is the location of the equipment when the fault occurs (operating altitude,
ambient temperature, high dust concentration, etc.)?
© 05/00
Foreword
Further questions should be worked down according to the attached questionnaire so as to

keep the troubleshooting input down and thus minimize time and cost consumption.
Counterquestions may also speed up the cause finding procedure, for example:
– When does the malfunction not occur?
– Under which conditions does the malfunction not occur?
Cause finding
The cause finding process will be the simpler, the more additional information is available. Not
only the fault should be found and remedied as quickly as possible, but also the source having
caused the malfunction should be determined in order to prevent a possible fault recurrence.
Operating media
The use of unsuitable or non-permissible operating media (lube oil, fuel, coolant) affects
reliable engine operation and may lead to failures. It is recommended to first check the used
operating media for conformity with the specification in the operation manual before starting
complex troubleshooting or a costly repair. Initial systematic questioning may considerably
shorten the fault diagnosis, e.g.:
– What is written on the labels of operating media on the engine?
– What does the user say concerning the operating media used?
– Only as a last step should an analysis of the operating medium concerned

be arranged for.
General information
We are aiming at continuously improving and extending the contents of this first edition. In
this connection the experience reported by the users will be appreciated as great help.
Should you request amendments, extensions, improvements, etc., please contact us (Abt.
Instandhaltungstechnik Motoren (Maintenance Technology Engines), VS-TI). Please make
ample use of this possibility. You will thus help that the next edition will be even more up-to-
date. We will careully follow up each feedback and will make available a new edition of
this brochure in due time. We thank you in anticipation of your assistance.
Yours
DEUTZ AG
Maintenance Technology Engines
© 05/00
Table of Contents
Questions on fault localization
Diagnosis chart / cause / effect
Complaint / source of fault
Measuring and test equipment
Checking engine components
Index
© 05/00
6
Questions on
fault localization
© 05/00
Questions on
Table of contents fault localization
1. Questions on fault localization Page
1.1 Complaint __________________________________ 1.01
1.2 Localization of malfunction __________________________________ 1.01
1.3 Cause finding of malfunction __________________________________ 1.01
1.4 Processing the malfunction __________________________________ 1.01
1.5 Questionnaire __________________________________ 1.02 - 1.03
© 05/00
Questions on
Diagnosis Procedure fault localization
1.1 Complaint
General information by user on malfunction
__________________________________________________________________________
1
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
1.2 Localization of malfunction
Specified information by user through systematic questioning by service personnel.
– For listing of questions see pages 1.02 - 1.03.
It is recommended to copy the following pages (1.02 - 1.03) for each malfunction and to enter
the relevant information.
1.3 Cause finding of malfunction
Systematic troubleshooting
Preparing a troubleshooting manual.

Compiling previously observed symptoms and their interrelations.
– Fault/defect on systems
– Fault/defect on components
Analytical evaluation, i.e. logical combination of symptoms and their interrelations.
– Cause of malfunction
1.4 Processing the malfunction
Systematic “Working down“ of checked items to find a remedy.
1.01 © 05/00
Questions on
fault localization 1.5 Questionnaire
Question ▼ Information by user ▼ Other information ▼
1. What type of malfunction

does occur?
1 2. Where does the malfunction

occur?
3. In which function group does

the
malfunction occur?
4. On which part does the

malfunction occur?
5. When did the malfunction occur

for the first time?
6. Did the malfunction occur only

once?
7. Does the malfunction occur

continuously?

sporadically?
9. When does the malfunction

not exist?

under specific circumstances?
11. Under which operating statuses

does the malfunction occur?
12. Under which operating

conditions does the malfunction
occur?
13. At which applications does the

malfunction occur?
14. Under which ambient conditions

does the malfunction occur?
© 05/00 1.02
Questions on
1.5 Questionnaire fault localization
Question ▼ Information by user ▼ Other information ▼
15. Which parts might

probably cause such a
malfunction?
16. What happened directly

before the malfunction?
1
(e.g. was servicing or
repair work carried out?)
17. Was the specified care

and servicing work
carried out?
18. Was the specified

maintenance work
carried out?
19. What was repaired?

(if servicing or repair
work was carried out)
20. Which parts were replaced?
21. Which parts were reused?
22. Might previous servicing

or repair work be related
to the malfunction?
23. Did the engine shut down

trouble-free when operated last?
24. Was the engine damaged

externally?
25. Was the engine improperly

operated?
26. What was observed which might

be related to the malfunction?
Other information:
1.03 © 05/00
Questions on
fault localization
© 05/00
Diagnosis chart /
cause / effect
© 05/00
Diagnosis Chart
Table of Contents Cause / Effect
2. Diagnosis chart / cause / effect Page
Start not in order
1. Engine does not react during starting attempt _____________________________ 2.01
2. Only a “click“ to be heard during starting attempt _________________________ 2.01
3. Engine does not reach starting speed during starting attempt ________________ 2.01
Start in order
4. Engine does not fire or shuts off ________________________________________ 2.02
5. Engine runs unevenly or stalls ________________________________________ 2.02
6. Engine gives poor performance ________________________________________ 2.03
7. Engine does not fire on all cylinders ____________________________________ 2.03
8. Engine knocks / hard engine running ____________________________________ 2.03
9. Engine overheats / temperature monitor gives warning _____________________ 2.04
10. Engine has low or no oil pressure ______________________________________ 2.05
11. Engine oil consumption too high _______________________________________ 2.05
12. Blue smoke ________________________________________ 2.06
13. Black smoke ________________________________________ 2.06
14. White smoke ________________________________________ 2.06
15. Engine jerks / poor stability ________________________________________ 2.07
© 05/00
Fault Diagnosis Diagnosis Chart
High-Speed Engines Cause / Effect
Effect Remedy
1. Engine does not react during starting attempt Page
2. Only a “click“ to be heard during starting attempt Page
3. Engine does not reach starting speed during starting attempt Page
Cause
1.1 Battery master switch not closed 3.01
1.2 Cable connections battery / starter disconnected 3.01
1.3 3.3 Battery discharged / defective 3.01 3.04
1.4 Cable connections starter switch disconnected 3.01 2
1.5 Starter switch defective 3.02
2.1 3.1 Driven machine not decoupled 3.03 3.04
2.2 Magnetic switch defective 3.03
2.3 Starter defective 3.03
2.4 Starter pinion / ring gear damaged 3.03
3.2 Battery capacity too low 3.04
3.4 Voltage drop too high 3.04
3.5 Lube oil level too high 3.05
3.6 Lube oil viscosity not conforming to specification 3.05
2.01 © 05/00
Effect Remedy
4. Engine does not fire or shuts off Page
5. Engine runs unevenly or stalls Page
Cause
4.2 5.1 Fuel quantity / fuel tank empty / position of fuel tank too low 3.06 3.14
4.3 5.2 Fuel tank ventilation clogged / wrong filler cap 3.06 3.14
2 4.4 Fuel shutoff valve (on fuel tank) closed 3.06
4.5 5.3 Fuel quality not conforming to specification 3.07 3.14
4.6 Engine shutdown lever / speed control lever not in starting position 3.07
4.7 5.4 Fuel line damaged /leaky 3.07 3.14
4.8 5.5 Fuel line to supply pump clogged / insufficient cross section 3.07 3.15
4.9 5.6 V-belt of fuel supply pump not tensioned / defective 3.08 3.15
4.10 5.7 Intake air cleaner soiled (service switch defective) 3.08 3.15
4.11 Intake air temperature too low (below starting limit temperature) 3.08
4.12 Starting aid defective 3.08
4.13 5.8 Air in fuel system (gas bubbles at high fuel temperature) 3.09 3.15
4.14 5.9 Fuel filter cartridge / prefilter / strainer clogged 3.09 3.16
4.15 5.10 Fuel pressure holding valve leaky / not existing (supply pressure in fuel gallery too low) 3.09 3.16
4.16 5.11 Fuel supply pump does not deliver 3.09 3.16
4.17 Control rod not in starting position /sluggish 3.10
4.18 Control rod sticking (1011 / 1012 / 1013 / 2013) 3.10
4.19 Shutdown solenoid incorrectly fitted / defective 3.10
4.20 Injection pump resinified (1011 / 1012 / 1013 / 2013) 3.10
4.21 5.12 Toothed belt (1011) defective 3.11 3.16
4.22 5.13 Valve clearance maladjusted 3.11 3.17
4.23 Excess starting fuel release does not release control road 3.11
4.24 Engine governor defective 3.11
5.14 Fault localization on injection system 3.17
4.25 5.15 Injection line(s) leaky / damaged (queezed) 3.12 3.17
4.26 5.16 Injector(s) leaky / dripping / carbonized 3.12 3.17
4.27 5.17 Injection pump(s) / no uniform delivery / incorrect prestroke / commencement of delivery 3.12 3.18
4.28 5.18 In-line injection pump / incorr. commencement of del. (1008 / 912 / 913 / 413 / 513 / 1015) 3.12 3.18
5.19 Roller tappets worn 3.18
4.29 5.20 Injection pump(s) worn 3.13 3.18
4.30 5.21 Pistons / piston rings / liners worn 3.13 3.19
4.30 5.21 Cylinder head gasket / valves leaky 3.13 3.19
© 05/00 2.02
Effect Remedy
6. Engine gives poor performance Page
7. Engine does not fire on all cylinders Page
8. Engine knocks / hard engine running Page
Cause
8.1 Engine overloaded 3.30
8.2 Engine mounting loose / defective / incorrect engine mounting 3.30
6.1 Engine power not adjusted to operating altitude 3.20
6.2 Thermal short-circuit / intake temperature too high 3.20 2
6.3 8.3 Intake air cleaner soiled (service switch defective) 3.20 3.30
6.4 8.4 Dust in intake manifold 3.20 3.30
6.6 Fuel quantity (fuel supply pressure too low 3.21
6.7 Fuel temperature too high 3.21
6.8 Fuel filter cartridge / prefilter / strainer clogged 3.21
6.9 8.5 Fuel quality not conforming to specification 3.22 3.31
6.10 V-belt of fuel supply pump not tensioned / defective 3.22
6.11 8.6 Charge air cooler soiled / leaky 3.22 3.31
6.12 Charge air pressure too low / leakage in system / turbocharger worn 3.22
6.13 Charge air pipe leaky 3.23
6.14 LDA* connecting line leaky / LDA does not release control rod 3.23
6.15 Engine governor / break-away speed (high idling) too low 3.23
6.16 Exhaust manifold / exhaust silencer soiled 3.23
6.17 8.7 Turbocharger soiled / worn / leaky 3.24 3.31
6.18 Injection pump resinified (1011 / 1012 / 1013 / 2013) 3.24
6.19 Control rod sticking (1011 / 1012 / 1013 / 2013) 3.24
6.20 Air in fuel system (gas bubbles at high fuel temperature) 3.24
6.21 Fuel supply pump soiled / worn 3.25
6.22 7.1 8.8 Valve clearance maladjusted 3.25 3.28 3.31
6.24 7.2 8.9 Fault localization on injection system 3.25 3.28 3.32
6.25 7.3 8.10 Injection line(s) leaky / damaged (sqeezed) 3.26 3.28 3.32
6.26 7.4 8.11 Injector(s) leaky / dripping / carbonized 3.26 3.28 3.32
6.27 7.5 8.12 Injection pump(s) / no uniform del. / incorrect prestroke / commencement of del. 3.26 3.29 3.32
6.28 7.6 8.13 In-line injection pump / incorrect commencement of delivery 3.26 3.29 3.33
6.29 7.7 8.14 Injection pump(s) worn 3.27 3.29 3.33
6.30 7.8 8.15 Pistons / piston rings / liners worn 3.27 3.29 3.33
6.30 7.8 8.15 Cylinder head gasket / valve leaky 3.27 3.29 3.33
8.16 Valve gear damaged 3.33
8.17 Big end / main bearing clearance too large 3.34
* LDA = manifold pressure compensator
2.03 © 05/00
Effect Remedy
9. Engine overheats / temperature monitor gives warning Page
Cause
9.1 Engine overloaded 3.35
9.3 Lube oil filter cartridge / oil centrifugal filter soiled 3.35
2 9.4 Coolant level too low 3.35
9.5 Thermal short-circuit / heating up of cooling air 3.36
9.6 Air in cooling system 3.36
9.7 Bleeding pipe from coolant heat exchanger clogged 3.36
9.8 Intake air cleaner soiled (service switch defective) 3.36
9.9 V-belt for coolant pump not tensioned 3.37
9.10 Blower V-belt (912 / 913) not tensioned / monitoring switch defective 3.37
9.11 Cooling fins (912 / 913 / 413 / 513) soiled / clogged 3.37
9.12 Air cowling (912 / 913 / 413 / 513) loose /cracked / missing 3.37
9.13 Hydraulic blower clutch (912 / 913 / 413 / 513) defective 3.38
9.14 Blower (912 / 913 / 413 7 513) worn 3.38
9.15 Coolant pump worn 3.38
9.16 Air in oil suction pipe / pipe clogged 3.38
9.17 Lube oil pump worn / defective 3.39
9.18 Coolant heat exchanger soiled / defective 3.39
9.19 Coolant pipe soiled / clogged 3.39
9.20 Lube oil cooler soiled 3.39
9.21 Charge air cooler soiled / leaky 3.40
9.24 Exhaust thermostat (912/913/413/513) sticking /defective 3.40
9.25 Turbocharger leaky / soiled / worn 3.41
9.26 Temperature sensor / coolant temperature alarm system defective 3.41
9.27 Temperature sensor cylinder head / engine oil / gear oil (912 / 913 / 413 / 513) defective 3.41
9.28 Temperature sensor / solenoid valve (912 / 913 / 413 / 513) defective 3.41
9.29 Coolant thermostat defective 3.42
9.31 Injector(s) defective 3.42
9.32 Pistons / piston rings / liners worn 3.42
9.32 Cylinder head gasket / valves leaky 3.42
© 05/00 2.04
Effect Remedy
10. Engine has low or no oil pressure Page
11. Engine oil consumption too high Page
Cause
11.1 Engine run-in phase not completed 3.46
11.2 Idling operation too long 3.46
11.3 External oil leakages 3.46
11.4 Lube oil level too high 3.46 2
10.1 Lube oil level too low 3.43
10.2 Excessive engine inclination 3.43
10.3 11.5 Lube oil viscosity not conforming to specification 3.43 3.47
11.6 Lube oil quality not conforming to specification 3.47
10.4 Lube oil filter cartridge / lube oil centrifugal filter soiled 3.43
10.5 Lube oil pressure sensor / switch / plug-in connection defective 3.44
10.6 Lube oil pressure relief valve sticking / defective 3.44
10.7 Lube oil cooler soiled / oil flow (oil side) obstructed 3.44
10.8 11.7 Lube oil cooler leaky 3.44 3.47
10.9 Lube oil pipe leaky / clogged 3.45
10.10 Lube oil pump worn / defective 3.45
10.11 Big end and main bearing clearances too large 3.45
11.8 Lube oil in coolant (oil cooler leaky) 3.47
11.9 Crankcase breather clogged / defective (overpressure in crankcase) 3.48
11.10 Oil mist escaping from crankcase breather 3.48
11.11 Oil leakage at hydraulic pump and air compressor drives 3.48
11.12 Turbocharger leaky (ingress of lube oil in intake air) 3.48
11.13 Lube oil in combustion chamber 3.49
11.14 Valve stem seals defective 3.49
11.15 Cylinder head gasket leaky / crack in cylinder head 3.49
11.16 Pistons / piston rings / liners worn 3.49
2.05 © 05/00
Effect Remedy
12. Blue smoke Page
13. Black smoke Page
14. White smoke Page
Cause
12.1 Engine run-in phase not completed 3.50
12.2 Long idling periods 3.50
12.3 Excessive engine inclination 3.50
2 12.4 Lube oil level too high 3.50
12.6 Crankcase breather clogged / defective (overpressure in crankcase) 3.51
12.7 13.8 Turbocharger leaky / soiled / worn 3.51 3.54
12.8 Lube oil in combustion chamber 3.51
12.9 Valve stem seals defective 3.52
12.10 Cylinder head gasket leaky / crack in cylinder head 3.52
12.11 Piston rings incorrectly fitted 3.52
12.12 13.15 14.10 Pistons / piston rings / liners worn 3.52 3.56 3.59
13.15 14.10 Cylinder head gasket / valves leaky 3.56 3.59
13.1 Engine power not adjusted to operating altitude 3.53
13.2 Thermal short-circuit / intake air temperature too high 3.53
13.3 Intake air cleaner soiled (service switch defective) 3.53
13.4 Charge air cooler soiled 3.53
13.6 LDA* is sticking / incorrect fuel charge limiting 3.54
13.9 Valve clearance maladjusted 3.55
13.10 Injection system (fault localization) 3.55
13.11 14.6 Injector(s) leaky / burst 3.55 3.58
13.12 Injection pump(s) / no uniform delivery (1011 / 1012 / 1013 / 2013 ) 3.55
14.7 Injection pump(s) / no uniform del. / commencement of del. retarded 3.58
13.13 In-line injection pump / incorrect commencement of delivery 3.56
14.8 In-line injection pump / commencement of delivery retarded 3.58
13.14 14.9 Injection pump(s) worn 3.56 3.59
14.1 Intake air temperature during cold start too low 3.57
14.2 Flame heater plug system defective (912 / 913 / 413 7 513 / 2013 / 1015) 3.57
14.3 Water content in fuel (condensate in tank) 3.57
14.4 Fuel quality not conforming to specification 3.57
14.5 LDA* setting incorrect (NA-engine based fuel charge too high) 3.58
14.11 Cylinder head / gasket defective (engine “consumes“ coolant) 3.59
* LDA = manifold-pressure compensator
© 05/00 2.06
Effect Remedy
15. Engine jerks / poor stability Page
Cause
15.1 Engine speed too low 3.60
15.2 Engine mounting loose / defective / improper engine mounting 3.60
15.3 Engine block / flywheel housing has contact with frame 3.60
15.4 Coupling / coupling elements loose / defective 3.60 2
15.5 Overall installation (excessive vibrations) 3.61
15.6 Excessive vibrations, fault localization (poor combustion / alignment / imbalance) 3.61
15.7 Poor combustion (e.g. fuel supply pressure too low) 3.61
15.8 Imbalance found 3.61
15.9 Alignment engine / driven machine not conforming to specification 3.62
15.11 Injection system 3.62
15.12 Injector(s) defective 3.62
15.13 Injection pump(s) / no uniform del. / incorrect prestroke / commencement of del. (1011 / 1012 / 1013 / 2013) 3.63
15.14 In-line injection pump /incorrect commencement of delivery (1008 / 912 / 913 / 413 / 513 / 1015) 3.63
15.15 Injection pump(s) worn 3.63
15.16 Engine balancer incorrectly installed / defective 3.63
2.07 © 05/00
Effect Remedy
© 05/00
Complaint / source of fault
© 05/00
Complaints /
Table of Contents Source of Faults
3. Complaint / source of fault Page
Start not in order
1. Engine does not react during starting attempt __________________________ 3.01 - 3.02
1.1 Battery master switch ________________________________________ 3.01
1.2 Battery cable / starter cable ________________________________________ 3.01
1.3 Battery ________________________________________ 3.01
1.4 Starter switch cable connection ______________________________________ 3.01
1.5 Starter switch ________________________________________ 3.02
2. Only a “click“ to be heard during starting attempt ______________________ 3.03

2.1 Use / driven machine ________________________________________ 3.03
2.2 Magnetic switch ________________________________________ 3.03
2.3 Starter ________________________________________ 3.03
2.4 Starter pinion / ring gear ________________________________________ 3.03
3. Engine does not reach starting speed during starting attempt _____________ 3.04 - 3.05
3.1 Use / driven machine ________________________________________ 3.04
3.2 - 4 Battery ________________________________________ 3.04
3.5 Lube oil level ________________________________________ 3.05
3.6 Lube oil viscosity ________________________________________ 3.05
Start in order
4. Engine does not fire or shuts off _____________________________________ 3.06 - 3.13

4.2 Fuel quantity ________________________________________ 3.06
4.3 Fuel tank ventilation ________________________________________ 3.06
4.4 Fuel shutoff valve ________________________________________ 3.06
4.5 Fuel quality ________________________________________ 3.07
4.6 Engine shutdown lever / speed control lever ____________________________ 3.07
4.7 - 8 Fuel line(s) ________________________________________ 3.07
4.9 V-belt for fuel supply pump ________________________________________ 3.08
4.10 Intake air cleaner ________________________________________ 3.08
4.11 Intake air temperature ________________________________________ 3.08
4.12 Starting aid ________________________________________ 3.08
4.13 Fuel system ________________________________________ 3.09
4.14 Fuel filter ________________________________________ 3.09
4.15 Fuel pressure holding valve ________________________________________ 3.09
4.16 Fuel supply pump ________________________________________ 3.09
4.17 - 18 Control rod ________________________________________ 3.10
4.19 Shutdown solenoid ________________________________________ 3.10
4.20 Injection pump(s) ________________________________________ 3.10
4.21 Toothed belt ________________________________________ 3.11
4.22 Valve clearance ________________________________________ 3.11
© 05/00
Complaints /
Source of Faults Table of Contents
Complaint / source of fault Page
4.23 Excess starting fuel release ________________________________________ 3.11

4.24 Engine governor ________________________________________ 3.11
4.25 Injection line(s) ________________________________________ 3.12
4.26 Injector(s) ________________________________________ 3.12
4.27 Injection pump(s) ________________________________________ 3.12
4.28 In-line injection pump ________________________________________ 3.12
4.29 Injection pump(s) ________________________________________ 3.13
4.30 Compression ________________________________________ 3.13
5. Engine runs unevenly or stalls ______________________________________ 3.14 - 3.19

5.1 Fuel quantity ________________________________________ 3.14
5.2 Fuel tank ventilation ________________________________________ 3.14
5.3 Fuel quality ________________________________________ 3.14
5.4 - 5 Fuel line(s) ________________________________________ 3.14 - 3.15
5.8 Fuel system ________________________________________ 3.15
5.9 Fuel filter ________________________________________ 3.16
5.10 Fuel pressure holding valve ________________________________________ 3.16
5.11 Fuel supply pump ________________________________________ 3.16
5.12 Toothed belt ________________________________________ 3.16
5.13 Valve clearance ________________________________________ 3.17
5.14 Injection system ________________________________________ 3.17
5.15 Injection line(s) ________________________________________ 3.17
5.16 Injector(s) ________________________________________ 3.17
5.17 Injection pump(s) ________________________________________ 3.18
5.19 Roller tappets ________________________________________ 3.18
5.20 Injection pump(s) ________________________________________ 3.18
5.21 Compression ________________________________________ 3.19
6. Engine gives poor performance _____________________________________ 3.20 - 3.27

6.1 Operating altitude ________________________________________ 3.20
6.2 Intake air ________________________________________ 3.20
6.4 Intake manifold ________________________________________ 3.20
6.5 Lube oil level ________________________________________ 3.21
6.6 Fuel quantity ________________________________________ 3.21
6.7 Fuel temperature ________________________________________ 3.21
6.8 Fuel filter ________________________________________ 3.21
6.9 Fuel quality ________________________________________ 3.22
6.11 Charge air cooler ________________________________________ 3.22
6.12 Charge air ________________________________________ 3.22
6.13 Charge air pipe ________________________________________ 3.23
6.14 LDA* / LDA line ________________________________________ 3.23
© 05/00
Complaints /
6.15 Engine governor ________________________________________ 3.23

6.16 Exhaust manifold / exhaust silencer ___________________________________ 3.23
6.17 Turbocharger ________________________________________ 3.24
6.18 Injection pump(s) ________________________________________ 3.24
6.19 Control rod ________________________________________ 3.24
6.20 Fuel system ________________________________________ 3.24
6.21 Fuel supply pump ________________________________________ 3.25
6.22 Valve clearance ________________________________________ 3.25
6.24 Engine governor ________________________________________ 3.25
6.25 Injection line(s) ________________________________________ 3.26
6.26 Injector(s) ________________________________________ 3.26
6.27 Injection pump(s) ________________________________________ 3.26
6.29 Injection pump(s) ________________________________________ 3.27
6.30 Compression ________________________________________ 3.27
7. Engine not firing on all cylinders ____________________________________ 3.28 - 3.29

7.1 Valve clearance ________________________________________ 3.28
7.3 Injection line(s) ________________________________________ 3.28
7.4 Injector(s) ________________________________________ 3.28
7.5 Injection pump(s) ________________________________________ 3.29
7.7 Injection pump(s) ________________________________________ 3.29
7.8 Compression ________________________________________ 3.29
8. Engine knocks / hard engine running _________________________________ 3.30 - 3.34

8.1 Engine loading ________________________________________ 3.30
8.2 Engine mounting ________________________________________ 3.30
8.4 Intake manifold ________________________________________ 3.30
8.5 Fuel quality ________________________________________ 3.31
8.7 Turbocharger ________________________________________ 3.31
8.8 Valve clearance ________________________________________ 3.31
8.10 Injection line(s) ________________________________________ 3.32
8.11 Injector(s) ________________________________________ 3.32
8.12 Injection pump(s) ________________________________________ 3.32
8.14 Injection pump(s) ________________________________________ 3.33
8.15 Compression ________________________________________ 3.33
8.16 Valve gear ________________________________________ 3.33
8.17 Bearing clearances ________________________________________ 3.34
© 05/00
Complaints /
9. Engine overheats / temperature monitor gives warning __________________ 3.35 - 3.42

9.1 Engine loading ________________________________________ 3.35
9.2 Lube oil level ________________________________________ 3.35
9.3 Lube oil filter ________________________________________ 3.35
9.4 Coolant level ________________________________________ 3.35
9.5 Heating up of cooling air ________________________________________ 3.36
9.6 Cooling system ________________________________________ 3.36
9.7 Bleeding pipe ________________________________________ 3.36
9.9 V-belt for coolant pump ________________________________________ 3.37
9.10 V-belt / monitor ________________________________________ 3.37
9.11 Cooling fins ________________________________________ 3.37
9.12 Air cowling ________________________________________ 3.37
9.13 Blower clutch ________________________________________ 3.38
9.14 Blower ________________________________________ 3.38
9.15 Coolant pump ________________________________________ 3.38
9.16 Lube oil suction pipe ________________________________________ 3.38
9.17 Lube oil pump ________________________________________ 3.39
9.18 Coolant heat exchanger ________________________________________ 3.39
9.19 Coolant pipe ________________________________________ 3.39
9.20 Lube oil cooler ________________________________________ 3.39
9.22 Charge air pipe ________________________________________ 3.40
9.24 Exhaust thermostat ________________________________________ 3.40
9.25 Turbocharger ________________________________________ 3.41
9.26 - 27 Temperature sensor ________________________________________ 3.41
9.28 Temperature regulator ________________________________________ 3.41
9.29 Thermostat ________________________________________ 3.42
9.30 Engine governor ________________________________________ 3.42
9.31 Injector(s) ________________________________________ 3.42
9.32 Compression ________________________________________ 3.42
10. Engine has low or no oil pressure ____________________________________ 3.43 - 3.45

10.1 Lube oil level ________________________________________ 3.43
10.2 Engine inclination ________________________________________ 3.43
10.4 Lube oil filter ________________________________________ 3.43
10.5 Lube oil pressure sensor ________________________________________ 3.44
10.6 Lube oil pressure relief valve ________________________________________ 3.44
10.7 - 8 Lube oil cooler ________________________________________ 3.44
10.9 Lube oil pipe ________________________________________ 3.45
10.10 Lube oil pump ________________________________________ 3.45
10.11 Bearing clearances ________________________________________ 3.45
© 05/00
Complaints /
11. Engine oil consumption too high _____________________________________ 3.46 - 3.49

11.1 Engine run-in ________________________________________ 3.46
11.2 Engine loading ________________________________________ 3.46
11.3 External condition ________________________________________ 3.46
11.4 Lube oil level ________________________________________ 3.46
11.6 Lube oil quality ________________________________________ 3.47
11.7 - 8 Lube oil cooler ________________________________________ 3.47
11.9 - 10 Crankcase breather ________________________________________ 3.48
11.11 Hydraulic pump / air compressor _____________________________________ 3.48
11.12 Turbocharger ________________________________________ 3.48
11.13 Combustion chamber ________________________________________ 3.49
11.14 Valve guides ________________________________________ 3.49
11.15 Cylinder head ________________________________________ 3.49
11.16 Pistons / cylinders ________________________________________ 3.49
12. Blue smoke ________________________________________ 3.50 - 3.52

12.1 Engine run-in ________________________________________ 3.50
12.2 Engine loading ________________________________________ 3.50
12.3 Engine inclination ________________________________________ 3.50
12.4 Lube oil level ________________________________________ 3.50
12.6 Crankcase breather ________________________________________ 3.51
12.7 Turbocharger ________________________________________ 3.51
12.8 Combustion chamber ________________________________________ 3.51
12.9 Valve guides ________________________________________ 3.52
12.10 Cylinder head ________________________________________ 3.52
12.11 Piston rings ________________________________________ 3.52
12.12 Pistons / cylinders ________________________________________ 3.52
13. Black smoke ________________________________________ 3.53 - 3.56

13.1 Operating altitude ________________________________________ 3.53
13.2 Intake air ________________________________________ 3.53
13.5 Charge air pipe ________________________________________ 3.54
13.6 LDA* / governor ________________________________________ 3.54
13.8 Turbocharger ________________________________________ 3.54
13.9 Valve clearance ________________________________________ 3.55
13.11 Injector(s) ________________________________________ 3.55
13.12 Injection pump(s) ________________________________________ 3.55
13.14 Injection pump(s) ________________________________________ 3.56
13.15 Compression ________________________________________ 3.56
© 05/00
Complaints /
14. White smoke ________________________________________ 3.57 - 3.59

14.1 Intake air temperature ________________________________________ 3.57
14.2 Starting aid ________________________________________ 3.57
14.3 Fuel tank ________________________________________ 3.57
14.4 Fuel quality ________________________________________ 3.57
14.5 LDA* setting ________________________________________ 3.58
14.6 Injector(s) ________________________________________ 3.58
14.7 Injection pump(s) ________________________________________ 3.58
14.9 Injection pump(s) ________________________________________ 3.59
14.10 Compression ________________________________________ 3.59
14.11 Coolant ________________________________________ 3.59
15. Engine jerks / poor stability ________________________________________ 3.60 - 3.63

15.1 Engine speed ________________________________________ 3.60
15.2 - 3 Engine mounting ________________________________________ 3.60
15.4 Coupling ________________________________________ 3.60
15.5 - 6 Overall installation ________________________________________ 3.61
15.7 Combustion ________________________________________ 3.61
15.8 Imbalance ________________________________________ 3.61
15.9 Alignment ________________________________________ 3.62
15.10 Engine governor ________________________________________ 3.62
15.12 Injector(s) ________________________________________ 3.62
15.13 Injection pump(s) ________________________________________ 3.63
15.15 Injection pump(s) ________________________________________ 3.63
15.16 Engine balancer ________________________________________ 3.63
© 05/00
1. Engine does not react Complaint /
during starting attempt Source of Fault
Source of fault Cause Remedy

1.1 Battery master switch Battery charge warning lamp Close master switch.
does not light up;
Master switch not closed.
Action successful
No Yes No Yes
End
1.2 Battery cable / Cable joint disconnected. Check, clean, tighten cable joints,
Starter cable apply pole grease, renew cable if
necessary.
Observe operation manual.

Action successful
No Yes No Yes
End
3
1.3. Battery Battery discharged or defective. Check battery liquid.
Charge battery, renew if
necessary.

Action successful
No Yes No Yes
End
1.4 Starter switch Cable joints disconnected. Check, clean, tighten cable joints,
Cable connections apply pole grease, renew cable if
necessary.

Action successful
No Yes No Yes
End
3.01 © 05/00
Complaint / 1. Engine does not react
Source of Fault during starting attempt

1.5 Starter switch Starter switch defective Check starter switch, replace
if necessary.

Action successful
No Yes No Yes
End
Other cause
Action successful
No Yes No Yes
End
3
Action successful
No Yes No Yes
End
Action successful
No Yes No Yes
End
© 05/00 3.02
2. Only a “click“ to be heard Complaint /
during starting attempt Source of Fault

2.1 Use / Driven machine not decoupled Decouple driven machine
Driven machine (excessive cranking resistance) (if possible).

Action successful
No Yes No Yes
End
2.2 Magnetic switch Starter pinion does not engage. Check magnetic switch, replace
if necessary.
Action successful
No Yes No Yes
End
3
2.3 Starter Starter defective. Check starter, repair if necessary
or replace.

Action successful
No Yes No Yes
End
2.4 Starter pinion / Starter pinion does not engage. Check ring gear and starter pinion,
Ring gear repair if necessary or replace.
Observe workshop manual.

Action successful
No Yes No Yes
End
Other cause
3.03 © 05/00
Complaint / 3. Engine does not reach starting
Source of Fault speed during starting attempt

3.1 Use / Driven machine not decoupled Decouple driven machine
Driven machine (excessive cranking resistance) (if possible)

Action successful
No Yes No Yes
End
3.2 Battery Battery capacity too low. Use battery with sufficient capacity.

Action successful
No Yes No Yes
End
3
3.3 Battery Battery discharged or defective. Check battery fluid. Charge battery,
replace if necessary.

Action successful
No Yes No Yes
End
3.4 Battery Voltage drop towards starter Check voltage, observe supply and
too high. return line.
Action successful
No Yes No Yes
End
© 05/00 3.04
3. Engine does not reach starting Complaint /
speed during starting attempt Source of Fault

3.5 Lube oil level Lube oil level too high. Check oil level, drain oil
if necessary.

Action successful
No
No Yes No Yes
End
3.6 Lube oil viscosity Incorrect lube oil viscosity Fill in lube oil of specified viscosity
(Lube oil too viscous). (Observe SAE class).
Observe operation manual. Observe operation manual.

Action successful
No
No Yes No Yes
End
3
Other cause
Action successful
No Yes No Yes
End
Action successful
No Yes No Yes
End
3.05 © 05/00
Complaint / 4. Engine does not fire
Source of Fault or shuts off

4.1 Lube oil viscosity Incorrect lube oil viscosity Fill in lube oil of specified viscosity
(Lube oil too viscous). (observe SAE class).
Viscosity increase due to
contamined lube oil).

Action successful
No Yes No Yes
End
4.2 Fuel quantity No fuel in tank, fuel level dropped, Check position of fuel tank,
fuel tank is too low. change position if necessary, fill up
fuel tank. Bleed fuel system.

Observe installation manual.
Action successful
No Yes No Yes
End
3
4.3 Fuel tank ventilation Fuel tank ventilation clogged. Ensure free passage of fuel tank
Incorrect filler cap fitted. ventilation, replace filler cap if
necessary.

Action successful
No Yes No Yes
End
4.4 Fuel shutoff valve Fuel shutoff valve closed. Open fuel shutoff valve. Bleed fuel
system.
See page 5.07

Action successful
No Yes No Yes
End
© 05/00 3.06
4. Engine does not fire Complaint /
or shuts off Source of Fault

4.5 Fuel quality Fuel quality does not conform to Fill in commercially available fuel of
fuel specification. specified quality.

Action successful
No Yes No Yes
End
4.6 Engine shutdown lever / Engine shutdown lever / speed Bring engine shutdown lever /
Speed control lever control lever not in start position. speed control lever in operating
position.

Action successful
No Yes No Yes
End
3
4.7 Fuel lines Fuel line(s) damaged or leaky. Seal fuel line(s), replace if
necessary. Bleed fuel system.
See page 5.07

Action successful
No Yes No Yes
End
4.8 Fuel lines Fuel line(s) clogged (cross section Fit line(s) with correct cross
of line to fuel supply pump too section. Bleed fuel system.
small, throttling points existing). See page 5.07

Action successful
No Yes No Yes
End
3.07 © 05/00

4.9 V-belt for Fuel supply quantity / pressure too Adjust V-belt tension, replace V-
fuel supply low (V-belt / toothed V-belt for fuel belt / toothed V-belt if necessary.
pump supply pump not tensioned).

Action successful
No Yes No Yes
End
4.10 Intake air cleaner Intake air cleaner soiled. Clean intake air cleaner, replace if
necessary (check service switch /
indicator, service and replace if
necessary).

Action successful
No Yes No Yes
End
3
4.11 Intake air Intake air temperature too Check intake air temperature, take
temperature low (fallen below starting limit remedy measure if necessary (e.g.
temperature). preheat intake air, preheat lube oil,
use starting aid).

Action successful
No Yes No Yes
End
4.12 Starting aid Starting aid defective: Check starting aid, repair or replace
- Peheating unit if necessary (top up liquid tank of
Engine version- - Flame heater plug ether starting unit if necessary).
dependent - Ether starting unit
- Heating tube
Action successful
No Yes No Yes
End
© 05/00 3.08

4.13 Fuel system Air in fuel system (gas bubbles at Bleed fuel system.
high temperature in fuel system). See page 5.07

Action successful
No Yes No Yes
End
4.14 Fuel filter Fuel filter cartridge, fuel prefilter, Replace fuel filter cartridge, clean
fuel strainer clogged. fuel prefilter, fuel strainer, replace if
See page 5.07

Action successful
No Yes No Yes
End
3
4.15 Fuel pressure Fuel pressure holding valve leaky Check fuel pressure holding valve,
holding valve (fuel supply pressure in fuel gallery replace if necessary and install.
too low). Valve not existing.

Action successful
No Yes No Yes
End
4.16 Fuel supply pump Fuel supply pump does not deliver. Repair fuel supply pump (valves,
diaphragm), replace if necessary.
Bleed fuel system.

Action successful
No Yes No Yes
End
3.09 © 05/00

4.17 Control rod Control rod not in start position. Bring shutdown lever in operating
Control rod moves sluggishly. position. Move control rod by hand
back and forth until it moves easily.

Action successful
No Yes No Yes
End
4.18 Control rod Control rod sticks. Make sure that control rod
moves easily.
1011
1012 / 1013
2013
Action successful
No Yes No Yes
End
3
4.19 Shutdown solenoid Shutdown solenoid defective Check shutdown solenoid, replace
or incorrectly fitted. if necessary.

Action successful
No Yes No Yes
End
4.20 Injection pump(s) Injection pump resinified. Before putting engine into
operation, move control rod by
1011 (Injection pump may resinify hand back and forth until it moves
1012 / 1013 after extended downtime of more easily.
2013 than 6 months).
Action successful
No Yes No Yes
End
© 05/00 3.10

4.21 Toothed belt Toothed belt damaged. Adjust toothed belt tension, replace
toothed belt if necessary.
1011

Action successful
No Yes No Yes
End
4.22 Valve clearance Valve clearance maladjusted. Check valve clearance, adjust
if necessary.

Action successful
No Yes No Yes
End
3
4.23 Excess starting fuel Excess starting fuel release does Check plug-in connections, repair
release not release control rod. if necessary and/or replace excess
starting fuel release.
Action successful
No Yes No Yes
End
4.24 Engine governor Engine governor defective. Have engine governor, checked,
set, replaced if necessary (by Deutz
service partner).

Action successful
No Yes No Yes
End
3.11 © 05/00

4.25 Injection line(s) Injection line(s) leaky (damaged on Remove injection line(s), check and
sealing cone). replace if necessary.
See page 6.02

Fault Action successful
localization successful
No Yes No Yes
End
4.26 Injector(s) Injector(s) leaky, drips, carbonized. Check injector(s), (visual

inspection and test with nozzle
tester), replace if necessary.
See pages 5.03 - 5.04

Action successful
No Yes No Yes
End
3
4.27 Injection pump(s) Injection pump(s) incorrectly set Check uniform delivery, commen-
(no uniform delivery, incorrect cement of delivery and prestroke of
1011 prestroke, incorrect commen- injection pump(s), set if necessary.
1012/1013 cement of delivery). See pages 5.05 . 5.06
2013
Action successful
No Yes No Yes
End
4.28 In-line injection pump Injection pump incorrectly set Check commencement of delivery
(incorrect commencement of of injection pump, set if necessary.
1008 delivery).
912 / 913
413 / 513
1015
Action successful
No Yes No Yes
End
© 05/00 3.12

4.29 Injection pump(s) Injection pump(s) worn. Replace injection pump(s) and set.

Action successful
No
No Yes No Yes
End
4.30 Compression Pistons, piston rings, liners worn, Check compression pressure,
cylinder head gasket, valves leaky. repair or replace liners if necessary,
replace piston rings, pistons,
cylinder head gasket, valves if
necessary.
Action successful
No
No Yes No Yes
End
3
Other cause
Action successful
No Yes No Yes
End
Action successful
No Yes No Yes
End
3.13 © 05/00
Complaint / 5. Engine runs unevenly
Source of Fault or misfires

5.1 Fuel quantity No fuel in tank, fuel level dropped, Check fuel tank, change position
fuel tank is too low. if necessary. Fill up fuel tank, bleed
fuel system.

Action successful
No Yes No Yes
End
5.2 Fuel tank ventilation Fuel tank ventilation clogged. Ensure free passage of fuel tank
Incorrect filler cap fitted. ventilation, renew filler cap if
necessary.

Action successful
No Yes No Yes
End
3
5.3 Fuel quality Fuel quality does not conform to Fill in commercially available fuel
fuel specification. of specified quality.

Action successful
No Yes No Yes
End
5.4 Fuel line(s) Fuel line(s) damaged or leaky. Seal fuel line(s), replace if
See pages 5.05 - 5.06

Action successful
No Yes No Yes
End
© 05/00 3.14
5. Engine runs unevenly Complaint /
or misfires Source of Fault

5.5 Fuel line(s) Fuel line(s) clogged. (Cross section Fit line(s) with correct cross
of line to fuel supply pump too section. Bleed fuel system.
small, throttling points existing). See page 5.07

Action successful
No Yes No Yes
End
5.6 V-belt for Fuel supply quantity / pressure too Adjust V-belt tension, replace V-
fuel supply low (V-belt / toothed V-belt for fuel belt / toothed V-belt if necessary.
pump engine supply pump not tensioned.
series-dependent
Action successful
No Yes No Yes
End
3
necessary. (Check service switch /
indicator, service, replace if
necessary).

Action successful
No Yes No Yes
End
5.8 Fuel system Air in fuel system (gas bubbles at Bleed fuel system.
high temperature in fuel system). See page 5.07

Action successful
No Yes No Yes
End
3.15 © 05/00

5.9 Fuel filter Fuel filter cartridge, fuel prefilter, Replace fuel filter cartridge. Clean
See page 5.07

Action successful
No Yes No Yes
End
5.10 Fuel pressure Fuel pessure holding valve leaky Check fuel pressure holding valve,
holding valve (fuel supply pressure in fuel gallery replace if necessary and reinstall.
too low). Valve not existing.

Action successful
No Yes No Yes
End
3
5.11 Fuel supply pump Fuel supply pump does not deliver. Repair fuel supply pump (valves,
diaphragm), replace if necessary.
Engine series-dependent Bleed fuel system.

Action successful
No Yes No Yes
End
5.12 Toothed belt Toothed belt damaged. Adjust toothed belt tension, replace
toothed belt if necessary.
1011

Action successful
No Yes No Yes
End
© 05/00 3.16

5.13 Valve clearance Valve clearance maladjusted. Check valve clearance, adjust if
necessary.

Action successful
No Yes No Yes
End
5.14 Injection system Possible causes on: Fault localization with stethoscope
- Injection line(s) and/or temperature measurement
- Injector(s) (identification of defective cylinder).
- Injection pump(s) See pages 4.01 - 4.04
Fault Action
localization
successful
successful
No Yes No Yes
Continue on defective cylinder End

3
5.15 Injection line(s) Injection line(s) leaky, damaged on Remove injection line(s), check,
sealing cone. replace if necessary.
See page 5.02

Action successful
No Yes No Yes
End
5.16 Injector(s) Injector(s) leaky, drips, carbonized. Check injector(s) (visual inspection
and test with nozzle tester), replace
if necessary.
See pages 5.03 - 5.04

Action successful
No Yes No Yes
End
3.17 © 05/00

(no uniform delivery, incorrect cement of delivery, and prestroke
1011 prestroke, incorrect commen- of injection pump(s), set if
1012 / 1013 cement of delivery). necessary.
2013 See pages 5.05 - 5.06
Action successful
No Yes No Yes
End
5.18 In-line Injection pump incorrectly set Check commencement of delivery

injection pump (incorrect commencement of of injection pump, set if necessary.
delivery).
1008
912 / 913
413 / 513
1015 Action successful
No Yes No Yes
End
3
5.19 Roller tappets Roller tappets worn. Replace roller tappets.
1011
1012 / 1013
2013
Action successful
No Yes No Yes
End

Action successful
No Yes No Yes
End
© 05/00 3.18

cylinder head gasket, valves leaky. repair or replace liners if necessary,
necessary.
Action successful
No
No Yes No Yes
End
Other cause
Action successful
No Yes No Yes
End
3
Action successful
No Yes No Yes
End
Action successful
No Yes No Yes
End
3.19 © 05/00
Complaint /
Source of Fault 6. Engines gives poor performance

6.1 Operating altitude Operating altitude too high. Check engine power depending
on operating altitude (derate if
necessary).

Action successful
No Yes No Yes
End
6.2 Intake air Thermal short-circuit (intake Remove thermal short-circuit

temperature too high). (reduce intake air temperature).

Action successful
No Yes No Yes
End
3
necessary).
Observe opration manual.

Action successful
No Yes No Yes
End
6.4 Intake manifold Dust in intake manifold. Clean intake manifold, replace if
necessary.
Check compression pressure.

Action successful
No Yes No Yes
End
© 05/00 3.20
Complaint /
6. Engines gives poor performance Source of Fault

6.5 Lube oil level Lube oil level too high. Check lube oil level, drain lube oil if
necessary.

Action successful
No Yes No Yes
End
6.6 Fuel quantity Fuel supply pressure too low Check suction pipe from fuel tank,
(suction pipe from fuel tank , fit pipe with appropriate cross
cross section too small). section, if necessary. Bleed fuel
system.
Action successful
No Yes No Yes
End
3
6.7 Fuel temperature Fuel temperature too high. Check fuel temperature, reduce if
necessary.

Action successful
No Yes No Yes
End
6.8 Fuel filter Fuel filter cartridge, fuel prefilter, Replace fuel filter cartridge, clean
necessary.
See page 5.07

Action successful
No Yes No Yes
End
3.21 © 05/00
Complaint /


Action successful
No Yes No Yes
End
6.10 V-belt for Fuel supply quantity/pressure too Adjust V-belt tension, replace V-
fuel supply pump low (V-belt / toothed V-belt for fuel belt / toothed V-belt if necessary.
supply pump not tensioned).
Engine series-dependent

Action successful
No Yes No Yes
End
3
6.11 Charge air cooler Charge air cooler (air side) soiled. Clean charge air cooler, replace if
Charge air cooler leaky. necessary.

Action successful
No Yes No Yes
End
6.12 Charge air Charge air pressure too low. Eliminate leakages, repair
(system leakage, turbocharger turbocharger, replace if necessary.
worn).

Action successful
No Yes No Yes
End
© 05/00 3.22
Complaint /

6.13 Charge air pipe Charge air pipe leaky. Seal charge air pipe.

Action successful
No Yes No Yes
End
6.14 LDA / LDA line LDA (manifold pressure compen- Seal LDA connecting line, replace
sator) does not release control rod. LDA if necessary.
LDA connecting line leaky.
Action successful
No Yes No Yes
End
3
6.15 Engine governor Break-away speed (high idling) Increase speed (high idling).
too low.
Action successful
No Yes No Yes
End
6.16 Exhaust manifold Exhaust manifold / exhaust silencer Clean exhaust manifold, replace
Exhaust silencer soiled (exhaust backpressure too exhaust silencer if necessary.
high).

Action successful
No Yes No Yes
End
3.23 © 05/00
Complaint /

6.17 Turbocharger Turbocharger soiled or worn. Repair turbocharger, replace if
necessary.

Action successful
No Yes No Yes
End
6.18 Injection pump(s) Injection pump(s) resinified. Before putting engine into
operation, move control rod by
1011 (Injection pump may resinify hand back and forth until it
1012 / 1013 after extended downtime of more moves easily.
2013 than 6 months).
Action successful
No Yes No Yes
End
3
6.19 Control rod Control rod sticks. Ensure that control rod moves
easily.
1011
1012 / 1013
2013
Action successful
No Yes No Yes
End
6.20 Fuel system Air in fuel system (gas bubbles at Eliminate leakages on suction
high temperature in fuel system). pipes. Bleed fuel system.
See page 5.07

Action successful
No Yes No Yes
End
© 05/00 3.24
Complaint /

6.21 Fuel supply pump Fuel supply pump soiled, worn Clean fuel supply pump, repair
(fuel supply pressure too low). (valves, diaphragm), replace if
Engine series-dependent necessary. Install prefilter, bleed
fuel system.

Action successful
No Yes No Yes
End
necessary.

Action successful
No
No Yes No
No Yes
End
3
6.23 Engine governor Engine governor defective. Have engine governor, checked,
set, replaced if necessary (by Deutz
service partner).

Action successful
No
No Yes No
No Yes
End
- Injector(s) (identification of defective cylinder)
Fault Action
successful
No
No Yes No
No Yes
3.25 © 05/00
Complaint /

6.25 Injection line(s) Injection line(s) leaky (damaged on Remove injection line(s), check,
See page 5.02

Action successful
No Yes No Yes
End
6.26 Injector(s) Injector(s) leaky, drips, carbonized. Check injector(s), (visual

See pages 5.03 - 5.04

Action successful
No Yes No Yes
End
3
6.27 Injection pump(s) Injection pump(s) incorrectly Check uniform delivery, commen-
set (no uniform delivery, incorrect cement of delivery, and prestroke
1011 prestroke, incorrect commen- of injection pump(s), set if
1012 / 1013 cement of delivery). necessary.
2013 See pages 5.05 - 5.06
Action successful
No Yes No Yes
End

delivery).
1008
912 / 913
413 / 513
No Yes No Yes
End
© 05/00 3.26
Complaint /


Action successful
No
No Yes No Yes
End
cylinder head gasket, valves leaky. repair liners or replace if necessary,
necessary.
Action successful
No
No Yes No Yes
End
3
Other cause
Action successful
No Yes No Yes
End
Action successful
No Yes No Yes
End
3.27 © 05/00
Complaint / 7. Engines does not fire
Source of Fault on all cylinders

necessary.

Action successful
No Yes No Yes
End
Fault Action
localization
successful
successful
No Yes No Yes

3
7.3 Injection line(s) Injection line(s) leaky (damaged on Remove injection line(s), check,
See page 5.02

Action successful
No Yes No Yes
End
7.4 Injector(s) Injector(s) drips. Check injector(s), (visual

See pages 5.03 - 5.04

Action successful
No Yes No Yes
End
© 05/00 3.28
7. Engines does not fire Complaint /
on all cylinders Source of Fault

7.5 Injection pump(s) Injection pump incorrectly set Check uniform delivery, commen-
(no uniform delivery). cement of delivery and prestroke of
1011 injection pump(s), set if necessary.
1012 / 1013
2013
Action successful
No Yes No Yes
End
7.6 In-line Injection pump incorrectly Check commencement of delivery

injection pump set (incorrect commencement of injection pump, set if necessary.
of delivery).
1008
912 / 913
413 / 513
No Yes No Yes
End
3
7.7 Injection pump(s) Injection pump(s) worn. Replace injection pump(s).

Action successful
No Yes No Yes
End
7.8 Compression Pistons, piston rings, liners worn. Check compression pressure,
Cylinder head gasket, valves leaky. repair or replace liners if necessary,
necessary.
Action successful
No Yes No Yes
End
Other cause
3.29 © 05/00
Complaint / 8. Engine knocks /
Source of Fault hard engine running

8.1 Engine loading Engine overloaded. Reduce engine load.
Action successful
No Yes No Yes
End
8.2 Engine mounting Engine mounting loose or Check engine mounting, tighten
defective. engine mounting elements and
Improper engine mounting. replace if necessary.

Action successful
No Yes No Yes
End
3
necessary).

Action successful
No Yes No Yes
End
8.4 Intake manifold Dust in Intake manifold. Clean intake manifold, replace
if necessary. Check compression
pressure.

Action successful
No Yes No Yes
End
© 05/00 3.30
8. Engine knocks / Complaint /
hard engine running Source of Fault


Action successful
No Yes No Yes
End
8.6 Charge air cooler Charge air cooler (air side) soiled. Clean charge air cooler.

Action successful
No Yes No Yes
End
3
8.7 Turbocharger Turbocharger soiled, leaky or worn. Repair turbocharger, replace if
necessary.

Action successful
No Yes No Yes
End
necessary.

Action successful
No Yes No Yes
End
3.31 © 05/00

F
Fault Action
localization
successful
successful
No Yes No Yes
8.10 Injection line(s) Injection line(s) leaky Remove, check injection line(s) and
(damaged on sealing cone). replace if necessary.
See page 5.02

Action successful
No Yes No Yes
End
3
8.11 Injector(s) Injector(s) drips. Check injector(s), (visual
See pages 5.03 - 5.04

Action successful
No Yes No Yes
End
8.12 Injection pump(s) Injection pump(s) incorrectly set Check uniform delivery,
(no uniform delivery). commencement of delivery and
1011 prestroke of injection pump(s),
1012 / 1013 replace if necessary.
2013
Action successful
No Yes No Yes
End
© 05/00 3.32
8. Engine knocks / Complaint /
hard engine running Source of Fault

delivery).
1008
912 / 913
413 / 513
No Yes No Yes
End

Action successful
No Yes No Yes
End
3
8.15 Compression Pistons, piston rings, liners, worn. Check compression pressure,
Cylinder head gasket, valves leaky. repair liners or replace if
necessary; replace piston rings,
pistons, cylinder head gasket,
valves if necessary.
Action successful
No Yes No Yes
End
8.16 Valve gear Valve gear damaged. Check valve gear, repair if
necessary.

Action successful
No Yes No Yes
End
3.33 © 05/00

8.17 Bearing clearances Clearances of big end and main Replace bearings.
bearings too large.

Action successful
No Yes No Yes
End
Other cause
Action successful
No Yes No Yes
End
3
Action successful
No Yes No Yes
End
Action successful
No Yes No Yes
End
© 05/00 3.34
9. Engine overheats / Complaint /
temperature monitor gives warning Source of Fault

9.1 Engine loading Engine overloaded. Reduce engine load.
Action successful
No Yes No Yes
End
9.2 Lube oil level Lube oil level too high. Check lube oil level, drain lube oil if
necessary.

Action successful
No Yes No Yes
End
3
9.3 Lube oi filter Lube oil filter / oil centrifugal filter Replace lube oil filter cartridge,
soiled. clean oil centrifugal filter, replace
if necessary.

Action successful
No Yes No Yes
End
9.4 Coolant level Coolant level too low. Top up coolant as specified.
Liquid-cooled
engines

Action successful
No Yes No Yes
End
3.35 © 05/00
Complaint / 9. Engine overheats /
Source of Fault temperature monitor gives warning

9.5 Heating up of Thermal short-circuit (heating up of Check cooling air supply and
cooling air cooling air). discharge, correct if necessary.
Avoid cross section restriction.
Eliminate thermal short-circuit.

Action successful
No Yes No Yes
End
9.6 Cooling system Air in cooling system. Bleed cooling system.
Liquid-cooled
engines

Action successful
No Yes No Yes
End
3
9.7 Bleeding pipe Bleeding pipe from coolant heat Check bleeding pipe, restore free
exchanger clogged. passage if necessary.
Liquid-cooled
engines
Action successful
No Yes No Yes
End
9.8 Intake air cleaner Intake air cleaner soiled. Clean air intake cleaner, replace if
necessary).

Action successful
No Yes No Yes
End
© 05/00 3.36

9.9 V-belt for V-belt for coolant pump not Adjust V-belt tension, replace V-
coolant pump tensioned. belt if necessary.
Liquid-cooled
engines
Action successful
No Yes No Yes
End
9.10 V-belt / Blower V-belt not tensioned (V-belt Adjust V-belt tension, replace
monitoring monitoring switch defective). V-belt if necessary (check V-belt
monitoring switch, replace if
912 / 913 necessary).

Action successful
No Yes No Yes
End
3
9.11 Cooling fins Cooling fins on cylinder head and Blow out cooling fins (starting from
liner soiled (clogged). exhaust air side).
912 / 913
413 / 513

Action successful
No Yes No Yes
End
9.12 Air cowling Air cowling loose, cracked or Check air cowling, repair, replace if
missing. necessary.
912 / 913
413 / 513

Action successful
No Yes No Yes
End
3.37 © 05/00

9.13 Blower clutch Hydraulic blower clutch soiled or Clean hydraulic blower clutch,
defective. repair or replace if necessary.
912 / 913
413 / 513
Action successful
No Yes No Yes
End
9.14 Blower Blower worn. Repair blower, replace if necessary.
912 / 913
413 / 513

Action successful
No Yes No Yes
End
3
9.15 Coolant pump Coolant pump worn. Check coolant pump, replace if
necessary.
Liquid-cooled
engines

Action successful
No Yes No Yes
End
9.16 Lube oil Air in oil suction pipe, Check pipe for free passage,
suction pipe pipe clogged. replace if necessary, bleed
lubrication system.

Action successful
No Yes No Yes
End
© 05/00 3.38

9.17 Lube oil pump Lube oil pump worn. Check lube oil pump, replace
if necessary.

Action successful
No Yes No Yes
End
9.18 Coolant Coolant heat exchanger worn Clean coolant heat exchanger,
heat exchanger or defective. replace if necessary.
Liquid-cooled
engines
Action successful
No Yes No Yes
End
3
9.19 Coolant pipe Cooling pipe soiled or clogged. Clean coolant pipe, replace
if necessary.
Action successful
No Yes No Yes
End
9.20 Lube oil cooler Lube oil cooler soiled. Clean lube oil cooler, replace
if necessary.

Action successful
No Yes No Yes
End
3.39 © 05/00

9.21 Charge air cooler Charge air cooler soiled. Clean charge air cooler.

Action successful
No Yes No Yes
End
9.22 Charge air pipe Charge air pipe leaky. Seal charge air pipe.

Action successful
No Yes No Yes
End
3
9.23 Exhaust manifold / Exhaust manifold / exhaust silencer Clean exhaust manifold / exhaust
Exhaust silencer soiled (exhaust backpressure too silencer, replace if necessary.
high).

Action successful
No Yes No Yes
End
9.24 Exhaust thermostat Exhaust thermostat sticks / Replace exhaust thermostat if

defective. necessary.
912 / 913
413 / 513

Action successful
No Yes No Yes
End
© 05/00 3.40

9.25 Turbocharger Turbocharger leaky, soiled or Repair turbocharger, replace
defective. if necessary.

Action successful
No Yes No Yes
End
9.26 Temperature sensor Coolant temperature warning Check coolant temperature sensor /
system defective. temperature indicator, replace if
Liquid-cooled necessary.
engines

Action successful
No Yes No Yes
End
3
9.27 Temperature sensor Temperature sensor (cylinder head / Check temperature sensor, replace
engine oil / gear oil) defective. if necessary.
912 / 913
413 / 513

Action successful
No Yes No Yes
End
9.28 Temperature controller Electronic temperature controller or Replace if necessary electronic

solenoid valve defective. temperature controller / solenoid
912 / 913 valve.
413 / 513

Action successful
No Yes No Yes
End
3.41 © 05/00

9.29 Thermostat Coolant thermostat defective. Replace coolant thermostat.
Liquid-cooled
engines
Action successful
No Yes No Yes
End
9.30 Engine governor Engine governor defective (releases Have engine governor, checked, set
excessive fuel). and replaced if necessary (by Deutz
service partner).

Action successful
No Yes No Yes
End
3
9.31 Injector(s) Injector(s) defective. Check injector(s) (visual inspection
and test on nozzle tester), replace if
necessary.
See pages 5.03 - 5.04

Action successful
No Yes No Yes
End
Cylinder head gasket, valves leaky. repair liners or replace if necessary,
necessary.
Action successful
No Yes No Yes
End
Other cause
© 05/00 3.42
10. Engine has low or Complaint /
now oil pressure Source of Fault

10.1 Lube oil level Lube oil level too low (lube oil Check lube oil level, top up lube oil
pressure warning system has if necessary.
responded ).

Action successful
No Yes No Yes
End
10.2 Engine inclination Engine inclination excessive. Check engine inclination, correct if
necessary.
Observe engine pocket book.

Action successful
No Yes No Yes
End
3
10.3 Lube oil viscosity Incorrect lube oil viscosity. Fill in lube oil of specified viscosity
(Observe SAE class).

Action successful
No Yes No Yes
End
10.4 Lube oil filter Lube oil filter / oil centrifugal filter Replace lube oil filter cartridge,
soiled. clean oil centrifugal filter, replace if
necessary.

Action successful
No Yes No Yes
End
3.43 © 05/00
Complaint / 10. Engine has low or
Source of Fault now oil pressure

10.5 Lube oil Lube oil pressure sensor / switch Replace lube oil pressure sensor /
pressure sensor defective. Electric plug-in connection switch, replace plug-in connections
defective. if necessary.

Action successful
No Yes No Yes
End
10.6 Lube oil Lube oil pressure relief valve soiled Clean lube oil pressure relief valve,
pressure relief valve or jammed. replace if necessary.

Action successful
No Yes No Yes
End
3
10.7 Lube oil cooler Lube oil cooler soiled (oil side), Clean lube oil cooler, replace
flow in cooler obstructed. if necessary.

Action successful
No Yes No Yes
End
10.8 Lube oil cooler Lube oil cooler leaky. Seal lube oil cooler, replace
if necessary.

Action successful
No Yes No Yes
End
© 05/00 3.44
10. Engine has low or Complaint /
now oil pressure Source of Fault

10.9 Lube oil pipe Pipe clogged, leaky. Check connections for leakage,
check pipe for free passage,
replace if necessary.

Action successful
No
No Yes No Yes
End
10.10 Lube oil pump Lube oil pump worn or defective. Repair lube oil pump, replace
if necessary.

Action successful
No
No Yes No Yes
End
3
10.11 Bearing clearances Clearances of big end and main Replace bearings (repair engine).
bearings too large.

Action successful
No
No Yes No Yes
End
Other cause
Action successful
No Yes No Yes
End
3.45 © 05/00
Complaint / 11. Engine oil consumption
Source of Fault too high

11.1 Engine run-in Engine not sufficiently run in. Let engine run in (run-in phase
is completed after around 200
operating hours).

Action successful
No Yes No Yes
End
11.2 Engine loading Engine is mainly operated at Avoid long idling periods.
low load.

Action successful
No Yes No Yes
End
3
11.3 External condition External oil leakages (e.g. radial Seal off oil leakages.
shaft seal).

Action successful
No Yes No Yes
End
11.4 Lube oil level Lube oil level too high. Check lube oil level, drain lube
oil if necessary.

Action successful
No Yes No Yes
End
© 05/00 3.46
11. Engine oil consumption Complaint /
too high Source of Fault

(observe SAE class).

Action successful
No Yes No Yes
End
11.6 Lube oil quality Incorrect lube oil quality. Fill in lube oil of specified quality
(observe API or ACEA classification).

Action successful
No Yes No Yes
End
3
11.7 Lube oil cooler Lube oil cooler leaky. Replace lube oil cooler.

Action successful
No Yes No Yes
End
11.8 Lube oil cooler Lube oil in coolant Check lube oil cooler, replace
(lube oil cooler leaky). if necessary.

Action successful
No Yes No Yes
End
3.47 © 05/00
Complaint / 11. Engine oil consumption
Source of Fault too high

11.9 Crankcase Crankcase breather squeezed, Restore free passage of crankcase
breather clogged or defective (overpressure breather, replace if necessary.
in crankcase).

Action successful
No Yes No Yes
End
11.10 Crankcase Heavy oil mist discharge from Check piston rings, liners, repair
breather crankcase breather. engine or replace if necessary.

Action successful
No Yes No Yes
End
3
11.11 Hydraulic pump / Lube oil leakage at PTO for Replace shaft seal at engine drive
Air compressor hydraulic pump or air compressor. end if necessary.

Action successful
No Yes No Yes
End
11.12 Turbocharger Turbocharger leaky (lube oil can Repair turbocharger, replace
escape via exchaust pipe unburnt if necessary.
or enters intake air).

Action successful
No Yes No Yes
End
© 05/00 3.48
11. Engine oil consumption Complaint /
too high Source of Fault

11.13 Combustion chamber Lube oil in combustion chamber Fault localization by visual
(blue smoke). inspection or gauging of parts.

Fault Action
localization
successful
successful
No Yes No Yes
11.14 Valve guides Valve stem seals defective. Replace valve stem seals.

Action successful
No Yes No Yes
End
3
11.15 Cylinder head Cylinder head gasket defective or Replace cylinder head gasket,
crack in cylinder head. repair cylinder head or replace if
necessary.

Action successful
No Yes No Yes
End
11.16 Pistons / cylinders Pistons, piston rings or liners Replace pistons, piston rings or
worn. liners, repair engine or replace if
necessary.

Action successful
No Yes No Yes
End
Other cause
3.49 © 05/00
Complaint /
Source of Fault 12. Blue smoke

12.1 Engine run-in Engine not sufficiently run in. Let engine run in (run-in phase
is completed after around 200
operating hours).

Action successful
No Yes No Yes
End
12.2 Engine loading Engine is mainly operated at Avoid long idling periods.
low load.
Action successful
No Yes No Yes
End
3
12.3 Engine inclination Engine inclination excessive. Check engine inclination, correct
if necessary.

Action successful
No Yes No Yes
End
12.4 Lube oil level Lube oil level too high. Check lube oil level, drain lube oil
if necessary.

Action successful
No Yes No Yes
End
© 05/00 3.50
Complaint /
12. Blue smoke Source of Fault

(observe SAE class).

Action successful
No Yes No Yes
End
12.6 Crankcase Crankcase breather squeezed, Restore free passage of crankcase

breather clogged or defective (overpressure breather, replace if necessary.
in crankcase).

Action successful
No
No Yes No
No Yes
End
3
12.7 Turbocharger Turbocharger leaky, soiled or Repair turbocharger, replace
worn. (Lube oil can escape unburnt if necessary.
via exhaust manifold or enters the
intake air).

Action successful
No
No Yes No
No Yes
End
12.8 Combustion chamber Lube oil in combustion chamber. Fault localization by visual
inspection or gauging of parts.

Fault Action
successful
No
No Yes No
No Yes
3.51 © 05/00
Complaint /
Source of Fault 12. Blue smoke

12.9 Valve guides Valve stem seals defective. Replace valve stem seals.

Action successful
No Yes No Yes
End
12.10 Cylinder head Cylinder head gasket leaky or crack Replace cylinder head gasket,
in cylinder head. repair cylinder head or replace if
necessary.

Action successful
No Yes No Yes
End
3
12.11 Piston rings Piston rings incorrectly fitted. Check pistons, piston rings or
liners, repair engine or replace if
necessary.

Action successful
No Yes No Yes
End
12.12 Pistons / cylinders Pistons, piston rings or liners Replace pistons, piston rings or
worn. liners, repair engine or replace if
necessary.

Action successful
No Yes No Yes
End
Other cause
© 05/00 3.52
Complaint /
13. Black smoke Source of Fault

13.1 Operating altitude Operating altitude too high. Check engine power depending
on operating altitude (derate if
necessary).

Action successful
No Yes No Yes
End
13.2 Intake air Thermal short-circuit (intake air Eliminate thermal short-circuit
temperature too high). (reduce intake air temperature).

Action successful
No Yes No Yes
End
3
necessary).

Action successful
No Yes No Yes
End
13.4 Charge air cooler Charge air cooler soiled. Clean charge air cooler.

Action successful
No Yes No Yes
End
3.53 © 05/00
Complaint /
Source of Fault 13. Black smoke

13.5 Charge air pipe Charge air pipe leaky. Reseal charge air pipe.

Action successful
No Yes No Yes
End
13.6 LDA / governor LDA (manifold pressure compen- Limit NA engine-based fuel charge,
sator) sticks (acceleration smoke check LDA, replace if necessary.
puff due to incorrect fuel charge
limiting).
Observe service bulletin.
Action successful
No Yes No Yes
End
3
13.7 Exhaust manifold / Exhaust manifold / exhaust silencer Clean exhaust manifold, replace
Exhaust silencer soiled (exhaust backpressure too exhaust silencer if necessary.
high).

Action successful
No Yes No Yes
End
13.8 Turbocharger Turbocharger leaky, soiled or worn. Clean turbocharger, repair, replace
if necessary.

Action successful
No Yes No Yes
End
© 05/00 3.54
Complaint /
13. Black smoke Source of Fault

13.9 Valve clearance Valve clearance maladjusted. Check valve clearance, adjust
if necessary.

Action successful
No Yes No Yes
End
- Injector(s) and/or temperature measurement
- Injection pump(s) (identification of defective cylinder)
See pages 4.01 - 4.04
Fault Action
localization
successful
successful
No Yes No Yes

3
13.11 Injector(s) Injector(s) leaky, burst. Check injector(s) (visual inspection
and test with nozzle tester), replace
if necessary.
See pages 5.03 - 5.04

Action successful
No Yes No Yes
End
1012 / 1013 See pages 5.05 - 5.06
2013
Action successful
No Yes No Yes
End
3.55 © 05/00
Complaint /
Source of Fault 13. Black smoke

delivery)
1008
912 / 913
413 / 513
No Yes No Yes
End

Action successful
No Yes No Yes
End
3
necessary.
Action successful
No Yes No Yes
End
Other cause
Action successful
No Yes No Yes
End
© 05/00 3.56
Complaint /
14. White smoke Source of Fault

14.1 Intake air temperature Low intake air temperature during Run engine up to service
cold start. temperature at medium speeds
and alternating load.
Action successful
No Yes No Yes
End
14.2 Starting aid Flame heater plug defective Check flame heater plug, repair or
(afterburning) replace if necessary.
912 / 913
413 / 513
2013
1015
Action successful
No Yes No Yes
End
3
14.3 Fuel tank Water content in fuel too high (e.g. Fill in commercially available fuel of
condensate in fuel tank). specified quality.

Action successful
No Yes No Yes
End
14.4 Fuel quality Fuel quality does not conform to Fill in commercially available fuel
fuel specification. of specified quality.

Action successful
No Yes No Yes
End
3.57 © 05/00
Complaint /
Source of Fault 14. White smoke

14.5 LDA setting LDA setting incorrect (NA engine- Check governor / LDA, set, repair
based fuel charge too high). or replace if necessary.

Observe service bulletin.
Action successful
No Yes No Yes
End
14.6 Injector(s) Injector(s) leaky, burst. Check injector(s) (visual inspection

and test with nozzle teser), replace
if necessary.
See pages 5.03 - 5.04

Action successful
No Yes No Yes
End
3
(no uniform delivery, commencement of delivery and prestroke of
1011 cement of delivery retarded). injection pump(s), set if necessary.
1012 / 1013
2013
Action successful
No Yes No Yes
End

injection pump (commencement of delivery of injection pump, set if necessary.
retarded).
1008
912 / 913
413 / 513
No Yes No Yes
End
© 05/00 3.58
Complaint /
14. White smoke Source of Fault


Action successful
No
No Yes No Yes
End
necessary.
Action successful
No
No Yes No Yes
End
3
14.11 Coolant Crankcase, cylinder head, Repair or replace engine.
cylinder head gasket defective
(engine “consumes“ coolant).

Action successful
No
No Yes No Yes
End
Other cause
Action successful
No Yes No Yes
End
3.59 © 05/00
Complaint / 15. Engine jerks /
Source of Fault poor stability

15.1 Engine speed Engine speed too low. Increase speed (reduce power
requirement, decouple driven
machine if necessary).

Action successful
No Yes No Yes
End
15.2 Engine mounting Engine mounting loose or Carry out visual inspection, tighten
defective. Improper engine engine mounting elements, replace
mounting. if necessary.

Action successful
No Yes No Yes
End
3
15.3 Engine mounting Engine block / flywheel housing Carry out visual inspection, modify
has contact with frame. engine mounting if necessary.

Action successful
No Yes No Yes
End
15.4 Coupling Coupling / coupling elements loose Carry out visual inspection,
or defective. tighten coupling / coupling
elements, replace if necessary.

Action successful
No Yes No Yes
End
© 05/00 3.60
15. Engine jerks / Complaint /
poor stability Source of Fault

15.5 Overall installation Vibrations (subjective) too high. Determine vibration values by
measurement (e.g. DIN 6280 /
VDI 2063) and trace cause.
Values
Actionwithin
successful
limits
No Yes No Yes
Conduct order analysis End
15.6 Overall installation Fault possibilities due to: Fault localization through order
- Poor combustion analysis.
- Alignment
- Imbalance
Fault Action
localization
successful
successful
No Yes No Yes
Continue tracing cause End

3
15.7 Combustion Poor combustion, e.g. fuel supply Determine cause of poor or non-
pressure too low (increased uniform combustion, eliminate if
vibration of 0.5th order noticed, i.e. necessary, e.g. increase fuel supply
1 vibration per 2 revolutions). pressure.
Action successful
No Yes No Yes
End
15.8 Imbalance Imbalance noticed Determine cause of imbalance,

(increased vibration of 1st order, eliminate imbalance if necessary.
i.e. 1 vibration per revolution).
Action successful
No Yes No Yes
End
3.61 © 05/00
Complaint / 15. Engine jerks /
Source of Fault poor stability

15.9 Alignment Incorrect alignment engine / driven Check alignment engine / driven
machine (increased vibration of 1st machine, realign if necessary.
order noticed, i.e. 1 vibration per
revolution).

Action successful
No Yes No Yes
End
15.10 Engine governor Engine governor defective. Check engine governor and
optimize, replace if necessary.

Action successful
No Yes No Yes
End
3
- Injector(s) (identification of defective cylinder)
(mostly results in vibration
of 0.5th order).
Fault Action
localization
successful
successful
No Yes No Yes
15.12 Injector(s) Injector(s) defective. Check injector(s), (visual

See pages 5.03 - 5.04

Action successful
No Yes No Yes
End
© 05/00 3.62
15. Engine jerks / Complaint /
poor stability Source of Fault

1012 / 1013 See pages 5.05 - 5.06
2013
Action successful
No Yes No Yes
End

delivery).
1008
912 / 913
413 / 513
No Yes No Yes
End
3

Action successful
No Yes No Yes
End
15.16 Engine balancer Engine balancer incorrectly Check engine balancer, repair or
installed or defective. replace if necessary.
(Four-cylinder)
912 / 913
1012
2013
Action successful
No Yes No Yes
End
Other cause
3.63 © 05/00
Complaint /
Source of Fault
Action successful
No Yes No Yes
End
Action successful
No Yes No Yes
End
3
Action successful
No Yes No Yes
End
Action successful
No Yes No Yes
End
© 05/00
Measuring and test equipment
© 05/00
Table of Contents Measuring and Test Equipment
4. Measuring and test equipment Page
4.1 Checking with stethoscope __________________________________ 4.01
4.2 Stethoscope - use and procedure __________________________________ 4.02
4.3 Electronic testing with engine tester __________________________________ 4.02
4.4 Checking with infrared hand thermometer ________________________________ 4.03
4.5 Infrared hand thermometers - use __________________________________ 4.04
© 05/00
Stethoscope Measuring and Test Equipment
4.1 Checking with stethoscope
The stethoscope is a simple but effective “sounding device“ for assessing and localizing mechanical damage
on mobile parts of engines and equipment.
Accoustic signals are transmitted to the ear from the steel prod via a diaphragm and a plastic hose.
Mechanical damage or defects can thus be localized on the relevant components and systematically
defined.
The stethoscope is obtainable under order No. 8122 from M/s Wilbär, D-42826 Remscheid, Postfach 140580,
Fax 02101 - 81092.
4
4.01 © 05/00
Stethoscope /
Measuring and Test Equipment Engine Tester
4.2 Stethoscope - Use and procedure
● To diagnose possible mechanical defects in the injection system, it is necessary that the
engine runs at low idle speed and has reached service temperature, if possible. A fault diag-
nosis under load or at high idling is very difficult to perform with the stethoscope as the hissing
noise of the properly firing cylinders overlaps that of the defective cylinder.
● Engine runs in steady state at low idling.
● Position stethoscope with the prod at the upper end of the injection line (just before the rubber
socket to the rocker cover).
● Listen to all cylinders several times on the injection lines. A noise that differs from the noise
characteristics of the other cylinders indicates the incorrectly firing cylinder.
4 ©
4.3 Electronic testing with engine tester
A fault diagnosis with an electronic engine tester for diesel engines is in the development and testing stage.
With the application of ultra-modern technology a fault can be diagnosed on highest technical standard, e.g.
compression test, preheating time measurement, engine smooth-running characteristics, commencement
of delivery, pressure characteristics of injector, uniform delivery of injection pump, etc.
You will be informed in due time.
© 05/00 4.02
Infrared-
Hand Thermometer Measuring and Test Equipment
4.4 Checking with infrared hand thermometer
The infrared hand thermometer is a simple means for contactless temperature measurement in the field of
diagnostics and helps to notice and localize faults and defects on engines and equipment.
The infrared hand thermometer is obtainable in the following version:
– Standard model with laser sighting unit,
– Acoustic and visual limit value alarms,
– Measured-value memory,
– Mean-value and temperature difference computation
– Temperature range: -32 ... 500 °C
The infrared hand thermometer is obtainable against order No. 8121 from M/s Wilbär, D-42826 Remscheid,
Postfach 140580, Fax 02191-81092.
1 Laser (only model with Laser sight unit)

2 Recessed ocular
3 Battery
4 Battery chamber lock
5 Key (on / off)
6 LCD display
7 Eyelet attachment
4.03 © 05/00
Infrared-
Measuring and Test Equipment Hand Thermometer
4.5 Infrared hand thermometer - use
With the infrared hand thermometer temperatures can be easily measured,with the surface temperatures of
the object to be measured being sensed through heat radiation without touching the object. Owing to the
deviating surface condition of the parts to be measured, absolute temperature values can only be condition-
ally measured. The system primarily serves to ascertain comparative temperatures.
The device is very easy to use. Focusing, calibrating or a special training are not necessary.
Thanks to the short measuring time and convenient measuring from a distance, it is also possible to sense non-
accessible or live parts. The contactless measurement prevents any soiling and damage.
© 05/00 4.04
Checking engine components
© 05/00
Injection System Checking Engine Components
5.1 Notes on damage prevention on injection system
Contaminated diesel fuel frequently causes problems in the injection system , on injection pumps and injectors.
It is therefore advisable to take relevant preventive action.
– Install a water separator in the fuel system.
– Clean the environment of the fuel filter before changing it.
– Make sure that only genuine DEUTZ filters with the correct filter efficiency are mounted.
– Mount the new filter (it is recommended to install a fuel hand feed pump). Wet the gasket with
pure diesel fuel.
– Never fill the new filter with diesel fuel before mounting as dirt particles may penetrate while
doing this.
– If possible, refill the fuel tank at the end of a working day. You will thus prevent any whirled up
dirt particles from being drawn in by the fuel pump.
– Adhere precisely to all service intervals, as specified in the operation manual. An absolutely
clean and water-free fuel system extends the lifetime of injection pumps and injectors.
5.01 © 05/00
Checking Engine Components Injection System
5.2 Checking the injection line
● Disassemble rocker covers.
● Remove injection line.
● Visually inspect injection line for bending, damage or squeezing.
okay not okay
Attention !
As the injection line (with 1012 / 1013 / 2013 series) must always be renewed after having been disassembled,
it is reasonable to remove the injector as well and check it prior to reassembly (see pages 5.03 - 5.04).
© 05/00 5.02
Injector Checking Engine Components
5.3 Checking the injector
Check in accordance with the workshop manual whether atomization, spray pattern, injection pressure and
buzzing characteristics are in order.
A malfunction may be caused, for instance, by a sticking nozzle needle or carbonized nozzle cone.
5.03 © 05/00
Checking Engine Components Injector
5.4 Repairing / fitting the injector
In accordance with the workshop manual:
● Repair and set the injector.
● Install injector with new seal.
● Mount new injection line (1012 / 1013 / 2013 series).
5.5 Test run
Thereafter start engine and let it run at low idling in steady state condition. Once again listen to all cylinders
positioning the stethoscope on the injection lines. If the fault has been remedied, there should be no more
difference in noise between the individual cylinders.
In accordance with the workshop manual:
● Mount rocker cover with new gasket.
If the difference in noise continues to exist, check the injection pump (1012/1013/2013: see pages 505-506).
© 05/00 5.04
Injection pump Checking Engine Components
5.6 Checking the injection pump (1012 / 1013 / 2013)
If no fault, defect or damage could be traced on the injection line and injector, it must be checked whether
uniform delivery of the injection pump is correctly set. If uniform delivery of the injection pump is in order,
the injection pump is to be tested on an injection pump test bench and replaced if necessary. It must be stated
here that damage to the injection pump is very rare; this may be the case as a result of poor fuel filtration in
the fuel system or wear of the engine after many operating hours.
5.7 Checking uniform delivery (1012 / 1013 / 2013)
● To find out whether uniform delivery was correctly set, a line marking has to be applied before
loosening the injection pump.
● For setting uniform delivery see workshop manual, chapter 4:

Press control rod in stop position (using special tool 100 830).
5
Set uniform delivery (using wrench 8117).
If after this setting the applied marking coincides again, uniform delivery was in order. If not, this may have
been the cause.
5.05 © 05/00
Checking Engine Components Injection Pump
5.8 Checking plunger and barrel assemblies (1012 / 1013 / 2013)
We sometimes think that we know the cause of an engine malfunction from previous experience. We then
project this experience to the present situation. This would mean in our case that the mechanic removes
the injection line in the field to check whether the injection pump is in order and delivers the required fuel.
In this connection the experience gathered with injection pumps with constant-pressure valve is inappro-
priately projected.
Both systems are equivalent in their function, but have different pressure relief valves. Upon actuation of the
starter the injection pump with delivery valve injects the fuel intermittently at high pressure. With the
same procedure on the injection pump with constant-pressure valve the fuel only wells out of the delivery
valve. The mechanic will then draw the wrong conclusion that the injection pump is worn and needs to be
replaced. Injection pump wear can thus only be evidenced on an appropriate injection pump test bench.
© 05/00 5.06
Kraftstoffsystem Checking Engine Components
5.9 Bleeding the fuel system
As it frequently happens that wrong conclusions are drawn when carrying out service work on the fuel system,
we describe in the following the method for “bleeding the fuel system“, which has been tried and tested in the
field (see operation manual).
Bleeding of the fuel system is required in case of recommissioning, service work or completely drained fuel
tank.
● Move engine governor to stop position.
● Loosen bleed screw, if any, on fuel pre-

filter.
● Loosen pressure holding valve on engine.
● Bleed with hand feed pump until bubble-

free fuel escapes on the prefilter (stand-
ard equipment on 912 / 913 series.
An optional assembly kit is available for
other series).
● Start engine, with due consideration of

the specified starting period, until bubble-
free fuel escapes at the pressure holding
valve (tighten pressure holding valve).
With this method the bleeding time is considerably

reduced. © 5
Series 1012 / 1013 / 2013
Note !
Catch any escaping fuel and dispose of in accordance with anti-pollution regulations.
5.07 © 05/00
Checking Engine Components
© 05/00
Index
© 05/00
Fault Diagnosis
High-Speed Engines Index
Keyword Page
A
Air compressor _____________________________________ 3.48
Air cowling ________________________________________ 3.37
Alignment _________________________________________ 3.62
B
Battery ____________________________________________ 3.01 / 3.04
Battery cable _______________________________________ 3.01
Battery master switch ________________________________ 3.01
Bearing clearances __________________________________ 3.34 / 3.45
Black smoke _______________________________________ 2.06 / 3.53 - 3.56
Bleeding pipe _______________________________________ 3.36
Blower ____________________________________________ 3.38
Blower clutch _______________________________________ 3.38
Blue smoke ________________________________________ 2.06 / 3.50 - 3.52
C
Charge air _________________________________________ 3.22
Charge air cooler ____________________________________ 3.22 / 3.31 / 3.40 / 3.53
Charge air pipe _____________________________________ 3.23 / 3.40 / 3.53
Combustion ________________________________________ 3.61
Combustion chamber ________________________________ 3.49 / 3.51
Compression _______________________________________ 3.13 / 3.19 / 3.27 / 3.29 / 3.33 / 3.42 / 3.56 / 3.59
Control rod ________________________________________ 3.10 / 3.24
Coolant ___________________________________________ 3.59
Coolant heat exchanger _______________________________ 3.39
Coolant level _______________________________________ 3.35
Coolant pipe _______________________________________ 3.39
Coolant pump ______________________________________ 3.38
Cooling fins ________________________________________ 3.37
Cooling system _____________________________________ 3.36
Coupling __________________________________________ 3.6
Crankcase breather __________________________________ 3.48 / 3.51
Cylinder ___________________________________________ 3.49 / 3.52
Cylinder head _______________________________________ 3.49 / 3.52
6.01 © 05/00
6
Fault Diagnosis
Index High-Speed Engines
Keyword Page
D
Diagnosis chart(s) ___________________________________ 2.01 - 2.07
Driven machine _____________________________________ 3.03 / 3.04
E
Engine balancer _____________________________________ 3.63
Engine components __________________________________ 5.01 - 5.07
Engine governor ____________________________________ 3.11 / 3.23 / 3.25 / 3.42 / 3.62
Engine inclination ___________________________________ 3.43 / 3.50
Engine loading ______________________________________ 3.30 / 3.35 / 3.46 / 3.50
Engine mounting ____________________________________ 3.30 / 3.60
Engine run-in _______________________________________ 3.46 / 3.50
Engine shutdown lever _______________________________ 3.07
Engine speed _______________________________________ 3.6
Excess starting fuel release ____________________________ 3.11
Exhaust manifold ____________________________________ 3.23 / 3.40 / 3.54
Exhaust silencer ____________________________________ 3.23 / 3.40 / 3.54
Exhaust thermostat __________________________________ 3.4
External condition ___________________________________ 3.46
F
Fuel filter __________________________________________ 3.09 / 3.16 / 3.21
Fuel filter cartridge ___________________________________ 3.09 / 3.16 / 3.21
Fuel line(s) _________________________________________ 3.07 / 3.14 / 3.15
Fuel prefilter _______________________________________ 3.09 / 3.16 / 3.21
Fuel pressure holding valve ____________________________ 3.09 / 3.16
Fuel quality ________________________________________ 3.07 / 3.14 / 3.22 / 3.31 / 3.57
Fuel quantity _______________________________________ 3.06 / 3.14 / 3.21
Fuel shutoff valve ____________________________________ 3.06
Fuel strainer ________________________________________ 3.09 / 3.16 / 3.21
Fuel supply pump ___________________________________ 3.09 / 3.16 / 3.25
Fuel system ________________________________________ 3.09 / 3.15 / 3.24 / 5.07
Fuel tank __________________________________________ 3.57
Fuel tank ventilation __________________________________ 3.06 / 3.14
Fuel temperature ____________________________________ 3.21
© 05/00 6.02
6
Fault Diagnosis
Keyword Page
H
Heating up of cooling air ______________________________ 3.36
Hydraulic pump _____________________________________ 3.48
I
Imbalance _________________________________________ 3.61
In-line injection pump ________________________________ 3.12 / 3.18 / 3.26 / 3.29 / 3.33 / 3.56 / 3.58 / 3.63
Infrared hand thermometer ____________________________ 4.03 / 4.04
Injection line(s) _____________________________________ 3.12 / 3.17 / 3.26 / 3.28 / 3.32 / 5.02
Injection pump(s) ___________________________________ 3.10 / 3.12 / 3.13 / 3.18 / 3.24 / 3.26 / 3.27 / 3.29 /
3.32 / 3.33 / 3.55 / 3.56 / 3.58 / 3.59 / 3.63
Injection system ____________________________________ 3.17 / 3.25 / 3.28 / 3.32 / 3.55 / 3.62 / 5.01
Injector(s) _________________________________________ 3.12 / 3.17 / 3.26 / 3.28 / 3.32 / 3.42 / 3.55 / 3.58 /
3.62 / 5.03 / 5.04
Intake air __________________________________________ 3.20 / 3.53
Intake air cleaner ____________________________________ 3.08 / 3.15 / 3.20 / 3.30 / 3.36 / 3.53
Intake air temperature ________________________________ 3.08 / 3.57
Intake manifold _____________________________________ 3.20 / 3.30
L
LDA (manifold pressure compensator) / LDA line ___________ 3.23
LDA / governor _____________________________________ 3.54
LDA setting ________________________________________ 3.58
Lube oil cooler ______________________________________ 3.39 / 3.44 / 3.47
Lube oil filter _______________________________________ 3.35 / 3.43
Lube oil level _______________________________________ 3.05 / 3.21 / 3.35 / 3.43 / 3.46 / 3.50
Lube oil pipe _______________________________________ 3.45
Lube oil pressure relief valve ___________________________ 3.44
Lube oil pressure sensor ______________________________ 3.44
Lube oil pump ______________________________________ 3.39 / 3.45
Lube oil quality _____________________________________ 3.47
Lube oil suction pipe _________________________________ 3.38
Lube oil viscosity ____________________________________ 3.05 / 3.06 / 3.43 / 3.47 / 3.51
M
Magnetic switch ____________________________________ 3.03
Measuring equipment ________________________________ 4.01 - 4.04
6.03 © 05/00
6
Fault Diagnosis
Index High-Speed Engines
Keyword Page
O
Oil consumption ____________________________________ 2.05 / 3.47 - 3.49
Oil pressure ________________________________________ 2.05 / 3.43 - 3.45
Operating altitude ___________________________________ 3.20 / 3.53
Overall installation ___________________________________ 3.61
P
Piston ____________________________________________ 3.49 / 3.52
Piston rings ________________________________________ 3.52
Plunger-and-barrel assemblies _________________________ 5.06
Power loss _________________________________________ 2.03 / 3.20 - 3.27
Q
Questions on fault localization __________________________ 1.01 - 1.03
R
Ring gear __________________________________________ 3.03
Roller tappet _______________________________________ 3.18
S
Service switch ______________________________________ 3.08 / 3.15 / 3.20 / 3.30 / 3.36 / 3.53
Shutdown solenoid __________________________________ 3.1
Speed control lever __________________________________ 3.07
Stability ___________________________________________ 2.07 / 3.60 - 3.63
Starter ____________________________________________ 3.03
Starter cable _______________________________________ 3.01
Starter pinion _______________________________________ 3.03
Starter switch ______________________________________ 3.02
Starter switch cable connection _________________________ 3.01
Starting aid ________________________________________ 3.08 / 3.57
Starting attempt _____________________________________ 2.01 / 3.01 - 3.03
Starting speed ______________________________________ 2.01 / 3.04 - 3.05
Stethoscope ________________________________________ 4.01 / 4.02
© 05/00 6.04
6
Fault Diagnosis
Keyword Page
T
Temperature controller _______________________________ 3.41
Temperature sensor __________________________________ 3.41
Temperature warning system __________________________ 2.04 / 3.35 - 3.42
Test equipment _____________________________________ 4.01 - 4.04
Test run ___________________________________________ 5.04
Thermostat ________________________________________ 3.42
Toothed belt ________________________________________ 3.11 / 3.16
Turbocharger _______________________________________ 3.24 / 3.31 / 3.41 / 3.48 / 3.51 / 3.54
U
Uniform delivery ____________________________________ 5.05
Use ______________________________________________ 3.03 / 3.04
V
V-belt for coolant pump _______________________________ 3.37
V-belt for fuel supply pump ____________________________ 3.08 / 3.15 / 3.22
V-belt monitoring switch ______________________________ 3.37
Valve clearance _____________________________________ 3.11 / 3.17 / 3.25 / 3.28 / 3.31 / 3.55
Valve gear _________________________________________ 3.33
Valve guides _______________________________________ 3.49 / 3.52
W
White smoke _______________________________________ 2.06 / 3.57 - 3.59
6.05 © 05/00
6
Beschnitt U4_Imp_A4_eps_0297 9742 en Beschnitt
DEUTZ AG
Service-Technik
Maintenance Technology Engines
Deutz-Mülheimer Str. 147-149
D-51057 Köln
Telefon: 02 21-8 22-0
Fax: 02 21-8 22-53 58
http: //www.deutz.de
Printed in Germany
All rights reserved
1st Edition, © 05/00
Knowing it’s DEUTZ. Order No.: 0297 9742 en
Beschnitt MAGENTA = HKS 14K SCHWARZ Beschnitt

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Notes on the brochure

Benefits of a methodical fault diagnosis

– Long engine repairs and downtimes are avoided.

– Unnecessary parts replacements are excluded.

– Recurrent malfunctions following a repair are avoided.

– Service competence is substantiated towards customers.

In principle, there are no objections against spontaneous troubleshooting which, based on

Questions on marginal conditions

Further questions should be worked down according to the attached questionnaire so as to

– When does the malfunction not occur?

– Under which conditions does the malfunction not occur?

– What is written on the labels of operating media on the engine?

– Only as a last step should an analysis of the operating medium concerned

Maintenance Technology Engines

Questions on fault localization

Diagnosis chart / cause / effect

Complaint / source of fault

Measuring and test equipment

Checking engine components

1. Questions on fault localization Page

1.1 Complaint __________________________________ 1.01

1.2 Localization of malfunction __________________________________ 1.01

1.3 Cause finding of malfunction __________________________________ 1.01

1.4 Processing the malfunction __________________________________ 1.01

1.5 Questionnaire __________________________________ 1.02 - 1.03

General information by user on malfunction

1.2 Localization of malfunction

Specified information by user through systematic questioning by service personnel.

– For listing of questions see pages 1.02 - 1.03.

1.3 Cause finding of malfunction

Preparing a troubleshooting manual.

Analytical evaluation, i.e. logical combination of symptoms and their interrelations.

1.4 Processing the malfunction

Systematic “Working down“ of checked items to find a remedy.

Question ▼ Information by user ▼ Other information ▼

1. What type of malfunction

1 2. Where does the malfunction

3. In which function group does

4. On which part does the

5. When did the malfunction occur

6. Did the malfunction occur only

7. Does the malfunction occur

8. Does the malfunction occur

9. When does the malfunction

10. Does the malfunction occur

11. Under which operating statuses

12. Under which operating

13. At which applications does the

14. Under which ambient conditions

Question ▼ Information by user ▼ Other information ▼

15. Which parts might

16. What happened directly

17. Was the specified care

18. Was the specified

19. What was repaired?

20. Which parts were replaced?

21. Which parts were reused?

22. Might previous servicing

23. Did the engine shut down

24. Was the engine damaged

25. Was the engine improperly