undefined(SEBP1573 - 08) - Código SMCSPage 1 of 33 Cerrar SIS Pantalla anterior Producto: GEN SET ENGINE Modelo: 3516 GEN SET ENGINE 73Z Configuración: undefined Pruebas y Ajustes 3500 Generator Set Engines Número de medio -SENR2362-01 Fecha de publicación -01/07/2002 Fecha de actualización -15/07/2002 i01659906 Troubleshooting SMCS - 1000 Introduction Troubleshooting can be difficult. The following pages contain a list of possible problems. In order to make a repair to a problem, refer to the cause and the correction of the problem. The list on the following pages will provide the following information: z Known problems z Probable causes of known problems z Repairs in order to correct known problems Normally, additional repair work is needed beyond the recommendation in the list. Remember that a problem is not normally caused by only one part. The problem's cause can be related to problems with other parts. This list does not include all possible problems and corrections. The service technician must find the problem and the problem's source. After the problem's source is determined, the service technician can make the necessary repairs. Note: A CD-ROM based system contains additional advanced diagnostics. Contact your local Caterpillar dealer for a subscription. Troubleshooting Problem List 1. The Engine Crankshaft Will Not Turn When The Start Switch Is On. 2. The Engine Will Not Start. The Governor Terminal Shaft Does Not Move. 3. The Engine Will Not Start. The Governor Terminal Shaft Moves. https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisw... 23/06/2006 undefined(SEBP1573 - 08) - Código SMCS Page 2 of 33 4. The Engine Overspeeds On Start-Up. 5. The Engine Speed Does Not Have Stability. 6. The Engine High Idle Speed Is Too Low. 7. The Engine's High Idle Declines After Start-Up. 8. The Engine Cannot Be Shutdown Through The Governor. 9. The Engine Is Misfiring Or The Engine Is Running Rough. 10. The Engine Stalls At Low RPM. 11. The Engine Does Not Have Enough Power. 12. The Engine Has Too Much Vibration. 13. The Engine Has A Loud Combustion Noise (Knock). 14. The Engine Has A Valve Train Noise (Clicking). 15. The Engine Has A Loud Valve Train Noise. 16. Engine Oil Is In The Cooling System. 17. Fuel Is In The Coolant. 18. The Engine Has A Mechanical Noise (Knock). 19. Fuel Consumption Is Too High. 20. Little Valve Lash Or No Valve Lash Is Present. 21. Too Much Valve Lash Is Present. 22. The Valve Rotocoil Is Free Or Spring Lock Is Free. 23. Engine Oil Is At The Exhaust. 24. The Engine Has Early Wear. 25. Coolant Is In The Engine Oil. 26. Too Much Black Smoke Or Gray Smoke Is Present. 27. Too Much White Smoke Or Blue Smoke Is Present. 28. The Engine Oil Pressure Is Low. https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisw... 23/06/2006 undefined(SEBP1573 - 08) - Código SMCS Page 3 of 33 29. The Engine Oil Pressure Is High. 30. The Engine Uses Too Much Lubrication Oil. 31. The Engine Crankcase Pressure Is Too High. 32. The Engine Coolant Temperature Is Too High. 33. The Exhaust Temperature Is Too High. 34. The Engine Oil Temperature Is Too High. 35. The Air Inlet Temperature Is Too High. 36. The Air Starting Motor Does Not Turn. 37. The Air Starting Motor Turns Slowly Or The Air Starting Motor Has A Loss Of Power. 38. The Air Starting Motor Runs And The Pinion Engages. After The Pinion Engages, The Air Starting Motor Does Not Turn The Flywheel. 39. The Air Starting Motor Pinion Does Not Engage Correctly With The Flywheel. 40. The Air Starting Motor Pinion Does Not Disengage Correctly From The Flywheel. 41. The Electric Starting Motor Does Not Turn. 42. The Alternator Provides No Charge. 43. The Alternator Charge Rate Is Low Or The Alternator Charge Rate Is Not Regular. 44. The Alternator Charge Rate Is Too High. 45. The Alternator Has Noise. Troubleshooting Problems Problem 1 The Engine Crankshaft Will Not Turn When The Start Switch Is On. Probable Cause 1. Problem With The Air Starting Motor Refer to "Problem 35" through "Problem 40". 2. Problem With The Electric Starting Motor https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisw... 23/06/2006 Possible internal problems include the following conditions: { Bearing seizure { Piston seizure { Valve and piston contact Problem 2 The Engine Will Not Start. Inspect the cylinders for fluid while the crankshaft is being turned. Low Oil Pressure In The Governor The governor oil pump relief valve may be stuck in the open position or the valve may be leaking. Check for plugged oil supply passages from the engine. The Governor Terminal Shaft Moves. Make a repair or a replacement of the faulty accessory. 3. If the engine is not equipped with the manual valves. Probable Cause 1.. When the oil is hot the governor does not develop the oil pressure that is needed to move the linkage. Fluid in the Cylinders Open the manual valves (Kiene valves) that measure cylinder pressure on each cylinder. Air Compressor. Problem With Accessory Equipment (Hydraulic Pumps.jsp?returnurl=/sisweb/sisw. Refer to 3161 Governor Service Manual. 23/06/2006 . Too Much Binding In Control Linkage The engine can start when the engine is cold. An Internal Problem Prevents The Turning Of The Engine Crankshaft. etc) Disconnect the driven equipment until the faulty accessory can be found. inspect the engine for other internal problems. 5.. 2. The Governor Terminal Shaft Does Not Move. remove the cylinder pressure relief valve or the plug. If the crankshaft remains unable to be turned.undefined(SEBP1573 . Probable Cause https://sis.08) . the engine must be disassembled. Problem 3 The Engine Will Not Start. SENR3028.com/sisweb/sisweb/techdoc/techdoc_print_page. Check the linkage effort and correct the linkage effort. After disassembling the engine.cat. 4.Código SMCS Page 4 of 33 Refer to "Problem 41". This may be corrected by disassembly and cleaning of the governor. No Fuel To Fuel Injectors Check the fuel level in the fuel tank and fill the fuel tank. The Air Inlet Shutoff Valve Is Tripped.undefined(SEBP1573 . the minimum fuel pressure from the fuel transfer pump must be 415 kPa (60 psi). Fuel lines that are blocked should be cleaned and fuel lines that are broken should be replaced. Install new fuel filters. Refer to Testing And Adjusting.com/sisweb/sisweb/techdoc/techdoc_print_page. inspect the fuel system for air in the fuel system. Reset the air inlet shutoff valve. Slow Cranking Speed Refer to "Problem 37". 23/06/2006 . Low Quality Fuel Or Water In Fuel Remove the fuel from the fuel tank. as needed. Ensure that the governor linkage is correctly engaged. 4. "Fuel Injector Timing".. This condition can exist after a governor has been assembled incorrectly during an overhaul.Código SMCS Page 5 of 33 1. Make replacements.cat. Use the priming pump in order to remove any air from the fuel system. Low Fuel Pressure At starting rpm. Fuel Control Linkage Inspect the fuel control linkage for one or more of the following conditions: { Incorrect assembly after overhaul https://sis. 6. if necessary. If the fuel pressure is still low. if necessary. change the fuel filters. If the fuel pressure is less than 415 kPa (60 psi). 2. Check the fuel transfer pump for damage and/or wear. Problem 4 The Engine Overspeeds On Start-Up.08) . 5. The governor linkage is not connected to the internal rack linkage. check the fuel bypass valve and the fuel transfer pump for correct operation. Probable Cause 1. Put a good grade of clean fuel in the fuel tank. Install new fuel filters.. Wrong Fuel Injection Timing Make adjustment to timing. 3. After changing the fuel filters.jsp?returnurl=/sisweb/sisw. 23/06/2006 . Rough Governor Drive Worn splines and/or high gear clearances can cause rough governor drive. 6.08) . 2. remove the governor and install the governor again in order to ensure that the engine is engaged correctly with the governor drive.com/sisweb/sisweb/techdoc/techdoc_print_page. 4.undefined(SEBP1573 . Bound Linkage Or Worn Linkage With Flat Spots And High Clearances Inspect the linkage. Seized Injector Replace the injector. SENR3028.cat. Probable Cause 1. Inspect parts and replace parts whenever this is necessary. Also. Ensure that the governor is driven by the engine. Governor Problem Refer to 3161 Governor Service Manual.jsp?returnurl=/sisweb/sisw.. Governor Problem Refer to 3161 Governor Service Manual. check for drive components in the governor and the engine that are worn or damaged. 3. 5. The Governor Actuator Is Not Engaged In The Drive Coupling. Seized Piston And/Or Stuck Piston Rings Replace piston assembly and cylinder liner. If necessary.Código SMCS { Bound fuel control linkage { Bound fuel control linkage in FUEL-ON position { Governor output lever to control housing lever out of adjustment Page 6 of 33 Make adjustment or repair. Repair the linkage or replace the linkage. SENR3028. https://sis.. Problem 5 The Engine Speed Does Not Have Stability. as needed. 3. 2. Engine Misfiring Refer to "Problem 9". Problem 7 The Engine's High Idle Declines After Start-Up.08) . Refer to 3161 Governor Service Manual. Probable Cause 1. check the engine fuel setting in order to ensure that the engine fuel setting is correct. SENR3028. The 3161 has an internal adjustable speed droop which is set at the factory. 23/06/2006 .. Check the speed control linkage and the pneumatic controls for restrictions. Incorrect High Idle Adjustment If necessary. Problem 8 The Engine Cannot Be Shutdown Through The Governor. Loss Of Normal RPM The Loss of approximately 20 rpm can be expected as the engine warms to operating temperature. Faulty Shut Down Solenoid https://sis. Incorrect High Idle Adjustment The governor speed setting shaft is against the high idle stop and the high idle is too low. If adjustment is necessary.undefined(SEBP1573 .. Also. 3.com/sisweb/sisweb/techdoc/techdoc_print_page. make an adjustment in order to correct high idle. Adjustable Speed Droop Is Incorrect. carry out repairs or replacement.Código SMCS Page 7 of 33 Problem 6 The Engine High Idle Speed Is Too Low.jsp?returnurl=/sisweb/sisw. check the engine fuel setting in order to ensure that the engine fuel setting is correct. 2. refer to 3161 Governor Service Manual. Probable Cause 1. Probable Cause 1. If necessary. 2. SENR3028. The Speed Setting Control Shaft Is Not Against The High Idle Stop.cat. Also. The Speed Setting Solenoid Adjustment of the Woodward PGEV Governor is not correct. 4. Make adjustment to correct high idle. Low Fuel Pressure The fuel pressure at the outlet of the fuel filter housing must be a minimum of 450 kPa (65 psi) at 900 rpm. Incorrect Installation Of Governor Actuator Ensure that the governor control lever or the actuator terminal shaft is engaged correctly with the fuel control linkage stop lever. Look for leaks or bends in the fuel line between the fuel tank and the fuel transfer pump. Incorrect Wiring The Shutdown signal is not wired correctly to the 2-pin connector. Also look for a faulty return fuel pressure regulating valve. 4. Governor In Need Of Repair Disassemble the governor and clean the governor components. 3. In order to achieve the correct polarity between the solenoid and the 2-pin connector.jsp?returnurl=/sisweb/sisw. Probable Cause 1. https://sis. Problem 9 The Engine Is Misfiring Or The Engine Is Running Rough. 2.cat. Make a replacement of parts. Inspect the governor components for wear and damage..com/sisweb/sisweb/techdoc/techdoc_print_page.. check the following items: { Plugged fuel filters { Fuel transfer pump Make sure that there is fuel in the fuel tank. 3. 23/06/2006 . If there is air in the fuel system. as needed. If fuel pressure is lower than the above pressure.08) . 2. { The "B" terminal is negative.Código SMCS Page 8 of 33 The solenoid may have shorted wires or broken wires. The solenoid may be stuck in the open position. Air In Fuel System Find the air leak in the fuel system and correct the air leak.undefined(SEBP1573 . Look for air in the fuel system. use the following method: { The "A" terminal is positive. Inspect the solenoid and replace the solenoid. Leakage Or Breakage In Fuel Line Between Fuel Manifold And Cylinder Head Install a new fuel line. the air generally enters the fuel system on the suction side of the fuel transfer pump. a faulty valve should be suspected.. 5. 7. Defect In Fuel Injector When the engine runs at rated load. If any one cylinder varies by more than 50 °C (90 °F). This may be an indication of a fuel injector with a defect. 9. Faulty Inlet Or Exhaust Valve When the engine runs at rated load. "Valve Lash and Valve Bridge Adjustment". Excessive Engine Load Lighten the load in order to observe any change in the engine operation. Fuel Has Cloud Point Higher Than Atmospheric Temperature. 23/06/2006 . Drain the fuel tank.. Cloud Point Is The Temperature When Wax Is Formed In The Fuel. Bent Pushrod Or Broken Pushrod Make a replacement of pushrod.com/sisweb/sisweb/techdoc/techdoc_print_page. Probable Cause https://sis. Extra high temperature at an exhaust manifold port can be an indication of a valve with a defect. 10. fuel lines and fuel manifolds. This may also be caused by a fuel injector with a defect. Refer to Testing And Adjusting. if necessary. Low temperature at an exhaust manifold port is an indication of no fuel to the cylinder. Wrong Fuel Injection Timing Make adjustment to timing. Wrong Valve Lash Make adjustment to valve lash. a faulty fuel injector should be suspected. the temperature of an exhaust manifold port can be an indication of the condition of the inlet and exhaust valves. Some installations require the use of fuel heaters in order to ensure fuel flow. Problem 10 The Engine Stalls At Low RPM. Fill the tank with fuel that has the correct cloud point. Change the fuel filter. If any one cylinder has an exhaust port temperature that is 50 °C (90 °F) higher than the average of the exhaust port temperatures on the bank.08) .cat. Remove the air from the system with the priming pump. Refer to Testing And Adjusting. Also. 6.jsp?returnurl=/sisweb/sisw.Código SMCS Page 9 of 33 4. the exhaust manifold port temperature can be an indication of the condition of a fuel injector.undefined(SEBP1573 . Extra high temperature at an exhaust manifold port can be an indication of too much fuel to the cylinder. 8. the use of fuel heaters prevents filter blockage from fuel wax. Note: The variance in temperature can be an increase or a decrease. "Fuel Injector Timing". disconnect the accessories and test the engine. If necessary. Return fuel serves to remove heat from the fuel injectors. Also look for a faulty return fuel pressure regulating valve. Problem 11 The Engine Does Not Have Enough Power. a replacement of the filter is recommended. a fuel cooler may be necessary..jsp?returnurl=/sisweb/sisw. Low Engine Idle RPM Make adjustment to the governor. Ensure that the idle rpm setting matches the rpm that is listed in Technical Marketing Information (TMI). 3. A fuel cooler is recommended in order to prevent excessive power loss and a fuel cooler is recommended in order to maintain an acceptable injector life. check the following items: { Plugged fuel filters { Fuel transfer pump Make sure that there is fuel in the fuel tank.undefined(SEBP1573 . If fuel pressure is lower than the above pressure. Probable Cause 1. Look for air in the fuel system. Defect In Fuel Injector Refer to "Problem 9". 2. 2.com/sisweb/sisweb/techdoc/techdoc_print_page. Look for leaks or bends in the fuel line between the fuel tank and the fuel transfer pump. 23/06/2006 .Código SMCS Page 10 of 33 1. Low Fuel Pressure The fuel pressure at the outlet of the fuel filter housing must be a minimum of 450 kPa (65 psi) at https://sis. Engine Accessories Check engine accessories for damage and make repair or replacement. 3.08) . 4.. Dirty Fuel Filters If the pressure differential between the inlet port of the fuel filter housing and the outlet port of the fuel filter housing is 70 kPa (10 psi). High Fuel Temperature If the fuel supply temperature is 38 °C (100 °F) or more.cat. Low Fuel Pressure The fuel pressure at the outlet of the fuel filter housing must be a minimum of 450 kPa (65 psi) at 900 rpm. Wrong Fuel Injection Timing Make adjustment to timing. The Fuel ratio control may be restricting the travel of the control linkage. Incorrect Fuel Setting Make adjustment to timing. Leaks In Air Inlet System Check the pressure in the air inlet manifold (Plenum). Ineffective Aftercooler Check temperature of inlet and outlet coolant supply. b. "Fuel Setting". If necessary. If the fuel pressure is still low.. "Valve Lash and Valve Bridge Adjustment". 4.jsp?returnurl=/sisweb/sisw. Look for air in the fuel system.undefined(SEBP1573 . Also look for a faulty return fuel pressure regulating valve. if necessary. 9. "Fuel Injector Timing". Install new parts for those parts that have damage or defects. 11. Governor And Fuel Control Linkage Ensure that the governor is moving the fuel control linkage against the fuel setting stop.com/sisweb/sisweb/techdoc/techdoc_print_page. Check high idle and adjust. 7.Código SMCS Page 11 of 33 full load speed. 23/06/2006 . Refer to Testing And Adjusting. Check for low boost pressure. if necessary. https://sis. If the control linkage is not against the stop and the engine runs below rated speed under load. 6. check the fuel transfer pump.. 10. Carbon Deposits On Turbocharger Or Other Causes Of Friction Inspect the turbocharger. 8. Make sure that there is fuel in the fuel tank.08) . Refer to Testing And Adjusting. perform the following inspections: a. Remove any external restrictions or internal restrictions. 5. Defect In Fuel Injector Refer to "Problem 9". Adjust. Look for leaks or bends in the fuel line between the fuel tank and the fuel transfer pump. If fuel pressure is lower than the above pressure. Low boost pressure is 10 percent below initial boost pressure. Make adjustment in order to get the full travel of the linkage. Repair the turbocharger. Wrong Valve Lash Make adjustment to valve lash. install new fuel filter elements. Refer to Testing And Adjusting. Look for leak paths in the air cleaner pipe assemblies and the clamped joints.cat. Tighten all mounting bolts. if necessary. Probable Cause 1.08) . 2. Loose Vibration Damper Inspect the vibration damper for damage.jsp?returnurl=/sisweb/sisw. Faulty Vibration Damper Inspect the vibration damper for leakage and inspect the vibration damper for a damaged case assembly. Check alignment and balance. Either of the above conditions can cause the weight to come into contact with the housing. 6.Código SMCS Page 12 of 33 12. 2. Wrong Fuel Injection Timing Make adjustment to timing. Your Caterpillar dealer can perform a torsional vibration measurement. Refer to Testing And Adjusting.com/sisweb/sisweb/techdoc/techdoc_print_page. replace the vibration damper bolt holes with new parts. 4.undefined(SEBP1573 . 23/06/2006 . Install new components. Not Enough Air For Combustion Check the air cleaner for restrictions and check the aftercooler for restrictions. 5. The Engine Is Misfiring Or The Engine Is Running Rough. Driven Equipment Is Not In Alignment Or Driven Equipment Is Not In Balance. External Causes of Vibration Check the equipment in the engine and around the engine for the source of the vibration. Problem 12 The Engine Has Too Much Vibration. "Fuel Injector Timing". Correct alignment and balance. Probable Cause 1. Defect In Fuel Injector https://sis. Problem 13 The Engine Has A Loud Combustion Noise (Knock).. Refer to "Problem 9". if necessary. Tighten the bolts.cat. If the vibration damper bolt holes have damage or wear. Engine Supports Are Loose Or Faulty. if necessary. 3. the operation of the vibration damper is affected. If the weight contacts the housing.. 4. Refer to Testing And Adjusting. Problem 14 The Engine Has A Valve Train Noise (Clicking). Probable Cause 1.cat. Replace worn parts or damaged parts. There must be a strong flow of engine oil at high rpm. "Valve Lash and Valve Bridge Adjustment". 2. as required. 3. Problem 15 The Engine Has A Loud Valve Train Noise. Oil passages must be clean.undefined(SEBP1573 . Damage To Valve Springs https://sis. There must be a small flow of engine oil at low rpm.jsp?returnurl=/sisweb/sisw.. The oil passages that send the engine oil to the cylinder head are particularly important. Damage To Valve Train Components Inspect all of the following valve train components: { Valves { Springs { Camshafts { Lifters { Rocker arms { Pushrods Check for worn parts or damaged parts. Valve Recess On engines that use distillate fuel. adjust the valve recess. Probable Cause 1.Código SMCS Page 13 of 33 Refer to "Problem 9".08) . 23/06/2006 . Not Enough Lubrication Check the lubrication in the valve compartment.. Too Much Valve Lash Make adjustment to valve lash.com/sisweb/sisweb/techdoc/techdoc_print_page. Defect In Fuel Injector Sleeve Remove the fuel injectors. Inspect the fuel injector sleeve in the injector sleeve bore in the cylinder head. If any problems are seen.cat. Problem 16 Engine Oil Is In The Cooling System. Inspect the lobes of the camshaft for damage. as required. Replace the damaged valve lifters. Repair any faulty engine oil cooler or replace any faulty engine oil cooler. Cavitation on the inside may be due to air bubbles in the fuel. If necessary. 2. Refer to Testing And Adjusting. Defect In Core Of Engine Oil Cooler Inspect each engine oil cooler. https://sis.undefined(SEBP1573 . 2. "Valve Lash and Valve Bridge Adjustment". Probable Cause 1. If the camshaft is replaced. Remove the fuel injector sleeve from the cylinder head. Look for signs of cavitation erosion or signs of cracks.. Air bubbles may be due to a leak on the suction side of the fuel transfer pump. Clean the engine thoroughly.jsp?returnurl=/sisweb/sisw. Probable Cause 1.. 23/06/2006 .08) .Código SMCS Page 14 of 33 Replace the damaged components. Check for cracks at the fuel injector sleeve near the fuel injector nozzle. Cavitation erosion on the outside of the fuel injector sleeve could indicate an incorrect coolant conditioner concentration. For the proper procedure for the removal and for the installation of fuel injectors. replace the fuel injector sleeve with a new fuel injector sleeve. Look for valves that do not move freely. Air bubbles may also be caused by combustion gas leakage. 3. new valve lifters are necessary. 3.com/sisweb/sisweb/techdoc/techdoc_print_page. Faulty Water Pump Seal Check the water pump. Damage To Camshaft Replace the damaged components. Failure Of Cylinder Head Water Seals Install new cylinder head water seals in the seal plates. Make adjustments to the valve lash. repair the water pump. Problem 17 Fuel Is In The Coolant. refer to Disassembly And Assembly. Damage To Valve Lifter Clean the engine thoroughly. Wrong Adjustment Of Fuel Injector Adjust the fuel injector. Probable Cause 1.08) . Fuel System Leaks Tighten or make replacement of parts at points of leakage. Wrong Fuel Injection Timing Make adjustment to timing.Código SMCS Page 15 of 33 Problem 18 The Engine Has A Mechanical Noise (Knock).com/sisweb/sisweb/techdoc/techdoc_print_page. 23/06/2006 . 2. Install new parts. 6. Refer to Testing And Adjusting. Refer to Testing And Adjusting. Probable Cause 1. Fuel And Combustion Noise (Knock) Refer to "Problem 9" and "Problem 13".. Damaged Gears Install new parts.undefined(SEBP1573 . as required.cat. as required. "Fuel Injector Timing".. 5. 2. Failure Of Bearing For Connecting Rod Inspect the bearings for the connecting rods and the bearing surfaces (journals) on the crankshaft. 3. Damaged Crankshaft Make replacement of the crankshaft. Wrong Adjustment Of Valve Bridge Adjust valves and valve bridges. Defect In Accessory Equipment Repair the faulty components or install new components.jsp?returnurl=/sisweb/sisw. "Valve Lash and Valve Bridge Adjustment". https://sis. Problem 19 Fuel Consumption Is Too High. 4. 3. 6.undefined(SEBP1573 . "Camshaft Timing".08) . Excessive Exhaust Back Pressure Refer to Testing And Adjusting. 4. 23/06/2006 . Problem 20 Little Valve Lash Or No Valve Lash Is Present. Refer to Testing And Adjusting. check the delivery of oil from the mister. Not Enough Lubrication Check the lubrication in the valve compartment. Incorrect High Idle Adjust high idle setting. Refer to Testing And Adjusting. Wrong Crankshaft/Camshaft Timing Make adjustment to camshaft timing. 3. Refer to Testing And Adjusting. "Valve Lash and Valve Bridge Adjustment".cat. "Restriction of Air Inlet and Exhaust". 2. Valve Bridge Out Of Adjustment Make adjustment to the valve bridge.jsp?returnurl=/sisweb/sisw. Make adjustment to valve lash. Open Mister For Oil On engines that use distillate fuel...com/sisweb/sisweb/techdoc/techdoc_print_page. Problem 21 Too Much Valve Lash Is Present. Worn Valve Seat Or Worn Valve Face Reconditioning of the cylinder head is required. There must be a strong flow of engine oil at https://sis. 5. Defect In Fuel Injector Refer to "Problem 9". 7. "Valve Lash and Valve Bridge Adjustment". Probable Cause 1. Overloaded Engine Do not exceed recommended capacities.Código SMCS Page 16 of 33 4. Probable Cause 1. Make adjustment to valve lash. Clean the engine thoroughly. Check the camshaft for wear. Broken Valve Spring Install a new valve spring.Código SMCS Page 17 of 33 engine high rpm. Refer to Testing And Adjusting. 7.08) . Make adjustment to valve lash. Refer to Testing And Adjusting.cat. Check for free movement of valves or bent valve stem. Broken Locks Broken locks can cause the valve to slide into the cylinder. "Valve Lash and Valve Bridge Adjusment". Check for free movement of valves or bent valve stems. 23/06/2006 . "Valve Lash and Valve Bridge Adjusment". https://sis.jsp?returnurl=/sisweb/sisw. There must be a small flow of engine oil at low rpm. 3. install new valves. 2. Check for wear on camshaft lobes. Install new valve lifters. Make adjustment to valve lash. install new pushrods. Worn Pushrods If the pushrods have too much wear. "Valve Lash and Valve Bridge Adjustment". as required. Worn Valve Bridges Make an adjustment or replacement. Install a new camshaft. 2. install new parts or rocker arms. Worn Rocker Arm If the face of the rocker arm that makes contact with the valve bridge has too much wear. Make adjustment to valve lash. The oil passages that send the engine oil to the cylinder head are particularly important.. 6.. Worn Valve Stem If the end of the valve stem has too much wear. Refer to Testing And Adjusting. Probable Cause 1. Problem 22 The Valve Rotocoil Is Free Or Spring Lock Is Free. "Valve Lash and Valve Bridge Adjustment". 4. Oil passages must be clean. Refer to Testing And Adjusting.com/sisweb/sisweb/techdoc/techdoc_print_page.undefined(SEBP1573 . Worn Camshaft Check valve lash. Make adjustment to valve lash. This will cause much damage. 5. Broken Valve Lifters Or Worn Valve Lifters Install new valve lifters. "Valve Lash and Valve Bridge Adjustment". Refer to Testing And Adjusting. 3. Dirt In Engine Oil Remove dirty engine oil. 23/06/2006 . as required. Ensure that the engine oil level is at the recommended capacity. Install new filter elements. 1. Lack Of Lubrication Ensure that the engine oil is the proper viscosity.cat. The cause must be corrected.08) . Worn Piston Rings Inspect piston rings and install new parts. 3.. as required. Probable Cause 1. Check engine oil filter bypass valves for wear or broken springs. Make repairs if leaks are found.jsp?returnurl=/sisweb/sisw.. Probable Cause Note: Internal engine components wear due to abrasion. https://sis. oil. 2. Each of the following systems must be inspected in order to determine the source of abrasion within that system: air. Air Inlet Leaks Inspect all gaskets and connections. Problem 23 Engine Oil Is At The Exhaust. fuel and water. Too Much Engine Oil In The Valve Compartment Be sure that the plugs are installed in the ends of the rocker arm shaft. 4. 2.undefined(SEBP1573 . Check the components and replace the components. Excessive Idle Time Do not idle the engine for long time periods. Put clean oil in the engine. Problem 24 The Engine Has Early Wear. Worn Valve Guides Reconditioning of the cylinder head is required.com/sisweb/sisweb/techdoc/techdoc_print_page. Broken Valve Replace the valve and the other damaged parts.Código SMCS Page 18 of 33 3. Clean the centrifugal oil filters. Failure Of Cylinder Liner Seals Replace cylinder liner seals. Make repairs if leaks are found.undefined(SEBP1573 . Problem 25 Coolant Is In The Engine Oil. Probable Cause 1.. Repair the cylinder head or replace the cylinder head. Crack Or Defect In Cylinder Block Pressurize the cooling system in order to locate the damage. inspect the cylinder head in order to determine the extent of the damage. 5.Código SMCS Page 19 of 33 4. as required. 3. 4. 6.com/sisweb/sisweb/techdoc/techdoc_print_page. Drain the crankcase and refill the crankcase with clean lubricant. This condition may also increase the engine oil level in the crankcase. Problem 26 Too Much Black Smoke Or Gray Smoke Is Present. Failure Of Any Of The Engine Oil Cooler Cores Install a new core for the faulty engine oil cooler. https://sis. Install new parts. Crack Or Defect In Cylinder Head Pressurize the cooling system in order to determine whether the cylinder head needs repair. Faulty Water Pump Check the water pump for leakage. as required. Inspect the cylinder block. 2. Probable Cause 1.08) . Fuel Leakage Into Lubrication Oil This will cause high fuel consumption and low engine oil pressure. 23/06/2006 . Repair the cylinder block or replace the cylinder block.jsp?returnurl=/sisweb/sisw. While the cylinder head is removed from the engine. Install new engine oil filters. Not Enough Air For Combustion Check the air cleaner and the aftercooler for restrictions.cat. as required. Faulty Water Cooled Valve Seat Insert Replace the cylinder head.. Código SMCS Page 20 of 33 2. as required. 4. Wrong Fuel Injection Timing Make adjustment to timing. Wrong Fuel Injection Timing Make adjustment to timing. Problem 27 Too Much White Smoke Or Blue Smoke Is Present.. Faulty Fuel Injectors Install new fuel injectors. 5.com/sisweb/sisweb/techdoc/techdoc_print_page. 6. 23/06/2006 . "Fuel Injector Timing". Overloaded Engine Do not exceed recommended capacities..jsp?returnurl=/sisweb/sisw. Find the source of the extra engine oil. Worn Piston Rings Or Improperly Installed Piston Rings Inspect piston rings and install new parts. 6. 3. Worn Valve Guides Reconditioning of cylinder head is required. The Engine Is Misfiring Or The Engine Is Running Rough. Failure Of Turbocharger Oil Seal https://sis. "Fuel Injector Timing". Put the correct amount of oil in engine.08) . Broken Exhaust Valve Replace the broken components and the damaged components.cat. 3. Refer to "Problem 19". Refer to "Problem 9". as required. Refer to Testing And Adjusting. 4. Refer to Testing And Adjusting. Probable Cause 1. 5. Fuel Consumption Is Too High. 2. Too Much Lubrication Oil In Engine Remove extra engine oil.undefined(SEBP1573 . 08) . Faulty Oil Pump Suction Pipe Replacement of oil pump suction pipe is required. Oil Pump's Suction Strainer Is Fouled. Problem 28 The Engine Oil Pressure Is Low. Remove dirty engine oil from the engine.undefined(SEBP1573 . as required. Faulty Valve Lubricator Pumps Check the setting and the delivery of the valve lubricator pumps. Install new engine oil filters. Put clean oil in the engine. 3. Install new engine oil filter elements. 23/06/2006 .. Dirty Engine Oil Filters Or Engine Oil Cooler Check the operation of bypass valve for the oil filters. Clean engine oil cooler cores or install new engine oil cooler cores. Diesel Fuel In Engine Oil Find the source of the leakage of the diesel fuel into the engine oil.cat. 4. Worn Cylinder Liner Check cylinder liners. Install new parts. Make repairs. Change engine oil.Código SMCS Page 21 of 33 Check the air inlet manifold (Plenum) for oil and repair the turbocharger.. Remove the engine oil that has been contaminated with diesel fuel. 7. 7. 5.com/sisweb/sisweb/techdoc/techdoc_print_page. as required. Probable Cause 1. as required. 9. Faulty Oil Pressure Gauge Install new gauge. Too Much Clearance Between Rocker Arm Shaft And Rocker Arms Check lubrication in valve compartments. Faulty Priority Valve https://sis. Clean centrifugal oil filters. 8. 6.jsp?returnurl=/sisweb/sisw. Clean the strainer. 2. Faulty Aftercooler Core Check aftercooler core for leaks. 23/06/2006 . 13.08) .cat. 15. There is a restriction in the engine lubrication system. Too Much Clearance Between Camshaft And Camshaft Bearings Inspect the camshaft and the camshaft bearings.Código SMCS Page 22 of 33 Inspect the priority valve and replace damaged parts or worn parts.jsp?returnurl=/sisweb/sisw.undefined(SEBP1573 . 10. Loose Oil Plugs For Crankshaft or Missing Oil Plugs For Crankshaft Check the torque of the oil plugs for the crankshaft. 9. 11. Loose Plugs In Rocker Arm Shaft Or Missing Plugs In Rocker Arm Shaft Check plugs in the ends of the rocker arm shafts. Stuck Open Oil Pressure Relief Valve Clean the valve and the housing. as required. Too Much Clearance Between Crankshaft And Crankshaft Bearings Inspect the crankshaft bearings and make replacement. The priority valve is faulty. Use various pressure taps in order to determine the problem area and repair the problem area.. 2. Problem 29 The Engine Oil Pressure Is High.. Loose Engine Oil Supply Line In Box For Lifter Check the engine oil supply line from the cylinder block to the cylinder head behind the lifter assemblies. Loose Retainer On The Idler Gear For The Rear Gear Train Or Missing Retainer On The Idler Gear For The Rear Gear Train Check the retainer on the idler shafts of the rear gear train. Replace the camshaft and the camshaft bearings. Install new parts. 8. Faulty Engine Oil Pump Repair the engine oil pump or replace the engine oil pump.com/sisweb/sisweb/techdoc/techdoc_print_page. 14. Probable Cause 1. as required. https://sis. 12. as required. Too Much Engine Oil In The Valve Compartment Be sure that the plugs are installed in the rocker shafts. 7. Make repairs. Failure Of Turbocharger Oil Seal Check the air inlet manifold (Plenum) for engine oil and repair the turbocharger. Install new engine oil filters. Problem 30 The Engine Uses Too Much Lubrication Oil. Worn Valve Guides Reconditioning of the cylinder head is required. The incorrect viscosity of the engine oil is used. Install new parts. Find the source of the extra engine oil. Drain the engine oil and refill with engine oil of the correct viscosity.jsp?returnurl=/sisweb/sisw. as required. Engine Oil Leaks Find all engine oil leaks. The output of the engine oil pump is too high.cat.. 2. Failure Of Crankshaft Seal Replace crankshaft seals. 3.com/sisweb/sisweb/techdoc/techdoc_print_page. Probable Cause 1. Worn Piston Rings Or Improperly Installed Piston Rings https://sis. 8. High Engine Oil Temperature Check operation of engine oil cooler and oil temperature regulator. as required. 23/06/2006 . as required. Too Much Lubrication Oil In Engine Remove the extra engine oil. 3.Código SMCS Page 23 of 33 Inspect the priority valve. 4. Replace damaged parts or worn parts. Check for dirty crankcase breathers.undefined(SEBP1573 . 4. The wrong engine oil pump is installed.. 5. Put the correct amount of engine oil in the engine. 6. Clean the engine oil cooler cores. Repair the engine oil pump or replace the engine oil pump.08) . . 2. Faulty Turbocharger Seal Replace the turbocharger seal. 5. Problem 31 The Engine Crankcase Pressure Is Too High. Seized Piston And/Or Stuck Piston Rings Replace piston assembly and cylinder liner. Remove extra engine oil. Faulty Pressure Cap https://sis. Restricted Crankcase Breathers Check and clean crankcase breather elements and tubes.08) . 3. Probable Cause 1. Problem 32 The Engine Coolant Temperature Is Too High. Find the source of the extra engine oil.cat. 23/06/2006 . Probable Cause 1.Código SMCS Page 24 of 33 Inspect piston rings and install new parts..undefined(SEBP1573 . Restriction Of Coolant Flow Through Radiator Core Tubes Clean the radiator or the heat exchanger and flush the radiator or the heat exchanger. 9. Check for leaks. Low Coolant Level Add coolant to the cooling system. Loose Fuel Injector Ensure that all fuel injectors are tight. 2. Engine Oil Level Is Too High.com/sisweb/sisweb/techdoc/techdoc_print_page. 4.jsp?returnurl=/sisweb/sisw. 3. Faulty Valve For Continuous Prelube Check operation of continuous prelube system. as required. Put the correct amount of oil in the engine. 23/06/2006 . Too Much Load On The System Reduce the load on the system. Inlet Air Leakage Check the following locations and the associated piping for air leakage. "Fuel Injector Timing". Incorrect Coolant And/Or Flow The system is not balanced correctly.Código SMCS Page 25 of 33 Check operation of the pressure cap. as required. Faulty Water Temperature Regulators Check water temperature regulators for correct operation. Make repairs.. 11. Faulty Aftercooler Pump Make repairs to the aftercooler pump. Scale Buildup Clean the cooling system. Install new parts.cat. 4. 6. Combustion Gases In Coolant Find the source of the leakage of combustion gases into the cooling system.undefined(SEBP1573 . 7. 8. as required. Wrong Fuel Injection Timing Make adjustment to timing. make the https://sis. Probable Cause 1.jsp?returnurl=/sisweb/sisw. Problem 33 The Exhaust Temperature Is Too High. Faulty Jacket Water Pump Make repairs to the jacket water pump. as required. 10. Check the water temperature gauge for correct operation. If necessary..08) . Install a new pressure cap. 9. Refer to Testing And Adjusting.com/sisweb/sisweb/techdoc/techdoc_print_page. as required: { Cylinder liner { Water cooled valve seat insert 5. as required. as required. Repair the system. Faulty Exhaust Valve Check exhaust valves for damage and replace exhaust valves.08) .75 kPa (15 inches of H2O) when the filters and the piping are dirty. Make repairs. "Fuel Injector Timing". as required.undefined(SEBP1573 .jsp?returnurl=/sisweb/sisw.00 inches of H2O) when the filters and the piping are clean.5 kPa (10 inches of H2O).Código SMCS Page 26 of 33 corrections. Low boost pressure is 10 percent below initial boost pressure. 7. The Air Inlet Temperature Is Too High. Leakage At Exhaust System Find the cause of the exhaust leak. Repair the turbocharger.5 kPa (5. 4. Wrong Fuel Injection Timing If necessary. 8. Faulty Turbocharger Inspect the turbocharger. Refer to Testing And Adjusting. 6. make adjustments to timing. Fouled Turbocharger Ensure that both the compressor side and the turbine side of the turbocharger are not fouled. 3.. https://sis.com/sisweb/sisweb/techdoc/techdoc_print_page. { O-ring seals between the compressor and the aftercooler { Air inlet shutoff { Plugged sections { Gaskets within aftercooler { Plenum 2. Check for low boost pressure. 5.cat.. as required. 9. Excessive Exhaust Restriction Ensure that the air pressure drop between the outlet of the turbocharger and the atmosphere is less than 2. Ensure that the pressure drop between the inlet of the filters to the turbocharger inlet is less than 3. Insufficient Air Passage Through Filters Or Inlet Air Piping Ensure that the pressure drop between the inlet of the filters to the inlet of the turbocharger is less than 1. 23/06/2006 . if necessary. 2 °C (0. 2. 2.80 °F) increase in the aftercooler inlet water temperature.08) . Probable Cause https://sis.0 °C (1. 23/06/2006 . Low Coolant Level Refer to "Problem 32". 5.Código SMCS Page 27 of 33 Refer to "Problem 35"..90 °F) for every 1. Faulty Oil Temperature Regulators Check the oil temperature regulators for correct operation.0 °C (1. Check the oil temperature gauge for correct operation. 3. as required. The exhaust manifold temperature will increase approximately 1. The exhaust manifold temperature will increase approximately 0. 4. Use the following guidelines in order to determine if a rise in exhaust temperatures is the result of a change in ambient conditions.undefined(SEBP1573 .. Crankcase Pressure Is Too High. 10. Refer to "Problem 32". Problem 35 The Air Inlet Temperature Is Too High. Probable Cause 1. Excessive Pressure Drop Through The Aftercooler (Air Side) Ensure that the air side of the aftercooler is not restricted or too contaminated with soot and debris.jsp?returnurl=/sisweb/sisw. Engine Coolant Temperature Is Too High. Problem 34 The Engine Oil Temperature Is Too High. Check for faulty main bearings and connecting rod bearings.36 °F) for every 1. 1. Install new parts.6 °C (2. Restriction Of Oil Flow Through The Engine Oil Cooler Clean the engine oil cooler and flush the engine oil cooler.80 °F) increase in the inlet air temperature.cat.com/sisweb/sisweb/techdoc/techdoc_print_page. undefined(SEBP1573 . This is due to a blockage that is only in one part of the water side of the aftercooler. 1.jsp?returnurl=/sisweb/sisw. Drilling of the covers will be required. Check the operation of the air compressor. Engine Coolant Temperature Is Too High. Problem 36 The Air Starting Motor Does Not Turn. The Pinion Is Not Engaged. as required. This occurs because the temperature is taken at a point that yields an average temperature. Replace the oil pressure valve. Low Air Pressure Check the system for leaks. Faulty Oil Pressure Valve (Intermittent Operation) Check the operation of the oil pressure valve. Restriction Of Coolant Flow Through Aftercooler Cores Clean the aftercooler cores and flush the aftercooler cores.. as required.08) . Ensure that the pinion is engaged with the flywheel ring gear. Additional temperature measurements must be made at the ends of the inlet manifold. Inoperative Relay Valve Check the operation of the relay valve. Refer to "Problem 32". a hot front section or a hot back section can be undetected. https://sis. High inlet manifold temperature may occur on only the front half or the back half of the engine. 5.Código SMCS Page 28 of 33 Note: Inlet air temperatures should be compared to trends in the performance data in addition to data that is supplied by the factory. 2. Faulty Air Start Control Valve Repair the air start control valve or replace the air start control valve. Set the oil pressure valve to open at 7 kPa (1 psi). as required. 6. Repair the relay valve or replace the relay valve. as required. Faulty Air Starting Motor Repair the air starting motor or replace the air starting motor. 23/06/2006 .cat. 3. Probable Cause 1. Do not rely on the setpoint of the alarm only.com/sisweb/sisweb/techdoc/techdoc_print_page. 2. When the inlet manifold temperature is being measured at the middle of the aftercooler.. 4. Fill the lubricator and adjust the drip rate.com/sisweb/sisweb/techdoc/techdoc_print_page.undefined(SEBP1573 . Apply 205 kPa (30 psi) air to the inlet and put the unit in nonflammable fluid for 30 seconds. Replace rotor bearings if any roughness or looseness is apparent in the bearings.25 inch) at either end. Worn Motor Parts Disassemble the air starting motor and inspect the parts. Check the manual barring group and the switches.cat. b. Replace the rotor if the body has deep scoring that cannot be removed with the use of emery cloth. 4. Low Air Pressure Check the system for leaks.Código SMCS Page 29 of 33 7. Install a set of new vanes if any vane is cracked or damaged. Clean up end plate scoring with emery cloth that is placed on a flat surface. Probable Cause 1. The following guideline should be used for determining the reusability of the motor parts: a. Air Leakage Check the air starting motor for worn seals.. 8. Also. Check the operation of the air compressor. e. remove the cylinder pressure relief valve or plug. replace the motor seals. If bubbles appear. External Resistance https://sis. Problem 37 The Air Starting Motor Turns Slowly Or The Air Starting Motor Has A Loss Of Power. install a set of new vanes if any vane's width is 32 mm (1. Malfunctioning Lubricator Check the lubricator for correct operation. c. Plug the exhaust. Inspect the cylinders for fluid while the crankshaft is being turned. 2. If the engine is not equipped with the manual valves. 23/06/2006 . The Manual Barring Group Is Engaged. 3. 5.08) .jsp?returnurl=/sisweb/sisw. Fluid In the Cylinders Open the manual valves (Kiene valves) that measure cylinder pressure on each cylinder.. Replace the air cylinder if there are any cracks or deep scoring. d. Gears Or Clutch Jaws Replace the parts. Replace the bearings. Probable Cause 1. Broken Shafts.undefined(SEBP1573 . High Air Pressure Check air supply pressure and the air pressure regulator.cat. Broken Clutch Jaws Or Other Broken Parts Replace the parts. Probable Cause 1. as required. 3. 2. as required. Problem 39 The Air Starting Motor Pinion Does Not Engage Correctly With The Flywheel.Código SMCS Page 30 of 33 Disconnect driven equipment. 23/06/2006 . Incorrect Timing Of Crank Termination Check the controls of the air starting motor for the correct setting for crank termination.jsp?returnurl=/sisweb/sisw. 2. Problem 41 The Electric Starting Motor Does Not Turn. Probable Cause 1..08) ..com/sisweb/sisweb/techdoc/techdoc_print_page. The Air Starting Motor Does Not Turn The Flywheel. Problem 38 The Air Starting Motor Runs And The Pinion Engages. Faulty Bearing In Air Starting Motor Check the condition of the bearings in the air starting motor. After The Pinion Engages. Problem 40 The Air Starting Motor Pinion Does Not Disengage From The Flywheel. https://sis. as required. Worn Pinion Engagement Piston Replace the pinion engagement piston and the seal. . make repairs or replacement. Starting Motor's Solenoid Is Faulty. as needed. Note: Install a new rotor for brush type alternators only. 3.cat. 4. Faulty Rotor (Field Coil) Install a new rotor.com/sisweb/sisweb/techdoc/techdoc_print_page.Código SMCS Page 31 of 33 Probable Cause 1. Install a new solenoid. make repairs. Low Voltage To Starting Motor Check power supply to the starting motor. Clean connections. Faulty Ground Return Circuit Or Faulty Battery Connections Inspect all cables and inspect all connections. If necessary. Faulty Brushes (If Equipped) Install new brushes. Probable Cause 1.undefined(SEBP1573 . Loose Drive Belt Adjust the drive belt to the correct tension. Problem 43 The Alternator Charge Rate is Low Or The Alternator Charge Rate Is Not Regular.08) . 23/06/2006 . If necessary. 4. The Wiring Is Faulty Or The Switch Is Faulty. Tighten connections. The Starting Motor Is Faulty. Replace parts. Problem 42 The Alternator Provides No Charge. Probable Cause https://sis. 3. 2.jsp?returnurl=/sisweb/sisw. If necessary. 2. Faulty Charging Circuit. repair the starting motor or replace the starting motor.. Loose Drive Belt Adjust the drive belt to the correct tension. Problem 45 https://sis. 6. Refer to Testing And Adjusting. Refer to Testing And Adjusting.cat.. 23/06/2006 . Replace parts.Código SMCS Page 32 of 33 1. Note: Install a new rotor for brush type alternators only.jsp?returnurl=/sisweb/sisw. Faulty Alternator Regulator Install a new alternator regulator. Faulty Charging Circuit. "Alternator Regulator". Clean connections. 3. 2. 3. Incorrect Alternator Regulator Adjustment Some alternator regulators can be adjusted and some alternator regulators can not be adjusted. 5. Faulty Rectifier Diodes Replace the faulty rectifier diode.undefined(SEBP1573 .com/sisweb/sisweb/techdoc/techdoc_print_page. Problem 44 The Alternator Charge Rate Is Too High. Incorrect Alternator Regulator Adjustment Some alternator regulators can be adjusted and some alternator regulators can not be adjusted. Tighten connections. Faulty Alternator Regulator Install a new alternator regulator. Faulty Ground Return Circuit Or Faulty Battery Connections Inspect all cables and inspect all connections. Faulty Rotor (Field Coil) Install a new rotor. "Alternator Regulator". Loose Connections On The Alternator Or Loose Connections On The Alternator Regulator Tighten all connections. 2. 4. as needed. Probable Cause 1..08) . 6. 4.com/sisweb/sisweb/techdoc/techdoc_print_page. The Alternator Drive Belt Is Not In Alignment With The Drive Pulley. If the groove is worn. Todos los derechos reservados. 2.undefined(SEBP1573 . Probable Cause 1. Align the drive belt with the drive pulley.08) . Red privada para licenciados del SIS. install a new pulley. Refer to Specifications for the correct torque value.. Worn Alternator Bearings Install new bearings in the alternator. 5.jsp?returnurl=/sisweb/sisw..2006 Caterpillar Inc. Loose Alternator Drive Pulley Check the groove in the pulley that holds the pulley in place. 23/06/2006 . Shorted Out Rectifiers Install a new diode assembly. 3. Faulty Drive Belt Install a new drive belt for the alternator.cat. Tighten the pulley nut.Código SMCS Page 33 of 33 The Alternator Has Noise. Bent Rotor Shaft Install a new rotor shaft. Fri Jun 23 11:47:31 EST 2006 https://sis. Copyright 1993 .