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Troubleshooting

The document provides troubleshooting information for Caterpillar 3512C and 3516C engines, emphasizing the importance of safety precautions during operation, maintenance, and repair. It details the electronic control systems, diagnostic codes, and various troubleshooting procedures for common engine issues. Additionally, it includes a list of required and optional service tools for effective diagnostics and repairs.

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Ahmed Tolba
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229 views188 pages

Troubleshooting

The document provides troubleshooting information for Caterpillar 3512C and 3516C engines, emphasizing the importance of safety precautions during operation, maintenance, and repair. It details the electronic control systems, diagnostic codes, and various troubleshooting procedures for common engine issues. Additionally, it includes a list of required and optional service tools for effective diagnostics and repairs.

Uploaded by

Ahmed Tolba
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF or read online on Scribd
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CATERPILLAR a az Troubleshooting 3512C and 3516C Engines LLB1-Up (Engine) PESt-Up (Engine) Pao) nips Important Safety Information Most accidents that involve product operation, maintenance and repair are caused by failure to observe basic safely rules or precautions. An accident can often be avoided by recognizing potentially hazardous ( situations before an accident occurs. A person must be alert to potential hazards, This person should also have the necessary training, skills and tools fo perform these functions properly. Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result in injury or death. Do not operate or perform any lubrication, maintenance or repair on this product, until you have read and understood the operation, lubrication, maintenance and repair information. Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings. are not heeded, bodily injury or death could occur to you or to other persons. ‘The hazards are identified by the "Safely Alert Symbol" and followed by a “Signal Word" such as “DANGER’, "WARNING" or “CAUTION”. The Safaty Alert ‘WARNING" label is shown below. The meaning of this safety alert symbol is as follows: Attention! Become Alert! Your Safety Is involved, ‘The message that appears under the warning explains the hazard and can be elther written or pictorially presented, Operations that may cause product damage are identified by "NOTICE" labels on the product and in this publication, Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in this publication and on the product are, therefore, not all inclusive. If a tool, procedure, work method or operating technique that is not specifically recommended by Caterpillar 's used, you must satisty yourself that its safe for you and for others. You should also ensure that ( the product will not be damaged or be made unsafe by the operation, lubrication, maintenance or fepair procedures that you choose. The information, specifications, and illustrations in this publication are on the basis of information that was available at the time that the publication was written, The specifications, lorques, pressures, Measurements, adjustments, illustrations, and other items can change al any lime. These changes can affect the service that is given to the product. Obtain the complete and most current informalion before you start any job. Caterpilar dealers have the most current information available WN) When replacement parts are required for this product Caterpillar recommends using Caterpil- lar replacement parts or parts with equivalent specifications including, but not limited to, phys- leal dimensions, type, strength and material. Failure to heed this warning can lead to prema- ture failures, product damage, personal injury or doath, KENR5070-02 Table of Contents Troubleshooting Section Electronic Troubleshooting System Overview 4 Selt-Diagnostics 9 Electrical Connectors and Functions 10 Electronic Service Tools 42 Electronic Display Module : 15 iagnostic Code List 7 Event Code List 24 Programming Parameters Programming Parameters 0.0. 34 Factory Passwords 34 Faclory Passwords Worksheet 31 Flash Programming 32 ‘System Configuration Parameters 33 ‘Customer Parameters Worksheet 37 Replacing the ECM 39 Troubleshooting without a Diagnostic Code Symptoms 42 Air Starling Motor 42 ‘Alternator 43 Can Not Reach Top Engine RPM esceateAd| Coolant in Engine 44 Coolant Temperature is Too Low 45 Coolant Temperature Is Too High 45 Grankcase Pressure (High)... a ECM Will Not Accept Factory Passwords wn 47 ECM Will Not Communicate with Other Systems or Display Modules 48 Electronic Service Tool Will Not Communicate with ECM epeeeieieeetey Engine Cranks but Will Not Start 49 Engine Has Early Wear 51 Engine Misfires, Runs Rough or Is Unstable... 61 Engine Oil in Cooling System .. 52 Engine Overspeed ccvnnnnnnnnnnnnnennn 53 Engine Stalls at Low RPM 53 Engine Will Not Crank... nnn 64 Excessive Engine Oil Consumption . 68 Excessive Black SMOKE vn 56 Excessive White Smoke ‘ 87 Exhaust Temperature Is Too High ecg Fuel Dilution of Engine Oil .....urmnnnnnnnes 58) Fuel Filter Restriction ae 60. Fuel in Coofing System z so 6O igh Altitude Derate :6t Inlet Air Restriction 62 Intermittent Engine Shutdown .. vee 6B Intermittent Low Power or Power Cutout... 64 Low Engine Oil Pressure 65 Low Power/Poor or No Response to Throtlle .... 68 Mechanical Noise (Knock) in Engine ...... 68 Noise Coming from Cylinder u..1smnnnsnnnnnn 68 Poor Futel Consumption onsen 68 ‘Too Much Valve Lash 70 Too Much Vibration onnnnnnnnn TH 3 Table of Contents Valve Rotocoil or Spring Lock Is Free maa} Diagnostic Functional Tests Air Shutoff System ..... 72 Analog Sensor (Active) . 80 ‘Analog Sensor (Passive) . 89 93 sone 98, "400 105 110 CAN Data Link enn nnsnnsnn Cat Data Link wen Direct Fuel Control Mod Electrical Power Supply Emergency Stop Svitch Emergency Stop Switch (Remote). AT Engine Conta! Sich (CS)... "427 Engine Speed/Timing Sensor 135 Injector Solenoids ..... 140 Inspecting Electrical Connectors « 449 Prelubrication System e..nas one 154 Pulse Width Modulated Sensor 160 ‘Sensor SUPPIY rn * 165 Speed Control onnnnenn “474 Starting Motor System". * 175 Calibration Procedures Engine Speed/Timing Sensor - Calibrate... 184 Index Section Index : 186 4 Troubleshooting Section Troubleshooting Section Electronic Troubleshooting sot9901 System Overview SMCS Code: 1901-038; 1924 The engine is designed for electronic control of most engine operating functions. The electronic system consists of the following components: Electronic Control Module (ECM), wiring hamesses, switches, sensors, and electronic unit injectors (EU). Electronic Controls Electronic Control Module ‘The ECM consists of two main components, the control computer (hardware) and the flash file (software). The ECM consists of a microprocessor and electronic circuitry. The flash file is the software for the control computer which contains operating maps that define power and torque curves. The ECM monitors the engine parameters during operation. ‘The ECM supplies signals to the injector solenoids. ‘The ECM governs engine speed. Desired engine speed is determined by the throttle signal and by certain sensor readings. Actual engine speed is supplied to the ECM by the engine speeditiming sensor. Fuel Injection The ECM controls the timing of the engine by varying {he signals to the electronic solenoids that control fuel injection, Fuel is injected only while an injector solenoid Is energized by a 106 volt signal from the ECM. By controling the timing and duration of the 105 volt signal, the ECM controls the fuel injection timing, the quantity of fuel and the desired engine ‘speed. Injection timing depends on desired engine speed, load, and other operational factors. The ECM limits engine power during cold mode ‘operation, The ECM may modify the injection timing and the ECM may cul out certain engine eylinders in ‘cold mode operation. This will increase startabilty ‘and this will reduce warm up time. Cold mode is activated whenever the engine coolant temperature falls below a predetermined value, Cold mode remains active until the engine coolant temperature hhas risen above a set temperature. KENR5070-02 ‘The ECM Is programmed at the factory to limit the quantity of fuel that can be injected. The position of the Fuel Ratio Control (FRC) controls the fuel limit for exhaust smoke. The FRC Is based on the maximum allowable ratio of fuel to air. The FRC fuel position is increased when the ECM senses a higher turbocharger compressor outlet pressure. This will allow more fuel into the oylinder. The rated fuet position is a limit that is based on the engine power raling. This is similar to the rack stops and the torque spring on a mechanically governed engine. The rated fuel positon limits the power curve and the torque curve for a specific engine family Hlustration 4 is a block diagram of the engine's electrical system, KENR5070-02 5 Troubleshooting Section peteroic Senter en ce Sezai |p cuore nga stone one . n Ep Postgres abt et At Teese Seer | Scalp rome Tenens Sse | ‘agho tpecatinng Soar Ancol esse Gait ( ey scar 2] fey ete a re }——}—

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